N3220517Q4558_MSFSC_SWI_19_31.pdf

Military Sealift Fleet Support Command (MSFSC) Standard Work Items

Item No. 19 22 March 2010

MOTOR AND VENTILATION FAN REPAIRS

1. ABSTRACT

This standard item provides requirements for repairs to motors and ventilation fans. This item includes UNIVERSAL REQUIREMENTS, which apply to all work covered in this standard work item, and menu-type COMPONENT REQUIREMENTS that detail the work required for specific motors and vent fans. This standard item will be incorporated into a MSFSC vessel work package by reference, and the base item in the work package will indicate which menu-type COMPONENT items are to be accomplished.

2. References Note: Reference documents include a mix of public and private information. To the maximum extent possible, all reference information is included in the reference folder which is provided with the MSFSC Standard Work Item package. Private documents, such as SOLAS, ASME or SSPC, are not provided but are considered to be common ship repair industry documents which are available through subscription to the publishing organizations.

IEEE Std 45-2002, Recommended Practice for Electrical Installations on Ships

3. ITEM LOCATION/DESCRIPTION

Locations are as specified in the base item.

4. GOVERNMENT FURNISHED MATERIAL/ EQUIPMENT/ SERVICE: None

5. Notes: None

6. QUALITY ASSURANCE REQUIREMENTS:

Contractors and/or subcontractors used to accomplish ventilation cleaning requirements as specified in this standard work item shall be certified under the auspices of reference 2.1.

7. STATEMENT OF WORK REQUIRED

A. Universal Requirements

In conjunction with ship’s force, electrically tag out motors and vent fans as designated in the base work item. Disconnect units and rig from the ship to the shop.

Upon completion of all repairs and satisfactory inspection by the MSCREP, convey the units back to the ship and reinstall. Motor alignments shall be in accordance with the equipment tech manual.

Perform the following electrical tests (AC Service) and record results:

Voltage Surge Comparison:

Test voltage to be applied shall be 1.4 times voltage computed in the following table. E = Operating voltage of equipment under test

Armature Circuits Field Circuits Motors rated above 250V 2E + 1000 10E but not less than 1500v nor more than 3500v Motors rated not more than 250v or 0.5 hp 900 900 except those listed below

Bracket fan motors 600

Motors rated not more than 35v 500 500

Direct Current Hi-Pot Test:

Et = Maximum voltage to be applied E = Operating voltage of equipment under test

Et = 1.6(2E + 1000)

Locked Rotor Test.

Perform the following electrical tests (DC Service) and record results:

Voltage Surge Comparison:

Test voltage to be applied shall be 1.4 times voltage computed in the following table. E = Operating voltage of equipment under test

Armature Circuits Shunt Field Circuits Motors rated above 250V 2E + 1000 2E + 1000 Motors rated not more than 250v or 0.5 hp 900 900 except those listed below

Bracket fan motors 600 600

Motors rated not more than 35v 500 500

Direct Current Hi-Pot Test:

Et = Maximum voltage to be applied E = Operating voltage of equipment under test

Et = 1.6(2E + 1000)

Bar to Bar Test.

All surfaces of the fan and fan housing or motor frame exterior shall be grit blasted to bare metal. Apply one (1) coat primer and one (1) finish coat to match surrounding areas for units located within the interior of the ship. Units exposed to weather deck areas shall receive two coats of primer and one finish coat.

Dynamically balance the rotor and the fan or motor as a unit. Final balance weight adjustments shall be made. The MSCREP shall witness final balancing. Final unbalance shall not exceed the manufacturer's specifications for a new unit or, in the absence of this, value determined by:

a) For speeds in excess of 1000 RPM;

4 x weight of rotor and fan (lbs.)

Unbalance (oz ins) = Max. operating RPM of unit

b) For speeds between 150 and 1000 RPM:

4000 x weight of rotor and fan (lbs.)

Unbalance (oz ins) = (Max. operating RPM of Unit squared)

c) For speed below 150 RPM:

Unbalance (ounce inches) = 0.177 x wt of rotor & fan (lbs.)

Dress all bearing housings to accept new bearings.

Install new bearings and grease seals as original and lubricate. Renew internal leads and connections as required. Completely reassemble the motor. Renew assembly hardware and gaskets on covers, inspection plates, and between the external connection box and frame.

Perform the following shop test and prove all work satisfactory to the MSCREP: Perform a

500 volt megger insulation and continuity test on all windings. Record results. Measure and record air gaps. Inspect shaft for freedom of rotation. Turn by hand at least three turns. Measure resistance value of each winding temperature detector using a low voltage ohmmeter. Test equipment at operating speed(s) for a minimum of 15 minutes. Measure and record voltage and current.

Test under actual operating conditions for minimum of one hour after temperatures stabilize.

Record current, voltage, speed and frame and bearing temperature rise at 15 minute intervals.

Clean, prime and paint all new and disturbed areas to match the surroundings.

B. Recondition Squirrel Cage (AC Service) Motors and Vent Fans

Completely disassemble the motor or fan, thoroughly clean and examine all parts. Protect machined surfaces. Inspect the armature for defective bars.

Inspect and dimensionally measure end bells, frame, shaft, sleeve, bearings, keyways, and running surfaces for wear, eccentricity, and other defects. Record as found readings.

Additional repairs deemed necessary by the MSCREP shall be the subject of a change order.

Bake windings and rotor to remove all moisture. The windings shall then be impregnated with

Class F insulating varnish and baked IAW latest IEEE STD 45 regulations.

C. Rewind (AC Service) Motors and Vent Fans

Completely disassemble the motor or fan, thoroughly clean and examine all parts. Protect machined surfaces. Inspect the armature for defective bars.

Inspect and dimensionally measure end bells, frame, shaft, sleeve, bearings, keyways, and running surfaces for wear, eccentricity, and other defects. Record as found readings.

Additional repairs deemed necessary by the MSCREP shall be the subject of a change order.

Completely strip and clean the armature and field coils. Rewind using new wire of proper size and type as specified by the fan or motor manufacturer.

The windings shall then be impregnated with Class F insulating varnish and baked IAW latest

IEEE STD 45 regulations.

D. Recondition (DC Service) Motors and Vent Fans machined surfaces. Inspect armature for defective bars, connecting rings, commutators, and for wear limits using equipment tech manual for guidance. Inspect and dimensionally measure end bells, frame, shaft, sleeve bearings, key ways, fan, and running surfaces for wear, eccentricity and other defects. Record as found readings. Inspect brush rigging for cracks, chips, worn Areas, failed or missing springs and distortion.

Additional repairs deemed necessary by the MSCREP shall be the subject of a change order.

Bake windings and rotor to remove all moisture. The windings shall then be impregnated with

Class F insulating varnish and baked IAW latest IEEE STD 45 regulations.

Replace internal leads and connectors.

Check commutator for eccentricity and depth of undercut. True up the commutator and undercut the mica. Eccentricity is not to exceed 0.001 inch total indicator reading. Chamfer the bar edges and remove rough surfaces in accordance with the equipment instruction manual.

Set brush holders as per equipment tech manual. Replace brushes and set brush tension to manufacturer's specifications. Seat new brushes to fit the curvature of the commutator. Brushes shall have surface contact of 100 percent and shall not be chipped or broken on either heel or toe.

Remove sand, carbon and other foreign matter resulting from fitting new brushes.

E. Rewind (DC Service) Motors and Vent Fans machined surfaces. Inspect armature for defective bars, connecting rings, commutators, and for wear limits using equipment tech manual for guidance. Inspect and dimensionally measure end bells, frame, shaft, sleeve bearings, key ways, fan, and running surfaces for wear, eccentricity and other defects. Record as found readings. Inspect brush rigging for cracks, chips, worn Areas, failed or missing springs and distortion.

Additional repairs deemed necessary by the MSCREP shall be the subject of a change order.

Completely strip and clean the armature, field coils and interpole coils. Rewind using new wire of proper size and type as specified by the fan or motor manufacturer.

Windings and armature shall be vacuum pressure impregnated with Class F insulating varnish and baked IAW IEEE 45 requirements.

The commutator is to be burnished with hard wood (preferably teak wood) and coarse canvas.

Assemble the brush rigging. Set brush holders as per equipment tech manual. Replace brushes and set brush tension to manufacturer's specifications. Seat new brushes to fit the curvature of the commutator. Brushes shall have surface contact of 100 percent and shall not be chipped or broken on either heel or toe. Remove sand, carbon and other foreign matter resulting from fitting new brushes.

8.0 General Requirements: None

Item No. 31 22 March 2010

MOTOR DRIVEN PUMP OVERHAULS

1. ABSTRACT

This standard item provides requirements for the overhaul of motor driven pumps.

This item includes UNIVERSAL REQUIREMENTS, which apply to all work covered in this standard work item and menu-type COMPONENT REQUIREMENTS that detail the work required for specific types of motor driven pumps. This standard item will be incorporated into a MSFSC vessel work package by reference.

2. References:

Note: Reference documents include a mix of public and private information. To the maximum extent possible, all reference information is included in the reference folder which is provided with the MSFSC Standard Work Item package. Private documents, such as SOLAS, ASME or SSPC, are not provided but are considered to be common ship repair industry documents which are available through subscription to the publishing organizations.

S6226-JX-MMA-010, Instruction Manual for the Indicator Reverse Method of

Pump Shaft Alignment

3. ITEM LOCATION/DESCRIPTION

Locations are as specified in the base item.

4. GOVERNMENT FURNISHED MATERIAL/ EQUIPMENT/ SERVICE:

None

5. Notes: None

6. QUALITY ASSURANCE REQUIREMENTS: None

7. STATEMENT OF WORK REQUIRED

A. Universal Requirements

For the pumps designated in the base work item, drain and disconnect pump from piping, motor and foundation. Clean and retain for reinstallation all removed bolting, gauge lines, fittings, etc., in way of removals. Blank all open ended piping with blind flanges, screw caps or plugs as appropriate. Cardboard or sheet metal blanks or wooden plugs shall not be permitted. Remove existing coupling. Transport pump to repair facility. Report to the MSCREP any pipe misalignment and deteriorated or defective foundations.

All replacement parts shall be OEM (original equipment manufacturer's) factory parts. Where factory parts are unavailable, the contractor may fabricate new parts with the approval of the MSCREP. Documentation showing unavailability of OEM parts shall be provided as justification for manufacturing replacement parts.

Prior to installing pump, pump foundation shall be machine scaled and painted with two (2) coats of primer and one (1) finish coat to match existing color scheme.

Transport pump to ship. Remove blanks and reconnect piping without transmitting piping strains to pump. Use new gaskets and fasteners. Align and connect pump to drive unit in accordance with manufacturer's requirements. Shaft/coupling alignment shall be accomplished per the guidance provided in the reference document S6226- JX-MMA-010. Fasten pump/motor units to foundation using new fasteners. Examine foundation mounts and if soft foot conditions are found, follow the recommendations provided in the reference document S6226-JX-MMA-010, Section 2-2. Contractor shall be responsible to stone pads, add shims, reposition mounts as necessary to verify solid contact.

Rotate pump by hand and verify freedom of rotation.

B. Centrifugal Pumps

Completely disassemble pump. Bead blast and thoroughly clean the interior and exterior of casings. Protect machined surfaces. Inspect the casings and pump components for wear and defects in the presence of the MSCREP. Provide a condition report to the MSCREP detailing conditions found and recommendations. If interior erosion is found, contractor shall coat pump casing interior surfaces with contractor furnished epoxy ceramic coating. Exterior surfaces of the pump casing shall be coated with GFM epoxy coatings.

Build up worn and eroded areas of pump casing by welding with parent metal and machine to original configuration. Epoxy ceramic coating material applied in an approved manner may be used for low stress areas when authorized by the MSCREP.

This material shall not be permitted for potable water or nuclear rated (T-AS vessel) pumps. Inspect pump shaft for distortion, defects, deterioration and conformance to manufacturer's specifications. Straighten shaft to within manufacturer’s provided tolerance. Correct minor irregularities on running surfaces by polishing.

Replace with new all bearings, wearing rings, shaft sleeves, couplings, keys, locks, and nuts to restore the pump to the original design condition. Reassemble pump using new gaskets, packing, seals and grease fittings. If the base work item indicates that mechanical seals are in place on a particular pump, the contractor shall furnish and install a new mechanical seal, of like configuration and service parameters. Hand dress mating and sealing surfaces to remove raised metal. All clearances and tolerances shall be within manufacturer's specifications. Notify the ABS surveyor and the MSCREP for inspection four (4) hours prior to closing of the pump. Dynamically balance the rotating assembly to manufacturer’s specifications in the presence of the MSCREP. Record and provide a written report of "as released" clearances.

Reinstall pump, ensuring proper alignment to both the motor coupling and piping attachments per the guidance provided in the reference document S6226-JX-MMA-

010 and operationally test during dock trials to verify proper operation. Ensure unit is properly lubricated before operation. Accomplish a Hot Alignment Check per the guidance provided in the reference document S6226-JX-MMA-010, Section 1-6.

C. Reciprocating Pumps

Disassemble/reassemble pump using following general guidance. Actual procedures shall be those specified in the equipment technical manual.

Disassemble, clean, inspect and reassemble plunger assemblies: remove plunger stuffing box(es) from the fluid cylinder assemblies. Remove plungers. Remove existing stuffing box packing. Clean stuffing box bore and junk rings. Inspect all parts for excessive wear or damage. Clean stuffing box(es) with emory cloth. Clean plungers with steel wool. Provide and install new stuffing box packing. Reassemble using new pins, springs, o-rings, seals and gaskets.

Disassemble, clean, inspect and reassemble the fluid cylinder: Disassemble the fluid cylinder assembly. Remove existing disc valves and seats. Provide and install new disc vales (suction and discharge) and seats. Where reed valves are installed, these shall also be renewed. Replace any missing or damaged dowel pins. Reassemble using new o-rings, seals and gaskets.

Disassemble, clean, inspect and reassemble the pump power end: Remove the plungers and plunger rods. Remove plunger rod seal housings. Inspect plunger rods for damage. Reassemble with new plunger rod o-rings and new seal housing seals.

Renew any additional o-rings, seals and gaskets. Remove back cover and back cover gasket from the power frame. Remove the connecting rod end caps. Slide the rod bearing halves from each connecting rod. Clean and inspect the bearing halves for wear and damage. Clean and inspect the crankshaft journals. Clean the sump area of the power frame. Provide and install new connecting rod bearings. Reassemble with new pins, o-rings, seals and gaskets. Refill pump power frame with proper amount of lubricating oil.

D. Rotary Pumps (gear type, vane type, screw, sliding shoe, multiple piston)

Disassemble/reassemble pump using following general guidance. Actual procedures shall be those specified in the equipment technical manual.

Disassemble, clean, inspect and reassemble fluid head: remove, clean and inspect cover o-ring, pump seals and rotor nut assembly. Replace cover, rotor nut and rotor hub keys, washers and o-rings upon reassembly. Replace mechanical seal rotating seal seats, shaft o-rings, stop pins and wave springs.

Disassemble, clean, inspect and reassemble gear case: remove gear case oil drain plug. Reinstall for reassembly. Remove gear case cover. Renew cover oil seal upon reassembly. Remove bearing retainers. Press shafts out of gear case for those pumps where shaft removal is recommended in the manufacturer’s tech manual. Inspect pump shaft for distortion, defects, deterioration and conformance to manufacturer's specifications. Straighten shaft to manufacturer’s specifications. Upon reinstallation use new OEM recommended shims to attain proper backface clearance. Remove gear spacers, keys and gears. Inspect gears for wear. Renew keys upon reassembly.

Remove front bearing seals. Renew bearing seals upon reassembly. Remove shims and retain for reinstallation. Remove rear oil seals. Renew upon reassembly. Remove bearings. Renew upon reassembly.

Reassemble gear case components with new parts as specified above. In addition, contractor shall provide and renew all additional keys, pins, nuts, lockwashers, lock tabs, o-rings, seals and gaskets not otherwise mentioned. Upon reassembly turn pump by hand to demonstrate proper reassembly. Record and provide a written report of "as released" clearances.

8.0 General Requirements: None

, Exterior Stack Painting

SWI 024, Propeller Shaft Weardown Readings and Rope Guards