SO_FY16-048_REV_C_NR_1_ _4_SSTG_ _GCC.pdf

Vessel: USS EMORY LAND (AS 39)

Port Engineer: Michael Jensen Phone (671) 339 6046 Date: 21 March 2016 SSU Job # FY16-048 REV C

VRR# VR15-0083 and 15-0100 CASREP#

1.0 ABSTRACT

1.1 This item describes the requirement to Renew #1 SSTG Turbine Rotor, Renew #4 SSTG Generator Slip Ring and Cleaning of the 9 Group Control Centers.

2.0 REFERENCES/ENCLOSURES:

2.1 NAVSEA Technical Manual 0961-LP-071-7014, “2500 AC Ship Service Turbine Generator” (Available onboard ship)

2.2 Sketch, “Engine Room Group Control Centers”

2.3 Sketch, “Fire Room Group Control Centers”

3.0 ITEM LOCATION/DESCRIPTION/QUANTITY

3.1 Location:

Engine Room: 7-110-0-E

Fire Room: 7-123-0-E

3.2 Description:

3.2.1 (1 ea) Steam Turbine Rotor, NSN 00-588-4790, PT# 3304985PC17, 26” Dia X 72” Long, Weight 1,100 lbs.

3.2.2 Engine Room 3-110-0-E, (5 ea.) Group Control Centers:

GCC 5-121-2: (i.e. SSTG and Main Propulsion Equipment) GCC 5-119-2: (i.e. SSTG and Main Propulsion Equipment) GCC 5-122-1: (i.e. A/C, Bilge Pumps, Distiller) GCC 5-121-1: (i.e. OWS, Fuel & Lube Oil Transfer Pumps & Distiller) GCC 5.118-1: (i.e. Engine Room Ventilation)

3.2.3 Fire Room 3-123-0-E, (4 ea.) Group Control Centers:

GCC 5-123-8: (i.e. HPAC Compressors & Potable Water Pumps) GCC 5-123-6: (i.e. LPAC Compressors & Potable Water Pumps) GCC 5-123-4: (i.e. Fire Room Ventilation) GCC 5-123-2: (i.e. Booster Feed Pumps and Boiler Control)

4.0 GOVERRNMENT FURNISHED MATERIAL:

4.1 (1 ea) Steam Turbine Rotor, NSN 00-588-4790, PT# 3304985PC17, 26” Dia X 72” Long, Weight 1,100 lbs.

5.0 NOTES: NONE

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 The requirements of this Work Item shall be accomplished to the satisfaction of the MSCREP.

6.2 The requirements of this Work Item shall be accomplished in accordance with current Regulatory Body rules and regulations.

7.0 STATEMENT OF WORK:

7.1 Provide the services of an Authorized Field Service Engineer to accomplish replacement of the #1 SSTG Steam Turbine Rotor, replacement of the #4 SSTG Generator Slip Ring Assembly and Cleaning of the (9 ea.) Group Control Centers. The Field Service Engineer shall have specialized knowledge and extensive experience of the Delaval Marine Ships Service Turbine Generators and Group Control Centers onboard the USS Emory S Land (AS-39) to be considered qualified to accomplish the following requirements of this service order:

NOTE 1: The government shall provide shipyard rigger, outside machinist, lagging, general labor and electrician support in the removal and installation of interferences and Nr. 1 SSTG turbine casing, rotor and diaphragms and shop ash blast of the diaphragms, the Nr. 4 SSTG Generator Slip Ring renewal and GCC cleaning.

7.2 #1 SSTG Turbine Rotor Replacement:

7.2.1 Accomplish a high speed balance of the Government Furnished SSTG Turbine Rotor. Provide a detailed balance report that shows the current conditions of the Turbine Rotor to the MSCREP.

a) MSC will make arrangements to ship the replacement rotor from W-143 Warehouse to the balance facility and from balance facility to the USS Emory S Land (AS-39) for Installation.

b) Remove the rotor from crate & clean Cosmoline from the Government Furnished Rotor. Retain the crate for reuse in 7.2.1.e for shipping the rotor to the vessel for installation.

c) Accomplish a High Speed Balance and set Overspeed Trip on the Government Furnished Rotor.

d) Upon completion of High Speed Balance recoat the rotor with Cosmoline to preserve the rotor during shipment to the USS Emory S Land (AS-39) for installation.

e) Repack the Government Furnished Rotor in the Crate retained in 7.2.1.b for shipment to the USS Emory S Land for installation.

f) Notify the MSCREP when the rotor is ready for shipment. The MSCREP will make arrangements for a third party pick up of the rotor from the contractor’s facility for shipment to the USS Emory S Land for installation.

7.2.2 Prior to open, inspect and removal of the #1 SSTG Turbine Upper Casing Half, take and record the following readings:

a) Turbine Thrust bearing clearance

b) Turbine nozzle clearance

c) Total float clearance

d) Turbine to high speed pinion alignment

e) Bearing oil temperatures –during operation

7.2.3 Using OEM recommended methods and procedures perform the following:

a) Temporarily remove all interferences in way of gland seal housings, turbine casing and high speed coupling in preparation for lifting the #1 SSTG Turbine upper casing half.

b) Unbolt the #1 SSTG Turbine upper casing half and steam chest.

c) Rig, remove and set aside the #1 SSTG Turbine upper casing half and steam chest in an unobstructed, protected and dry area. Clean, prepare, NDT and inspect same by in the presence of the MECREP and ABS.

7.2.4 Provide to the MSCREP (3) three copies of an "as-found" condition report denoting all the “as-found” clearances, measurements and alignment of the turbine, reduction gear and lube oil pump Take and record the following readings:

a) Turbine labyrinth packing and turbine wheel to diaphragm clearances.

b) Turbine to gear alignment.

7.2.5 Perform an in place inspection of the existing turbine rotor. Take and record a digital photographic record of the “as found” condition.

Measure, take and record all critical dimensions and wear areas.

Provide a digital and 3 paper copies of the “as found” condition report to the MSCREP and ABS upon completion of the inspection of the existing rotor.

7.2.6 Stone/scrape/machine turbine casing mating surfaces to provide a steam tight joint. Demonstrate fit of turbine casing mating sealing surfaces to the satisfaction of the MSCREP and ABS. A minimum of 80 (%) percent contact across total mating surface is required.

7.2.7 Match mark, temporarily remove and store the turbine fwd and aft rotor journal bearing upper housings. Prepare for reinstallation and reinstall during turbine assembly re-installation process.

7.2.8 Match mark for easy identification and remove the upper and lower casing diaphragms. Remove turbine rotor as required.

7.2.9 Temporarily remove and layout all labyrinth packing, upper and lower sections, diaphragms, upper and lower sections and seals for inspection by the OEMREP, MSCREP and ABS.

7.2.10 Provide OEM oversight of GFS shipyard Fly-Ash-blast of the diaphragms to remove foreign deposits. NDT in accordance with ABS requirements. NDT shall be witnessed by the MSCREP and ABS. Take and record a digital photographic record and provide a digital and 3 paper copies of the results of the inspection to the MSCREP and ABS. Provide a condition as found report denoting all conditions “as found” and any recommended repairs.

NOTE 2: GFS shipyard shall fly-ash blast of the diaphragms in accordance with OEM recommended methods and procedures noting that the blast material shall not be sand, ash, or walnuts shells. IAW NSTM Chapter 231- 8.19.1, “To prevent excessive surface roughening and base material removal, control of the cleansing agent and agent article size is essential when blast cleaning steam turbine internals (rotors, lading, casing internal surfaces).

When choosing the type of blast cleaning material, consider the turbine manufacturer’s recommendations. Care shall be taken to not to burn through surfaces of blades through intense, prolonged blasting in one area. On the basis of previous experience and equipment manufacturers’ recommendations, the following guidance is provided:

A. One approved turbine diaphragm cleaning agent is aluminum oxide with a particle size no coarser than 220. Other Cleaning agents, such as glass beads, are considered acceptable provided the finishing result is equivalent to that provided by 220 grit aluminum oxide. Do not use sand, ash, or walnut shells.

7.2.11 Fit and install CFM (Contractor Furnished) labyrinth packing sections springs and hardware. Record measurements to insure proper fit at journal.

7.2.12 Clean and prepare the upper and lower turbine casing specifically in way of all the diaphragm seating areas.

7.2.13 Reinstall diaphragms, fit , shim as required to obtain the proper clearances re-drill and re-tap holes for locking tabs and screws, fit locking tabs as necessary. Take and record the clearances.

7.2.14 Remove the Government Furnished rotor from crate & clean Cosmoline from all surfaces in preparation for installation. Retain the crate for reuse in 7.2.25 for shipping the existing rotor to a repair facility.

7.2.15 Accomplish an NDT inspection of the new turbine rotor as required by ABS. The NDT inspection shall be witnessed by the MSCREP and ABS. Take and record a digital photographic record of same and provide a digital and 3 paper copies of same to the MSCREP.

Provide a condition “as-found” report denoting all conditions “as found” and recommended repairs.

7.2.16 Polish the bearing and oil deflector journals.

7.2.17 Blue contact bearing to journals to prove fit and proper contact.

7.2.18 Install and connect the Government Furnished Turbine Rotor.

7.2.19 Take and record all “as installed” clearances, measurements and alignment of the turbine, reduction gear and lube oil pump Take and record the following readings:

a) Turbine labyrinth packing and turbine wheel to diaphragm clearances.

b) Turbine to gear alignment.

7.2.20 Provide a digital and 3 paper copies of an "as-installed" condition report to the MSCREP and ABS denoting all the “as-installed” clearances, measurements and alignment of the turbine, reduction gear and lube oil pump.

7.2.21 Install the forward and after gland assemblies on the turbines.

Provide steam tight joints for mating, sealing fit surfaces.

7.2.22 Re-install the turbine upper casing using OEM recommended methods, procedures and torque specifications.

7.2.23 Operationally test to maximum attainable load during dock and sea trials to the satisfaction of the MSCREP and ABS.

7.2.24 Demonstrate parallel operations for all configurations to the satisfaction of the MSCREP and ABS.

7.2.25 Demonstrate satisfactory reverse current operation to the satisfaction of the MSCREP and ABS.

7.2.26 At the end of the repair availability coat the removed turbine rotor with Cosmoline and pack the rotor in the existing crate retained in

7.2.13 and turn over to the MSCREP for disposition.

7.2.27 Prepare, prime and paint all new and disturbed areas to match surroundings. Restore all painted markings on renewed turbine Insulation.

7.2.28 Provide the MSCREP and ABS with an electronic and 3 paper copies of a comprehensive repair report upon completion of repairs.

7.3 #4 SSTG Generator Slip Ring Replacement:

7.3.1 Procure and crate for oversea shipment a replacement slip ring assembly.

7.3.2 Temporarily remove all interferences in way of renewing the #4 SSTG slip ring assembly.

7.3.3 Take and record continuity, insulation resistance and ground tests prior to removal.

7.3.4 Heat and remove the existing slip ring assembly from the rotor.

7.3.5 Using contractor furnished induction heater, heat and install the new slip ring assembly on the rotor to design form fit and function.

7.3.6 Stone and machine the new slip rings as required for concentricity to the generator axis and provide the design surface finish and condition for optimum slip ring operation.

7.3.7 Reinstall the existing brush rigging with new ship’s spare brushes and seat the brushes to the new slip rings. Adjust brush holder spring tension to design, form, fit, and function.

7.3.8 Take and record continuity, insulation resistance and ground tests on the newly installed slip ring assembly.

7.3.9 Prove #4 SSTG generator slip ring/ brush ring assembly function as designed in the presence of the Chief Engineer and Port Engineer under varying electrical loads.

7.3.10 Provide the Chief Engineer and Port Engineer with an electronic copy of a detailed “as found” and “as released” service report of all tests and repairs performed with photographic record prior to departing.

7.4 Group Controller Cleaning:

7.4.1 Accomplish the requirement to inspect, clean, tighten, burnish, take and record power cable insulation and continuity checks, perform thermographic surveys and correct electrical “hot spots” identified in the Ship’s nine (9) Group Control Centers and the one hundred and four (104) circuits and circuit breakers located in the Engine Room and Fire Room.

7.4.2 Temporary install and maintain lighting and power independent from the ship to perform work on the Ship’s (5) Engine Room and (4) Fire Room Group Control Centers. Provide and install temporary lighting from the Ship’s quarterdeck to each of these spaces, in these spaces and to provide sufficient light to perform all Group Control Centers work.

7.4.4 Provide journeyman level electricians, vacuums and cleaning material suitable for cleaning the Group Control Centers.

7.4.5 Provide the MSCREP with a detailed production plan for securing and cleaning the Group Control Centers 7-days prior to Contractor planned start of work for approval of the Ship’s Captain and Chief Engineer.

7.4.6 All Group Control Centers work shall be done at night from 1900 hours to 0600 hours after which the Group Control Centers shall be closed up in good order and re-energized.

7.4.7 Perform a joint lock out and tag out of the de-energized Group Control Centers prior to start of Group Control Centers work and using a multi-meter check the Group Control Centers buss and control circuits for electrical power to verify the Group Control Centers is “Dead” prior to commencing work on the Group Control Centers.

7.4.8 Temporary open each Group Control Centers circuit breaker panel front and back where accessible and close in good order upon completion of each shift and restore power to the Group Control Centers.

7.4.9 Close inspect the cable runs and connections for signs of insulation fatigue, overheating, chaffing and looseness from the SWBD to the Group Control Centers and from the circuit breakers to the motors. Provide the MSCREP with a “condition as found” report with a photographic record of each defect noting the location, circuit and equipment served.

a) Engine Room Group Control Centers: A total of sixty-two (62) active and eleven (11) spare circuit breakers shall be dealt with.

b) Fire Room Group Control Centers: A total of twenty-five (25) active and six (6) spare circuit breaker circuits.

c) Provide the MSCREP with a condition “as found” and “as released” report on all cable test results and recommendations.

7.4.10 Clean the Group Control Centers using Contractor furnished vacuums, soft brushes and clean distilled water. Remove all dust, rust, dirt, debris, and foreign material from the switchboards, and electrical components including, frames, panels, racks, wiring and decks.

7.4.11 Clean all electrical components free of carbon, oil, grease and foreign material using an approved electrical cleaning solvent that will not damage the insulation of control and meter wiring inside the Group Control Centers.

Provide the MSCREP with a copy of the MSDS for the electrical cleaning solvent prior to using same.

7.4.12 Replace Group Control Centers circuit breaker overload fuses with new per original size, rating, capacity and design function. Burnish fuse clips.

a) Engine Room Group Control Centers: A total of sixty-two (62) active and eleven (11) spare circuit breakers shall be dealt with.

b) Fire Room Group Control Centers: A total of twenty-five (25) active and six (6) spare circuit breaker circuits.

7.4.13 Inspect and tighten bus bar connections and terminal connections.

7.4.14 The MSC Port Engineer and Chief Engineer shall inspect the SWBD for cleanliness and absence of loose tools or material inside the SWBD prior to FINAL close up of the switchboards.

7.4.15 Provide the services of a Marine Thermal Infrared Imaging Survey company to attend dock and sea trials and perform, take and record Thermal Marine Infrared Imaging Surveys of the Ship’s nine (9) Group Control Centers and all one hundred and four (104) circuit breakers while under load. Correct all hot spot deficiencies in the presence of and to the satisfaction of the Chief Engineer and MSC Port Engineer. Provide the MSCREP with three (3) CD/DVD copies of the survey report within five (5) days of completion of the survey.

7.5 Manufacturers Representative:

7.5.1 Manufacturers Rep: The equipment addressed in this Statement of Work (SOW) is categorized as critical equipment in accordance with MSC policy on the classification of critical shipboard systems and equipment. The Technical Representative shall have superior knowledge of and significant experience with the equipment onboard the USS Emory S Land (39). The Technical Representative shall be capable of working on the mechanical and electrical systems of each piece of equipment including oversight and guidance on all aspects of equipment as-found condition inspection, removal, disassembly, reassembly, repairs, modifications, reinstallation and testing as applicable.

POP: 1-30JUN16 15 APRIL thru 30 JUNE 2016

LOCATION : Onboard USS Emory S Land (AS-39) at Naval Base Guam.

RECOMMENDED SOURCE:

TURBOGEN CONSULTING SERVICE

12476 Creekview Dr.

San Diego, CA 92128 POC: Gene A Bucci Phone: 858-204-6787 Fax: 858-748-6984

MI-TECH, INC.

6685 Jet Park Drive N. Charleston, SC 29406 POC: Bobby Mimms Office: 843-553-2743 Fax: 843-553-5541