SOW_SSTG_Turbine_Repairs.doc

USS FRANK CABLE

(AS-40)

MACHINERY, AUXILIARY

N32205-19-R-XXXX

4 JANUARY 2019

WORK ITEM NO. 501 CATEGORY "A"

MSC N754/BARTON/DLB

#2 SSTG TURBINE REPAIRS (ABS) (VR 17-204)

1.0 ABSTRACT:

1.1 This item describes the requirement to reassemble the Steam Turbine and Reduction Gear for the #2 Ship Service Turbine Generator (SSTG) for ABS Special Survey.

2.0

REFERENCES/ENCLOSURES:

2.1 Technical Manual 0961-LP-071-7014, 2,500 AC Ship Service Turbine Generator 2.2 TurboGen Service Report #2 SSTG Turbine & Reduction Gear Repairs (Dated 7 Jan 2018)

2.3 NAVSEA Drawing AS40-845-7362894 (AS-40 NUCLEAR/NON-NUCLEAR INTERFACE BOOKLET – FOUO) 3.0

ITEM LOCATION/DESCRIPTION/QUANTITY:

3.1 Location:

ENGINE ROOM 7-110-0-E

3.2 Description/Quantity:

3.2.1 SSTG Turbine (1 ea.):

Mfr: DeLaval

Type: GJ Serial #: 654270

Speed: 8929 RPM Steam Pressure: 570 PSIG

Steam Temperature: 850 Deg F.

Exhaust Pressure: 4 HgA Overspeed Trip Speed: 9,825-10,000 RPM Nr Turbine Rotor Wheels: 8 Rows Bearing Span: 51-1/4” Rotor Dimension: Approx 26” Dia. x 72” L Rotor Weight: 1,003 lbs Turbine Upper Case with Diaphragms Weight: 2,245 lbs 3.2.2 SSTG Reduction Gear Set (1 ea.):

Mfr: DeLaval

Size: KD Special

Serial #: 654271

Type: Single Reduction, Speed Ratio 7.44:1

Gear Case Upper Half Weight: 750 lbs.

4.0 GOVERRNMENT FURNISHED MATERIAL/SERVICES:

4.1 Government furnished Material:

4.1.1 SSTG Turbine Assembly, Delaval Dwg H-5107, Serial #’s 654270

PIECE#

QTY

DESCRIPTION

PART #

OIL GUARD

GJ-588V U/L

BEARING ASSEMBLY

DWG C-62434

PHILLY GEAR #395-0150

OIL GUARD

GJ-4288B

FLEX GASKET

A-9914

TIGHTENING RING

GJ-141ARX1

TIGHTENING RING

GJ-141ARX2

TIGHTENING RING

GJ-141APX2

SPRING

VSGJ235

BEARING ASSEMBLY

DWG C-62436

PHILLY GEAR #395-0509

OIL GUARD

LJ-588A U/L

THRUST BEARING ASSY

PM-1067F

KINGSBURY 5” JHJ WITH OIL CONTROL RING #4466

SHIM

GJ-298L U/L

BUSHING

RGR-215K

CAPSCREW 60, 55-5-86

1/2”-13-1

TYPE VI COR RES STL

TIGHTENING RING

GJ-141ADX1

COLLAR

MS-555B

OIL GUARD

GJ-201D U/L

LABRYINTH RING

GJ-4241E

GUARD

GJ-588CP

4.1.2 SSTG Turbine Rotor Assembly, PT # 2080B, Dwg E-27816

Parts for Overspeed Trip Unit

PIECE#

QTY

DESCRIPTION

PART #

EMERGENCY RING

M-250C

PIN

M-774DV

SPRING

M-258MT

PLUG

M-170CH

BUSHING

M-215JK

PIN

M-774DH

SLIPPER

M-586GF

RING

M-201A

PINION

GJ-416 H

4.1.3 SSTG Turbine Nozzle & Operating Gear Assy, Dwg F-5795

PIECE#

QTY

DESCRIPTION

PART #

1” VALVE SEAT

KJ-62BN

1” VALVE

KJ-225SX8

NUT

KJ-402A

25/32” VALVE SEAT

KJ-62BM

25/32 VALVE

KJ-225PX7

WASHER

PD-586

SPACER

NJ-297A

NUT

KJ-402LX1

BUSHING

NC-215 CT

SPINDLE

M-159V

BUSHING

NC-215CTX1

FORK

M-1841AW

SELF ALIGN BUSHING

AB10-9L

FORK

M-1841AWX1

SPRING

DC-235B

BUSHING

GJ-215

4.1.4 SSTG Turbine Lube Oil Pump Drive & Tach Drive Assy, Dwg E-26298

PIECE#

QTY

DESCRIPTION

PART #

BEARING

H-4268

OIL GUARD

GJ-588M U/L

SHIM

GJ-298E

SPACER

GJ-18386

RETAINING RING

COMMERCIAL INTRUARC

N6000-650

BALL BEARING

5209X1A

BUSHING

HD-215P

CHECK NUT

RD-402KX1

SHIM

GJ-298E

BEARING

M-263S

4.1.5 SSTG Turbine Oil Sight Flow Assy, Dwg C-60801

PIECE#

QTY

DESCRIPTION

PART #

GASKET

MS-327

OIL GUARD

RGR-686B

WASHER 1½” ID X 1-13/16”

OD X 0.014” THK, MIL-S-16782

BUSHING

RGR-215K

4.1.6 SSTG Turbine Hydraulic Trip Assy, Dwg P-58985

PIECE#

QTY

DESCRIPTION

PART #

SPRING

C 600-063-1000M

BALL BUSHING

A-61064

OILLITE BEARING

AA-521-1

0-RING

11-012

SPRING

C 240-042-0810M

BEARING BALL ONLY

.25” DIA

4.1.7 SSTG Turbine High Exhaust Pressure Trip Valve, Dwg D-56476

PIECE#

QTY

DESCRIPTION

PART #

BUSHING

MV-215IV

SPRING

M-258NB

BELLOWS

M-738AD

O-RING

7446-70X11-012

4.1.8 SSTG Turbine Trip Throttle Valve, Gimble Machine Dwg S-22 (Page 300)

PIECE#

QTY

DESCRIPTION

PART #

GASKET SPIRAL WOUND

NK-756-1

STUD, STEEL A193 B16

NL-590-4

¾”-10NC X 3½”

NUT, STEEL A193-GR4

¾” 10-NC2

4.1.9 SSTG Turbine Y-Type Steam Strainer, Dwg NP-294 (Page 302)

PIECE#

QTY

DESCRIPTION

PART #

GASKET SPIRAL WOUND

NK-190-1

STUD, STEEL A193-B16

NL 1101-4

NUT, STEEL A194-GR4

NP-294-7

4.1.10 SSTG Turbine Atmospheric Relief Valve, Gimble Machine Dwg S-895(Page 305)

PIECE#

QTY

DESCRIPTION

PART #

STEM BUSHING

NL-540-1

SPRING

NK-738-1

4.1.11 SSTG Turbine Steam Seal Manifold, Gimble Machine Dwg S-920 (Page 308)

PIECE#

QTY

DESCRIPTION

PART #

THREADED BUSHING

S-203-9

GLAND NUT

S-203-11

GLAND

S203-23

BUSHING

S-203-25

VALVE STEM

S-203-10

GASKET INCONEL

S-203-7

YOKE

S-203-12

VALVE STEM

S-203-20

GASKET INCONEL

S-203-35

VALVE STEM

NL-333-1

4.1.12 SSTG Turbine High Speed Coupling, Dwg HR-2764

PIECE#

QTY

DESCRIPTION

PART #

HS COUPLING SPOOL

MR440GGX1

HS COUPLING HUBS

MR4441BX4

HS COUPLING RETAINER RING 321112

4.1.13 SSTG Turbine Attached Lube Oil Pump, Type 3DDX-250 Dwg SF-5325

PIECE#

QTY

DESCRIPTION

PART #

O-RING (BUNA)

023-1

O-RING (BUNA)

023-2

4.1.14 SSTG Turbine Rotor Rotor, Guide Blade Ring and Diaphragms

PIECE#

QTY

DESCRIPTION

PART #

1 1

TURBINE ROTOR ASSEMBLY

GJ2080B

2 1

GUIDE BLADE RING

GJ25BGX1

3 1

TURBINE DIAPHRAGM

GJ52GP

4 1

TURBINE DIAPHRAGM

GJ52GR

5 1

TURBINE DIAPHRAGM

GJ52GS

6 1

TURBINE DIAPHRAGM

GJ52GT

7 1

TURBINE DIAPHRAGM

GJ52GV

8 1

TURBINE DIAPHRAGM

GJ52GW

5.0 NOTES:

5.1 The contractor and all subcontractors, regardless of tier, must consult the General Technical Requirements to determine applicability to this Work Item. In performance of this Work Item, the contractor and all subcontractors, regardless of tier, must comply with the requirements of all applicable GTR’s, including but not limited to, GTR’s 1 through 7, 22, 23, and 29.

5.2 The contractor and all subcontractors, regardless of tier, are advised to review all other Work Items under this contract to determine their effect on the work required under this Work Item. Many of the definitions relating to the performance of this Work Item are found in Work Item 001.

5.3 THE CONTRACTOR AND ALL SUBCONTRACTORS SHALL CONTACT THE RADIOLOGICAL CONTROLS OFFICER (RCO) OR HIS DESIGNATED REPRESENTATIVE PRIOR TO PERFORMING ANY REPAIRS IN NAVSEA 08 AREAS OF CONCERN AS OUTLINED IN REFERENCE 2.3. THE RADIOLOGICAL CONTROLS OFFICER (RCO) WILL DETERMINE IF THERE ARE SPECIAL REQUIREMENTS ASSOCIATED WITH THIS REPAIR BASED ON ITS LOCATION AND WORK REQUIRED. THE RADIOLOGICAL CONTROL OFFICER (RCO) SHALL ENSURE ALL RADIOLOGICAL REQUIREMENTS AND PRECAUTIONS OF NAVSEA 0989-058-8000 FIGURE 1A-24 OR 1B-24 (AS APPLICABLE) ARE MET.

5.4 The Rotor, Diaphgrams and Guide Ring have been previously removed from the #2 SSTG Steam Turbine.

5.5 The Guide Blade Ring and Diaphragms provided in Paragraph 4.1.14 were manufactured with an oversize OD and will require machining to fit the existing Lands in the turbine casing prior to installation.

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 ABS Regulatory Body rules and regulations.

7.0 STATEMENT OF WORK:

7.1 Arrangement/Outfitting:

7.1.1 Remove all interference items necessary to accomplish the requirements of this Work Item. Mark, protect and properly store all interference items removed. Reinstall interference items and prove them operational when the requirements of this Work Item are complete.

7.1.2 Provide and erect all scaffolding or mechanical staging required to accomplish all requirements of this Work Item. Ensure compliance with all safety standards. Remove the scaffolding or mechanical staging when all requirements of this Work Item are complete.

7.1.3 Provide and maintain temporary lighting and ventilation required to accomplish all requirements of this Work Item. Remove the temporary lighting and ventilation when all requirements of this Work Item are complete.

7.1.4 Remove insulation / lagging required to accomplish the requirements of this Work Item. Upon completion of all repairs, install new insulation / lagging to replace that removed to accomplish the requirements of this Work Item.

7.2 Mechanical:

7.2.1 Prior to disassembly of the #2 SSTG Turbine, accomplish an inventory of the loose parts and items provided in 4.1 in the presence of the MSCREP. Determine that all parts required to reassemble the #2 SSTG are available.

7.2.2.

Submit a typed written report to the MSCREP listing the results of the inventory accomplished in 7.2.1. The report shall provide the “As Found” conditions for all of the parts and identify any items that are missing and required to complete the reassembly of the #2 SSTG Turbine.

7.2.3 Disassemble the #2 SSTG Turbine to the extent necessary to install the Rotor, Guide Blade Ring and Diaphgrams and accomplish the 5 Year ABS Inspection using Reference 2.1 for guidance.

7.2.4 Clean and inspect all Bearings and High Speed Coupling for the #2 SSTG Turbine using Reference 2.1 for guidance.

7.2.4.1 Fit the coupling hubs Provided in 4.1.12 to the corresponding hub on the Trubine Rotor and Reduction Gear. Ream the holes to provide required diameter to fabricate new fitted Coupling Bolts. Take and record measurements required to fabricate new fitted bolts for each coupling hub. Match mark each coupling hub to identify the orientation of each matched set.

7.2.5 Take all clearance measurements required to accomplish the 5 Year ABS Inspection of the #2 SSTG Turbine to include the Rotor, all Bearings and High Speed Coupling using Reference 2.1 for guidance.

7.2.5.1 Take and record the measurements of each Land for the Guide Blade Ring and Diaphragms in the turbine casing. This information is required to accomplish final machining of the Guide Blade Ring and Diaphragms prior to installation. The Guide Blade Ring and Diaphragms provided in Paragraph 4.1.14 were manufactured with an oversize OD and will require machining to fit the existing Lands in the turbine casing prior to installation.

7.2.6 Accomplish all NDT Testing required to accomplish the 5 year ABS Inspection of the #2 SSTG Turbine using Reference 2.1 for guidance.

7.2.7 Accomplish a visual inspection of the #2 SSTG Turbine in the presence of the MSCREP and ABS Surveyor.

7.2.8 When directed by the MSCREP reassemble the #2 SSTG Turbine using using material provided as GFM in 4.1, new gaskets and hardware in accordance with Reference 2.1.

7.2.8.1 Machine the Guide Blade Ring and each Diaphragm provided in 4.1.14 to fit the existing lands in the turbine casing using the measurements taken in 7.2.5.1 and Reference 2.1 for guidance.

7.2.8.2 Fabricate and install new fitted bolts and nuts for each coupling hub using the measurements taken in 7.2.4.1 and Reference 2.1 for guidance.

7.2.9 Accomplish a Hot Oil Flush of the #2 SSTG Turbine, Reduction Gear and Generator Lube oil system by temporarly connecting a contractor furnisted hot oil flush rig to the lube oil sump suction and discharge to the Turbine, Reduction Gear and Generator Lube Oil piping system. Contractor shall provide and install bearing jumper hoses, sump flanges with hose fittings, clean lube oil rig, heater and ten micron filter, (Muslin) bags.

7.2.9.1 Perform a hot lube oil flush at 160-170 degree F temperature until a clean muslin bag is obtained (zero metallic particles) to the satisfaction of the MSCREP and Cheng. Upon completion of flush install sump cover and lube oil piping to restore operational configuration.

7.2.9.2 Prove all new and disturbed joints leak free during initial operation. After 24 hours of turbine operation tighten and torque all casing bolts.

7.2.10 Disasseble, clean and inspect the Nozzle Control Valves for the #2 SSTG Turbine in the presence of the MSCREP and ABS Surveyor using Reference 2.1 for guidance.

7.2.10.1 Accomplish an NDT inspection of the Nozzle Control Valves using Reference 2.1 for guidance.

7.2.10.2 Submit a typed written report to the MSCREP listing the results of the inspections accomplished in 7.2.10.1. The report shall provide the “As Found” conditions for the Nozzle Control Valves and any recommendations for repair.

7.2.10.3 When directed by the MSCREP reassemble the Nozzle Control Valves using new gaskets and hardware in accordance with Reference 2.1.

7.2.11 Upon completion of the 5 Year Inspection of the #2 SSTG Turbine and Reduction Gear and Nozzle Control Valves, when directed by the MSCREP reinstall the insulation and lagging removed in 7.1.4.

7.2.12 Submit a typed written report to the MSCREP providing the “As Found” and “As Released” condition for the #2 SSTG Turbine, Reduction Gear and Nozzle Control Valves(with photographs) recording all conditions, repairs, NDT’s, balancing, alignments, clearances, post repair test results and any recommendations for future repairs.

7.3 Inspection / Test:

7.3.1 Accomplish an operational test of the #2 SSTG Turbine and Reduction Gear during Dock Trial and Sea Trials to the satisfaction of the MSCREP and ABS Surveyor using Reference 2.1 for guidance.

7.4 Paint:

7.4.1 Accomplish surface preparation, prime and paint all new and disturbed surfaces in way of the requirements of this work item to match surrounding areas.

7.5 Manufactures Representative:

7.5.1 Provide the services of an OEM Recogonized Repair Facility to accomplish repairs to to the #2 SSTG Turbine listed in 3.2. ALL WORK TO THE TURBINE AND REDUCTION GEAR IS TO BE ACCOMPLISHED BY A RECOGONIZED REPAIR FACILITY. The following are Recogonized Repair Facilities for the requirements of this work item:

Cutriss-Wright

1101 Cavalier Blvd

Chesapeake, Virginia 23323

POC: Bryan Murphy

Phone: (757) 592-0973

E-mail: bryan.murphy@siemensgovt.com

MI-Tech Inc.

6685 Jet Park Road

North Charleston, SC 29406

POC: Bill Totten

Phone: (843) 553-2743

E-mail: bill@mi-tech.net

PJ Schwalbenberg & Associates Inc

26 Spear Mill Road

Cushing, Maine 04563

POC: Pete Schwalbenberg

Phone: (207) 354-0700

E-mail: office@turbinesandgears.com

8.0 GENERAL REQUIREMENTS: NONE

501-9