DraftSpecification_forFBO.doc

Specification for

Turbine Driven Main Feed Pumps (MFP)

1.0 BACKGROUND

Existing Main Feed Pumps are antiquated designs that are becoming obsolete. The Main Feed Pumps are critical equipment as they provide feed water to the main propulsion boilers. When repair parts cannot be acquired due to obsolescence, the pumps are rendered out of commission and jeopardize the ship's mission capabilities.

1.1 SCOPE OF WORK

The Main Feed Pump (MFP) unit will be driven by a steam turbine on a common solid shaft (no couplings). Pumps shall be horizontally mounted. This specification provides the requirements for the Turbine Driven Main Feed Pump. The Main Feed Pump (MFP) unit shall be designed for the purpose of providing feed water to the main propulsion boilers with the following requirements:

REQUIREMENT - MFP Performance Requirements:

· Approx. boiler 100% maximum sustained steam production rate of 350K lbs/hr = 730 gal/min.

· Pump must be sized to provide 730 gpm of useable flow @ 850 psig discharge. NPSHR must not exceed 45 Feet.

· Operating Conditions (these flows do not account for required recirculation rates):

· Min power = Steam Inlet Pressure 700 psig @ 570 Deg F, flow Rate ~ 15.0 gal/min

· Normal Cruise = Steam Inlet Pressure 656 psig @ 645 Deg F, Feed flow Rate ~ 250 gal/min

· Normal Max Power (routine) = Steam Inlet Pressure 560 psig @ 662 Deg F, Feedflow rate 730 gal/min

· Steam Exhaust Pressure = Ranges from 15-25 psig, Design for this pressure range at all power rates

· The pump must be able to operate continuously with a discharge pressure of 300 - 400 psig (standby mode).

· In standby mode the pump will only discharge flow based on the capability of the recirculation orifice sizing.

· There must be no concern about mechanical seal overheating or insufficient recirculation flow during standby mode of operation.

· MFP unit must have instantaneous start-up capability with no warm-up and with no limitation on steam flow rate increase during acceleration from stop to maximum power. This would be considered a rapid acceleration to maximum power not to exceed two (2) seconds.

1.1 Technical Data Package

The Contractor shall use this Specification to produce the required First Article and all other production units. The contractor shall be responsible for the engineering, development, testing, and qualification for one (1) First Article Test (FAT) unit and all documentation and special tools as outlined in the Specification. The first unit will be examined and refurbished as needed and provided to the Navy as the designated test unit.

1.2 First Article Testing

The first Main Feed Pump unit will be fabricated for First Article Testing and fully pass shock and vibration requirements. All testing will encompass pre-assembly inspection, performance testing, Shock test, vibration test, post shock test performance testing, post shock test and inspection. MFP Performance testing shall provide the full range of pump performance including:

- Capacity (GPM)

- Total Head (PSIG)

- NPSHR

- Water Temperature

- Steam inlet Pressure

- Steam inlet Temperature

- Steam Bowl Pressure

- Steam flow (lbs/hr)

- Exhaust Pressure

- Exhaust Temperature

- Sump oil Temperature

- Bearing temperature/rise

- Shaft Speed

- Lube Oil Pressure

- Lube Oil Cooler inlet & outlet temperature

- Mechanical Seal flushing water inlet & outlet temperature

- Mechanical Seal seawater cooling pressure

- Mechanical Seal seawater inlet & outlet temperature

All test procedures must be approved prior to testing. All testing shall be witnessed, by the Naval Surface Warfare Center Philadelphia.

1.3 General Design. The design and construction of the MFP unit shall be in accordance with the space and weight requirements as specified. The pump unit shall perform under the list, pitch, roll, and trim conditions. Pumps shall operate continuously at any point within the entire flow range and design conditions as specified.

1.4 Reliability. The requirements of the Specifications are imposed exclusively to obtain equipment of utmost reliability for the service intended. The assurance of maximum reliability shall be the paramount controlling principle in the design, fabrication, assembly, and testing of this equipment. Users of and Contractors to this Specification are urged to communicate, any findings related to the requirements or lack of requirements of this Specification whereby improvement of equipment reliability can be achieved.

1.5 Maintainability. The equipment specified herein shall be operated, maintained, and repaired on board Navy ships. Attention is directed to the high equipment density of shipboard machinery spaces, to the fact that maintenance and repair will be made underway in heavy seas, which equipment will operate unattended, and that maintenance personnel may not be seasoned mechanics. The requirements for maximum reliability directly relate to those shipboard environmental and service conditions and those requirements shall be fully considered in the pump design and selection. The aspects of “human engineering” shall also be fully explored and considered in the equipment design to minimize the possibility of failure through improper operation and maintenance and to preclude personnel safety hazards. These are all critical in the design selection criteria. Vendor will provide a maintenance demonstration plan. This maintenance demonstration (a.k.a. demo) must be provided to NSWCDPD on an actual MFP unit at the vendor's facility. This demo can be accomplished during the shock tear down and inspection and refurbishment which will incorporate a complete disassembly and assembly of the MFP unit. In the process of the demo all special tools must be utilized and/or demonstrated, as many as practical. The maintenance demo will provide the needed training to NSWCPD to attain the necessary knowledge and competence for maintaining and/or repairing MFP units’ onboard Navy ships.

1.6 Maintenance. The equipment shall have maximum repair accessibility for ease of examination of wearing parts and for simplicity of disassembly and proper reassembly.

1.7 Service Life. The amount of measured wear and deterioration of the expected wear parts upon completion of the 500 hour endurance test shall be interpolated to show the wear is not excessive and is commensurate with the expected wear after 10,000 hours of operation. All non-wear parts inside and out of the Main Feed Pump should show zero wear or deterioration after the completion of the 500 hour endurance test. In addition, offerers shall demonstrate based off of past history and experience of MFP as they relate to Navy shipboard applications that these conditions have been met and/or exceeded.

1.8 Production

The Contractor shall begin design and development of the First Article MFP unit. This unit will be used to qualify the design of the FAT unit. Once First Article Testing has been completed, and test reports accepted and approved by the Contracting Agency, the Contractor shall correct any manufacturing or parts defects exposed during First Article Testing on the FA unit.

1.8.1 Critical Manufacturing Points (CMP)

Naval Surface Warfare Center (NSWC) or a NSWC designated agent will review and inspect ongoing design and manufacturing efforts at the critical points listed below during manufacturing of the First Article unit as well as at any time during manufacture of any future production MFP units.

Critical Manufacturing Points (CMP) are defined as:

a. At a point during the initial development of the design process.

b. At a point where design is in the final development and initial list of components and materials of construction has been developed.

c. At a point where detailed drawing development for the FAT MFP unit is approximately 50 percent complete and majority of components have been selected.

d. At a point where the detailed drawing development for the MPF unit is 100 percent complete, all the components have been selected, and prior to actual start of fabrication. Detailed drawings shall be provided to the Navy as part of this contract.

e. After unit fabrication is 75 percent complete.

f. After final assembly.

g. At the start of each of the first article tests.

h.

At the half way point of the 500 hour endurance test.

i. At the final unit inspection follows completion of shock testing and vibration testing.

j. At the start of final first article unit conformance/acceptance testing prior to unit delivery.

The Contractor shall notify NSWC one week prior to reaching the above CMPs. Notification will be provided to NSWC via a conference agenda and conference minutes. Contractor shall provide project planning chart no more than 30 days following contract award.

2.0 APPLICABLE DOCUMENTS

2.1 General

The following documents shall form a part of this specification to the extent specified herein. The latest revision may not be listed herein. Please refer to the links listed for the latest revision.

2.2 Government Documents

2.2.1 Specifications, Standards, and Handbooks

The following specifications, standards, and handbooks form a part of this specification to the extent specified herein. (Copies of these documents are available online at http://dodssp.daps.dla.mil/, http://assist.daps.dla.mil, http://assist.daps.dla.mil/quicksearch/, IHS Engineering, Englewood, CO, http://www.ihs.com, or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other Government Documents, Drawings, and Publications

The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Military publications can be obtained from:

Defense Logistics Agency

Document Automation and Production Service

DAPS Headquarters 5450 Carlisle Pike Bldg. 09 PO Box 2020 Mechanicsburg, PA 17055-0788 Call toll free 1-877-DAPS-CAN https://tmpods-b.daps.dla.mil or http://nll.ahf.nmci.navy.mil.)

The Department of Defense Single Stock Point for Military Specifications, Standards, and Related Publications http://www.dodssp.daps.mil/ or

IHS Engineering

Englewood, CO http://www.ihs.com

PUBLICATIONS

NAVAL SEA SYSTEMS COMMAND (NAVSEA)

S9074-AR-GIB-010/278 - Requirements for Fabrication Welding and Inspection and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels

S9074-AQ-GIB-010/248 - Welding and Brazing Procedure and Performance Qualification

T9074-AS-GIB-010/271 - Requirements for Non-Destructive Testing Methods

0900-LP-001-7000 with Change 1 dated January 1981 - Fabrication and Inspection of Brazed Piping Systems

DRAWINGS

NAVAL SEA SYSTEMS COMMAND (NAVSEA)

NAVSEA Drawing 803-1385850J - Piping, Instrument Pressure for all Service

NAVSEA Drawing 803-1385884 - Unions, Fittings and Adapters, Butt and Socket Welding, 6000 PSI WOG NPS

2.3 Non-Government Publications

The following documents form a part of this specification to the extent specified herein. These publications must be procured from the applicable standards organization.

ASQ/ANSI/ISO 9001:2015 - Quality Management Systems-Requirements

(Copy of this document may be purchased from the American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203. http://www.asq.org)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B16.5 - Pipe Flanges and Flanged Fittings

ASME Boiler and Pressure Vessel Code, Section VIII Division I - Pressure Vessels

B31.1 - Power Piping

Y14.1 - Decimal Inch Drawing Sheet size and Format

Y14.2 - Line Convention and Lettering

Y14.3 - Multiview and Sectional Drawings

Y14.5 - Dimensioning and Tolerancing

(Copies of these documents are available from ASME International, 22 Law Drive, PO Box 2900, Fairfield, NJ 07007-2900 or online at www.asme.org.)

AMERICAN SOCIETY FOR TESTING MATERIALS (ASTM)

A354 - Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

A380/A380M - Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment and Systems

A563 - Standard Specification for Carbon and Alloy Steel Nuts

A967/A967M - Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts

F467 - Standard Specification for Non-Ferrous Nuts for General Use

F468 - Standard Specification for Non-Ferrous Bolts, Hex Cap Screws, and Studs for General Use

F593 REV A - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

F594 - Standard Specification for Stainless Steel Nuts

F992 - Specification for Valve Label Plates

F998 - Standard Specification for Centrifugal Pump, Shipboard Use

F1166 - Human Engineering Design for Marine Systems, Equipment, and Facilities

F1508 - Specification for Angle Style, Pressure Relief Valves for Steam, Gas, and Liquid Use

(Copies of these documents are available from ASTM International, 100 Barr Harbor Dr., PO Box C700, West Conshohocken, PA 19428-2959 or online at www.astm.org.)

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS

IEEE 45 dated 11 October 2002 - Recommended Practice for Electric Installations on Shipboard

IEEE 315A dated 31 October 1975 - Graphic Symbols for Electrical and Electronics Diagrams

(Copies of these documents are available from IEEE 445 Hoes Lane Piscataway, New Jersey 08854-1331, or online at www.ieee.org.)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

MG 1 - Motors and Generators

(Copies of these documents are available from National Electrical Manufacturers Association 1300 North 17th Street, Suite 1752, Rosslyn, Virginia 22209, or online at www.nema.org.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

J1453-1 - Specification for O-ring Face Seal Connectors

J1926-1 - Connections for General Use and Fluid Power—Ports and Stud Ends with ASME B1.1 Threads and O-Ring Sealing

(Copies of these documents are available from SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001 or online at www.sae.org.)

HYDRAULIC INSTITUTE

American National Standard for Centrifugal Pumps (ANSI/HI 1.1 – 1.4 and 14.6) (Copies of these documents are available from the Hydraulic Institute, PO box 34289, Newark NJ 07189-0289 online at www.pumps.org.)

MANUFACTURER’S STANDARDIZATION SOCIETY OF THE VALVE AND FITTING

INDUSTRY

MSS SP-119 - Bell End Socket Welding Fittings, Stainless Steel and Copper Nickel

(Application for copies should be addressed to the Manufacturers

Standardization Society, 127 Park Street, NE, Vienna, VA 22180-4602)

2.4 Order of Precedence

In the event of a conflict between the text of this specification and the references cited herein (except for related associated specifications or specification sheets) the text of this specification takes precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0. REQUIREMENTS

3.1 Characteristics

The Main Feed pump (MFP) unit shall be designed for the purpose of providing feed water to the main propulsion boilers and must be fully designed to perform as described in Paragraph 1.0. Feedwater, seawater, and steam connection interfaces.

3.1.1 MFP envelope dimensions and weight - The MFP envelope dimension shall not exceed 62" length x 44" width x 49" Height, all of which shall include the base plate and all components. Both these weights and envelope dimensions will provide for maximum space savings.

3.1.2 MFP shaft - Both the pump and turbine shall have one solid common shaft with no couplings. The Main Feed Pump Turbine wheel shall be on one side of the shaft and the pump assembly on the other end of the shaft. The shaft shall be able to be removed from the turbine end with a minimum space of 55" from the turbine end of the MFP to facilitate maintenance and repairs.

3.1.3 MFP Turbine - The turbine shall be a single stage, impulse, (2) two bucket row, velocity compounded, axial flow type.

3.1.4 MFP Pump unit - The pump assembly will contain the impeller, shaft sleeves, impeller nut, diffusers, wear rings, and inboard and outboard mechanical seals. The pump will be high speed, single stage, centrifugal, diffuser type. Impeller shall be double suction type. Pump suction flange shall be on the top of the MFP unit and the discharge flange will be on the left side of the MFP unit looking at the unit from the pump end . The discharge must have a pump recirculation line with orifice device.

3.1.5 Vents and Drains - Vents and drains shall be installed to facilitate complete draining of pump volute for maintenance. The pump access cover shall have a vent and drain to sufficiently drain pump to enable access cover to be removed. Vents and drains will also be installed on the MFP unit to enable thoroughly draining of all components of all feedwater, seawater, steam condensate, and lube oil. These drains and vents will be flanged to facilitate connections with shipboard piping interfaces come time for installation of the MFP.

3.1.6 Mechanical Seals - Both inboard and outboard Mechanical seals will have flush lines. The flush lines will be supplied from feedwater supplied off of the MFP discharge. The flushing water will be cooled by a cooler which uses seawater as the primary coolant. Each mechanical seal will have its own individual tell-tale drain and vent piping. Drain piping is essential for detection of seal face leaks.

3.1.7 Bearings - The MFP shaft shall be supported by two main type bearings and one thrust type bearing. Suitable bearings shall be installed in each pump unit for counteracting (a) any unbalanced hydraulic or mechanical thrust in either direction and (b) the fact that rolling, pitching, listing, and trim, and the athwart ships, fore and aft, and the vertical distance from the pump to the ship’s rolling and pitching center may introduce loads even though the unit is in hydraulic balance. The Contractor shall calculate the resulting static and dynamic loads on the bearings and determine that the bearings are suitable for this loading. Oil lubricated bearings shall be separate from and independent of the pump stuffing boxes and adequately protected from gland/seal leakage. Means shall be provided to prevent the escape of oil around the shaft. Bearing housings shall have adequate sealing so that regardless of the length of time the unit is idle, the bearings will have an adequate supply of oil.

3.1.8 Gear box -The MFP shaft will pass through a main gear box which will be central to the MFP unit. The gear box being the central MFP unit component will be mounted on the main foundation plate. The pump and the turbine ends will be attached to the main gear box and will not have foundations but may have supports if needed to meet the requirements of shock and vibration.

3.1.9 Attached lube oil pump - The main bearings will be lubricated by oil by means of an attached pump that is driven by gears off of the MFP shaft. This same attached pump will also lubricate the main gear box and the attached pump gears. The attached pump will be geared down to a fraction of the main shaft speed. This pump will provide lubrication to the bearings and other intended components immediately as the MFP shaft begins to turn.

3.1.10 Sight Glass indicators - Sight glass indicators will be provided for each component that is lubricated so that steady oil flow can be visually verified.

3.1.11 Electric Pre-lubrication pump - There will be an electric motor driven lube oil pump that will pre-lubricate the bearings and other components before the start-up of the MFP, and until the MFP comes up to speed and lube oil pressure is satisfactory for the attached pump to take over. This electric pump shall have a 110volt, 1 phase motor.

Electric motors shall meet the requirements, and shall have the following characteristics:

a. NEMA Design B

b. Class F Insulation

c. 50 degrees C, ambient

d. Continuous duty

e. TEFC, severe duty

f. Airborne noise 80 dbA

g. Bearing temperature rise 40C measured on the bearing outer ring The horsepower (hp) rating of each motor shall be in accordance with the motor ratings, but not less than 1.05 times the brake horsepower of the driven pump under rated conditions of capacity and pressure.

3.1.12 Oil pressure regulator -A pressure regulator shall be installed to allow for a constant oil pressure of approximately 40 PSI.

3.1.13 Oil Sump - Central to the MFP unit, and containing the bearings and gears, shall be an oil sump. This oil sump shall have a capacity of no less than 6 U.S. gallons. Both the attached pump and electric prelube pump will draw from the same sump. Lube oil shall return to the oil sump by gravity feed. Lube oil in the sump shall be maintained between 122 degree (F) and 158 degrees (F) using 2190-TEP lubricating oil. Oil shall have rust, oxidations, and foam inhibitors. An oil level stick shall be installed for manually checking sump oil levels. A drain connection with drain valve must be supplied to enable draining of lube oil in the sump. Sufficient room should be provided to enable sampling of lube oil from the drain valve. An access cover must be installed to enable manual cleaning of sump and for visual inspection of shaft, gears, and bearings.

3.1.14 Lube oil cooler - A two (2) pass, shell and tube heat exchanger with a shell made of Steel, and tubes and tube sheet made of 90-10 Copper-Nickel, will be integral to the MFP unit and will be used for cooling the lube oil. The lube oil cooler will use seawater as the primary coolant. Zinc anode plugs shall be provided to reduce/eliminate corrosion.

3.1.15 Oil filter - Lube oil will be kept clean via a replaceable filter element and will have inlet and outlet pressure and temp gages.

3.1.16 Lube oil pressure switch - A lube oil pressure switch with low and high pressure trips must be installed at the discharge of the MFP unit attached lube oil pump and before the check valve. This is needed for low pressure lube oil alarm and to stop the aux electric lube oil pump.

3.1.17 Lube oil check valves - Check valves will be installed on the outlet piping of each the Aux electric pump and the attached pump before the two lines come together to service the MFP unit.

3.1.18 Thermometers and pressure gages - There shall be a pressure gage before the lube oil filter and one after. A thermometer will be installed at the lube oil cooler outlet and one at the thrust bearing outlet. All pump and turbine inlet and outlet points shall have the appropriate connections for reading pressure and temperature. Temperature gages must be installed to read the main thrust bearing oil temperature returning to the sump. High temperature interface will be provided for remote reading lube oil high temperature at this same point.

3.1.19 Although the Contractor will be required to test the MFP with a throttling control valve, the MFP will not have a steam emission valve or governor as these components will be external to the MFP.

3.1.20 The vendor must fully performance test the MFP using 600# steam and meet all parameters detailed in this specification.

3.1.22 Automated controls interfaces for NSWC control systems.

The following information is being provided pertaining to the interfaces. In addition, the following requirements are required to interface the MFP with the automated controls (provided by NSWCPD Code 413):

Controls, Instrumentation, Indication, Alarms:

· Government shall provide steam pressure and flow control system equipment for feedpumps delivered in support of shipboard installation.

· Government shall provide throttle control valves, emergency shutdown valves, magnetic pickups, over-speed protection programmable logic controllers (PLC), and pump discharge pressure transmitters in support of shipboard installation.

· OEM shall provide temperature indication gauges as needed.

Magnetic Speed Pick Up (Hall Effect Sensor) – Functionality and Purpose:

· A provision for a magnetic pickup is required. Magnetic pickup will see pulses from a gear or flywheel as used to measure speed (or some ratio of rotor speed) and provide overspeed protection.

· Magnetic pickup female port shall be threaded for either 5/8”-18 UNF-2A or 3/4"-20 UNF-2A.

· At maximum rotor speed, frequency of gear-tooth used for speed feedback shall not exceed 10,000 pulses per second.

· Government shall provide a magnetic pick up and incorporate that with the PLC for overspeed protection.

Steam Throttle and Emergency Shutdown Valve Control:

· For shipboard installation, the steam throttling control valve and secondary shutdown valve shall be provided by Government.

· The steam turbine and pump combination unit shall be provided with no steam throttling, control, or over-speed protection.

These features and functions shall be provided by Government.

· The shutdown of the throttle valve and emergency shutdown valve shall be controlled by the Government. The magnetic pickup speed indication sent to a PLC will be one of several parameters that will determine if the pump needs to be shutdown.

Low Suction Shutdown:

· Low feedwater suction pressure switch shall secure the main feedpump via interface with the PLC which will shut the throttle and emergency shutdown valves based on this pressure switch opening on low pressure. OEM will provide the pressure switch.

· Government recommends use of ITT-Neodyne 100P41CC3S or equivalent shock and vibration approved switch.

Electric Lube Oil Pump Stop Pressure Switch:

· Low lube oil pressure switch provided by the OEM shall secure the main feedpump via interface with the PLC which will shut the throttle and emergency shutdown valves based on this pressure switch opening on low pressure.

· Government recommends use of ITT-Neodyne 100P41CC3S or equivalent shock and vibration approved switch.

Overload Nozzle:

· Pump turbine section shall be equipped with an overload nozzle to permit higher power operations via additional steam flow path to nozzles.

This approach allows controllable low power pump while operating at standby or low power operation.

3.1.23 Pressure connections must be provided on MFP unit for alarm/shut-down trips for Low suction pressure and Low lube oil pressure. The lube oil pressure connection point must be common to both the electric and attached pumps.

4.0 Materials:

4.1 The Pump end components shall be made from the following materials:

Diffuser and Cover

Stainless Steel

ASTM A240 type 304

Main Shaft

Alloy Steel

ASTM A193 GR. B7

Wear rings

Stainless Steel

ASTM A743 GR. CF-16F

Pump impeller

Stainless Steel

ASTM A743 GR. CF-8M

Pump Housing

Carbon steel

ASTM A216 GR. WCB

Pump Diaphragm

Stainless Steel

ASTM A743 GR. CA-15

Mechanical Seals

As Required

ASTM F 1511-07

Impeller Inlets

Stainless Steel

ASTM A747 GR.CB7CU-1

Seal sleeves

Stainless Steel

ASTM A276 Type 316

4.2 The Turbine end components shall be made from the following materials:

Turbine Diaphragms Carbon Steel

ASTM A217 GR. WC9

Turbine shaft gland

Bronze

ASTM B584

Turbine Rotor Sleeve Stainless Steel

ASTM A743 GR. CA-15

Turbine Wheel

Forging Alloy Steel ASTM A471 Class 11

Turbine Buckets

Stainless Steel

Type 403 SS

Turbine Stator Buckets Stainless Steel

Type 403 SS

Turbine Nozzle Ring Stainless Steel

ASTM A182 GR. F6A Class 2

Steam Chest Manifold Carbon Steel

ASTM A217 GR. WC9

Turbine Housing

Alloy Steel

ASTM A217 GR. WC9

Bearing Housing

Carbon Steel

ASTM A216 GR. WCB

4.3 Connections to interface with ship's piping:

Pump Discharge flange - 4 Inch, 600# ANSI B16.5

Pump Suction flange - 8 Inch. 150# ANSI B16.5

Turbine inlet flange - 2 Inch, 600# ANSI B16.5

Turbine exhaust flange - 8" 150# ANSI B16.5 Flat Face studded w/nuts

Turbine exhaust pressure - 1/2 Inch, 150# Flange

Turbine Gland leak-off flange - 1-1/4 Inch, 150# ANSI flange

Lube oil cooler seawater inlet and outlet - 1 Inch, 150#, Pump Recirculation - 1-1/2 Inch, 600# S.W.

Mechanical seal cooler seawater inlet and outlet - Navy 150# Flanges

Turbine drain - 1/2" NPT

Pump suction vent - 1/2 Inch, 150# flange

Pump suction drain - 1/2 Inch FNPT

Pump discharge vent - 1/2 Inch, 600# Flange

Pump discharge volute vent - 1/2 Inch, 600# flange

Pump discharge drain - 1/2 Inch, 600# flange

Mechanical Seal Flush connections - 1/2" FNPT

Base Plate drain - 1/2 Inch FNPT

Oil Sump drain valve - 3/4 Inch FNPT

Turbine end Studs/bolts - ASTM A193,Grade B7,(steam < 775 degrees F)

Turbine end nuts - ASTM A194, Grade 2H, (steam < 775 degrees F)

Turbine end Studs/bolts - ASTM A193, Grade B16 (Temps range 776 - 975 degrees F)

Turbine end Studs/bolts - ASTM A194, Grade 7, (Temps range 776 - 975 degrees F)

Pump end Studs/bolts - ASTM A193, Grade B7

Pump end nuts - ASTM A194, Grade 2H

4.4 Welding and Brazing

Welding and inspection of pressure vessels, castings and piping shall. There shall be no pockets, crevices, porosity, or notches, which could become points of stress concentrations. The use of backing strips in pressure vessels shall not be permitted. Vendor shall provide a welding procedure and a welding procedure qualification test report

4.5 Casting Inspection and Repair

Inspection and repair of castings shall meet the requirements of sections 12 and 13 of publication, NAVSEA S9074-AR-GIB-010/278. Requirements for nondestructive testing shall conform to publication, NAVSEA T9074-AS-GIB-010/271.

4.6 Frames and Bedplates

The frames and bedplates used to mount the MFP unit components shall not contain pockets where moisture can accumulate. Frame design shall provide access to all areas below the MFP unit for cleaning and routine painting.

4.7 Painting

MFP unit pump unit components shall be coated or painted in accordance with the following:

a. External nonmetallic and internal nonferrous (including resilient mounts cables and hoses) surfaces shall not be painted.

b. The total paint system shall last a minimum of 20 years without blistering, cracking, pealing, or flaking. Paint shall be selected in accordance with NSTM 631 preservation of ships, general.

4.8 Pump Balancing

All rotating components and assemblies in centrifugal type pumps shall be balanced. Clamped or glued weights are unacceptable.

4.9 Grounding

Grounding of equipment shall meet the requirements.

4.10 Technical Manuals

Enclosed with each delivered MFP Unit shall be technical manuals and operational documentation. Two bound hard copies and two electronic copies of the technical manuals and operational documentation shall be provided for each MFP system

4.11 Illustrations.

The manual shall contain illustrations to support the text. Illustrations shall be suitable for locating and identifying all components. Illustrations shall be prescreened, sharp, and with good contrast. Illustrations shall be line drawings or photographs. Line drawings are preferred over photographs. Illustrations shall not be free hand sketches.

4.12 Preparation for use.

The manual shall contain instructions for unpacking, assembling, and readying for operation.

4.13 Operation.

Operating instructions shall include the principles of operation; illustrations and explanation of the uses and functions of all controls and indicators; initial set up; initial settings; and start up, normal operation, calibration, shutdown, and emergency shutdown procedures.

4.14 Maintenance.

The manual shall include the manufacturer’s maintenance required for the MFP Unit and shall be delineated such that it can be applied by the intended Government user. The manual shall include planned and corrective maintenance and overhaul procedures with lists of required test equipment, special tools and materials. The nomenclature, part/model number and materials shall be included. Diagnostic tests and tests to ensure satisfactory performance shall be detailed.

4.15 Troubleshooting.

The manual shall include troubleshooting procedures for all possible failure modes. The procedures shall include a description of the trouble, a possible cause, and a remedy. The remedy shall either provide the corrective action or refer the user to the section in the manual, which provides the corrective action.

4.16 Parts list, illustrations and diagrams.

The manual shall include a parts list, which identifies all parts of the system. The parts list shall include the actual manufacturer or vendor name, the part number, and a generic description necessary to obtain replacement parts. Clear and legible illustrations shall identify all component parts and parts relationships. Electrical point to point wiring diagrams with wire numbers shall be provided. System diagrams shall be included as necessary

4.17 Provisioning Data

Provisioning data shall be provided for the first production MFP unit in the Contractor’s format. All lines, symbols, letters and numerals shall be readable and in accordance with industry standard.

4.18 Provisioning parts list

The provisioning parts list shall include piece part information on all user replaceable parts. CAGE and part number information shall be for the actual manufacturer of the complete finished part as used in the MFP unit. Data required for each item as follows:

a. Manufacturer’s CAGE

b. Manufacturer’s Part Number

c. Nomenclature

d. Unit Price

e. Remarks (mandatory change-out or other part information)

4.19 Supplementary provisioning technical documentation

Supplementary provisioning technical documentation shall be provided for each item on the provisioning parts list. Supplementary provisioning technical documentation is technical data used to describe parts of equipment. It consists of specifications, standards, drawings, photographs, sketches, descriptions, assembly and arrangement drawings, schematic diagrams, wiring and cabling diagrams needed to indicate the physical characteristic, actions and function of the item. Supplementary provisioning technical documentation shall be provided in the following order of precedence:

a. Government or recognized industry specifications or standards (identification only, copies are not required).

b. Commercial drawings.

c. Commercial catalogs or catalog description.

d. Sketches or photographs with brief descriptions of dimensional, material, mechanical, electrical, or other descriptive characteristics. When sketches or photographs are provided for an assembly, a parts list shall also be provided.

4.20 Drawings

Drawings shall be prepared in accordance with ASME Y14.1, Y14.2, Y14.3, and Y14.5 and all text written in the English language. All drawings shall be completely legible and suitable for reproduction as needed to support system maintenance and repair over the life of the system

4.21 Types of Drawings

The following types of drawings shall be prepared

4.21.1 Outline Drawing

An external arrangement drawing shall be prepared that shows all necessary external views of the MFP unit and shall include the center of gravity, weight (dry and operating), and all external dimensions required for reproduction of ship’s machinery arrangement drawings. These drawings shall provide guidance to the shipyard in designing the foundation structure for installing the unit. It shall show connection of the unit to the external piping including vents, and drains. The drawing shall show the space required for removing the MFP shaft and other components. All lifting lugs or eyebolts and their dimensional openings shall be shown on the drawing.

4.21.2 Assembly Drawing

A drawing showing completed longitudinal and transverse cross‑sectional views of the MFP unit shall be prepared that depicts the relationship of all parts and components. The Top Assembly drawing shall identify by correspondence number and date, the acceptance for Navy shock and vibration, testing, where applicable. Liberal use of enlarged views or sections shall be made. Subassembly drawings conforming to the above shall be furnished to aid in the clarity of individual components. The drawings shall be such that a thorough understanding of the design material selection and construction of the apparatus may be obtained without reference to related detailed drawings.

4.21.3 List of Materials

The assembly drawing shall contain a list of materials showing the names of parts with identifying numbers and materials of all parts. The identifying numbers shall also be shown adjacent to the part shown in the various views, with arrows pointing to the parts. Each item shall be easily located with a find number in a minimum of two views.

4.21.4 Detailed Drawings

Component arrangement and sectional drawings shall contain sufficient information that discloses a design approach suitable to support the manufacture of a production FAT and lists all of the component parts and material specifications. The drawings shall be completely dimensioned, with finishes and welding symbols indicated as required for manufacture.

4.21.5 Diagrammatic Drawings

The diagrammatic piping arrangement drawing (Process and Flow diagrams) shall show the complete piping required for operating the MFP unit. Piping furnished with the unit and piping furnished by the Contractor shall be clearly indicated. Location of gages, thermometers, valves, orifice plates, shall be indicated. The drawing shall also indicate pipe size, orifice size, flow rates, flow directions, set-points, pressure at the various points, minimum supply pressure, and all operating parameters at terminal points. The actual location of each instrument connection and component shall be the same as that on the assembly drawings. The symbols used shall be in accordance with ASTM F1000.

4.21.6 Wiring Drawings

Wiring assembly drawings showing terminal connections shall be provided for all electrical components furnished with the MFP unit.

4.21.7 Electrical Drawings

The electrical drawings shall consist of separate schematic (elementary) and connection (point-to-point wiring) diagrams to clarify the control functions and simplify the wiring.

4.21.8 Legends

Standard legends and symbols specified in ANSI 315A shall be used on all electrical drawings.

4.21.9 Purpose of Drawings

Sufficient drawings shall be prepared to:

a. Provide design information to ensure conformance to requirements of this specification, including compatibility with ship and ship systems.

b. Evaluate performance and maintenance capability.

c. Enable shipyard installation without Contractor’s assistance.

d. Enable naval ship and shore activities to repair and maintain the item without assistance from the original Contractor.

5.0 QUALITY ASSURANCE PROVISION

5.1 Responsibility for Inspection

Unless otherwise specified in the contract, the Contractor is responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract, the Contractor may use his own or any other facilities suitable for the performance of the inspection and compliance requirements specified herein. NSWC reserves the right to perform any of the inspections set forth in the contract where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. Any inspections performed by NSWC shall not relieve the Contractor of its responsibility for quality assurance and for providing MFP units, which conform to the contract requirements. Contractor shall provide any relevant status report to NSWC in a timeframe that will not delay testing or production.

5.1.1 Quality Program Requirements

The Contractor shall provide and maintain a quality system that, as a minimum, adheres to the requirements of ASQ/ANSI/ISO 9001:2015 and supplemental requirements imposed by the resultant contract. Conformance with these requirements shall not be construed as relieving the Contractor of final responsibility to furnish equipment and services meeting specification requirements. Utilization of a material review board requires the written approval of NSWC.

5.1.3 Classifications of Inspections

The inspection requirements specified herein are classified as follows:

a. First article inspection

b. Conformance inspection

6.0 First Article Inspection

First article inspection shall consist of examinations and tests specified within this specification (See Table I).

Table I - First Article Inspection

FAT examination/test

Requirement

Examination/test

Design characteristics

1.0, 1.2, 3.1, 9.0

3.1.21, 16.4.1

Envelope size

3.1.1

3.1.1

Maintenance access

3.1.2

3.1.2

Interface connections

4.0

4.3

Materials Pump/turbine

4.1, 4.2

Mechanical soundness

16.0

16.1, 16.2

Performance 100hr

16.4

16.4.1

Endurance test 500hr

16.7

16.11

Inclined test

17.7 - 17.3

17.7.1

Shock test

17.0

17.4, 17.5

Vibration test

17.9

17.9

Hydrostatic test

15.1.1 - 15.1.6

15.1.1 - 15.1.6

Balancing Rotor assembly 11.0, 12.0 11.0, 12.0

Over-speed test

15.1.2

15.1.2

Welding/brazing

4.4

4.5, 16.3

Note: Procedures contained in the Specification requirements paragraphs listed in Table I.

6.1 Conformance Inspection

Conformance inspection shall be performed on all MFP units prior to delivery and shall consist of applicable examinations and tests specified in Table II. All components of the MFP will be visually inspected to verify that they are installed and each one checked for any signs of defects.

Table II - Conformance Inspection

Examination or test

Requirement

Quality Conformance test Design characteristics

1.0, 1.2, 3.1, 9.0

3.1.21, 16.4.1

Performance 100hr

16.4

16.4.1

Interface connections

4.3

Label plates

Paint/preservation

4.7

4.7

Components:

MFP unit

Bedplate

4.6

4.6

Oil sump

3.1.13

Oil Pressure regulator

3.1.12

Lube oil cooler

3.1.14

Oil filter and element

3.1.15

Attached Lube oil Pump

3.1.9

Electric Lube oil Pump

3.1.11

Lube oil pressure switch

3.1.16

Lube oil check valves

3.1.17

Press & temp gages

3.1.18

Special Tools

7.0

Note: Procedures contained in the Specification requirements paragraphs listed in Table II

6.2 Examination Tests

Each MFP unit shall be examined and tested for compliance with the requirements specified in Sections 3.1 and 9.1.1. Contractor shall notify NSWC of all scheduled tests 14 calendar days prior to start of test (CDRL A006). Any necessary redesign or modification following failure to meet the specified requirements shall receive particular attention for adequacy and suitability. This element of inspection shall encompass all visual examinations and dimensional measurements. Where possible, pressure boundary welds for both freshwater and seawater service shall be examined to verify that the welds are free of crevices, notches, porosity and pockets. Noncompliance with any specified requirements or presence of one or more defects preventing or lessening maximum efficiency shall constitute cause for rejection. The MFP unit shall be checked (by the procuring activity representative) with respect to material, finish, construction, assembly, dimensions, weight, and marking of identification and description plates. For conformance inspections, this examination shall be limited to those inspections that can be performed without disassembling the unit in such a manner that its performance, durability, or appearance would be affected. The completed MFP unit shall be examined to ensure that the required controls, indicators, valves, electrical equipment and other components are installed. Parallel or combined testing is permitted, provided the intent of any test is not compromised.

7.0 Maintenance of MFP:

Both the turbine and pump ends shall be easily accessible to facilitate maintenance. Turbine end shall have access cover enabling maintenance and repairs to turbine wheel, seals, and stators. Pump end shall have access cover enabling maintenance and repairs to impeller, wear rings, shaft sleeves and mechanical seals. Both the pump end access cover and Turbine end cover, when removed, shall enable complete and easy removal of the MFP shaft for replacement/repair to the shaft and bearings. All necessary special tools for accomplishment of these maintenance and repair tasks will be provided with each Main Feed Pump and will come complete with a tool chest. Each MFP will be supplied with a complete set of recommended spare parts in a separate tool box Minimum space envelope from Turbine inside access cover flange face will be no less than 55" to facilitate removal of main shaft from MFP unit. This will ensure that the shaft can easily be removed onboard ship with no interferences from adjacent shipboard equipment.

8.0 Shelf Life

The Contractor shall adhere to FAR 52.246-17 Warranty of Supplies of a Noncomplex Nature (June 2003). Shelf life capability of the MFP shall be no less than 12 months. Shelf life is the period of time from delivery until system startup. Following the shelf life period the MFP shall still have the specified operational service life without component or part replacement, adjustment, or maintenance action.

9.0 Performance:

9.1.1 Pump hydraulic performance: The Main Feed pump (MFP) unit shall be designed for the purpose of providing feed water to main propulsion boilers as specified in paragraph 1.0.

9.1.2 Head capacity curve: The head-capacity curve of the pump shall rise continuously from rated capacity to shut-off so that, at constant rated speed, the shut-off pressure will be at least 15 percent greater than at rated capacity

10.0 Casings:

10.1.1 Design: The casings shall be designed to facilitate the ready removal and replacement of pump shaft, internal bearings, impellers, and turbine rotor.

10.1.2 Thickness: Casing thickness of the pump and turbine shall include an allowance for corrosion and the possibility of core shift. The minimum thickness shall be 1 inch.

10.1.3 Strength: Casings shall be sufficiently rugged to withstand without fracture or distortion the strains to which they may be subjected.

10.1.4 Clearance: Clearance shall be provided around bolt heads and nuts to permit the use of ordinary tools.

10.1.5 Fitted Bolts and dowel pins: Fitted bolts or dowel pins shall be provided to ensure maintenance of alignment in assembly.

10.1.6 Forcing bolts: Forcing bolts (a.k.a. jacking bolts) shall be provided for breaking joints

10.1.7 Gaskets:

Gasket compression and tolerance shall not affect bearing, bushing, and wearing ring fits to an extent that will adversely affect reliability and performance.

10.1.8 Casing wearing rings: For the pump, casings shall be fitted with removable casing wearing rings. In addition to the standard sized casing rings, casing rings shall be made available machined at least 0.050 inch on the diameter in order to permit finish machining during shipboard installation to mate with used/worn impellers.

10.1.9 Joint gaskets: All gaskets shall meet and/or exceed the requirements for the intended design and service

11.0 Impellers:

11.1.1 Impeller type: Impellers shall be double suction type.

11.1.2 Impeller Keys: Impellers shall be keyed on the shaft.

11.1.3 Impeller hubs: Impellers shall not be fitted with wearing rings. The impeller hub wearing surfaces shall have material thickness to permit reaching the diameter of the impeller hubs by as much as .050 inch to accommodate undersized casing wearing rings to restore design running clearances.

11.1.4 Impeller dynamic balancing: Each impeller shall be dynamically balanced.

12.0 Rotating Assembly:

12.1.1 Dynamic Balance: rotors shall be dynamically balanced with all rotating parts connected thereto. However, rotating parts may be balanced individually provided that, when assembled, the imbalance shall not exceed the limits.

12.1.2 Maximum operating speed: The pump design shall be such and calculations shall be made to demonstrate that the operating speed of the pump will be not less than 120 percent of the first critical speed.

12.1.3 Pumps shall be hydraulically balanced.

13.0 Mechanical Seals:

Pump seals shall be designed to ensure that leakage is reduced to a minimum and cannot reach the bearings, be thrown over bearing housings, or enter the driving units. Ample drip pockets, spray shields, and drains shall be provided.

14.0 Examination:

Pumps shall be examined in accordance with a completed parts examination checklist accompanying each part or assembly. The examination shall be performed by inspection personnel not engaged in the fabrication and assembly of the part. The specific attributes which determine the part's acceptability are:

a. Dimensions: Dimensions shall be as indicated on the approved design drawing. Rotating parts shall be examined for balance and maximum permissible run-out as indicated on the drawings.

b. Materials: Materials shall be visually examined for compliance with approved design drawings. Any appearance of nonconformance shall be further verified by appropriate tests.

c. Cleanliness: Examination for cleanliness shall apply equally to parts examination prior to assembly as well as subassemblies of the completed product.

d. Missing Parts: This examination applies primarily to the completed product prior to shipment.

e. Assembly: During assembly, positioning tolerances and wear ring or impeller running clearances shall be verified.

f. Alignment: The equipment and its subassemblies shall be examined to ensure that the alignment is as specified.

g. Adjustment: The adjustment of safety, control, and monitoring devices shall be verified and the settings recorded. Settings which should not be tampered with, once adjusted, shall be tagged with an appropriate precautionary warning.

h. Preservation: The preservation used, the methods of application, and recommended procedure for removal of preservation prior to placing the unit in service shall be stated on a supplemental sheet and attached to the checklist.

15.0 Test Methods

15.1.1 Hydrostatic pressure test:

Pressure boundary parts shall be tested hydrostatically to a pressure one and one-half times the maximum discharge pressure, but in no case less than 50 psi. The hydrostatic test pressure shall be maintained for at least 30 minutes or longer as necessary for examination of entire casing.

15.1.2 Overspeed

Each unit shall be tested in the shop of the Manufacturer or Contractor at 25 percent above the speed corresponding to full load rating by a continuous nonstop run of at least 30 minutes. This test shall check operation and smoothness of running. While running at this speed, the pump need not be loaded except as necessary to prevent injury. The MFP shall be vibration monitored during overspeed testing.

15.1.3 Casings

Unless otherwise specified, all turbine casings other than steam chests, including all fittings and connections subject to steam pressures, shall be tested hydrostatically to a pressure at least 50 percent greater than the maximum working pressure, but in no case less than 50 PSI.

15.1.4 Steam fittings

Inlet steam fittings and…