S6225-W6-MMA-010 Tech Manuel.pdf

TECHNICAL MANUAL

FOR

NAVY STANDARD TITANIUM

CENTRIFUGAL PUMP

1000 GPM

(NAVSEA DRAWING NO. 803-5773203)

OPERATION, MAINTENANCE, AND ILLUSTRATED PARTS

BREAKDOWN

SUPERSEDURE NOTICE: THIS MANUAL SUPERSEDES S6225-W6-MMA-010,

DATED, 30 AUGUST 2006, AND ALL CHANGES THERETO.

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE/OPERATIONAL USE; 30 AUGUST 2006. OTHER U.S. REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NSWC PHILADELPHIA, CODE 314.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE

ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2751, ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979 (TITLE 50, U.S.C., APP 2401 ET SEQ.), AS AMENDED. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH THE

PROVISIONS OF DOD DIRECTIVE 5230.25.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS

OR RECONSTRUCTION OF THIS DOCUMENT.

S6225-W6-MMA-010

REVISION 6

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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

*0910LP1155186* 15 MAR 2016

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@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

REVISION NO. DATE TITLE OR BRIEF DESCRIPTION

0 15 FEB 1985 INITIAL ISSUE

1 15 AUG 1995 INCORPORATED CHANGE A PACKAGE.

2 30 AUG 2006 INCORPORATE CHANGES RESULTING FROM CVN 77 NEW CON-

STRUCTION. UPDATED PARTS LIST IN TABLE 7-2.

3 31 AUG 2009 THIS REVISION DOCUMENTS SHIPALT 6766.02D.

CHANGED INFORMATION INCLUDES THE FOLLOWING:

PARAGRAPH(S) D

4 15 JUL 2011 THIS REVISION INCORPORATES SCD-79185 (MA-670) WHICH PRO-

VIDES GALVANIC ISOLATION BETWEEN THE TITANIUM PUMP

AND SYSTEM PIPING.

CHANGED INFORMATION INCLUDES THE FOLLOWING:

PARAGRAPH(S) 4-6, 6-4, 6-6, 6-7 AND 8-9

TABLE(S) 6-2. AND 7-2.

FIGURE(S) 8-4.

5 30 APR 2012 INCORPORATES TMDER N65540-12-C006 TO CLARIFY

DEENERGIZING AND TAG OUT PROCEDURES. CHANGES AUTHO-

RIZED BY CODES 938 AND 944. THE FOLLOWING WAS CHANGED:

PARAGRAPH(S) 6-4, 6-6, 6-7, 6-8, A-3.4, A-5.3, A-5.4, A-5.5, A-6.1,

A-6.3.1, A-6.3.2, A-6.4.1, A-6.4.2, A-6.5.1, A-6.5.2, A-9.1, A-9.3, A-9.4, A-9.5, C-3.4, C-5.3 AND C-5.4

6 15 MAR 2016 ADDED FIRE PUMP EMI FIX KIT AND UPDATED PARTS LIST

DESCRIPTION. THE FOLLOWING WAS CHANGED:

PARAGRAPH(S) A-2.3.2.1 AND A-8.6

TABLE(S) C-7.

FOR OPTIMAL VIEWING OF THIS TECHNICAL MANUAL, THE PAGE LAYOUT IN ADOBE ACROBAT

READER SHOULD BE SINGLE PAGE. CONTINUOUS PAGE DISPLAY CAN CAUSE PROBLEMS WITH

LINK REFERENCES AND THE BOOKMARKS.

S6225-W6-MMA-010

RECORD OF REVISIONS-1 / (RECORD OF REVISIONS-2 Blank)

RECORD OF REVISIONS-2

FOREWORD

This technical manual provides description, operation, maintenance, troubleshooting, repair and parts list information for the Navy Standard, Titanium Centrifugal pump, 1000 gpm (NAVSEA Drawing No. 803- 5773203). This technical manual is intended for guidance of and use by personnel operating and maintaining the equipment described herein.

This manual consists of one volume arranged in eight chapters and four appendices as follows:

Chapter 1 - General Information and Safety Precautions

Chapter 2 - Operation

Chapter 3 - Functional Description

Chapter 4 - Scheduled Maintenance

Chapter 5 - Troubleshooting

Chapter 6 - Corrective Maintenance

Chapter 7 - Parts List

Chapter 8 - Installation

Appendix A - Hansome, General Electric, and Mawdsley’s Limited Motors

Appendix B - Tech Systems Motor Data For LSD 41 Class (CV)

Appendix C - Reliance Electric Motor

Appendix D - Cutler-Hammer Motor Controller 6962ED3264

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for maximum practical use and evaluation of NAVSEA technical manuals. All errors, omis-sions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER

CODE 310 TMDERs

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY, BLDG 1389

PORT HUENEME CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom.

One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA Form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency submittals via the Naval Systems Data Support Activity web site located at:

https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm

FOREWORD-1 / (FOREWORD-2 Blank)

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . 1-1

1-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.1 Warning/Caution/Note Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.2 Additional Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 EQUIPMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4 RELATIONSHIP OF COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-5 REFERENCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-3 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-4 OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-4.1 Pre-Operational Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-4.2 Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-4.3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-4.4 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 PUMP DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.1 Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.2 Seal Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.3 Wearing Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.4 Impeller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.5 Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-3 PUMP OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-4 PUMPING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 i

TABLE OF CONTENTS - Continued

4-2 PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . 4-1

4-3 VISUAL INSPECTION OF THE PUMP MECHANICAL SEAL FOR LEAKAGE. . 4-1

4-4 EXTENDED SHUTDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-5 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-6 INTERMEDIATE AND DEPOT LEVEL MAINTENANCE. . . . . . . . . . . . . . . 4-2

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3 TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-4 PRELIMINARY TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-4.1 Common Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-4.2 Immediate Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-4.3 Probable Causes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-4.4 Corrective Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-5 PERFORMANCE MONITORING CHARTS. . . . . . . . . . . . . . . . . . . . . . . 5-2

5-6 MECHANICAL SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . 5-2

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION II ADJUSTMENTS AND ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 ADJUSTMENTS AND ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION III REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-3 REPAIR PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-4 RENEWAL OF WEARING RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-5 CASING STUD REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . 6-10

6-6 RENEWAL OF SHAFT SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 ii

6-7 RENEWAL OF IMPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-8 EMERGENCY PACKING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 6-28

7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 LIST OF MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3 PARTS LIST TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-3.1 Figure and Index Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-3.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-3.3 Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-3.4 CAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-3.5 Manufacturer’s Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-4 PARTS LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2 INSTALLATION DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3 SITE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-4 PREPARATION OF FOUNDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-5 REFERENCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-6 TOOLS AND MATERIAL REQUIRED FOR INSTALLATION. . . . . . . . . . . . 8-1

8-7 UNPACKING AND PACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-7.1 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-7.2 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-7.3 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-8 INPUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-9 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8-10 INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-11 ADJUSTMENTS AND TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-12 GROUNDING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 iii

8-13 STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

A HANSOME, GENERAL ELECTRIC, AND MAWDSLEY’S LIMITED

MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A-1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . . A-1

A-1.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A-1.2 GENERAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A-1.3 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A-2 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A-2.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A-2.2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

A-2.2.1 Rotating Element. . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A-2.2.2 Stationary Element. . . . . . . . . . . . . . . . . . . . . . . . . . A-3

A-2.3 DESCRIPTION OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . A-3 A-2.3.1 Motor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A-2.3.2 Temperature Monitor System. . . . . . . . . . . . . . . . . . . . A-3

A-2.3.2.1 Fire Pump EMI Fix Kit. . . . . . . . . . . . . . A-4 A-2.3.3 Controller Output. . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A-2.3.4 Relay Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A-2.3.5 Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A-2.3.6 Fail Safe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

A-3 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A-3.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A-3.2 GENERAL CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A-3.3 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

A-3.4 MEASUREMENT OF INSULATION RESISTANCE. . . . . . . . . . . . . . A-6

A-3.5 MOTOR BEARING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . A-7

A-4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 A-4.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 A-4.2 TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . A-9

A-5 CORRECTIVE MAINTENANCE (HANSOME MOTOR) . . . . . . . . . . . . . . . A-10

A-5.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 A-5.2 BEARINGS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . A-11

A-5.3 REMOVAL AND REPLACEMENT OF THE OPPOSITE DRIVE END

BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

A-5.4 MOTOR DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . . . . . . A-14

A-5.5 CORRECTING THE INSULATION RESISTANCE. . . . . . . . . . . . . . A-22

A-6 CORRECTIVE MAINTENANCE (GENERAL ELECTRIC MOTOR) . . . . . . . . A-24

A-6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 A-6.2 BEARINGS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . A-24 iv

A-6.3 REMOVAL AND REPLACEMENT OF THE OPPOSITE DRIVE END

BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24

A-6.3.1 Group 1 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 A-6.3.2 Group 2 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27

A-6.4 REMOVAL AND REPLACEMENT OF THE DRIVE END BEARING. . . A-30

A-6.4.1 Group 1 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 A-6.4.2 Group 2 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33

A-6.5 MOTOR DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . . . . . . A-35

A-6.5.1 Group 1 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35 A-6.5.2 Group 2 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43

A-7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46 A-7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46 A-7.2 PARTS LIST TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46

A-8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-50 A-8.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-50 A-8.2 INSTALLATION DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . A-50 A-8.3 REFERENCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-50

A-8.4 TOOLS AND MATERIAL REQUIRED FOR INSTALLATION. . . . . . . . A-50

A-8.5 INPUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-51 A-8.6 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . A-51 A-8.7 INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . A-52 A-8.8 ADJUSTMENT AND TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . A-52

A-9 CORRECTIVE MAINTENANCE (MAWDSLEY’S LIMITED MOTOR) . . . . . . A-83

A-9.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-83 A-9.2 BEARINGS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . A-83

A-9.3 REMOVAL AND REPLACEMENT OF THE OPPOSITE DRIVE END

BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-83

A-9.4 MOTOR DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . . . . . . A-86

A-9.5 CORRECTING THE INSULATION RESISTANCE. . . . . . . . . . . . . . A-94

B TECH SYSTEMS MOTOR DATA FOR LSD 41 CLASS (CV) . . . . . . . . . . B-1

C RELIANCE ELECTRIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C-1 RELIANCE ELECTRIC MOTOR GENERAL INFORMATION AND SAFETY

PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C-1.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C-1.2 GENERAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C-1.3 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C-2 RELIANCE ELECTRIC MOTOR FUNCTIONAL DESCRIPTION . . . . . . . . . . C-2

C-2.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C-2.2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C-2.2.1 Rotating Element. . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 v

C-2.2.2 Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C-2.2.3 Stationary Element. . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C-2.2.4 Sealed Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C-2.2.5 DESCRIPTION OF OPERATION. . . . . . . . . . . . . . . . . . C-2

C-2.3 QUIET OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

C-2.4 TEMPERATURE MONITORING. . . . . . . . . . . . . . . . . . . . . . . . C-3

C-2.4.1 Controller Output. . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 C-2.4.2 Fail Safe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

C-3 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C-3.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C-3.2 GENERAL CLEANLINESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C-3.3 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

C-3.4 MEASUREMENT OF INSULATION RESISTANCE. . . . . . . . . . . . . . C-5

C-3.5 MOTOR BEARING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . C-6

C-4 RELIANCE ELECTRIC MOTOR TROUBLESHOOTING . . . . . . . . . . . . . . C-8

C-4.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8 C-4.2 TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . C-8

C-5 RELIANCE ELECTRIC MOTOR CORRECTIVE MAINTENANCE . . . . . . . . . C-10

C-5.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10

C-5.2 REMOVAL AND REPLACEMENT OF FRONT AND REAR END

BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10

C-5.3 REMOVAL AND REPLACEMENT OF FRONT END BEARING. . . . . . C-10

C-5.4 REMOVAL AND REPLACEMENT OF REAR END BEARING. . . . . . . C-13

C-6 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-21 C-6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-21 C-6.2 PARTS LIST TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-21

C-7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25 C-7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25 C-7.2 INSTALLATION DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . C-25

C-7.3 TOOLS AND MATERIAL REQUIRED FOR INSTALLATION. . . . . . . . C-25

C-7.4 STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25 C-7.5 INPUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26 C-7.6 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . C-26 C-7.7 INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . C-26

D CUTLER-HAMMER MOTOR CONTROLLER 6962ED3264 . . . . . . . . . . . D-1

D-1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 vi

LIST OF TABLES

Table Title Page

1-1. Pump Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2. Pump Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3. Principal Design Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-4. Equipments, Accessories, and Documents Supplied . . . . . . . . . . . . . . . . . . . 1-3

4-1. Planned Maintenance Schedule (Pump End) . . . . . . . . . . . . . . . . . . . . . . . 4-1

5-1. Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6-1. Impeller Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-2. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

7-1. Navy Standard Titanium Centrifugal Pumping Units . . . . . . . . . . . . . . . . . . 7-1

7-2. Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Multi-Spring Mechanical Seal Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-4. Navy Standard Single-Spring Mechanical Seal Parts List . . . . . . . . . . . . . . . . 7-9

A-1. Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A-2. Performance at Rated Voltage and Frequency (Hansome) . . . . . . . . . . . . . . . A-2

A-3. Performance at Rated Voltage and Frequency (General Electric) . . . . . . . . . . . . A-2

A-4. Performance at Rated Voltage and Frequency (Mawdsley’s Limited) . . . . . . . . . A-2

A-5. Planned Maintenance Schedule (Motor) . . . . . . . . . . . . . . . . . . . . . . . . . A-5

A-6. Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

A-7. Hansome Motor Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13

A-8. G.E. Motor Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26

A-9. Motor Parts List-Hansome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46

A-10. Motor Parts List-Mawdsley’s Limited . . . . . . . . . . . . . . . . . . . . . . . . . . A-48

A-11. Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-51

A-12. Mawdsley’s Limited Motor Torque Values. . . . . . . . . . . . . . . . . . . . . . . . A-85

C-1. Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C-2. Performance at Rated Voltage and Frequency . . . . . . . . . . . . . . . . . . . . . . C-1 vii

LIST OF TABLES - Continued

Table Title Page

C-3. Planned Maintenance Schedule (Motor) . . . . . . . . . . . . . . . . . . . . . . . . . C-4

C-4. Lubricating Conditions and Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . C-7

C-5. Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

C-6. List of Manufacturers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-21

C-7. Fire Pump Electric Motor Parts List - Reliance Electric . . . . . . . . . . . . . . . . C-21 viii

LIST OF ILLUSTRATIONS

Figure Title Page

1-1. Fire Pump - Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-2. Performance Curve - 125 PSI, 750 GPM . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3. Performance Curve - 150 PSI, 750 GPM . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-4. Performance Curve - 125 PSI, 900 GPM . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-5. Performance Curve - 125 PSI, 1000 GPM . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-6. Performance Curve - 150 PSI, 1000 GPM . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-7. Performance Curve - 175 PSI, 1000 GPM . . . . . . . . . . . . . . . . . . . . . . . . 1-10

6-2. Impeller Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-3. Method for Checking Impeller Runout . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-4. Method for Holding Motor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6-5. Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-6. Impeller and Mechanical Seal Retainer Engagement . . . . . . . . . . . . . . . . . . 6-32

6-7. Pump Assembly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

7-1. Pump Sectional Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-2. Multi-Spring Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-3 Navy Standard Single-Spring Mechanical Seal . . . . . . . . . . . . . . . . . . . . . 7-10

8-1. Unit Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-2. Resilient Mount Arrangement and Unit Footprint . . . . . . . . . . . . . . . . . . . . 8-9

8-3. Shipping Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-4. Galvanic Isolation Component Arrangement (Installed by SCD-79185 (MA-670) or Other Means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

A-1. Temperature Monitor System Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . A-54

A-2. Elementary Diagram for Pumping Unit Motor Controller with Thermal Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-55

A-3. Hansome Motor (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-57

A-4. General Electric Motor (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . A-63

A-5. Mawdsley’s Limited Electric Motor A/505DZ/7 (Sheet 1 of 2) . . . . . . . . . . . . A-75

A-6. Mawdsley’s Limited Electric Motor A/505DZ/8 (Sheet 1 of 2) . . . . . . . . . . . . A-79 ix

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

B-1. Certification Data, AC Motor 505TNDZ . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B-2. AC Motor, Dwg. No. 225B7022 (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . B-3

C-1. Major Motor Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C-2. Motor Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

C-3. Reliance Motor Master Drawing (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . C-17

C-4. Reliance Motor Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-27

D-1. Cutler-Hammer Motor Controller 6962ED3264 Wiring Diagram . . . . . . . . . . . D-3

D-2. Cutler-Hammer Motor Controller 6962ED3264 Schematic Diagram . . . . . . . . . . D-5 x

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the general or spe-cific safety precautions, the Commanding Officer or other authority will issue orders as deemed necessary to cover the situation. No work shall be undertaken on energized equipment or circuits until approval of the Com-manding Officer is obtained, and then only in accordance with Naval Ship’s Technical Manual (NSTM) S9086- KC-STM-010/Chapter 300.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances shall repair or adjustment of energized equipment be attempted alone. The imme-diate presence of someone capable of rendering first aid is required. Before making adjustments, be sure to pro-tect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to attempting repairs. Equipment should be deenergized and properly tagged out according to the ship’s Standard Operating Procedures.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a metal-cased test meter must be held, ground the case of the meter before starting measurement. Do not touch live equipment or personnel working on live equipment while holding a test meter. Do not ground any measuring devices; these devices should not be held when taking measurements.

INTERLOCKS - SAFETY DEVICES

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended. Never tamper with or render ineffective any safety device, interlock, ground strap or similar device intended to protect operators or the equipment without specific approval of the Commanding Officer. Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at the distribution source.

MOVING EQUIPMENT

Personnel shall remain clear of moving equipment. If equipment requires adjustment while in motion, a safety watch shall be posted. The safety watch shall be qualified to administer CPR, have a full view of the operations being performed, and have immediate access to controls capable of stopping equipment motion.

FIRST AID

An injury, no matter how slight, shall never go unattended. Always obtain first aid or medical attention immediately, and file an injury report in accordance with OPNAVINST 5102.1 series, subj: Mishap Investigation and Reporting.

xi

SAFETY SUMMARY - Continued

RESUSCITATION

Personnel working with or near high voltage shall be familiar with approved methods of resuscitation.

Should someone be injured and stop breathing, begin resuscitation immediately. A delay could cost the victim’s life. Resuscitation procedures shall be posted in all electrically hazardous areas.

GENERAL PRECAUTIONS

The following general precautions are to be observed at all times.

1. Install and ground all electrical components associated with this system/equipment in accordance with applicable Navy regulations and approved shipboard practices.

2. Ensure that all maintenance operations comply with Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 series.

3. Observe precautions set forth in NSTM S9086-KC-STM-010/Chapter 300 with respect to electrical equipment and circuits.

4. Ensure that protective guards and shutdown devices are properly installed and maintained around rotating parts of machinery and high voltage sources.

5. Do not wear loose clothing while working around rotating parts of machinery.

6. Ensure that special precautionary measures are employed to prevent applying power to the system/ equipment any time maintenance work is in progress.

7. Do not make any unauthorized alterations to equipment or components.

8. Before working on electrical system/equipment, use the correct tag out procedure and check with voltmeter to ensure that system is not energized.

9. Consider all circuits not known to be “dead,” “live” and dangerous at all times.

10. When working near electricity, do not use metal rules, flashlights, metallic pencils, or any other objects having exposed conducting material.

11. Deenergize all equipment before connecting or disconnecting meters or test leads.

12. When connecting a meter to terminals for measurement, use range higher than expected voltage.

13. Before operating equipment or performing any tests or measurements, ensure area is dry of water or other liquid conductive material and that frames of all motors and starter panels are securely grounded.

14. Ensure that area is well-ventilated when using cleaning compound or solvent. Avoid prolonged breathing of fumes and compound or solvent contact with skin or eyes.

WARNINGS AND CAUTIONS

Specific warnings and cautions applying to the system/equipment covered by this manual are summarized below. These warnings and cautions appear elsewhere in the manual following paragraph headings and immedi-ately preceding the text to which they apply. They are repeated here for emphasis.

xii

SAFETY SUMMARY - Continued

An operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury or death of personnel. (Page 1-1)

Never start the pump if it is not filled with water. Operating the pump in an air-locked or dry condition will damage close running internal surfaces. (Page 2-1, page 6-10, page 6-19, page 6-27, page 6-29)

Follow the general safety notices and general precautions set forth in the Safety Summary. (Page 6-2, page 6-12, page 6-20, page 6-28, page A-6, page A-7, page A-9, page A-11, page A-14, page A-22, page A-24, page A-27, page A-30, page A-33, page A-35, pageA-43,pageA-51,pageA-83,pageA-86,pageA-94,pageC-5,pageC-6,pageC-8, page C-11, page C-13, page C-26)

Prior to working on equipment, ensure all switches and circuit breakers have been placed in the open (off) position and tagged as follows, using applicable shipboard tag out procedure. Ensure all remotely supplied alternate sources are also open and tagged out. One cannot assume a single power source supplies all equipment internally. (Page 6-2, page 6-12, page 6-20, page 6-28, page A-6, page A-11, page A-14, page A-22, page A-24, page A-27, page A-30, page A-33, page A-36, page A-43, page A-83, page A-86, page A-94, page C-6, page C-11, page C-13)

Failure to completely isolate the pump and tag all valves out of service in accor-dance with ship procedures may result in injury to or death of personnel. (Page 6-2,page6-12,page6-20,page6-28,pageA-11,pageA-14,pageA-25,pageA-28,page A-30,pageA-33,pageA-36,pageA-43,pageA-83,pageA-86,pageC-11,pageC-14) xiii

The pump casing weighs approximately 110 pounds. Failure to use proper rig-ging and hoisting procedures may result in injury to or death of personnel. (Page 6-3, page 6-9, page 6-14, page 6-18, page 6-21, page 6-26)

The pump seal head weighs approximately 110 pounds. Failure to use proper rigging and hoisting procedures may result in injury to or death of personnel.

(Page6-4,page6-7,page6-14,page6-16,pageA-16,pageA-20,pageA-37,pageA-40, page A-88, page A-92)

Pressurized air may drive particles into eyes and skin if handled improperly. To prevent injury to personnel, wear proper protective gear including goggles. (Page 6-11, page A-6, page C-5)

Excessive or repeated skin contact with anaerobic adhesive/sealants may cause skin irritation. In case of contact with skin, remove promptly by washing. To avoid skin contact, use an applicator. (Page 6-11)

Do not wear loose clothing while working around rotating machinery. (Page 6-29, page A-7, page C-6)

Asbestos is recognized as a major health hazard. Inhalation of fibers of this material can lead to serious impairment of health in subsequent years. The insu-lation installation on the piping may contain asbestos material. The industrial hygienist at the repair activity should be notified whenever asbestos is found in the pipe insulation. The industrial hygienist will supervise the correct removal of the asbestos insulation from the pipe. (Page 8-3) xiv

Observe all safety precautions when troubleshooting the motor. Carelessness can result in serious injury to personnel and damage to equipment. If electrical power is connected, a 440-volt potential is present to the pump electrical motor.

Extreme care must be taken when the electrical box is opened. (Page A-9, page C-8)

Take precautions to prevent possible burn hazard when handling the heated bear-ing. (Page A-13, page A-26, page A-29, page A-32, page A-34, page A-85, page C-12, page C-15)

Ensure that all switches and circuit breakers are still tagged out before reconnect-ing the electrical wiring to the pump motor. (Page A-14, page A-22, page A-27, page A-30,pageA-32,pageA-35,pageA-42,pageA-46,pageA-86,pageA-94,pageC-13)

The pumping unit weighs approximately 2,300 pounds. Failure to use appropri-ate rigging and hoisting procedures may result in injury to or death of personnel.

(Page A-15, page A-37)

Before proceeding, make certain that the equipment is disconnected from the 440 VAC power source, and the 440 VAC power source is tagged out. (Page A-53)

The pumping unit weighs 2530 pounds. Failure to use appropriate rigging and hoisting procedures may result in injury to or death of personnel. (Page A-87) xv

An operating or maintenance procedure, practice, condition, or statement, etc., which, if not strictly observed, could result in damage or destruction of equip-ment or loss of mission. (Page 1-1)

This equipment is designed and built for quiet operation. Extreme care must be taken when handling this equipment to prevent any damage which might increase operating noise levels. (Page 1-2)

The pump must not be operated with a flow rate less than 30 GPM or the pump will overheat and seize. (Page 3-2)

Do not install emergency packing rings unless there is a leakage of more than 45 drops per minute. If leakage is insufficient (i.e. less than 45 drops per min.) to cool the emergency packing, damage will occur to the pumping unit. (Page 4-1, page 6-28)

Safeguard loose titanium and Inconel parts. Use of other than the approved pump material (i.e. titanium or Inconel 625) may cause pump corrosion leading to catastrophic pumping unit failure and flooding. (Page 6-2, page 6-13, page 6-20, page 6-28)

Use care when assembling or disassembling parts to prevent damage to internal surfaces having close machined tolerances. (Page 6-3, page 6-9, page 6-14, page xvi

6-18, page 6-21, page 6-26, page A-12, page A-15, page A-25, page A-28, page A-31, page A-33, page A-36, page A-43, page A-84, page A-87, page C-11, page C-14)

The distance 0.122 - 0.125 inch must be the same at pump reassembly to ensure impeller dowel pins (2.1) are in mechanical seal retainer slots to engage and turn the seal retainer. (Page 6-4, page 6-15)

Do not use HARSH ABRASIVE that might scratch or otherwise mar surface finishes. (Page 6-5, page 6-15, page 6-22, page 6-23)

Do not turn wear area beyond the required dimension to establish the 125 EMS finish. (Page 6-5, page 6-22)

Use of other than an Inconel 625 impeller key (8) may result in a key disinte-grating. This will allow the lock nut (5) to become free and allow the impeller to come into contact with the casing, leading to catastrophic pumping unit failure.

Do not use a key that exhibits corrosion. (Page 6-7, page 6-16, page 6-24)

If the mechanical seal drive pins (2.1) are not in line with the slots in the seal when the impeller is installed, the springs in the seal will be fully compressed by the pins when the impeller is tightened. This will prevent the impeller from seat-ing on the shaft sleeve, resulting in one of the following:

a. The seal may rotate and the impeller pins fall into the slots. The resulting free play between the impeller and the shaft sleeve will keep the seal from operating properly. The seal will leak and the pump will vibrate due to the loose impeller.

xvii

b. The pins may not fall into the slots, causing the seal faces to be loaded too heavily. The faces will burn up quickly.

The end result in either case is catastrophic failure of the pumping unit. (Page 6-8, page 6-17, page 6-24, page A-20, page A-41, page A-92)

Do not wedge, pry or chain fall piping into position to align flanges. Excessive/ undue stress put on pump casing will change internal clearances of pump, thus causing unsatisfactory operation or failure. (Page 6-9, page 6-18, page 6-26)

Galvanic isolation must be maintained between the titanium pump flanges and the system flanges to prevent corrosion. (Page 6-9, page 6-18, page 6-26, page 8-4)

For equipment with galvanic isolation kits (installed by SCD-79185 (MA-670) or other means), the suction and discharge flange fasteners should not be torqued to greater than 60 Ft-Lbs to avoid damaging the galvanic isolation components.

(Page 6-10, page 6-19, page 6-27, page 8-4)

Primers and chlorinated cleaning solvents are not to be used with titanium. (Page 6-11)

To avoid equipment damage, ensure that low pressure air used to dry components is clean and dry. Moisture in an air line causes rust. (Page 6-11, page A-6, page C-5) xviii

Do not turn wear area beyond that dimension required to establish the 125 EMS finish. (Page 6-15)

The Navy Standard Titanium Centrifugal Pump has been designed and manufac-tured to minimize mechanical and electrical vibrations and noise to the extent that the pumping unit is considered to be a precision machine. It should be handled as such. Abuse by rough handling could upset the super precision bal-ance built into this unit. (Page 8-3)

In all installations and particularly new installations, use extreme care when con-necting piping to ensure that no foreign matter such as dirt, chips, pipe scale, and welding beads are in the piping as this debris will be drawn into the pump and cause internal damage. Thoroughly flush the system before connecting it to the pump. (Page 8-4)

To prevent galvanic corrosion, fitting failure, and flooding, titanium tubing and fittings should be used for gage and vent lines. (Page 8-5)

Do not overgrease. Too much grease will cause churning of grease, which can lead to overheating of the bearings. The total grease capacity for the DE bearing is 2.75 oz, while the ODE bearing contains 3 oz. The bearing lubricant shall conform to DOD-G-24508. (Page A-8)

Never start the pump if it is not filled with water. Operating the pump in an air-locked or dry condition will damage close running internal surfaces. (Page A-8) xix

Disassembly of AC motors should be accomplished by authorized personnel at authorized maintenance activities only. Disassembly by unauthorized personnel may result in equipment damage. (Page A-11, page A-24, page A-83, page C-10)

The distance 0.122 - 0.125 inch must be the same at pump reassembly to ensure impeller dowel pins (2.1) are in mechanical seal retainer (10.5) slots to engage and turn retainer 10.5. (Page A-16, page A-38, page A-88)

Do not allow machined surfaces to contact other surfaces without protection against nicks, scratches, burrs, etc. (Page A-17, page A-38, page A-89)

To avoid damage to motor windings and shaft bearings, brace motor rotor securely while end brackets/shields are removed. (Page A-17, page A-39, page A-44, page A-89)

The pumping unit is positioned on studs. The unit must be lowered straight down to protect studs and reamed holes in motor housing feet. (Page A-21, page A-42, page A-93)

Do not use lead or zinc paints on internal parts of the motor. Use only air dry-ing insulating varnish. (Page A-23, page A-95) xx

Do not overgrease. Too much grease will cause churning of grease, which can lead to overheating of the bearings. The bearing lubricant shall conform to DOD- G-24508. (Page C-7) xxi / (xxii Blank) xxii

CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. INTRODUCTION.

This manual covers the description, installation, operation, scheduled maintenance, troubleshooting, correc-tive maintenance, and parts lists of the pumping unit, Navy Standard Drawing No. 803-5773203 and is appli-cable to the following ratings (table 1-1):

Table 1-1. Pump Ratings

Rating Configuration

125 PSI 750 GPM Figure 1-2 150 PSI 750 GPM Figure 1-3 125 PSI 900 GPM Figure 1-4 125 PSI 1000 GPM Figure 1-5 150 PSI 1000 GPM Figure 1-6 175 PSI 1000 GPM Figure 1-7

1-2. SAFETY PRECAUTIONS.

1-2.1 Warning/Caution/Note Usage. Warnings and cautions appearing throughout this technical manual are critical to the safety of personnel and equipment. Before operating, troubleshooting, or performing maintenance actions on the motor driven Navy Standard Titanium Centrifugal Pump (hereinafter referred to as the pumping unit), review all warnings and cautions in this technical manual. Refer to the Safety Summary for a complete listing of warnings and cautions. Warnings, cautions, and notes are defined as follows:

An operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury or death of personnel.

An operating or maintenance procedure, practice, condition, or statement, etc., which, if not strictly observed, could result in damage or destruction of equip-ment or loss of mission.

An essential operating and maintenance procedure, precondition, or statement.

1-1

1-2.2 Additional Warnings. Operating procedures presented in this manual are not intended to modify or replace approved operating procedures for the pumping unit.

1-3. EQUIPMENT DESCRIPTION.

The pumping unit (figure 1-1) was designed by Worthington Pump Division of Dresser Industries, Inc. and is built in accordance with MIL-P-17639E dated 23 March 1979 as modified by contract N00024-84-C-4261. It is a horizontal, single stage, double volute centrifugal pump used to develop the required sea water pressure for the ship’s fire fighting system. The pump is close coupled to a constant speed driving motor which is secured to the ship’s foundation at the motor feet. For ships that require low noise installations, the unit is mounted on a common bedplate which in turn is mounted to the ship’s foundation by means of four resilient mounts (figure 8-2). The pump suction and discharge flanges are secured to the ship’s suction and discharge piping manifolds, respectively. These units were designed and manufactured to minimize vibration and noise by the use of quiet operation bearings and a specially designed motor fan.

This equipment is designed and built for quiet operation. Extreme care must be taken when handling this equipment to prevent any damage which might increase operating noise levels.

For performance capabilities of the pumping unit, refer to the pump test curves, figures 1-2 through 1-7.

1-4. RELATIONSHIP OF COMPONENTS.

For a pictorial illustration depicting the components comprising the pumping unit, relative sizes, and rela-tionships to each other, see figure 8-1.

1-5. REFERENCE DATA.

The pump characteristics are contained in tables 1-2, 1-3, and 1-4.

Table 1-2. Pump Characteristics

Rating (PSI) 125 150 125 125 150 175

(GPM) 750 750 900 1000 1000 1000

Liquid Pumped Sea water Specific gravity 1.03 Liquid temperature 85°F max Speed at capacity 3585 rpm Efficiency at capacity 70.3% 71.5% 74% 75% 75% 76% Rated input at capacity (BHP) 78 92 89 97 117 134 Max input at any condition (BHP) 95 116 101 115 134 167 Actual shutoff head (PSI) 147 170 154 161 183 207 Hydrostatic test pressure 315 PSIG NPSHR, Max (Ft) 13 13 16.5 18.5 18.5 18.5 NPSHA, Max (Ft) 55 Ft Critical speed 6533 RPM

1-2

Table 1-2. Pump Characteristics - Continued

Maximum axial thrust load 31.3 lbs toward suction

Table 1-3. Principal Design Dimensions

Size of discharge 5 inch, MIL-F-20042; 250#

Size of suction 6 inch; MIL-F-20042; 250# Size of casing vent 7/8-14 UNF; MS16142 Size of casing drain 3/4-16 UNF; MS16142 Size of seal head drain 3/4-16 UNF; MS16142 Size of seal vent 9/16-18 UNF; MS16142 Size of gage connections 9/16-18 UNF, MS16142 Running clearances (figure 7-1):

Impeller (2) vs casing wearing ring (1.2) 0.018-0.020 inch radial Impeller (2) vs seal head wearing ring (3.2) 0.017-0.019 inch radial Impeller (2) vs seal head (3) 0.026-0.037 inch radial

Table 1-4. Equipments, Accessories, and Documents Supplied

Qty Item Name or Nomenclature Overall Dimensions (inch) Weight and Volume

1 Pumping Unit Uncrated: Uncrated:

52 5/8 long 34 1/2 wide 28 1/8 high

2495 lbs

31.3 cu ft

Crated: Crated:

59 long 40 wide 40 high

2700 lbs

54.6 cu ft

1 Pump 13 long 26 wide

24 5/8 high

300 lbs

4.7 cu ft

1 Motor, frame 505Z Hansome:

39 5/8 long

34 wide 28 1/8 high

2195 lbs

21.5 cu ft

General Electric:

49 long

32 3/4 wide 23 1/2 high

2086 lbs

21.8 cu ft

1 Motor, frame 505DZ Mawdsley’s Limited

47.60 long

32 wide 28 high

2230 lbs

1 Baseplate (For low noise applications) 27 1/2 long 29 wide

6 3/8 high

380 lbs

3.0 cu ft

4 Resilient Mounts (For low noise applications) Type 6E900 2 S6225-W6-MMA-010, Technical Manual for Navy

Standard, Titanium Centrifugal Pump, 1000 GPM (NAVSEA Drawing No. 803-5773203)

8 1/2 x 11 x 3/4

1-3

Figure 1-1. Fire Pump - Horizontal

1-4

Figure 1-2. Performance Curve - 125 PSI, 750 GPM

1-5

Figure 1-3. Performance Curve - 150 PSI, 750 GPM

1-6

Figure 1-4. Performance Curve - 125 PSI, 900 GPM

1-7

Figure 1-5. Performance Curve - 125 PSI, 1000 GPM

1-8

Figure 1-6. Performance Curve - 150 PSI, 1000 GPM

1-9

Figure 1-7. Performance Curve - 175 PSI, 1000 GPM

1-10

CHAPTER 2

OPERATION

2-1. INTRODUCTION.

Under normal conditions the firemain, sea water cooling, and flushing systems on various class ships are supplied by the motor driven Navy Standard Titanium Centrifugal Pump.