JDD So Fish U-3_O and M Manual.pdf

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Manufactures of

HYDRAULIC TURBINES

1978 Commerce Circle—Springfield, Ohio USA 45504-2012

Phone (937) 322-0116 Telefax (937) 322-0467

OPERATION and MAINTNANCE MANUAL for

JOHN DAY DAM SOUTH FISH TURBINE- UNIT 3

JOHN DAY DAM

RUFUS, OREGON

CONTRACT: W9127N-10-C-0029

US ARMY CORPS OF ENGINEERS,

PORTLAND DISTRICT, PORTLAND, OREGON

LEFFEL UNIT W3036-3

REFURBISHMENT PROJECT R-120627

g2ecddp9 Stamp

Main Contents.docx

HYDRAULIC TURBINES

MAIN CONTENTS

Section 1 Description of Refurbishment

Section 2 Operation

Section 3 Maintenance

Section 4 Paint and Coating Products

Section 5 Parts Catalog

Section 6 Spare Parts List

Section 7 Refurbishment Drawings

Section 8 Re-installation Data

Section 9 Original O&M Manuals

Section 10 Operator Notes

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HYDRAULIC TURBINES

SECTION 1

Outline Description of Refurbishment.docx Page 1 of 2

HYDRAULIC TURBINES

SECTION 1

OUTLINE DESCRIPTION of REFURBISHMENT

TURBINE

The Leffel turbine was refurbished according to this contract W9127N-10-C-0029 including the incorporation into the turbine of new rough and pre-machined parts originally provided by The James Leffel & Co. under 2002 contract DACW57-02-P-0050, a few newly manufactured and procured components under this contract, and additional work brought on by as-found conditions.

In general, the turbine refurbishment included replacement of all wear and rotating parts to include runner, shaft, wicket gates, links, and linkage pins. The bottom ring was replaced new in stainless, the head cover was fitted with a stainless facing plate and bronze thrust plate, the spiral case was true-up machined on working surfaces, and a new packing box was provided. The pivot junctions in the wicket gate operating mechanism was converted to a grease-free design with the old grease lube system abandoned.

All existing components refurbished for re-use were first cleaned and inspected per the specification and to the extent required to assure the components were acceptable for the planned refurbishment.

All carbon steel, ductile iron, and cast iron components were prepared and painted in accordance to spec section 09 97 02.00 26 with MIL-DTL-24441D, Type III Expoxy Polymide. The paint manufacture was Sherwin Williams and product data is provided later in this manual.

Outside of converting the gate mechanism lube system to a "greaseless" system, the refurbishment did not change the operation of the turbine.

Outline Description of Refurbishment.docx Page 2 of 2

PUMP

The pump was refurbished according to modifications to the contract including the incorporation into the pump new rough machined parts provided by the government, a few newly manufactured and procured components under this contract, and additional work brought on by as-found conditions.

In general, the pump refurbishment included replacement of the lower pump shaft, true-up machining of the upper pump shaft, true-up machining of the upper and lower bearing mounting flanges and spigot bores on the cover plate and diffuser, and true-up machining of the diffuser extension cone. The propeller itself had its blade tips built up with weld and re-machined a proper clearance (nominally 1/8" radial clearance) to the pit liner. In addition the propeller center bores were true-up machined for proper fit (0.004-0.006" clearance) to the new lower shaft. The upper and lower bearings were fitted with greaseless bearing liners and the shafts existing stainless bearing journals were replaced with spares provided by the government that were originally supplied by Worthington Pump.

All existing components refurbished for re-use were first cleaned and inspected per the specification and to the extent required to assure the components were acceptable for the planned refurbishment.

All carbon steel components were prepared and coated in accordance to spec section 48 13

13.12 26 with Enecon CL + AC coating. The Enecon CL + AC product data is provided later in this manual.

The refurbishment did not change the operation of the pump.

REFURBISHMENT DRAWINGS

The refurbishment drawing section of this O&M lists the refurbishment drawings for both the turbine and pump. These drawings provide a thorough representation of the refurbishment work of which reduced copies are included in the refurbishment drawings section. It should be noted these drawings generally only address the refurbishment work, therefore the original drawings should be consulted as need for further clarification and information.

Section 2 Tab.docx Page 1 of 1

HYDRAULIC TURBINES

SECTION 2

Operation.docx Page 1 of 1

HYDRAULIC TURBINES

SECTION 2

OPERATION

As the work performed under this refurbishment contract did not alter or add to the original operation of the turbine or pump, refer to the "Original O&M" section of this manual for operating information in the original turbine O & M and original pump O & M.

Areas in the manuals dealing with grease lubrication can be ignored and have been crossed out in the original O & M's.

Section 3 Tab.docx Page 1 of 1

HYDRAULIC TURBINES

SECTION 3

Maintenance.docx Page 1 of 7

HYDRAULIC TURBINES

SECTION 3

MAINTENANCE

TURBINE MAINTENANCE and CONTROL

To keep a Francis turbine and related equipment in satisfactory function, a certain amount of maintenance and inspection must be regularly performed.

Continuous condition control and monitoring are of great importance. This will provide opportunities to take action at an early stage and thereby limit the extent of possible damage to a minimum. Changes in sound characteristics during unit operation may indicate developing malfunctions.

A maintenance plan should be established as per the outline provided on the following page.

Maintenance.docx Page 2 of 7

MAINTENANCE SCHEDULE

FRANCIS TURBINE

FREQUENCY

ACTIVITY 1 month 6 months 1 yr 2 yrs

I TURBINE AND PUMP

- Routine Inspection X

- RPM Shutdown Curve X

- Wicket Gate Leakage Check X

- Shaft Run Out X

II ROTATING PARTS

- Runner X

III WATER CHANNELS

- Spiral Casing X

- Draft Tube X

IV WICKET GATE MECHANISM

- Upper and Lower Cover Guide Surfaces X

- Wicket Gates X

- Wicket Gate Bearings X

- Wicket Gate Stems, Arms, Links X

- Gate Operating Ring X

V SEAL RINGS X

VI SHAFT MAIN SEAL X

VII BEARINGS X

Maintenance.docx Page 3 of 7

I TURBINE and PUMP

Routine Inspection

Visual inspect the complete turbine and pump. Look for possible leakages and inspect bolted connections. Drain pumps, if any, from upper cover should be inspected and level switches should be tested.

RPM Shutdown Curve The RPM shutdown curve should be drawn from nominal RPM to standstill. The RPM should be recorded with a selected equal-time intervals from the time of wicket gates closing to standstill of the unit. Record the instance of turbine shut-off valve is in closed position.

Comparison to previous tests should be made and studied to alert of possible issues

Leakage Control, Wicket Gates Record the RPM (if any) with the turbine with shut-off valve open and the wicket gates closed. Increased RPM indicate more leakage caused by a wicket gate(s) out of position due to slippage, damage, or foreign object.

Unit rotation in this condition might be created by one or more of the following:

-foreign object wedged between two gates when the wickets gates are closed -improper squeeze on wicket gates due to wear, damage, or looseness in the linkages (Design squeeze is 1/16") -broken component in the wicket gate linkage -in proper operation or bleed-off of the wicket gate operator cylinder -wear of the surfaces of head and bottom cover opposite the ends of the wicket gates -erosion of the wicket gates end faces

Shaft Run-Out Record the shaft run-out by means of dial indicator instrument against the shaft at the exposed area between the turbine/gearbox and between the gearbox/pump. Record the run out at different loads on the unit. The run out experienced during commissioning at steady load will be used for comparing the TIR value. In the event this is increased to above 4/1000” at all times of steady load, this condition should be investigated. Conditions that might impact this, uneven wear of the seal rings or an object caught in the runner.

Maintenance.docx Page 4 of 7

II ROTATING PARTS

Runner and Propeller

Visual inspection of the runner and propeller is required in order to record possible cavitation and erosion damages as well as cracks in buckets near hub and/or band. At inlet and particularly at discharge edges of buckets, dye penetrant inspection should be performed.

Any cracking, wear, cavitation or erosion should be recorded.

Any suspect findings in the above inspections should give cause for further investigation and possible corrective actions.

III WATER CHANNELS

Inspection of the water channels, including inlet pieces, spiral casing draft tube, and pump pit should look for abnormities, foreign objects, paint and coat degradation, and erosion/cavitation.

For painted surfaces in general, possible wear to the paint should be cleaned and the area repainted as part of the annual maintenance.

IV WICKET GATE MECHANISM

Upper and Lower Covers, Guide Surfaces

A portion of the guide surfaces can be inspected from the spiral casing. Possible wear should be recorded for later comparison. A more thorough inspection of the guide surfaces can be made with open wicket gates.

CAUTION!

The wicket gate operator should be disconnected or locked out during any inspection through or between the wicket gates.

This inspection is to determine possible wear from sand or other suspended matter. Possible waviness can be measured with a straight edge and a set of feeler gauges.

Maintenance.docx Page 5 of 7

Wicket Gates

Visual inspection of surfaces. This inspection should look for abnormities including blow marks from foreign objects on the inside (runner side) of the wicket gates,.

The front-rear/heal-toe clearances between the wicket gates and head cover and bottom ring should be checked using feeler gauges.

The gap between wicket gates at squeeze gate (gate closure) should be checked using feeler gauges.

The wicket gate operator should be disconnected or locked out during the above inspections.

The results of the above checks should be compared to the re-commissioning measurements and retained as comparison of future checks.

Wicket Gate Bushings and Packing

There are three wicket gate bushings. The outer one is located in the wicket gate stem support housing, the middle one is located in the head cover, and the lower (or rear) is located in the bottom ring. Wear can be checked for visually, by feeler gauges, and/or by checking shake.

Wicket gate packing is made up of braided packing three rings and a bronze packing gland.

Gland should be adjusted (tightened or loosened) as need to allow a minor amount of leakage.

Wicket Gate Levers, Links, Pins

Check connections between wicket gate stems, arms, links and pins for abnormal operation, slop, or lack of movement.

DO NOT insert hands into this mechanism when operating as this can cause severe bodily injury.

Observe operation and use extra lighting for closer scrutiny.

Maintenance.docx Page 6 of 7

Gate Operating Ring, Connecting Rods, and Rocker Arm

Check the connection between the gate operating ring and connecting rods/gate links, between the connecting rods and rocker arm, and between the rocker arm and operator lever arm and operator linkages.

Pay special attention to the pins, retaining clips, and nuts.

Inspect the wicket gate mechanism pre-stressing (squeeze). Again, this should be in the 1/16" range.

V RUNNER SEAL RINGS

Front and Rear Seal Rings

The unit is provided with bronze static seal rings at the runner crown and runner band. The design radial clearance at both locations is 0.020" Wear can be assessed by measurement of the clearance between the runner and stationary seal rings.

Additional the position of the runner between the covers can be checks. The design here is that the runner crown and bottom plate is set inside the seals 1/16".

This check should be carried out as given in the inspection schedule. Increased clearance or mis-position will cause loss of water; therefore, this should be weighed against replacement cost.

Access is made from spiral case side with the wicket gates fully open.

The wicket gate operator should be disconnected or locked out during the above inspections.

Maintenance.docx Page 7 of 7

VIII BEARINGS

Turbine Bearings There are two turbine bearings. The bearing closest to the turbine is a combined radial/thrust bearing, known as the Inboard Bearing [I.B.] The other bearing is a radial bearing, known as the Outboard Bearing [O.B.]

Both bearings are babbitt-oil lubricated-water cooled type.

Inboard Bearing The I.B. lubrication is provided by the a pump with the oil being circulated through an through an oil cooler. Reference original drawing 50712 for Water Piping and drawing 51701 for Oil Piping.

The I.B. includes a Kingsbury adjustable shoe 6-seqment thrust bearing. Reference Kingsbury drawing 27-13-1/2-13E of which a copy is provided at the end of this section.

manual.

Clearances:

Radial: 0.008/0.010" diametrically Thrust: 0.02" total laterally

Outboard Bearing

The O.B. lubrication is provided by oil rings bring oil up on the shaft and bearing by oil rings from a reservoir inside the bearing housing. The bearing is cooled by water following through a water jacket in the lower portion of the housing. Reference original drawing 50712 for Water Piping.

Additional references:

For additional maintenance information reference the following:

-Original Leffel Turbine O&M (See Original O & M Section of this manual) -Original Worthington Pump O&M (See Original O & M Section of this manual)

-Original Leffel drawing 50604 (Inboard Bearing) -Original Leffel drawing 50580 (Outboard Bearing

Section 4 Tab.docx Page 1 of 1

HYDRAULIC TURBINES

SECTION 4

Paint and Coat Products.docx

HYDRAULIC TURBINES

SECTION 4

PAINTING and COATING PRODUCTS

The turbine and pump was painted per their respective specifications s noted in "Description of Refurbishment" section. Following are the products used for painting and coating:

Turbine Paint Sherwin Williams N10-30 Series 2 pages

Pump Coating Enecon CeramAlloy CL + AC 2 pages

MIL-DTL-24441D, TYPE III

EPOXY POLYAMIDE

N10-350 SERIES

Protective

Marine Coatings

9.32Revised 7/10 www.sherwin-williams.com/protective

PRODUCT DESCRIPTION

MIL-24441, Type III is a low VOC epoxy polyamide system, formu-lated for immersion service and to protect surfaces from environ-mental attack. For use where air pollution regulations for marine coatings are restricted to a maximum of 340 g/L or 2.8 lb/gal.

PRODUCT CHARACTERISTICS

Finish: Low sheen

Colors:

Primer: 150 Green Finishes: 151 Haze Gray, 152 White, 153 Dark Gray, 154 Dark Gray, 155 Dark Gray, 156 Matte Red Volume Solids:

Primer:

Formula 150 Green 59.2 ± 1% Finish:

Formula 151 Haze Gray 58.6 ± 1% Formula 152 White 58.1 ± 1% Formula 153 Dark Gray Ro 1.8 58.5 ± 1% Formula 154 Dark Gray Ro 3.6 58.4 ± 1% Formula 155 Dark Gray Ro 6 58.4 ± 1% Formula 156 Matte Red 61.0 ± 1%

VOC (EPA Method 24): <340 g/l; 2.8 lb/gal, maximum, mixed

Mix Ratio: 1:1 by volume

Recommended Spreading Rate per coat:

Primer Topcoats

Min. Max. Min. Max.

Wet mils (microns) 5.0 125 6.0 150 3.5 88 5.0 125 Dry mils (microns) 3.0 75 4.0 100 2.0 50 3.0 75 ~Coverage sq ft/gal (m2/L) 236 5.8 315 7.7 310 7.6 464 11.4 Theoretical coverage sq ft/ gal (m2/L) @ 1 mil/25 micron dft

928 (22.7)

NOTE: Brush or roll application may require multiple coats to achieve maximum fi lm thickness and uniformity of appearance.

Drying Schedule @ 5.0 mils wet (125 microns):

35-40°F

(1.6-4.5°C) 41-60°F

(4.5-16°C) 61-80°F

(16-27°C) 81-100°F (27-38°C)

50% RH

Dry to touch: 12 hours 8 hours 6 hours 4 hours To recoat:

minimum (epoxy): 24 hours 18 hours 12 hours 8 hours minimum (non-epoxy)*: 12 hours 8 hours 6 hours 4 hours maximum: 14 days 12 days 10 days 7 days Cure to service: 6 days 5 days 4 days 64 hours

*An anti-foulant topcoat must be applied before the previous epoxy topcoat has hardened and while the epoxy is in a slightly tacky con-dition. This overcoat period is mainly dependent on the existing en-vironmental conditions. If the epoxy is not tacky, an additional coat of epoxy must be applied to provide the required tacky condition.

Pot Life: 5 hours at 77°F/25°C, 50% RH Sweat-in-Time: @ 35-60°F (1.6-16°C): 2 hours

@ 61-70°F (16-21°C): 1-1.5 hours @ 71-90°F (21-32°C): 30 minutes - 1 hour @ >90°F (>32°C): none continued on back

PRODUCT CHARACTERISTICS (CONT'D)

Shelf Life: 36 months, unopened Store indoors at 40°F (4.5°C) to 100°F (38°C)

Flash Point: 100°F (38°C), PMCC, mixed Reducer/Clean Up: Reducer #130, R7K130

RECOMMENDED USES

For use over prepared substrates such as steel and aluminum in industrial and marine environments where a hard, durable, chemical resistant coating is desired.

• Marine vessels: bilges, tanks, and underwater hulls

• Off shore platforms

For use where air pollution regulations for marine coatings are restricted to a maximum of 340 g/L or 2.8 lb/gal.

PERFORMANCE CHARACTERISTICS

Complies with Military Specifi cation MIL-DTL-24441, Type III and is listed on NAVSEA QPL-24441

Color Product/Rex Number

Primer:

Green - 150, Part A N10G350 Hardener for Primer 150, Part B N10V350

Finishes:

Haze Gray - 151, Part A N10A351 White - 152, Part A N10W352 Dark Gray - Ro 1.8 153, Part A N10A353 Dark Gray - Ro 3.6 154, Part A N10A354 Dark Gray Ro 6 155, Part A N10A355 Hardener for 151-155, Part B N10V351

Red - 156, Part A N10R356 Hardener for 156, Part B N10V356

9.32

MIL-DTL-24441D, TYPE III

EPOXY POLYAMIDE

N10-350 SERIES

Protective

Marine Coatings www.sherwin-williams.com/protective

SURFACE PREPARATION

Surface must be clean, dry, and in sound condition. Remove all oil, dust, grease, dirt, loose rust, and other foreign material to ensure adequate adhesion.

Refer to product Application Bulletin for detailed surface prepara-tion information.

Minimum recommended surface preparation:

Iron & Steel Atmospheric: SSPC-SP6/NACE 3, 2.0 mil (50 micron) profi le Immersion: SSPC-SP10/NACE 2, 1.0-3.0 mil (25-75 micron) profi le Aluminum SSPC-SP7 or Power Wire Brush

Surface Preparation Standards Condition of Surface

ISO 8501-1

BS7079:A1

Swedish Std.

SIS055900 SSPC NACE

White Metal Sa 3 Sa 3 SP 5 1 Near White Metal Sa 2.5 Sa 2.5 SP 10 2 Commercial Blast Sa 2 Sa 2 SP 6 3 Brush-Off Blast Sa 1 Sa 1 SP 7 4 Hand Tool Cleaning Rusted C St 2 C St 2 SP 2 -

Pitted & Rusted D St 2 D St 2 SP 2 - Power Tool Cleaning Rusted C St 3 C St 3 SP 3 -

Pitted & Rusted D St 3 D St 3 SP 3 -

TINTING

Do not tint.

APPLICATION CONDITIONS

Temperature:

air and surface: 35°F (1.6°C) minimum, 100°F (38°C) maximum material: 60°F (16°C) minimum At least 5°F (2.8°C) above dew point Relative humidity: 85% maximum

Refer to product Application Bulletin for detailed application information.

ORDERING INFORMATION

Packaging: 1 gallon (3.78L) and 5 gallon (18.9L) containers

~Weight: ~10.3 - 11.5 ± 0.2 lb/gal ; 1.2 - 1.4 Kg/L mixed, depending on color

SAFETY PRECAUTIONS

Refer to the MSDS sheet before use.

Published technical data and instructions are subject to change without notice.

Contact your Sherwin-Williams representative for additional technical data and instructions.

WARRANTY

The Sherwin-Williams Company warrants our products to be free of manufactur-ing defects in accord with applicable Sherwin-Williams quality control procedures.

Liability for products proven defective, if any, is limited to replacement of the defec-tive product or the refund of the purchase price paid for the defective product as determined by Sherwin-Williams. NO OTHER WARRANTY OR GUARANTEE

OF ANY KIND IS MADE BY SHERWIN-WILLIAMS, EXPRESSED OR IMPLIED,

STATUTORY, BY OPERATION OF LAW OR OTHERWISE, INCLUDING MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

PRODUCT INFORMATION

RECOMMENDED SYSTEMS

Dry Film Thickness / ct.

Mils (Microns) Steel:

1 ct. MIL-24441, Type III Primer 3.0-4.0 (75-100) 2 cts. MIL-24441, Type III Epoxy 2.0-3.0 (50-75)

Steel, non-immersion (exterior):

1 ct. MIL-24441, Type III Epoxy 3.0-4.0 (75-100) 2 cts. MIL-PRF-24635 1.5-2.5 (40-63)

Steel:

1 ct. MIL-24441, Type III Primer 2.0-4.0 (50-100) (Formula 150 only) 1 ct. MIL-24441, Type III (No. 156) 2.0-4.0 (50-100) 1 ct. MIL-24441, Type III (No. 152) 2.0-4.0 (50-100) Total system to be 8.0 mils (200 microns) minimum,

12.0 mils (300 microns) maximum.

Aluminum:

1 ct. MIL-24441, Type III Primer 3.0-4.0 (75-100) (Formula 150 only)

2 cts. MIL-24441, Type III Epoxy 2.0-3.0 (50-75)

The systems listed above are representative of the product's use, other systems may be appropriate.

DISCLAIMER

The information and recommendations set forth in this Product Data Sheet are based upon tests conducted by or on behalf of The Sherwin-Williams Company.

Such information and recommendations set forth herein are subject to change and pertain to the product offered at the time of publication. Consult your Sherwin- Williams representative to obtain the most recent Product Data Information and Application Bulletin.

T M

C e ra m A llo y C

L A C

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for rebuilding, resurfacing and protecting all types of revolutionary products . . .

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Apply by Brush, Roller or Flexible Applicator

Requires No Heat

Unlimited Shelf Life

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Safe & Simple To Use

(Advanced Composite)

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TMMETALCLAD CeramAlloy CL+AC

TMMETALCLAD CeramAlloy CL+AC is a two component, 100% solids, liquid polymer composite used for repairing, resurfacing and coating components to provide outstanding fluid flow erosion and corrosion resistance.

When mixed, is a viscous liquid. CL+AC cures to a hard, ceramic-like material with an extremely smooth surface finish.

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6 Platinum Court · Medford, NY 11763-2251

Tel: 516 349 0022 · Fax: 516 349 5522

Email: info@enecon.com

Toll Free: 888-4-ENECON

The Fluid Flow Systems Specialists.

Corporation www.enecon.com o o41 F 5 C 4 hrs 48 hrs 96 hrs 10 days o o59 F 15 C 2 hrs 24 hrs 48 hrs 5 days o o77 F 25 C 1 hr 12 hrs 24 hrs 3 days o o86 F 30 C 40 min 8 hrs 20 hrs 2 days

Cure Times Chemical Immersion

Ambient Temperature

Working Life

Machining Light Load

Full Mechanical

2Compressive strength 13,500 psi 945 kg/cm ASTM D-695 2Flexural strength 8,000 psi 560 kg/cm ASTM D-790

Izod impact strength 1.3 ft lbs/in 0.69 j/cm ASTM D-256 Hardness - Shore D 85 ASTM D-2240

15Surface resistivity 1 x 10 ohms ASTM D-257 15Volume resistivity 1 x 10 ohm/cm ASTM D-257

Dielectric constant 7.5 ASTM D-150 Dielectric strength 652 volts/mil ASTM D-115 Breakdown voltage 6.1 Kv ASTM D-115

2Steel 4000 psi 280 kg/cm 2Aluminum 2500 psi 175 kg/cm 2Copper 3000 psi 210 kg/cm 2Stainless steel 4100 psi 287 kg/cm

Tensile Shear Adhesion

Typical Values Physical Properties

Test Method

All information contained herein is based on long term testing in our laboratories as well as practical field experience and is believed to be reliable and accurate. No condition or warranty is given covering the results from use of our products in any particular case, whether the purpose is disclosed or not, and we cannot accept liability if the desired results are not obtained.

®Copyright © 2010 by ENECON Corporation. All rights reserved. No part of this work may be reproduced or used in any form or by any means - graphic, electronic or mechanical including photocopying, recording, taping or information

®storage and retrieval systems - without written permission of ENECON Corporation.

Printed in the USA February, 2010

®Your Local ENECON Fluid Flow Systems Specialist

TM

Chemical Resistance

EX - Suitable for most applications including immersion.

G - Suitable for intermittent contact, splashes, etc.

Acetic acid (0-10%) . . . . . . . . EX Acetic acid (10-20%) . . . . . . . G Acetone . . . . . . . . . . . . . . G Aviation fuel . . . . . . . . . . . . EX Butyl alcohol . . . . . . . . . . . EX Calcium chloride . . . . . . . . . EX Crude oil . . . . . . . . . . . . . EX Diesel fuel . . . . . . . . . . . . . EX Ethyl alcohol . . . . . . . . . . . G Gasoline . . . . . . . . . . . . . EX Heptane . . . . . . . . . . . . . . EX Hydrochloric acid (0-10%) . . . . . EX Hydrochloric acid (10-20%) . . . . G Kerosene . . . . . . . . . . . . . EX

Methyl alcohol . . . . . . . . . . G Methyl ethyl ketone . . . . . . . . G Nitric acid (0-10%) . . . . . . . . EX Nitric acid (10-20%) . . . . . . . . G Phosphoric acid (0-5%) . . . . . . EX Phosphoric acid (5-10%) . . . . . G Potassium chloride . . . . . . . . EX Propyl alcohol . . . . . . . . . . . EX Sodium chloride . . . . . . . . . . EX Sodium hydroxide . . . . . . . . . EX Sulfuric acid (0-10%) . . . . . . . EX Sulfuric acid (10-20%) . . . . . . G Toluene . . . . . . . . . . . . . . G Xylene . . . . . . . . . . . . . . EX

Volume capacity per kg.

Mixed density

Coverage rate per kg.

@ 12 - 15 mils

Shelf life

Volume solids

336 in / 592 cc

30.061 lbs per in / 1.69 gm per cc

2 2 14 - 16 ft / 1.4 m

Technical Data

Mixing ratio Base Activator

By volume 3.3 1

By weight 6 1

+Using CeramAlloy CL AC Surface Preparation

Mixing & Application

Health & Safety

Cleaning Equipment

TM - METALCLAD CeramAlloy CL+AC should be applied only to clean, dry and well roughened surfaces.

1. Remove all loose material and surface contamination and clean with a suitable solvent which leaves no residue on the surface after evaporation such as acetone, MEK, isopropyl alcohol, etc.

2. Clean/roughen surface by abrasive blasting.

3. If necessary, apply moderate heat and/or allow the component(s) to ‘leach’ to remove ingrained contaminants.

4. Thoroughly roughen surfaces by abrasive blasting to achieve a ‘white metal’ degree of cleanliness and an anchor pattern of 3 mils.

Please note: In situations where adhesion is not desired, such as when making molds and patterns or to ease future disassembly, apply a suitable release agent (mold release compound, paste wax, etc.) to the appropriate surfaces.

- For your convenience, the TMMETALCLAD CeramAlloy CL+AC Base and Activator have been supplied in precisely measured quantities.

Simply pour the entire contents of the Activator container into the Base container and, using a spatula, putty knife or other appropriate tool, mix thoroughly until the

TMCeramAlloy CL+AC reaches a uniform, streak-free color.

Apply the mixed material to the prepared surface using a stiff-bristled brush, applicator or roller. As a guide, an even thickness of approximately 12-15 mils per coat should be obtained. A minimum two coat application is required.

Overcoating should ideally be performed when the previously applied coat is just surface tacky; and certainly within 8 hours of the previous coat.

- Every effort is made to insure that ®ENECON products are as simple and safe to use as possible. Normal industry standards and practices for housekeeping, cleanliness and personal protection should be observed.

Please refer to the detailed MATERIAL SAFETY DATA

SHEETS (MSDS) supplied with the material (also available on request) for more information.

- Wipe excess material from tools immediately. Use acetone, MEK, isopropyl alcohol or similar solvent as needed.

Technical Support ® - The ENECON engineering team is always available to provide technical support and assistance. For guidance on difficult application procedures or for answers to simple questions, call your ®local ENECON Fluid Flow Systems Specialist or the

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Indefinite

100%

ASTM D-1002

ASTM D-1002

ASTM D-1002

ASTM D-1002

Section 5 Tab.docx Page 1 of 1

HYDRAULIC TURBINES

SECTION 5

Parts Catalog.docx

HYDRAULIC TURBINES

SECTION 5

PARTS CATALOG

The following catalog data is provided:

Turbine Inboard Bearing Oil Cooler Tate Andale Oil Cooler B-2 Type 202........................... 6 pages

Turbine Inboard Bearing Oil Pump Roper 17F5 SPEC 0 Pump............................................. 3 pages

Turbine Inboard Bearing Oil Pump Motor Baldor-Reliance CL3504 Motor.................................... 10 pages

Greaseless Bearings Trelleborg (Orkot) Engineering Manual....................... 28 pages

B-25003140 Tate Andale Oil Cooler B-2 Type 202

ROPER 17F5 SPEC 0 PUMP

OIL PUMP FOR TURBINE I.B. BEARING

1, 2, 17, 18 F1-F5 SPEC 0 & SPEC 5

F1 F3 F5

QTY PART NO. QTY PART NO. QTY PART NO.

1 Case Assy 1 N22-171 1 N22-170 1 N22-169 5 Case Gasket 2 D11-17 2 D11-18 2 D11-19 8A Pipe Plug, Foot Mtd BP 2 G56-14 2 G56-14 2 G56-14 16 Bearing 4 G5-17 4 G5-18 4 G5-19 20 Backplate, Foot Mtd 1 P2-641 1 P2-642 1 P2-643

Backplate, Flg Mtd 1 P2-657 1 P2-658 1 P2-659 22 Hex Hd Cap Screw, Plain 8 G49-025175 8 G49-025225 8 G49-025225

Soc Hd Cap Screw, RV 8 G45-025150 8 G45-025225 8 G45-025225 23 Needle Brg, Pkg 1 G40-62 1 G40-62 1 G40-62 25 Lube Ftg 1 G63-1 1 G63-1 1 G63-1 45 Faceplate, Plain 1 P3-17 1 P3-18 1 P3-19

Faceplate, RV 1 P3-161 1 P3-162 1 P3-163 46 Poppet 1 D16-50 1 D16-125 1 D16-52 47 Bonnet 1 D19-1 1 D19-1 1 D19-3 48 Spring (75 PSI) 1 G10-97 1 G10-97 1 G10-196

Spring (150 PSI) 1 G10-99 1 G10-99 1 G10-212 Spring (300 PSI) 1 G10-113 1 G10-113 1 G10-228

49 Spring Guide 1 N/A 1 N/A 1 D8-83 50 Gasket, RV Cap 2 G11-101 2 G11-101 2 G11-101 51 RV Cap 1 D20-4 1 D20-4 1 D20-4

51A Plug Cap 1 D21-1 1 D21-1 1 D21-3 52 Nut 1 G44-29 1 G44-29 1 G44-29 53 Adjusting Screw 1 D15-1 1 D15-1 1 D15-3 54 Gasket, RV 2 D11-295 2 D11-295 2 G11-100 70 Key, Drive 1 D30-80 1 D30-80 1 D30-80 72 Drive Shaft & Gear, Mech Seal 1 N1-126 1 N1-127 1 N1-128

Drive Shaft & Gear, Pkg 1 N1-120 1 N1-121 1 N1-122 73 Idler Shaft & Gear 1 D2-862 1 D2-855 1 D2-852 80 Hex Hd Cap Screw, Mech Seal 4 G49-019050 4 G49-019050 4 G49-019050

Hex Hd Cap Screw, Pkg 4 G49-019062 4 G49-019062 4 G49-019062 85 Nut, Pkg 4 G44-28 4 G44-28 4 G44-28 86 Pkg Gland Clip 2 D42-9 2 D42-9 2 D42-9 87 Pkg Gland 1 P10-15 1 P10-15 1 P10-15 88 Lip Seal, Mech Seal 1 D83-30 1 D83-30 1 D83-30

Lip Seal, Pkg 2 D83-30 2 D83-30 2 D83-30 89 Stud, Pkg 2 D22-69 2 D22-69 2 D22-69 91 Pkg Set 1 N43-10 1 N43-10 1 N43-10 92 Pkg Washer 1 D8-162 1 D8-162 1 D8-162 93 Brg Cage, Mech Seal 1 P4-39 1 P4-39 1 P4-39

Pkg Housing, Pkg 1 P9-12 1 P9-12 1 P9-12 93A Gasket 1 D11-34 1 D11-34 1 D11-34 96 Mech Seal 1 G14-263 1 G14-263 1 G14-263 97 Ret Ring 1 G41-72 N/A N/A

KEY NO. DESCRIPTION

OUTLET

PORT

INLET

PORT

Product Information Packet

CL3504

.5HP,1725RPM,1PH,60HZ,56C,3421L,TEFC,F1

Copyright © All product information within this document is subject to Baldor Electric Company copyright © protection, unless otherwise noted.

Product Information Packet: CL3504 - .5HP,1725RPM,1PH,60HZ,56C,3421L,TEFC,F1

Part Detail

Revision: Y Status: PRD/A Change #: Proprietary: No

Type: AC Prod. Type: 3421L Elec. Spec: 34WG5422 CD Diagram:

Enclosure: TEFC Mfg Plant: Mech. Spec: 34C062 Layout:

Frame: 56C Mounting: F1 Poles: 04 Created Date:

Base: RG Rotation: R Insulation: B Eff. Date: 10-07-2011

Leads: 6#18 Literature: Elec. Diagram: Replaced By:

Nameplate NP1256L

CAT.NO. CL3504

SPEC. 34C62-5422

HP .5

VOLTS 115/230

AMP 7.4/3.7

RPM 1725

FRAME 56C HZ 60 PH 1

SER.F. 1.25 CODE J DES N CLASS B

NEMA-NOM-EFF 68 PF 66

RATING 40C AMB-CONT

CC USABLE AT 208V 4.3

DE 6203 ODE 6203

ENCL TEFC SN

SFA 8.2/4.1

Parts List

Part Number Description Quantity

SA008618 SA 34C62-5422 1.000 EA

RA005065 RA 34C62-5422 1.000 EA

EC1270A02SP ELEC CAP, 270-324 MFD, 125V, 1.48D X 3. 1.000 EA

NS2512A01 INSULATOR, CONDUIT BOX X 1.000 EA

34CB3002A CB CAST W/.88 DIA HOLE 1.000 EA

34GS1029A01 GASKET, CONDUIT BOX 1.000 EA

51XB1016A07 10-16 X 7/16 HXWSSLD SERTYB 2.000 EA

11XW1032G06 10-32 X .38, TAPTITE II, HEX WSHR SLTD U 1.000 EA

51XW0832A07 8-32 X .44, TAPTITE II, HEX WSHR SLTD SE 2.000 EA

34EP3102A01SP FR ENDPLATE, MACH 1.000 EA

NS2500A01 INSULATOR, AUTO THER PROT 1.000 EA

34CB4800SP CAPACITOR COVER, STAMPED 1.000 EA

34GS3000SP GASKET, CAPACITOR BOX 1.000 EA

51XB1016A05 10-16X5/16HX WA SL SR TYB (F/S) 2.000 EA

WD1000A03 41531 AMP FLG.TERM,4M/REEL(2.5MIL) 1.000 EA

HW5100A03SP WAVY WASHER (W1543-017) 1.000 EA

34EP3300A24SP PU ENDPLATE, MACH 1.000 EA

51XN1032A20 10-32 X 1 1/4 HX WS SL SR 2.000 EA

34FN3002A01SP EXTERNAL FAN, PLASTIC, .637/.639 HUB W/ 1.000 EA

34FH4002A01 IEC FH NO GREASER 1.000 EA

51XW1032A06 10-32 X .38, TAPTITE II, HEX WSHR SLTD S 3.000 EA

34CB4517 CB LID 4 MTG HOLES .22 DIA STAMPED, FOR 1.000 EA

34GS1031A01 GASKET, FLAT CONDUIT BOX LID (LEXIDE) 1.000 EA

51XW0832A07 8-32 X .44, TAPTITE II, HEX WSHR SLTD SE 4.000 EA

Parts List (continued)

Part Number Description Quantity

HW2501D13SP KEY, 3/16 SQ X 1.375 1.000 EA

HA7000A04 KEY RETAINER 0.625 DIA SHAFTS 1.000 EA

MG1000G27 PAINT- S9282E CHARCOAL GREY 0.014 GA

10XF0440S02 04-40 X 1/8 TYPE F HEX HD STAINLESS STIC 2.000 EA

SP5056A24 MODEL 34 TYPE L STATIONARY SWITCH WITH L 1.000 EA

HA3100A44 THRUBOLT 10-32 X 8.000 4.000 EA

LB1125C01 STD (STOCK) CARTON LABEL BALDOR WITH FLA 1.000 EA

LC0001A01 CONN LABEL / WARNING LABEL (LC0001 / LB1 1.000 EA

NP1256L ALUM UL CSA CC 1.000 EA

34PA1005 PACKING GROUP, BALDOR 1.000 EA

Performance Data at 230V, 60Hz, 0.5HP (Typical performance - Not guaranteed values)

General Characteristics

Full Load Torque: 1.5 LB-FT Start Configuration: DOL

No-Load Current: 2.8 Amps Break-Down Torque: 4.13 LB-FT

Line-line Res. @ 25°C.: 4.44 Ohms A Ph / 3.19 Ohms B Ph Pull-Up Torque: 3.6 LB-FT

Temp. Rise @ Rated Load: 63 C Locked-Rotor Torque: 4.65 LB-FT

Temp. Rise @ S.F. Load: 77 C Starting Current: 16.5 Amps

Load Characteristics

% of Rated Load 25 50 75 100 125 150 S.F.

Power Factor: 32.0 46.0 59.0 66.0 72.0 80.0 72.0

Efficiency: 42.0 58.0 65.0 68.0 69.0 68.0 69.0

Speed: 1783.0 1765.0 1750.0 1730.0 1710.0 1680.0 1710.0

Line Amperes: 2.8 3.0 3.3 3.7 4.1 4.8 4.1

Performance Graph at 230V, 60Hz, 0.5HP Typical performance - Not guaranteed values

Performance Data at 115V, 60Hz, 0.37KW (Typical performance - Not guaranteed values)

General Characteristics

Full Load Torque: 2.03 N-M Start Configuration: DOL

No-Load Current: 5.6 Amps Break-Down Torque: 5.6 N-M

Line-line Res. @ 25°C.: 1.06 Ohms A Ph / 3.13 Ohms B Ph Pull-Up Torque: 4.88 N-M

Temp. Rise @ Rated Load: 63 C Locked-Rotor Torque: 6.3 N-M

Temp. Rise @ S.F. Load: 77 C Starting Current: 33.0 Amps

Load Characteristics

% of Rated Load 25 50 75 100 125 150 S.F.

Power Factor: 35.0 47.0 57.0 64.0 70.0 72.0 70.0

Efficiency: 41.9 58.2 64.8 67.9 68.9 67.9 68.9

Speed: 1783.0 1765.0 1750.0 1730.0 1710.0 1680.0 1710.0

Line Amperes: 5.6 6.0 6.6 7.4 8.2 9.6 8.2

Performance Graph at 115V, 60Hz, 0.37KW Typical performance - Not guaranteed values

Engineering Manual Version 4.2

Orkot® Marine Bearings Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

Contents

About this Manual

A Global Approach

Orkot® Marine Bearings

Management Systems and Classification

Material Properties

Service and Support

Web Site

World Wide Availability

Marine Stock Tube Sizes

Standard Production Capacity Guidelines

Contact Details

Rudder Bearings

Bearing Design Pressure

Material Selection

Lubrication

Housing and Shaft Requirements

Housing

Shaft

Design

Wall Thickness

Bearing Interference

Bearing Clearance

Machining Tolerance

Water Lubricated Stern Tube Bearings

Bearing Design Pressure

Material Selection

Shaft Requirements

Design

Multi Groove Bearing

Twin Groove Bearing

Special Designs

Staves

Water Flow Rate

Bearing Interference and Clearance

Machining Tolerance

Fitting Methods

Freeze Fitting

Press Fitting

Bonding

Machining Instructions

Health and Safety Data

Calculation Sheets

Trelleborg Sealing Solutions

Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

About this Manual The information in this manual allows the user to correctly design Orkot® Marine Bearings and gives guidance on machining and fitting. It is intended for use by persons with technical training at their own discretion. The design of Orkot® Marine Bearings should take into account the current rules and regulations of the relevant classification society.

A Global Approach Trelleborg Sealing Solutions is a world leading manufacturer and supplier of bearings to the shipping and marine industries.

Supported by an extensive global network of manufacturing plants, agents and distributors, Trelleborg Sealing Solutions are able to offer the highest levels of quality of service associated with a leading company within the marine industry.

Part of the Trelleborg group of companies, Orkot®

Marine Bearings have been supplied to the Marine and shipping industries for over 30 years.

Extensive experience has been gained within the shipbuilding and offshore industries with a wide range of applications on board both merchant and military vessels.

Orkot® Marine Bearings Orkot® Marine Bearings are manufactured from a unique synthetic composite incorporating solid lubricants for dry running to ensure outstanding wear life. Virtually no swelling in sea water and very low thermal coefficient of expansion provide dimensional stability in arctic and tropical seas. It does not corrode or promote corrosion of the housing and tolerates both edge loading and misalignment.

Management Systems and Classification Trelleborg Sealing Solutions operate a fully integrated management system which incorporates, ISO 9001 Quality Management System, ISO 14001 Environmental Management System and OHSAS 18001 Health and Safety Management System

Strict quality control and testing ensure material conformance and batch traceability. Routine testing is performed to simulate the extreme operational environments where the materials are used.

Type approval certification is held for Orkot® TLM Marine and TXM Marine grades from the worlds leading classification societies. We can supply full listing of the certificates we hold upon request.

This listing can also be found on our website:

www.orkotmarine.com

Properties Unit TLM Marine TXM Marine

Compressive Strength Normal to Laminate N/mm2 300 280 Parallel to Laminate N/mm2 90 90

Tensile Strength N/mm2 60 55

Flexural Strength N/mm2 65 65

Elastic Modulus Bending N/mm2 x 104 0.19 0.18 Tensile N/mm2 x 104 0.32 0.32

Shear Strength N/mm2 80 80

Impact Strength (ISO179/1987 Charpy Impact Unnotched)

Normal to Laminate KJ/m2 122 122

Hardness - Rockwell M 100 100

Density g/cm3 1.3 1.3

Swell in Water, % of wall thickness % 0.1 0.1

Operating Temperature Range for normal use. (Without special precautions) oC -30/65 -30/65 Max operating temperature oC 130 130 Min. operating temperature oC -150 -150

Thermal Expansion Coefficient 20 - 100 °C (per °C x 10-5) Normal to laminate oC x 10-5 9 - 10 9 - 10 Perpendicular to laminate oC x 10-5 5 - 6 5 - 6

Sliding Properties Typical coefficient of friction running dry against a corrosion resistant surface such as stainless steel. Bearing pressure 15N/mm2 0.13 0.05 - 0.10

Orkot® Marine Bearings Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

Material Properties

Table 1: Metric

Properties Unit TLM Marine TXM Marine

Compressive Strength Normal to Laminate lbs/in2 43511 40611 Parallel to Laminate lbs/in2 13053 13053

Tensile Strength lbs/in2 8702 7977

Flexural Strength lbs/in2 9427 9427

Elastic Modulus Bending lbs/in2 x 104 27.557125 26.10675 Tensile lbs/in2 x 104 46.412 46.412

Shear Strength lbs/in2 11603 11603

Impact Strength (ISO179/1987 Charpy Impact Unnotched)

Normal to Laminate KJ/in2 0.079 0.079

Hardness - Rockwell M 100 100

Density lbs/in3 0.047 0.047

Swell in Water, % of wall thickness % 0.1 0.1

Operating Temperature Range for normal use. (Without special precautions) oF -22/149 -22/149 Max operating temperature oF 266 266 Min. operating temperature oF -238 -238

Thermal Expansion Coefficient 68 - 212 °F (per °F x 10 -5) Normal to laminate oF x 10-5 5.0 - 5.5 5.0 - 5.5

Perpendicular to laminate oF x 10-5 2.7 - 3.3 2.7 - 3.3

Sliding Properties Typical coefficient of friction running dry against a corrosion resistant surface such as stainless steel. Bearing pressure 2175lbs/in2 0.13 0.05 - 0.10

Orkot® Marine Bearings Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

Material Properties

Table 2: Imperial

Reference od id Length Weight od id Length Weight

(mm) (mm) (mm) (Kg) (inch) (inch) (inch) (lbs)

TLM 13 95 47.6 500 3.5 3.7 1.9 19.7 7.7

TLM 21 118 66.7 500 4.9 4.6 2.6 19.7 10.8

TLM 22 150 88.9 500 7.5 5.9 3.5 19.7 16.5

TLM 23A 170 108 500 8.8 6.7 4.3 19.7 19.4

TLM 23 190 120.7 600 12.5 7.5 4.8 23.6 27.6

TLM 24 230 146.1 700 21.9 9.1 5.8 27.6 48.3

TLM 26 305 177.8 780 49.1 12.0 7.0 30.7 108.2

TLM 29 370 235 650 53.3 14.6 9.3 25.6 117.5

TLM 29A 400 270 650 57.8 15.7 10.6 25.6 127.4

TLM 31 445 295 570 64.6 17.5 11.6 22.4 142.4

TLM 32 480 381 590 51.4 18.9 15.0 23.2 113.3

TLM 34 520 403 700 77.2 20.5 15.9 27.6 170.2

TLM 36 595 450 710 110.0 23.4 17.7 28.0 242.5

TLM 39 650 500 800 134.0 25.6 19.7 31.5 295.4

TLM 42 735 600 840 154.0 28.9 23.6 33.1 339.5

Service and Support Trelleborg Sealing Solutions have a team of experienced and highly skilled engineers who offer a full and complete service tailored to your specific requirements. Some aspects of this service are:

● Recommendations on adapting our bearings to specific environmental and operational conditions.

● Calculation of bearing dimensions for pre-despatch or on site machining

● Technical assistance with bearing installations

● Full technical backup and support throughout the service life of the bearing

● 24 hour emergency support

This extensive support service is complimented by a comprehensive range of technical documentation and the Orkot® Marine Bearings calculation program.

Web Site Visit our website on: www.orkotmarine.com for general and technical information on Orkot® Marine Bearings products and applications. You will be able to view and download certificates, literature and other documents.

World Wide Availability Orkot® Marine Bearings distribution network is set up to meet the urgent demands of modern ship repairing.

Standard Orkot® TLM Marine tubes, which can be shipped the same day, are stocked world wide by local distributors in the major ship repairing centres. These are backed up by additional large stocks in our manufacturing plants.

Our modern, well equipped facilities can manufacture specific sizes of raw material in both tube and sheet form for despatch within 24 hours. They can also supply a full range of finished-machined products quickly and economically, including:

● Plain bearings

● Flanged bearings

● Grooved bearings

● Staves

● Thrust bearings

● Spherical bearings

● Wear rings

● Pads

● Strips

● Washers

Orkot® Marine Bearings Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

Marine Stock Tube Sizes Table

Table 3

Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

Standard Production Capacity Guidelines With our current standard equipment and production processes we are able to manufacture parts within the following guidelines. However we specialise in engineering solutions so please do not hesitate to contact us if your requirements fall outside of these limits.

● Tube products up to 2500mm (98”) outside diameter and 1250mm (49”) long

● Sheets products up to 860mm (33”) wide and 3000mm (118”) long

● Rod products up to 200mm (8”) outside diameter and 500mm (19”) long

Contact Details Please refer to our web site for the contact details of your local agent or distributor. Alternatively you can contact one of our manufacturing plants on the following:

Trelleborg Sealing Solutions Rotherham, South Yorkshire, UK:

Phone: +44 1709 789828

Fax: +44 1709 789802

E-mail: enquiries@orkotmarine.com

24 hour emergency mobile phone: +44 1709 789840

Trelleborg Sealing Solutions Eugene, Oregon, USA:

Phone: +1 541 688 5529

Fax: +1 541 688 2079

E-mail: inquiries.americas@orkotmarine.com

24 hour emergency mobile phone +1 800 546 7568

Engineering Manual for Rudder and Water Lubricated Propeller Shaft Bearings

Rudder Bearings This section provides general advice on rudder bearing design. It also provides the information required to allow the user to calculate the machining sizes of a rudder bearing before and after fitting.

Page 25 shows a completed example of the Orkot®

Marine Bearings calculation for you to examine.

Page 24 contains a blank for you to complete your own calculation. Alternatively please feel free to contact your local agent, distributor or manufacturing plant and we will be happy to advise you of the machining sizes.

A spreadsheet based calculation program is available upon request.

Prior to carrying out any calculation, the following information must be available:

● Minimum bearing operating temperature

● Approximate ambient temperature during machining

● Housing and shaft sizes with tolerances

Bearing Design Pressure

Orkot® TLM Marine has classification approval for up to 15N/mm2 (2,176 lb/in2) in rudder bearing applications, while TXM Marine has approval for up to 10N/mm2

(1,450 lbs/in2). Clearly, this is linked to the application and the other components involved. When looking only at the properties of Orkot® Marine bearings much higher loads can be sustained. Orkot® Marine bearings are in use in many other applications such as deck cranes, hatch cover slide pads, mooring systems and ships stabilisers operating at bearing pressures ranging from 25 up to 100 N/mm2 (3,626 - 14,504 lb/in2).

Material Selection

Orkot® TLM Marine is the preferred material grade for rudder stock, pintle, neck and carrier bearings. It incorporates solid lubricants which enable dry running to ensure outstanding wear life for all rudder bushes operating above or below the draft line. The material will operate without lubrication at pressures of 30 N/mm2 (4,351 lb/in2) for short periods and has been tested at pressures of 14.5 N/mm2 (2,103 lb/in2) with a velocity of 1.3 m/min (4.3 ft/min) for 1.5 million cycles with minimum lubrication.

Orkot® TXM Marine is a high performance material which exhibits lower friction and wear properties than our TLM Marine grade. It is approved to operate without lubrication in rudder bearing applications and has been tested, with lubrication against stainless steel for submarine steering gear at 57 N/mm2 (8,267 lb/in2) at 1 m/min (3.3 ft/min).

Lubrication

Water, grease or oil can provide bearing lubrication depending on the application. No axial grooves are required with lubricated rudder bearings. Orkot® TLM Marine rudder bearings are capable of intermittent dry running against K-Monel®, Inconel® 625, Stellite®, duplex stainless and suitable corrosion resistant stainless steels.

Housing and Shaft Requirements

Housing

The bearing housings internal diameter, particularly on refits, should be measured in at least three positions along its length. At least two measurements should then be taken at 90 degrees to each other in the radial plane and the resultant figures used to obtain the average diameters of each position. If the housing is oval or tapered Orkot® can still be used if the problem is not excessive (0.1mm per 100 mm or 0.004” per 4”), the material has some elasticity, but it will not compensate for severe wear. It should be noted that the bearing will take the shape of the housing when fitted with an interference.

The housing should be provided with an adequate chamfer to prevent shaving the bearing when press fitting.

After fitting the bearing should be retained at one end by a shoulder and for additional axial security a keeper ring may be used at the other. The following diagram illustrates this method.

Figure 1: Fitted bearing

Shaft

The shaft or liner surface in contact with an Orkot®

Marine bearing when lubricated by water must be of corrosion resistant material to ensure low wear.

Suitable materials are seawater corrosion resistant stainless steel, phosphor bronze, gunmetal, Inconel®

625 and Stellite®.

The shaft should be smooth, without cutting edges.

The ideal shaft surface finish is between 0.1 and 0.8 Ra micrometers or 4 and 32 Ra micro inches.

Design

Wall Thickness

Normally in refits, the wall thickness of the bearing is fixed by the shaft and housing dimensions.

For new bearing designs the optimum wall thickness should be calculated as:

0.035 x shaft diameter plus 2 mm (0.08”).

Any bearing design with a wall thickness below this value should always be checked by our engineering department to ensure it meets our minimum requirements.

It should be noted that when an Orkot® Marine bearing of the optimum thickness is fitted into a housing the interference is reflected as a reduction of the bearings internal diameter after fitting, i.e. the wall thickness before and after fitting will normally remain constant. Bearings with thicker than optimum walls may give less ”bore closure“.

Operating Value of "m" Temp Machining Temperature (°C)

(°C) 0 5 10 15 20 25 30

0 0.00131 0.00155 0.00178 0.00202 0.00225 0.00249 0.00273 -10 0.00178 0.00202 0.00225 0.00249 0.00273 0.00296 0.00320 -20 0.00229 0.00253 0.00277 0.00300 0.00324 0.00347 0.00371 -30 0.00291 0.00311 0.00331 0.00351 0.00371 0.00391 0.00411

Operating Temp Value

(°C) of "c"

0 -0.125 -10 -0.125 -20 -0.143 -30 -0.158

Table 4 Table 5

Operating Value of "m" Temp Machining Temperature (°F)

(°F) 32 41 50 59 68 77 86

0 0.00131 0.00155 0.00178 0.00202 0.00225 0.00249 0.00273 -10 0.00178 0.00202 0.00225 0.00249 0.00273 0.00296 0.00320 -20 0.00229 0.00253 0.00277 0.00300 0.00324 0.00347 0.00371 -30 0.00291 0.00311 0.00331 0.00351 0.00371 0.00391 0.00411

Operating Temp Value

(°F) of "c"

32 -0.00492 14 -0.00492 -4 -0.00563

-22 -0.00622

Table 6 Table 7

Bearing Interference

As with all polymer bearings, the interference required to hold the bearing in place during operation is higher than that required by metal bearings because the modulus of polymer materials is lower.

Tables 4, 5, 6 and 7 show the various values for “m” and “c” that are required to calculate the recommended interference for Orkot® Marine rudder bearings. These values are dependent upon the minimum operating temperature of the bearing and the temperature of the machine shop at the time of machining. These temperature figures should be used in relation with these tables when selecting the values of “m” and “c”.

Once these values have been obtained from the tables they should be entered into the following equation in order to calculate the required interference.

Interference = (m x Housing ID) + c

Once an interference value has been calculated it can be entered into the…