forced draft blower

LESSON PLAN

FOR

FORCED DRAFT BLOWER MAINTENANCE

A-651-0074B

PREPARED BY

CENTER FOR NAVAL ENGINEERING, LEARNING SITE, SAN DIEGO3975 NORMAN SCOTT RD, SUITE 1, SAN DIEGO, CA 92136-5588

PREPARED FOR

NAVAL EDUCATION AND TRAINING COMMAND250 DALLAS AVENUE, PENSACOLA, FL 32508-5220

DECEMBER 2005

(DECEMBER 2005)

LESSON PLANA-651-0074B

CHANGE RECORD

Number and Description of Change(s) Entered By Date

1. none CORRAL 03 Feb 2006

2. NA figueroa 24 Mar 2003

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TABLE OF CONTENTS

Contents Page

Change Record .............................................................................................................................. 2

Security Awareness Notice .............................................................................................................................. 4

Safety/Hazard Awareness Notice .............................................................................................................................. 5

Terminal Objectives .............................................................................................................................. 9

UNIT 1: FORCED DRAFT BLOWER MAINTENANCE, PRINCIPLES AND PRACTICES

Lesson Topic 1.1: COURSE INTRODUCTION AND ORIENTATION

Lesson Topic 1.2: DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE

Lesson Topic 1.3: FORCED DRAFT BLOWER MAINTENANCE PRINCIPLES AND PRACTICES

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SECURITY AWARENESS NOTICE

In the event that classification information is added, course documents shall be marked and handled in accordance with the regulations of the latest edition of the Department of the Navy Supplement to the DOD Information Security Program Regulation OPNAVINST 5510.1 Series.

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SAFETY/HAZARD AWARENESS NOTICE

The Forced Draft Blower Maintenance Course uses dangerous pressures and temperatures that may be fatal to operating or maintenance personnel. Extreme caution must be exercised during laboratory sessions. While every practical precaution has been incorporated into this course, it is not possible or practical to try to list every condition or hazard that you may encounter. In addition, attention is directed to the Navy Occupational Safety and Health Program, OPNAVINST 5100.23 (series) and Safety Policy and Procedures for Conducting Training, CNETINST 1500.20 (series). Therefore, all operation or maintenance personnel must at all times observe as a minimum, the following:

DON'T SERVICE OR ADJUST ALONE.Under no circumstance will a person operate or maintain equipment without the immediate presence or assistance of another person capable of rendering aid. Unless under direct supervision of a qualified person, no person shall operate or maintain equipment of which he is not qualified.

DON'T TAMPER WITH INTERLOCKS.Reliance on interlock circuits to remove power from the equipment is never to be assumed. Until operation of the interlock is verified, equipment is assumed to be in the hazardous mode of operation. Under no circumstances will any access gate, door, or interlock switch be removed, bypassed or modified in any way by other then authorized maintenance personnel and then only after observing proper tag-out procedures.

Ensure the appropriate valves are open/closed, tagged, or secured as required.

Never place any part of the body into moving machinery.

Do not wear jewelry, necktie, or loose fitting clothing while operating equipment.

Stand clear of the valve outlet when pressure is applied to the relief valve.

TRAINING TIME OUT

5


SAFETY/HAZARD AWARENESS NOTICE (CONT.)

(1) Ensure all students are briefed on TTO policy and procedures prior to each high or moderate-risk evolution or laboratory. For multi-day evolutions, TTO shall be rebriefed prior to the start of training following major breaks, such as meal times. Evolution-specific TTO procedures should be added where needed. These procedures should be standardized to conform with established fleet distress indicators where appropriate (e.g., standard small arms range procedures, diving distress signals, etc.). Emphasis shall be placed on specific verbal and nonverbal signals to be used by students and instructors.

(2) A TTO may be called in any training situation where a student or instructor expresses concern for personal safety or requests clarification of procedures or requirements. TTO is also an appropriate means for student to obtain relief if he or she is experiencing pain, heat stress, or other serious physical discomfort.

(3) Instructors are responsible for maintaining situational awareness and shall remain alert to signs of student panic, fear, extreme exhaustion, or lack of confidence that may impair safe completion of training exercise. Instructor shall cease training immediately when they consider such action appropriate.

(4) Following TTO, the situation shall be examined and additional explanation and instruction shall be provided as needed to allow safe resumption of training. Once the lead instructor on scene is fully apprised of the problem, he/she shall direct all training to cease or training with unaffected students to continue, based on the situation.

(5) If a student refuses to participate in training after being instructed or after an unsafe condition has been corrected, or uses TTO excessively to disrupt training, that student shall be removed from training and referred for further counseling or administrative processing.

Student Briefing

(1) A Training Time Out (TTO) may be called by any student or instructor in any training situation where they are concerned for their own or another's safety, or they request clarification of procedures or requirements.

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(2) The purpose of TTO is for a student to obtain relief if he or she is experiencing pain, heat stress, or other serious physical discomfort, provide clarifying information, or remove the student or instructor from the possible hazardous environment.

(3) A TTO may be signaled by a student raising their hands in a "T" and orally gain the instructor's attention by calling (name and rate) and saying "TIME OUT" or by the instructor using a clear voice saying "TIME OUT-ALL STOP".

(4) If the TTO signal is not acknowledged, the signaler shall shout "Time Out".

(5) The instructor shall attempt to relieve and remove the student from the possible hazardous environment. If an adequate number of instructors are available to allow training to continue safely, the lead instructor may elect to do so. However, if this is not practical, training will be stopped until the situation is corrected.

HOW SHOULD A TTO BE CALLED?By Trainee:Raise hands in a "T" and orally gain the instructor's attention by calling (name and rate) and saying "TIME OUT."

By Instructor:Using a clear voice say "TIME OUT-ALL STOP"

PROCEDURES AFTER A TTO IS CALLEDTrainees:1. Discontinue all work.2. Remove hands from controls.3. Place test equipment down.4. Face instructor.

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Instructors:1. Ensure that all trainees comply with TTO requirements.2. Review correct procedures to use with entire class3. Ensure that the particular trainee who called for the TTO (if the TTO was requested by a trainee) completely understands a questioned procedure.4. Ensure that any unsafe conditions have been corrected before resuming training.

REPORT ALL HAZARDS.If at any time you detect a hazard, it is your responsibility to report the hazard to ensure that it is corrected. If at any time you detect a "new" or "suspected new" hazard, particularly due to equipment installation, modification or repair, it is your responsibility to ensure that a SAFETYGRAM is submitted to the Naval Safety Center, Norfolk, VA, in accordance with OPNAVINST 5100.9 series. This will ensure that this hazard will be investigated, publicized, or corrected, as required.

Pre-Mishap PlanThe Pre-Mishap Plan explains the procedures to follow and essential telephone numbers to call in case of an accident or emergency. It is located by the emergency exit in the laboratory.

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TERMINAL OBJECTIVES

1.0 PERFORM Preventive and Corrective Maintenance on Forced Draft Blowers in accordance with Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010. (CTTL item # 1)

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LESSON PLAN

Unit 1. FORCED DRAFT BLOWER MAINTENANCE, PRINCIPLES AND PRACTICES A-651-0074B

CLASS PERIODS: 1LAB PERIODS: 0

PA PERIODS: 0

Topic 1.1 COURSE INTRODUCTION AND ORIENTATION

Enabling Objectives:

1.1 DESCRIBE the course introduction and orientation of the Forced Draft Blower Maintenance course.

Trainee Preparation Materials:

A. Trainee Support Materials:

1. None

B. Reference Publications:

1. None

Instructor Preparation:

A. Review Assigned Trainee Material


1. None

C. Training Materials Required:

1. Slides

a. FTC Site Map, 1–1–1

b. Bldg. 3280 Diagram, 1–1–2

2. VI Equipment

a. Computer, Power Point, 563001

b. LCD Projector, SL8620150

1-1-1

LESSON PLAN



DISCUSSION POINT RELATED INSTRUCTOR ACTIVITY

1. Introduction 1. Establish Contact.

Introduce yourself and give any background on yourself that might be of interest.

Establish Readiness.

Motivating Statements.

Tell trainees how they will use the course material.

Prepare the Computer, Power Point, 563001.

Prepare the LCD Projector, SL8620150.

a. Student(s) introduce themselves

b. Choose Class Leader

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LESSON PLAN




2. Purpose: This course orientation is designed to give trainees a brief overview of the course and prepare trainees for training.

3. Trainee Check-in

a. Collect orders

b. Verify Per DIem Requirements. PCS Trainees Check In with PLR's

4. Class Rules

a. Uniform of the day for classroom

b. For the lab, utilities for E-6 and below, wash khaki for E-7 and above, and safety shoes or equivalent working uniform for civilian(s).

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c. Morning Muster at 0730 with the class leader

d. Breaks

(1) Ten minute break every hour

(2) One hour lunch break from 1130-1230.

e. Secure for the day at 1600. Class leader is responsible for clean-up.

f. Smoking area is behind Bldg. 3290

g. Vending machines are located between A and B-wing, next to the staff / student gym.

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LESSON PLAN




h. If a student / trainee is going to be late or has some other emergency, call the office at (619) 556-7537, and / or contact the class leader.

5. Fire / Flood / Earthquake 5. Display Power Point Slide 1-1-1, FTC Site Map.

Display Power Point Slide 1-1-2, Bldg. 3280 Diagram.

a. Exit building through the nearest exit and muster with the Class Leader in front of Bldg. 3290.

b. Last person out of the room ensure all windows and doors are closed (if time permits).

6. Restrooms and Facilities

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a. Male restrooms are located at the west end of the 1st deck passageway in C-wing; female restrooms are located on the east end of the 1st deck passageway and on the west end of the 2nd deck passageway.

b. Lockers for trainees are located on the first deck B-wing.

c. Cleaning gear locker is located on the east end of the 1st deck passageway in B-wing.

7. Instructor's expectations of the trainees

a. Be on time for class, ready to start by 0730.

b. Complete homework, if turned in incomplete, it will not count for full grade (no copies).

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LESSON PLAN




c. Homework must be legible and on 81/2" x 11' paper.

d. Turn in homework by 0730 on the due date, if not done or is incomplete, trainee will stay behind to complete.

e. If you have any questions raise your hand.

f. No horseplay.

g. Follow all saefty precautions.

h. Recommend taking notes - they are a good study guide.

i. Classroom clean-up as directed by the instructor.

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LESSON PLAN




8. Course Length

a. Four calender days.

b. Four class days.

(1) Classroom - 1 day

(2) Laboratory - 3 days

9. Topics Covered

a. Forced Draft Blower Maintenance Technical Documentation

b. Forced Draft Blower Maintenance Principles and Practice

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LESSON PLAN




10. Requirements for satisfactory completion of the course

a. Pass safety test.

(1) Ten questions

(2) Time limit is one hour.

(3) Closed-book

(4) Cannot use notes

(5) Passing grade is 100

(6) Must pass safety test to go into the lab

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b. Final Written Comprehensive Test

(1) Thirty questions

(2) Time limit is three hours

(3) Open book and can use notes

(4) Passing grade is 70

c. Final Performance Test

(1) Satisfactory performance is 70

(a) Three hours

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LESSON PLAN




(b) In groups of one to five trainees

(c) Consists of the application of classroom training

(d) Presented in the lab

(e) Passing grade is 70

11. Trainee academic programs

a. Fail test

b. Academic counseling

c. Remedial training after hours

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LESSON PLAN




d. Retest

e. Fail retest - academic counseling

f. Academic Review Board

(1) If the retest is failed, the ARB will try to determine what the cause of the failure is and if the student will be dropped from the course or remain in school.

12. Critique Sheets

a. Critique of the course

b. Critique of the instructor

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LESSON PLAN




c. Quality of Life critique

13. Present trainees the instructional materials

a. Issue Trainee Guide

b. Issue Technical Manuals

c. Issue and fill out trainee performance record sheets

d. Introduce trainees to the trainee guide

e. Inventory assigned TM's and sign inventory sheets

14. Review and Summary

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LESSON PLAN




a. Purpose

b. Trainee check-in

c. Class Rules

d. Fire / Flood / Earthquake

e. Restrooms and Facilities

f. Instructor expectations of the trainee

g. Course Length

h. Topics Covered

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LESSON PLAN




i. Satisfactory completion of the course

j. Trainee Academic Review Board

k. Critique Sheets

l. Present trainees the instructional materials

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LESSON PLAN



PA PERIODS: 0

Topic 1.2 DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE


1.2 DESCRIBE the terminology, design characteristics, operation, symptoms, probable cause(s) of malfunction, and maintenance of the Hardie Tynes and Westinghouse horizontal forced draft blowers as per applicable technical references.

1.3 DESCRIBE the personnel and equipment safety precautions to be observed while performing maintenance on forced draft blowers in accordance with applicable technical references.

1.5 ADHERE to personal and equipment safety precautions in accordance with Navy Safety Precautions For Forces Afloat, OPNAVINST 5100.19 Series.



1. DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE, Outline Sheet 1–2–1

2. DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE, Assignment Sheet 1–2–2


1. Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010

2. Equipment Manual for Main Forced Draft Blower (FF 1054-1066), NAVSEA 0953-009-7010

3. NSTM 554, Forced Draft Blowers, NAVSEA 0910-LP-554-0000




1. Review Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010

2. Review Equipment Manual for Main Forced Draft Blower (FF 1054-1066), NAVSEA 0953-009-7010

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LESSON PLAN



3. Review Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series)

4. Review NSTM 554, Forced Draft Blowers, NAVSEA 0910-LP-554-0000

5. Review Safety Precautions for Conducting Training, CNETINST 1500.20 series


1. Instruction Sheets

a. DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE, Outline Sheet 1–2–1

b. DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE, Assignment Sheet 1–2–2

2. Equipment

a. Journal Bearing (Mock-Up)

b. Shaft (seal) Gland

c. Thrust Bearing

3. Slides

a. HTH Casing Sections, 1–2–1

b. HTH Casing Sections, 1–2–2

c. HTH Integral Spacer, 1–2–3

d. HTH Internal Setup, 1–2–4

e. HTH Shaft Assembly, 1–2–5

f. HTH Turbine, 1–2–6

g. HTH Thrust Bearing Assembly, 1–2–7

h. HTH Lube Oil System, 1–2–8

i. HTH Oil Control Block, 1–2–9

j. WHH Casing, 1–2–10

k. WHH Casing (other end), 1–2–11

l. WHH Compressor Assembly, 1–2–12

m. WHH Internal Setup, 1–2–13

n. WHH Journal Bearing, 1–2–14

o. WHH Internal Setup, 1–2–15

p. HTH Thrust Bearing Assembly, 1–2–16

q. WHH Lube Oil System, 1–2–17

4. Training Devices

a. Visual Aid Panel

5. VI Equipment

a. Computer, Power Point, 563001

b. LCD Projector, SL8620150

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LESSON PLAN







Motivating Statements.

Tell trainees how they will use the course material.

Tell trainees why they need to know the lesson material.

Prepare the Visual Aid Panel for classroom use.

Prepare the Computer, Power Point, 563001.

Prepare the LCD Projector, SL8620150.

Prepare the Journal Bearing (Mock-Up) for classroom demonstration.

1-2-3

LESSON PLAN




Prepare the Shaft (seal) Gland for classroom demonstration.

Prepare the Thrust Bearing for classroom demonstration.

Direct trainees to Outline Sheet 1-2-1, DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE.

Direct trainee to Assignment Sheet 1-2-2, DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE.

2. General Description of Hardie Tynes Horizontal and Westinghouse Horizontal Forced Draft Blowers.

a. General Description.

(1) Usually takes a suction from the the space between the inner and outer stack casing.

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LESSON PLAN




(2) The propeller type blower pushes air through the blower in the same manner as an ordinary fan.

(3) Air flow is axial in the propeller forced draft blower.

(a) The propeller forces the air to move in a direction parallel to the axis of the shaft.

(4) Propeller type blowers are better suited to handle higher pressure and larger capacities.

(a) Multi-stage units deliver higher pressure and larger capacities.

(5) Multi-stage units are usually found on ships with 1200 PSI systems.

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LESSON PLAN




(a) Each stage serves to compress the air to a higher pressure.

NOTE: Propeller type blowers may be horizontal or vertical, being of one, two or three stages. Two and three stageas are most common in modern Naval use.

NOTE: Black oxide fasteners should not be used in any Level 1 components or systems exceeding 200 degrees F, foundation attachments, or hull integrated components

3. Description of the Hardie Tynes (Horizontal) Forced Draft Blower

3. Show Power Point Slide 1-2-1, HTH Casing Sections.

a. This blower is classified as a two-stage, horizontally mounted, turbine driven, axial flow propeller type forced draft blower, mounted on a common shaft with a Curtis type turbine.

1-2-6

LESSON PLAN




(1) The forced draft blower has a rated horsepower of 600 HP and a rated capacity of 31,000 CFM at 5515 RPM.

(2) A typical arrangement is four blowers per ship on board.

(3) There are two blower rooms with two blowers each.

(4) Blowers are located on the main deck above the boilers. They take air form the plenum chamber and series of ducts.

(5) The blower shafts are mounted horizontally with the inlet at one end, discharge on the bottom. The discharge flange also serves as the base and mounting support.

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LESSON PLAN




(6) Inlet steam connection on one side and exhaust on the other.

(7) Each unit has an integral lube oil system, sump and turbine speed control system

(8) All steam passes through a steam strainer, governor controlled steam inlet valve, and into the steam chest.

(a) Steam chest has nozzles of sufficient size to enable unit to operate at full power.

(b) Hand nozzle (overload) is normally closed and should never be opened unless boiler power in excess of normal is required. It is used only to bring the unit to its rated speed of 5515 RPM.

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LESSON PLAN




(c) The hand nozzle is also opened when pressure is below 1200 PSI, and the temperature is below 675 degree F.

(9) Operating speed is controlled by a Woodward PG-PL governor.

NOTE: MACHALT 251-48001-179 replaced PG-PL Governor model 9900-047 with model 9900-356. It also provided the Woodward governor with a hydraulic amplifier power cylinder. This aids the governor by amplifying the low level governor oil output to a useable level to activate the steam admission valve operator. This MACHALT also provided replacement of steam admission valve seat, labyrinth seal plug and valve stem, valve linkage pins and bearings with newly revised design components.

b. Major Parts

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LESSON PLAN




(1) Forced Draft Blower Casing

(a) Consists of a number of steel weldments and casings, which support and enclose rotating parts.

(b) It also encloses and directs the flow of steam and air.

(c) The four main divisions of the casing are as follows: The thrust bearing bracket and cover, the turbine case, the discharge elbow, and the blower casing.

(d) Thrust bearing bracket cover, with lube oil drive assembly houses and carries the thrust bearing lube oil pump and governor drive, the tachometer generator and drive

(d) Show Power Point Slide 1-2-2, HTH Casing Sections.

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LESSON PLAN




(e) The turbine case is made up of the exhaust case, the turbine case cover and the exhaust case cover.

(f) The steam inlet valves and the nozzle valves are attached to the exhaust case cover.

(g) The steam turbine casing halves are bolted together with a metal to metal fit.

(h) The discharge elbow forms the center barrel of the unit, carrying the main shaft bearings.

(i) The elbow receives air discharge from the fan wheels and turns it about 90 degrees.

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LESSON PLAN




(j) The blower casing consists of the inlet section, stator housing, and two propeller type fan wheels.

(k) The frame which serves as a base for the blower contains the oil sump and passageways for air discharged from the elbow. The inlet valve operator is mounted on the frame.

(l) The arrangements of horizontal and vertical joints is such that the turbine wheel can be removed without dismantlling the discharge elbow or the blower end of the assembly.

(m) Conversely, the inlet section, the stator and fan wheels may be removed without dismantling the discharge elbow or the turbine end of the assembly.

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LESSON PLAN




(2) Blower Elements (2) Show Power Point Slide 1-2-3, HTH Integral Spacer.

(a) The blower elements consist of two propeller type fan wheels, two stationary or stator blades and an inlet section. Each fan wheel is keyed to the shaft by two keys.

(b) The first stage fan wheel discharges through first stage stator blades. These stator blades straighten out and direct the air flow to the second stage fan wheel.

(c) The first stage stator blades are pressed into the stator housing and tack welded.

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LESSON PLAN




(d) The second stage fan wheel discharges air to the second stage stator blades and are welded to the inner and outer annular members of the stator housing.

1) All parts are machined from stainless steel forgings.

2) The fan wheels have helical slots in the outer rim in which the fan blades are inserted and retained by dowels.

3) The second stage fan wheel has an integral spacer shrunk on the wheelrim and serves as fairing between the wheels.

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LESSON PLAN




(e) The inner or second stage fan wheel bears against a sholder on the shaft. The first satge fan wheel bears against the second stage wheel and is retained by a locknut and lockplate.

(f) Both first and second stage fan wheels are mounted on a shaft on a continuous taper.

(g) The diameters of the tapered fan wheel bores and the lengths of the central bosses are very accurately machined to insure the correct stress when the wheels are mounted on the shaft.

(h) The first method of disassembly involves removing both fan wheels and the turbine bucket wheel from the shaft while it is supported in its bearings (most practical aboard ship).

(h) Show Power Point Slide 1-2-4, HTH Internal Setup.

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LESSON PLAN




(i) The second method involves removing upper and lower half of the complete casing so that the rotor assembly may be removed as a unit. This method is used by Navy shipyards for checking balance of rotor or re-balance of rotor.

(3) Blower Shaft Seals (3) Show Power Point Slide 1-2-5, HTH Shaft Assembly.

(a) Approximately full blower static discharge exists at the inboard side of the second stage fan wheel.

(b) Air leakage into the journal bearing cavity would cause foaming and aeration of lube oil. To prevent this, an edge type-annular seal is provided.

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LESSON PLAN




(c) A series of radial hole in the center of this seal are vented to the atmosphere, through passageways in the bearing housing and discharge elbow.

(d) An edge-type annular seal is also provided on the turbine side of the turbine bearing to keep foreign matter out of the bearing.

(4) Bearings

(a) Two journal bearings are used to support the rotating element of each blower and to absorb the radial load of the blower shaft.

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LESSON PLAN




(b) The two main jounal bearings shells are interchangeable and positioned by dowels so that oil grooving in each shell is in the proper position in relation to the bearing load and direction of rotation.

(c) A third smaller journal bearing is an integral part of the thrust bearing.

(d) An integral oil pump supplies oil to the grooves in the bearing shells at a pressure of 10 to 15 PSI at all speeds above 3000 RPM.

(e) Oil pressure decreases to approximately 2 PSI at 800 RPM at which pressure the low pressure oil shutdown valve located inside the governor is activated, causing the steam admission valve to close down.

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LESSON PLAN




(5) Turbine Glands

(a) Two Labyrinth Type sealing glands are provided where the rotor shaft leaves the turbine casing, one at the outboard end, one at the inboard end.

(b) These glands serve as seal to prevent the escape of exhaust steam from the turbine casing.

(c) Each packing piece is divided into four, spring loaded sections.

(d) Staggered annular knife edges on the inner diameter of the packing rings have a slight positive clearance over corresponding shoulders on rotor shaft.

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LESSON PLAN




(e) If contact occurs between the shaft and the knife edges of packing, the latter may move radially outward to relieve the rubbing pressure.

(f) If contact occurs, the material of the packing ring is such that it will tend to wear off instead of scoring the shaft.

(g) The annular space between the two sealing elements in each packing case is connected with the leak off flanges on the outside of the turbine case.

1) This allows all steam leaking past the inner sealing members to be collected, along with some air leaking in past outer sealing members.

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LESSON PLAN




(6) Turbine Assembly Working Elements (6) Show Power Point Slide 1-2-6, HTH Turbine.

(a) The turbine assembly consists of the turbine wheel and the stator ring assembly.

(b) The turbine wheel consists of two rows of blading mounted on its outer rim.

(c) The stator ring carries the stationary blading and the nozzle block.

(d) The nozzle block is two sets of nozzles welded together so as to form a continuous band.

(e) Steam from the nozzles enters the first row of blading on the bucket wheel.

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LESSON PLAN




1) Since the steam leaving the first row of blading still has a high velocity, to improve the thermodynamic efficiency of the forced draft blower.

2) The stator blading directs the steam against the second row of bucket wheel blading.

(7) Kingsbury Type Thrust Bearing (7) Show Power point Slide 1-2-7, HTH Thrust Bearing Assembly.

(a) Thrust bearing consists of three main elements: The thrust collar, the combined journal/plain thrust bearing, and the pivoted shoe type thrust bearing.

(b) The two bearing elements are prevented from rotation by dowels.

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LESSON PLAN




(c) The thrust collar is keyed to the shaft with two keys and located axially by a shoulder on the shaft and retained on the shaft by a nut.

(d) The axial positions betweeen the two thrust elements is adjusted be selecting a spacer of proper thickness while the end play of the rotor assembly is adjusted by grinding spacers to proper thickness.

(e) When the blower is in operation, the pivoted-shoe thrust bearing assembly will take all of the thrust load. Steam pressure on the bucket wheel and air pressure on the fan wheels will tend to push the rotor toward the fan end.

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LESSON PLAN




(f) Lubricating oil connections are provided to both of the bearing elements. Since the drain is on top of the bearing assembly, some oil will normally be retained in the lower half to help provide lubrication when starting up.

(8) Overload Nozzle Control Valve

(a) It is manually operated valve that is used during emergencies and when the steam pressure is below 1200 psi and the steam temperature is below 675 degrees. It is either fully open or fully closed.

(9) Electric Tachometer

(a) Consists of a stator, and a permanent magnet rotor.

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LESSON PLAN




(10) Lubricating Oil System (10) Show Power Point Slide 1-2-8, HTH Lube Oil System.

(a) The lube oil sump has a capacity of 32 gallons of 2190 TEP at high level and 28 gallons low level.

(b) The attached circculating pump is a Tuthill reversing type pump, rated at 13 GPM and 75 PSI at 5515 RPM's.

(c) Provides protection to the unit during windmilling conditions.

(d) Lube oil pump discharge relief valve. Range 65-95 PSIG set at 90 PSIG

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LESSON PLAN




(e) Lube Oil Strainer. knife edge type. By-pass relief valve set at 10 PSIG (differential Pressure).

(f) The 4-way valve is installed to allow the cooler to be bypassed during warm-up. Replaced in some applications with thermostatic L.O. Temp. Control valve.

(g) Two Pressure switches control the motor driven L.O. pump.

1) The first switch (Registered at the oil control block), starts the pump at 30 psi, and stops it at 36 psi.

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LESSON PLAN




2) Second swtich is connected to air signal Pressure, it starts the pump when control air drops to 15 psi and stops the pump when air signal reaches 21 psi.

(h) Lube Oiil Cooler. Shell and tube type heat exchanger.

(i) Thermostatic Temperature Regulating Valve. Automatically controls cooling water flow through the cooler.

(j) Oil Control Block. H.P. valve maintains 65 PSI in L.O. cooler and Steam admission valve operator by draining the excess oil pressure back to the sump. Back pressure valve holds 2 PSI above bearing oil supply pressure.

(j) Show Power Point Slide 1-2-9, HTH Oil Control Block.

1-2-27

LESSON PLAN




(k) Bearing oil relief valve. Maintains 9-15 PSI oil pressure to bearings. A speeds above 3000 RPM, it provides cooling medium to governor L.O. cooler.

4. Dicription of the Westinghouse ( Horizontal) Forced Draft Blower.

4. Show Power Point Slide 1-2-10, WHH Casing.

a. The Westinghouse Horizontal Forced Draft Blower is a two-stage axial flow, turbine driven forced draft blower. Technical specifications are as follows:

(1) Operating steam pressure is 900-1250 psig.

(2) Operating steam temperature range is 620-675 degrees F.

(3) Full air discharge capacity is 31,700 CFM.

1-2-28

LESSON PLAN




(4) Woodward PG/PL type govenor limits speed at 7400 RPM. This setting will vary in accordance with PMS.

CAUTION: Do not permit blower to exceed 7844 RPM.

(5) Estimated critical speed is 10,800 RPM.

(6) Blower overspeed test is 9250 RPM.

(7) Governor will shut down the unit if lube oil pressure drops to 5-6 psi.

b. A typical arrangement is four blowers per ship.

(1) Two units serving each Boiler.

1-2-29

LESSON PLAN




(2) Two blowers rooms with two blowers per blower room.

(3) Blowers are mounted on the main deck.

(4) Each blower draws air from the intake louvers located on the stack.

(5) The fireroom is under atmospheric pressure.

(6) The blower shafts are mounted horizantally.

(a) Has a conical end intake and a rectangular bottom discharge.

1-2-30

LESSON PLAN




(7) Blowers are balanced automatically with counter weighted shutters between blowers and boiler casing which permit shutdown of a blower when air flow demands are reduced.

(a) No blower anti-rotation pin are used to prevent shaft windmilling from back draft, once the blower is shut off.

(b) However, the attached lubicating oil pump does provide lubrication to blower bearing under windmilling conditions.

(8) Each blower has a rigid casing enclosing two axial flow propellers mounted on a common shaft and driven by a single-stage Curtis turbine, consisting of two rotating rows of blades on a signal rotor disc. The casing also encloses a single partial row of statioinary blades.

1-2-31

LESSON PLAN




(9) External shaft-driven oil pump provides oil pressure and flow for cooling journal bearings and thrust bearings.

(10) Has an auxiliary electric lubricating oil pump.

(11) The blower speed is regulated by a Woodward governor.

(12) All steam enters the F.D.B steam chest via the steam governor valve. The turbine steam chest nozzle are divided into two groups by connecting passages.

(12) Show Power Point Slide 1-2-11, WHH Casing (other end).

(a) The primary consists of two nozzles and the secondary group consists of four nozzles.

1-2-32

LESSON PLAN




(b) Blower air delivery requirements up to full power are met by steam flow through the primary nozzle group, with the steam admission valve in the fully open position.

1) Due to repeated failures caused by high steam impact forces on the turbine blades, the overload nozzle should be locked open.

(c) This Provides a continuously open steam path to the addition four nozzle in the secondary chamber area, thereby increasing the number of nozzle for the same steam flow.

1-2-33

LESSON PLAN




1) Where ShipAlt FF1052 786D has been accomplished, the steam overload nozzle valve has been removed and blank installed to simulate the valve in the locked-open position.

c. Blower Casing

(1) The discharge casing is horizontally divided into upper and lower halves, fastened together by a flanged and bolted joint to the inlet casing.

(2) The inlet casing consists of a curved inlet cone and flanged at each end.

d. Stationary Guide Vanes d. Show Power Point Slide 1-2-12, WHH Compressor Assembly.

1-2-34

LESSON PLAN




(1) Two stationary blade rings, one between the two propellers, another downstream of the propellers reduces turbulent air flow and thus increases overall efficiency of the unit.

(2) The stationary blading housing is bolted.

e. Propellers

(1) The propellers are forged stainless steel disc with stainless steel blades.

(a) The blades have truncated, bulb shaped roots attached in equally-spaced annular grooves across the hub of the propeller disc.

1-2-35

LESSON PLAN




(b) Each blade is magnetic particle testested for cracks then individually weighed for proper weight distribution.

(c) The blades are held in place be a locking pin; and blades are tightened in place by upsetting the metal in the propeller disc.

(d) The propellers are keyed to the shaft and secured on a taper fit with a locknut an lock screw on each stage.

(e) Heat is used on the rotor disc to tighten the locknut in place on both propeller stages.

(f) Second stage disc has a larger bore than the first stage.

1-2-36

LESSON PLAN




(g) Both blades are dynamically balanced on the shaft by metal removal from the propeller disc.

(h) Threaded balance holes in the propeller disc along with similar holes in the turbine disc make infield balancing possible.

f. Rotor Shaft f. Show Power Point Slide 1-2-13, WHH Internal Setup.

(1) Machined from solid steel forging.

(2) Mounted on the rotor shaft are the tachometer rotor shaft, propeller discs, turbine rotor disc, thrust bearing collar and pump pinion.

1-2-37

LESSON PLAN




(3) The direction of rotation is clockwise viewed from the inlet end of the blower.

g. Oil and Air Seals

(1) Oil seals are located on both sides of the blower end journal bearing, also on the turbine cylinder side of the thrust end journal bearing.

(2) Air seals on the blower end is vented to the atmosphere through drilled passages providing for air leakage.

h. Journal Bearings

(1) Two bearings, one on the blower end and one on the thrust end, position the shaft radially.

1-2-38

LESSON PLAN




(2) These segmented, tilting shoe type journal bearings, carry the weight of the entire assembly.

(a) The bearing consist of aligning ring, two shoe retaining plates, five shoes and the necessary pins.

(a) Show Power Point Slide 1-2-14, WHH Journal Bearing.

(b) Aligning ring consists of two half sections, held together by aligning ring joint taper pins.

(c) Fixed in position so that it will not rotate by an aligning pin dowel through the aligning ring into the casing.

(d) Drilled passages in the aligning ring supplies oil to the bearing surfaces.

1-2-39

LESSON PLAN




(e) Five journal bearing shoes are positioned by two shoe stop pins. This permits the small angular movement necessary for the information of an oil film wedge between the babitted surface of each shoe and the journal surface of the rotating shaft.

(f) Oil draining from the bearing passes from the grooves radially outward through six drilled holes.

i. Steam Glands i. Show Power Point Slide 1-2-15, WHH Internal Setup.

(1) Steam glands on both sides of the turbine cylinder prevents steam leakage along the blower shaft. An annular space between these steam glands is connected to the auxiliary gland exhaust system maintained under 10" H2O vacuum.

1-2-40

LESSON PLAN




(2) Glands are of the labyrinth type.

(a) Each gland consists of four nickel-bronze labyrinth seal sections which are held togehter as a ring by circumferential tensioning srping.

(3) A slight clearance is maintained so that steam flow leakage is minimized at low metal temperatures while adequate clearance is kept at high metal temperatures.

j. Turbine Assembly

(1) Single Stage Curtis turbine consisting of two rows of rotating blading, mounted on single rotor disc with single partial row of stationary blades.

1-2-41

LESSON PLAN




(2) Turbine rotor is keyed to blower shaft and axially secured against a raised shoulder by a rotor disc locknut.

(a) Locknut is held in place by a set screw.

k. Thrust Bearing k. Show Power Point Slide 1-2-16, HTH Thrust Bearing Assembly.

(1) Kingsbury type thrust bearing.

(2) Provides dual process - provides dual direction load distribution as well as axial rotor adjustment.

(3) Reverse thrust caused by shock accelerations or windmilling is carried by an identical three-shoe section on the opposite side of the thrust collar.

1-2-42

LESSON PLAN




l. Tachometer

(1) Same as other blowers.

m. Lube Oil System m. Show Power Point Slide 1-2-17, WHH Lube Oil System.

(1) Sump

(a) 41 gallon 2190 TEP.

(b) 4 bolted access openings to allow for cleaning.

(c) Flanged drain connection at bottom.

(d) Internal baffles to minimize sloshing.

1-2-43

LESSON PLAN




(2) Attached L.O. Pump

(a) Tuthhill reversing.

(b) 20.5 GPM, 45 PSIG @ 1070 RPM.

(3) Auxiliary L.O. Pump

(a) Motor driven.

(b) Manual or automatic.

(c) Auto - on at 10 PSIG, off at 24 PSIG.

1-2-44

LESSON PLAN




(d) Manual operation is used during start-up of the blower. Once the blower is started, the pump is switched to automatic. The pressure switch is set to shut down the pump automatically when the system pressue reaches 24 PSI.

(e) Electrically driven pump delivers 40 PSIG and rotates at approximately 1850 RPM.

(4) Ball Check Valves.

(a) Both lube oil pump discharge lines.

(b) Oil pressure on operating pump pushes its ball valve open and forces the idle pump ball valve shut.

1-2-45

LESSON PLAN




(5) Oil Filter

(a) Duplex type.

(b) 33 micron elements.

(c) Bypass relief @ 10 PSI differential.

(d) Two filters connected in parallel.

(6) Relief Valve

(a) Set @ 45 PSIG, relieves back to the sump.

(7) Four-Way Bypass Valve.

1-2-46

LESSON PLAN




(a) Provided in the lubrication line to and from the oil cooler so that it may be cut out of the system without interrupting the flow to the bearings.

(b) Used primarily at start-up to promote more rapid warm-up of the blower.

(8) Thermostatic 3-way Oil Temperature Control Valve

(a) Installed on some ships in conjunction with ShipAlt FF 1052-639 to replace the four-way bypass valve.

(b) Located in the lubrication line to and from the cooler.

1-2-47

LESSON PLAN




(c) The fully automatic operation is designed to blend in cooler oil without restricting oil flow to the bearings.

(d) The preset temperature elements provide tamper proof operation. These elements control the mixing of the fluids from two independent sources.

(e) As the oil temperature increases exceeding the parameters of the thermostatic element, the bypass valve closes. The outlet side froim the cooler opens allowing lube oil to pass from the cooler into the lube oil system.

(f) Elements must be changed to adjust temperature settings.

1-2-48

LESSON PLAN




(g) Maintains oil temperature between 120 to 130 degrees F to bearings.

(9) Lube Oil Cooler

(a) Shell and tube type heat exchanger. Lube oil absorbs the heat by passing around the tube bundle and is cooled by the sea water flow through the tubes.

(b) Some installations have a lube oil temperature regulator valve on the sea water outlet line which keeps the bearing oil temperature between110 and 130 degrees F.

1) Other installations have the thermostatic oil temperature regulating valve as previously discussed.

1-2-49

LESSON PLAN




(c) A 7/16" orifice is installed on the outlet side of the cooler to help maintain the cooler in a flooded state.

(d) Cooler designed to pass oil to bearings @ 6 gpm.

(10) Pressure Switch.

(a) Controls auxiliary L.O. pump.

(b) Closes and starts pump @ 10 psig.

(c) Opens and stops pump @ 24 psig.

(11) Governor L.O. Cooler.

1-2-50

LESSON PLAN




(12) Bearing Oil Supply Orifices.

(a) Located in the individual bearing oil supply lines control the oil flow rate to each bearing.

(b) 2.0 GPM to thrust bearing.

(c) 1.8 GPM to thrust end journal bearing.

(d) 1.5 GPM to blower end journal bearing.

(e) 6 GPM to governor lube oil cooler.

5. Maintenance Procedures.

1-2-51

LESSON PLAN




a. Hardie Tynes Horizontal Forced Draft Blower a. Refer to Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010, Chapter 6 Section 4.

b. Westinghouse Horizontal Forced Draft Blower b. Refer to Equipment Manual for Main Forced Draft Blower (FF 1054-1066), NAVSEA 0953-009-7010, Chapter 5 Section 4 through 6.

6. Safety Precautions. 6. Reference Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series).

Reference Safety Precautions for Conducting Training, CNETINST 1500.20 series.

Reference Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series).

a. Personnel

1-2-52

LESSON PLAN




(1) Never place any part of the body into moving machinery.

(2) Never attempt to ride machinery which is not designed for transport.

(3) Do not wear jewelry, neckties, or loose fitting clothing while operating equipment.

(4) Wear proper protective clothing and equipment suited to the operation being performed (i.e. hearing protection, eye, hand and foot protection, dust, and paint respirators).

(5) Wear fire retardant clothing when operating fuel-fired equipment or while standing watch or perforrming maintenance in piping systems.

1-2-53

LESSON PLAN




(6) Wear long sleeved shirts when performing maintenance in machinery spaces where steam is circulating in piping systems.

(7) Observe manufacture's safety precautions and warning labels when handling flammable liquids.

(8) Ensure that the ventilation is adequate. Avoid breathing toxic fumes; wear proper personnel protective equipment.

b. Equipment b. Refer to Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010, Safety Summary.

Refer to Equipment Manual for Main Forced Draft Blower (FF 1054-1066), NAVSEA 0953-009-7010, Safety Summary.

1-2-54

LESSON PLAN




Refer to NSTM 554, Forced Draft Blowers, NAVSEA 0910-LP-554-0000, Safety Summary.

(1) Ensure equipment is deenergized and/or depressurized and properly tagged out of service before attempting to perform maintenance.

(2) Prior to turbine overhaul, ensure the Combined Exhaust/Relief Valve (CERV) is placed in the "safety" position.

(3) Always know the strength and condition of the rigging equipment that will be used and the weight of the unit or component that will be lifted. Always leave at least 50 percent safety factor.

1-2-55

LESSON PLAN




(4) After turbine overhaul, reset the Combined Exhaust/Relief Valve (CERV) to the relief position.

(5) Inspect all pipe openings to ensure they are free of all foreign material prior to making of connections.

(6) Promptly reinstall shaft guards, coupling guards, deckplates, handrails, flange shields, and other protective devices removed as interference immediately after completion of maintenance on machinery, piping, valves, or other system components.

7. Training Time Out (TTO) Procedures.

1-2-56

LESSON PLAN




a. A Training Time Out (TTO) may be called by any trainee or instructor in any training situation where they are concerned for their own or another's safety, or they request clarification of procedures or requirements.

(1) TTO is also an appropriate means for student to obtain relief if he or she is experiencing pain, heat stress, or other serious physical discomfort.

(2) The purpose of the TTO is to correct the situation of concern, provide clarifying information, or remove the trainee or instructor from the possible hazardous environment.

(3) A TTO may be signaled by (insert appropriate non-verbal, alarm, or hand signal).

1-2-57

LESSON PLAN




(4) If the TTO signal is not acknowledged, the signaler shall shout "TIME OUT" (or other action as required by the training facility).

(5) The instructor shall attempt to relieve and remove the trainee from the possible hazardous environment.

(6) If an adequate number of instructors are available to allow training to continue safely, the lead instructor may elect to do so. However, if this is not practical, training will be stopped until the situation is corrected.

b. How Should A TTO Be Called?

(1) By Trainee:

1-2-58

LESSON PLAN




(a) Raise hands in a "T" and orally gain the instructor's attention by calling (name and rate) and saying "TIME OUT".

(2) By Instructor:

(a) In a clear voice say "TIME OUT-ALL STOP".

c. Procedures after a TTO is called.

(1) Trainees:

(a) Discontinue all work.

(b) Remove hands from controls.

1-2-59

LESSON PLAN




(c) Place test equipment down.

(d) Face instrructor.

(2) Instructor

(a) Ensure all trainees comply with TTO.

(b) Review correct procedures to use with entire class.

(c) Ensure that the particular trainee who called for the "TTO" (if the TTO was requested by the trainee) completely understands a questioned procedure.

(d) Ensure that any unsafe conditions have been corrected before resuming training.

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LESSON PLAN




8. SUMMARY 8. Review Main Teaching Points and paraphrase EO's covered.

Have students describe the parts and functions of the different Force Draft Blower components.

a. Forced Draft Blower General Description

(1) Forced Draft Blower: Hardie Tynes Horizontal

(2) Forced Draft Blower: Westinghouse Horizontal

b. Required Preventive Maintenance

c. Symptoms and Probable Cause of Malfunction

d. Maintenance Procedures

1-2-61

LESSON PLAN




e. Safety Precautions

f. Training Time Out Procedures

9. EVALUATION 9. A written comprehensive test will be given at the end of the course.

Refer to Proctor Guide and Testing Plan and administer the Written Safety Test.

10. ASSIGNMENT 10. Direct trainee to Assignment Sheet 1-2-2, DESCRIPTION OF FORCED DRAFT BLOWER MAINTENANCE.

1-2-62

LESSON PLAN



PA PERIODS: 0

Topic 1.3 FORCED DRAFT BLOWER MAINTENANCE PRINCIPLES AND PRACTICES


1.4 INSPECT internal installed parts and replacement parts on the Hardie Tynes Horizontal Forced Draft Blowers as per applicable technical references.



1. FORCED DRAFT BLOWER MAINTENANCE PRINCIPLES AND PRACTICES, Outline Sheet 1–3–1


1. Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010

2. Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series)




1. Review Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010

2. Review Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series)

3. Review Safety Precautions for Conducting Training, CNETINST 1500.20 series


1. Instruction Sheets

a. Review FORCED DRAFT BLOWER MAINTENANCE PRINCIPLES AND PRACTICES, Outline Sheet 1–3–1

b. Review Hardie Tynes Horizontal Forced Draft Blower Maintenance, Job Sheet 1–3–2

2. Hand Tools

1-3-1

LESSON PLAN



a. Mechanical Hand Tool Set as needed to provide students in a sufficient quantity.

1-3-2

LESSON PLAN







Motivate Statements:

Tell Trainees how they will use the course material.

Tell trainees why they need to know the lesson material.

Direct trainees to Outline Sheet 1-3-1, FORCED DRAFT BLOWER MAINTENANCE PRINCIPLES AND PRACTICES.

Direct trainee to Job Sheet 1-3-2, Hardie Tynes Horizontal Forced Draft Blower Maintenance.

Prepare the Mechanical Hand Tool Set as needed to conduct training.

1-3-3

LESSON PLAN




2. Safety Precautions 2. Discuss Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series).

Discuss Safety Precautions for Conducting Training, CNETINST 1500.20 series.

a. Personnel a. Review Training Time Out Procedures.

b. Equipment b. Refer trainees to Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010, for safety summary.

3. Corrective Maintenance on Hardie Tynes Horizontal Forced Draft Blower

3. Divide trainees into groups per ratios in the course master schedule.

NOTE: Westinghouse Horizontal Forced Draft Blower will not be covered in the laboratory due to unavailability of training equipment.

1-3-4

LESSON PLAN




NOTE: Ensure there are enough instructors per ratio in the Course Master Schedule to supervise the laboratory session.

a. Demonstrate technique required to check potential failed components.

a. Ensure trainees observe safety precautions.

Ensure second group of students are in classroom for quiet study.

Ensure first group of students are in classroom for quiet study.

Critique Job Sheets to check trainees understanding.

4. Comprehensive Written Test 4. Refer to Proctor Guide and Testing Plan and administer Comprehensive Written Test.

5. Safety Precautions 5. Discuss Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series).

1-3-5

LESSON PLAN




Discuss Safety Precautions for Conducting Training, CNETINST 1500.20 series.

a. Personnel a. Review Training Time Out Procedures.

b. Equipment b. Refer trainee to Description, Operation, and Maintenance Main Forced Draft Blower (FF 1078-1097), NAVSEA S9251-AZ-MMA-010, for safety summary.

6. Comprehensive Performance Test 6. Refer to Proctor Guide and Testing Plan and administer Comprehensive Performance Test.

1-3-6


ANSWER SHEET

Assignment Sheet 1-2-2 1. Briefly describe the functions of the following forced draft blower components.

a. Hardie Tynes Horizontal - Thrust bearing:

Any time the blower is in operation, the pivoted-shoe thrust bearing assembly

will take on all the thrust load.

Reference: NAVSEA S9251-AZ-MMA-010, Para. 2-33, Pg. 2-3.

b. Hardie Tynes Horizontal - Bearing Oil Relief Valve:

Regulates the maximum oil pressure to the bearings between 10 and 15 psi. At

speeds above 3000 rpm, it passes the oil to the governer heat exchanger.

Reference: NAVSEA S9251-AZ-MMA-010, Para. 2-81 and 2-82,

Pg. 2-7.

c. Westinghouse Horizontal - Stationary Guide Vanes:

Direct the air flow and minimize the rotation of the air stream.

1


ANSWER SHEET (CONT.)

Reference: NAVSEA 0953-LP-009-7010, Para. 2.1.2, Pg. 2-1.

d. Westinghouse Horizontal - Air and oil seals:

Provide for air leakage through drilled passageways & prevent oil leakage into

the air stream.

Reference: NAVSEA 0953-LP-009-7010, Para. 2.2.4, Pg. 2-3.

2. Briefly describe design characteristics/specifications of the following forced draft blower

components.

a. Hardie Tynes Horizontal Forced Draft Blower -

(1) Total Static Pressure (Inches of Water)

(a) Normal - 9"

(b) Cruising - 53"

(c) Rated - 106"

Reference: NAVSEA S9251-AZ-MMA-010, Table 1-2, Pg. 1-3.

2



b. Westinghouse Horizontal Forced Draft Blower

(1) Capacity (CFM)

(a) Maximum Rated - 31,700 CFM

(b) Full Power - 22,400 CFM

(c) Cruising - 14,100

(2) Maximum Rated Static Pressure (Inches of Water) Full Power - 106"

(3) Critical Speed, RPM (estimated) - 10,800 RPM

(4) Overspeed test, RPM - 9,250 RPM

Reference: NAVSEA 0953-LP-009-7010, Table 1-3, Pg. 1-2.

3. Describe the operating charachteristics of the following forced draft blower lube oil

systems.

a. Hardie Tynes Horizontal -

(1) Attached lube oil pump; discharge pressure/pump capacity -

3



Rotary, internal gear, reversing pump, 13 GPM @ 75 PSI


(2) Lube oil pressure the bearings(psi) - 10 to 15 PSI

Reference: NAVSEA S9251-AZ-MMA-010, Para. 2-81, Pg. 2-7.

(3) High pressure oil valve setting -

65 PSI at blower speed of 3000 RPM or About 60 PSI by figure 2-1

Reference: NAVSEA S9251-AZ-MMA-010, Table 1-12, Page 1-10, or Fig. 2-1.

4. State the most probable cause(s) of the symptoms for each observation of a Hardie Tynes

Horizontal Forced Draft Blower. In addition, for each cause listed, write a brief

statement describing the actions you as the operator/maintenance person would take to

troubleshoot the problem and restore the equipment to normal operation.

4



a. Watchstander notices low lube oil pressure to the bearings.

(1) Probable cause (list three):

(a) Pump suction clogged

(b) Low sump level

(c) Improper adjustment of bearing oil relief valve

(d) Improper adjustment of high pressure oil relief valve

(e) Worn/damaged oil pump

(f) Auxiliary lube oil pump not running at low speed

(2) Corrective procedures required:

(a) Drain oil; open, inspect, and clean sump

(b) Fill sump to high mark on dipstick

(c) Adjust bearing oil relief valve

5



(d) Adjust high pressure oil relief valve

(e) Disassemble, inspect and repair oil pump

(f) Start auxiliary lube oil pump at low speed IAW EOSS

Reference: NAVSEA S9251-AZ-MMA-010, Table 5-1, Pg. 5-5 and 5-7.

b. The blower is operating in standby status. The messenger, while taking his

reading, finds the oil temperature to the bearings has risen 25 degrees from

his last reading with no demand change.

(1) Probable causes (list two):

(a) Insufficient cooling water flow through cooler

(b) Clogged or plugged tubes on waterside of cooler

(c) Excessive sludge deposits on oil side of oil cooler

6



(d) Thermostatic regulating valve not functioning properly


(a) Ensure cooling system is aligned IAW EOSS procedures. Throttle

cooler outlet as needed.

(b) Disassemble and inspect oil cooler as described in Chapter 6,

Section IV.

(c) Disassemble and clean oil cooler as described in Chapter 6,

Section IV.

(d) Disassemble and inspect thermostatic regulating valve as

described in Chapter 6, Section IV.

Reference: NAVSEA S9251-AZ-MMA-010, Table. 5-1, Pg. 5-7.

c. The blower is in the warm up stage and the speed is 1000 RPM. A new demand

to 4000 RPM is required. While starting its upward ramp, the blower starts

7



vibrating excessively.

(1) Probable causes (list 6):

(a) Blower blading is fouled by foreign matter, damaged or

missing parts causing unbalance.

(b) Wiped or worn bearings.

(c) Excessive thrust clearance causing possible rubbing of

internal parts.

(d) Damaged turbine blading, possible rubbing of internal parts.

(e) Rotating elements not assembled properly.

(f) Blower operating in a stall region.


(a) Disassemble, inspect and clean blower blading.

8



(b) Disassemble, inspect and repair bearings

(c) Check condition of thrust bearing and adjust thrust clearance

(d) Disassemble, inspect and repair turbine blading.

(e) Disassemble and check matchmarks on all rotating elements.

(f) Slow blower speed until vibration stops, open more registers

on boiler. Check that automatic shutters and dampers are open.


d. When taking lube oil samples on the blower, the messenger notices water in

the sample.

(1) What are the most probable causes:

(a) Salt water leak inside cooler.

9



(b) Fresh water leak.

-Condensation formation over prolonged period of time.

-Excessive leakage past turbine glands.

-Leak back through high pressure drains.

-Leakage of exhaust/relief valve when unit is secured.


(a) Disassemble and repair cooler

(b) Purify oil

-Refer to steam leaking from packing glandstroubleshooting procedures.

-Insure all HP drains are aligned.

-Disassemble and inspect exh/relief valve.


10



e. Blower runs normally but will not come up to rated power. (Turbine

will not develop rated RPM)

(1) Probable causes (list three):

(a) Low steam inlet pressure.

(b) Clogged steam strainer.

(c) Improper adjustment of linkage between actuator and steam

inlet valve.

(d) Nozzle control valve not fully open.

(e) Improper adjustment of governor.

(2) Corrective procedures required.

(a) Check steam inlet valve for full open position.

(b) Disassemble, clean and inspect steam strainer.

(c) Adjust linkage as described in Chap VI.

11



(d) Fully open nozzle control valve

(e) Adjust Woodward governor as described in Appendix

C of the manual.

Reference: NAVSEA S9251-AZ-MMA-010, Table 5-1, Pg. 5-11 and 5-13.

5. State the most probable cause(s) of the symptoms for each observation

of a Westinghouse Horizontal Forced Draft Blower. In addition, for each

cause listed, write a brief statement describing the actions you as theoperator/maintenance person would take to troubleshoot the

problem andrestore the equipment to normal operation.

a. Sluggish response to change of control air pressure:

(1) Probable cause:

Needle valve closed too tightly

(2) Corrective procedure required:

12



Adjust. If needle valve must be kept closed to achieve stable

governor operation, check governor mechanism.

Reference: NAVSEA 0953-LP-009-7010, Table 5-3, Pg. 5-6.

b. There is low oil pressure or high temperature to the bearings on an

operating forced draft blower.

(1) Probable causes:

(a) Oil pressure relief valve not set properly.

(b) Auxiliary oil pump bypass valve not set properly.

(c) Oil pressure switch not set properly.

(d) External oil piping flange leaks.

(e) Oil pump drive damaged.

(f) Oil pump damaged internally.

(g) Thrust bearing oil seal rings worn/damaged.

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(h) Clogged lube oil pump inlet.

(i) Oil check valve stuck open.


(a) Adjust oil pressure to the proper setting.

(b) Check aux. oil pump bypass valve; adjust to obtain 30

psig at 1100 rpm.

(c) Check pressure switch setting an assure that auxiliary

oil pump cuts out at 24 psi and cuts in at 10 psi.

(d) Tighten leaking flanges or replace gasket.

(e) Remove inspection plate, and replace or repair oil

pump drive as necessary.

(f) Remove and disassemble oil pump, replace worn or

damaged parts as necessary.

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(g) Remove thrust end bearing cover and replace seal rings.

(h) Clean inlet pipe.

(i) Clean or replace check valve.

Reference: NAVSEA 0953-LP-009-7010, Table 5-3, Pg. 5-7 and 5-8.

c. Blower fails to start when the electric oil pump is running and the steam

inlet valve is opened.

(1) State the most probable causes:

(a) Drain valve open too wide.

(b) Cut out valve not open wide enough.

(c) Bearing oil pressure too low to cause start-up cylinder

to lift steam inlet valve.


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(a) Close drain valves and open moderately.

(b) Open cut-out valve wide.

(c) Check auxiliary oil pump bypass valve setting.

Reference: NAVSEA 0953-LP-009-7010

6. Describe Training Time Out (TTO) Procedures

Reference: Trainee Guide A-651-0074, Change 2, Safety/Hazard Awareness

Notice, Training Time Out, Page v.

Job Sheet 1-3-2 N/A

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forced draft blower

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