Forced Draft Blower

LESSON PLAN
FOR
FORCED DRAFT BLOWER MAINTENANCE
A-651-0074B
PREPARED BY
CENTER FOR NAVAL ENGINEERING, LEARNING SITE, SAN DIEGO
3975 NORMAN SCOTT RD, SUITE 1, SAN DIEGO, CA 92136-5588
PREPARED FOR
NAVAL EDUCATION AND TRAINING COMMAND
250 DALLAS AVENUE, PENSACOLA, FL 32508-5220
DECEMBER 2005
(DECEMBER 2005)
LESSON PLAN
A-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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LESSON PLAN
A-651-0074B
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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LESSON PLAN
A-651-0074B
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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LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
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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LESSON PLAN
A-651-0074B
(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 CALLED
Trainees:
1. Discontinue all work.
2. Remove hands from controls.
3. Place test equipment down.
4. Face instructor.
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LESSON PLAN
A-651-0074B
Instructors:
1. Ensure that all trainees comply with TTO requirements.
2. Review correct procedures to use with entire class
3. 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 Plan
The 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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LESSON PLAN
A-651-0074B
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)
9
LESSON PLAN
Unit 1. FORCED DRAFT BLOWER MAINTENANCE, PRINCIPLES AND PRACTICES A-651-0074B
CLASS PERIODS: 1
LAB 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, 111
b. Bldg. 3280 Diagram, 112
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
1-1-2
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).
1-1-3
LESSON PLAN
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.
1-1-4
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
1-1-5
LESSON PLAN
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).
1-1-6
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.
1-1-7
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
1-1-8
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
1-1-9
LESSON PLAN
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
1-1-10
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
1-1-11
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
1-1-12
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
1-1-13
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
1-1-14
LESSON PLAN
i. Satisfactory completion of the course
j. Trainee Academic Review Board
k. Critique Sheets
l. Present trainees the instructional materials
1-1-15
LESSON PLAN
CLASS PERIODS: 5
LAB PERIODS: 0
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 121
2. DESCRIPTION OF FORCED DRAFT BLOWER
MAINTENANCE, Assignment Sheet 122
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
1-2-1
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
121
b. DESCRIPTION OF FORCED DRAFT
BLOWER MAINTENANCE, Assignment Sheet
122
2. Equipment
a. Journal Bearing (Mock-Up)
b. Shaft (seal) Gland
c. Thrust Bearing
3. Slides
a. HTH Casing Sections, 121
b. HTH Casing Sections, 122
c. HTH Integral Spacer, 123
d. HTH Internal Setup, 124
e. HTH Shaft Assembly, 125
f. HTH Turbine, 126
g. HTH Thrust Bearing Assembly, 127
h. HTH Lube Oil System, 128
i. HTH Oil Control Block, 129
j. WHH Casing, 1210
k. WHH Casing (other end), 1211
l. WHH Compressor Assembly, 1212
m. WHH Internal Setup, 1213
n. WHH Journal Bearing, 1214
o. WHH Internal Setup, 1215
p. HTH Thrust Bearing Assembly, 1216
q. WHH Lube Oil System, 1217
4. Training Devices
a. Visual Aid Panel
5. VI Equipment
a. Computer, Power Point, 563001
b. LCD Projector, SL8620150
1-2-2
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.
1-2-4
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.
1-2-5
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.
1-2-7
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.
1-2-8
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
1-2-9
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.
1-2-10
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.
1-2-11
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.
1-2-12
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.
1-2-13
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.
1-2-14
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.
1-2-15
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.
1-2-16
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.
1-2-17
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.
1-2-18
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.
1-2-19
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.
1-2-20
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.
1-2-21
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.
1-2-22
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.
1-2-23
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.
1-2-24
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
1-2-25
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.
1-2-26
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
OPNAVINST 5100.19 (series).
Reference Safety Precautions for Conducting Training,
CNETINST 1500.20 series.
Reference Navy Occupational Safety and Health
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.
1-2-60
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
CLASS PERIODS: 0
LAB PERIODS: 17
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
131
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 131
b. Review Hardie Tynes Horizontal Forced Draft Blower
Maintenance, Job Sheet 132
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
Discuss Safety Precautions for Conducting Training,
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
1-3-5
LESSON PLAN
Discuss Safety Precautions for Conducting Training,
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
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
(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
LESSON PLAN
A-651-0074B
(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
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
(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
LESSON PLAN
A-651-0074B
(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 glands
troubleshooting procedures.
-Insure all HP drains are aligned.
-Disassemble and inspect exh/relief valve.
10
LESSON PLAN
A-651-0074B
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
LESSON PLAN
A-651-0074B
(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 the
operator/maintenance person would take to troubleshoot the
problem and
restore 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
LESSON PLAN
A-651-0074B
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.
13
LESSON PLAN
A-651-0074B
(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.
14
LESSON PLAN
A-651-0074B
(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.
15
LESSON PLAN
A-651-0074B
(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
16

Forced Draft Blower

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