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GENERAL ELECTRIC COMPANY Post Office Box 1038, Newport News, Virginia INSTALLATION AND SERVICE ENGINEERING . DEPARTMENT July 8, 1963 Newport News Shipbuilding & Dry Dock Company Newport News, Virginia Attention: Ship Repair Department Subject: SS Esso Gettysburg Gentl emen: We are pleased to transmit three (3) copies of Mr. C. A. Driscoll's June 10, 1963 report of his inspections of turbines aboard this ship. Please let us know if you should have any questions relative to this report. Very truly yours HR BURCHAM:mu ENGINEER EXX-MOR-005977 GENE RAL COMPANY Post Office Box 1038, Newport News, Virginia INSTALLATION AND SERVICE ENGINEERING DEPARTMENT July 8, 1963 Newport News Shipbuilding & Dry Dock Company Newport News, Virginia Attention: Ship Repair Department Subject: SS Esso Gettysburg Gentlemen: We are pleased to transmit three (3) c opies of Mr, C, A, Driscoll's June 10, 1963 report of his inspections of turbines aboard this ship. Please let us know if you should have any questions relative to this report. Very truly yours. HR BURCHAM:mu ENGINEER EXX-MOR-005978 AH-23V (5 t&ts) (3-60) GENERAL^ ELECTRIC File No.._,,. Place ..Newfiort._New*A...ya.,............ r>at> Jbb 10, Customer....Newport News Shipbuilding & Dry Dock C.@s Customer Order No. 1963 Subject.......S$ E.nso Gettysburg.............................. ... Nameplate rating. 19.9.a...340..HP DP...Tarb,itt.es D. W. J. No.- Supervisor's Name C.fc...Aa. Driscoll................ Contract No. Telegraph address 1821 Caaterbgry Road CompLaint No Mail address . H.Siptb.#. I.irjiaij........ Copies to:.... C fe, e.$.ajR *..I$|8.,,. Mr......... le. Barekm............................................................... ......... ..... IMS...................... ....... .................................................. Dept......N.fwj.#rl...N.ew.s.e. Office ........................ mswa (D............. 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Ser. *112195 1. The TTV had wrong nut on cup. end of stem. This was corrected by installing proper nut. 2. Governor stem locked tight to cup valve and s tern* ben^ Renewed stem and nut. 3. Slight leakage between valve seat and casing bore. No seat available. 4. Baffle plate missing fro top of oil strainer. Made and installed new plate, 5. Operating cup valve spring eroded. Installed new spring. 6. The valves were lightly 1apped-in to clean valve and seats. 7. The operating oil cylinder assembly cleaned and inspected. New springs should be ordered for all units. 8. Hand speed changer disassembled and cleaned. 9. One-fourth inch pipe nipple cracked on air motor. Installed new nipple. 10. OS trip would not operate at 6900 RPM. Removed .145" fro trip, 11. The pin that locks the low oil pressure trip arm to the latch pin was sissing, therefore, the turbine oil trip could not operate. Installed new pin. See attached sheets for operation data, *2 C.O.P.T. Ser,, #112196 The valve seat was found to leak and two cracks were noted across continued EXX-MOR-005980 PJIGE TS1EE SS ESSO GETTYSBURG TOO, STS, 340 HP W TURBINES seating area, The seat was packed with dry ice aid removed by a jack belt a id plat fastened to operating end of chest The aid seat was fe@ked with micrometers at eight C83 places sad found to be rssid, aid tte diameter Has 4*4995". The chest bore was cheeked tssiag the save aicrometers aid found t fee 4,999" diameter. This resalts la oily a ,0005" interference fit. The M seat diameter * 4,503". This r es al t$ in an interference fit of , 0035", Th sew seat was cooled aging liquid nitrogen and installed. A jack plat mss used to hold the. seat down is chest b@r t pretest sells and rising. After seat had expanded, a aieroaeter cheek was aad fro top of chest t top seat and at 3 aad 6 'clock measurement 5.058"; at 9 and 12 'sleek 5.059", A new operating cap valve, stem, at sd spring was installed. The threads were found striked in the cover plate aoiaatiag holes for *,he operating cylinder. The plate was sent to R. M. shop, holes welded, sradrilled and tapped. 011 epeH&ia cylinder opened and cleaned. The spring, pt. 89, a Bwf. 81C 1725 foaad very pitted and eroded, and ship should order new springs. See attached sheets for operation, , The TTY, tnrbine a4 gear easing were opened for inspection and the fallowing conditions notedi 1, ?T cip had approximately i/4" eoveistnt between stem and enp In stalled new stern and ant. SI, The IF end j oumal was ml ridged and snderslze .012". Hicreeeter eontiaeed ; ' >y \ ';: EXX-MOR-005981 PAGE FOUR SS ESSO GETTYSBURG 700, 575, 340 HP DP TURBINES . measurement 2,487 to 2,489", 3, The center or second ring of carbon packing journal had worn an elliptical undercut approximately 1/3 the shaft circumference, 4, The outside fit had a slight undercut in the same axial plane approx, ,007" to ,010" deep. 5, All three rings of carbon packing found broken and frozen in pack ing box. The box fits had a heavy deposit of built up rust. This was removed by hand scraping and machine wire brushing. 6, The first stage nozzle and intermediates are badly eroded and new parV should be ordered and installed at next availability. 7, Water was found approximately 3/4" deep in exhaust easing. It is requested that the factory check their drain connection drawings and, if possible, relocate this drain from its present location in the vertical wall to the bottom of casing, thereby eliminating this condition. The rotor was removed to SM shop, cleaned and the bearing journals were chrome plated. The packing journal were metal sprayed and journals machined to original size and rotor balanced. Rotor was landed in casing new journal and thrust bearing installed and clearances checked. Also, the turbine-to-gear alignment was checked and clearances are show on attached sheet. MM The gear casing was opened, high speed pi non and oil pan removed to clean sump tank. Approximately 1" of oil sludge and water remained in the gear casing. The ship's crew, when changing oil, drained the tank using the drain valve that is provided, then refilling sump with new oil. continued EXX-MOR-005982 PA FIVE SS ESSO GEXTfgBDftG 700@ 575t 340 HP DP fUlBINEg ' 4s eta be noted, the part that needs cleaniag is left unattended, It is this writer's pinion that heed h@i cover plates should be provided t.o allow assess to the stamp task Also the drain valve should he ia the bo11ob task aad sot a the vertical wall* Mr* John Ireland pert magiaear* aad ship's crew also expressed the s awe opinioa a the above tioa, Tfe piaioa aad gear beariags wr@ cheeked aad found satisfactory* Clearaaees show on attached sheet* The oil 1iae fr&m the L0 cooler to the low oil trip was found rested oat completely i n two pltces stppr xi@a tely 6" apart In removing this > line it rumbled let three sections* The fard did aot have the steel tubing therefore copper tnbiag was used as a $sfe$titat@ for repairs The vrsp@d trip would !s throttle at 5500 1PM It was neces sary to add e ,125" spacer t trip ia order t p@r@r gatisfictorily 10 EKcesiive steam leakage at the valve stea leak-off drains New bashings required on all units, T&e trip tferettlt valve seat was found te leak as ieseribei rlir ia this report bat ae aew seat was available at this verhaal. fhe apptr feushisg was missiag fro the cover plate oa operating valte A mew bashing assembly was fastened The governor ste sad spri&f were renewed. The ste was iotaad bent aad fretted The upper half f trbiae casiag was removed along with rotor. The @aditioas feaad wr as follows? I* The exha ast casiag at ceapiiaf ead was bowed approximately 3/16", EXX-MOR-005983 PACE SIX SS ESS GETTYSBUEG 700, 575, 340 BP DP TUEBINES 2, The low pressure end packing box was cracked a the lower section* This crack is located just forward of the casing fit and extends fro herizsatal joint down approxieately 2" on each side* The box was sent to EM shop and repaired by brazing and remachining. 3 Nozzle and intermediates in very poor condition and should be re placed as seen as possible* 4* Carbon packing rings broken and frozen in box. 5* The HP end bearing journals ,012" undersize. The rotor was sent t shop and cleaned, chrome plated HP and LP end bearing journals, polished carbon packing fits, and rotor halaaced. When the rotor was returned to ship, I recheeked bearing and packing fits and found the shdp had machined the LP fits down to 2.490". This, they stated, was necessary to round journals* I miked all journals be fore sending to shop and sizes are as follows; IP bearing journal 2*488" LP 2,4985". IP end peeking journals 2,498" at 3 places along shaft. LP end packing journals 2,498" at 3 places along shaft. After rotor return, the HP end 2.495" to 2,496" and low pressure end 2,490", It was therefore necessary to hand fit all carbon rings fee provide a .008" to ,015" clearance. Due to the distorted easing, it was neeessary to add a .020" shim It the lower bearing bracket to provide suitable bearing to journal contact, Kotor was landed on new bearings and a new thrust plate in stalled, Sheel clearances were cheeked and are shown on attached sheet. A new operating cap valve was installed as old cup badly pitted ad lip heavily chipped, cntlBBd ... EXX-MOR-005984 PAGE SEVEN SS ESSO GETTYSBURG 700 575, 340 HP DP TURBINES One 3/4" socket tap bolt in the operating valve plate was found feroke off. This was drilled a ad tapped using the coyer plate and a drill basing as a guide. The verspeed would not operate at 115% rated speed. It was necessary to reaove ,075" spacer fro trip This concludes the trials and tribulations on the above machines. There are two suggestions I sight add that could be included in the Instruction Book: 1 A sketch showing clearance between the operating valve stem and the underside of the valve, It seems the nuts are tightened against the eep;locking the cep valve to stem. 2, A sketch showing the intermediate blade bolting as thore are three different combinations that can be used HP End IP END Thrust Resale R I S BEG. JOURNALS PACKING FITS PACKING New 2.4985" 2,495" 2.508 New 2.4995" 2.490" 2.500" ,014" ,060" .045" .066" .073" continued EXX-MOR-005985 PAGE EIGHT ( SS ESSO GETTYSBURG " TOO, STS, 340 IIP BP TURBINES . f v~ #3 j.O.p.T. o .LB AA Ate fur*, lad Pimp 2nd pinin Brg. 3,506 250SS J ourual 8,4-995 3 4995 Gg&j T&rust ,008 3 TMrust ,00? lessl I 038 14 060* R 060" .059" Saarfeen Packing Journals 2.9988 PackU* 3,013 i -jfvo a hit 3 f i 12198 Geer Brg 4,0065s 4,006s Jeurnal 3 3S9 s 3,999 . - ./; 7 ,r // J J |[ / i- 'T7> R% i* ^, 'V L ,/ r U,v, .- V fT i 'S' \' ' '/*? ' r.U A,' 8' p CARGO AMD BALLAST fUKB1ME OPERATIONS furs9 & Pup I T113196 P-1 f 113196 P-3 T113198 iws f111196 f 113193 Ballast H.PSa 6000 1850 6000 18 6000 1850 6000 1850 1??5 1775 St@a PSXG 535 800 j&tr 800 535 @00 535 800 535 900 Gait le* irerped Trip S8 GIJIR OIL SZK. 8U0T. DISCi* Pressi. PSIG r 15 2 s 140 a 10 110 fURB OIL psig F 1 110 30 IB 145 3 10 100 11 95 35 2 140 8 10 11 1 110 20 a 140 3 37# 6 100 10 100 10 <3% - i 10 11 13 6&SS 6550 3 645 4 655 Ball a* t 197S H,gM ip@4 St@p BiioM Relief Y&lTe furte* Oil Trip 8psa4 Q@ai Oil Trip Sp#e4 BsieOil at trip Gear Oil Press at trip iir Pres s B@es Turte step fey ff La. 8 St@p Tmrte* L, Bs Step Fwp 6000 6000 10 730 700 700 675 a3 55 13 12.5 Yes Y@e 4700 1450 6000 725 700 3 5 13 i 6000 675 700 2.5 5 18.5 a# 4450 ISbO 1775 136 65 a -a13 Yea EXX-MOR-005986 F4SE MIME SS ESSO GETTYSBURG TOO, 575 340 IP OP TURBINES ' The tsgrbine ms reaped r@a its storage aboard ship to the RM Slop# There it was coapletely disMnteld and rebuilt using a sew xiaist easing and parts are listed on attefe@d sheet The trip throttle valve seat was found t leak under a 65& air and water test. The seat was resowed and both seat and casing boxes were ekeeked at six places. Results are shown at end of report. The chest was welded and remachined to 4,500" and a new seat in stalled with a ,00375" interference fit. Seat tested and found satis factory, Clearances were checked, unit completely assembled and in stalled aboard ship and aligned to pump. Results are shown below. The unit was started and over speed trip tested and operated 5200 RPM The costing made ap and unit pot on line feeding the boiler at a discharge pressure of 950* at 3750 RPM , and all owed to operate for approximately 12 hears, I a shifting lead fro* #1 t 3 unit, the operating cap valve was aeted to stick and hang open, preventing governing of turbine. The cap valve was removed and impression markings of the ring glide and supports could be noted. The cup was hand polished and checked with nitrometers and diameter was fand to be 2,438", The unit was assembled and after five mi nates of operation the @up valve would stick and not respond to the hand speed or air motor, She cup valve was then sent to the Yard tool makers shop a ad the inside diameter was increased .004", This eliminated all sticking and resulted H smooth operation on both the hand speed changer and air motor controls, : continued ..........................- . -. ............................. , -v................................................ ........- - EXX-MOR-005987 ( PAGE TEN S.S ESSO GETTYSBURG TOO, 5T5S 340 HP PP TURBINES Hot g I @aid appreciate tit faetery eo*eats a whether the bst?i@a a gess g8t @ad se old e&p valve wonld result is the above conditio. The TT cap beisg new operated satisfactorily i tke nn seat. Id seat aiMMfiS 4.5025 at 6 plses Mew seat 4.50375 Chest Bore 4. 500-4. 50 1 welded die t st@an eat asd resaebiaed t 4 500 Csrboa Packing J^ssraaig Coupling etsd 2492e Governor ead 2495 Besrlf 2e49@ frsped trip 520 Total float .078 TUEBINE SO POMP ALIGNMENT >00 a Biozsle *039 Tkrtis t m ,011 *039 ih .003 -hoof >( ft *050 s .057 ooy* The tsrfefs easi^fs @r@ p@a#d sad r@tr$ removed for insptetios 1 ieszle pistes were feind in very p@@r omdltioa. W@ nozzles lestailed. 2 iBi^rsediaies ik f@g@d I fair enditia~*"sl igMt sitting has started ersg fel$d@ sing, (No bw intermediates available) 3a Bearing jearns Is andersise and scarred @n 2 unit* E@t@r ge^t fep leased ebrome plated j@@rialge aehi@d and balanced i^aaifaw^*j**>a^*M*h>i* ,>***.^ - eontiened ........ wm^maaa^i EXX-MOR-005988 PJISE ELEFIM SS ISSO GETTYSBURG . 700 575e 340 HP DP TUSBiMES J@ursals oa 3 unit satisfactory. The rotors were landed @n new beaiwsfg and tfersst, Fsr rings @ carbon packing installed in each h@x instead thre as requested by Sr9 Ireland Clearances cheeked and are shown a attached sheets. 4 The oil governor and lib il cooler reaoved and cleaned. The @lers were tstd r leakage and foand satisfactory. 5 New diaphragm assemblies installed in hand speed changer Units were started a ad orr speed trip tested and found satisfactory. De to the original @r@r capacity of the pumps the turbines must Is operated very near the Lg.step. At 3750 EPI the pump discharge is 9S0? therefore the high speed stop aust fe set t lisit the hand speed changer to ppr sciuttely 3/4 of a turn. The vessel departed rs local yard a June 6 1963 Thrust .015 JJUJJIl. Resale .@40 N .040 I .052 $ .076 HP tearing Journal 2.500 LP Bearing Journal 2.500 Carbon Packing fits 2.498-2.499 OS Trip 5200 Packing 2.509-2.511 continued EXX-MOR-005989 \ \ >/' EPAGE TiELfE ' gg ESSO GETTYSBURG 700, 575* 340 HP DP TURBINES mm Thrust ,010 Nozzle *030 N .040 R ,058 S .070 HP End Bearing2.506 LP End Bearing 2.509 Orerspeed trip 5250 Journal 2.4985 Installed new bearings in " 2,497 HP & LP end. C. A. Driscoll ^. EXX-MOR-005990