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TABLE OF CONTENT
PART 1 GENERAL
1.1
GENERAL INFORMATION
1.1.1
Description of Work
1.1.2
Description of Thrust Bearings
1.2
REFERENCES
1.3
SUBMITTALS
1.4
PART 2 PRODUCTS
2.1
2.2
2.3
BABBITTING MATERIALS
MATERIAL AND WORKMANSHIP
ISO CERTIFICATION
PART 3 EXECUTION
3.1
SHIPPING
3.1.1
Shipping General
3.1.2
Shipment of Thrust Bearing Shoes
3.2
3.3
ANNEX 1
ANNEX 2
Page 1
GENERAL INFORMATION
1.1.1
Description of Work
This section covers the required refurbishment work on one set of 10 thrust shoes. Work requires refurbishment
through re-babbiting existing thrust shoes.
The shoes are currently in Unit 11 and unavailable for packaging and shipping. The Government will provide the
Contractor with a Notice of Shoe Availability prior to 14 July, 2013. After the Contractor receives this notice, the
shoes shall be refurbished and received back at Bonneville within 150 calendar days. Further packaging and shipping
requirements are in Paragraph 3.1.
1.1.2
The existing set of thrust shoes are springbed type shoes that are 30.25" in length, 25.25" wide at the outer diameter
and 10.180" wide at the inner diameter, and 2.277" thick. (see drawing 2-55311-001). Each shoe weighs
approximately 340 lbs. All shoes have a 3 1/2" x 0.08" deep counterbore for oil lift near the center of each shoe. Note
that the desired design thickness of the rebabbited shoes shall be 2.250" rather than what is indicated in drawing 255311-001 (2.277").
1.2
REFERENCES
The publications listed below form a part of these specifications to the extent referenced. The publications are
referred to in the text by the basic designation only.
ASME INTERNATIONAL (ASME)
ASME BPVC SEC V
Page 2
1.3
SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are
for information only. When used, a designation following the "G" designation identifies the office that will review the
submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00.
SD-01 Preconstruction Submittals
Schedule for Thrust Bearing Shoe Refurbishment: Submit 10 calendar days in advance of refurbishment, "Paragraph
3.2.2.m, General Requirements".
SD-03 Product Data
Chemical Analysis Of the Babbitt And Tin: Submit 7 calendar days prior to tinning, "Paragraph 2.1.d, Babbitting
Materials".
Proof of ISO 9000 certification or equivalence: Submit 7 calendar days following the Government's request,
"Paragraph 2.3, ISO Certification".
NDT Personnel/Laboratory Qualifications: Submit 10 calendar days prior to performing any NDT, "Paragraph
3.3.3.1, Examination of the Babbitt Bonding".
SD-04 Samples
Samples Of Materials: Submit within 10 days of request, " Paragraph 2.2, Materials and Workmanship".
SD-06 Test Reports
Thrust Bearing Shoe Finished Inspection Report; G: Submit 5 calendar days following inspections and prior to
shipment," Paragraph 3.2.3.f, Thrust Shoe Finished Inspection/Final Report".
SD-07 Certificates
Notice Of Thrust Shoe Finished Inspection: Submit 7 calendar days in advance of inspections," Paragraph 3.2.3.c,
Thrust Shoe Finished Inspection/Final Report".
SD-08 Manufacturer's Instructions
Thrust Bearing Shoe Refurbishment Procedure; G: Submit 10 calendar days in advance of repairs," Paragraph 3.2.2.a,
General Requirements".
SD-09 Manufacturer's Field Reports
Pre-Shipping Damage Inspection Report; G: Prior to shipment from the project," Paragraph 3.1.1.a, Shipping
General".
1.4
Final inspection and acceptance for full compliance with the Specifications will be made by the Government upon
delivery to the project. Any materials or workmanship not complying with the provisions of these specifications will
be cause for rejection. Corrections shall be made at the expense of the Contractor, and are subject to approval. Tests
may be repeated at the project site to ensure that materials and workmanship conform to contract requirements. Tests
will be at the Contractor's expense if the refurbished components do not meet contract requirements.
Page 3
PART 2 PRODUCTS
2.1
BABBITTING MATERIALS
All materials, parts, and components supplied shall be new and unused and of the best available kind and quality.
Workmanship shall be of the highest grade and in accordance with the best modern standard practice.
Samples of Materials shall be submitted upon request.
2.3
ISO CERTIFICATION
The workshop where the thrust bearing will be refurbished shall be ISO 9000 certified or equivalent as approved by
the Government. Proof of ISO 9000 Certification or Equivalence shall be submitted to the Government upon request.
PART 3 EXECUTION
3.1
SHIPPING
3.1.1
Shipping General
a. The Contractor shall visually inspect the components' condition prior to shipment from the site. Any existing
damage shall be recorded and submitted as a Pre-Shipping Damage Inspection Report prior to shipment. All damage
will be witnessed and "signed off" by the Government.
b. All components shall be prepared for shipment in a manner to protect them from damage and the Contractor shall
be responsible for and make good at no extra cost to the Government damage resulting from improper preparation, as
well as for damage occurring during inspection, shipping, or refurbishment.
c. Prior to shipment, coat components with a suitable preservative.
d. The crates and all packaging shall become the property of the Government.
3.1.2
a. Prior to shipping cover all inlets and outlets to exclude dirt, water, etc.
b. The Contractor shall provide packaging as required, package for shipment and provide transportation roundtrip for
individual shoes or one set of thrust shoes between the project and the refurbishment workshop.
c. New shipping boxes shall be provided as necessary to assure delivery of the thrust shoes in satisfactory,
undamaged condition. Each shoe shall be packaged in a separate box that shall be suitable for handling with a lift
truck.
3.2
3.2.1
General
Page 4
The requirements governing the refurbishment of thrust bearing shoes shall apply to an entire set of shoes. Note that
the shoes shall be received back to the project after refurbishment within 150 calendar days per paragraph 1.1.1.
3.2.2
Refurbishment Including Babbitting
The Contractor shall refurbish the thrust bearing shoes as specified below. Refurbish means removing the existing
babbitt, pouring new babbitt, babbitt machining including the provision of oil supply grooves and other detail, and
machining the shoe backside. The refurbishment shall return the shoes to the dimensional tolerances listed in the
tolerances sheets at the end of this section.
a. The Contractor shall submit a detailed Thrust Bearing Shoe Refurbishment Procedure a minimum of 10 calendar
days prior to commencing the refurbishment work, including a detailed step-by-step babbitting procedure. The
Contractor shall not perform any work until receiving written approval from the Government.
b. A sample of the babbitt shall be taken and marked for identification at the time that the babbitt is poured. A sample
shall be taken for each heat; i.e. if more that one shoe is poured simultaneously, only one sample is required. An
independent testing laboratory shall analyze each sample, unless otherwise approved, with the results linked to
individual shoes and included in the final report.
c. The Contractor shall prepare the shoes for babbitting according to the procedure approved by the Government.
Remove the existing babbitt and tinning material. Machine or shot blast, including dovetail grooves if applicable, and
proceed immediately with tinning. Special care shall be taken to protect all holes and surfaces of the shoes not
receiving babbitt. Precautions shall be taken to minimize shoe distortion during babbitting.
d. The babbitt shall be poured at a high temperature. The form and shoe shall be pre-heated. The pouring shall be
continuous. Cold checks will not be acceptable.
e. The shoes shall be machined and/or ground to a thickness of 2.250" +0.001"/-0.000", unless otherwise approved.
The Contractor's refurbishment procedure shall list any additional thickness of babbitt to be added to the shoes. The
shoe backside shall be finished prior to finishing the babbitt running surface. Note, this final thickness is different
from what is shown on the reference drawing 2-55311-001.
f. If necessary, the backside of the shoes shall be machined and/or ground as required to enable the machining of the
babbitted surface to achieve the tolerances listed on the tolerance sheets at the end of this section. The machining of
the backside shall be performed prior to the machining of the babbitted face. Material removal shall be uniform over
the shoe backside and consistent from shoe to shoe.
g. Machine and/or grind the poured babbitt layer to achieve the tolerances (flatness, runout, thickness, and surface
finish) listed on the tolerance sheets at the end of this section. Provide oil supply grooves, radius edges, and other
details identical to that found for the existing shoes.
h. The requirements for the refurbished shoes (flatness, runout, thickness and surface finish) are listed on the
inspection sheets at the end of this section.
i. Finish dimensions and runout checks shall be made while the shoes are still on the machining table or by an
approved method.
j. All non-babbitted surfaces (including the shoe's ID, OD and sides) and holes shall be thoroughly cleaned without
the removal of metal, unless approved in writing.
k. No more than 0.020 inches shall be removed from any surface or from the entire thickness of the shoes, unless
otherwise approved in writing. The Contractor's procedures shall state how this reduction in thickness will impact the
thrust bearings operation, if the reduction in thickness should be compensated for, and if so how.
l. Perform Non-Destructive Testing (NDT) of the babbitt bond according to paragraph 3.9.
m. A Schedule for Thrust Bearing Shoe Refurbishment, i.e. dates, shall be submitted for all phases of the shoes'
refurbishment a minimum of 10 calendar days in advance of the beginning of the work. The schedule shall be
Page 5
updated and revised as required. The Government will use this schedule for witnessing refurbishment processes and
will notify the Contractor as to which process will be witnessed.
3.2.3
3.3.1
General
Paragraph 3.3 contains both NDT processes and acceptance criteria. The intent is that the acceptance criteria should
only be applied to refurbished shoes, and should not be used in non-final inspections. The NDT performed during
non-final inspections is not to assess the acceptability of the babbitting work, but rather to provide the Government
with information to aid in the evaluation of the shoes existing condition. The acceptance criterion for final inspections
of refurbished shoes is contained in Paragraph 3.3.7.
3.3.2
NDT
The metallurgical bonding of the babbitt to the thrust bearing shoes shall be examined using the Ultrasonic Test (UT)
and Liquid Penetrant (PT) method The Pulse-Echo Method of UT inspection shall be employed. Examination shall be
offrom
nondestructive
made
the babbitt side andtesting.
100 percent of the babbitted area shall be inspected. UT examination shall be
performed in accordance with the applicable portions of ASTM E 114 or of Article 5 of the ASME BPVC SEC V. The
UT procedure which is to be used shall be submitted for approval.
The Government at its discretion may witness
any inspections.
3.3.3
UT Inspectors Qualifications
agreeable between the Government and the Contractor. Prior to the performance of any tests, the laboratory name,
location and qualifications shall be submitted as part of the NDT Personnel/Laboratory Qualifications submittal.
3.3.3.2 Technician(s)
Technician(s) performing the inspection shall be certified in accordance with the American Society for
Nondestructive Testing (ASNT). The inspector who is performing the UT inspection or who is acting as a
representative from an independent testing lab shall, as a minimum, be NDT: ASNT-TC-1A level 2 qualified, with a
minimum of 3 years experience at Level 2 in the last 5 years. Prior to the performance of any tests, the inspector's
qualifications shall be submitted as part of the NDT Personnel/Laboratory Qualifications submittal. The inspector
shall locate bonded and unbonded areas on the "Reference Blocks" in the presence of the Government's quality
assurance representative.
3.3.4
Equipment
Procedure
The entire babbitt surface of each shoe segment shall be scanned, overlapping scan paths by at least 20 percent of the
effective transducer width. Scanning rates shall not exceed 3 inches per second. Unbonded babbitt areas will result
in an increase in the size of the reflection or indications of multiple reflections at the interface of the babbitt and base
metal. Babbitted areas located over anchoring dovetail grooves will be excluded from UT inspection. All unbonded
babbitted areas shall be carefully scanned to determine their size and configuration. The outside edges of all
unbonded areas shall be marked on the surface of the Babbitt and recorded on inspection sheets.
3.3.6
b. The surface area of the babbitt, including oil grooves, shall be PT examined for cracks and porosity any and all
indications recorded on inspection sheets or documented in photos.
Page 8
3.3.7
Acceptance Standards
A written report from the independent laboratory, whether they perform or witness the testing, shall be submitted as
part of the final report. The report shall include a complete description of the UT procedures used, equipment used, a
mapping of the areas tested, shoe number, and interpretation of results. The report shall specifically address areas of
lack of bond between the babbitt and the shoe and their accumulated total surface area relative to the area allowed
area for the zone. PT results shall include a mapping of indications at the bond lines or photos. The report shall also
address porosity, cracking and other surface defects.
3.3.9
Babbitt Repairs
If repairs are required to the babbitt surface or to the babbitt-to-backing material interface a repair procedure shall be
submitted, if not already submitted as part of the rebabbitting procedure. Puddling will be acceptable for small areas
on the surface, and to correct a localized lack of bond between the babbitt and backing material; however, the total
lack of bond repaired by puddling shall not exceed 10 percent of the total babbitted surface.
3.3.10
If a shoe's babbitt bond does not meet the above acceptance criteria it shall be repaired or completely rebabbitted and
retested at the Contractor's expense until the bond is acceptable in accordance with these specifications.
The thickness variation of the 8 evenly spaced measurements on each shoe shall be within 0.001 inches, i.e.
maximum thickness minus minimum thickness must be less than 0.001 inches.
The 8 evenly spaced measurements shall then be averaged to be considered the shoe thickness. the variation of each
shoe to the average of all shoe thicknesses (the average of each individual shoe thicknesses) shall be compared and
shall not exceed 0.0012 inches, i.e. the absolute value of the individual shoe thickness minus the average of all shoe
thicknesses must be less than 0.0012 inches.
5. SURFACE FINISH
The babbitted surface and backside of the shoes shall have a finished surface of 16 and 63 microinches or better,
respectively. The finish shall be measured using a digital profilometer, or as approved.
0.0005 inches
0.0015 inches
0.0015 inches
Prior to performing each sweep, zero the measuring device using the same location in the center of the shoe. report
low spots as a negative reading and high spots as positive.
2. FLATNESS OF BACKSIDE
The backside shall be measured for flatness using a planekator and shall be flat within 0.001 inches. A minimum of
4 measurements along each edge (1 inch in from edge) and 2 diagonal measurements from the i.d. to o.d. corners
shall be taken.
3. VARIATION IN THICKNESS
A minimum of 8 evenly spaced measurement per shoe shall be taken as shown below, on 3 circles concentric with the
bore, i.e., near the i.d., center, and o.d. of the shoes.
The thickness variation of the 8 evenly spaced measurements on each shoe shall be within 0.001 inches, i.e.
maximum thickness minus minimum thickness must be less than 0.001 inches.
The 8 evenly spaced measurements shall then be averaged to be considered the shoe thickness. The variation of each
shoe to the average of all shoe thicknesses (the average of each individual shoe thicknesses) shall be compared and
shall not exceed 0.0012 inches, i.e. the absolute value of the individual shoe thickness minus the average of all shoe
thicknesses must be less than 0.0012 inches.
4. SURFACE FINISH
The babbitted surface and backside of the shoes shall have a finished surface of 16 and 63 microinches or better,
respectively. The finish shall be measured using a digital profilometer, or as approved.