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USER MANUAL Rolls-Royce Tunnel Thruster TT2200 AUX CP Mechanical and Hydraulic system Yard and hull no. Unit no. Date
Rolls-Royce Tunnel Thruster
: JIANGSU YANGZIJIANG SHIPYARD YZJ2007-797 : T13504 : 29 September 2009
User Manual
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User Manual
Rolls-Royce Tunnel Thruster
TABLE OF CONTENTS
1.
INTRODUCTION ......................................................................................5
1.1 1.2 1.3 1.4
Purpose .............................................................................................................................5 Warranty ............................................................................................................................5 Structure of this User Manual ............................................................................................5 Abbreviations .....................................................................................................................6
2.
SAFETY ...................................................................................................7
2.1 2.2 2.3
General statement .............................................................................................................7 Safety Annotations ............................................................................................................8 Declaration of Conformity..................................................................................................8
3.
SYSTEM DESCRIPTION .........................................................................9
3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9
System Overview...............................................................................................................9 Design..............................................................................................................................10 Tunnel..............................................................................................................................12 Thruster unit ....................................................................................................................12 Gravity tank .....................................................................................................................13 Seal tank..........................................................................................................................13 Hydraulic module.............................................................................................................13 Oil cooler .........................................................................................................................14 Drain pump unit ...............................................................................................................15 Drain pump ......................................................................................................................15 Pitch feedback device......................................................................................................16
4.
DELIVERY SPECIFICATION .................................................................17
5.
TECHNICAL DATA ................................................................................19
5.1 5.1.1 5.1.2 5.2
Oil recommendations.......................................................................................................19 Approved lubrication oil ...................................................................................................19 Grease for Couplings.......................................................................................................20 Standard painting specifications......................................................................................20
6.
OPERATION ..........................................................................................23
6.1 6.2 6.3 6.4 6.5
Before start ......................................................................................................................23 Start .................................................................................................................................23 Normal operation .............................................................................................................23 Stop .................................................................................................................................24 Emergency operation ......................................................................................................24
7.
MAINTENANCE .....................................................................................25
7.1 7.2 7.3 7.4 7.5 7.6 7.6.1
Maintenance overview.....................................................................................................26 Routine maintenance activities........................................................................................27 Lubrication of drive shaft coupling...................................................................................28 Filter insert replacement ..................................................................................................29 Replacement of feedback pickup device.........................................................................31 Pressure Switch / Transmitter replacement ....................................................................34 Test of pressure switch / transmitter ...............................................................................34
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7.6.2 7.7 7.8 7.9 7.10 7.11
Pressure switch / transmitter replacement ..................................................................... 35 Change flexible coupling element (hydraulic module).................................................... 37 Hydraulic pump replacement .......................................................................................... 38 Flushing of propeller shaft seal....................................................................................... 40 Change and refilling of oil in thruster .............................................................................. 41 Docking procedure.......................................................................................................... 42
8.
TROUBLE SHOOTING ......................................................................... 43
8.1 8.2 8.3 8.4 8.5 8.6 8.7
Drive motor ..................................................................................................................... 44 Drive shaft coupling ........................................................................................................ 44 Drive shaft seal ............................................................................................................... 44 Propeller shaft seal ......................................................................................................... 45 Pitch feedback ................................................................................................................ 46 CP hub ............................................................................................................................ 47 Lubrication oil.................................................................................................................. 47
9.
CONTACT INFORMATION ................................................................... 51
10.
SPARE PARTS ..................................................................................... 55
10.1 10.2 10.3
Ordering Spare Parts...................................................................................................... 55 Spare Parts List .............................................................................................................. 55 Preservation.................................................................................................................... 55
11.
TOOLS .................................................................................................. 57
12.
DESIGN DRAWINGS ............................................................................ 59
12.1 12.2 12.3
Mechanic ........................................................................................................................ 59 Hydraulic ......................................................................................................................... 59 Electric ............................................................................................................................ 59
13.
REVISION.............................................................................................. 61
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User Manual
Rolls-Royce Tunnel Thruster
1. INTRODUCTION 1.1
Purpose
The User manual provides the information necessary to operate and maintain the Rolls-Royce Tunnel Thruster safely and correctly and must always be available to the technical staff. The manual includes general information about the Rolls-Royce Tunnel Thruster, as well as project specific information and technical data.
1.2
Warranty
The product has a limited warranty. Please note that the warranty will be void if the equipment is misused or not handled in accordance to prescribed standards, for example dismantling the equipment to a level greater than described.
1.3
Structure of this User Manual
The first part of this manual describes the Rolls-Royce Tunnel Thruster. This helps in understanding the maintenance procedures in the subsequent chapters.
Chapters 1, 2 and 3 provide general Tunnel Thruster information.
Chapters 4, 5, 10, 11, 12 and 13 provide project specific information.
Chapters 6 and 7 describe the relevant operation and maintenance procedures.
Note! A separate manual for installation is available, and may be ordered specifically from Rolls-Royce Marine as required. Note! All pictures used in this manual are for illustration only.
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1.4
Abbreviations
Abbreviation
Description
CP
Controllable pitch (propeller)
FP
Fixed pitch (propeller)
cSt
Centistoke (oil viscosity)
Hz
Hertz (frequency)
ºC
Centigrade (temperature)
kg
Kilogram (weight)
kW
Kilowatt (power)
l/min
Liters per minute (flow)
MCR
Maximum continuous rating (power rating)
mm
Millimeters (lengths and diameters)
RPM
Revolutions per minute (rotation speed)
V
Volt (voltage)
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2.
SAFETY
Please take the time to read this chapter carefully, as it concerns your safety.
2.1
General statement
"UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR INDIRECTLY CREATE RISKS TO: [1] THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING THE WORK OR, [2] THE PRODUCT AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN. IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY, LEGAL AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE PERSONS UNDERTAKING THE WORK. IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED BY THIS DOCUMENT TO PROTECT AGAINST RISKS TO THE ROLLS-ROYCE REDUCTION GEAR AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN. NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM THEIR RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND PRECAUTION REFERRED TO ABOVE ARE IMPLEMENTED. IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME AWARE OF ANY ROLLS-ROYCE MARINE PRODUCT DESIGN RELATED FEATURE WHICH COULD CREATE RISK TO A PERSON UNDERTAKING WORK OR TO THE PRODUCT AND/OR ITS COMPONENTS PLEASE CONTACT THE RESPECTIVE TECHNICAL PRODUCT MANAGER AT ROLLS-ROYCE MARINE AS IMMEDIATELY."
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2.2
Safety Annotations
All safety directions must be respected in order to avoid damage to personnel, environment and equipment. The annotations used in this manual and the significance of each are listed below: Warning Indicates hazardous or unsafe practices, which COULD result in fatal or severe personnel injuries and/or substantial product or property damage, if the requisite precautions are not taken.
CAUTION! Indicates hazardous or unsafe practices, which COULD result in minor personnel injuries and/or property damage, if the requisite precautions are not taken. Note Draws attention to specific information of technical significance that might not be immediately obvious to the specialist personnel, or points to important information in the procedures to follow.
2.3
Declaration of Conformity
Rolls-Royce Products are designed and built as per one of the following standards:
Det Norske Veritas (DNV)
American Bureau of Shipping (ABS)
Lloyds Register (LR)
Germanisher Lloyds (GL)
Bureau Veritas (BV)
RINA
Russian Maritime Register of Shipping (RS)
Korean Register of Shipping (KR)
Nippon Kaiji Kyokai (NK)
A Class Certificate is issued for each product in accordance with the Class of the vessel.
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3.
SYSTEM DESCRIPTION
This section provides detailed information about the system to ensure safe and efficient operations. Refer to Chapter 12 for the project specific assembly drawings from Rolls-Royce Marine.
3.1
System Overview
The Rolls-Royce Tunnel Thruster is mounted in a separate tunnel that is welded to the ship’s hull. There are two propeller types available of Rolls-Royce Tunnel Thrusters: Controllable Pitch (CP) and Fixed Pitch (FP). The main difference in function is that the CP thruster has remotely adjustable propeller blades, while the FP thruster has fixed blades. Auxiliary versions are designed with standard hydraulic system. Normal draft versions are designed with a standard hydraulic system, including flushing of the seal box. Deep draft versions are delivered with a deep drain arrangement, including an extra drain tank unit and an extra sealing at the pinion. The main versions of Rolls-Royce Tunnel Thrusters
Dynamic Positioning (DP)
Auxilliary (AUX)
Ice class duty (Ice)
The DP-thrusters have been designed for continuous running operation and are derated compared to the AUX thruster. The DP thrusters are also equipped with a heavy duty wear resistant propeller hub and skewed propeller blades for high efficiency/low noise. A shaft seal with Viton superlip seal rings running on a ceramic coated liner and with a separate lubrication system is installed to withstand longer running hours.
The AUX thruster is the standard design Rolls-Royce Tunnel Thruster optimized for maximum power and with intermittent running profile and limited running hours/year. The thruster is equipped with skewed propeller blades for high efficiency and low noise.
The ICE thrusters have been designed to withstand the ice conditions required for ICE 1A Super and are derated compared to the AUX thruster. The ICE thrusters are also designed for limited running hours/year. The ice thrusters are equipped with stainless steel propeller hub and kaplan blades for increased strength.
CP or FP
CP or FP
CP
Normal draft or deep draft
Normal draft or deep draft
Normal draft
Super Silent (TT2200 , TT2400 and TT2800)
NA
NA
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3.2
Design
A typical CP thruster configuration is shown in the figure below. Refer to the table on the next page for component names and reference.
= Hydraulic = Control = Mechanical
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Components not included in the standard Rolls-Royce Tunnel Thruster delivery are colored light blue and may be ordered separately. Pos. Component
TT version
Comment
Chapter
1
Tunnel
A
3.2.1
2
Thruster unit
A
3.2.2
3
Shaft seal
A
4
Propeller
A
5
Pitch feedback
CP
6
Tooth coupling
A
7
Drive motor
8
Gravity tank
A
3.2.3
9
Drain pump (hand pump)
A
3.2.8
10
Hydraulic module
A
3.2.5
11
Hydraulic pump
A
12
Pitch control
13
Oil cooler
14
Drain pump unit
15
Seal tank
16
Drive motor starter cabinet.
A
17
DOL starter (hydraulic pump).
A
18
DOL starter (drain pump).
A
19
Drive motor starter.
20
Remote control
3.2.9
From Rolls-Royce Marine or external supplier.
A
CP DP (AUX) A
3.2.6 Only deep draught.
DP
A
3.2.7 3.2.4
Option.
Only deep draught. From Rolls-Royce Marine or external supplier.
A
A = Available on all TT versions, CP = only available on CP thrusters, DP = only available on DP systems.
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3.2.1
Tunnel
The thruster unit (3.2.2) is mounted into a transverse tunnel in the hull, normally with the standard single wall design. The Rolls-Royce Super Silent Tunnel Thruster is designed for exceptionally low noise operation and is ideal for offshore vessels where low noise and vibration levels are vital. It has double walls for the full tunnel length and a flexible mounted inner tunnel. It is equipped with leakage detectors between the walls. To further decrease noise levels, Super Silent thrusters have reduced propeller tip speed. If required, the tunnels can have a stainless steel layer in the propeller area for erosion protection.
3.2.2
Thruster unit
The thrusters are designed to give a transverse thrust to the port and starboard sides, to move the hull sideways. The Rolls-Royce Tunnel Thruster consists of a propeller hub with blades and a propeller shaft, one spherical roller bearing, and two axial roller bearings that support the shaft. A shaft seal prevents water penetration and oil leakage. The propeller is driven by a bevel gear, through a vertical shaft, extending into the ship’s hull. There are two alternative propeller configurations: Controllable pitch (CP): The direction of thrust is regulated by the pitch of the propeller blades.
Fixed pitch (FP): The direction of thrust is regulated by running the propeller in alternate directions.
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3.2.3
Gravity tank
The oil tank will work both as a main oil tank and a gravity tank and must be installed according to specifications by Rolls-Royce Marine. The gravity tank may also be delivered as a pressurized gravity tank. It is then possible to pressurize the tank with air to compensate for a lower placement in the ship. The tank is equipped with a level switch (LS51 at Hydraulic system diagram) for "low level alarm" and “high level alarm”. The switch can be easily dismantled at testing. A temperature switch (TS51) for "alarm, high oil temperature" is installed in the oil tank. The gravity tank is also equipped with a valve for shutting off the oil flow.
3.2.4
Seal tank
Only for DP thrusters (TT>1100) The purpose of this tank is to maintain oil pressure inside the shaft seal. It is equipped with a level switch for high and low level alarm.
3.2.5
Hydraulic module
It is important to maintain the system in such a way that it is always in the best condition. Remember to follow the oil recommendations, as well as the instructions given in the maintenance chapter. The pumps (1 or 2 in number) are vertically mounted on the module, and driven by an electric motor. An oil filter is mounted on the module and is equipped with an indicator that provides a warning when the element needs to be replaced. The filter is also provided with a by-pass valve, in case of extreme clogging, or a cold start.
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Some installations (standard DP, optional on AUX) may be equipped with a duplex filter, allowing for a change of filter element in one of the filter bowls, while the other runs normally. Note! The indicator can show "red" on operation with cold oil. This does not necessarily mean that the filter element is clogged, but may be caused by the high viscosity of the cold oil. The hydraulic module is equipped with 3 different pressure switches (5 in the case of 2 pumps) indicating either:
Alarm, low pressure.
Interlock, stop drive.
Alarm, high pressure.
(Autostart, pump I and pump II)
3.2.6
Oil cooler
Check the technical specification for clarification of scope of supply. The oil cooler is located between the hydraulic module (3.2.4) and the thruster unit (3.2.2). Its main purpose is to cool the hydraulic oil, using sea water or fresh water. The cooler is equipped with a thermostatic valve for constant oil temperature, two thermometers for the visual inspection of temperature, and a spring loaded check valve for protecting the oil cooler against pressure peaks.
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3.2.7
Drain pump unit
Check the technical specification for clarification of scope of supply. The drain tank is connected to the flushing of the input shaft seal and bearing arrangement. A level switch will control the motor running the pump, pumping the oil from the tank back into the system gravity tank.
3.2.8
Drain pump
A hand pump is provided for draining of oil and for oil sampling.
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3.2.9
Pitch feedback device
CP thrusters only. The pitch feedback device monitors the pitch of the propeller. The feedback pick-up device is placed on the top flange of the thruster unit, and is bolted to the propeller unit. The mechanical movement is transmitted by means of a link and lever to the potentiometer that is electrically connected to the remote control system.
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4.
DELIVERY SPECIFICATION
This chapter contains the delivery specification defined by the Rolls-Royce Marine sales representative in consultation with the customer.
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Technical Specification 16 Units, Bow #1 on 16 Vessels Type
:
Kamewa Ulstein TT2200 AUX CP
Quotation no. Version Date Author
: : : :
10--07-01837-BT1 Rev B 3 Jul 2007 JLL
Customer Customer proj.no.
: :
Jiangsu Yangzijiang Shipyard
Shipyard Yard no.
: :
Jiangsu Yangzijiang Shipyard YZJ2006-767 ,YZJ2006-768 ,YZJ2006-769 and YZJ2006-770 YZJ2006-775 ,YZJ2006-776 ,YZJ2006-777 and YZJ2006-778 YZJ2006-787 YZJ2006-788 ,YZJ2006-789 and YZJ2006-790 YZJ2006-797 ,YZJ2006-798 ,YZJ2006-822 and YZJ2006-823
RRM Unit no.
:
T13496/97/98/99/T13500/01/02/03/04/05/06/07/08/09/10/11
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
Page 1 of 15
Technical Specification
Illustration only
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Page 2 of 15
Technical Specification Table of Content 1
Scope of supply / Technical Specification........................................................ 5 1.1 General Information...................................................................................... 5 1.2 Tunnel Thruster unit Controllable pitch........................................................ 7 1.3 Hydraulic System.......................................................................................... 7 1.4 Remote Control System Helicon-X .............................................................. 9 1.5 Thruster Motor System ............................................................................... 13 1.6 Spare Parts & Tools .................................................................................... 15
Document revision Rev
-
A B C D E
Date 3 Jul 2007 9 November 2007
Sign JLL JLL
Changed pages 1
Description Add hull number and unit number.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
Page 3 of 15
Technical Specification 0 System Description Application info Type ............................................................................................... TT2200 AUX CP Application..................................................................................... Auxillary use Classification society ..................................................................... GL (Germanisher Lloyds) Vessel type ..................................................................................... 4250 TEU,Container vessel Vessel class notation ...................................................................... GL+100 A5,Container ship,IVV,NAVO,RSD,SOLAS II-2 Reg.19,+MC,AUT
Thruster motor Thruster motor type........................................................................ Electric AC motor. Thruster motor number of poles..................................................... 6 Poled motor Thruster motor cooling and protection........................................... Totally enclosed fan cooled - IP55 Thruster motor construction form / insulation ............................... V1 / F Thruster motor operation ............................................................... S2-30 Thruster motor power..................................................................... 1600 kW Thruster motor nominal/ design speed ........................................... 1200/1190 rpm (Constant speed) Thruster motor rotational direction ................................................ Counter-clockwise Thruster motor power supply ......................................................... 3 x 3.3 kV 60Hz Thruster motor heating elements power supply ............................. 220V Thruster motor termistor elements ................................................. 1 set 135° and 1 set 155°
Thruster motor starter Thruster motor starter type............................................................. Auto trafo starter Power supply for system pump unit............................................... 8,6 kW / 3 x 440V 60Hz
Thruster/Tunnel Propeller speed............................................................................... 303 rpm Reduction gears.............................................................................. 109613/217402 12/47 Calculated thrust ............................................................................ 220 kN Propeller tip speed.......................................................................... 34,9 m/s Direction of propeller rotation ...................................................... Clockwise Propeller blade diameter ............................................................... 2200 mm Propeller blade design.................................................................... Skew design Propeller type ................................................................................. Controllable pitch Number of propeller blades ........................................................... 4 Propeller material, hub / blades...................................................... Ni.Al Bronze / Ni.Al.Bronze Tunnel diameter, inner ................................................................... 2230 mm Tunnel length ................................................................................. 2300 mm Cathodic protection ........................................................................ 5 Years - Zink
Hydraulic System Pitching time full - starboard / port ................................................ 15 Seconds (Approx.) Oil pump flow ................................................................................ 31,1 l/min Oil volume in thruster unit ............................................................. 440 Litres Oil volume in gravity tank ............................................................. 180 Litres Required oil volume for total installation. ..................................... 620 Litres
Remote Control Type of electronic remote control ................................................. Helicon X Required main power supply to remote control ............................ 220 VAC Reqired Back-up power supply...................................................... 24 VDC (from battery)
Weights Weight of thruster and tunnel (dry) ............................................... 8100 kg Weight of electric Drive Motor and starter .................................... Installation info
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
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Technical Specification 1 Scope of supply / Technical Specification. 1.1
General Information
1.1.1
Equipment Not Supplied Scope of supply is defined in scope of supply / technical specification. Not included in scope of supply are: • • • • • • • •
Shaft brake. Special mounting and dismounting tools. Piping interface to yard’s piping. Tunnel grids. ( RRM may assist in the design work.) Oil and lubrication grease. External hydraulic piping. Electric cables with supports and protection. Cable glands.
1.1.2
Technical Information - Installation manual Necessary technical information for shipyard engineering and mounting of thruster into the ship, commissioning, starting-up and seatrial are part of the installation manual issued for each installation. Number of manuals, see system description.
1.1.3
Propeller Blade Design Tunnel thrusters are delivered with skewed propeller blades in order to reduce the tip cavitation tendancy. This will give a major reduction of the propeller induced vibrations and therefore reduction of the propeller induced noise.
1.1.4
Location of Tunnel / Thruster in Hull RRM recommend adherence to the guidelines given in drawing no. 216841 "Location of Tunnel / thruster in hull". An optimal location / tunnel inlet design will reduce noise / vibration excitation forces from the thruster and maximize manoeuvring performance.
1.1.5
Torsional Vibration Calculation Torsional vibration calculations for electrical driven system, will be performed if required by classification society.
1.1.6
Workshop Testing Thruster system is workshop tested according to the class requirement and RRM standard.
1.1.7
Corrosion Protection And Surface Treatment The thruster unit is treated with one coat of corrosion preventing primer, and is intended for protection under normal transport conditions and storage period. Inboard parts are finish treated. All according to following spesification.
Tunnel w/ motor foundation - Sandblasting to SA 2.5 (ISO 8501-1) - One layer of Epoxy Primer, Interguard 269 EGA, 088 / 089, approx. 40 – 80 micron. • Tunnel stainless steel layer - One layer of Epoxy Primer, Interguard 269 EGA, 088 / 089, approx. 40 – 80 micron. • Thrusterunit - Sandblasting to SA 2.5 (ISO 8501-1) - Touch-up painting. - One layer of Epoxy Primer, Interguard 269 EGA, 088 / 089, approx. 40 – 80 micron. • Oiltanks - Sandblasting to SA 2.5 (ISO 8501-1) - One layer of Epoxy Primer, Interguard 269 EGA, 088 / 089, approx. 40 – 80 micron. - One layer Interlack DQE 322, green color, Ral 6019, appr. 50 micron. • Thruster Motor - Delivered acc. to the sub-supplier's standard painting specification. • Thruster Motor Starter cabinet This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. •
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Technical Specification •
- Delivered acc. to the sub-supplier's standard painting specification. Electronic equipment - Control panel Finished painted RAL 9011, black - Electronic cabinet Finished painted RAL 7035, grey - Starter cabinet Finished painted RAL 7035, grey
• 1.1.8
Shipment Depending on transport methods and delivery times, components may be shipped separately. Installation into the ship and mounting of components are client's responsibility if not otherwise stated.
1.1.9
Safe Storage All equipment is prepared for storage in dry and dustfree environments for up to 6 months from delivery, according to specification given in installation manual.
1.1.10
Interfacing, Piping And Cabling
1.1.11
Piping and cabling between components supplied by Rolls-Royce Marine and components supplied by others are the responsibility of the client. Type of pipes and cables are given in the diagrams and mounting instructions as part of the installation manual. Installation, Commissioning, Starting Up And Seatrial Installation of the thruster system in the ship and mounting of components are the client's responsibility if not otherwise stated. Instruction for installation, commissioning, starting up and seatrial is part of the installation manual.
1.1.12
User Manuals Number of User Manuals is mentioned in System Description. All drawings, documents and sign plates on the equipment are delivered in English language.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
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Technical Specification 1.2
Tunnel Thruster unit Controllable pitch If not otherwise stated the, thruster is mounted in the tunnel, ready for welding into the ship.
1.2.1
1x Tunnel • Tunnel made of certified mild steel plates (EN-10163), equipped with two radial ribs and a foundation plate for thruster connection. • Three extra ribs see drawing 111191. • The tunnel is supplied with a stainless steel plate at the propeller blade tip area, thickness 4 mm. The stainless steel plate will be acid treated and primed. The priming of the stainless steel layer is for protection during transportation and installation • The tunnel is supplied with cathodic protection. Number of years and anode material according to datasheet.
1.2.2
1x Thruster Motor Foundation The motor foundation for the vertical Thruster Motor is bolted to the tunnel. Bolts, washers and nuts for the connection are included.
1.2.3
1x Thruster Unit The thruster unit is bolted to the tunnel at the top and has a horizontal supporting bracket at the lower gearbox. The unit consist of: • CP Propeller hub cast in one piece, with the propeller blades bolted to the propeller by stainless steel bolts. The propeller hub incorporates the main pitch setting servomotor and its internal parts are lubricated by the hydraulic oil, a system for flushing of oil through hub is included. The hub is flange mounted to the hub coupling on the propeller shaft. • Propeller blades machined, polished and balanced according to the requirements of ISO R 484 class II. • Gear housing designed as a combined speed reduction and pitch actuating unit. Gear house made of Nodular cast iron. • Propeller shaft of forged steel, hollowed bored and with a hydraulic mounted flange coupling for connecting hub to shaft. • Spherical and Conical roller bearings to support propeller shaft and drive shaft. The thrust in each direction is absorbed by conical roller bearings. Bearing lifetime calculated according to class requirements. • Gear wheels are of high quality spiral bevel gear type, made of case hardened alloy steel. Calculated according to class requirements. • Propeller shaft seal of radial lip seal 3 ring type, sealing rings of material perbunan running on a steel liner. • A Rope Guard is mounted on gearhousing to protect the propeller shaft seal. Cathodic protection is mounted under the rope guard. • Vertical drive shaft seal of radial lip seal type, running on an adjustable steel liner. Sealing ring is made of Viton. The sealing is protected from dirt by a V-ring seal. • OD-Box is located on the forward end of the oil distribution pipe.
1.2.4
1x Pitch feedback arrangement Pitch feedback is mechanically transmitted from the propeller mechanism to the electrical feedback transmitter, mounted outside on the thruster top.
1.2.5
2 Halves. Shaft Coupling Flexible coupling, to connect the thruster input shaft to the Thruster Motor shaft. Drive shaft coupling is mounted on thruster drive shaft , and on the Thruster Motor output shaft. The coupling can be removed without removing the Thruster Motor.
1.3
Hydraulic System
1.3.1
1x Hydraulic Module The delivery contains one hydraulic module. The location of the module is important and shall be located in accordance to RRM requirement. Following hydraulic components are built on a module including internal piping and cabling:
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
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Technical Specification •
•
•
•
• •
• •
1.3.2
1x System Pump Unit. - Pump type: Gear pump. - The hydraulic system including one pitch / cooling oil pump, with 100% delivery. 1x El. Motor. - Marine squirrel cage type for direct online starting, - Enclosure IP 54, - Insulation class F, - Certification ( IC 41). 1x Single Inline Pressure Oil Filter. - Single inline filter. - Equipped with a visual and electric sensor for clogged filter element. 1x Pitch Control Valve. - Proportional control valve, load independent, combined direction and position control for electric remote control and local emergency activation. The valve has incorporated sequence and safety valve for pitch oil pressure. 1x Pressure gauge for pitch servo oil pressure, with shut-off valve. 3x Pressure switch (on/ off) - Alarm low servo oil pressure sensor (on/ off). - Alarm high servo oil pressure sensor (on/ off). - Interlock Thruster Motor (on/ off). - The pressure sensors are supplied with shut-off valves and control connection. Junction box for internal and external cable connections. 1x System Pump Starter in Thruster Motor Starter Cabinet - Direct online starter with thermal relay for overload protection, start / stop push button with run indication. - The starter is incorporated in the Thruster Motor starter cabinet.
1x Gravity Oil Tank The tank is equipped with: • Oil filling / air breather cap. • Sounding rod. • Sensor for high and low oil level alarm. • Sensor for high oil temperature alarm. The tank shall be located to give a positive oil pressure inside thruster at max. thruster immersion. A calculation sheet for tank location is part of the installation manual.
1.3.3
1x Hand Pump for emptying of thruster The unit consist of: • Hand pump. • Shut-off valves.
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Page 8 of 15
Technical Specification 1.4
Remote Control System Helicon-X Remote Control System Helicon-X for Tunnel Thruster with Fixed Speed Electric Thruster Motor.
1.4.1
1x Main Bridge Control Panel The panel is facing forward. The Control panel is made for desk mounting. Cable access is through a coverplate in the bottom of the panel box. The coverplate can be removed for fitting of cable glands. Protection degree is IP54.
The panel contains the following functions: • Pitch control lever. • Pitch indicator. • Load indicator 0-110% - Corresponding to amperes through Prime Mover. • In Command. Illuminated push button. • Start System Pump Illuminated push button. • Stop System Pump. Push button. • Start thruster / In operation. Illuminated push button. • Stop thruster. Push button. • Emergency stop thruster. Push button hardwired directly to the Thruster Motor starter for stop of thruster. • Thruster failure. Illuminated push button for alarm and reset of alarm buzzer. (Common alarm) • Auto stop. Illuminated push button for alarm and reset of alarm buzzer. • System failure. Alarm buzzer and signal light. • Pitch reduced Signal lamp. • Lamp test • Dimmer. 1.4.2
1x Slave Panel (#1) The panel is facing forward. The Control panel is made for desk mounting. Cable access is through a cover plate in the bottom of the panel box. The cover plate can be removed for fitting of cable glands. Protection degree is IP54.
The panel contains the following functions: • Pitch control lever. • Pitch indicator. • Load indicator 0-110% - Corresponding to amperes through Prime Mover. • In Command. Illuminated push button. • Start System Pump Illuminated push button. • Stop System Pump. Push button. • Start Thruster / In operation. Illuminated push button. • Stop Thruster. Push button. • Emergency Stop Thruster. Push button hardwired directly to the Thruster Motor starter for stop of thruster. • Thruster failure. Illuminated push button for alarm and reset of alarm buzzer. (common alarm) • Auto stop. Illuminated push button for alarm and reset of alarm buzzer. • System Failure. Alarm buzzer and signal light. • Pitch reduced Signal lamp. • Lamp test This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
Page 9 of 15
Technical Specification • 1.4.3
Dimmer.
1x Slave Panel (#2) The panel is facing forward. The Control panel is made for desk mounting. Cable access is through a cover plate in the bottom of the panel box. The cover plate can be removed for fitting of cable glands. Protection degree is IP54.
The panel contains the following functions: • Pitch control lever. • Pitch indicator. • Load indicator 0-110% - Corresponding to amperes through Prime Mover. • In Command. Illuminated push button. • Start System Pump Illuminated push button. • Stop System Pump. Push button. • Start Thruster / In operation. Illuminated push button. • Stop Thruster. Push button • Emergency Stop Thruster. Push button hardwired directly to the Thruster Motor starter for stop of thruster. • Thruster failure. Illuminated push button for alarm and reset of alarm buzzer. (common alarm) • Auto stop. Illuminated push button for alarm and reset of alarm buzzer. • System Failure. Alarm buzzer and signal light. • Pitch reduced Signal lamp. • Lamp test • Dimmer. 1.4.4
1x Electronic unit The electronics are assembled in a cabinet for bulkhead mounting. Cable access is through a cover plate that can be removed for fitting of cable glands. Location of the unit should be selected with emphasis on service access. The electronic unit contains the following: • Power supply • CPU Microprocessor card • Circuitry monitoring w/ alarm output • Indication circuitry • Keypad for adjustments, maintenance and troubleshooting. Power Supply requirement: • Main supply 220 VAC (± 15%) 50/60 Hz • Back-up supply 24 VDC (+30% - 25%) (Battery back-up) • Power consumption typical 100 - 200 watt
1.4.5
1x Thruster Alarm Unit A PLC is assembled in a cabinet for bulkhead mounting in the thruster room. Cable access is through a cover plate that can be removed for fitting of cable glands. Location of the unit should be selected with emphasis on service access. The alarm unit contains the following: • PLC for monitoring thruster alarms. • Alarm output for each alarm to the ships central alarm system. • One common thruster alarm for bridge indication. Power Supply requirement: • 24 VDC (+30% - 25%)
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Page 10 of 15
Technical Specification 1.4.6
Approvals The Remote Control System is designed to correspond with Dnv's Regulation Pt.4, Ch.5, Sec.5-B. Type approved by DnV, ABS, LRS, BV, RINA and GL.
1.4.7
Load Control System The load control system is designed to protect the thruster and the Thruster Motor when it is subjected to abrupt maneuvering or other load variations due to external conditions. The load control continuously monitors the power output from the Thruster Motor and the propeller pitch is automatically adjusted in response to the load changes detected. The remote control system requires the following signal from the motor starter: • Motor current signal 4-20 mA galvanic isolated. (Full load at approx. 18 mA).
1.4.8
Interface to Electric Thruster Motor Starter The following signals are given to the Thruster Motor starter: • Zero Pitch Signal. A potential free relay contact (max. 220V AC / 1 A) for interlock start thruster motor. The contact is closed at zero pitch position. • Start motor. Impulse push button for start of motor (normally open - closes for start) (Max. contact rating: 220V AC / 1A). • Stop motor Impulse push button for stop of motor (normally closed - opens for stop) (Max. contact rating: 220V AC / 1A). • Emergency stop motor. Impulse push button for emergency stop of motor.( normally closed – opens for stop) (Max. contact rating: 220V AC / 1A). • System Pump running. Potential free relay contact from servo pump starter, opens when servo pump stops. The following signals are required from the Thruster Motor starter to the thruster control system: • Running signal, a potential free relay closing contact when the motor is running and ready for thruster operation. Indication light on the START push button on Main Bridge Panel. The following signals are required from the Thruster Motor starter to the thruster alarm unit: • Overload signal (high temp. in windings). A potential free relay contact from the thermal relay for alarm indication in control panels. • Emerg. Stop loop failure. Potential free relay contact from Thruster Motor starter, opens when wire break or short circuit in emg.stop loop.
1.4.9
Interface to System Pump motor starter (may be incorporated in the Thruster Motor starter cabinet). Signals available from the thruster control system to the System Pump starter: • Start System Pump. Impulse push button for start of motor (normally open - closes for start) (Max. contact rating: 220V AC / 1A). • Stop System Pump. Impulse push button for stop of motor (normally closed - opens for stop) (Max. contact rating: 220V AC / 1A). The following signals are required from the System Pump motor starter to the thruster control system: • Running signal. A potential free relay closing contact when the System Pump motor is running. Indication light in the Start System Pump push buttons on control panel(s). •
1.4.10
Interface to Voyage Data Recorder (VDR) The remote control system is provided with interface for VDR.
Signals available to the VDR: • In command from each control station. Closing contact (potential free) when the control station is in command. • Pitch order signal. (Galvanic isolated at ROLLS-ROYCE) - 4 mA for full starboard. - 12 mA for 0-pitch. - 20 mA for full port Input resistance minimum 20 kohm This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
Page 11 of 15
Technical Specification •
• • •
Pitch feedback signal. (Galvanic isolated at ROLLS-ROYCE) - 4 mA for full starboard. - 12 mA for 0-pitch. - 20 mA for full port Input resistance minimum 20 kohm Backup control activated. Closing contact (potential free) when the backup control is activated. Thruster running
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Page 12 of 15
Technical Specification 1.5
Thruster Motor System Fixed Speed Electric Thruster Motor.
1.5.1
General Design references: IEC 92-301 and IEC 34-1 and Ship Class society rules. Design is not limited to the above IEC standards.
1.5.2
1x El. Motor • Three-phase squirrel cage induction motor with 2 contact points pr phase, for star connection. • Motor type offered is based on intermittent operation S2-30 at ambient temperature max. 45°C. • Protection is IP55 according to IEC 34-5 for the three-phase squirrel cage induction motor and insulation class F / Temp rise class F. The motor is totally enclosed fan cooled (TEFC) IC411 according to IEC34-6 • • The noise level figures are measured according to IEC 34-9. • Motor is balanced with half key according to IEC 34-14 and ISO2373 class N. • Motor colour is manufacturers standard. The motor is equipped with following accessories • PTC-Thermistors at 135°C, embedded in stator windings (one pr. phase), suitable for overheat indication with signal to alarm plant. • PTC-Thermistors at 155°C, embedded in stator windings (one pr. phase), suitable for overheat detection with initiating of shut down. • . Anti-condensation heating, 2 elements 220V. Frame size >= 315
1.5.3
General starter information Standard colors for indication lamps. • Power available - White. • Running - Green • Alarm / Stop - Red. • Stand by - Yellow. • Space heater on - Orange. • The starter cabinet is mounted complete and all necessary control signals are connected to a terminal strip. The Thruster Motor supply to be connected directly to the Power bar, and marked according to standard. • Earthing equipment is included according to class requirements.
1.5.4
Caution plates • Caution plates to be written in English. • Name plate to be phenol plate or brass with engraved lettering.
1.5.5
1x Auto Trafo starter for Thruster Motor, including starter for System Pump. The starter cabinet consist of: • Cabinet steel plated according to IP44 with hinged door for access and maintenance. • Thermic protection relay, for shutdown of Thruster Motor as well as the System Pump Motor, and alarm signal on overload current. • Contactors for auto trafo start of Thruster Motor. S2-30. • Colour, makers standard RAL 7035. • Anti - condensation heater 220V. • Tubular fuses. • Terminal lugs for outgoing main cables to be provided according to agreements. • Load Signal 4-20 mA. 20mA = 110% load. • Cable entrance. The cabinet is arranged for Bottom Inlet. • Contactor for DOL start of System Pump. The starter requires service power supply.
1.5.6
Instrumentation and equipment on cabinet door. • Main switch. • Door switch. • Start Thruster. Illuminated push button with green light when running. • Stop motor, black switch. • Start System Pump. Illuminated push button with green light when running.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
Page 13 of 15
Technical Specification • • • • • • • • • • • • • • • • •
Stop System Pump, black switch. Thruster Motor overload. Thermal switch with red light. System Pump Motor overload. Thermal switch with red light. Alarm Thruster Motor. 135 °C with red light. Alarm auto trafo. 140 °C with red light. Stop overtemp thruster motor. 155 °C with red light. Stop overtemp auto trafo 160 °C red light. Power 220 V for heating available white light. Power 440 V for servo and control available white light. Power “High Voltage” for Thruster Motor available white light. Start blocking Thruster Motor yellow light. Heater on selector Manual / Auto orange light. Alternative power for System Pump and Control. Selector inside cabinet. Test / Normal. Selector inside cabinet. Amp. meter for Thruster Motor. Amp. meter for System Pump. Amp. meter with red mark for heating elements.
• Hour meter for running hours Thruster Motor. The starter is prepared to start / stop the ventilation fan when start / stop of prime mover. The prime mover is interlocked against start if fan is not running. 1.5.7
1x Auto Trafo • Color, Makers standard RAL 7035. • Protection IP44 • Rating Min 5 starts pr hour, or max 60 seconds pr hour. • Heating element. 220V Supplied and controlled from starter. This supply must be available from main switch board, when supply for System Pump and Thruster Motor is switched off. • PTC-Thermistors at 140°C, embedded in windings (one pr. phase), suitable for overheat indication with signal to alarm plant. • PTC-Thermistors at 160°C, embedded in windings (one pr. phase), suitable for overheat detection and prevent new start. • Spare PTC-Thermistors at 140°C, embedded in windings (one pr. phase), suitable for overheat indication with signal to alarm plant. • Cables are fed from bottom. • Terminal lugs for outgoing cable to be provided according to agreement.
1.5.8
1x Step-up Trafo • Color, Makers standard RAL 7035. • Protection IP44 • Rating S2-30 and 5 starts pr hour. • Heating element. 220V Supplied and controlled from starter. This supply must be available from main switch board, even when System Pump and Thruster Motor is switched off. • PTC-Thermistors at 140°C, embedded in windings (one pr. phase), suitable for overheat indication with signal to alarm plant. • PTC-Thermistors at 160°C, embedded in windings (one pr. phase), suitable for overheat detection with initiating of shut down. • Spare PTC-Thermistors at 140°C, embedded in windings (one pr. phase), suitable for overheat indication with signal to alarm plant. • PT-100 elements for local alarm and shut down. Embedded in windings (one pr. phase). • PT-100 elements for vessels alarm plant. Embedded in windings (one pr. phase). • Cables are fed from bottom. • Terminal lugs for outgoing cable to be provided according to agreement. Opt
1.5.9
General The starter cabinet is mounted complete and all necessary control signals are connected to a terminal strip. The main supply to be connected directly to the conductor bar.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to do so is a violation of copyright laws. T13496-T13511_revB.doc
Page 14 of 15
Technical Specification 1.6
Spare Parts & Tools 2x 1x 1x 10x 10x 1x
Filter elements (one to be used for commissioning). Wrench for drive shaft coupling Injector pump. Fuses of each type Bulbs of each type Lamp tool
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Page 15 of 15
5.
TECHNICAL DATA
5.1
Oil recommendations Warning
Using oil other than that specified by Rolls-Royce Marine may cause malfunctions when manoeuvring the vessel. This may cause personal injury and equipment damage.
Before using other brands, please contact Rolls-Royce Marine.
.
5.1.1
Approved lubrication oil
The following lubrication oils are approved and recommended by Rolls-Royce Marine: Manufacturer
Type
BP
ENERGOL GR-XP 68
CALTEX
REGAL MARINE 500
CASTROL
ALPHA SP 68
CHEVRON
NL GEAR COMPOUND 68
ELF
EPONA-Z 68
ELF
VISGA 68
FRANCE PETROLEUM
TOTAL CARTER EP 100
MOBIL
MOBIL GEAR 600 XP
SHELL
OMALA OIL
TEXACO
MEROPA 68
Caution! Do not mix motor oil with other types of oil. Even very small amounts of motor oil in the hydraulic oil, will considerably lower the quality of these oils. Change the oil when laboratory tests show:
High neutralising number
Low remaining amount of EP-additives
High amounts of insoluble particles in the oil
The viscosity is not within limits.
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5.1.2
Grease for Couplings
The preferred greases are: Manufacturer
Type
TEXACO
Coupling Grease KP 0/1 K-30
SHELL
Albida GC-1
MOBIL
Mobil Grease XTC
KLUBER
Klüberplex GE 11-680
These greases are to be used under the following conditions:
Angular misalignment less than 35 degrees.
Coupling surface temperature lower than 70ºC.
Speed not too high. (< 3000 rpm)
Speed not too low. (> 200 rpm)
No shocks, no big reversing loads.
Good sealing conditions and no severe environment.
5.2
Standard painting specifications
The paint coating offers protection against corrosion under normal transportation, in storage and during outfitting periods.
The yard carries out the final treatment according to the total painting system for the ship.
Preparation before coating: Specification
Applies to
ISO 8501-1
Surface preparation.
ISO 8501-3
Visual assessment of surface cleanliness (Grade P3)
ISO 8503-1
Steel roughness. (Medium (G) Ry 50-80 micron.)
ISO 8502-3
Dust-free testing before painting.
ISO 8502-4
Climatic conditions during painting.
Note! Air temperature and steel temperature must at a minimum be +10°C or 3°C above dew point, whichever is higher. Page 20 of 61
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Rolls-Royce Tunnel Thruster
The components are delivered according to the following specification: Sandblasting and Primer
Amount
Sandblasting to SA 2,5 Strip coating before one layer of Epoxy Primer Interguard 269 EGA 088/089 (Red)
40 – 80 microns
Parts Tunnel Motor foundation Stay Thruster unit Oil tank Hydraulic module
Paint
Amount
One layer Intershield 300 (Bronze).
min. 150 microns
One layer Intershield 300 (Alu).
min. 150 microns
Part Tunnel, non-accessible areas after mounting (Dwg. K141514) TT Super Silent ; area between inner and outer tunnel
Paint
Amount
Interprime 198 (Grey)
40 - 80 micron
One layer Interlack DQE322, RAL 6019 (Green)
40 - 80 micron
Part Oil tank Hydraulic module
Electronic equipment
Paint
Control panel
RAL 9011, black
Electronic cabinet and Starter cabinet
RAL 7032, grey
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6.
OPERATION Warning
6.1
If any malfunction is detected when operating the Rolls-Royce Tunnel Thruster, the malfunction must be investigated and remedied. Operating a Rolls-Royce Tunnel Thruster with a malfunction in the control system or hydraulic system may cause personal injury or equipment damage. Similarly, any malfunction that might occur in the systems when the RollsRoyce Tunnel Thruster is in operation, must be remedied or the Thruster taken out of service.
Be aware of the fact that the Rolls-Royce Tunnel Thruster is a pump with a large inlet duct. People or material close to the tunnel can be sucked in. Always keep a safe distance on both sides of the ship. Also be aware of the risk of erosion caused by the water flow in harbours with quays built of material that erodes.
Before start
1. Ensure that power is available. 2. Start the hydraulic pump. 3. Check that there is no alarm. The pitch will automatically go to zero (CP only).
6.2
Start
1. Start the drive motor. 2. Check that the drive motor has started. The lamp indicates drive motor running. The Rolls-Royce Tunnel Thruster is now ready for use.
6.3
Normal operation
1. Select the control panel by pushing the “COMMAND REQUEST” push button, when the system is “IN COMMAND” mode. 2. When the lamp lights, the control panel is in command. 3. The propeller thrust can now be manoeuvred in the desired direction by means of the control lever. The propeller thrust is approximately proportional to the position of the control lever, through the pitch curve. Rolls-Royce Tunnel Thruster
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6.4
Stop
1. Set the control lever to the zero position. 2. Stop the drive motor. 3. Stop the hydraulic pump.
6.5
Emergency operation
A Rolls-Royce Tunnel Thruster is normally controlled by the remote control system. However, in an emergency, it may be locally operated from the hydraulic module as follows. 1. Unplug the cable to the remote control system [1] 2. Operate the thruster by using the operating lever [2] on the hydraulic module. Observe the motor load on the starter box ampmeter. Note that the pitch will be drifting in this mode and has to be compensated for manually to avoid overload.
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7.
MAINTENANCE
This chapter describes all relevant maintenance procedures and activities to be carried out by the ship’s crew. Warning
Never work alone when installing heavy components, even when using secure lifting equipment such as lockable block and tackle. Most lifting devices require two people, one to oversee to the lifting device and the other to ensure that the components do not get caught and damaged.
Always wear protective goggles if there is a risk of splinters, grinding sparks and splashes from acid or other chemicals. Eyes are extremely sensitive and an injury to them can result in loss of sight.
Using hydraulic oil other than the one specified in this manual may cause malfunctions when manoeuvring the vessel. This may cause personal injury and equipment damage.
Caution!
Most chemicals intended for the product (engine and gearbox oils, glycol, gasoline and diesel), or the workshop (degreasing agent, paints and solvents) are harmful to your health. Read the instructions on packaging carefully! Always follow protective measures such as using a protective mask, goggles, gloves etc. Ensure that other personnel are not unknowingly exposed to harmful substances in the air that they breathe; ensure adequate ventilation. Dispose used and excess chemicals according to instructions.
Ensure that the warning or information decals on the product are always visible. Replace decals that are damaged or painted over.
Take care of the hydraulic oil when replacing parts in the hydraulic system. Any oil spillage, even a small one, will cause environmental damage. Used filter elements and worn out hydraulic oil should be disposed safely.
If hydraulic oil disappears from the system and there is a risk that this oil is polluting the seawater, the system must be immediately shut down and inspected.
Do not use the Rolls-Royce Tunnel Thruster if local rules do not permit this.
Use spare parts produced by Rolls-Royce Marine, or by a manufacturer approved or licensed by them. Use of other than approved spare parts will void the warranty and may result in system failure or reduced lifetime.
Note!
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7.1
Maintenance overview
The following table lists the maintenance procedures. Procedures
Condition
Chapter
Routine maintenance
See separate table for routine maintenance activities.
7.2
Lubrication of drive shaft coupling.
Every 6 months or 3000 working hours.
Filter insert replacement
Alarm and local dirt indicator.
Replacement of feedback pickup device.
Non-responsive / no signal.
Pressure Switch / Transmitter replacement.
Non-responsive.
Change flexible coupling element
Pump not running, while motor is.
Hydraulic pump replacement.
Pump not running, while motor is.
Flushing of propeller shaft seal.
Every 2 weeks.
Change and refilling of oil in thruster.
Oil analysis indicates contamination.
Docking procedure
Before docking
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User Manual
7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11
Rolls-Royce Tunnel Thruster
7.2
Routine maintenance activities
The table lists maintenance activities to be carried out by the ship’s crew at regular intervals. Activity:
How often: D
W
M
Y
1
Inspection for noise and abnormal vibrations of the drive motor.
X
2
Check that the oil level is normal and that there is no leakage in the hydraulic system.
X
3
Check the intermediate shaft, couplings and bearings.
X
4
For an electrical driving motor, check and follow the lubrication instructions given on the lubrication schedule of the motor.
X
5
Check the brushes and the slip rings on the wound-rotor AC motors in order to discover any wear and tear.
X
6
Clean the brushes mentioned above.
X
7
Take oil samples and have them analyzed by the supplier.
X
8
Change the oil if needed, according to the results of the analysis.
X
9
Check the gear backlash.
X
10
Check and refill grease in the intermediate shaft bearing and the gear couplings.
X
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7.3
Lubrication of drive shaft coupling
Spare parts
Ref. no
Special tools and test equipment
Qty
Reference documents
Consumables
Qty
Oil requirements, chapter 5.1
Grease
Re-lubricate every 6 months or 3000 working hours.
Inspection every 24 months or 8000 working hours.
1. Turn the coupling so that flange lubrication holes are in position according to the figure below. 2. Remove the A-in and A-out plugs and pump grease into the A-in hole until grease leaks out from A-out. 3. Insert the plugs and repeat with the remaining two holes (B-in and B-out). 4. Clean the hub surfaces near the o-rings of rust or dirt before moving the sleeves. 5. Remove the flange bolts and the flange o-ring. 6. Control the gears and seals. 7. Dispose the old grease.
Tightening torque of the bolts given for dry tightening: TT size
1100
1300
1650
1850
2000
2200
2400
2650
2800
3000
3300
Coupling HCCV 25
30
35
35
40
45
50
55
60
65
70
Torque [Nm]
108
230
230
230
230
325
325
325
325
565
108
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7.4
Filter insert replacement
Spare parts
Ref. no
Special tools and test equipment
Qty
Filter insert
1
Bucket
1
Consumables
Qty
Reference documents
A clogged filter will be indicated by an alarm, and locally on the dirt indicator [1].
Duplex filter 1. If the system has a duplex filter [3], turn the handle [2] to the closed position for the filter in question. The system will still be in function, as the other filter will function as normal. 2. Place bucket under the filter bowl. 3. Remove the filter bowl. 4. Change the filter element [4] 5. Refit the filter bowl.
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Single filter: 1. Shut down the hydraulic pump unit. 2. Close valve V51. This valve is situated on the hydraulic line between the gravity tank and the hydraulic module. 3. Place bucket under the filter bowl. 4. Remove the filter bowl. 5. Change the filter element [4] 6. Refit the filter bowl. 7. Open valve V51.
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7.5
Replacement of feedback pickup device
Spare parts Feedback device potentiometer and/or electronic print card.
Ref. no
Special tools and test equipment
Qty
Allen wrench
1
Copper bit
Reference documents
Consumables
Qty
Tin solder
Note! It is not necessary to change both the print card and the potentiometer if only one of them is worn out or malfunctioning. 1.
Locate the feedback pickup device [1], situated on the top flange of the thruster unit [2].
2.
Remove the domed nuts and gaskets [3] on top of the casing.
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3.
Remove the casing; you will now have access to the electronic print card [4] and potentiometer [5].
4.
Using a small screwdriver, release the wiring attached to the connectors [6] on the print card [4].
5.
Release the potentiometer using a small allen wrench [7].
6.
Remove the screws [8].
7.
Remove the spacers [9].
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8.
Lift the print card [4] and potentiometer [5] out.
9.
If only one of these is to be changed, the wires [10] connecting the two parts need to be soldered off.
10.
Replace the worn/malfunctioning part.
11.
If only one part was changed, the wires [10] need to be soldered back in place.
12.
Insert the assembly back on the rods and remember to place the spacers [8] between parts.
13.
Retighten the screws on top of the rods.
14.
Refit the cable connections [6] to indicators/control system on the print card[4].
15.
Secure the assembly as shown in paragraph 5.
16.
Refit the metal casing, and ensure that all gaskets and screws [3] are tightened properly.
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7.6
Pressure Switch / Transmitter replacement
Spare parts
Ref. no
Special tools and test equipment
Pressure switch
Allen wrench
Reference documents
Consumables
7.6.1
Qty
Qty
Test of pressure switch / transmitter
1. Remove the protecting cap and connect the test equipment to the connection point [2] on the pressure test block. 2. Close the valve [1]. 3. Pump up the pressure and check the trigger point for the pressure switch. Confirm correct setting for rising or dropping. 4. Disconnect the test equipment and install the protection cap. 5. Open the valve [1]. CAUTION! Do not carry out the calibration while the machinery is in normal use.
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Rolls-Royce Tunnel Thruster
7.6.2
Pressure switch / transmitter replacement
1. Close the valve [1] located directly below the test point [2]. 2. Unscrew the securing screw on the socket.
3. Unplug the electrical connection [3].
4. Remove the pressure switch by removing the 2 screws [4] fastening the pressure switch to the test block. 5. Install the new pressure switch and retighten the screws [4]. 6. Reinstall the electrical connection[3].
Rolls-Royce Tunnel Thruster
User Manual
Page 35 of 61
7. After replacing the pressure switch, it has to be calibrated. 8. Remove the protection cap [5] in the front of the pressure switch.
9. Connect a multimeter to the two actual connecting pins N.O / N.C (Normally Open / Normally Closed). Use the pressure switch calibration tool to send correct setting according to the alarm list. The set point is adjusted by an allen key as shown at the picture.
Page 36 of 61
User Manual
Rolls-Royce Tunnel Thruster
7.7
Change flexible coupling element (hydraulic module)
Spare parts
Ref. no
Special tools and test equipment
Qty
Consumables
Qty
Flexible coupling element
Reference documents “Hydraulic system diagram”
1. Close valve V51. 2. Make sure that there is no electrical power to the motor. 3. Loosen the bolts [1] situated around the electric motor [2].
4. Lift the electric motor [2] off the hydraulic module. 5. Replace the flexible coupling [3] with a new. 6. Carefully lower the electric motor [2] back in its place. 7. Retighten the bolts [1]
Rolls-Royce Tunnel Thruster
User Manual
Page 37 of 61
7.8
Hydraulic pump replacement
Spare parts
Ref. no
Special tools and test equipment
Qty
Consumables
Qty
Hydraulic pump
Reference documents “Hydraulic system diagram”
1. Close valve V51 mounted on the top of the hydraulic module. 2. Make sure that there is no electrical power to the motor.
3. Loosen the bolts [1] situated around the electric motor [2].
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User Manual
Rolls-Royce Tunnel Thruster
4. Lift the electric motor [2] off the hydraulic module.
5. Remove the flexible coupling [3] if it didn’t follow the motor shaft out. 6. Lift out the pump connector [4].
7. Remove the pump [7] by unfastening the nuts [5] and bolts [6]. 8. Insert the new pump, and fasten the nuts [5] and the bolts [6]. 9. Refit the pump connector [4]. To achieve this, it needs to be heated before mounting, as it is connected with a slight shrink fit. 10. Refit the flexible element [3], if loose. 11. Lower the electric motor [2] back in place, and fasten the bolts [1].
Rolls-Royce Tunnel Thruster
User Manual
Page 39 of 61
7.9
Flushing of propeller shaft seal
Spare parts
Ref. no
Special tools and test equipment
Pressure switch
Oil sample connector
Reference documents
Consumables
“Hydraulic system diagram”
Oil
Qty
Qty
The seal has to be flushed every two weeks. 1. The shut off valve on the seal tank V80 is to be opened. 2. The shut off valve on the thruster top V81 is to be opened. 3. Flush the seal till the new fresh oil drains from the VVD. 4. The shut off valve on the thruster top V81 is to be closed. 5. The shut off valve on the seal tank V80 is to be closed. 6. Oil-sample from seal drained from VVD is to be visual inspected for water contamination. 7. Seal tank needs to be refilled with new clean oil after flushing of seal. Note! When operating in bad weather and/or at minimum draft, small oil leaks may occur from the Seal tank. To avoid oil leaks from the Seal tank, the shut off valve V57 on the Seal tank pipe should be closed in these conditions. Do not forget to reopen V57 for normal operation.
The shut off valve on the seal tank pipe V57 is to be closed in the dry-dock. Small oil leaks may occur from the seal when ship is in the dry-dock due to the gravity tank pressure.
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Rolls-Royce Tunnel Thruster
7.10
Change and refilling of oil in thruster
Spare parts
Ref. no
Special tools and test equipment
Qty
Reference documents
Consumables
Qty
“Hydraulic system diagram”
Oil
Oil requirements, chapter 5.1
The hydraulic/lubrication oil is to be changed if an oil analysis indicates that the oil is impure or in a bad condition.
Take oil samples at least once a year and have them analyzed by the oil supplier.
Drain of oil: 1. The installed pump (P1) is to be used for drainage. 2. Close valve V54 and open valve V53. 3. Open valve V56 to avoid underpressure. 4. Drain the oil. Note It is possible to exchange the hand pump with an external electrical pump (with maximum capacity 20 l/min).
Refilling of oil using an external electrical pump: 1. Open valve V56 and start filling oil through the filling connection, ZZ. 2. Check the oil level in the tank.
Rolls-Royce Tunnel Thruster
Figure 1 Simplified hydraulic system diagram
User Manual
Page 41 of 61
7.11
Docking procedure Warning
.
Do not start the prime mover when in dry dock! Running the unit out of water will damage the propeller shaft sealing.
Note! Any dismantling of the unit should be carried out in the presence of a representative from RollsRoyce Marine. Before docking, the unit is to be carefully inspected with respect to noise, vibrations and leaks (ref. Routine Maintenance). Oil samples should be taken and analyzed (ref. procedure for oil sampling). This will give an indication of the extent of work needed to be carried out during the docking period. If any abnormal observations/phenomena are identified during the inspection, the unit is to be dismantled when dry docked to enable further examination.
Turn the propeller by hand in order to check that the bearings and gears do not jam.
Carry out a pressure testing of the hub.
Take oil samples from the hydraulic oil system. If the oil contains water or other impurities, then it has to be changed.
Check the hull tunnel for corrosion and erosion damage. Pay special attention to the area in the vicinity of the propeller.
Check the condition of the anodes, and replace any corroded anodes.
Check the condition of the painting and renew when required.
Lubricate the driving motor as instructed by the lubrication chart of the motor.
Lubricate the intermediate shaft and the bearing for the intermediate shaft (if it exists) with grease.
Before, or during docking, close valve V57. Just before launching open valve V57.
Page 42 of 61
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Rolls-Royce Tunnel Thruster
8.
TROUBLE SHOOTING
Please refer to the tables in this chapter for trouble shooting and corrective actions. Each row represents a unique issue.
No
Part
Chapter
(1)
Drive motor
8.1
2
Drive shaft coupling
8.2
3
Drive shaft seal
8.3
4
Propeller shaft seal
8.4
5
Pitch feedback
8.5
6
CP hub
8.6
(7)
Lubrication oil
8.7
Rolls-Royce Tunnel Thruster
User Manual
Page 43 of 61
8.1
Drive motor
Symptoms Propeller blocked outside
Not starting
Mechanical blockage inside gear box
Possible faults
Components
Corrective actions
Wires or ropes around propeller
Propeller
Remove wires or ropes. Look for damages
Gear and bearings
Overhaul damaged parts
Damage of gear wheels or bearings Particles in oil
Pressure switch, Interlock functions Interlock functions activated 0-pitch contact
8.2
Drive shaft coupling
Symptoms
Possible faults
Vibrations
Misalignment
Overheating
Noise
8.3
Refer to manual for the remote control
Components
Corrective actions Check alignment
Lack of lubricant
Gear coupling
Add lubricant
Misalignment, wrong element used
Flexible element
Check alignment
Lack of lubricant
Gear coupling
Add lubricant
Misalignment, defective element
Flexible element
Check alignment
Possible faults
Components
Corrective actions
Damaged sealing surfaces or seal rings
Sealing rings
Renew damage seals
Seal liner
Repair seal
Drive shaft seal
Symptoms Damaged sealing parts
Leakage Movement or throw caused by unbalance
Page 44 of 61
Damaged bearings or gear wheels Damage at externally mounted coupling
User Manual
Bearings Gear wheels
Renew damaged parts
Shafts Gear coupling
Renew damaged parts
Rolls-Royce Tunnel Thruster
8.4
Propeller shaft seal
Symptoms
Possible faults
Leakage to thruster room
Components
Corrective actions
Piping system
Repair leakages
Shaft seals
Repair leakages
Gear housing
Repair leakages
Steering motor
Repair leakages
Leakage from propeller shaft seal
Seal rings
Replace worn seals
Seal liner
Renew liner and seals
Throw
Seal liner
Line up or renew liner
Leakage from steering column seal
Seals
Renew seal
Liner
Repair or renew worn liner
Leakages
Leakage to sea
Loosing oil from main oil system
Oil level in main system increasing
Other leakage Leakage at cover from gear housing seals
Replace worn seals.
Other leaks
Repair
Locking bolts
Repair or renew cooler
Cooler leakage
Oil in cooling water
Leakage to shaft seal tank
See topic ‘Shaft seal tank overflowing’
Oil leakage from shaft seal system
Loosing oil from seal tank
Throw at shaft seal liner
Repair seal
Leak oil cooler
Water in the oil
Oil cooler
Repair cooler
Leakage to sea
Oil at sea surface
Seal leaking
Repair seal
Throw at liner
Line up liner
Oil cooler
Clean freshwater system, if any
Throw at seal liner Shaft seal Loosing oil from shaft seal tank
Leakage to main oil system
Leakage to thruster room
Shaft seal tank overflowing
Leakage from main system
Rolls-Royce Tunnel Thruster
Main gravity tank air pressure is too low
Leakages
Loosing oil from gear oil system. Oil is clear
User Manual
Repair seal
Air reduction valve Adjust air main gravity tank pressure Pipes
Repair leak
Valves
Repair leak
Gravity tank
Repair leak at shaft seal
Shaft seal leaking
Repair seal, check throw at liner
Page 45 of 61
Symptoms
Possible faults Sea water entering
8.5
Components
Corrective actions
Oil emulated Seal leaking (mixed with water)
Repair seal, check throw at liner
Possible faults
Corrective actions
Pitch feedback
Symptoms
See Remote Control System manual
Fluctuating pitch control
Pitch operation is not possible using remote control
Components
Feedback problems
Feedback
See Remote Control System manual Possible to operate at manual Mechanical lever valve does not Proportional valve control only move
Repair feedback
Renew activator (or clean if possible)
Not possible to See symptoms ‘Pitch operation not working properly at operate at manual manual control’ control either Pitch feedback Repair fault Pitch has gone to Renew el actuator one end position Pitch control valve for valve and remains there fault Repair valve High friction in hub mechanism Stop water ingress - Water in oil Repair worn parts
Pitch operation is not working properly at manual control
Pitch oil pressure reaching high level, equal to the relief valve setting
Pitch operation is only possible in - Worn parts astern direction, or when drive motor Mechanical is stopped blockage in hub
Pitch is not responding at all
Pitch operation is not working properly at manual control
Pitch oil pressure did not rise to relief valve setting when in end position
Pitch operation is only possible when drive motor is stopped
Damage blades
Repair damaged parts
Feedback
Repair feedback
Mechanical blockage in hub
Repair damaged parts
Damage blades
Repair blades
Hydraulic blockage in filters or valves
Remove blockage
By-pass of oil in the hydraulic system outside of the gear housing Relief valve setting
Page 46 of 61
User Manual
Repair damaged parts
Relief valve pressure (inside valve). Pitch pump Clean valve, readjust setting
Rolls-Royce Tunnel Thruster
Symptoms
Possible faults
Components
Corrective actions
Oil pump
Repair or renew pump Renew oil inlet ring at forward end propeller shaft Repair pipes or hoses
By-pass of oil inside gear housing
Repair leakage between flanges. Repair leakage in servo motor
High oil temperature Pump not running No pitch oil pressure at all
See same topic under “Abnormal oil conditions” Starter
Start pump
El motor
Change motor Bleed air
El. motor running but no pressure
Pump
Repair or renew pump
Coupling for pump Change coupling
8.6
CP hub
Symptoms
Possible faults
Leakage
Emulsified oil
8.7
Components
Corrective actions
Blade seal Plugs
Change seal / plugs
Possible faults
Components
Corrective actions
Emulated oil
Oil in system
Repair leakages and renew oil
Lubrication oil
Symptoms Water mixed in oil
Air leakages
Stop leakage at suction side (pipes, filter, etc.)
Suction side of Foam and bubbles system in the oil Oil is white or grey Air in the oil
Noise from the hydraulic system
Oil clears up after period of still stand
Pump drive shaft seal
Stop leakage at pump shaft etc.
Noise in the system
Pump
Bleed air from system where needed
Pump
Repair the pump
Mechanical fault in Particles in oil components
Rolls-Royce Tunnel Thruster
User Manual
Page 47 of 61
Symptoms
Possible faults Valves etc. playing
Fluctuating pressure
Mechanical noise when running Vibrations
Corrective actions
Reduction-, reliefor check valves
Check valves and adjust
Air in the oil
Repair air leakage and bleed air
Gear wheels
Renew gearwheels
Bearings for drive Renew bearings and propeller shaft Pump
Renew pump
Gearwheels
Renew gear wheels
Bearings
Renew bearings
Manoeuvre problems
Pump
Renew pump
Broken mechanical parts
Mechanical parts
Repair defect parts
Steel/iron particles Particles in filters
Particles or others in the thruster oil
Components
Pitch problems Bronze particles
Renew oil inlet Oil distribution arr. bushing, seals at forward end of and other parts propeller shaft necessary Oil inlet bushing in Renew bushings steering gear on seals Renew bushings
Other
Water in the oil
Painting inside gear housing
Change filter inserts regularly and/or strip down and remove loose paint
High system pressure
Pitch in end position
Remote control
Adjust
Cooler water flow
Increase cooling water flow
Cooling water temperature
Reduce cooling water temperature
Cooler condition
Clean cooler
Thermostat valve
Repair or renew valve
Cooling water capacity
High oil temperature
Other bushings
Too high oil temperature
Oil flow Oil flow through cooler
Wrong oil viscosity Oil specification Page 48 of 61
User Manual
Gear box
Repair leak inside gear box
Pump
Repair or renew pump
Oil
Renew oil to correct viscosity Rolls-Royce Tunnel Thruster
Rolls-Royce Tunnel Thruster
User Manual
Page 49 of 61
9.
CONTACT INFORMATION
Country
Norway
Address
Telephone
Fax
Rolls-Royce Marine AS
+ 47 815 20 070
Spares:
Propulsion - Ulsteinvik
Mob:
+47 70 01 40 18
Sjøgata 98
+47 900 10 997*
Tech support: +47 70 01 40 12
N-6065 ULSTEINVIK, NORWAY [email protected]
* 24 hr emergency
North America Rolls-Royce Canada Ltd
+1 902 468 2883
+1 905 468 2759
+1 504 464 4561
+1 504 464 4565
+1 954 745 5400
+1 954 745 5401
+1 508 660 6328
+1 508 660 6210
+1 206 782 9190
+1 206 782 0176
(GSN Commercial Marine) Canada
196 Joseph Zatzman Drive, Unit 9 Dartmouth, Nova Scotia Canada B3B 1N4 Rolls-Royce Marine Inc 200 James Drive West St. Rose, LA 70087 USA Rolls-Royce Commercial Marine 4350 Oakes Road, Suite 528
USA
Fort Lauderdale, FL 33314 USA Rolls-Royce Marine Inc 110 Norfolk Street Walpole, MA 02081 USA Rolls-Royce Marine Seattle 4451 – 14th Avenue NW Seattle, WA 98107-4696
South America Rolls-Royce Marine Ltda Brazil
+55 21 2277 0100 +55 21 2262 1952
Av. Almirante Barroso 52 20031-000 RIO DE JANEIRO Brazil
Asia
China
Rolls-Royce Marine Shanghai
+86 21 638 78808 +86 21 538 25793
RM 911-915 Lippo Plaza
Mob:
No. 222, Huaihai Road (M)
+86 21 628 14228
200021 SHANGHAI China
Rolls-Royce Tunnel Thruster
User Manual
Page 51 of 61
Country
Hong Kong
Address
Telephone
Fax
Rolls-Royce Maine Hong Kong Ltd
+852 2526 6937
+852 2868 5344
+91 22 820 45 41
+91 22 820 45 42
+81 3 3237 6861
+81 3 3237 6846
+82 51 831 4100
+82 51 831 4101
+7 4232 495484
+7 4232 495484
3303-3305 Shui On Centre 6-8 Harbour Road, Wanchai HONG KONG SAR Rolls-Royce
India
Mumbai, India Rolls-Royce Marine Japan K.K Tobunsha Bldg. 4F
Japan
2-5-1, Kudan-Minami Chiyoda-ku TOKYO 102-0074 JAPAN Rolls-Royce Marine Korea Ltd Noksan State Industrial Complex 18B2L
Korea
1578-1, Songjeong-dong, Gangseo-gu BUSAN 618-270 Korea Rolls-Royce Marine Vladivostok Rep Office
Russia
5F, 3-B, Streinikova Str. 690065 Vladivostok, Russia Rolls-Royce Marine Singapore Pte Ltd Service:
Singapore
Service:
No 6 Tuas Drive 1, Jurong
+65 9632 1347
+65 862 8390
SINGAPORE 638673
Spares:
Spares:
+65 960 39198
+65 862 5386
Mob: +65 98466277* Europe
Benelux
Denmark
Finland
Rolls-Royce Marine Benelux B.V.
+31 10 409 0920
P.O. Box 666 (Werfdijk 2)
Mob:
3195 HV Pernis Netherlands
+31 0651 531528*
Rolls-Royce Marine AS
+45 98 11 49 55
Værftsvej 23
Mob:
DK-9000 AALBORG Denmark
+45 40 19 49 55
Rolls-Royce Marine Oy Ab
+358 2 83791
PO Box 220 (Suojantie 5)
Mob:
FIN-26101 RAUMA Finland
+358 49 666 678
Page 52 of 61
User Manual
+31 10 409 0921
+45 98 11 49 45
+358 2 8379 4874
Rolls-Royce Tunnel Thruster
Country
France
Address
Telephone
Fax
Rolls-Royce Marine France
+33 1 468 62811
+33 1 468 79398
+49 40 780 9190
+49 40 780 91919
Immeuble de Monaco 4 Place des Etas-Unis F-94150 RUNGIS France Rolls-Royce Marine Deutschland Gmbh
Germany
Kamerunweg 7
Mob: +49 40 780 9190*
D-20457 Hamburg Germany
Greece
Kaminco Overseas Inc
+30 1 45 28 240
Presented by KAMINIS Co Ltd
Mob:
57 Akti Miaouil PO Box 80115
+30 1 42 93 355
+30 1 42 94 887
GR-PIRAEUS 18510 Greece
Italy
Poland
Rolls-Royce Marine Italia s.r.l.
+39 010 572 1922 +39 010 572 1950
Piazza delia Vittoria 14/19
Mob:
I-16121 GENOVA Italy
+39 348 7121506*
Rolls-Royce Marine Poland
+48 587 820 655
+48 587 820 656
+34 977 296 444
+39 010 572 1950
+46 550 84000
Spares:
Mob:
+46 550 84776
46 70 528 6566*
Service:
Alfa Plaza Building Batorego 28-32 str. 81336 GDYNIA Poland Rolls-Royce Espana SA
Spain
PO Box 894 E-43080 TARRAGONA Spain Rolls-Royce AB Box 1010
Sweden
S-681 29 Kristinehamn Sweden
+46 550 84671
[email protected]
Tech support:
[email protected]
UK
Rolls-Royce Commercial Marine Ltd (UK) Green Street, Green Road
+46 550 84771 +44 1322 394 300 +44 1322 394 3026 Mob:
Dartford Kent DA1 1QG UK
+44 790 151 7070*
Perth Office
+61 8 9336 7910
1 Mouat Street
Mob:
Fremantle, WA 6160 AUSTRALIA
+61 418 567 523*
Australia
Australia
Rolls-Royce Tunnel Thruster
User Manual
+61 8 9336 7920
Page 53 of 61
Country
Address
Telephone
Fax
Melbourne Office
+61 3 9873 0988
+61 3 9873 0866
Office 4, 5 Redland Drive
Mob:
Mitcham, VIC 3132 AUSTRALIA
+61 417 323 077*
Page 54 of 61
User Manual
Rolls-Royce Tunnel Thruster
10. SPARE PARTS 10.1
Ordering Spare Parts
When ordering spare parts, the following information must be given:
Installation no., vessel’s name and owner’s name.
Shipping address and invoicing address.
Drawing Number, Position Number, Article Number (Art.no.) and Quantity.
10.2
Spare Parts List
The following spare parts and given quantities are recommended: Art.no.
Description
Qty. Installed Qty. Spare
Comment
992200/-
Filter insert
1
2
For single filter
992200/-
Filter insert
2
4
For double filter
10.3
Preservation
Spare parts should be kept in a dry and dust free environment.
Rolls-Royce Tunnel Thruster
User Manual
Page 55 of 61
11. TOOLS The following tools are delivered with the Rolls-Royce Tunnel Thrusters: Art. no.
Description
Qty. Comment
91787/-
Injector
1
87313/-
Adapter
1
87314/-
High pressure tube
1
83181/-
Plug
1
K141467/- Mounting tool
Rolls-Royce Tunnel Thruster
1
Tools for dismounting/pumping the gear coupling of the pinion
Tool for mounting the gear coupling to the pinion
User Manual
Page 57 of 61
12. DESIGN DRAWINGS 12.1
Mechanic
Drawing / document
Drawing number
Dimension drawing
314587/C
Tunnel and propeller unit
111139/-
Propeller unit assembly
109481/C
Propeller hub assembly
109485/B
Motor foundation assembly
218805/A
Gear coupling
K141356/C
Feedback device assembly
K141995.6/D
12.2
Hydraulic
Drawing / document
Drawing number
Hydraulic system diagram
109401/C
Alarmlist
416906/A
Hydraulic connections on thruster top
217330/A
Arrangement pump unit
312504/A
Filter arrangement
312475/C
Gravity tank
217255/B
Hydraulic module
217216/A
Arr. hand pump for drain of thruster
311290/D
12.3
Electric
Drawing / document
Drawing number
Drive motor
See remote control man.
Drive motor starter
See remote control man.
Rolls-Royce Tunnel Thruster
User Manual
Page 59 of 61
Page 1 of 1
Sequence No.
BOM Line
ERP BOM Quantity
111139/--Thruster Lower Module (view)
Unit Of Measure pcs
K983946/A-Stay
1
1.000000
pcs
./--Tool
2
0
pcs
109481/C-Thruster Lower Gear Housing (view)
3
1.000000
pcs
109485/B-Propeller Hub (view)
4
1.000000
pcs
K969323/C-Propeller Blade (view)
5
4.000000
pcs
109613/A-Pinion Shaft
6
1.000000
pcs
217402/A-Bevel Gear Wheel
7
1.000000
pcs
108565/C-Tunnel Thruster Mounting (view)
8
1.000000
pcs
K141995.6/D-Feedback Unit (view)
9
1.000000
pcs
file://C:\Temp\iMANprint45040.html
05.10.2009
Page 1 of 4
Sequence No.
BOM Line
ERP BOM Quantity
109481/C-Thruster Lower Gear Housing (view)
Unit Of Measure pcs
108462/C-Gear House (view)
1
1.000000
pcs
K141444/B-Bearing Housing (view)
2
1.000000
pcs
K983412/B-Cover
3
1.000000
pcs
./--Tool
4
0
pcs
../--Tool
5
0
pcs
109258/A-Propeller Shaft (view)
6
1.000000
pcs
K141450/--Bearing Housing (view)
7
1.000000
pcs
K141452/B-Bearing Cover (view)
8
1.000000
pcs
109477/B-Propeller Hub Coupling (view) 9
1.000000
pcs
216400/--Pitch Control Pipe (view)
10
1.000000
pcs
K983725/B-Bush
11
1.000000
pcs
216649/A-Feedback Unit (view)
12
1.000000
pcs
K983663/E-Oil Distribution Ring
13
1.000000
pcs
K983947/A-Washer
14
1.000000
pcs
K141449/--Lever
15
1.000000
pcs
K141464/--Lever
16
1.000000
pcs
K983828/A-Rod
17
1.000000
pcs
109484/A-Rope Guard
18
1.000000
pcs
K983838/A-Plate
19
1.000000
pcs
K141460/--Connector
21
1.000000
pcs
K983666/A-Plate
22
1.000000
pcs
K983717/B-Cover
23
1.000000
pcs
K112176/D-Bush
24
1.000000
pcs
K141455/A-Washer
25
1.000000
pcs
K983839/A-Sleeve
27
1.000000
pcs
83179/--Plug
28
2.000000
pcs
K983678/D-Tube
29
1.000000
pcs
file://C:\Temp\iMANprint45041.html
05.10.2009
Page 2 of 4
K983679/D-Plug
30
2.000000
pcs
K141469/--Connector
31
1.000000
pcs
K983183/B-Distance Ring
32
6.000000
pcs
K954022/B-Plug
34
1.000000
pcs
991393/--Pipe Clamp
37
6.000000
pcs
991399/--Plate
38
3.000000
pcs
991396/--Plate
39
4.000000
pcs
312006/A-Shaft Seal (NXView)
40
1.000000
pcs
992448/--Bearing
42
1.000000
pcs
86005/--Bearing
43
1.000000
pcs
91984/--Bearing
44
1.000000
pcs
992034/--Taper Roller Bearing
45
1.000000
pcs
93212/--Bearing
46
1.000000
pcs
992447/--Bearing
47
1.000000
pcs
99864/--Lock Nut
48
1.000000
pcs
87338/--Lock Nut
49
1.000000
pcs
992035/--Bearing
50
1.000000
pcs
992038/--Piston Ring
51
1.000000
pcs
992803/--Seal Ring
53
1.000000
pcs
992039/--Piston Ring
54
1.000000
pcs
992041/--Stripper
56
1.000000
pcs
992449/--Seal Ring
58
1.000000
pcs
93045/--Seal Washer
59
2.000000
pcs
91495/--Seal Washer
61
2.000000
pcs
90750/--O-Ring
62
1.000000
pcs
992042/--O-Ring
63
1.000000
pcs
82233/--O-Ring
64
1.000000
pcs
992043/--O-Ring
65
2.000000
pcs
992044/--O-Ring
66
1.000000
pcs
94228/--O-Ring
67
1.000000
pcs
file://C:\Temp\iMANprint45041.html
05.10.2009
Page 3 of 4
94565/--O-Ring
68
1.000000
pcs
93287/--O-Ring
69
1.000000
pcs
90080/--O-Ring
70
1.000000
pcs
992805/--O-Ring
71
1.000000
pcs
992802/--O-Ring
72
1.000000
pcs
93751/--Retaining Ring
75
1.000000
pcs
90036/--Retaining Ring
76
1.000000
pcs
92334/--Grub Screw
79
3.000000
pcs
94285/--Grub Screw
80
2.000000
pcs
84995/--Grub Screw
81
6.000000
pcs
90577/--Hexagon Head Screw
82
6.000000
pcs
84540/--Socket Screw
83
8.000000
pcs
992053/--Hexagon Head Screw
84
2.000000
pcs
91453/--Hexagon Head Screw
85
8.000000
pcs
97237/--Hexagon Head Screw
86
3.000000
pcs
91905-UL/--Socket Screw
89
8.000000
pcs
92482/--Socket Screw
90
2.000000
pcs
92371/--Socket Screw
91
2.000000
pcs
91905-UL/--Socket Screw
92
4.000000
pcs
95237/--Socket Screw
94
2.000000
pcs
84614/--Socket Screw
95
6.000000
pcs
90569/--Socket Screw
96
6.000000
pcs
92749/--Socket Screw
97
12.000000
pcs
91564/--Socket Screw
98
10.000000
pcs
97437/--Socket Screw
99
12.000000
pcs
90506/--Socket Screw
100
6.000000
pcs
85179/--Washer
103
3.000000
pcs
90005/--Hexagon Nut
104
1.000000
pcs
90067/--Lock Wire
105
0.100000
m
97298/--Threaded Rod
106
0.200000
m
file://C:\Temp\iMANprint45041.html
05.10.2009
Page 4 of 4
992517/--Ball Joint
108
3.000000
pcs
83374/--Pipe Coupling
110
2.000000
pcs
93822/--Pipe Coupling
111
2.000000
pcs
992816/--Hose
112
2.000000
pcs
992960/--Hose
113
1.000000
pcs
92263/--Plug
114
1.000000
pcs
83183/--Plug
115
2.000000
pcs
92263/--Plug
116
2.000000
pcs
83181/--Plug
117
4.000000
pcs
90509/--Plug
118
3.000000
pcs
90189/--Plug
119
2.000000
pcs
992049/--Plug
120
2.000000
pcs
902667/--Pipe Clamp
122
8.000000
pcs
992809/--Plug
124
1.000000
pcs
992235/--Plug
125
1.000000
pcs
992006/--Locking Compound
126
0
pcs
992051/--Locking Compound
127
0
pcs
93415/--Sealing Compound
128
0
pcs
91327/--Pipe Coupling
1096
6.000000
pcs
file://C:\Temp\iMANprint45041.html
05.10.2009
Page 1 of 2
Sequence No.
BOM Line
ERP BOM Quantity
109485/B-Propeller Hub (view)
Unit Of Measure pcs
K986271/H-Propeller Hub Body (view)
1
1.000000
pcs
K986272/I-Piston Rod (view)
2
1.000000
pcs
K986278/A-Crank Ring (view)
3
4.000000
pcs
85207/--Washer
4
24.000000
pcs
312392/A-Sliding Shoe (view)
5
4.000000
pcs
312393/A-Blade Bolt (view)
6
24.000000
pcs
416687/--Cylindrical Pin (view)
7
4.000000
pcs
416688/--Cylindrical Pin (view)
8
4.000000
pcs
312128/--Connector (view)
9
1.000000
pcs
K954022/B-Plug
10
3.000000
pcs
312394/--Sliding Bar
11
1.000000
pcs
312130/--Spring Retainer
12
1.000000
pcs
992042/--O-Ring
13
1.000000
pcs
85241/--Washer
14
12.000000
pcs
900802/--Guide Ring
17
1.000000
pcs
992290/--Piston Ring
18
2.000000
pcs
992042/--O-Ring
19
3.000000
pcs
992291/--O-Ring
20
4.000000
pcs
91117/--O-Ring
21
1.000000
pcs
992292/--Hexagon Head Screw (view) 22
12.000000
pcs
90601/A-Socket Screw
23
4.000000
pcs
992003/--Spring
24
3.000000
pcs
992004/--Locking Plate
25
16.000000
pcs
992293/--Locking Plate
26
8.000000
pcs
992006/--Locking Compound
28
1.000000
pcs
992007/--Locking Compound
29
1.000000
pcs
93415/--Sealing Compound
30
0
pcs
file://C:\Temp\iMANprint45043.html
05.10.2009
Page 2 of 2
992009/--Grease
31
1.000000
pcs
992010/--Lubricant
32
0
pcs
file://C:\Temp\iMANprint45043.html
05.10.2009
Page 1 of 1
BOM Line
Sequence No. ERP BOM Quantity Unit Of Measure
218805/A-Foundation (view) 111843/A-Foundation (view)
pcs 1.000000
pcs
94266/--Hexagon Head Screw 02
12.000000
pcs
93318/--Hexagon Head Screw 03
16.000000
pcs
90250/--Hexagon Nut
04
16.000000
pcs
85141/--Plain Washer
05
16.000000
pcs
85678/--Straight Pin
06
2.000000
pcs
file://C:\Temp\iMANprint45044.html
1
05.10.2009
Page 1 of 1
BOM Line
ERP BOM Quantity
Sequence No.
K141356/C-Toothed Coupling (view)
Unit Of Measure pcs
992553/--Toothed Coupling Hub
1
1.000000
pcs
993008/--Toothed Coupling Hub
2
1.000000
pcs
992556/--Toothed Coupling Sleeve
3
2.000000
pcs
992557/--Disc
4
1.000000
pcs
992555/--Flange
5
8
pcs
992559/--Lock Nut
6
8
pcs
K141463/--Plate
7
1.000000
pcs
992558/--Spacer
8
1.000000
pcs
992563/--Screw
9
1.000000
pcs
992560/--O-Ring
10
2.000000
pcs
992561/--O-Ring
11
2.000000
pcs
992562/--Transport Bracket
12
1.000000
pcs
file://C:\Temp\iMANprint45045.html
05.10.2009
Page 1 of 1
BOM Line
Sequence No. ERP BOM Quantity Unit Of Measure
K141995.6/D-Feedback Unit (view)
pcs
K993764/C-Bracket
1
1.000000
pcs
K993766/--Lever
2
1.000000
pcs
K993765/A-Lever
3
1.000000
pcs
900459/--Threaded Rod
4
1.000000
pcs
90174/--Hexagon Head Screw
5
2.000000
pcs
90455/--Socket Screw
6
2.000000
pcs
90957/--Socket Screw
7
3.000000
pcs
93462/--Hexagon Nut
8
2.000000
pcs
992048/--Ball Joint
9
2.000000
pcs
K984664/--Transmitter Box
10
1.000000
pcs
992006/--Locking Compound
11
1.000000
pcs
93537-UL/--Hexagon Head Screw
12
1.000000
pcs
K145092/--Lever
13
1.000000
pcs
84730/--Hexagon Head Screw
14
2.000000
pcs
K145093/--Indicator
15
1.000000
pcs
K145091/--Scale
16
1.000000
pcs
99977/--Rivet
17
2.000000
pcs
313670/B-Spring (view)
18
1.000000
pcs
313672/B-Spring Retainer (view)
19
1.000000
pcs
903383/--NOT CATEGORIZED
20
1.000000
pcs
file://C:\Temp\iMANprint51947.html
24.09.2009
Page 1 of 1
Sequence No.
BOM Line
ERP BOM Quantity
217330/A-Pipe Connection Arrangement (view)
Unit Of Measure pcs
312144/C-Mounting Plate (view)
1
1.000000
pcs
311900/A-Mounting Plate (view)
2
1.000000
pcs
87499/--Pipe Coupling
4
2.000000
pcs
95140/--Pipe Coupling
5
2.000000
pcs
901381/--Fluid Sample Point
6
2.000000
pcs
83422/--Pipe Coupling
7
2.000000
pcs
990784/--Pipe Coupling
8
1.000000
pcs
92998/--Pipe Coupling
9
3.000000
pcs
901382/--Fluid Sample Point
10
2.000000
pcs
94366/--Non Return Valve
11
1.000000
pcs
990935/--Pipe Coupling
13
2.000000
pcs
83515/--Pipe Coupling
14
1.000000
pcs
95134/--Pipe Coupling
15
1.000000
pcs
991109/--Pipe Coupling
17
6.000000
pcs
991123/--Pipe Coupling
18
5.000000
pcs
990936/--Pipe
20
2.000000
m
80311/--Pipe
21
2.000000
m
90700/--Pipe Coupling
22
1.000000
pcs
991115/--Pipe Coupling
23
2.000000
pcs
94559/--Pipe Coupling
24
1.000000
pcs
90083/--Pipe Coupling
25
1.000000
pcs
90085/--Pipe
26
1.000000
m
file://C:\Temp\iMANprint45046.html
05.10.2009
Page 1 of 1
BOM Line
Sequence No. ERP BOM Quantity Unit Of Measure
312504/A-Pump Unit (view)
pcs
901300/--Electrical Motor
1
1.000000
pcs
901301/--Gear Pump
2
1.000000
pcs
901298/--Bell Housing
3
1.000000
pcs
96962/--Flexible Coupling Hub
4
1.000000
pcs
96960/--Flexible Coupling Element 5
1.000000
pcs
901299/--Flexible Coupling Hub
6
1.000000
pcs
416714/--Adapter Plate
7
1.000000
pcs
80311/--Pipe
8
1.000000
m
312473/A-Hose
9
1.000000
pcs
84135/--Ball Valve
10
1.000000
pcs
901121/--Non Return Valve
11
1.000000
pcs
95140/--Pipe Coupling
12
1.000000
pcs
95134/--Pipe Coupling
13
1.000000
pcs
90599/--Pipe Coupling
14
1.000000
pcs
94698/--Pipe Coupling
15
1.000000
pcs
90287/--Pipe Coupling
16
1.000000
pcs
91479/--Pipe Coupling
17
1.000000
pcs
90286/--Pipe Coupling
18
2.000000
pcs
83554/--Pipe Coupling
19
2.000000
pcs
83374/--Pipe Coupling
20
1.000000
pcs
83421/--Pipe Coupling
21
1.000000
pcs
990463/--Fluid Sample Point
22
2.000000
pcs
991428/--Plug
23
1.000000
pcs
991099/--Pipe Coupling
24
1.000000
pcs
991123/--Pipe Coupling
25
5.000000
pcs
84627/--Socket Screw
26
4.000000
pcs
90869/--Spring Washer
27
4.000000
pcs
94902/--Plain Washer
28
4.000000
pcs
file://C:\Temp\iMANprint45047.html
05.10.2009
Page 1 of 1
BOM Line
Sequence No. ERP BOM Quantity Unit Of Measure
312475/C-Filter (view)
pcs
901307/--Filter
1
1.000000
pcs
901308/--Indicator
2
1.000000
pcs
992200/--Filter Cartridge
3
1.000000
pcs
91406/--Pipe Coupling
4
2.000000
pcs
83423/--Pipe Coupling
5
1.000000
pcs
83554/--Pipe Coupling
6
1.000000
pcs
990463/--Fluid Sample Point
7
1.000000
pcs
991113/--Pipe Coupling
8
1.000000
pcs
94169/--Hexagon Head Screw 9
4.000000
pcs
91341/--Spring Washer
10
4.000000
pcs
417482/--Bracket (view)
11
1.000000
pcs
file://C:\Temp\iMANprint45048.html
05.10.2009
Page 1 of 1
BOM Line
Sequence No. ERP BOM Quantity Unit Of Measure
217255/B-Gravity Tank (view)
pcs
992389/--Tank
1
1.000000
pcs
992392/--Cap
2
1.000000
pcs
900701/--Level Switch
3
1.000000
pcs
992387/--Temperature Switch
4
1.000000
pcs
83181/--Plug
5
4.000000
pcs
991310/--Plug
6
1.000000
pcs
413247TT/--Name Plate
7
1.000000
pcs
90006/--Pipe Coupling
8
1.000000
pcs
93767/--Pipe Coupling
9
1.000000
pcs
84144/--Ball Valve
10
1.000000
pcs
90599/--Pipe Coupling
11
3.000000
pcs
991123/--Pipe Coupling
12
3.000000
pcs
99014/--Thermometer
13
1.000000
pcs
file://C:\Temp\iMANprint45049.html
05.10.2009
Page 1 of 1
Sequence No.
BOM Line
ERP BOM Quantity
217216/A-Hydraulic Power Pack (view)
Unit Of Measure pcs
312024/D-Foundation
1
1.000000
pcs
312493/C-Control Valve (view)
4
1.000000
pcs
312480/A-Pressure Sensor Block (view)
5
1.000000
pcs
901321/--Manometer
6
1.000000
pcs
98718/--Fluid Sample Point
7
2.000000
pcs
901344/--Hose
8
1.000000
pcs
312575/--Hose
9
1.000000
pcs
98967/--Pipe
10
1.000000
m
80311/--Pipe
11
0.500000
m
903210/--Screw
12
3.000000
pcs
312599/--Junction Box (view)
13
1.000000
pcs
413247TT/--Name Plate
14
1.000000
pcs
409438/--Name Plate
15
1.000000
pcs
83179/--Plug
16
1.000000
pcs
file://C:\Temp\iMANprint51951.html
24.09.2009
Page 1 of 1
BOM Line
Sequence No. ERP BOM Quantity Unit Of Measure
311290/D-Hand Pump (view)
pcs
84311/--Hand Pump
1
1.000000
pcs
84135/--Ball Valve
2
3.000000
pcs
94061/--Pipe Coupling
3
2.000000
pcs
90599/--Pipe Coupling
4
8.000000
pcs
991123/--Pipe Coupling
5
8.000000
pcs
94563/--Bonded Seal
6
6.000000
pcs
file://C:\Temp\iMANprint51932.html
24.09.2009
13. REVISION Revision -
Reason for revision
Date
Release
29 September 2009
Signature
