STERN TUBE SEAL AIRGUARD® 4AS-B - 3 PIPING SYSTEM - INSTRUCTION MANUAL SealSize : #900 Ship Name Shipowner : Shipyard : DAEWOO SHIPBUILDING & MARINE ENGINEERING CO.,LTD. Hullo. — : §319/20/21/22 Wartsila Japan Ltd. @® Japan Marine Technologies “Tokyo HQ: Sth Floor, NTC Building 1-11-2 Kyobashi, Chuo-ku Tokyo 104-0031 Japan TEL: #81 3 5159 8700 FAX: +81 351598710 “Toyama Factory: 14-37, 7-Chome, Mukaishinjo-Machi, Toyama, Japan 930-0916 TEL. +81 76-451-3150 FAX +81 76451-3161CONTENTS 4. GENERAL OUTLINE 2, STRUCTURE 2.4 STERN TUBE SEAL 2A, AFT SEAL 2.1.2 FWD SEAL 2.2 NAMES OF RESPECTIVE PARTS FOR AIRGUARD® 4AS-B 3. EQUIPMENT AND PIPING SYSTEM 4, WEAR DOWN MEASURING 5. METHOD OF USE 5.1 PREPARATION AND CONFIRMATION BEFORE USE 5.2METHOD OF USE. 5.3 MEASURES UNDER REST CONDITION 6. ROUTINE WORKS FOR CHECK AND OPERATION 6.1 ITEMS TO BE CHECKED UP AND CARRIED OUT AT THE TIME OF WATCH 62 ITEMS TO BE CARRIED OUT ON OCCASION 63 ITEMS TO BE CARRIED OUT PERIODICALLY 6.4 ITEMS TO BE REPLACED PERIODICALLY 7. CONFIRMATION METHOD OF TROUBLES OR ABNORMALITIES AND COUNTERMEASURES, 8 WORLD WIDE SERVICE NETWORK 9, RECOMMENDED L.O. FOR STERN TUBE BEARING AND SEAL ATTACHED 1. MAINTENANCE FOR MICRO-MIST SEPARATOR 2. LUBE OIL FOR STERN TUBE SEAL AND BEARING 3. STERN TUBE SEAL DRAWINGS 4, PIPING DIAGRAM 5, FLUSHING PROCEDURE FOR AIR SUPPLY AND DRAIN LINE OF AIRGUARD® ASB 6. DATAOF AIRGUARD 4AS-B SEAL SYSTEM 7. LO. LEAKAGE FROM STERN TUBE SEAL AND WATER MIXED IN LO. AT THE SHIP IN OPERATION 8, MEASURING POINTS OF STERN TUBE SEALS AND ALLOWANCE WHEN INSTALLATION 9. INNER DIAMETER OF SEAL RING AND MACHINING ALLOWANCE4. GENERAL OUTLINE AIRGUARD® 4AS-B" contains 4pcs of seal ring. And fd seal is the same as conventional MKII type containing 2pcs of seal ring, * AIRGUARD® 4AS-B" as aft seal device shuts out sea water ingress by means of air bleeding from aftmost seal ring. By bleeding air pressure into the sea, sea water pressure at aft seal is detected automaticaly. And it gets to control the pressure of the oil circulation going through seal chamber forward side of air chamber (between #2 - #3 seal rings) and stem tube. Consequently it brings lightening a load to seal rings. Furthermore, it is possible to save man power by adopting system components combining with air Control and oil circulation line and watch the conciion ofthe seal. The following explanation will assist for safety ocean going. 2, STRUCTURE 2.4 STERN TUBE SEAL 2.4.4 AFT SEAL (Refer to Attached 3-1/2) ‘The aft seal consists of three major parts, ie. (1) four rubber seal rings and Ping, (2) a metal housing holding the rubber seal ings, and (3) liner which rotates together withthe propeller shaft ‘The metal housing is made up, in the order from the stem frame side, of spacer, aft casing flange, aft intermediate ring A, B&C and a splt-type seal cover & Ping cover. Rubber seal rings are inserted between three metal rings, and bolted together. The clamp section of each seal rings are securely fitted to the metal ring's inner circumferences and to the small grooves on the inner side of the metal rings, 50 that the clamp part is made rigidly ol-and-water-tight. Provide P-ring between seal cover and P-ring cover so protection against fishing nets. ‘The material of the liners highly resistant to corrosion and wear. 2.4.2 FWD SEAL (Refer to Attached 3 - 2/2) “The fund seal consists of four major pars, i.e, (1) two rubber seal rings, (2) a metal housing holding the rubber seal rings, (3) a liner which rotates together with the propeller shaft, and (4) a clamp ring which holds the ner. ‘The metal housing is made up, n the order from the stem side, of casing flange, intermediate ring and seal cover. ‘The metal rings of the fwd seal are bolted together, so that the rubber seal rings can be readily clamped and assembled, similar as in the case of the at seal ‘The material of the liner is used excellent wear-resistant and liplubricating properties. 2.2 NAME OF PARTS FOR AIRGUARD® 4AS-B ‘Attached 3 for STERN TUBE SEAL “AIRGUARD® 4AS-8" shows name of parts for "AIRGUARD® AASB. 3. EQUIPMENT AND PIPING SYSTEM A piping diagram is shown in the attached 4. Flow controller in the air control unit transfer the air of ‘constant flow into the air chamiber (between #1 and #2, #0 and #1 seal rings) and purges the air to the ssea water side. Air relay controls the air pressure of the L.O. tank unit and maintains the ol pressure in the oll chamber (between #2 and #3 seal rings), and in the stem tube (between #3 and #4 seal rings) ‘constantly higher tan the air pressure in the air chamber. ‘Assmall amount of the ar flows constantly from the air chamber to inboard, thus leaking sea water and lube oil can be collected by the drain collection unit and press. gauge unit. ‘The functions of each chambers are as follows.‘OA chamber between #0 and #1 seal ings ‘Sea water ingress is completely prevented by this chamber. Air purges at the #0 seal ring to the sea water side since the air pressure in the chamber is maintained a litte higher than the sea water pressure. ‘Ofir chamber between #1 and #2 seal rings ‘Sea water and lube oil are completely separated by this chamber. Air purges at the #1 seal ring to ‘the #0-#H seal ring chamber since the air pressure in the chamber is maintained a litle higher than the #041 seal ring chamber. Thus #1 seal ring seals the seawater completely. When seawater or lube oll leaks into this chamber, they can be led to inboard and collected ‘OCI chamber between #2 and #3 seal ings ‘Apart of oil delivered from stem tube L.O. pump is delivered into chamber of #2 and #3 seal rings, and retum into stem tube through #3 seal rng. LO. tank unit keeps oil pressure always higher than the pressure ofthe air chamber (between #1 and #2 seal ings) and follows the ship drat ‘OO chamber between #3 and #4 seal rings (i the ster tube) lis usually circulated by stem tube L.O. pump. The pressure in the stem tube is automatically set about 0.015 MPa lower than the pressure in the #2 and #3 seal rings, and change following draft. ‘OO chamber between #4 and #5 seal rings (Fwd seal) ‘Automatic circulation system. (CCM) Table 1 summarizes the above. Table 1. Composition and condition of respective sealing chambers Tem ‘Composition and condition P ® a @ 6 @ 6 (Outboard) Pow Pas Pa Pa Bearing Pes ‘Arrangement partof ofseatings | | | | semtube | Poy Working fluid Ol Hi Oil i Pee Pressure f Condition 0.009~0.017 MPa) | Automatic cereulaton (CCM) Pressuriang croulaon Condition of pressure - Equipped. None control following to change of the draft HE ? t ‘Two Number of Two ‘one pipings e No (erdrain) | (inkt) | (ete fe ert Two4.WEARDOWN MEASURING ‘After completely instaling main engine, shafting and aftfd seal, it records the outcome measured with wear down gauge. ‘This measuring is to be realized every docking. And when repairing and overhauling seal, itis to be done before and after them. Its recommendable to consider the outcome, to measure wear down when ‘overhauls on repairing seal, as the standard valve forthe future. Incase of vessel adopting in-water survey, it depends on the manual No. 03-3679. 5. METHOD OF USE ‘The method of using this device is explained refering to attached 4. In the air control unit, change over periodically “A — LINE” and "B — LINE”. Stem tube LO. pump are periodically change overed. The handling of a forward sealing device is as usual Before carrying out the operation in next §.1~5.3, confim that main shaft is in stop condition in all cases, Note) Adjustment of the aft seal pressure at fist installation and in case of replacing each parts is ‘acoording to "INSTALLATION MANUAL”, 5.1. PREPARATION AND CONFIRMATION BEFORE USE. 41) Supplyollto stern tube and #2-#3 L.O. circulation ine. © Confirm that respective valves V15,V21,V22,V24,V25,V27,V28,V28,V32,V35,V57 and VSB are open. ® Confirm that respective valves V17,V19,'30,V'34,V'50, 51, VS4 and V56 are closed. ® Close V17, open V18 and supply L.O. into the L.O. tank unit by L.O. supply pump. Next, push the automatic closing valves at the upper and lower parts ofthe oil level gauge of the L.O. tank nit for Confirmation of cil evel. When ol level nthe level gauge rising, open V17, @ When the oi level in the L.O. tank unit has reached the position about between high and low level, cose V18, © When airin olin the L.O. circulating line is nearly disappeared, close V21. 2) Confirm the condition ofthe valves forthe air contol unit and the drain collection unit ® Confirm that V1,81,V6,V201 and VO on the air control nit are closed, and other valves (including 20 on the top ofthe LO. tank unit, and V1 in the vicinity of at bulkhead.) are open. @® Confirm that 100 and V103 are open, N1 is sightly open (Before shipment from our factory, it has been adjusted to discharge air at a rate of 4 NLimin.), and V36 is open , V101 is closed in the drain collection unit and V5 is closed. 3) Set respective changeover switch V1 on the air control unit on “A — LINE" side. 5.2 METHOD OF USE © Open VO on the air source line slowly, and fil air into ##1#2 chamber. ® Confirm that the indications of respective pressure gauges are starting. Incase of use "A-LINE": G2, G3, G4, G9, G10, and G13 Incase of use “B - LINE": G2, G3, G5, G9, G10, and G13 (When the which ever pressure gauges are not starting, please refer to confimation method of troubles and abnormalities and the countermeasures.) Tum the knob of the flow controller FC, and set the flow meter Qi around 35NLImin, (Usually, it has been adjusted before shipment from our factory)Note) If air venting from stem tube and piping is not sufficient, for a some time after operating, ol is replaced with air and of level is dropped to alarming in the LO. tank unt. In this case ilo be filed ‘according to the procedure of 6.2-2)-b), @ Open v15. © Adjust the valve V32, and set the flow meter C3 120 =t 50 LH, if necessary. With this, an aft seal and stem tube have become working condition, The pressure in respective chambers at the center of ‘a main shaft can be determined as follows from the indicated values of pressure gauges G10,G13 and others. (Unit: MPa) +Sea water “#41442 chamber (MPa) : Pra “#248 chamber (MPa) : Pzs= Pay + 0.015 +Stem tube (MPa) : Ps, = G13+ (70x H3x0.0098) Where, 75: specific gravity of sea water (1.025) 0: Specific gravity of cil (0.90) Da : draft of a ship (m) Hs : height from ship bottom to the center of a main shaft (m) H : height from the center of a main shaft to G13 (m) ‘Accordingly from these pressure values, the differential pressure on each seal ring can be caloulated. 5.3 MEASURES UNDER REST CONDITION In the anchorage for a short period in voyage, as far as an aft seal and stem tube are in the usable ‘condition as mentioned in 5 2, adiustment is not necessary at all. In the folowing cases, put an aft seal in rest condtion by following the procedure shown respectively. 1) Incase of dry docking ® Switch off the alarm panel @ Close V0 on the air source line and open B1 in the air control unit, after escape air, close B1,V3tand 36. @ Stop the stem tube L.O. pump, and open V21 on the top ofthe L.O. tank unit to escape the ai. ‘At the time of the restoration, please bring an aft seal in the usable condition by the procedure opposite to this. 2) Following s disassembling procedure @ Open the valve V19,V51 and V54 to discharge the olin stern tube and L.O. tank unit © Open valve V56 and remove the plugs of at the top and bottom of intermediate ring to discharge the oil between #2 to #3 chamber. © With this, an aft seal casing has become the condition of disassembling. ‘At the time of the restoration, please bring an aft seal in the usable condition by the procedure ‘opposite to this, 3) Incase of stopping a shaft fora long period on the sea (for example, laying up and others) © Switch off the alarm panel. @® Close V0 on the air source line and open Bt inthe air contol unit after escape air, close B1,V3tand vo6. @ Stop the stem tube L.O. pump, escape air pressure by opening V21 at LO. tank unit. @® Close the valves V32 and V35 in the vciniy of the aft bulkhead. © Close the valve V15 and V17 in the vicinity ofthe L.O. tank unit. In case of using again, please bring a system in the usable condition by the procedure opposite tothis, Note) 1. If possible to supply electric power and air to this system, itis not necessary to stop the system. 2.In case that the system is remained stopping without air for long time, drain may come out through the drain collection unit, when supplying air again. Before starting the system, drain out ‘operation through the valves VSS is recommended. 3. After stopping air supply to the system, there is a possibilty of oll transtation from fwd seal tank to stem tube side, due to decreasing air pressure, inthis case supply ol to fwd seal tank after air ‘supplying. In shallow draft condition (within 1 meter from shaft center to sea waterline), operate some as 1). In this condition, do not rotate the shat. 6, ROUTINE WORKS FOR CHECK UP AND OPERATION 6.1 ITEMS TO BE CHECKED UP AND CARRIED OUT AT THE TIME OF WATCH AFT SEAL ‘AND “AIRGUARD® 4AS-8” SYSTEM 1) Are the indications of below respective pressure gauges are starting’? Incase of use “A-LINE”: G2, G3, G4, G9, G10 and G13, Incase of use "B — LINE": G2, G3, G5, G9, G10 and G13 2) Is the flow meter Q1(Q2) on the air contol unit indicating around 35NLimin ? 3) Is the element for MICRO-MIST SEPARATOR F1 normal condition?(Is indicator of the condition When the above condtions are not satisfied, refer to next 6:2 or 7, the confirmation method of troubles and abnormalities and the countermeasures.6.2 ITEMS TO BE CARRIED OUT OCCASION 1) Confirm the level of drain by sight glass at bottom part of MICRO-MIST SEPARATOR, and also confirm fiter condition by a checker on top of it. 2) In case of increase or decrease, the oil level in the L.O. tank unit. (Confirm by referring to the flowcharts in fig 1-4.) a) Case of increase By opening a valve V19, discharge oll in the tank until normal level, there after, clase V19. b) Case of decrease @ Open V18 to supply L.O. to L.O. tank unit. @® Close V18 afte fil up to the proper ol evel 6.3 ITEMS TO BE CARRIED ON PERIODICALLY 1) Exchange ofthe element F3, F4 of regulators in the air control unit: ‘once every four years. Exchange the element of the fter by the following procedure. @ Switch the changeover switch FV1 on the air conrol unit. @ By pushing the lever at the lower part of a bow, lower the pressure, thereafter, take off the bow, exchange the element, and fix the bow! back. ® Change back the switch FV1. 2) Cleaning of after at drain collection unit inlet: once every year. ® Close the V36, and clean the fiter by he following procedure. @ Take off the plug of fter, take out the element and clean it, thereafter, insert it and attach the plug again. @® Open the V36. 3) Maintenance of pneumatic equipment on the air control unit once every four years. ‘As for the pneumatic equipment used for the air control unit maintenance to be replaced once every four years at the time of periodical survey in a principle. Note) Maintenance manual fr pre fiter(F1), drain iter (F3, F4) are according to attached 1 4) Cleaning ofthe LO. fiter By shipyard standard, 5) Battery in the flow meter (23) The life of battery in the flow meter depends on the condition. When the battery has run down, a fickering alarm “BATT” appears on the register display. The battery should be replaced as soon as possible. 6.4 ITEMS TO BE REPLACED PREODICALLY TEMS ‘SYMBOL QUANTITY PERIOD ‘AIR CONTROL UNIT FILTER ELEMENT FOR PREFILTER Fl 1 2 YEARS FORMICRO-MIST SEPARATOR FILTER ELEMENT FOR REGULATOR i 2 ene FILTER ELEMENT FOR REGULATOR lk : alee FLOW METER: BATTERY @ 7 ZS YEARS7. CONFIRMATION METHOD OF TROUBLES AND ABNORMALITIES AND COUNTERMEASURES ‘When an abnormality ocourred during the use of 4AS-B, investigate into the cause and take the countermeasures by refering to the flowcharts in Fig1-1~8. (As to the symbols used for flowcharts, see attached 4). When the cause is unknown or the countermeasures are dificult, please make inquiry to Wits Japan Lid. When contacting with us, please submit attached: 6 data sheet aftr fil up necessary data on it + Conversion of #1-#2 chamber to ordinary oil pressed type from air control type. For instance, no control air for lng periods, etc., 4AS-B seal can be converted to ordinary oil pressed type from air control type inthe #1-#2 chamber. ‘The method of changeover and handling are shown as follows. ® Switch off the alarm panel. @ Close V100 at drain collection unit. @ Connect a temporary piping between valve V55 and V56, using vinyl tube as below figure. @ Open B1 on the ar control unit, close V4V7, V8 and inlet cock of pressure switch (PS1), © Open valves V55 and V6. © Under the condition of stem tube LO. pump running, supply L.O. to the #1-#2 chamber while ‘supplying ol to LO. tank unit from L.O. supply line. ® when ol level in vinyl tube reaches at about 200 mm below shaft center, stop LO. supplying to #142 seal chamber by closing valve V56 and V'18, After that, close B1, V9.V18,V55 and V6. ® Chose vatve V35. @ Adjust the pressure of stem tube so as to give 0.015~0.03 MPa higher pressure than the sea water pressure by adjusting of valve V15. @ With this, conversion rom 4AS-B to ol pressed type has been done, Atthe time of restoration @ Open B1,V15, V36 and V35. @ Disconnect a temporary piping between valves VS and V56, after that, open valve V5 to drain L.O. out @ Close B1,V55 and open V100 and inlet cock of pressure switch (PS1}). @ Open V7 and V8, open V4 on air control unt slowly. © Switch on the alarm panel. Further, LO. remained in the #1-#2 chamber is collected to inboard by drain collection uni. Please pay attention, when air supplying, there is a possibilty o cause small amount of L.O. containing in the air TEpoLaRy ee