STERN TUBE SEAL AIRGUARD® 4AS-B —3 PIPING SYSTEM— INSTALLATION MANUAL Seal Size: #900 Ship Name Shipowner Shipyard : DAEWOO SHIPBUILDING & MARINE ENGINEERING CO. LTD. Hull No. 5319/20121/22 Wartsila Japan Ltd. @ Japan Marine Technologies ‘Tokyo HQ : 5” Floor, NTC Building 1-11-2 Kyobashi, Chuo-ku Tokyo 104-0031 Japan Tol: 03 5159 8700 Fax: 03 5159 8710 Toyama Factory : 14-37, 7-Chome, Mukaishinjo-Machi, Toyama, 930-0916 Japan TEL: 076-451-3150 FAX: 076-451-3161© WARTSILA Wartsila Japan, Ltd. @ Japan Marine Technologies ‘CAUTIONS 1. Keep the sealing device clean and away from any harmful substances like neither dusts nor paints etc., and watch spatter at welding work. For thal, we recommend that itis always fully covered at your site. 2. Do not expose the sealing device to high temperature. 3. Take care that the sealing device would not be bumped, hit or heavily loaded. 4. Do not leave the sealing device outdoor. Especially for Fwd seal, pay attention not to make it wet. Hfyou miss these cautions, you take a great risk for the serious damage that possibly happened on the sealing device. ate! 1, SMM PITS RAY HERR, BUS F ICL $91 RAFREOA VCE BISL. VRB RICRERUCE, REE DICR OED, AmesEDLOLCE, WEEERRORE CRAICMELBUCE, * SSICMMS BROAN NE RENSTE, LRRROLESRAOTHNTOBBAIS, MMC BARE SRST CMGIET OC, BARI T EREWSCES MECHNI-SI3R, 3 1.14344 Se] AZ), BA, HVE, S50] B aol 9} a Bal] Sol} VA AAS wseps Fas) 84a ole £4 SAAS Fl ao dg. ZRLY Mal E20] 77] Val ABA} BS So}ok MYT. 3.4 BAF SAS SMS AAG AS HSS 7] PH)2. 44 BAY BIS HAD YA BALA MIO wep} Ss] A se] SAP of FA] PPA] 9. 58) Ave 24) AF) 47] SES FS] BH 2. AB?) NAA FADS 21717] BO Aza B54 SAG BH] SF NOU AAS as Al 29 eg, ER 1. EGHAM), TRS. MIR, TINE, BT ARO SIGES, SCTTIEN, ER RMS, 2, MSSM ERS i, 3. DAREN SOR, AE. 4, RUSTE A AR HEH EE RENAE) SUAMBEHEM, MPLA, WTAE DRT LARS IOT, WSR TEAR, BOER.CONTENTS 1,OUTLINE 2. EQUIPMENT INSTRUCTIONS AND PRECAUTIONS FOR EACH EQUIPMENT OF "AIRGUARD® 4AS-B" AIR SEAL SYSTEM 2-1 Names and piping system diagram of each equipment 2-2 Locations of each equipment for installation 23 Precautions for piping work 2-4 Check on equipment and precautions before installation 2-5 Precautions in installing the equipment 25-1 Air control unit 25-2 Drain collection unit 2-5-3 L.0. tank unit 25-4 Pressure gauge unit 3, LEAKAGE TEST FOR AIR LINE AND L.O.LINE, FLUSHING THE L.O.LINE 3-1 Leakage test for piping line from the aft bulkhead to the stem boss. 3-2 Leakage test for piping line of inboard side 3-2-4 leakage test for airline 3-2-2 Leakage test for L.O. circulation line 3-2-3 Flushing the L.O. line 4, OIL SUPPLY AND LEAKAGE TEST FOR STERN TUBE AND SEAL 444 Leakage test (stern tube) 4-2 Oil supply and leakage test for stern tube seal 4.21 Forward seal 4-2-2Aft seal 43 Precautions during the period from oil supply to afloat condition, and during outfit after faunching 5, ADJUSTING THE AFT SEAL AND STERN TUBE PRESSURE JUST BEFORE TRIAL4. OUTLINE Fig.1 shows the stern tube sealing device of “AIRGUARD® 4AS-B" air seal system. The forward seal is the same as conventional type. The aft seal requires three pipings, two of which are for supplying air and for discharging the drain between #1-#2 chamber, and the other one is used to supply L.O. between #2-#3 chamber. The major feature of this system is, unlike conventional seal, to purge the compressed air of constant flow from the aftermost seal ring to outboard at all times, and according to the air pressure, to automatically control the L.O. pressure in stem tube and #2-#8 seal chamber. This system is composed of the air control unit which controls the air amount and pressure, the ster tube L.O. tank unit which adjusts the L.O. pressure at the #2-#3 chamber and in stem tube, LO. circulation pump unit, drain collection unit and press. gauge unit, etc. This instruction specifies the installation of equipment and precautions to properly function this 4ASB air seal system For the installation of the aft and forward seal assembly (same as conventional products) and instruction during navigation, refer to the separate manual. 2. EQUIPMENT INSTRUCTIONS AND PRECAUTIONS FOR EACH EQUIPMENT OF ‘AIRGUARD® 4AS-B” AIR SEAL SYSTEM 2-4 Names and piping system diagram of each equipment Fig.2 shows the names of each equipment and example of piping system diagram. Our scope of supply includes the aft and forward seal assembly, air control unit, dain collection unit. 2-2 Locations of each equipment for installation ‘Table 1 shows the place of each equipment shall be located for installation, ‘Table 4. Location of each equipment for installation EQUIPMENT NAME LOCATION INSTALLATION HEIGHT Air control unit (About 2m above the shaft center) AA suitable position from the aft bulkhead to the engine aft alas side (Arrange together in a place as much as possible) About 1m above the shaft center 1m from the shaft center Below the shaft center(recommend) Near the aft bulkhead ‘About 1~ 2m above the shaft center Fwd seal tank About 1~ 2m above the shaft center2:3 Precautions of piping work (See Fig.2) 1) The material and diameter for each piping shalll be based on Table 2. ‘Table 2. Material and size of piping, and type of pipe fiting (Standard SYMBOL | PIPING LINENAME | MATERIAL OF PIPING] SIZE TPE OF PIPE FITTING IN: Bite joint for 815 ‘OUTA : Bite joint for 15 ‘QUT? : Bite joint for 15 0A INLET GOAI25A20A ‘OUTLET, $16 IN: Bite joint ford 15 58 OUT : Bite joint for_ 8 Bite joint for 68 LO. cit. fine STPG Drain collection unit Pressure gauge unit 2) Stee! pipes for L.O. piping line, should be cleaned by pickling before use. 3) For the L.O. piping line, prevent from such inverse U-shape that air stays. When piping over along distance, always slope. 4) Securely fx the piping to prevent vibration. 2-4 Check on equipment and precautions before installation 1) Unpack the packings, and check the equipment and their quantity specified in the packing list. ‘Also carefully check for damages during transport. 2) To transport equipment with liting eye bolts, pass a wire through them. For light or small ones, be careful not to lose them and transport them to the place for installation. 3) The pipe fitting has been attached with seal tape or blind plug before shipment. Do not remove nti immediately before installation. 2-5 Precautions in installing the equipment Install number plates, which are supplied by us, at valves, gauges and etc. for easy operation. 2-5-1 Air control unit (See Fig.6) 41) The air control unit has mounting holes 12mm dia. of eight places in total four places at the back ‘and four places at the bottom. To prevent vibration of the control parts in the panel, be sure to provide vibro-solating support for installation. 2) Each end connecting port is located under the panel. Each port has name plate. The names of ‘each port to the piping line are given below. board diy air source for control inlet of aft seal #1 - #2 chamber joura = LO. tank unit (iT (ei) ug (for emergency) 3) The air supply valve on the air control unit shall be closed until the trial operation. 4) After installing, cover the unit to protect from dust and welding spatter during the work. 25-2 Drain collection unit (See Fig.7) 1) Install the drain collection unit in the place by welding. 2) After that apply paint to the welded portion, bolts and nuts. 3) Secure the piping to prevent vibration. ‘4) When installing the system above the drain piping outlet, install a valve (even one with small boremay be used) inthe piping at the lowest position as shown in Fig.3. Be sure to attach a blind plate to the outlet flange of the valve. This valve is used to check the drain leakage condition, and is let closed at all times. 5) Install this system to such a position which can be viewed as easily as possible. When it is compelled to be located under the floor plate, elc., maintenance and inspection shall be Considered for arrangement of the unit. | a enna —sesitn | Fig.3 Valve Mounting Diagram 2-5-3 L.O. tank unit (by shipyard) 1) Install the L.O. tank unit securely to prevent vibration, 2) The name of each part to the piping line are given below. ARIN = Air control unit IN. Return line from stern tube ‘OUT = Inletto L.O. pump unit [IN] 3) Securely fix the cable to prevent vibration, 44) The cable of level switch should be connected to the alarm panel with protector and fixed with cable clamp. 2:54 Pressure gauge (by shipyard) 4) The connecting port to the oullevinlet of the stem tube, shall be arranged near by the aft bulkhead to more accurately measure the pressure in the aft seal chamber and stern tube. (required to adjust the pressure.) 2) When connecting by the copper tube tothe pressure gauge, be careful not to apply an excessive force to the pressure gauge. 3) Secure the piping to prevent vibration3. LEAKAGE TESTS FOR AIR LINE AND L.O. LINE, FLUSHING THE L.O. LINE. (Before installing the aft seal, see Fia.2) 3-1 Leakage test for piping line from the PRESS. GAUGE aft bulkhead to the stem boss. The leakage test shall be performed for all the three lines. 41) Attach a plug othe piping porton je AR the stem boss side. ini 2) Provide the inboard side piping port BULKHEAD O.5MPa with valves and a pressure gauge 1 eee Laose AFTER as shown in Fig.4, and close the Rrecomane A valve after pressurizing at air pressure of about 0.5MPa Fig 4 Test Procedure Diagram 3) After allowing to stand alone for about 30 minutes, using a pressure gauge, to make sure that the pressure does not lower. Apply soapy water, elc. to the joints and welded parts, and check for leakage during pressurizing, 4) After the leakage test, use flushing ol to clean the inside of the piping and air blow until coming ut no flushing oil completely. 3-2 Leakage test for inboard side piping line Perform the test while the piping line is connected to the equipment. 3-2-4 Leakage test for air line 41) Close the valve V20 on the airline forthe L.O. tank unit 2) Disconnect an air supply line to aft seal, at the nearest position to aft bulkhead. And put a temporary valve on it. After slightly open it, supply air from the air control unit. (Regulator pressure : 0.4MPa air low rate 35NLUimin) 3) After supplying air, adjust so that pressure of about 0.2MPa is applied to the piping line at the ‘opening ofthe valve which has been slightly opened in item 2. 4) Apply soapy water, etc. tothe joints and check for leakage during pressurizing. 5) After the test, stop the air and restore the air supply line to original condion. Also open the valve \V20 inthe airline for the L.O. tank unit 6) For the drain collection unit and press. gauge line, check for leakage when adjusting the pressure at afloat condition. 3-2-2 Leakage test for L.O. circulation line “The leakage test for L.O, circulation line will be described in item 4, Oil supply and leakage test for stern tube and seal 3-23 Flushing the L.O. line 41) The equipment to be supplied by us does not need to be flushed since they have been cleaned before shipment from our factory 2) Flushing the L.O. line between #2+#3 chamber @ For the inboard side, remove the piping on the IN and OUT sides of the L.O. circulation unit, and ‘connect the circulation pump for flushing, tank and fiter (will be arranged by the shipyard) between them. @ For the stem boss side, use pipe, etc. to connect the piping for the outlet and inlet between #248 chamber. @ Operate the circulation pump, flush for more than eight hours. Ifthe fter is dirty after flushing for eight hours, continue to lush until foreign particles do not adhere to the fier. @ Hammer the L.O. line during flushing, © After the flushing, completely, drain off the flushing oll, and return tothe original piping. 3) Flushing the stern tube L.O. line @ Remove the piping for outlet and inlet of the stern tube, and use pipe, etc. to connect the outlet to the inlet @ Remove the piping on the IN and OUT sides, and connect the circulation pump for flushing, tankand fiter (will be arranged by the shipyard) between them. @ Perform the same operation as items @) to ©) of 2) Flushing the LO. line between #243 chamber. 4) Flushing the forward seal @ Use pipe, etc. to connect the outlet piping to the inlet one for the forward seal @ Perform the same operation as items @ to @) of 3) Flushing the stem tube L.O. line. Note: The flushing may be executed in accordance with the work standard of the shipyard, 4. OIL SUPPLY AND LEAKAGE TEST FOR STERN TUBE AND SEAL ‘Completely finish the pioing work for air supply, drain piping and L.O. circulation line, leakage test and flushing of the line, then make sure that the forward and aff seals have been securely installed. ‘Supply oil to the LO. circulation line for seal leakage test. Oil supply and ke condition of main shaft 4-1 Leakage test (stern tube) 1) Close V35 and V20 between air control unit and L.O. tank unit. And open V18, V22, V24, V25, 27, V2B, V29 and V32. 2) Close V17 and open V18 and supply L.O. into stern tube by L.O. cit. pump. This time, for air venting in stem tube, open valve V21 of LO. tank unit 3)Fill up to stem tube line and when the oil evel in the L.O. tank unit has reached the high level at gauge, open V17 and close V18, 4)While viewing the G13, adjust the pressure in stern tube to become same pressure as full load sea water condition + 0.07 MPa by closing V15 slowly. 5)This time, remove the plugs of aft seal between #1-#2, #2-#3 and fud seal between #4-H5, make sure that not oil leakage from #3, #4 seal ring by confirmation of drain holes. 6) Allow to stand alone for more than eight hours, the leakage should be within 3LIBH. If exceed 3UUBH, the cause should be investigated. 7) Make sure that not oil leakage, install the plug of between #2-#8 and #4-#5 to drain holes. 4-2 Oil supply and leakage test for the stem tube seal Always sut the forws lying oi 4-2-1 Forward seal (the same as conventional forward seal) ‘Supply oil to the L.O. tank for forward seal and the fwd seal circulation line. Allow to stand alone for more than four hours, and check the #5 seal ring for leakage. The leakage should be within ‘1L/4H. If exceed 1L/4H, the cause should be investigated 4-2-2 Aft seal 1) Supply and leakage test of aft seal #2-#3 are to be executed after supply and leakage test of ster tube line. 2) Loose the plug of between #2-#8 top position of aft seal. Open V5 slightly, and tighten the plug after ol leakage from between #2-#83 top plug. After that, full open V36. 3) Allow to stand alone for more than eight hours, the leakage should be within 3L/8H. If exceed ‘SUBH, the cause should be investigated. 4) Make sure that not oil leakage, install the plug of between #1-#2 to drain holes and locked by wire, 5) Open V15 fully and stop pump. 6) Cleaning the filter. 7) Open L.O. supply line and operate pump. Close L.O. supply line when the oil level is raised near the middle between normal level and high alarm level Note) @ Oil supplying to the #1-#2 seal chamber is inhibited, because of air chamber. ® Confirm that all plugs at aft seal are completely tightened and locked by wire.4-3 Precautions during the period from oil supply to afloat condition and during out-fit after launching, (The same as conventional aft seal) 41) Cover the forward seal to prevent foreign particles from entering between liner and seal ring. 2) Cover the aft séal and the rope guard with vinyl sheeting, etc. until afloat condition, 3) The space between P-ring and #0 seal ring is fled with grease for protection of #0 seal ring during outfit. 4) Due to prevention of entering sludge and particle, vent holes on AFT seal cover are plugged using gum-tapes. Remove it before sea trial In case the out - fit period after launching is longer, please remove the gum-tape just before sea trial 5) Open VSS and confirm that drain does not invade. 5. ADJUSTING THE AFT SEAL AND STERN TUBE PRESSURE JUST BEFORE SEA TRIAL Aer the air and L.O. lines and the electric power supply are ready for use, adjust the pressure at the aft seal and stern tube. At this time, measure the depth of the draft at the ster beforehand. ‘Table 3 shows the pressure setting standard for each chamber. Table 3. Pressure Setting Standard for Each Chamber Under Forward sea Aftseal Bearing part water bial ‘Arrangement © A ® 4 6 of seal rings Paw Pos Pa Pas Pus Pas Type offid | con | preskl Preseutzng Press ing Lo. ee andsrcuaton| S02, | Fesswtng | “Greuaton’ | revlon’ | Pressurzng | Aomatc system (Btowep) | (board | (automatic | circulation | (eetn : drain) _| follow up) Pressure P= setting *Poy =Pswt | *Pi2=Port | Po=Pit | Po= Pos 0.009~ standard 0.01~0.015 | 0.01~0.015 | 0.03~0.05 | 0.015 0017 MPa KA pressure Py, P;gand Pz, does not need to be set by manual since it automatically becomes to the pressure of Po; =seawater + 0.01~ 0.015MPa Pi2=Po:+ 0.01~ 0.015MPa by pneumatic, control and Ps, = Pzs — 0.015MPa accordingly. ‘The pressure adjusting method for the aft seal and stern tube (See Fig.2) 1) Make sure that the L.O. circulation line for the aft seal and stem tube is securely filed with L.O. 2) Ensure that the open or close state of each valve for adjusting the pressure as shown in Table 4. Table 4. Open or Ciose State of Valves Closed valve No.__| V18,V19,V30,V34,V50, V51,V54,V56 L.O. circulation tine VA5,V17,V22,V24,V25,V27,V28,V29,V32,V35,V57, Opened Valve No. | Yas'yig7 inlet air control unit : VO Inside of air control unit : V1,V6,V201 and B1(plug) Closed valve No. | inside of drain collection unit : 101 Drain collection line : V55 Airline ‘Allvalves including V20, 21,31, 736, 710,103, Opened Valve No, | M108 ‘xcept the above valves N1® slightly open3) Operate L.O. circulation pump, this time, full open the all valves on LO. circulation line. 4) Adjust V32 at 120 + 50 L/H for flow meter Q3. '5) Close V21 on L.O. tank unit 6) Set each change over switch on air control unit to "A-LINE" side. 7) Open VO on air control unit and air supply. 8) Tum the “ALLINE® side knob for the flow controller on the air control unit to adjust so that the flow meter indicates 35NL/min, (Usually it has been adjust before shipment from our factory) 9) Make sure that a very small amount of air comes out (4NL/min) from top hole N1 of drain collection unit. Before shipment from our factory, ithas been adjusted to let out air at arate of 4 NL/min, 10) View the G13 on the pressure gauge unit, calculate the pressure on shaft center according to the below equations. (Unit : MPa) Prs= Poy + 0.015 (MPa) Py=G13+ Yo XH3 x 0.0098 (MPa) ‘Outlet pressure in stern tube (MPa) Pressure in #2-#3 chamber (MPa) = Pressure in stem tube (MPa) H = Height from the shaft center to pressure gauge G13 (m) 7.0= Specific weight of oil (about 0.9, for reference) 11) The differential pressure (Pzs—P.) is automatically controlled about 0.015 MPa. 12) To judge whether the calculated value is a proper pressure or not, use the following formula (Table 5) in the comparison with the air pressure in G10. Table 5. Guidetine for Pzs~ G10 LO. temperature at cooler outlet "C) Pa- G10 MPa 10 0.040~0.070 40 0.030~0.060 ifitis necessary to adjust the differential pressure P,,— G70, follow the method specified in item 74). 13) The differential pressure at #1 seal ing is determined by the following equations: (Unit: MPa) APo (MPa) = Poi -Paw (=0.01~0.015MPa) AP\(MPa)=G10—Ppy (=0.01~0.015MPa) Poy (MPa)= 75 x (Da—Hs) x 0.0098 AP» = Differential pressure at #0 seal ring (MPa) AP, = Differential pressure at #1 seal ring (MPa) Pay = Sea water pressure at the shaft center (MPa) Hs = Height from the base line to the center of a main shaft (mm) Da = Draft ofa ship atthe stern (m) 7/5 = Specific gravity of sea water (7.025)‘The pressure at #041 chamber is automatically maintained 0.01~0.015 MPa higher than the sea water pressure, and the pressure at #1-#2 chamber is automatically maintained 0.01~0.015 MPa higher than the pressure at #0-#1 14)When the differential pressure for Ps — G10 is different from the above guideline, adjust by using the following procedure: (Use the air relay (“A—LINE” side ; AR1,"B ~ LINE” side ; AR2) on the air control unit to adjust as. follows, QSet the air relay change over switch FV1 to “A-LINE” side. @Push the adjusting knob to touch the adjusting screw, tur clockwise of counter-clockwise to insert the end of adjusting knob into the slit ofthe adjusting screw. (See Fig.5) Note) A rubber ring stopper having set sit cut, is installed at air relay adjusting knob. Before adjustment, remove it. And after adjustment, re-install it @Tum the bias amount adjusting knob. Clockwise = Increasing the bias amount (pressure increase) Counter-clockwise = Decreasing the bias amount (pressure decrease) Check whether the valve for (P,; - G10) is the same value specified in Table 5. If not, repeat the adjustment operation again. With the air relay change over switch FV1 on “B -LINE® side, perform the same adjustment also on "A~ LINE” side. When the main shaft is rotating at the rated speed, adjust AR1 and AR2 by using the above ‘method again, (Final adlustment)BIAS AMOUNT. ‘ABIOSTING KNOB ALI a a BIAS AMOUNT "ADIUSTING SCREW E -sectional view of air rel 15) When there is a long period until trial after the adjustment, close master valve for air supply line, ‘and open 81 jin the air control unit, after completely escape air, close B1. This operate is importance of protect ingress sea water for #0 and #1 seal ring, 16) For handing after commission, refer to our “AIRGUARD® 4AS-B" instruction manual. Note) If air venting from seal and stern tube is not sufficient, for a some time after operating, oil level is dropped in L.O. tank unit by air venting slowly in the seal and stern tube. This phenomenon is not abnormal. In this case, ol to be filled according to the procedure of 4-2-2 7).| [Voor one, 7] ‘601 NYP ISI Ww 9 Voc tii |anz] ° ¥ -10- a a 8) | O@GE eee eRe Te of Lg ti-9, oR] A él I |__ea leo ‘$9 "foe "or=H[V_ ose . 0 Olona WERT! 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