oo Document tte Functional description system oO — aa [Sener nfo code ] System variant Issue Dato Page _| Doc. no. Rev. ne paeoora [8 F011 | C/b/E-hub, iptronie 7000 eyetem | 2005-08-20 Controllable pitch propeller functional description Introduction This section ex, | plain the funcona principles of the complete instalation nitro eysemes In order to tic : pment Provide a correct and complete explanation, the function or working of some equipr Not supplied by Lips is also briefly described Remote control system The scope of supply and execution of he remote control system Is dedicated tothe ship. The description in this. ‘chapter is based on the normal execution. For the final execution see the specif manuals "Operation and Remate con, ‘Scope of supply ‘he felevant contract specifies the Scope of Supply and i the only valid definition of the tems that areto be supped by tie * ue System overview Mainly the CPP (Controllable Pitch Propeller) system consists of the controllable pitch propeller, the shaft line, the hydraulic system and the control system. control system a" shailine e a ct trmioat tesdcoaniny «= SE ES al gearbox eS Fig.1.2. CPP standard configuration zs File name:DMHE000134_1.d0c, Last printed 17.6.2008 16:04:00 @ scanned with OKEN Scanner1.3 1.34 ——Frepelter ropeliertranstornis wie torque trom the prime mover main engine into the thrust Document tite: Functional description system Cc | Poe 25 DMHEOGOT34 Pav. of Functional principals of the CPP system Propelier and nozzle (if present) ime mover {main ane CPP (Contralable Pitch Propel transforms power fom ead or astern trust force onthe ship. ship. The propeller cor hub contains a com sists of propeler blades and the hub. The hub co ene actuating yoke and hydraulic double acing piston cjinder. The actuating yore is connected tthe iner oil pipe in the hollow bored shafi(s) for feedback. Noz2le (it present) , ice The nozzle is apart of, and integrated in, the ull structure. The propeller turns inside the nozzle. A nozzle is positioned around the propeller blade tps. It has a hydredynemic profile and improves the Propulsion thrust on the ship under pulling conditions. The nozzle is made of shipbuilding steel and is reinforced with rings, Mild or stainless steel plates can be applied inside the nozzle, depending ‘on ship demands 1.3.2 Stemtude The stertube penetrates the ull and supports the propeller shaft. The sternube is fled with Circulation ol or fud. Seals seal the ster-lube, A header tank, situated above the weterine, ensures that the oll pressure exceeds the pressure ofthe surrounding w 1.3.3 Shafftline ‘The shaft fine transmits the torque from the prime mover / main engine tothe propeller The shafts) has a hollow bore and contains two coavial ol pipelines. ‘The inner oil pipe in the hollow bored shafi(s) feeds back the actual propeller itch Bulkhead seal(s) Watertight seal to separate compartments, not the stern-ube seals, Shatt earth slip ring Slip ring fo earth the propeller shaft tothe ship's body to prevent galvanic corrosion on the propeller. An mV-meter shows the potential diference. Shaft bearing(s) Line shaft bearings to suppor the propeller shaft and the intermediate shaft(s), not the sterntube beatings. Sensors inform on the bearing conditions. Shaft brake oper Device to brake, stop and hold the propeller shat ine. Location can be also in the gearbox i shaft, behind the clutch (if present). Searbox input Shaft lock device Device to ook the propeller shaft ine. Shaft torque plek-up Device to measure the shaft torque forthe remote control system andor torque indicators. Shaft rpm pick-up ; Device to measure the shaft revolutions forthe remote contol andlor RPM indicators, 17-06-08 DMHE000134_1.doc > @ scanned with OKEN ScannerDocument tie: Functional description system © Bos 0 COR tere ear Poe Ss Shaalonary OD box, oi istibuton and feedback box atthe forward end ofthe gearbox ouput Shaft takes care of the su ipply and distribution of the ail forthe propeller pitch actuation. Oil flows mesh the OD box and shaft line into and out of the hub cylinder yoke compartments and hub nye inner oil pipe, connected tothe hub cylinder yoke, feeds back the actual propeller pitch to the feedback box. Potentiometers and. ‘on the actual propeller pitch position Emergency pitch setting FE ne ll Ppe inside the shat in he hub connected ote eynder yoke) Is connected toa fed Ta nechanisiy. This mechanism, wit slip ting anc spindle, is connected to-tworlinear—~~— a mechanical pointer. These potentiometers and pointer feed back and inform Fmergency propeller pitch setting is possible ifthe hydraulic system fails The procedure is des: peration". © A plug on the OD box must be remeved and an air driven pressure pump is connected Cilcan be pumped tothe hub cylinder (oitch ahead). After the pump is removed and the plu fitted the normal operational conditions are resumed. 1.3.5 Hydraulic system ‘cribed in the manual "Operation and remote control, section "emergency AA hydraulic system with pressurised oil fow takes care for propeller pitch control and propeller hub lubrication. The system generates by hydraulic pumps the hydraulic pressure to adjust the propeller blades (pitch) in any desired position. The pressurised oll lows through the inner and outer coaxial pipes into the cylinder yoke compartments in the hub, pushing the yoke backwards or forwards {sized pumps, one main and one stand-by generate pressurised oll. The pumps are not jonally one pump ‘designed to run in parallel, Normally both pumps are electrically driven. Occash (the main pump) is mechanically driven. The pumps are mounted on a hydraulic power pack. Normally the power pack is situated above the waterline ‘System components Pumps driven E-motors. ‘Switch off, pressure, non retum and contro! valves, pressure, lavel and temperature switches, restrictions. = Oilfiters, with by-pass to enable exchange of cartridges during operation. ‘Sensors to inform on system conditions, Propeller pitch control High-pressurised oil lows through the OD box and one shaft chann cavities. When the cylinder yoke moves the propeller blades (pitch) ‘The pitch control 4-way valve selects the channel and so the cylind Header tank with valve, level switch and dipstick or sight glass. Ar breathers with filing fiter, and dipsticks or sight glasses to monitor the oll levels, il coolers (if required) to control the oll temperature, el into one of the hub cylinder will be adjusted accordingly. ler side. The oil from the other cylinder side flows back through the other shaft channel into the OD box, and then retums in the hydraulic power pack. “The actual hydraulic pressure needed to adjust the conditions (hydrodynamic and revolutions). A load sensin in enables the s) hydraulic system runs at optimum eficiency at any time, needed for an adjustment. A safety ma’ y 17-06-08 DMHE000134_1.doc Propeller pitch depends on the propeller ig System supplies the lowest pressure yystem to react in due time, That's why the @ scanned with OKEN Scannera : | Dosueeai WARTSILA| Functional description system oO 1.3.6 17-06-08 DMHE0O Doe. na, 405) [DmHEoo0%34 Rev. ol Page, The pitch 4-way valve i activated bythe remote contol system, but an be manually controled (09 incase of a remote control failure, Propeler hub lubrication oe 1e Propeller hub is fully filled wi 12 il the hub cylinder flows through the hu! back to the OD box, hee : Propeller hub static pressure Zhe oil tank above the waterine (header tank) ensures that a '.Surrounding.water pressure, In cases. hub pressure.pump-elect Pump starts automatically when the hydraulic system is shut down or wi Pressure drops too low. the hub static pressure always exceeds ically. driven, is-applied, this --- nen the hydraulic system Hydraulic power failure ‘The propeller blades can be adjusted into an ahead position with hel where the hydraulic pressure fails, The blades stay blocked inthis adi propulsion system operates as a fied pitch propeller. Main engine revolutions the local main engine control stand. There can be no astern sailing. Aer the fallureis repaired normal operational conditions are resumed. Ip of special tools, in cases justed position and the ‘can be adjusted at Propulsion control system ‘An electronic propulsion control system transmits orders from the control station in command to the propulsion system. The propulsion control commands the propeller pitch setting and (if desired) the prime mover / main engine speed. The control has a main and a back-up system. Emergency control of the propeller pitch is possibl ‘A feedback signal informs on the actual propeller pitch. Th fever vrs command potentiometer-and the Acsignat 3 ‘As long as they are not equal the customised pitch controler will influence the hydraulic system for pitch control. Engine speed control is managed by the engine governor. The propulsion control System gives a desired order of speed. ropulsion control also monitors the load ofthe engine. And it controls the load of the engine the speed of changing pitch. It lso reduces pitch if the engine is overloaded. In this sion control system protect the engine from overloading. The pr by controling way the propu ‘As a back up there isa stand-alone manvally pitch control loop. This consists of an ahead or astern push button and indicators for monitoring the pitch setting. In back-up mode there is no load Ie limitation in the control system. push buttons and selector switches (de-activate circuits lke clutches, pumps, load programs, load Pontroller, etc. Indicators and lamps inform on the actual status of the equipment. Sensors inform Sh the propulsion control system conditions ‘Alarms inform on system fallures or dangerous situations. ‘There are control stations in the main machinery room and (several) on the bridge. Ci Thetmand transfer between the stations is done according to special procedures prepare propulsion plant, stane-by with Fre nein machinery station isthe master control stand, From here all propulsion equipment The ped on and presented tothe bridge in stand-by. Propeller pitch and main engine RPM control gait te main mactinery staton remains possible until control acceptance on the bridge. Normal operation : Normal operation ofthe ship takes place from one of the bridge stations, The main bridge station edges the control command from th : ‘coepts and acknowl m the main machinery stati accep *prige station can transfer the contol command to any ofthe other bridge stations, The The St ship is ready to sal A.doc 01341 4 @ scanned with OKEN ScannerDocument tite: 7 Functional description system C ) Bols Pose DiMHEOGOTSe Rev [ ot Fmergency operation mative operation modes can be 28618 Rendon oneor aya pve trate ep ble. C} trol stations “aleble. Check or (elegraph) communion soto he co secratol fa the clutch control Valve, respectively atthe pitch 4aay valve; both stuted on he 9° "evolutions can be adjusted atthe main engine local Hydraulic system failure ee 5 ee the hydraulic system, @ a 17-08-08 DMHE000134_1.doo 7 @ scanned with OKEN Scanner . i—L————<——=S WARTSILA |” PREPARE OPERATION re, 0 =e oe = — pee eee fener Lome | 14 Before operation 1.1.4. Before operation checks WARNINGS: i COMPONENTS._| ALWAYS BE CAREFUL WHEN YOU WORK. AROUND ROTATING » cneck rie equenT FREQUENTLY TO PREVENT POSSILE DANGEROUS ‘CONDITIONS. TMAKE SURE THAT THE DRIVE MOTOR CANNOT BE ACCIDENTALLY ‘STARTED. MAKE SURE THAT NO ONE IS WORKING ON THE EQUIPMENT BEFORE YOU ‘START THE PRIME MOVER. STANCES, START THE PRIME MOVER OR NING SIGN IS ATTACHED. + DO NOT, UNDER ANY CIRCUM! OPERATE EQUIPMENT WHEN A WAR! CAUTIONS i ® MAKE SURE THAT PRESSURE PUMPS CAN NOT RUN SIMUL EQUIPMENT IS NOT DESIGNED FOR SUCH PURPOSE. ING OF PUMPS CAN CAUSE SERIOUS DAMAGE TO TANEOUSLY. THE ‘+ SIMULTANEOUSLY RUNNI EQUIPMENT, Iany unusual situation is experienced, take corrective action, see chapter trouble-shooting or maintenance. General condition check of the equipment = The main engine remains shut down during the equipment check and default setting. ‘=__Be alert for the unusual indications =? = Fhe rod ne equren bos corporat, aks, pe, cables, es ‘stern-tube, shafts, bearings, gearbox, Propulsion Control and other system ‘components. [+ Camry out the dally inspection, see chapter maintenance. _| = Check that all system valves are in normal operating position, incl. cooling water valves. 4.1.2 Default setting When the CPP complies with the default settings listed below, it can be consi sidered to be it Contoled and safe condion and, from tis sition, ready for"Prepare propulsion plan, stand-by with. Main engine Action Result i ‘Switch toi Local conta ‘main Switch to local control ECS panel, lamp LOCAL RPM engine CONTROL is on. ‘Shut down mau, engine it i ‘+ Main engine is shut down, a rie name:oune000198.1.dc, Las pred 1782008 60400 a @ scanned with OKEN ScannerDocument tte: o PREPARE OPERATION oO eT! ren [2/4 [ “Allcontrat stations Tetion Result Lamp test ~~ | Press button LAMP TEST + Lamps are on i + Buzzer sounds tame — Sock DEO + Ilumination is brighter “Sermo — Fae LIGHT DOWN + Illumination is less brighter Joystick for Back-Up | Push Back-Up ON/OFF + Back-Up control Is active |_controt == Lever, follow up Sat levers AH — AS in zero (0) position + hydraulic pressure available «control station in command the propeller pitch moves to and stays in zero pitch ECS control station ‘Action’ Result Main engine Press CONSTANT RPM ON = Lampison RPM orders set to 100% Tum knob ENGINE RPM to MIN = Main engine pre-set is min RPM Gearbox clutch Press CLUTCH IN = Clutch sequence starts + Lamp flashes + Lamp is steady on Hydraulic system ‘Start PUMP 1 or PUMP 2 = Hydraulic system starts BCS control station Action Result ‘Main engine Press LOAD LIMITS OVERRULED) | + Lamps ON Transfer control fo ‘Action Result ECs cas +The responsiblity of pitch is at BCS = Push RESP CHANGE in EOS or ‘+ Lamps is flashing in BCS and ECS + Buzzers sound in BCS and ECS Line up the fevers . Push RESP CHANGE in ECS if . in ECS BCS started the transfer OR in BCS ON oP CHANGE In EcSis if ECS started the transfer ‘+ Lamp RESP CHANGE in BCS is OFF + Buzzers are OFF + The responsibilty of pitch is at ECS 4.1.3 Alarms Check all alarms, if an alarm Is active, take .arective action, see chapter trouble-shooting, 47-06-08 DMHE000138_1.doc @ scanned with OKEN ScannerDocument ite: WARTSILA PREPARE OPERATION Co [omrEcooras 1° 14 a cameos a0 a trom the actual customised alarm Hist {A general alarms ists given below (this ist may der depending on the CPP configuration). Propulsion Control ‘Ster-tube/shaft | — Hydraulle power Gearbox line pack Oil level stem-tube Dilevet header tank | Oillevel sump tank Voltage/fuse header tank Ait bearing Oilevel tank Gontaminated olfiter | Lever control faire —[c temperature ————}— oe __._—-|—___— — | Oillevel forward seal] Contaminated ol fiter | Oilfemperature Siand-by pump running header tank ‘Shaft bearing(s) Oil pressure too low Thrust bearing temperature Hiab pressure too ow term condition because oil pressures, temperatures ‘ures and cold system oil, the alarm ‘Contaminated ‘The propulsion installation always starts in al ‘and the clutch engaging time can =) lo, are ow or out of range, Wh fw tempera eit can bs acive srt because the fier rans In By-pS, be extended. stand-by with ... 1.2 Prepare propulsion plant, the propulsion plant is ready for operation from the ECS. 4. After finishing all default settings, 2, Systems have tobe started and made stand-by to the BCS, steps are: «set defaults, see Section 1.1.2- defaults setting | = EGS, check the propeller pitch response by pitch com ECS, move the lever to zero pitch, and check that the pitch is at zero position mands ahead and astern ‘+ switch on all other equipment that is needed + start the main engine(s), see main engine manual. 3, _Interlocks in the start circuit take care for a controlled and safe start of the main engine: GPP with clutch CPP without clutch =? 7 Guteh disengaged > irae pressure ‘= Zero propeller pitch 4.2.1 Mainengine, stand-by, MAK For stat (stand-by) and stop (shut down) procedure, see main engine manual. 47-06-08 DMHE000135_1.doc 3 @ scanned with OKEN ScannerH | Bosument i WARTSILA PREPARE OPERATION Co 414 oF Page 6 ee wz place) Action Results Defaults are set Lamp LOCAL RPM ‘CONTROL is on * Lamp CONSTANT RPM OFF is off «Engine pre-set at min RPM «Start interlocks are closed 7 » Engine runs Engine, local Start engine, see engine | |_control manual - - | Select remote engine RPM ECS panel = Lamp PUMP 1 (2) RUNNING is on ECS panel Press LOCAL RPM ~ Lamp LOCAL RPM CONTROL is off CONTROL «Engine RPM contol by lever 1.22 CPP, stand-by Place ‘Action’ Results, Defaults are set, main engine | + Lamp LOCAL RPM CONTROL Is off an «Lamp CONSTANT RPM OFF is off Engine pre-set at min RPM = Engine RPM control by lever 4 + Clutch (if present) disengaged ECS panel Present he contol ta the ~ STAND-BY with propulsion plant ge bridge Continue with control transfer 4.2.3. Control transfer between ECS / BCS See Instruction manual Propulsion control system. 4.2.4 Control transfer between the bridge stations ‘See Instruction manual Propulsion control system 417-06-08 DMHE000135_1.doc , @ scanned with OKEN ScannerDocument tile: WARTSILA Normal operation pao PO IDA severed Wenig ‘System coat 14 Introduction Normal operation includes all normal sailing cond ending at finished with engines’. For crash manoeuvre, see Section 1.5in this chapter. Toca | Systm vet | sve baie _| Pe a Tasazo1-14 | 173 fans starting from‘ nora this chapter — ror emergeney operation, ses struction Emeraency Overaton i is SESE ‘The CPP can be operated from different st The facilities and contro! modes avallab! Indication lights and buzzers inform the operator 1p) control the load contro load condition. During back-up (non follow u Fuel Rack light wil illuminate in an over ~~ , 1.2 Engine Control Station (ECS) “The ECS prepares the CPP Propulsion Control for normal operation. nat any moment (after alignin® id BCS by lamps ar ‘The ECS Is the main control station, and car take contrel back to ECS station, indicated on the ECS an: Below table informs the available control modes, to select ECS. tations and in several control no at each station 2 con the condition of is not active, but the OF sd below. Control mode ‘Select Propeller pitch [_ Main engine revolutions: Lever, follow up | ever, flow up | BACK-UP ONIOFF is OFF CONSTAN Constant BACK-UP ONIOFF is OFF | Lever, follow up CONSTANT RPM ON | Constant (ato selected) Back-up, non follow up 7 43 Clutch and shaft-brake control (If available) ‘The clutch is controlled from the ECS or BCS, or other stations, by “The propeller shaf-brake is controlled ftom the BCS pan: Inthe postion OFF the shaf-brake circuit is suiched off Inthe position ST.BY, and with the = CLUTCH OUT, the brake switches on automatically after a ti | BACK-UP ON/OFF is ON buttons, delay. - CLUTCH IN, the shaft-brake suitches automatically off. For further information; See Instruction manual Propulsion control system » Fie pare MHEG 180, (a8 pte 1782208 10400 @ scanned with OKEN Scanner(ROO. SSS ET * __| Document ttle: WARTSILA Normal operation oO 6 Doane, REDO Tore Tt Page 12/3) 1.4 Bridge control station (BCS) Normal operation of the ship takes pace from the BCS. ‘can at any moment (afer alignment of te control lever) sj on the ECS and BCS by lamps and buzzers. cand can at any moment (ater alignment of control fations. This is indicated on the BCS and other ‘The ECS is the main control station, and take control back from BCS panel, indicates The BCS isthe bridge main contrl statin, 3 lever take contrel back from wing cr af briése 5 ~pridge SANS bY ISTE aN UUATETE For crash manoeuvre press LOAD LINITS OVERRULED. ‘The load controller will remain active. Below tab informs the avatable contol modes, fo select BCS see Instruction Manual Propulsion Control ropelier pitch Lever, follow up “Lever, follow up BACK-UP ONIOFF is OFF CONSTANT RPM OFF PUSH-BUTTON CONTROL OFF ever, folow up Constant CONSTANT RPM ON Push-bution, non folow up Constant (auto selected) [PUSH-BUTTON CONTROL ON )VERLOAD light will illuminate in During back-up contol the load controler is not active, But the O' ‘an overload condition. | ~ cartels olleris not active_but the OVERLOAD light wil iluminet ‘an overload condition. 415 Crash manoeuvre WARNINGS. THE LOAD CONTROLLER IS NOT ACTIVE DURING BACK-UP CONTROL, BUT THE tha GVERLOAD LIGHT WILL ILLUMINATE IN AN OVERLOAD CONDITION. + CONTROL THE PROPELLER PITCH WITH SPECIAL CARI CONTROL THE PROPE L CARE TO AVOID A SHUT OFF Crash manoeuvre demands for immediate changes in ship's direct z rae ndfon ofthe propulsion plant ges in ship's direction and / or speed, in spite of All load programs must be overruled to have maximum eng il gine power available nly the babe overoad peecon system remain atve fo aoldpopusion plant shat ‘ALBCS panel, press the push button LOAD LIMITS OV: ‘ALECS and BCS panels, amps LOAD LIMITS OVERRULED are o ‘The load controller remains active. oe 16 railing propeller a ‘Trailing propeller conditions appear when: 17-06-08 [DMHE000136_1.doc 2 @ scanned with OKEN ScannerDocument title: WARTSILA Normal operation oC o Page 3/3 Ss Doe no DHE + main engine is stopped, propuls + the propeller shaft and the gearbox output ship. Trailing is permissible for: + Restrictions for the gear —+— Restrictions for the main engine; Rev fon plants shut down or out of operation, and itshaft are driven by (seawater, @.9. towing of box, see the gearbox manual. ee the main-engine manual- the 47-06-08 DMHE000136_1.doc @ scanned with OKEN Scannerc | Document WARTSILA EMERGENCY OPERATIONS oO ¢ eee ec RS TE ED OO pT a] Sts ee ODT scott [1/3 | omneooors7 | Ot] 14 Emergency operation modes (lever propeler pitch and main engine revs contol from a Normal operation is defined 2s folo-u “ . 7 e, 'WCS portside or ACS. bridge control station BCS, WCS starboard, ol system failure are listed below. Alternative operation modes in case of @ contr sqjeen BOS aN the OD SOX — cheek for fetegraph) communication between BCS and ECS, ‘ard (gearbox) and main engine local control stations, Control at WCS, WCS or ACS Fault ‘Ration Effect Lever control failure at | Select BACK-UP ON/OFF to ON Pitch control, joystick control 7 @ station in command RPM constant (auto selected) r Back-up control falure | Goto BCS, line-up LEVER and select | Control from BCS RESP CHANGE Control at BCS Fault Action Effect Lever control failure at | Select BACK-UP ON/OFF to ON Fitch contro, joystick control station in command RPM constant (auto select) Backaup control failure jeclandiransferconticlto EOS | Control from ECS Control at ECS Fault ‘Action Effect Tevercontrolfalure at | Select BACK-UP ON/OFF to ON Pitch control, joystick control station in command RPM control, constant or variable Engine RPM control Select LOCAL RPM CONTROL RPM control local at the engine BP [iaitre Bacicup contol faure | Control te PITCH VALVE manual on | Manual pitch adjustment at the pitch the hydraulic power pack™= valve Control at the hydraulic power pack Fault ‘ation Effect Fropusion Control alae | Select LOCAL RPM CONTROL RPM control local at the engine ‘Control the CLUTCH manually atthe | Manual clutch (di Sete Manual clue (s)engagementocal a Control the PITCH VALVE Manual pl i pn ‘Manual pitch ajusentat the ph Hydraulic power failure _| Insert take heme device Fixed pitch propeller installation re ame:oMHe001o7 1.40, Last pied 17.62008 16.0400 a @ scanned with OKEN ScannerSe | Deamon WARTSILA| — EMERGENCY OPERATIONS oO 8 Doan DHREDOOTST wae 8 WARNINGS NGCOMPONENTS. | WHEN YOU WORK AROUND ROTATI + ALWAYS BE CAREFULL ony ON IL NECESSARY SAFETY PRECAUTION: \ © MAKE SURE THAT Al + MAKE SURE THAT INCORRECT OPERATION IS NOT POSSIBLE. — ACT WITH-SPECIAL CARE DURING EMERGENC iS ARE OBSERVED. % ~ THE LOAD CONTROLLER IS NOT ACTIVE DURING EMERGENCY CONTROL. | + CONTROL THE PROPELLER PITCH WITH SPECIAL CARE TO AVOID A SHUT OFF OF A > IT IS NOT ALLOWED TO ENGAGE THE CLUTCH UNDER FULL LOAD. + ITIS NOT ALLOWED TO ENGAGE THE CLUTCH AT FULL REVOLUTIONS. ENGAGE THE CLUTCH WITH THE ENGAGING SPEED. = When orders, transmitted from any control station, to the propulsion plant are not executed, there is a Propulsion Control system failure, with an alarm. 7 a les »_________Insuchasit pitch must be controlled from local control stands. For the main engine and the (gearbox) clutch, see their manuals, Check for (telegraph) communication between BCS and ECS, and between BCS and the OD box (Gearbox) and main engine local control stations. “Take corrective action as soon as possible to restore normal operation, see chapter trouble shooting and maintenance. for the propeller pitch see below. Manual pitch control Control the propeller pitch by manual actuation of the pitch 4-way valv The valve is marked with AHEAD and ASTERN. . ileal ‘The propeller pitch is indicated at the OD box by a mechanical pointer. ‘The load controller is not active, nor is there any overload indication. Fig, 4.1-1 Manual pitch contol valve For manual pitch control follow the below procedure: + push in the corresponding button to change the pitch, restrict pitch ahead and aster. B® 47-06-08 DMHE000137_1.doc 2 @ scanned with OKEN ScannereC LULU [———— : Description of it WARTSILA, Fault finding procedures ‘System be propery of Warsia Prop Ro Soman awit earn te re ; " Ta Prophet be apes Shaw or coonizaledo 3 id 5 Info code | Efectvty ive Dala_| Page _| Doc. Rev 100) i TROUBLE-SHOOTING CONTROLLABLE PITCH P| ROPELLER, CPP 3 Trouble-shooting chart. rename DMIHEI0038 040% Ls printed 17.6200 60400 mL 4 @ scanned with OKEN ScannerWARTSILA, Fault finding procedures © Dos.no. | BMHEOOOIS8 Fe. iia Document tile 20f8 ® age. Introduction ion, Read the pefoce and all chapers of the operation manval before slaving any act ‘Only qualified and trained personnel should work on the equipment. i ie This chapter provides help fr trouble-shooting, in several occasions reference is made to chapt ‘maintenance. Keep records in the machinery journal of all tou! ‘appendix, journal and ordering Motes. — Respect the maintenance intervals, regular maintenance imp decreases the long-term maintenance costs ble-shooting actions or any unusually, see the roves operational safety, reliability and WARNINGS = ALWAYS BE CAREFUL WHEN YOU WORK AROUND ROTATING ‘COMPONENTS. TT WAKE SURE THAT YOU SHUT OFF THE DRIVE MOTORS AND ALL PUMPS, a Oe THRE ELECTRIC POWER SUPPLY AND CLOSE ALL RELEVANT VALVES, WHEN YOU WORK ON EQUIPMENT «MAKE SURE THAT THE DRIVE MOTOR CANNOT BE ACCIDENTALLY STARTED. = PUT WARNING SIGNS IN POSITION. «MAKE SURE THAT NO ONE IS WORKING ON THE EQUIPMENT BEFORE YOU ‘START THE PRIME MOVER. NOF-UNDER-ANY-CIRCUMSTANCES, START-THE PRIME MOVER OR OPERATE | ——— EQUIPMENT WHEN A WARNING SIGN IS ATTACHED. MAKE SURE THAT HIGH PRESSURISED OIL CAN NOT LEAK. PLACE PROTECTIVE GUARDS IN POSITION. ALWAYS WEAR PROTECTIVE GLASSES AND CLOTHES WHEN YOU WORK ON EQUIPMENT. DO NOT DISCONNECT HYDRAULIC PIPES OR HOSES WHEN PUMPS ARE OPERATING. > DISCONNECT THE MAINS AND BACK-UP POWER SUPPLIES WHE! ‘THE PROPULSION CONTROL SYSTEM AND PUT WARNING SIGNS IN POSITION. ‘THE PROPULSION CONTROL SYSTEM IS ALWAYS UNDER LIVE VOLTAGE. n ls? 17-06-08 DMHEO00138 940 Wartsilé Propulsion Service Department(s) are available to provide advice and assistance. User group : ‘This chapter is a part ofthe below manuals) and the intended user group(s) is (are): Manual Group ‘Operation manual |» _ Ship operator Maintenance manual_|» Ship engineering staff @ scanned with OKEN ScannerFault finding procedures ea Peer sores ler. The cll a pratt tu caren rote ct sty ‘ch for the source of problems. following chart is 01. General mechanical problems .... 01. Cavitating pump 02 Oitloss ssa 03. Oil fim in water behind ship... 04. Oil leaks from propeller hub. 05, Oil leaks from aft stern-tube 5 06. Water ingress into stern tube system... 07. Oilleaks from forward stern tube seal > 02. Hydraulic system problems... lee 02. Operating pressure too low or fluctuating... 03. Operating pressure too high... 04. Hub oil pressure too low / high (only: for systems with hub pressure pune). 03. _Interface Propulsion control system / Hydraulic system 7 01. No AUTO start of stand-by pur os 7 02, Unable to change pte wth he propulsion conto system. 7 ________03__Unable to change pitch uith the back-up control system, ia z (04. No pitch change on manual operation of proportional valve 7 05, Failure to attain ful pitch. 7 0, Pitch moves slouly orstops completly in certain situation 7 07. _ Imprecise pitch setting or oscillations. 8 08. Heavy pitch fluctuation at max position 8 09. Frequent pitch correction. is @ scanned with OKEN ScannerInstruction Manual i ping aa MP/S0068 [ GENERAL ‘Warts Propulsion order nurmber(s)_| MP/SO0%8 Hindustan Shipyard In 1010 Co t88.89 Twin screw dodger Dredge XV XV vat ce an ol A Dredging Corporation of India Lt C_ in Pron Mears BY E-II DOCUMENT HISTORY Comment First issue Wartsilé Propulsion Netherlands B.V. P.0, Box 6 ‘5150 8B Drunen The Netherlands, . Phone =: 431.410 398424 + Fax 431 416 379140 eMail Seo: http Iuwew.wartsiia.com http + httpvraw.wartsila.com Made by: Warsi Propulsion the Nethefands Orden, Flename: MP/s0068 ‘Created on: 25.7.2008 11:50:00 fe / @ scanned with OKEN Scanner/ARTSILA Instruction Manual oO CONTENTS MP/So068 14. General 4.1 How to use this manual 1.2 Technical data 1.3 Scope of supply 1.4 Spare parts 2. Installation commissioning & trails 2.1 Agreements and responsibilities = is, 2.2 Activities and responsibiities 2.3. Wotk preparations 2.4 Receive of goods, preservation and handling 2.5 Installation guidance and checklists | 2.6 Commissioning 2.7 Dock and sea trial 3. System description u 3.1. Functional description complete system, 4. System operations 4.1 Introduction 42 Prepare operation 4,3. Normal operation 4.4 Emergency operations Trouble shooting 5.4. Trouble shooting charts, 6. Maintenance 6.1. Maintenance schedules Made b Filename: y. wartsa Propuson te Nethaands Oreo, i his ecard We See Noting Hom hs publaton maybe epedied, or Geceed wihou pr wien approval Wala Propulsion Netarands BV. 7. Propeller & Blades 7.4 Data and product description 7.2 Installation procedures 7.3 Maintenance procedures 7.4 Tools and spare parts 7.8 Cathodic protection of the propeller 8. Shaft arrangement 8.1 Data and product description 8.2 Installation procedures 8.3 Tools and spare parts 9. Additional components & equipment for the shaft line 9.1 Components and systems manuals 10. Bearings & seals 10.1 Components and systems manuals seals & bearings 10.2 Maintenance procedures 10.3 Tools and spare parts 14. Oil Distribution box 411.1 Data & product description 411.2 Installation 11.3 Tools 12. Hydraulic system 12.1 Data and product description 12.2 Installation procedures 12.3 Maintenance procedures 13. Remote Control system 18.1 See separate manual (by A.B.B.) Created on: 13-08-2008 fo MPrsooss / Sons L a @ scanned with OKEN ScannerTHON FAS BEEN DRAG FOR A REATHAREED PROPOR @ scanned with OKEN ScannerA aim, Es So Se DOORSNEDE sp 8 ‘DE NAAF IS RECHTSORAAIENO GETEKEND THE HUB HAS BEEN ORAWN FOR A RIGHTHANDED PROPELLER _—_——————————————— 008 HET RONTEREN VAN CE BESCHERHAP DLHANOELEN HE VEPF SMELL CODA? CF aie za So | ier “BEFORE FITTONG THE FLAMGECOVER, nee ‘aaa, | wo | ao | Serene Ree —an Le wa bow Tow ena Br _| | uerosmoves ovr ‘I ase0 | | See Sere eae eye eA Tan ns PARED WH « MT BE LOPES @ scanned with OKEN ScannerDOORSMEDE. , SECTION ib 26 ee aus ag B (0 68) (3) (@) 2 06 ee a a @2) (25) 7) 48) paecen er one vet | eanAAL MOMENT yyy AdiwasinOveNT 26 raze, Cock ara Pave Yeeacweo Taeate | ‘auneo "Oeaue See ate ‘GOR TH PC orn os AAMUALIOENT 30 ey tt Mane ead DRAADLENGTE 20 VOOR BBSGSCHROE 6 | Beeaocensre 20 vooR aGacscesoer ne AAMUALHEMENT 39 n FOUR Te aoacen ner ovever ieee wa Pane @ > ay nourage apgey Fussew oige Matin BRL Fite assay Wit THES Haake 8 Movrase soxew Dep 2¢ 240, TAP Ta TiseaDoeetn 2069 OCH SCREW 0, OF FLbns Ev oe Garen Cr GeUinanoG | FTFLANEE an LES = SE (SHELL Axton 3 08 cOUALenr ) ayer eocrne oe 203 ee OTE a 2 Sse ee Tee | visa = menos Wvoeeomes aahaae ial @ scanned with OKEN Scanner: Document ile WARTSILA Fault finding procedures Bee no aeoooT ia ape eo Disturbance —[Posubte causw Taenification Remedial action TH, Ganoral mechanical problems 01. Cavitating Dilevelin power | Checkeollevel on dipstick | Determine and rectify cause pump pack's toolow fal loss, replenish oi Suction ne hasan | Check austin ne Tighten connections ew airleak Sannections with grease __| seals or pies 02, Ollloss Tipe Ine ake | Visbbe olleak fom pipes | Reclfy leak Cover leaks Visible oleaks from covers Clean mating faces, renew gaskets Taatoahanger | Vibe exemataiieak | Remove end covers, renew leaks, ovings Tramine covlantforot | Inspect heat exchanger ingress. Rar ol anaiysis iis found incoolant (possible there is cooiantin theo, Propoler hub leaks | See 07-04 Ster-vbe oaks | See 01-06, 06,07 03. Cilfiim in water | Heatexchanger | Run ollanalysis (possible Inspect heat exchanger Behind ship | leaks (none dosed | theres water the oi) cooing system) Propeller hub leaks | See 07-04 terndube leak 05, 8.0 Da. Oileake fom] Damaged or] Gheck power pack of evel | Replenish ol propelierhub | defecive hub seals | piverinspecion mightbe | Stopand investigate necessary. Lack of oll means danger Examine the blade foot _| forthe safety of the ship seals, protection cover Repair leak, and renew hub some, rotation covet _| Rega ek ans Check foloss or | Condon wien leaknoted: | Check, with running shat Wateringtessis | Running orstopped shaft? | the OD box static pressure foted Run oil analysis (possible —_| Check, with stopped shaft, there is water in the oil) the hub pressure pump D5 Ollieaks from | Lip sealngno.3 | Check ol level Flucluale siem bibe header aftstern-tube | leaks or is Runoil analysis (possible _| tank level in order to seal damaged However ntea” | decresse water ingress 06. Water ingress | Lip sealing no. 1 | Overflow of stem-tube tank — | Fluctuate stern tube header into stem tube | or 2 leaks oris | Run oil analysis (possible _| tank level in order to system damaged theroiswaterinthe of) __| deorease water ingress 17-96-08 DMAHEI00138_0.doe ‘ @ scanned with OKEN ScannerDocument tile WARTSILA Fault finding procedures Deena DMHE00OTSS Rev. a Page 50f8 Disturbance Possible cause Tdentification| Remedial action 01. General mechanical problems 07. Oilleaks from _] Lip seal ring of forward seal tank Temporarily plug overflow forward stern | Overflow no. 4 Descent of cil level of stern | Pipe on this tank. tube seal leaks oris tube tank Seal no. 5 takes over. damaged Replenish stern-tube tank . Repair | ——--—— ip seating no-6—| Oitteaks from seathousing—-[-Repair— == leaks oris and forward liner damaged ‘oring of clamping | Oil leaks from between Repair ting leaks propeller shaft and liner 17-06-08 DMHHED00138 0.400 @ scanned with OKEN ScannerDocument tile: WARTSILA| — General warnings & cautions Dee. na, Dw¥vi0000017 Rev [ot CAUTIONS * ALWAYS ATTACH LIFTING EQUIPMENT TO THE LIFTING POINTS OR TO PLACES AN INDICATED ON THE (TRANSPORT) DRAWINGS. USE SHACKLES OR SLINGS. * DONOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS, PIPING WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT. ~FOR PROPULSION PLANT ALIGNMENT, IT-IS MANDATORY-THA’ _— = THE SHIP IS AFLOAT WITH ABSOLUTELY NO CONTACT WITH THE SEABED ~ THE PROPELLER IS SUBMERGED ~ THE HULL STRUCTURE IS COMPLETED ~ ALL MACHINERY IS INSTALLED. + MAKE SURE THAT YOU PI TANK(S).. e: * BRAYS COLLECT AND REMOVE SPILLED OIL OR FLUID FROM (DIS)-ASSEMBLY PROCEDURES. ‘LACE SUFFICIENTLY SIZED OIL OR FLUID CATCH + MAKE SURE THAT You DRAIN SYSTEM OIL OR FLUID BEFORE EQUIPMENT DISASSEMBLY. * GAKE SURE THERE IS NO DIRT OR FOREIGN MATERIALS INTHE HYDRAULIC OR CIRCULATION SYSTEMS, THIS CAN CAUSE EXTENSIVE DAMAGE TO EQUIPMEN, DO NOT USE ALKALINE OR CHEMICAL DETEI SYNTHETIC OR PAINTED COMPONENTS. THi EQUIPMENT. WIPE WITH A DRY CLOTH ONL\ . RGENTS TO CLEAN, RUBBER, IEY CAN CAUSE DAMAGE TO © OAT PANEL ARTH SCREENED CABLES EXCLUSIVELY AT CABINET SIDE, NEVER AT PANEL NOR COMPONENT SIDE. * ELECTRIC WELDING INTRODUCES SPIKES. ALWAYS DISCONNECT THE MAINS AND Bat \CK-UP POWER SUPPLIES TO THE ELECTRONIC CABINET OR TO COMPONEN: TS CLOSE TO THE WELDING AREA. IS * DO NOT USE CONTROL PANELS OR ELE: -CTRICAL CABINETS AS AN EARTH POINT WHEN WELDING, THIS CAN CAUSE DAM, AGE TO ELECTRCAL COMPONENTS, ALWAYS CONNECT TO A GOOD EARTH Pt WELDING AREA TO AVOID DAMAGE TO ‘OINT WHEN WELDING, CLOSE To THE EQUIPMENT SURFACES, WHEN WELDING PROTECT THE SURROUNDING FROM WELDING ‘SPATTERS, 17-06-08 DMY10000017_1.doc Lae @ scanned with OKEN ScannerDosument ite eC MAIN PARTICULARS WARTSILA = FT WE Prop etn Cee aera ean a = ‘System code info code _| System vant ees tii | mpcmesaoe® | 00 5005 | Foze 14 Ship and main engine ‘Catch word Data Order number pis0068 oe Hindustan shipyard Yard NOW) Existing NB IHC CO1168 CO1189 Type of ship Dredger Classification Society LRS Glass notation ; ice cass noiaton : Wain engine Data Oe Make, ype [MAN 6 — 40/46 Engine power, MCR [kW] 72900 Engine power, CSR KW] |= Nominal engine revlutons av | 528 Gearbox Data Wako. pe (Tislng) Lohmann & Sioferont Layout of sats Horizontal offset Gearbox ato 505: 211.4 Power take off [KW] 314 (get pump) 1.2 Electrical power Catch ward a Vattage for E-rotors(VACHF|_| 0750 Vatage for conto Vakage to on Not applicable Vatage for emergency conditions [VDC] 24 1.3 Propulsion plant design criteria Propalierand shale Data Power [kW] (MGR) 2500 Revolutions pm] (UCR) ——[a11 Ship peed knot) 7 Gaia Direction of rotation: he top File name:MPCMPS0058.doe @ scanned with OKEN Scanner1.2 so 13 je SCOPE of SUPPLY ‘$000 [Foz Propeller tesue Date | Pax _| O20 [es72008 t/t Data Shaft line T Data ([Proselier sh 9, mass [ka] | One set of coupling bolts Shaft line accessories [ (Catch word T Data Shaft blocking device iz [Propeller shaft earthing devies i ‘Speed pickup i ([TTeraue measurement system ype E 44 Pitch servo unit [ Catch word T Date [ype | vi70-cx i | Location | Forward end of gearbox [Fitted to | Gear wheel shat Fie name SSYMPSOOE doe @ scanned with OKEN ScannerDocument ttle: WARTSILA | Service requirements and ordering oO of spare parts AL oh resered Nang ton is Benin maybe repeed er dined wo pla win spr a WN Pcpaaon Dos. no. Rev. | System code | Infocode | System vaant Issue Bala | Page Dwyiooooss | 05 | S000 Fo08 | Al 2004-04-16 _[ 114 44 Service requirements In case of a service requirement please contact the nearest Wartsilé service station using the Service card in this manual or through our web page (ywww.warisila.com) Please report the malfunction as detailed as possible (problem description, when did it occur and mee ‘under which conditions), - {n all correspondence please provide in preferential sequence: ‘The Wartsilé Propulsion order number of the subject equipment (to be found on the manual ‘cover sheet) ‘The Lloyds registration number b 4.2 Spare parts | case of a spare parts requirement please additionally provide the following details Tile of the assembly where the part belongs to, the list number and/or the drawing number Nem number and name and Article number as specified on the parts list The required quantity All orders should be confirmed in wilting with an official purchase order number and customer VAT number. 13 Spare parts cross-reference list ‘The cross-reference list lists all 2 components supe by Warsi Propulsion under his contact THelistsilndea er denting and enlany he eecton chan eae y Wsinavile mumar seqoreo Ind provides Information on the location(s) of an lem through: ‘Assembly drawing number(s) ~ atts lst number(s) = item number(s) Fle name:DMY1000064 95.40, Last printed 176.2008 16-0700 @ scanned with OKEN ScannerDocument tte: Propeller shaft installation procedure ed Wt Propo Fn maya ened, cond woul bx wile a Info coe | System valiant ssi Dato F720 | CP Propollors (¢ Int. shafts) 2008 06:19 Fw. 05 told Doe. 10. ‘bmyi0000007, a Propeller shaft installation procedure atlon procedure. = This section describes propeller shalt line in = For installation sulficiont space is needed. = Hoisting facilities must be arranged. 1.4.1 / Documents 5, See WARNINGS, CAUTIONS and Instructions. = Arrangement of shatting drawing. = Propeller Arrangement drawing for the weight and centro of gravity. - Assembly intermediate shaft drawing for the weight. + Storage, preservation and handling instructions. Shaft alignment instructions. = Mounting procedure shaft coupling instructions, = Installation of stemtube instructions, 1.1.2 Tools and equipment = _ Temporary supports. = Certified iting equipment. + Replaceable bolts. 1.1.3. Required condition + Allshafts unpacked close to ther final location inthe ship. + Stem-tube seats available. - Hydraulic sleeve coupling available. = All bearings aligned and fixed. 1.2 Preparations Pay attention fo the WARNINGS, CAUTIONS and Instructions. * Install qualified heisting points for iting the propeller and intermediate shafts) (if present) + Fresh and clean hydraulic oil '+ The stern tube assembly to be cleaned. Ensure th: Tre ee on ah ee oe, Ensur thatthe ster ube, paca the stern tubo + The stern tube seals o be cleaned and prepared, includ This can be omitted if he at sea iso lly spt ipa ee tlle + pe api iipack the propeller or intermediate shafts until the shafts are close to their position in ship. For transportation the shatts are Properly protected by m compound and wooden laths. Location for lting traps is marked ovina, rocking | ‘The propeller shaftis delivered with the propeller hub mounted. Al shatts are deivered with File namo:DMYI0000007_5.doc, Last printed 19.6.2008 13.08.00 @ scanned with OKEN Scanneri ocurnntie! WARTSILA Propeller shaft installation © » > procedure Dee no Daryiooo0007 Ree Page Zara {ho ol pipes installed, Leave the ol pipe covers for fixation and protection in place. Tho shattfango coupling ts delivered loose. + Boforo installation of any shaft the packing shall be removed. The shafts shall be properly ‘leaned from the corrosion protection compound and checked for transportation damages, see also Storage instructions, After inspection, the shafts shall be rubbed with clean oil. After Femoval of corrosion protection, the shafts are sensitive for corrosion and must therefore be installed shortly after cleaning, + Ifthe stern tube is faitly long, hatches in the stem tube for guiding the shaft must be considored. + During the installation, please pay special attention to the stem tube liners and the temperature sensor protecting pipe(s). Avoid wire straps to be in direct touch with the shaft. + For mounting the propeller blades, if delivered separately, see mounting propeller blades. By 1.3 Installation of the propeller shaft Pay attention to the WARNINGS, CAUTIONS and Instructions, 1. Do not unpack the propeller shaft. Position the propeller shait(s) close to their position in the shi ‘Check the port and starboard position if twin propellers, see installation drawings. Unpack, clean and lightly ol the propeller-shatt. Protect the propeller shaft surface, at the location where the coupling will be mounted. Mount the aft stern-tube seal assembly on the propeller shaft, This can be omitted if this seal is ~of fully splittype- See the sub-supplier documentati 5. Check that the oil pipes are inserted in the gearbox output shaft &. During the installation, pay special attention to the stern tube liners and pipes for temperature ‘sensor and ol pipes (i present). Note 7, tis strictly forbidden to fasten tackles, jacks or other ting devices on the oll pipe protection Cover at forward side ofthe shaft. This wil damage oil pipes. Lift and insert with care the shaftin the proper position inthe sterntube, see the Propeller Arrangement drawing forthe weight and centre of gravity. Liting can be done with singe while locally protecting the shaft Adjust the shaft to its final axial position by means of blocks and straps. Avci indirect touch withthe shatt. Sees 10. The propeller shaft to be mark the bulkhead, 14. Mount the fonward stern-tube documentation, ‘ed inside the vessel to state the correct axial position relative to Seal assembly onto the propeller shaft. See the sub-supplier Preliminary mount the hydraulic flange coupling For instructions see also: Mounting procedure shaft coupling in this chapter Lips strongly advises the presence of a service engineer for mounting the coupling. Pay attention to the WARNINGS AND CAUTIONS. 19-08-08 DMY10000007_5.doc @ scanned with OKEN Scannersument tile: Propeller shaft installation procedure Rov. 06 Page saa Td 12. Clean shaft and coupling, nd carfuly side the coupling over the shaft until the shaft end and flange end are in the same vertical plane. 413. Mount the propeller-shaft coupling in the appropriate position. 414, Secure the shaft axial and radial to prevent accidental moverent during outfiting and jaunching, A controlled rotation is needed for propeller blade mounting 418. Remove the protecting cover ofthe ol pipe at the forward end of the propeller shaft 416. ‘Secure the afi seal and fi temporary the forward Seal assemblies to the stern-tube. See the sub-supplier documentation. 17, Ifthe vessel has to be towed away, or the vessel is launched, before the installation is finished, the shalt has to be locked. The shaft flange must be shrunk ft to the required position for towing (eee separate instruction of the coupling flange). The flange bolt holes to be used for the propelier fing. For final instalation of the shaft flange, see the separate instructions. Stern-tube lubrication system For detailed instructions see: Installation of sterntube in stemtube chapter. To protect the sheft against corrosion itis advised to finish the stern-tube lubrication system shortly after installation ofthe shaft 18, Fitand flush the stern-tube lubrication system components. | 419. Fil the sterntube with system fluid while de-aerating, Mount the propeller blades For detailed instructions, see: Propeller blade mounting procedure, Lips strongly advises the presence of a service engineer for mounting the propeller blades. Pay attention to the WARNINGS AND CAUTIONS. 20, Mount the propeller blades to the hub (ifnot done already), 2. Fillthe propeller and shart wth oll as much as possible while de-aerating, 14 Installation of the intermediate shafts), if present WARNINGS jX._|¢ MAKE SURE THAT EQUIPMENT CAN NEITHER TILT NOR MOVE DURING LIFTING. . ‘+ OIL PIPES INSIDE INTERMEDIATE AND GEARBOX OU OUT DURING LIFTING, THEY MUST BE SECURED. Cerone, ee Pay attention to the WARNINGS AND CAUTIONS. ‘The inlermedite shafts are ipported orderto postion cach sha, wo support are needed fen 5 according with the drawir kos according with the crawing alignment open shaf, see the data sometimes by no bearing at all. In fry support(s) must be positioned in sheets, shaft line, and alignment 19-06-08 DMY10000007_5.doc @ scanned with OKEN Scanner2 “| Document tte: WARTSILA| | EMERGENCY OPERATIONS rey By Deena, “DMHEOOOTST Rev oF Page 313 1.4.2 Hydraulic power failure \When hydraule pressure, delivered by the hydraulic power system, drops foo low and the Propulsion Contfol orders to the propulsion plant can not be executed, there is a hydraulic power system failure, wth alarm. \With a hydraulic power failure, both pumps are not available; itis not possible to adjust the propeller pitch. ————nrsuchrarsituation the propeller pitch must be pre-set by emergency procedures; forinstructions ~~~ see next sections. ‘The main engine revolutions must be controled from the local control stand, see its manual. Check for (telegraph) communication between BCS and ECS, and between BCS and the OD box (gearbox) and main engine local control stations. ‘Take corrective action as soon as possible to restore normal operation, see chapter trouble >> shooting and maintenance. Notify the Service Department in case of operations under hydraulic power failure. 47-06-08 DMHE000137_1.doc 7 4 @ scanned with OKEN Scannerig : Document ie ; WARTSILA | Emergency propeller pitch setting procedure Nec nye a oi pn TN ‘System odo Tro coda | Sytemvariant Tesve Dato | Page _[ Doc. ro. Rew { $350 F145] VL70, 80, 90(C) OD-boxes. | 2003-05-28 | 1 of 4 | Dmvi000054 05 14 Emergency propeller pitch setting procedure When hydraulic pressure, delivered by the hydraulic power system, drops too low and the remote Meee jer tains propulsion plant cannot be executed, there is a hyéraulic power system failure, with alarm, Es ~ When a fyraule power fare takes place, tis assumed that Both purnps arent avalabie and their function cannot be restored in short time, In such a situation the propeller pitch must be pre-set to a sultable ahead position by emergency procedures, for instructions see next sections. ‘The main engine revolutions must be controlled from the local control stand, see its manual, DB». ‘The propeller installation can be driven like a fixed pitch propulsion system. The suitable pitch for ny starting and running of a fixed pitch propeller system is depending on the main engine and clutch (i available) characteristics. itis of importance to carry out atest during tals to determine a suitable pitch setting in which the ‘engine can be started and the clutch engaged with fixed pitch. Furthermore all necessary tools and equipment must be checked and tested on proper functioning, Check for (telegraph) communication between bridge and engine control room, and between bridge and the OD box (gearbox) and main engine local control stations. ‘Take corrective action as soon as possible to restore normal operation, see trouble-shooting and jntenance: Notify the Service Department in case of operations under hydraulic power failure. 4.4.4 Documents = See WARNINGS, CAUTIONS and Instructions. : = Chapter 12, Hydraulic power pack, drawing: Hydraulic diagram, sv + Chapter 11, Oil distribution box, drawing: Assembly of OD box. = Chapter 11, Oil distribution box, section: Tools and spare parts. = Chapter 8, Shaft arrangement, section: Tools and spare parts. 1.1.2 Tools and equipment = Temporary supports. + Certified iting equipment. + Pressurised air. = — Emergency tool set. 1.1.3 Required condition = Shut off main engine, - Disconnect the electric power supply to the power pack and close all relevant valves. File name:OMY1000084_5.doc, Last printed 17.6.2008 16:06:00 @ scanned with OKEN Scannera Document ie WARTSILA | Emergency propeller pitch setting oO >: procedure wR Deno. Dwaviaooasé fe Page [2ete 1.1.4 Preparations Pay attention to the WARNINGS, CAUTIONS and Instructions. + Prepare required tools. * Fresh and clean hydraulic oil - + _ Sufficient space. = + Cleaning material and clean the equipment. Emergency pitch setting 41.2 WARNINGS i q * ALWAYS BE CAREFUL WHEN YOU WORK AROUND ROTATING COMPONENTS. * MAKE SURE THAT YOU SHUT OFF THE DRIVE MOTORS AND ALL PUMPS, DISCONNECT THE ELECTRIC POWER SUPPLY AND CLOSE ALL RELEVANT VALVES, WHEN YOU WORK ON EQUIPMENT + MAKE SURE THAT THE DRIVE MOTOR CANNOT BE ACCIDENTALLY STARTED. + PUT WARNING SIGNS IN POSITION. = MAKE SURE THAT NO ONE IS WORKING ON THE EQUIPMENT BEFORE YOU START THE PRIME MOVER. + DO NOT, UNDER ANY CIRCUMSTANCES, START THE PRIME MOVER OR OPERATE EQUIPMENT WHEN A WARNING SIGN IS ATTACHED. + THE PROPELLER SHAFT TURNS IMMEDIATELY WHEN THE MAIN ENGINE IS STARTED. STOP THE MAIN ENGINE TO STOP THE PROPELLER SHAFT. CAUTIONS MAKE SURE THAT THE PUMPS CANNOT SUPPLY HYDRAULIC PRESSURE. + LIMIT THE PROPELLER PITCH TO AVOID A SHUT OFF OF THE MAIN ENGINE. + LIMIT THE ENGINE SPEED TO AVOID A SHUT OFF OF THE MAIN ENGINE. + ITIS NOT ALLOWED TO ENGAGE THE CLUTCH AT FULL REVOLUTIONS. ENGAGE THE CLUTCH WITH THE ENGAGING SPEED. Propeller blades can be adjusted to an ahead position with the tool for emergency pitch setting (seg also chapter 11, tools) and the high-pressure air driven pump (see chapter 8, tools and spare pat ‘The blades stay blocked in the adjusted position due to a blocking valvelin the inner oll pipe. Now the propulsion system operates as a fixed pitch propeller. udthere can be no astern sailing. 47-08-08 DMYI000054_5.doc. 7 @ scanned with OKEN Scanner‘Document tile: WARTSILA | Emergency propeller pitch setting re) procedure oF Page aoa Doc.ne | Barvio000s@ ew 14, fitthe tool fr pitch adjustment, see the appendix assembly drawvings tools for pitch adjustment during assembly 416. adjust the propeller pitch in alow ahead position, less then 60% of the max. pitch 16, mount the OD box, start from ‘note’ and point 4, see the appendix, installation and assembly drawings and datasheets OD box tools, see above emergency procedure. 417. fitthe emergen: Restore normal operation + Alter having repaired the hydraulic system falure, disconnect the high-pressure air-driven cil ump and remove the insert (11, 22, 24). + Place seal (1) and ft plug (10). + Store tools and equipment, and store a new drum with system oil for future use. + The normal condition of the propulsion plant is resumed. 17-06-08 DMY1000054_5.doo cea nan romana SeNNSE EEE EEE EES aero @ scanned with OKEN Scanner7 Document ie WARTSILA| Emergency propeller pitch setting oO procedure : Dee ne [pmviosooss Rov o Page Bole 7 The pitch setting for starting and running as a fixed pitch propeller system depends on the main engine and clutch (if available) characteristics. Notes Locate a drum with system oil (65 dm*) and the tools in the vicinity of the OD box. During the pitch adjusting operation, read the actual pitch on the OD box indicator. ~The blocking valve" rth shaft line will secure the pitclrin'the-adjusted positior-and-prevent — the tendency of the blades to move in the astern direction when the ship sails. Note Operating for a longer period in the emergency pitch mode, repeat the pitch setting procedure from time to time because of some small leakage in the system, Stop wise emergency procedure ‘See chapter 11, ol supply unit arrangement, fr item numbers. ‘And also chapter 11, tools, “Auxiliary tool for pitch adjustment” Op. CAUTIONS MAKE SURE THE AIRPRESSURE TO THE AIR DRIVEN PUP IS BELOW 7 BAR. ‘A PRESSURE OVER 1 BAR LEAD TO FAR TOO HIGH OIL PRESSURES IN THE HUB AND HYDRAULIC SYSTEM, RESULTING IN SERIOUS DAMAGE. Place warning signs at main engine local control stand. ‘Shutdown and secure the main engine against unintentional starting Remove, from the OD box, the plug (10) and seal (1) and fit the insert assembly (11, 22, 24) with female part for the quick-release coupling (5, 9). 4. Connect the hose ofthe high-pressure air-driven oll pump (W084833814 + W084833818) with quick-release coupling tothe insert (22). Pump oil into the OD box until the pitch is ahead, less then 60% of the max. pitch, When the pitch is already in head at 60% of the max. pitch or over, do net increase the pitch in order to keep a low start torque for the main engine, i 7. If the pitch is moving very slowly or does not move at all, activate the main pitch-actuating valve on the power pack (or gearbox) to the ahead position, This can be done by using non follow-up control with push ~ buttons or manually on the valve when electric power is not available. 8. Check and correct the oll level in the power pack or gear box, the level raises. 9. Insert and pump can be left in place until normal operation of the system is resumed. 10. Remove warning signs at the main engine local control stand. 11, Short circu stat circuit safety system, and start the main engine. See the main engine ‘manual. Now the propulsion system operates as a fixed pitch propeller. There can be no astern sailing. 12, Run the CPP with lowest possible main engine revolutions, less then 70% of the of rated spe ‘The main engine does not start because of a too high starting torque In case the main engine does not start because of a too high torque, e.g. the pitch is too far in | ahead position the following can be done: 13. de-mount the OD box, but leave the guide bush (18), see the appendix, installation and assembly drawings and datasheets OD box 47-08-08 DMYI000054_5.doc @ scanned with OKEN ScannerFF [TT cron: WARTSILA ‘Acceptance test CPP {aed Ha a i Pag ‘System code, — ic MEO Tota | OMHEO0DI20 ‘8000 ‘Accopted . Remarks |, Accomter Chock list acceptance test CPP emarks | aT oeoer | ele pump | Check hydraulic pumps remote st Siete a Starter(s) [Check start/standby function pump |__| 7 eae’ _[ check start /standby- function pump 2————} Control | Check control transfer ECR — wheelhouse transfer [Check control transfer wheelhouse - ECR Gheck contol ransfer wheelhouse = port wing | fsppicoba ‘Check contol transfer wheelhouse - stbd wing ‘Check control transfer wing = wing Check control transfer other panels 7 ‘Emerger | Check EM. operation ECR panel cy _ | Check EM. operation wheelhouse panel operation. | Check EM. operation port wing panel Check EM. operation stbd wing panel Check EM, operation other panels Check EM. control interlock ECR - wheelhouse, ‘Check EM, operation at solenoids ifapplcabe Pitch Check pitch indication 100% Ahead indication | Check pitch indication 100% Astern ‘Check pitch indication zero position Check equal indication all indicators Tim) ‘Rpnr [check 100% pr indication [Check zero rpm ‘Check equal indication al indicators Chi ‘continuing next page L For acceptance date: Wartsita Yard Ship-owner Class Propulsion name : signature Fe name DIAHEO00120_0 doc, Last preted 17.6 2008 16.05.00 i @ scanned with OKEN ScannerDocument ie WARTSILA| Check list acceptance test CPP re ae Coe Poon [20a opt [ Check ist acceptance test GPP (continuo) Romarka | Recent ‘emerg. | Cheek telegraph operation Wheothouso picabre telegraph | Check olegraph operation ECR ; ‘Check telegraph operation ER. I Tever [Check lever folow-up ECR L—.-Htotow-up— | control - | ck electie shai Tne uy a ea [Check elects shaft lino u oo Check ek oes |e Zero thrust ‘Check zero thrust pitch position at mir elke ‘adjustment | Check zero thrust pitch position at max RPI ca i ‘Check follow-up contol for zero thrust Pich7 J Cheek the pitch RPM scheduling according to tho control Tagrama provided by Wari RPM | Propulsion Final adjustments can bo roquifed for optinal porformars, Scheduling | Record final acjustments inthe adjuctmant data sheots Variable RPM_1/1 engine froo sailing op a Variable RPM 2/2 engina free sang : 7 Constant RPM1/7 engine ree sailing — | Constant RPM 2/2 engine free sailing : ia Variable RPM_1/ engine manoeuvring wappicaie a Variable RPM2/2 engine manoeuvring ~ : ‘Constant RPM_1/ {engine manoouvring I Constant RPM 2/2 engine manoeuvring Running — | Gheck the running up down times according to apecMfeaton oT gina mamfachursrandypaT up/down | ship-owner requirements times | Final adjustments ean be required for optimal performance. Record final aojustments in he adjustment data shaste Variable RPM_177 engine free sailing ifapplicable C Variable RPM_272 engine free sailing i Constant RPM 1/7 engine free saling Constant RPM 2/2 engine free sailing z Variable RPM_1/1 engine manoeuvring ‘applicable Variable RPM_2? engine manoeuviing —[~ Constant RPM 1/1 engine manoeuvring Sa arses ena f ‘Generator | Check generator mode frequency / RPM. if applicable mode ‘Check constant speed selection interlock » PTI mode [Check generator mode during crash stop ‘Check PTI mode: + continuing next page For acceplance aot Yard Ship-ownor Class Wartsila Propulsion mame signature: 47-06-08 DMHE000120_0.doc @ scanned with OKEN Scanner‘Document tie: WARTSILA | Check list acceptance test CPP © Dee, Rew. [ OMNEDOOTSO oo Page 3/4 - Check list acceptance test CPP (continue) | Remarks Accepted wad [omer | case | protecel. [ Check oad setaointashusiment Final adjustents on the Load control will be required during seatrials. Record final adjustments on adjustment data sheets and paramotor sheet of the dock & seatrail djusted according engine curve Check sverisad ph reduction le engine speed at overload h imum 8% of margin on governor limitation above load limit curve mum 6 % fuel-rack margin oblained before .anical limitation. ‘Check load slowdown function: ‘Check max load conditions Performance load control OK protecol Final adjustments on the windmill protection will be required during seatrials. Record final adjustments on adjustment data sheets and parameter sheet of the dock & seatrail (Gheek slowdown / stop running down pitch ‘Check engine speed within acceptable limits iFapplicable | ‘Check Lamp test (Check Lamp dimmers, ‘Contol functions panels OK Check emergency stop / shut down Check pitch to zero after shutdown applicable (Check engage clutch iWapptcable (Check disengage clutch a Check emergency de-clutch : ‘Check manual engage clutch ‘Chack manual disengage clutch (Check engage shaft brake ‘Check disengage shaft brake -[eseiae = —_t ‘continuing next page For acceptance Date Yard Ship-owner Class. (Wartsila Propulsion |name signature | 47-08-08 DMHE000120_0.doc | I @ scanned with OKEN Scanner