INSTALLATION DRAWINGS FOR BRUNVOLL RETRACTABLE AZIMUTH THRUSTER UNIT TYPE AR-63-LNC-1650 WITH ELECTRIC DRIVE MOTOR P.T. Batamee Shipyard Indonesia Newbuilding No. H7047 Note! All drawings are typical. Technical Specification Dated March 13 2007 Data Sheet TITIIN Installation drawings/instructive drawings: Instructions for installation of Brunvoll Azimuth thruster Arrangement details in trunk 5218.35 Installation details in thruster room 5218.34 Dimension weight for transport 3331.36 Bracket, flexible hoses 6750.94 lechanical system drawings: General arrangement of azimuth thruster unit 5218.33 Azimuth unit complete 3331.27 Yoke azimuth complete 3325.55 Locking unit azimuth 5218.47 ‘Thruster section 3330.66 Lubrication/servo system: Hydraulic power unit 6771.90 Hydraulic circuit diagram 6799.93 Lubrication/servo system TI74AA Flushing procedure for pipes installed by yard BTK 3.05411 Gravity tank 7967.02 “18897_AR_appr 23.01.2008 Page 1 of 3BRUNVOLL Location of Headet/Gravity Tank 7786.01 Determination of Header/Gravity Tank Height 7785.98 Instruction for filling and drainage of oil 7797.80 Lubrication chart, system oil 7782.96 Lubrication chart, column grease TTI2I5 Drive syster Electric drive motor Not part of Brunvoll delivery Remote control system: Cable arrangement 34-6817 ‘Terminal diagram 34-6821 Wiring diagram, Interface to Starter system 34-6836 Wiring diagram, Interface DP 34-6837 Wiring diagram, Interface Joystick 34-6838 Wiring diagram, Interface Autopilot 34-6839 Wiring diagram, Interface Conning 34-6840 Wiring diagram, Interface VDR 34-6841 Wiring diagram, Interface PMS/Ship speed log 34-6842 Wiring diagram, Interface Alarm IAS 34-6843, Watch call Interface 34-6670 Main control panel 6811.76 Indicator Thrust 6808.91 Indicator Azimuth 6808.92 Electronic cabinet, Bridge 6811.77 Electronic cabinet, Thruster room 6811.78 18897_AR_appr 23.01.2008 Page 2 of 3Starter cabinet Servo pump no. 1 6811.79 Starter cabinet Servo pump no. 2 6811.80 Starter cabinet Circulation pump 6811.81 Mischellancous: Preservation & Storage Instruction BIK 5.06.012 Pre-commissioning work by shipyard BTK 72-30 Pre-commissioning Check list BSV 330 BRUNVOLL AS, STRANDGT. 4-6, NO-6415 MOLDE, NORWAY PHONE: + 4771219600 FAX: +4771 219690 E-MAIL: @brunvoll.no WEB SITE: www.brunvoll.no offi “18897_AR_appr 73.01.2008) Page 3 of 3TECHNICAL SPECIFICATION BRUNVOLL RETRACTABLE AZIMUTH THRUSTER Date... ---March 13, 2007 .. 18897 Brunvoll project number....... .- AR63LNC1650 — 800 kW Brunvoll thruster type... Application... DynPos Duty Thruster locatior Bow Aft Vessel type... ...VS491 CD AHTSV Shipyard. .. Batamec Shipyard Hull No. XXX Shipowner. Consultant... .».Vik-Sandvik Main and Class Notations: Det Norske Veritas Class notations: DnV, +1A1, ICE-C, TUG, SUPPLY VESSEL, OILREC, SF, E0, DYNPOS-AUTR, NAUT-OSV, CLEAN DESIGN, COMF-V(3), Class notation, DK(+), HL(p), TMON, BIS. BRUNVOLL AS, STRANDGATA 4-6, N-6415 MOLDE, NORWAY E-MAIL: OFFICE@BRUNVOLL.NO WEB: WWW.BRUNVOLL.NO. PHONE: 47 71 21 96 00 FAX: 4771 219690$e) BRUNVOLL SENERAL DESCRIPTION the Thruster Unit is shaped like a long column, installed vertically in the thruster compartment. Iis of retractable azimuth type, rotatable through 360° with controllable pitch propeller of propulsion design in an asymmetric nozzle for optimal thrust performance in one direction, ‘Thruster is driven by an electric drive motor fitted on top of the vertically moving column. Through the control system for the propeller pitch/speed and azimuth movement, the magnitude and direction of the thrust is controlled. The Thruster Unit can be lowered into operating position and retracted into the hull by means of hydraulically operated lifting equipment. When Thruster is retracted, it is mechanically locked by ‘means of spring loaded locking devices and the hull opening will be closed by a flush-plate attached to the bottom of the propeller nozzle. The design/lay-out as well as fabrication of the flush-plate is the responsibility of the shipyard/consultant. Brackets for attaching the flush-plate are mounted by Brunvoll prior to delivery. The Thruster Unit is delivered with azimuth arrangement as well as retracting arrangement and guiding column in pre-assembled condition fitted on the tank top/sea chest integration plate. The integration plate has larger cross-section than the sub sea section and should be welded to the sea chest/trunk by the Yard with necessary brackets. This arrangement will allow for easy installation/integration of the complete Thruster Unit. Yard to arrange the sea chesttrunk for housing the propeller unit and nozzle when the Thruster Unit is in retracted position. When in lowered operating position the thruster plant is "locked" and pre-loaded in this position by means of the hydraulic lifting/lowering actuators. When the thruster is in operating position but not turning, the azimuth movement is locked by mechanical brakes. ‘The stem housing is moving through a combined sealing box and bearing housing which is mounted to the tank top/sea chest integration plate. Propeller blades are replaceable inside nozzle without special slot. ‘The retractable azimuth thruster contains of three separate main units: Sub sea section Azimuth unit with hydraulic cylinders guiding columns and locking devices Page 2 0f 8% BRUNVOLL THRUSTER UNIT ONE (1) Brunvoll Retractable Azimuth Thruster type AR-63-LNC-1650 Input power > 800kW Estimated thrust (static) : 143 KN (bollard pull) Propeller diameter 1650 mm Propeller type : Controllable pitch Input speed 1190 p.m. Propeller speed 364 rp.m No. of blades 4 Propeller blade design Propulsion Propeller nozzle Wageningen 19A, asymmetric Reversal time, propeller pitch Approx. 15 sec. Rotating speed, azimuth 1-2rp.m. (Adjustable) Time for lowering 25 - 80 sec. (Adjustable) Time for retracting 45 — 60 sec. (Adjustable) Operational limitations: Max. speed of ship for lowering /retracting : 6 knots Max. speed of ship for 360 degrees rotation: 8 knots Max. speed of ship for +/- 30 degrees rotation : 10 knots Materials: Propeller blades : Ni-Ab-bronze Propeller hub Ni-AL-bronze Propeller cap : Ni-Al-bronze Propeller shaft : Carbon steel Input shaft : Alloy steel Bevel gear 2 Alloy steel Gear housing : Spheroidal graphitic cast iron Propeller nozzle Ships quality steel, Grade A Erosion liner Stainless steel SEALING SYSTEM The propeller shaft sealing system is a double sealing system consisting of an outer and inner sealing unit, separated by an over-pressure oil gravity system with possibilities for drainage. The condition of the outer seal may constantly be monitored by draining samples of oil from the intermediate sealing or, safety chamber, for visual inspection or more thorough analysis. The outer sealing unit (shaft seal) is an axial type seal, and is replaceable without dismounting of the gearbox. ROPE GUARD Brunvoll Thrusters has a rope guard as a standard feature which effectively protects the seals from mechanical damage caused by foreign objects. Page 3 of 8#) BRUNVOLL RUG emunsiucas- ests wOLOE- NORWAY REMOTE CONTROL SYSTEM ‘The thruster is delivered with a complete electronic "follow-up" remote control, monitoring and alarm system. There is an extra electric impulse emergency control for the controllable pitch (CP) propeller and the azimuth rotation, The control system may be provided with interfaces to following system: - Interface to Starter System (Hardwired) - Interface to DP System (Hardwired) - Interface to Joystick System (Hardwired) - Interface to Power Management System (Hardwired) - Interface to Bridge Alarm System (Watch Call) (Hardwired) - Interface to Autopilot (Hardwired) - Interface to Ship Speed Log (Hardwired) - Interface to Voyage Data Recorder (VDR) (NMEA 0183) - Interface to Conning System (NMEA 0183) - Interface to Alarm IAS System (NMEA 0183) ‘The control system has interlocks to prohibit start of the main el-motor for: - Thruster unit in lowered position - Propeller in zero position ~ Servo pressure available - Starter for el. motor ready ie Power available Main Control Panel TWO (2) Main control panels of flush mounting type for forward and aft bridge consoles, ‘One panel is facing forward, one is facing backwards, Design enclosure is IP22. Terminal board connected via 2.0 m cable. The control panel will include the following control and monitoring facilities: - Control lever for individual control of propeller pitch and azimuth rotation - Push buttons for start/stop of servo unit, start/stop of drive motor and lowering/retracting of thruster - Push buttons for emergency control of propeller pitch - Push buttons for emergency control of thruster rotation - Push button for emergency stop - Push button "In command” to take control - Push buttons “Lamp test” and "Dimmer" - Indication lamps for "DP/Joystick", "Ready for start", "Power limited" ete = "Common alarm" (Individual alarms are laid to ship's central alarm system.) ~ Push button “Buzzer off” to acknowledge alarm TWO (2) Pitch indicators for overhead mounting or mounting in bridge console. TWO (2) Azimuth indicators for overhead mounting or mounting in bridge console. Page 40783%) BRUNVOLL Electronic Control Cabinet, Bridge ONE (1) Electronic control cabinet for wheelhouse installation Applied for interface with bridge systems as Joystick, Autopilot, DP and VDR. Collects and transfers information from control panels on bridge. Design enclosure: IP 55 (prior to any cable connections by Yard) Cable entry in bottom of cabinet. Power supply: 24V DC - 6 amps. Electronic Control Cabinet, Thruster Room ONE (1) Electronic control cabinet for installation in thruster room, Contains the electronic control system of type PLC. The unit is controlling the main functions of the azimuth thruster (azimuth movement, pitch movement, lifting/lowering, lock on/off and monitoring of thruster and alarm functions). In the cabinet it is installed a touch display with control, monitoring and alarm functions. Used for system set-up and adjustments and local control of the thruster. Design enclosure: IP 55 (prior to any cable connections by Yard) Cable entry in bottom of cabinet. Power supply: 230V AC and 24V DC ter Cabinet for Servo Pump TWO (2) Cabinets each with D.OLL. starter and interconnection for the hydraulic power unit, containing: motor protection relay, transformer, contactor, necessary relays, fuses terminals, internal wiring etc. On cabinet door: - Safety switch - Selector switch for local start/stop/remote start - Running light . Hour counter Design enclosure: IP 55 (prior to any cable connections by Yard) Cable entry in bottom of cabinet. Power supply: 3 x 450V / 60 Hz. Starter Cabinet for Circulation Pump ONE (1) Cabinet with D.O.L. starter for the circulation pump mounted on the azimuth unit. On cabinet door: - 1x Safety switch - 1x Selector switch for local start/stop/remote start - 1x Running light . 1 x Hour counter Design enclosure: IP 55 (prior to any cable connections by Yard) Cable entry in bottom of cabinet. Power supply: 3 x 450V / 60 Hz. Page 5 of 8| BRUNVOLL Feedback Units for azimuth rotation and propeller ONE (1) Feedback unit for the azimuth rotation follow-up system, Provided with cable gland for cable with max. 0.4. 21 mm. ONE (1). Feedback unit for the propeller pitch follow-up system. Provided with cable gland for cable with max. 0.4. 21 mm. ‘The feedback units are already mounted at delivery from Brunvoll AS, in a shielded position well inside the frame/foundation for the main electric drive motor. LUBRICATION/SERVO SYSTEM ‘The supply includes all main components in the lubrication/servo system. That is, a hydraulic power unit, a gravity tank, a circulation pump on the azimuth unit (mounted at delivery from Brunvoll AS) and asset of ‘flexible hoses between a central for fixed mounted components/ pipe connections and the vertically moving azimuth thruster. The thruster unit is completely oil filled to secure good lubrication for all mechanical functions. The thruster lubrication system is connected to a gravity tank installed in the upper part of the thruster compartment. Oil connections to the thruster are led via flexible hoses to tolerate the stroke of the retractable thruster. The total oil volume in the system is approximately 1200 litres Hydraulic Power it ONE (1) Hydraulic power unit for installation in thruster compartment. The hydraulic power unit is powering the following functions: a) Azimuth tuming motors with brakes b) Propeller pitch mechanism ©) Lowering/retracting of thruster 4) Pre-loading in operating position ©) Operating of locking devices For a.m. functions two (2) pumps/motors are provided, One pump/motor is stand-by. Each pump/motor is completely separated electtically/hydraulically to achieve 100 % redundancy. Power, each motor : 11 kW Power supply : 3x 450V/60 Hz ‘The servo system contains all necessary control valves, hydraulic components and fittings to control the main functions as listed in item a) through e) above. Gravity Tank ONE (1) Gravity tank for oil feeding to gearbox and hydraulic power unit. The gravity tank is delivered with oil level alarm for thruster's lubrication system. Level switch on gravity tank with gland for cable with max. 0.4. 11 mm. Gravity tank to be installed at a height determined from Brunvoll’s specification Page 6 ofSe BRUNVOLL ELECTRIC DRIVE SYSTEM Electric Drive Motor (Not included by Brunvoll AS) ONE (1) Electric squirrel cage marine motor. Output 800 kW Construction Vi Power supply 3.x 690 V — 60 Hz Duty S1-Continuous Speed 1190 r.p.m. Direction of rotation Clockwise looking on end of motor shaft ‘The drive motor shaft is connected, via an elastic coupling, to an intermediate shaft. The intermediate shaft is running through the azimuth unit/ stem housing and is connect via a tooth coupling, to the pinion shaft in the propeller unit Starter for El. Drive Motor (Not delivered by Brunvoll AS ONE (1) Starter designed to suit electric motor and Brunvoll’s control system for CPP thruster. OTE: Due to the vertical stroke of the thruster , all power and control cables to the thruster and motor should be led to the unit via a cable loop. Suitable cables to be selected, supplied and suspended by the shipyard. APPROX. WEIGHT OF COMPONENTS: Azimuth unit complete with hydraulic cylinders and guiding column Sub sea section (propeller and nozzle) Electronic Control Cabinet, Bridge Electronic Control Cabinet, Thruster Room Starter Cabinet, Servo Pump Starter Cabinet, Circulation Pump Hydraulic Power Unit Gravity Tank RELATED DRAWINGS (TYPICAL) Arrangement Drawing, Thruster Unit Electronic Cabinet, Bridge Main Control Panel Pitch Indicator Azimuth Indicator Electronic Control Cabinet, Thruster Room Starter Cabinet, Servo Pump No. 1/ No. 2 Starter Cabinet, Circulation Pump Hydraulic Power Unit Gravity Tank 11600 kg 3900 kg 40 kg 35 kg 25 kg 20 kg 410 kg 105 kg 5218.33 6800.16 6800.23 6795.62 6800.45 6800.17 6800.18/ 6800.19 6800.31 6771.90 7167.02 Page 70f88) BRUNVOLL sPECIFICATION s standard painting system is based on Hempel’s product line. Hempadur Zine Epoxy is a two component polyamide zine rich epoxy primer. Hempadur is a two component, polyamide adduct cured epoxy paint. GLOBIC 81900 is a high performance self-polishing and self-smoothening, 2003 compliant ‘TBT-free Anti Fouling with medium polishing properties. Following paint procedures will be applied by Brunvoll AS prior to delivery: ‘Thruster sub sea section Ist coat Hempadur Zinc 15360-1984 1x 40 my DFT 2nd coat Hempadur 17633-12170 1 x 150 my DFT 3rd coat Hempadur 17633-50630 1 x 150 my DFT. 4th coat Hempadur 45182-25150 1x 50 my DFT Sth coat AFGlobic 81900-51110 1x 125 my DFT 6th coat AF Globic 81900-60600 1x 125 my DFT 7th coat AFGlobic 81900-51110 1x 125 my DFT Azimuth section, machinery components, hydraulic power unit and gravity tank Manufacturer's standard. Topcoat: Hempalin engine enamel 5214-1217 (light grey) El. cabinets Manufacturer's standard. Topcoat: RAL 7032, Light grey Control panels Manufacturer's standard. Topcoat: RAL 9005, Dull black. BRUNVOLL AS, STRANDGATA 4-6, N-6415 MOLDE, NORWAY E-MAIL: OFFICE@BRUNVOLL.NO WEB: WWW.BRUNVOLL.NO. PHONE: 47 71 2196 00 FAX: 4771 21 96 90 ~~ Page 8 of 8BRUNVOLL PROJECT NO. SHIPYARD NEW BUILDING NO. ay ie) Sas DATA SHEET 18897 P.T. Batamec Shipyard Indonesia 7074 THRUSTER UNIT NO. 7975, Bow thruster A THRUSTER UNIT TYPE AR-63-LNC-1650 INPUT SPEED ON THRUSTER 1200 RPM. INPUT POWER ON THRUSTER 800 KW | PROPELLER SPEED 967 RPM. INTERNAL GEARING RATIO 11/36 DRIVE SYSTEM ELECTRIC DRIVE SYSTEM NOT PART OF BRUNVOLL DELIVERY EFFECT: 800 kW, St - cont. duty VOLTAGE: 3 x 440V- 60 Hz ‘STARTER FOR EL. DRIVE MOTOR NOT PART OF BRUNVOLL DELIVERY SERVO SYSTEM BPA 150 VREX ATOV ELECTRO MOTOR EFFECT: 11 kW VOLTAGE: 3x 440V-60H2 _ Date [23.01.2008 _] BRUNVOLL AS Author | ME 6415 MOLDE DATA SHEET Contr. 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Ti Azimuth rotasion 3 S-S: Olje til” fra servosylinder a MERK: Bokstavene p& tegningen er stemplet p3 3 7 enhetene. Enhetene leveres med Ermeto rararmatur| & ! & re, Rerkvalitet:; Presisjonsrar DIN 2391 3] ite 7 Maks. lengde p&_rer meliom servoaggregat og 2 is i propellennet: S8 korl sam praktisk mutig 3 PS t 7 als ai viKTIGI sts I Alle rar fra gravitasjonstanken m8 ha helling ned- ba gl 7) over, min. 10°, for 4 sikre problemfri oljeflyt ET | ‘| Dae NBI"_Unng8 “tuftiommer”| i! ti (esl ——————~ Veritsleveranse 1 | * VIKTIG! | Stengekrane, merket med + 8 i skjemaet, m8 alltid vere Apne nar thrusteren i kjares | 1 ! i Pipe A: Oil to sheft sealing system B: Drain from shaft seating system Pipe 0. Overflow from gravity tank Pipe E: Oil to gear housing Hr” Drain from gear housing (bottom) K Bleeding AZ To Azimuth rotation S-S: Ol to/ from serva-cylinder iS NOTE: The letters marked on drawing are : 4 stamped on the units. The units are equisped with ZJ Ermeto fittings. Steel tube quatty acc. to ON 2391 tock ev or equivalent standard Max. pipe length between servo-pump unit and thruster unit: Shortest practical possible | tock evi ; @s IMPORTANT! Alt pipes trom gravity tank must be installed with “slope down”, min. 10°, in order to ensure troublefree oil flow NBI___Avoid “air locks” Pipe inside dia. to be selected according to dim. indicated on drawing, eciceememee Yard delivery = WARNING SHUT OFF valve, marked with * on dagram, must always be apen when running thruster ‘Thruster sub sea section | ea. _|BRUNVOLL AS [Rec ase oe Tar TATE | sa, al ns | Smare-/servosystem AR63 frikopl vena ees, Lubrication/servo system AR63 een = AR63 LNC / LTC 7174.14 A |Prepared by: Date- ‘Chapter: | @ ar BRUNVOLL au BTK 3.05.411 Beane eeu uecse non a 15.05.00. revisto: Flushing Procedure pproved by: A Page | of 3 A Flushing Procedure For Azimuth Thrusters 1. General guidelines for design and installation 1.1 Pipes, hoses and fittings: ‘When mounting a hydraulic system, one must be sure to use pipes, hoses and fittings that are designed for the actual operating conditions that exist. An absolute requirement and condition to ensure that the thruster will be reliable is to maintain the highest possible degree of cleanliness during the installation. In addition, itis important that certain components, such as cylinders, oil tanks, ete. be protected against ingress of dust and dirt, During installation, all openings must be properly covered. In the installation of a hydraulic system, packing material or tow should not be used in connection with thread seals. 1.2. Welding connections: As a general rule, welding connections of hydraulie pipes is not allowed unless welding flanges are used. In the event that welded connections are used, all burrs and oxide scale must be removed, preferably by mechanical method followed by acid cleaning. Needed for this is a solution of 10% sulphuric acid and 90% water at a temperature of 50°C for a period of about 2 hours. Afterwards, the pipes are flushed with clean water and then dried by blowing compressed air through the pipes. The pipes must then be thoroughly sealed and the sealing material must not be removed until the pipes are ready to be installed. 1.3 Cleaning and flushing of hydraulic pipelines: All pipe-laying in hydraulic systems should be performed with "hydraulic" tubes and "Ermeto” bite ring fittings, or similar, Thread-tape, tow, etc. must never be used. It is important that burrs, scale and corrosion be removed, and that tubes are thoroughly cleaned before installation. We recommend the seamless pipes be thoroughly cleaned with special sponge-plugs shot through the pipes with compressed air (6-8 Bar). Air pressure forces the plugs through the pipes, absorbing dirt and cleaning the inner pipe wall. The plugs are to be used only once, and two shots are recommended. Be sure to use correct plug size for the size of pipes. ‘After flushing with the sponge-plugs (rough rinse) the pipes should be flushed with warm, clean oil S0cST. Shipyard's piping between/from header tank and possible oil reservoir must be flushed with cleaning plugs and subsequently flushed with oil. All equipment supplied by Brunvoll is flushed before shipment.1 Prepared by [Darter Chaprer BRUNVOLE || 0 | ssosqo | BIK 3.05411 Check by 05. visto: | Flushing Procedure | | APEROE A Page 2 of 3 kA 2. Flushing of hydraulic pipes for azimuth thrusters Flushing of E and O: (see enclosed lubricant/servo system drawing) Detach E and O pipes on both ends. Place clean plugs in all free connections in order to prevent fouling. Connect E and O pipes together under the gravity tank and to a flushing unit at the other end. With regard to design requirements to the Flushing Unit, see paragraph 4 below. Begin flushing by sending ‘warm (60°C) oil, 50 cSt. through the E pipe and back to the O pipe. The oil amount/speed is dependent upon the dimension of the pipe. See table on flushing flow in paragraph 5 below. Stop flushing when the particle counter just outside the filter shows satisfactory results. Purity requirements are from ISO 4406, class 19/17/14. (NAS 1638, class 8) Then re-attach the pipes in place on the gravity tank, Flushing of E and A: (see enclosed lubricant/servo system drawing) Close connection between A pipe and the gravity tank. Detach A pipe from the thruster. Flush through E pipe and A pipe backward, Flushing the other pipes: Repeat the procedure for the remaining piping by flushing in pairs. Start by flushing the largest diameter pipes, and try to combine pipes of similar size. If one pipeline is reused, it is important that the cleansed pipe is of larger diameter and that this is placed before the unflushed pipe. The particle counter should show the same purity reading after one hour's test running. 3. Flushing fluids: Fill oil through a 3 micron ABS filter on flush-aggregate 800 ~ 1500 litres. (Volume tank will be at least three times the oil flow.) As a flushing medium the same oil that will be filled in the thruster is used. | 4, Typical flush-aggregate: © Pump capacity adjustable up to 400 litres/minute, preferably pulsating oil flow, Re>4000. © Heater that warms the oil up to 60°C, 50 cSt. © Temperature measurement of oil to verify that oil stays at least at 60°C. © Filter pack, Six micro double-filters with indicators. The double-filters make it easier to change the elements while running. * Particle counter. Mounted for measuring in front of the flush filter. It should be the type of filter that doesn't disrupt the measurement even if air or water is in the oil. The particle counter shows, at regular intervals, the purity class that is obtained. Clean hoses for reconnecting pipes.Prepared oy] Date: Charen: @ BRUNVOLL, || f% BTK 3.05.411 sesxeer—_ 15.05.00 lpewsson Flushing Procedure [ Approved by) A Page 3 of 3 KA 5. Flushing flow: Pipe Flush mension amount (Itr/min.) 012/9 85 olS/I1 105, 16/12 115 o18/14 135, 020/15 145 022/18 170 028/24 230 030/24 230 935/29 280 035/30 285 042/36 340FILL, LEVEL a OPPFYLL. NVA in i it gy it 3 1 Oil level eyes tf Nivaglass i i i i i Vi Art, 19280 ie 026 || Art. 23874 & FF g fa a 03 028 a Overflow to pump tank (Pump aggregate) 380 Brunvall detivery 465 Level_switch Nivébryter Filler/breather Cap Fylle-/luttehette | art, 23874 aud rams7 oon’ po |" 7 |BRUNVOLL AS Fax [Frontage ater STW [_ te. ova er aan “9280. Ravers Gravitasjonstank 90L AZ (VVO) iSsxD, eo alot ee OL Gravity tank 90L AZ (VO) omensionat drawing —— SP 9565 35/28/35 (SP 9565 35/28/28) 7167.02 AProcedure for determination of header tank height Fal level Fyltniv’ tiniest of ae 8} 2B 70 | Header / 2 = © | | Gravity tank Ss i t 2 z \ i S| a . 8| = 2 £ 2 z 7 ‘| s 5 2 na * 2 2 a i EE a| 2 ¢ z | ie 2 ee, Hydr-Power 5 { |—— Unit Shaft immersion [ m ral The max. and min. heights are determined from max. and min, sg pressure differential, seawater - cil 3 The specification of gravity tank 2 heights refers to conditions where the = thruster is running 5 For actual heights, see the enclosed ¢| drawing entitled: a “Determination of Oil Header Tank ay. Height Exe fe 7 Thruster sub sea unit. Thruster undervannseksjon. Principle sketch Lubrication- /servo system (€xemplied tor CP propeller) Rev. | Enarig/MaacaFan Daa Rav, Foranarag7 Change Daas Fra av Oraw by | Prasens/Pracens arora area Proene. ie 010301 BM Ronin. eed vant 7waahr pas Tranear7 repaid Tama oaosot ka BRUNVOLL AS i /Cortered Palestac Sete Bradh. Brunvall Motorfabrkk AS Made, Norwa Sneha a Plassering av grav.tank nn 027631 Tan 7iraw ta Rev Location of Header / Gravity tank 7786.01 _|ADetermination of Oil Header Tank Height from max. and min. Ship Draught / Shaft Immersion for Thruster Operation, EK Mane Bar propeller shaft seal. 18 16 | 14 é #12 > : = 10 < & 5 8 3 3 z6 5 4 2 | 0 41° 2 3 4 5 6 7 8 9 10 Shaft immersion [m] nin. height — —Max. height See also principle procedure explained in drawing no 7786.01 (CP propeller) or 7786.94 (FP/AP propeller) |[Artno.: [030309 [Prod. gr: | ee [Date [04.05.2001 BRUNVOLL AS | Determination of Header/Gravity Tank Height 5#28_|K4/BM_| 6415 MOLDE Contr. NORGE EK Mane Bar propeller shat seal 7785.98 | ToflCONTENTS 1, GENERAL 2, FILLING OF OIL, Filling the hydraulic power unit tank. DRAINAGE OF OIL.. 3 3.3. Drainage of the thruster with the ship afloat. 3.4. Drainage of the hydraulic power unit tanl 4, GREASING POINT: aA Aaa he FILTER UNIT FOR O1 6. AMOUNT OF OIL AND GREASE IN UNITS 6.1. Amount of 6.1.1. Amount of oil for AR63A and ARSOA 6.1.2. Amount of oil for AR63C, AR8OC and AR100C 6.2. Amount of grease. Superseeds dwg, no 7761.31 [Art. no.: [033188 Date [24.08.05 || BRUNVOLL AS INSTRUCTION FOR FILLING Create [TH/m AND DRAINAGE OF OIL Contr. [KA 6415 MOLDE AR63A - AR63C - a lnonwin AR80A - AR80C - AR100C 7797.801, GENERAL The propeller shaft sealing system, gear housing and hub together with the azimuth unit are to be completely filled with oil prior to launching of vessel to prevent ingress of water in the system, Normally, the system should be filled-up with oil through the gravity tank, and a 3my filter. See the actual drawing of lubrication- and servo-system. Ensure use of the correct type of oil and grease shown on the lubricant chart. With the ship in operation change of oil should be planned to occur at regular docking. This instruction is also valid for Combi and Compact versions. NOTE! Ifa filling pump unit is used this unit must be equipped with a suitable (3my) filter. Additionally, the following precautions should be duly noted: WARNING! Ifa filling pump is connected directly to the gear housing (H-pipe), make sure not to pressurise above normal gravity pressure, maximum 1 bar. This can be achieved by keeping air ventilation (K-pipe) open and securing the pump pressure with a suitable relief valve. Excessive pressure can damage or blow out the blade seals. It is prohibited to connect pumping devices to the shaft sealing units A or B pipe Dorts. Art. no.: [033188 | Date [24.08.05 BRUNVOLL AS INSTRUCTION FOR FILLING Create |TA/m | AND DRAINAGE OF OIL Contr. [KA 6415 MOLDE AR63A - ARO3C - NORWAY AR80A - AR8OC - AR100C 7797.80 2of82. FILLING OF OIL The filling of oil should always be through a3 my filter. 24 Filling the thruster when ship is in a dry dock Oil is filled on the units when the azimuth thruster is in the lower position. The retractable units have an automatic system for lowering and retracting the unit. Start the servo pump unit by pushing soft button START SERVO on the touch display mounted in cabinet located in the thruster room to enable lowering and retracting operation, ‘When the soft-button THR. OUT on touch display mounted on cabinet in the thruster room is pushed the unit will first be lifted, then the locking device will be released, and subsequently the retractable unit is lowered, a) Turn the propeller until the breather plug on the propeller hub is at its highest point, and remove the plug. b) Fill oil into the gravity tank until the hub is completely filled with oil, and oil free of air comes out. Refit the breather plug, and remember the monel washer. Table for tightening torque: ©) Open the valves marked K (for air bleeding gear housing and azimuth unit), B (for bleeding propeller shaft seal unit) and H (for bleeding the pipeline to gear housing). All those valves are located on azimuth unit, 4) Continue with filling oil on the gravity tank until oil free of air comes out of valves K, B and H, and then close the valves. ©) Continue with filling until you can see oil in the middle oil level indicator on the gravity tank, marked FILL LEVEL, f) The thruster unit to be retracted by pressing and holding button THR. IN mounted on local operator panel inside electronic cabinet in thruster room, 2) When thruster is retracted and locked, the servo pump unit to be stopped by pressing soft button STOP SERVO on touch display located in thruster room. Art. no.: [033188 _| Date. 11.07.07 BRUNVOLL AS INSTRUCTION FOR FILLING | Created |IH/mn/HS AND DRAINAGE OF OIL Contr. KA eee AR63A - ARO3C - j——_1 _ AR80A - AR80C - AR100C 7797.80 3 of 82.2, Fi If draining and filling of the thruster unit have to be carried out with the ship afloat special precautions have to be taken in order to avoid water ingress and to ensure air evacuation after filling of oil. ing the thruster and the hydraulic power unit with the ship afloat With the ship afloat it is necessary to maintain the header tank pressure on the propeller shaft seal system (Pipe A) at all times. The thruster must also be retracted. Emptying of the thruster lubrication system at sea should preferable be carried out with the ship alongside a quay (calm waters), and should only be carried out if absolutely necessary, The reason being a certain risk of limited water ingress and the need for special precautions to evacuate air in the thruster unit. Ifa filling pump unit is used, the procedure for filling is: i, Connect PE (Pump Emptying Port) on the pump with the PE port on the "clean oil tank", and PF (Pump Filling Port) on the pump with the PF-port on the gravity tank. ii, Open the valves marked K (for air bleeding gear housing and azimuth unit) and H (for bleeding the pipeline to gear housing). These valves are located on azimuth unit. Fill the thruster and the Hydraulic Power Unit through the gravity tank. Overflow from gravity tank will fill the Hydraulic Power Unit when thruster is filled. iv. Open the valves marked B (for bleeding propeller shaft seal unit), and continue filling oil into the gravity tank until oil free of air comes out of valves K, B and H. Then close the valves. v. Stop filling when oil is show in the oil level glass on the Hydraulic Power Unit. Since there is no access to the air-bleeding plug on the hub when the ship is afloat, it is necessary to conduct additional air bleeding procedures. Subsequent to the filling and initial air bleeding, the Hydraulic Power Unit is first started. Then the pitch is activated from full forward to full backward, and continued repeated air bleeding (K-pipe) is conducted. vii, Then the thruster is started and run for a period of approx. 30 minutes at zero pitch, During this period the air-bleeding valve is repeatedly opened to check for air. Subsequently, when the thruster is operated with load (preferably from full forward to full backward pitch) air bleeding is again conducted. This procedure should be repeated during the first 3 to 4 hours of operation to minimise the risk of entrapped air in the lubrication and servo system. 2.3, Filling the hydraulic power unit tank The hydraulic power unit tank is filled to the upper oil level indicator. After testing of | the servo system, the tank is refilled to the upper oil level indicator. Ar. no.: [033188 Date [24.08.05 BRUNVOLL AS INSTRUCTION FOR FILLING Create [IHim | AND DRAINAGE OF OIL Contr. [KA | 6415 MOLDE AR63A - AR63C - NORWAY ARB80A - AR80C - AR100C 7797.80 4of83. 3.2. DRAINAGE OF OIL Drainage of the gravity tank For draining of the gravity tank it is not necessary to lower down the thruster unit. The gravity tank is drained through valve point H located on the azimuth unit. If the gravity tank is not to be drained, but only the azimuth unit, the gear housing and the propeller seal system, the valve under the tank must be closed. Drainage of the thruster when ship is in dry dock For service and maintenance of the thruster body ete. it is necessary to lower down the thruster unit while vessel is in dry-dock. NOTE! Necessary height/space under the keel/bottom of the vessels must be obtained. The following sequence for lowering and draining the thruster unit must be followed: a) Start the servo pump unit by pushing soft button START SERVO on the touchdisplay mounted in cabinet located in the thruste room. ©) Thruster unit to be lowered to desired position by pressing and holding push- button THR. OUT mounted on local operator panel inside electronic cabinet in thr. room. 4) The gravity tank is drained through valve point H on the azimuth unit. ©) The gear housing and the azimuth unit are drained through the plug on the cover under the gear housing, and the propeller hub through the breather plug on the propeller hub, The propeller blades are turned so that the plug is on the lower side. ‘The valve point K must be open for air bleeding. The speed of the draining could be somewhat controlled by restricting the airflow through the filling point on top of gravity tank and the valve point K. {) The propeller shaft sealing system is drained through valve point B. (Complete drainage is possible by use of suction pump). Art. no.: 1033188) I Date _ [24.08.05 BRUNVOLL AS INSTRUCTION FOR FILLING Create | [H/m 6415 MOLDE AR63A - AR63C - NORWAY AND DRAINAGE OF OIL Contr. | KA AR80A - AR80C - AR100C 7797.80 Sof 83.3. Drainage of the thruster with the ship afloat. See notes given in chapter 2.2. In particular note that the shaft seal outer barrier must be kept pressurised during the whole operation, and the thruster unit must be retracted. Let the thruster run for aprox. 30 min, to gain temperature and adequate viscosity in oil. Retract the thruster before draining the oil. Disconneet/close the connection to the A-pipe directly under/ adjacent to the gravity tank in order to maintain the static header tank pressure on the shaft seal system. iv. Connect PE-port on the pump with PE-port on the thruster (H-pipe), and PF-port on pump with PF on "Used oil tank" v. Let the pump run as long as it delivers oil, then stop the pump. 34. Drainage of the hydraulic power unit tank For service and maintenance of the inside of hydraulic power unit tank the complete drainage can be done through the drain plug on the tank, or using a suction pump. Ifa filling pump unit is used, the pump is to be reconnected PE on pump with PE on Hydraulic Power Unit before continuing the pumping of oil to the “used oil tank”. Stop the pump when there is no more oil to drain. GREASING POINTS The following items to be filled with grease according to the maintenance program. Type of grease is according to chart of grease lubricants. a) 2 off nipples on sealing box fitted in sea chest/tank top. b) 4 offfnipples on each locking unit together with the surface of the guiding block. | c) ‘Nipples on the electric drive motor. | NOTE! Type of grease and amount, see sign on electric motor. FILTER UNIT FOR OIL, | (Only for units with CJC Offline Fine Filter HDU 27/27) ‘An off line filter unit is attached to the thruster body piping, continuously circulating, filtrating and absorbing possible water from the lubricating oil. The unit is equipped with a bleeding/venting valve, which automatically take care of | bleeding/venting during filter bow! filling up and draining, [Art no.: [033188 Date [24.08.05 'BRUNVOLL AS INSTRUCTION FOR FILLING Create | TH/m AND DRAINAGE OF OIL Contr. |KA 6415 MOLDE. AR63A - AR63C - t NORWAY AR80A - AR80C - AR100C 7797.80 6of8Prior to first time starting, and after change of a filter element, note that the pump requires approx. 15 minutes to fill the filter bowl - 25 litres of oil. After this filling, period, the thruster oil reservoirs must be checked for correct oil level. Add oil if necessary. NOTE! For complete instructions, see: Operating manual CJC Fine Filter HDU 27/27. AMOUNT OF OIL AND GREASE IN UNITS Amount of oil ‘The amount of oil is exclusive piping system. “L” in table below indicates approx. stroke in (mm) for actual thruster type. Amount of oil for AR63A and ARSOA | | ARGA ARS0A | L=2200 L=2450 L=2700 L=2750 Gear housing | 135 litres 135 litres 135 litres 330 litres Propeller shaft | 4 Titres Flitres A litres 6 litres sealing unit Hydraulic litres 47 litres Si litres 110 litres cylinders ‘Azimuth unit | 750 litres 830 litres 910 litres 1360 litres 150 litres 150 litres 150 litres 00 litres aggregate tank Gravity tank 90 Titres 90 Titres 90 litres 190 litres Filter unit 25 litres Total amount | 1170litres | 1255litres | 1340litres | 2410litres | || Art. no.: | 033188 Date _ | 24.08.05 BRUNVOLL AS INSTRUCTION FOR FILLING Create [IH/m AND DRAINAGE OF OIL Contr. [KA 6415 MOLDE AR63A - AR63C - |NORWA' AR80A - ARSOC - AR100C 7797.80 Tos6.1.2. Amount of oil for AR63C, AR8OC and AR100C 80s TYPE AR63C AR80C AR100C Stroke L=2200 | L=2450 | L=2700 | L=2750 | L=3150 | L=3430 | L=3930 Gear housing! [170 Titres | 170 litres | 170 litres | 400 litres | 400 litres | 780 litres | 780 litres propeller hub Propeller shaft | 4 litres | litres | litres [ litres | Glitres | 10litres | 10 litres sealing unit Hydraulic | 42 litres | 47 litres | 5i litres | 110 litres | 130 litres | 340 litres | 380 litres cylinders _ Azimuth unit | 750 litres | 830 litres | 910 litres 1350 1500 2830 litres | 3175 litres litres__| _ litres Servo 150 litres | 150 litres | 150 litres | 400 litres | 400 litres | 600 litres | 600 litres | aggregate tank | Gravity tank | 90 Titres | 90 Titres | 90 Titres | 190 Titres | 190 litres | 190 litres | 190 litres Filter unit 25llitres | 25 litres | 25 litres | 25 litres Total amount 1205 1290 1375 2480 2650 4775 litres | 5160 litres of oil | Titres | titres | litres | titres | litres 6.2. Amount of grease Sealing box (AR63) 2-3kg Sealing box (AR80) 3—Skg. Sealing box (AR100) : 4~6kg. Locking unit : Until full. Guiding blocks As needed. Electric motor See sign on motor. Art no.: [033188 _ Date [24.08.05 INSTRUCTION FOR FILLING Create |IH/m BRUNVOLL AS AND DRAINAGE OF OIL Contr. [KA 6415 MOLDE AR63A - AR63C - Re AR80A - AR80C - AR100C 7797.80Brunvoll Thruster Units | List of Approved Oil Types to be filled into: + Hydraulic Power Unit + Gear House System (pipe " + Sealing System (pipe "A OTL COMPANY MINERAL OILS SYNTHETIC OILS BP ENERGOL GR-XP 68 CASTROL Alpha SP 68 Alphasyn HG/ EP 68 CHEVRON (FAMM) | MEROPA 68 (EP) EXXONMOBIL. MOBILGEAR 600 XP 68 | MOBILGEAR SHC MT 68 SHELL OMALA 68 OMALA HD 68, STATOIL LOADWAY EP68 MERETA 68, LOADWAY MARINE 68 1 (Ora ELF EPONA Z 68 General Requirements: @ Oil Viscosity Grade according to ISO 3448, ASTM D-2422: ISO VG 68. ~ Oils with lower viscosity grade must under all circumstances not be used. = Oils with ISO VG 100 may be applied for operation restricted to tropical and subtropical areas, and may exceptionally also be approved in colder climate provided that the oil’s viscosity index ensures a viscosity comparable to ISO VG 68 at low temperatures (0-10 °C), a Viscosity Index, VI> 95. The lubricant used shall be an Extreme Pressure - / EP- lubricant, with anti scuff additives. @ The FZG test failure stage according to ISO 14635-1, ASTM D 5182, DIN 51 534 (A/8.3/90) shall be: FZG > 12 (Le. 12+ or 13). The FZG failure load stage shall be documented with a test report from an independent laboratory, @ ‘Sufficiently high grey-staining resistance in accordance with FVA 54 grey-staining test, GS-criteria stage 10 or higher applies. The oil shall have good stability in presence of water and good demulsibility with rapid water separation. Ref. ASTM D 1401 on water separation time. Low degree of foaming with less than 15% foam formation in the FLENDER foam test Compatibility with elastomer materials of the shaft-sealing rings Compatibility with residues of corrosion-protection agent and run-in oils used by Brunvoll Compatibility with the paints used by Brunvoll in its gear-unit interiors Compatibility with liquid seals between bolted-joint surfaces. o ° oouce NOTE: In case an Oil Filtration Unit is used, it is recommended to use synthetic oil for ship operation in cold climates (e.g. North Atlantic). Mineral oil may be used if special precautions are taken (e.g. heating devices) to prevent foam formation in the thruster by the filtration pump. ‘Ait no, [026841 Prod G_ [UH BRUNVOLL AS CHART OF LUBRICANTS Due: [020108 | 6415 MOLDE | vol T on ees thTh Sign: | KA for Brunvoll Tunnel ai ‘Thrusters | NORWAY mel and Azimuth Thrusters |~“F e L Page ofl —Brunvoll Azimuth Thruster Units Recommendations for grease lubrication of sliding bearings for retractable azimuth thrusters Column Supports OIL COMPANY GREASE LUBRICATION BECHEM __| HIGH-LUB SW 2 __ BP ENERGREASE LC CASTROL SPHEEROL LMX CHEVRONTEXACO MOLYTEX EP CONOCOPHILLIPS TACNA 2000 DOW CORNING MOLYKOTE MULTILUB EXXONMOBIL MOBILGREASE XHP KLUBER CENTOPLEX 2 SHELL ALVANIA EP (LF) 2 STATOIL MOLYWAY LI 412 TOTALFINAELF CERAN WR 2. General Requirements: a Seawater resistant @ Operating temperature range: -20 °C to + 80°C | a Penetration: 265 — 280 (ISO 2137) Arno: [021957 | | _ Date [23.07.03 | | BRUNVOLL AS CHART OF LUBRICANTS. eee GREASE LUBRICATION 55 - 63 — 80 — 100 SERIES [NORWAY lof290 vas JANE re] tet nn nod enh Ei sposnaa ovaeano Lav- Ziv} z WOOe SSISTaAL Oe& ron m Zr lb ig i ig 8 oe bis z Zor ge 30 oF weary fa eit * Peoepp 4 3) seor[ FI Ci Se] ror} L_] rene] $e cen aie 88 sean Tear} 24 £8 ean ee 28) sene sere p88 $80 sop p88 Fee Fear p oo $8) rene a 28) een wry 8 Tron wort} S~son=] wor ]} 5S eo] “| weer|{f 28 Seon] ale Teaeif $3 sone] wor; 73 | 90 Tr elon] © erat OH oe aoe $3 weve] + 28 28) ee0n mrp mo seer ||} oe 1 TE] Bp zl = = wa} el g ae erin | Sern ort] Le Fen sap] FE 8} oro eee] 24 8 $8) srone i a mye CO | & zz Feo er ' 28 ern were] 2 ! is] lez ' eon wr ' eS wee]; I Se sraism vee] £2 ! Sete weve} I trai Tea | aiioniiiinie St sean pera] | . 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[E28 | a mom f—E) 8} 352 4 mares spe SEE | = 2ge Fama Ee: ila B28 | OSx- | 2a 2 Base a |e 5 gk i etl: wre f 2H |.) | EEE: TrStK= ut a Teal | & 3 | a L2| Tho | | 4 aero Cry fifa | Og |_] “ i S | Aor : 8 =e a ; | a g\g/3 2} ee} | Oy wl ie = : et HE aul ox Om ] | + | a | lq § alas OV | saees Mavis LY- a Svan>) Nn Huny =a) e65-¥ T =a ae =a ——<] Sy TIOANNYA su | | so vow WL meet ==] Nn 330g Sinan € z eK 1x oF a 7 as oy 05x or et zi 1 =}—__—__ Tae ae 3 6V- dhng nour Nevo Lv 08 aausTeL QY— ievo anes OY vorime 12 34-6821 Si essa Tae LiF Sessa OBE Su rong Oz S| Fone oar 5 si} te ») [oe B z vis 7 Ts ca | a 3 tae 4 en * a 3 aT Se TWOoT 4 7 7a 3 a te z = = < Sil -eosss oar 3| “asa > Sh an aos e | a a 3} rar a [pt Ss g C3 5 ud a voy ssn gy aanms eva sin woud TNS TERMINAL DIAGRAM THRUSTER ROOM AZIMUTH THRUSTER BRUNVOLL AS as9E89-%E. uses. TAN ca od so ono WALSAS 231815 [oy amma pine oe 1 s5v-e01N NANT a vavsowe sain | SY TIOANNE cso GNSS? 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I 1 [aw \ [uv aaa i i 1 i | suv eee i i 1 i ‘oan | 1 Yoav ws } i 2Z9-Sa } 1 [ew | site a10-VaHN ' I 1 Pauw = 7 | i 1 i [ww cd = i Le passe al AVS | i i TIOANTYE | SNIND | : : ; ; : ; z z r=| 1989-9 oy a era =p] os mr = st seems Sarno a [ae Sy TIOANTaA “sai | ne wana [oe cay | at ay | gaa ay sours 2s Bas uv a See ins sawowons vanes suv msn eos 3001 Swi HHS ath aly ce wy min ony eaae xy Tara ally ae rae Oy ie ony an suv ey ny ane ay pray zy uae uy ae a rove rae sed Boas HAUSA TIOANTYE é t 3 5| Z989-9E == == =“ =a men = ASUSMBAL HUMAIZ [ay aan mie a ‘Sv TOANTUS Ed CBI 7 = WAISAS ANSWGOYNYW= ae ae a a [=e] ape 1 ee oe oo UGLSMUAL HLNAIZY | gy reams mung son ae cal ayy Sv re a veswa Senin | SY TIOANTEE nese i i i i 2 i ata i Br ! i i i i vouvatazas avast owas snc swiss i i i i i i i i i i i i i i i i i i i i i zest i E910-VHN | zaus 3a i i i i i i i i i TIOANTYS | @ e z °= 0199-7 = ae =a =] ep z on a weiss 190 10108 | ormmmonmes a [en tN sa og 2 TIOANTYE i 6 e & 3 ist > - I z 1oLes Sv TIOANNYS alaldls as of of of on169089 859EE0 OU Ny nea a es Tres [oa mma een ee Wu 02-7 ‘SY -ARCRNOION yonURAG pee ava | < og oo | SW TIOANNYA or _ “a ppg 99/4Sdl ZOLXZOL HILId YOLVIIONI 00z veo ln in O}OJO|O|Ojo} lO} CaO JO}O|OJO|O\O} 96 ww Os, xOudde + yjGua) BI9e9 c6— eenoEs Gaur —= aa a car amas | aes I a wes Yu 02-9 | sy wnceunn » ave ; ‘ 6x98 | s¥ TOANNYE wl a 2 poe 99/4%Sd) ZOLXZOL HLNWIZY YOLWDION! L00Z OVO JOJO|OJO}O}O CaO OO} 96 JOJO|OJOJO|O} ww OgZ xoudde + yjbuay aIge7 26=I LUE SW TIOANNYS Tone atue eS SE O08 Oz mg ee= = eLUe9 s Sv TIOANTES savav ae © @@6Q @l. | ( 2 ® + J SeRBEo go0000 Q) @ 008 | O52 @ On ae | “LL x7 6L89 I a =f = Ta woe] ras fanacar any ‘S¥ TIOANNS | as = Xz ® 00z ® @ @ @ ee O@ a iS=I oswes == > 7 sn wa v | naman | — ia SW TIOANNYS: aes ® ® ® ®@ 7. Fy OO; : & to @E e @ © ® © ® 1 DD ( © fe QA a Ig @2® © @® <8 oe OE ©@ = @) ® es is 2 \ | OOS é® oom 200 Cable Inlet : 410 x 100Site BRUNVOLL Preservation & Storage Instruction for} TK | momourt-ssvoorson | Brunvoll Thruster Units 5.06.012 Prepared by ‘Approved by Tast Revised Date: | Revision Page no: KL ew 09.04.03 A Lof6_ 1, PRESERVATION BY THE VENDOR This description includes Brunvoll A/S preservation and storage regulations for products that are manufactured/supplied by BRUNVOLL. The object of these preservation and storage regulations is to prevent quality deterioration during transport, storage and installation | Products supplied by BRUNVOLL have been preserved against corrosion and packaged to give protection during transport and associated temporary storage. 2. GENERAL INITIAL PRESERVATION ‘The equipment shall be clean and without any corrosion prior to preservation. All exposed surfaces on welded fabrications are cleaned, shot blasted and painted with primer in accordance to specification. Internal surfaces of thruster gear-box and oil reservoirs are shot blasted and painted with Primer. Exposed unpainted and machined surfaces, shafts, flanges and other unpainted surfaces shall be coated with rust preventive of type Rocol 230. Hydraulic fittings/flanges of corrosive material shall be painted. | Note! If there is a risk of equipment (and especially equipment of stainless stee!) being exposed to welding and grinding spatter etc., after initial preservation, it shall be protected with aluminium-sheeted glass fibre cloth or similar fire resistant material. 3, THRUSTER INTERNAL SURFACES Flushing and testing of Thruster unit, Azimuth unit and Hydraulic components (fittings. pipes. hoses, motors, pumps) Special preservation of internal metallic surfaces including flange faces between thruster unit and tunnel/stem is provided for by the use of an oil-based corrosion inhibitor of type Cortec M-529. The unit shall be tested/flushed with clean (cleanliness level shall be equal or better than the requirements during operation) hydraulic oil (operational type) with 2.5% Cortec M-529 added. System to be drained after test/flushing, Hydraulic fittings/flanges of corrosive material shall be painted. If system shall be stored for more than 12 months spray cavity interior with Cortec M-529 concentrate using 0.5 liter per 1m? of enelosed space. The equipment shall be marked with a label indicating that it is protected with vapour corrosion inhibitor lll inlets/outlets on equipment shall be plugged or blanked. Openings (pipes, etc.) into thruster interior ate sealed. Threaded openings shall be plugged with plugs of metal witch is equal to the metal in the threaded opening, Plastic plugs shall be used on non-hydrautic/pneumatic systems when IP rating is maintained. ‘The gearbox sump contains remains of lubricating oil Esso Spartan EP68. This oi approved types of lubricating oil, as specified in BRUNVOLL’s Instruction Manu Maintenance manual). is mixable with other (Operation &«, BRUNVOLL ie a 2 n & Storage Instruction for | BTK ‘od BS orunvouas.crswowoe-nomma’ | Brunvoll Thruster Units 5.06.012 Prepared by: ‘Approved by: Last Revised Date: Page no: KL. KA. 09.04.03 20f6 | 4, THRUSTER EXTERNAL SURFACES 4.1 General on coating system sr and the Buyer, taking into account the Supplier’s standard painting system and the Buyer's, 1g system for the supply. 4.2 Azimuth units In addition to the general initial preservation described in Ch, 2., the following applies. The external surfaces of the stem housing and lifting cylinders are greased with lithium soap based grease and covered with wooden protective matting. The tank top sealing box is filled with calcium-soap grease of type Cazar K2 and exposed surf between sealing box and stem housing are covered with a lithium soap-based grease to prevent ingress of water or other harmfil particles. Alll flange faces, and threaded parts shall be thoroughly cleaned, greased and protected with suitable wooden or other substantial type covering, or plugged, to ensure their full protection. The locking unit spring plates and housing to be coated with lithium soap-based grease in order to prevent corrosion during extended periods of storage. For deliveries where the underwater unit is supplied separately the flange surface between stem and underwater unit is covered with a blinding flange that includes the necessary O-rings to seal the connection. 4.3. Tunnel thruster unit Sce Ch.2 on general initial preservation. When delivered separately, the connection flange between the underwater unit and tunnel is protected with a steel cover that includes necessary O-rings to prevent ingress of water. A steel plate covers blade bolt connection flanges. 5. ELECTRICAL CABINETS AND EQUIPMENT All electrical and electronic components, junction boxes, ventilated cabinets and feedback units with enelosed cavities shall be protected against moisture using vapor corrosion inhibitor Emitter of type Cortee VpCI-101to be used for volume up to 28 liters, VpCI-105 for volume up to 140 | liters, VpCI-110 for volume up to 283 liters and VpCI-111 for volume up to 310 liters, | Remote control equipment | The equipment is protected by plastic sheet. | Packaging consists of wooden boxes line ternally with paper/plastic sheets. Driving motors and other equipment Electric motors are painted with colours according to manufacturer standard. Motors with frame size from 400-560 have the rotor locked during transportation. Frame sizes 280-355 have no locking device and should be regularly turned during longer storage periods. Shafis on electrical motors shall be protected with rust preventative Motor is normally shipped on pallet covered with plastic sheet. For oversea wooden case. transport, motor is packed in | Large units such as pump units, hydraulic pumps/motors, system tanks ete., are painted or treated according to manufacturer standard. Inlets and outlets are protected. which can be treated with preservative, are coated with Rocol 730 and/or wrapped in plastic