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MARINVEST Rev.C PTI (EMERGENCY) PROPULSION m/t MARILEE m/t MARIBEL m/t MARI UGLAND m/t MARIANN TECHNICAL

MARINVEST

Rev.C

PTI (EMERGENCY) PROPULSION

m/t MARILEE m/t MARIBEL m/t MARI UGLAND m/t MARIANN

TECHNICAL MANUAL

m/t MARIBEL m/t MARI UGLAND m/t MARIANN TECHNICAL MANUAL Rev.   Date Sign. A Issued for

Rev.

 

Date

Sign.

A

Issued for internal review

2008-08-20

MHJ

B

Issued as final version

2008-09-29

MHJ

C

First published version, printed as PDF

2008-10-28

MHJ/RKA

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Table of CONTENTS 1. TECHNICAL DESCRIPTION 1.1 Introduction 1.2 Main components 1.3 Running of PTI

Table of CONTENTS

1. TECHNICAL DESCRIPTION

1.1

Introduction

1.2

Main components

1.3

Running of PTI system

2. OPERATING INSTRUCTIONS

2.1

m/t MARILEE (nb 448) & m/t MARIBEL (nb 449)

2.2

m/t MARI UGLAND (nb 450) & m/t MARIANN (nb 451)

3. FAULT ACTION LIST

3.1

Mechanical parts

3.2

Hydraulic part

3.3

Electrical parts

4. MAINTENANCE INSTRUCTIONS & SCHEDULES

5. PARTS LIST

5.1

m/t MARILEE (nb 448)

5.2

m/t MARIBEL (nb 449)

5.3

m/t MARI UGLAND (nb 450)

5.4

m/t MARIANN (nb 451)

1. TECHNICAL DESCRIPTION 1.1 INTRODUCTION What is a PTI? A PTI (Power take in) is

1. TECHNICAL DESCRIPTION

1.1

INTRODUCTION

What is a PTI?

A PTI (Power take in) is a system that allows propulsion of the vessel even when the Main Engine

(ME) power is not available. In this system this is done by utilizing the hydraulic power available from the FRAMO cargo and ballast system. A short PPT presentation is available here

Why a PTI? The PTI system is designed and built for two main purposes. 1) Emergency propulsion

In case of damage to the Main Engine the PTI can be connected and used as a “Take Me Home”

device. The speed in calm waters is then about 9-10 knots depending on load condition, and simulations have shown that the vessel can be manoeuvred in Sea states up to Beaufort 7 (about 16

m/s wind and 3.5 m waves, see SSPA Report 2005 3834-1: Panamax tanker P1013 – Investigation of manoeuvrability in wind and waves for reduced power). In flat water the vessel can manoeuvre in winds over 20 m/s.

2) Possibility to do maintenance during cargo operations Most terminals demand that the vessel shall be able to leave the terminal by its own power within 15 minutes during cargo operations. With the PTI system this can be fulfilled, and thereby giving the option of maintenance of the Main Engine while alongside.

How is it done? The propeller shaft is disconnected from the Main engine by the Disconnector. The propeller thrust

is still transmitted to the ME thrust pads through roller bearings in the Disconnector that transmit

the thrust.

A PTI is connected to the shaft aft of the Disconnector. The PTI is built up with Hydromotors that

take their power from the FRAMO systems. They drive the propeller shaft via a system of chains and a sprocket wheel connected to the shaft.

1.2 MAIN COMPONENTS This is just a brief description of the main components. Operating instructions

1.2 MAIN COMPONENTS

This is just a brief description of the main components. Operating instructions are found in chapter

2.

components. Operating instructions are found in chapter 2. Figure 1.0: PTI System overview. Hydraul ic piping

Figure 1.0: PTI System overview. Hydraulic piping omitted for clarity.

Disconnector The disconnector transmits the propeller thrust by means of two spherical roller bearings. Between

Disconnector The disconnector transmits the propeller thrust by means of two spherical roller bearings. Between the disconnector and the shaft flange there is a gap of 5 mm. The shaft torque in normal mode of operation will be transmitted across the gap by means of 10 cylindrical dowels fitted radially in grooves in each flange surface. The flange bolts are not fitted bolts but have a liberal radial play. When the bolts have been tightened the shaft torque in normal drive mode is being transmitted across the gap by shear forces in the radial dowels. When the nuts of the flange bolts have been released the bolts can easily be unscrewed by hand. There will be no problems like withdrawal of fitted bolts. After the radial dowels have been removed the propeller is free from the main engine and may be rotated by means of the hydraulic motors.

and may be rotated by means of the hydraulic motors. Figure 1.1: Disconnector and forward in

Figure 1.1: Disconnector and forward intermediate shaft, making up the disconnecting unit. To the left also the Banana flange, the Sprocket wheel and the Aft intermediate shaft can be seen

Hydromotors with chain wheels The hydromotors get their hydrauli c power from the FRAMO system

Hydromotors with chain wheels The hydromotors get their hydraulic power from the FRAMO system. They are set in a foundation that is bolted and welded to the tank top. A spline shaft with the chain wheel is fitted to transmit the power to the Sprocket wheel.

eel is fitted to transmit the power to the Sprocket wheel. Figure 1.2: Hydromotor fitted inside

Figure 1.2: Hydromotor fitted inside foundation, mainly the valves and the chain wheel are seen.

Sprocket wheel with chain wheels and chains The sprocket wheel is bolted to the Aft intermediate shaft (via the banana flange) when the PTI is to be run.

shaft (via the banana flange) when the PTI is to be run. Figure 1.3: Sprocket wheel

Figure 1.3: Sprocket wheel seen from aft. The triangular pieces inside the sprocket wheel houses the alignment bolts that centres the sprocket wheel on the shaft

Banana flange To be able to fit the Sprocket wheel to the interm ediate shaft

Banana flange To be able to fit the Sprocket wheel to the intermediate shaft in any position the holes for the bolts are elongated. This means it is always possible to fit ten bolts to fix the sprocket wheel to the shaft.

to fit ten bolts to fix the sprocket wheel to the shaft. Figure 1.4: Banana flange.

Figure 1.4: Banana flange. To see how it is fitted to the system see figure 1.

Cradle When the sprocket wheel is not in use it is lowered down about 20 mm and resting on a cradle fitted on the tank top.

about 20 mm and resting on a cradle fitted on the tank top. Figure 1.5: Cradle

Figure 1.5: Cradle with the Sprocket wheel resting on top.

Shaft locking device In cases when there is bad weathe r the shaft may start

Shaft locking device In cases when there is bad weather the shaft may start to rotate when it is disconnected from the Main Engine. Therefore a shaft locking device is fitted on the aft intermediate shaft to prevent it from rotating during the shifting to or from PTI mode.

it from rotating during the shif ting to or from PTI mode. Figure 1.6: Shaft locking

Figure 1.6: Shaft locking device. The link with the handle to the left is fitted to one of the key holes on the plate fitted to the shaft. A similar link is fitted on the other side of the shaft to lock it in the opposite direction as well.

Control cabinet in ER The control cabinet is used to c ontrol the running of

Control cabinet in ER The control cabinet is used to control the running of the PTI and for giving/receiving orders from the bridge.

the PTI and for giving/receiving orders from the bridge. Figure 1.7: Signal unit on the bridge

Figure 1.7:

Signal unit on the bridge The signal unit on the bridge is used for giving/receiving orders from the Engine Room. There is also a pressure transmitter showing the system pressure in the FRAMO system.

showing the system pressure in the FRAMO system. Figure 1.8: Signal unit at bridge For detailed

Figure 1.8: Signal unit at bridge

For detailed description, parts lists and drawings of all components see chapter 5.

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1.3 RUNNING OF PTI SYSTEM Below is a short summary descrip tion of how the

1.3 RUNNING OF PTI SYSTEM

Below is a short summary description of how the system is run. The full procedure for running the system is available in the Operation instructions, Chapter 2.

A) Setting up of Disconnector and PTI

There are two (2) main things to do in ER

1)

Open Disconnector, see Operating instructions, Chapter 2

2)

Connect Sprocket wheel to the shaft, see Operating instructions, Chapter 2.

1 and 2 can be done simultaneously if sufficient staff is available. This will reduce the time needed for connection

B) Running

START UP IN E.R.

a) Start up power packs with system pressure set to minimum (done in CCR with the “main

pressure set” regulator), open main valve in the Power-pack hydraulic room.

b) Start the rotation of the propeller at cabinet in ER.

c) Increase system pressure to maximum setting

d) During operation there shall always be at least one person with knowledge about the system

close to the PTI and control cabinet.

For detailed instruction, see Operating instructions, Chapter 2.

NOTE: Normally the FRAMO system is used for the Cargo/Ballast pumps. In this case you set an operating pressure. The system keeps this pressure by regulating the flow of hydraulic oil from the Powerpacks (PP). The cargo/ballast pumps never use the full capacity of the PP system if a sufficient number of pumps are started.

Since the control of the speed of cargo/ballast pumps is done by reducing the pressure to the pump with the valve at the pump stack there will be a pressure drop over the valve creating heat losses that have to be cooled away. Therefore the instruction is that you should just set the system pressure slightly higher than the pressure really needed at the pumps to minimize losses

The PTI, on the other hand, normally utilizes the full flow of the FRAMO system. When the propeller rotates the water around it will create a resistance, even when the Pitch is set to zero. This resistance creates a torque that has to be overtaken by the hydromotors, which then gives a pressure in the system. With all PP running this pressure of about 110 bar when the Pitch=0 see figure 1.9. The pressure will increase as the Pitch is increased. CAUTION: The FRAMO Power-Pack system must have minimum 50 bar working pressure. If the pressure drops, the admission valve will close partly to keep the pressure above 50 bar. This regulation causes a pressure drop over the valve, creating heat that will have to be cooled away by the FRAMO system (with 2 pumps running this heat is more than 100 kW). If at least 5 Power- Packs are running (45 RPM in the diagram, fig 1.9) the pressure will always be more than 50 Bar and no cooling is needed. Therefore, if possible start all PP pumps (or at least 5) before starting to run.

With all 7 pumps running the shaft speed will be about 63-64 RPM.

Figure 1.9: System pressure in Bar as function of propeller RPM. Pressure will not go

Figure 1.9: System pressure in Bar as function of propeller RPM. Pressure will not go above 250 Bar, so excessive Pitch will result in dropping RPM

RUNNING THE VESSEL FROM THE BRIDGE When the PTI is running the Captain can start using the system. This is done by adjusting the Pitch setting. As pitch is increased, the pressure in the Framo system will also increase. The PTI system is designed for a Pitch setting of up to about 8 on the handle. There is no limit to the Pitch setting, so if a too high Pitch is set with the handle the system will be overloaded. In this case the pressure reaches its maximum value and the FRAMO system will reduce the flow to avoid overpressure. This is done automatically and there is no risk of damaging the system. However, with the RPM going down the available power will be reduced. It is therefore important for the Captain to keep an eye on the RPM and system pressure. If the pressure reaches the maximum limit and the RPM goes down, the pitch has to be slightly reduced. To get the maximum power out of the system the pressure shall be kept as close as possible to the maximum without loss of RPM. This is a manual task that has to be done from the bridge by adjusting the Pitch. For manoeuvring back/forward etc the only thing that has to be done is adjusting the Pitch Normally a Pitch setting of about 5-6 will work when the vessel lies still on the water. As speed increases the load on the propeller decreases and the Pitch setting can slowly be increased. Also see figure 1.9.

STOPPING THE SYSTEM When the running with the PTI is to be stopped it should be done in accordance with the Operating instructions. The vessel should if possible be lying still in the water, the Pitch is set to zero, the system pressure is reduced in the CCR and the system is stopped at the cabinet in the ER. The stopping will be done over a time period, slowing down the propeller over a period of about 45 seconds. This is to avoid that the inertia in the system starts to drive the Hydraulic motors, “windmilling”. Windmilling may in severe cases cause damages to the Hydraulic motors.

2. OPERATING INSTRUCTIONS There are some minor differences in th e design of MARILEE/MARIBEL compared

2. OPERATING INSTRUCTIONS

There are some minor differences in the design of MARILEE/MARIBEL compared to MARI UGLAND/MARIANN. The differences are mainly on the Disconnector design, namely the bolts which separate the Disconnector from the short intermediate shaft connecting the ME flywheel to the Disconnector. MARILEE/MARIBEL uses 10 hydraulic nuts (M80) together with a high pressure hydraulic pump. MARI UGLAND/MARIANN uses 20 hexagon bolts (M42) together with a pneumatic torque multiplier. For this reason, there are two different Operating instructions as below.

2.1 Operating Instructions for MARILEE (nb 448) & MARIBEL (nb 449) CE = Chief Engineer

2.1 Operating Instructions for MARILEE (nb 448) & MARIBEL (nb 449) CE = Chief Engineer Pos.numbers refer to illustrations in appendix attached to this Instruction

 

START OF PTI:

1

Turning gear “IN” and Air master valve “CLOSED”. Start of Main engine is now blocked.

2

FRAMO system to be in operation. (2 pumps when “inching”, minimum 5 pumps when running)

3

Open gratings above PTI.

4

Decision to engage Shaft locking devices, pos.3, or not. (depending on weather).

5

Separating bolts (4xM24), pos.5, on the Disconnector to be tightened until contact with the Disconnector main body.

 

Paragraph 6 & 7 can be carried out simultaneously by two teams to reduce the setup time.

6

Disconnector to be opened:

a)

All hydraulic nuts (10 pcs), pos.19, to be removed acc. to separate instruction, using high pressure hoses, pos.20, and hydraulic pump unit, pos.21 (see manual). The hydraulic circuit is terminated via the end-plug, pos.22. M80 bolts (10 pcs.), pos.6, to be unscrewed. Applied hydraulic pressure shall be 1750 bar corresponding to axial pretension of the bolts equal to 1400 kN /bolt. Note: To remove the hydraulic nuts, an “over-lift” of approx. 6% will be required. This means, the required pressure for removal of the nuts will be approx. 1850 bar.

b)

Remove the dowel securing devices (10 pcs.), pos.4, and stow the loose parts in the designated box or shelf.

c)

Tighten the separation bolts (4xM24), pos.5, so that the gap increases about 0,3 mm. (Total gap is then 5,3 mm.)

d)

Remove the dowels (10 pcs.), pos.2, if necessary using the withdrawing tool.

e)

Remove the alignment bolts (2xM36), pos.7. Stow them in its designated stowage place.

f)

Unscrew the separation bolts (4xM24) , pos.5, 5 turns.

7

Sprocket wheel cylinder, pos.8, to be lifted and centered on the intermediate shaft:

a)

Remove the securing strap.

b)

Check that the bolts of the Alignment devices, pos.9, which are in position “4 o’clock” and “8 o’ clock” are fully tightened.

c)

Lift the cylinder, using the hydraulic jack, pos.1,until the Alignment devices, pos.9, are in contact at “4 o’clock” and “8 o’ clock”. Indication light: “Sprocket wheel lifted”.

d)

Tighten the “12 o’clock” bolts of the Alignment devices, pos.9.

e)

Ensure all six bolts of the Alignments devices are tightened hard and in contact with the intermediate shaft.

f)

Fit bolts M42 (10 pcs.), pos.10 & pos.11, engaging the sprocket wheel cylinder to the Banana flange, pos.12. Distance rings, pos.13, t=20 mm, to be fitted in the gap. Bolts to be lightly tightened.

8

Disengage the Shaft locking devices, pos.3, (if engaged).

9

Open hydraulic Master supply valve (manually). Indication light: “OPEN”. Check OPEN position for oil supply valve from FRAMO system tank.

10

Turn the Main switch, pos.14, to “PTI”. Chief engineer thereafter keeps the key in his pocket. Flushing oil pump starts automatically, cooling water supply opens automatically.

11 Test the PTI operation by opening the Inching valve, pos.15 , manually and see

11

Test the PTI operation by opening the Inching valve, pos.15, manually and see that the shaft rotates slowly and smoothly. Bolts in the Banana flange will slip in the slots and will eventually reach end stop. This is a normal procedure. Now tighten the M42 bolts, pos.11, with Torque: 3640 Nm

12

In the ECR, change KaMeWa-switch to “Constant RPM-On”.

 

Using the Telegraph:

 

13

Give signal to bridge: “I am ready to start”. Inform the bridge that RPM will now be kept constant and that the bridge is in charge of propeller pitch.

14

Await clearance from bridge “Starting is now allowed”.

15

Start the PTI by pressing “I am starting PTI”. A built in ramp will limit the acceleration time to 30 sec. to full RPM. The bridge can now manoeuvre with the propeller pitch to obtain desired speed.

16

To be noticed:

 

a)

There is a linear function between no. off hydraulic pumps in operation and max obtainable RPM.

1

pump = 9 rpm

(Inching only!)

2

pumps = 18 rpm

(Inching only!)

5

pumps = 45 rpm

7

pumps = 63 rpm

Normally, all pumps shall be in operation.

 

b)

Oil drip from the safety valve of the Disconnector is normal after PTI being in operation for

a long period of time due to rise in Chapter 4.

For oil level check and possible refill see

c)

Hydraulic oil pressure shall be stable. Check regularly.

d)

Check for not “stalling” the system. (RPM is dropping because of too high pitch). Captain to be informed.

 

STOP OF PTI:

 

17

Bridge telegraphs “STOP PTI”

 

18

CE orders to CCR: reduce FRAMO system pressure to 60 bar.

19

CE orders bridge to set pitch at “Zero”

 

20

Press button “PTI STOP”. RPM will now reduce to zero over a period of approx. 45 sec.

21

In the ECR, change KaMeWa-switch to “Constant RPM-Off”

22

Use the inching valve, pos.15, and turn the Sprocket wheel cylinder, pos.8, so that two alignment devices, pos.9, (one fwd & one aft) are positioned “twelve o’clock”.

23

CE stops PTI operation by turning the Main switch, pos.14, to “Normal” and keeps the key in his pocket.

24

Close hydraulic Master supply valve (manually). Indication light: “CLOSED”. FRAMO power packs can now be stopped.

25

Engage the Shaft locking devices, pos.3, if deemed necessary.

26

Sprocket wheel cylinder, pos.8, to be lowered, resting in its cradle:

a)

Remove flange bolts M42, pos.10 & pos.11, (10 pcs.) disengaging the sprocket wheel cylinder from to the Banana flange. Distance rings, pos.13, t=20 mm, to be stored in a designated shelf.

b) Retract, 5 turns, and secure the two (one fwd & one aft) alignment devices,

b)

Retract, 5 turns, and secure the two (one fwd & one aft) alignment devices, pos.9, which are positioned “twelve o’clock”. The Sprocket wheel cylinder will now rest in its cradle. The indication light “Sprocket wheel lifted” will go out.

c)

Attach the securing strap.

27

Disconnector to be closed:

a)

Turn the Main engine, using the turning gear, so that the holes for the alignment bolts, pos.7, come in line. Align the joint of the Disconnector by attaching the alignment bolts.

b)

Mount the dowels, pos.2, and secure them. Note!: There is an individual number marked on each dowel, corresponding to same number/position of the dowel-pocket in the Disconnector.

c)

M80 bolts (10 pcs.), pos.6, to be fixed.

d)

All hydraulic nuts (10 pcs), pos.19, to be fixed acc. to separate instruction, using high pressure hoses, pos.20, and hydraulic pump unit, pos.21. The hydraulic circuit is terminated via the end-plug, pos.22. Applied hydraulic pressure shall be 1750 bar corresponding to axial pretension of the bolts equal to 1400 kN /bolt.

28

CE checks that all Disconnector bolts are properly fitted and tightened, that the sprocket wheel cylinder is free from the shaft and is resting in its cradle with the securing strap fitted.

29

Add grease to the Disconnector stuffing box.

30

Disengage the Shaft locking devices, pos.3, (if fitted).

31

Turning gear “OUT” and Air master valve “OPENED”. Start of Main engine is now possible.

32

The main engine may now be started. Keep the PTI sprocket wheel cylinder and other mechanical parts under observation during start to make sure that everything is clear of any obstructions.

 

EMERGENCY STOP OF PTI FROM OPERATION CABINET, POS.16 :

33

Emergency stop is a drastic measure and shall never be tried just for the exercise. There may occur windmilling of the propeller causing undesired hydraulic shocks which may be damaging to the hydraulic system.

34

If absolutely necessary to perform an emergency stop:

a)

Press button “EMERGENCY STOP”, pos.17. The hydraulic valve will close over a short period (abt. 10 sec.) governed by hydraulic damping. During retardation there may occur hammering in the hydraulic motors and cavitations in the hydraulic system.

b)

The propeller pitch shall automatically go to zero. If this is not the case, assist the pitch to zero at the KaMeWa stand.

35

Resume service as described above.

 

FRAMO SYSTEM EMERGENCY STOP:

36

As an alternative way to make an emergency stop, the FRAMO system emergency stop may be used. Using the FRAMO system emergency stop not only stops the PTI functions but also stops the entire FRAMO system. For the rest, the cautions and procedures are the same as for an emergency stop from the operation cabinet.

 

IMPORTANT!

37

Never ever try to start the Main engine with the Disconnector open. The ME governor will not be able to control RPM sufficiently fast and serious damages may occur

Figure 2.1.1 Figure 2.1.2 18

Figure 2.1.1

Figure 2.1.1 Figure 2.1.2 18

Figure 2.1.2

Figure 2.1.3 Figure 2.1.4 19

Figure 2.1.3

Figure 2.1.3 Figure 2.1.4 19

Figure 2.1.4

Figure 2.1.5 Figure 2.1.6 20

Figure 2.1.5

Figure 2.1.5 Figure 2.1.6 20

Figure 2.1.6

Figure 2.1.7 Figure 2.1.8 21
Figure 2.1.7
Figure 2.1.7

Figure 2.1.8

Figure 2.1.7 Figure 2.1.8 21
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2.2 Operating Instructions for MARI UGLAND (nb 450) & MARIANN (nb 451) CE = Chief

2.2 Operating Instructions for MARI UGLAND (nb 450) & MARIANN (nb 451) CE = Chief Engineer Pos.numbers refers to illustrations in appendix attached to this Instruction

 

START OF PTI:

38

Turning gear “IN” and Air master valve “CLOSED”. Start of Main engine is now blocked.

39

FRAMO system to be in operation. (2 pumps when “inching”, minimum 5 pumps when running)

40

Open gratings above PTI.

41

Decision to engage Shaft locking devices, pos.3, or not. (depending on weather).

42

Separating bolts (4xM24), pos.5, on the Disconnector to be tightened until contact with the Disconnector main body.

43

Arrange suspension (counter-weighted), pos.24, for the pneumatic torque multiplier, pos.23.

 

Paragraph 44& 45 can be carried out simultaneously by two teams to reduce the setup time.

44

Disconnector to be opened:

a)

M42 bolts (20 pcs.), pos.25, to be unscrewed and removed using the pneumatic torque multiplier, pos.23. VARNING: Be cautious when handling the machine, avoiding jamming fingers or hands under the counteracting lever. Please read operating instructions for the machine prior to start using it.

b)

Remove the dowel securing devices (10 pcs.), pos.4, and stow the loose parts in the designated box or shelf.

c)

Tighten the separation bolts (4xM24), pos.5, so that the gap increases about 0,3 mm. (Total gap is then 5,3 mm.)

d)

Remove the dowels (10 pcs.), pos.2, if necessary using the withdrawing tool.

e)

Remove the alignment bolts (2xM36), pos.7. Stow them in its designated stowage place.

f)

Unscrew the separation bolts (4xM24) , pos.5, 5 turns.

45

Sprocket wheel cylinder, pos.8, to be lifted and centered on the intermediate shaft:

a)

Remove the securing strap.

b)

Check that the bolts of the Alignment devices, pos.9, which are in position “4 o’clock” and “8 o’ clock” are fully tightened.

c)

Lift the cylinder, using the hydraulic jack, pos.1,until the Alignment devices, pos.9, are in contact at “4 o’clock” and “8 o’ clock”. Indication light: “Sprocket wheel lifted”.

d)

Tighten the “12 o’clock” bolts of the Alignment devices, pos.9.

e)

Ensure all six bolts of the Alignments devices are tightened hard and in contact with the intermediate shaft.

f)

Fit bolts M42 (10 pcs.), pos.10 & pos.11, engaging the sprocket wheel cylinder to the Banana flange, pos.12. Distance rings, pos.13, t=20 mm, to be fitted in the gap. Bolts to be lightly tightened.

46

Disengage the Shaft locking devices, pos.3, (if engaged).

47

Open hydraulic Master supply valve (manually). Indication light: “OPEN”. Check OPEN position for oil supply valve from FRAMO system tank

48

Turn the Main switch, pos.14, to “PTI”. Chief engineer thereafter keeps the key in his pocket. Flushing oil pump starts automatically, cooling water supply opens automatically.

49

Test the PTI operation by opening the Inching valve, pos.15, manually and see that the shaft rotates slowly and smoothly. Bolts in the Banana flange will slip in the slots and will eventually reach end stop. This is a normal procedure. Now tighten the M42 bolts, pos.11, with Torque: 3640 Nm

50

In the ECR, change KaMeWa-switch to “Constant RPM-On”.

  Using the Telegraph:   51 Give signal to bridge: “I am ready to start”
 

Using the Telegraph:

 

51

Give signal to bridge: “I am ready to start”. Inform the bridge that RPM will now be kept constant and that the bridge is in charge of propeller pitch.

52

Await clearance from bridge “Starting is now allowed”.

53

Start the PTI by pressing “I am starting PTI”. A built in ramp will limit the acceleration time to 30 sec. to full RPM. The bridge can now manoeuvre with the propeller pitch to obtain desired speed.

54

To be noticed:

 

a)

There is a linear function between no. off hydraulic pumps in operation and max obtainable RPM.

1

pump = 9 rpm

(Inching only!)

2

pumps = 18 rpm

(Inching only!)

5

pumps = 45 rpm

7

pumps = 63 rpm

Normally, all pumps shall be in operation, minimum 5 pumps.

b)

Oil drip from the safety valve of the Disconnector is normal after PTI being in operation for a long period of time due to rise in temperature. For oil level check and possible refill see Chapter

4.

c)

Hydraulic oil pressure shall be stable. Check regularly.

d)

Check for not “stalling” the system. (RPM is dropping because of too high pitch). Captain to be informed.

 

STOP OF PTI:

 

55

Bridge telegraphs “STOP PTI”

56

CE orders to CCR: reduce FRAMO system pressure to 60 bar.

57

CE orders bridge to set pitch at “Zero”

58

Press button “PTI STOP”. RPM will now reduce to zero over a period of approx. 45 sec.

59

In the ECR, change KaMeWa-switch to “Constant RPM-Off”

60

Use the inching valve, pos.15, and turn the Sprocket wheel cylinder, pos.8, so that two alignment devices, pos.9, (one fwd & one aft) are positioned “twelve o’clock”.

61

CE stops PTI operation by turning the Main switch, pos.14, to “Normal” and keeps the key in his pocket.

62

Close hydraulic Master supply valve (manually). Indication light: “CLOSED”. FRAMO power packs can now be stopped.

63

Engage the Shaft locking devices, pos.3, if deemed necessary.

64

Sprocket wheel cylinder, pos.8, to be lowered, resting in its cradle:

a)

Remove flange bolts M42, pos.10 & pos.11, (10 pcs.) disengaging the sprocket wheel cylinder from to the Banana flange. Distance rings, pos.13, t=20 mm, to be stored in a designated shelf.

b)

Retract , 5 turns, and secure the two (one fwd & one aft) alignment devices, pos.9, which are positioned “twelve o’clock”. The Sprocket wheel cylinder will now rest in its cradle. The indication light “Sprocket wheel lifted” will go out.

c)

Attach the securing strap.

 
65 Disconnector to be closed: a) Turn the Main engine, usi ng the turning gear,

65

Disconnector to be closed:

a)

Turn the Main engine, using the turning gear, so that the holes for the alignment bolts, pos.7, come in line. Align the joint of the Disconnector by attaching the alignment bolts.

b)

Mount the dowels, pos.2, and secure

Note!: There is an individual number marked on

each dowel, corresponding to same number/position of the dowel-pocket in the Disconnector.

c)

M42 bolts (20 pcs.), pos.25, to be fixed using the pneumatic torque multiplier, pos.23. Applied torque shall be 3640 Nm. Calibrate and check against calibration-graph. VARNING: Be cautious when handling the machine, avoiding jamming fingers or hands under the counteracting lever. Please read operating instructions for the machine prior to start using it

66

CE checks that all Disconnector bolts are properly fitted and tightened, that the sprocket wheel cylinder is free from the shaft and is resting in its cradle with the securing strap fitted.

67

Add grease to the Disconnector stuffing box.

68

Disengage the Shaft locking devices, pos.3, (if fitted).

69

Turning gear “OUT” and Air master valve “OPENED”. Start of Main engine is now possible.

70

The main engine may now be started. Keep the PTI sprocket wheel cylinder and other mechanical parts under observation during start to make sure that everything is clear of any obstructions.

 

FRAMO SYSTEM EMERGENCY STOP FROM OPERATING CABINET, POS.16:

71

Emergency stop is a drastic measure and shall never be tried just for the exercise. There may occur windmilling of the propeller causing undesired hydraulic shocks which may be damaging to the hydraulic system.

72

If absolutely necessary to perform an emergency stop, the FRAMO system emergency stop, pos. 17, may be used. Using the FRAMO system emergency stop not only stops the PTI functions but also stops the entire FRAMO system

 

IMPORTANT!

73

Never ever try to start the Main engine with the Disconnector open. The ME governor will not be able to control RPM sufficiently fast.

Figure 2.2.1 Figure 2.2.2 26

Figure 2.2.1

Figure 2.2.1 Figure 2.2.2 26

Figure 2.2.2

Figure 2.2.3 27

Figure 2.2.3

Figure 2.2.4 28

Figure 2.2.4

Figure 2.2.5 Figure 2.2.6 29
Figure 2.2.5
Figure 2.2.5

Figure 2.2.6

Figure 2.2.5 Figure 2.2.6 29
3. FAULT ACTION LIST 3.1 MECHANICAL PARTS The mechanical parts of the PTI equipment ar

3. FAULT ACTION LIST

3.1 MECHANICAL PARTS

The mechanical parts of the PTI equipment are indeed robust. Any break-down, fatigue or malfunction on the mechanical parts can not be foreseen. However, following mechanical parts may be listed as “essential items” as they are the backbone of the PTI system.:

ITEM

Consequence following casualty

Recommended

Remarks

spare part

Chain

PTI can not be operated

No

Immediate stop of PTI.

Spherical roller bearings in Disconnector

PTI can not be operated

No

Immediate stop of PTI. See Note.1 below.

Hagglund’s hydro motors

PTI can not be operated

No

Immediate stop of PTI. See Note.2 below.

Note 1.: Check of oil level + oil analysis every 12 month. Audible control, using stethoscope, regularly. Note 2.: Refer to:

Hagglund Installation and Maintenance Manual Compact CB

20060809110318A_en683.pdf

for fault action.

3.2 HYDRAULIC PARTS

ITEM

Consequence following casualty

Recommended

Remarks

spare part

Hydraulic nuts for flange bolts

Disconnector can not be opened/closed.

1 piece

NB 448/449 only.

Hoses for

Disconnector can not be opened/closed.

1 piece

NB 448/449 only.

hydraulic nuts

Hydr. high

Disconnector can not be opened/closed

1 piece

NB 448/449 only

pressure pump

Oil flushing pump for PTI power failure

PTI can not be operated

No

Check “Lub and fuel oil consumers D.B.” fuse FU37-39 and thermal protection

QS13

Hydraulic hoses for hydro motors. Hose failure.

Admission valve will gradually close (approx. 60 sec,). (Or, FRAMO system will stop due to low oil level in system tank, whichever comes first.)

1

pc of hose:

This spare hose is universal i.e can be used in any position.

R42-32, 2’’ L=6000 mm

 

1 pc K6AV6-32-32

 

1 pc K6NV6-32-32

Oil flushing pump for PTI. Oil supply from suction side.

Valves (2 pcs.; one on FRAMO system tank, one mounted on the pump) must always be OPEN. Else, pump will break down.

No

These valves need never to be closed – always in OPEN position.

Oil flushing pump for PTI, oil pressure drop. Hydro motors not properly cooled. Hydro motors

Oil flushing pump for PTI, oil pressure drop.

Hydro motors not properly cooled. Hydro motors may over-heat

No

Check outgoing pressure on gauge point placed directly on pump. Correct pressure: 4-5 bar.

Heat exchanger – cooling water for Oil flushing pump for PTI.

Valves (2 pcs. water In- and Out) must always be Open. Else, hydro motors may over- heat.

No

These valves need never to be closed – always in OPEN position.

Shock valve for Hägglunds hydro motors

 

1 piece

Art.no. 903001-0528

Pilot valve for relief valve

 

1 piece

Art.no. CE080 NG 80

Filter unit for Oil flushing system.

 

1 piece

Art.no.

0660D020BNHC

3.3 ELECTRICAL PARTS

ITEM

Consequence following casualty

Recommended

Remarks

spare part

PTI system control cabinet power failure

PTI can not be operated

No

Check “power distribution board A24-A24.2” , fuse QF36, 10A

PLC (in operating cabinet)

PTI can not be operated

1 piece

Pre-programmed PROM to be included.

Circuit board 4-20 mV for analogue output

PTI can not be operated

1 piece

Control of Master supply valve.

Circuit board 4-20 mV for analogue input

PTI can not be operated

1 piece

Recording of hydraulic pressure.

Power-pack 10 VDC

PTI can not be operated

1 piece

Feeding potentiometer for RPM control.

Potentiometer for RPM control

PTI can not be operated

1 piece

 

Pressure sensor 0-400 bar

PTI can not be operated

1 piece

There are two identical sensors fitted on the hook- up panel.

Proximity switch – Master supply valve OPEN

PTI can not be operated

1 piece

Can be temporarily fixed using a jumper

Proximity switch – Master supply valve CLOSED

PTI can not be operated

1 piece

Can be temporarily fixed using a jumper

Proximity switch – Sprocket wheel lifted

Alarm on Operating cabinet

1 piece

Can be temporarily fixed using a jumper

Relay in operating cabinet

PTI can not be operated

1 piece

Can be temporarily fixed by switching position in between relays.

4. MAINTENANCE INSTRU CTIONS & SCHEDULES Following parts and items require main tenance as per

4. MAINTENANCE INSTRUCTIONS & SCHEDULES

Following parts and items require maintenance as per indicated schedule:

Task

Periodicity

Check hydraulic hoses for hydro motors for wear and tear.

Before starting up PTI unit.

Check all hydraulic flanges, fittings and couplings for leakage.

Following use of PTI.

Grease Disconnector

Following use of PTI. Approx. 1,0 cm 3

Oil in Disconnector

Oil change every 5:th year Oil level + Analysis every 12 month.

Oil on Chains

Following use of PTI.

Hagglund’s hydro motors

See Hagglund Installation and Maintenance Manual Compact CB 20060809110318A_en683.pdf

Pneumatic torque multiplier nb 450/451

See separate instruction

Manual torque multiplier nb 450/451

See separate instruction

Hydraulic nuts

See separate instruction

nb 448/449

Hydr.high pressure pump nb 448/449

See separate instruction

Exchange of filter unit for Oil flushing system.

Every 24 months.

Exchange of battery for memory back-up, PLC

Every 5:th year, or following alarm from LED on operating cabinet.

Following scheduled activities will be required to safeguard expected lifetime of major components of the system:

MONTHLY ROUTINE FOR AVOIDING BRINELLING IN BEARINGS:

74. Sprocket wheel cylinder is resting in its cradle. Ship is running using the Main engine for propulsion.

75. Retract , 5 turns, and secure the four (two fwd & two aft) alignment devices, pos.9, positioned “4 o’clock” and “8 o’clock”.

76. Open Master supply valve (manually).

77. Remove the securing strap.

78. Reset alarm “Reminder to close master supply valve”.

79. Using the inching valve, turn the sprocket wheel cylinder (which is resting in its cradle) 120 degrees so that next alignment device reach the “twelve o’clock” position.

80. Attach the securing strap.

81. Close the Master supply valve (manually).

82. Tighten the “4 o’clock” and “ 8 o’clock” bolts of the Alignment devices, pos.9.

MONTHLY ROUTINE FOR FLUS HING HYDRAULIC MOTORS: 83. Check OPEN position for oil supply valve

MONTHLY ROUTINE FOR FLUSHING HYDRAULIC MOTORS:

83. Check OPEN position for oil supply valve from FRAMO system tank.

84. On the starting box for the Flushing pump, turn the switch to “LOCAL”

85. Start the Flushing pump manually from the starting box.

86. Flush the system for 10 minutes.

87. Stop the Flushing pump

88. Turn the switch on the starting box to “REMOTE”

This page is intentionally left blank 34

This page is intentionally left blank

5. PARTS LIST There are some minor differences in th e design of MARILEE/MARIBEL compared

5. PARTS LIST

There are some minor differences in the design of MARILEE/MARIBEL compared to MARI UGLAND/MARIANN. This means, the drawings differ slightly and so do the mechanical-, hydraulic-, and electrical parts.

In brief, the components of the PTI equipment may be arranged in the following main groups:

Group

Supplier Brodosplit Shipyard Brodosplit Shipyard Marinvest

1.

Intermediate shaft and Disconnector shaft

2.

Disconnector

3.

Sprocket, Banana flange, Sprocket wheel disc & Splines shaft

4.

Chains

Vittsjö Mekaniska Verkstad – Sweden Marinvest Marinvest Hagglunds Marinvest Marinvest Marinvest Callenberg Engineering - Sweden Luna/Tentec–Sweden (NB 448 & 449) Luna/Norbar–Sweden (NB 450 & 451) Luna/Norbar–Sweden (NB 450 & 451)

5.

Cradle for sprocket

6.

Foundation for hydro motor

7.

Hydro motors

8.

Shaft locking device

9.

Hydraulic jack for sprocket

10.

Hydraulic system

11.

Electrical system

12.

Hydraulic nuts

13.

Pneumatic Torque Multiplier

14

Manual Torque Multiplier

5.1 m/t MARILEE (nb 448) Group Item No.off   Drawing 1 Intermediate shaft & Disconnector

5.1 m/t MARILEE (nb 448)

Group

Item

No.off

 

Drawing

1

Intermediate shaft & Disconnector shaft

   

1

01-634-403 rev.A

2

Disconnector Assembly

   

1

026-00008293-4

-

details and parts referred from Assembly drawing

 

3

Sprocket, Banana flange, Sprocket wheel disc

 

1

set

101-1 rev.C; 102-1 rev.B 103-1 rev.C

 

&

Splines shaft

(Assembly drawings)

 

4

Chain (1x49 links+1x 49 link+connect.link)/hydro motor

   

4

Duplex ISO 48B-2; 3’’ pitch

5

Cradle for sprocket

   

1

401-1 rev.B

-

details and parts referred from Assembly drawing

   

6

Foundation for hydro motor (2xLeft + 2x Right)

 

2+2

1016-Foundation-PTI

7

Hydro motor, Hagglund type CB400-360 SA0N0, with splines

 

4

0785007

rev.C

8

Shaft locking device

   

1

3001-B-Shaft locking device

9

Hydraulic jack for sprocket

   

1

701-1 rev.A

10

Hydraulic system

   

1

2-0107 ed.1

   

Spec-Marinvest-448

11

Electrical system

   

1

Draw.no’s beginning with:

   

no. 5454304

12

Hydraulic nuts at Disconnector

 

10

Tentec Art.no. TCHN:0080

5.2 m/t MARIBEL (nb 449)

Group

Item

No.off

 

Drawing

1

Intermediate shaft & Disconnector shaft

   

1

01-634-403 rev.A

2

Disconnector Assembly

   

1

026-00008293-4

-

details and parts referred from Assembly drawing

 

3

Sprocket, Banana flange, Sprocket wheel disc

 

1

set

101-1 rev.E; 102-1 rev.D 103-1 rev.D

 

&

Splines shaft

(Assembly drawings)

 

4

Chain (1x49 links+1x 49 link+connect.link)/hydro motor

   

4

Duplex ISO 48B-2; 3’’ pitch

5

Cradle for sprocket

   

1

401-1 rev.C

-

details and parts referred from Assembly drawing

   

6

Foundation for hydro motor (2xLeft + 2x Right)

 

2+2

1016-Foundation-PTI

7

Hydro motor, Hagglund type CB400-360 SA0N0, with splines

 

4

0785007

rev.C

8

Shaft locking device

   

1

3001-B-Shaft locking device

9

Hydraulic jack for sprocket

   

1

701-1 rev.A

10

Hydraulic system

   

1

2-0142 ed.0; 2-0142-1 ed.0 2-0142-2 ed.0; 2-0142-3 ed.0

   

Spec-Marinvest-449

11

Electrical system

   

1

Draw.no’s beginning with:

   

no. 5464433

12

Hydraulic nuts

 

10

Tentec Art.no. TCHN:0080

5.3 m/t MARI UGLAND (nb 450) Group Item No.off   Drawing 1 Intermediate shaft &

5.3 m/t MARI UGLAND (nb 450)

Group

Item

No.off

 

Drawing

1

Intermediate shaft & Disconnector shaft

   

1

78-634-204-401 rev.0

2

Disconnector Assembly

   

1

026-00004978

-

details and parts referred from Assembly drawing

 

3

Sprocket, Banana flange, Sprocket wheel disc

 

1

set

101-1 rev.E; 102-1 rev.D 103-1 rev.D

 

&

Splines shaft

(Assembly drawings)

 

4

Chain (1x49 links+1x 49 link+connect.link)/hydro motor

   

4

Duplex ISO 48B-2; 3’’ pitch

5

Cradle for sprocket

   

1

401-1 rev.C

-

details and parts referred from Assembly drawing

   

6

Foundation for hydro motor (2xLeft + 2x Right)

 

2+2

1016-Foundation-PTI

7

Hydro motor, Hagglund type CB400-360 SA0N0, with splines

 

4

0785007

rev.C

8

Shaft locking device

   

1

3001-B-Shaft locking device

9

Hydraulic jack for sprocket

   

1

701-1 rev.A

10

Hydraulic system

   

1

2-0147 ed.0; 2-0147-1 ed.0 2-0147-2 ed.0; 2-0147-3 ed.0

   

Spec-Marinvest-450

11

Electrical system

   

1

Draw.no’s beginning with:

   

no. 5474512

13

Pneumatic Torque Multiplier

   

1

Norbar Art.no. 18028 MTS

14

Manual Torque Multiplier

   

1

Norbar Art.no. 18008

5.4 m/t MARIANN (nb 451)

Group

Item

No.off

 

Drawing

1

Intermediate shaft & Disconnector shaft

   

1

78-634-204-401 rev.0

2

Disconnector Assembly

   

1

026-00004978

-

details and parts referred from Assembly drawing

 

3

Sprocket, Banana flange, Sprocket wheel disc

 

1

set

101-1 rev.E; 102-1 rev.D 103-1 rev.D

 

&

Splines shaft

(Assembly drawings)

 

4

Chain (1x49 links+1x 49 link+connect.link)/hydro motor

   

4

Duplex ISO 48B-2; 3’’ pitch

5

Cradle for sprocket

   

1

401-1 rev.C

-

details and parts referred from Assembly drawing

   

6

Foundation for hydro motor (2xLeft + 2x Right)

 

2+2

1016-Foundation-PTI

7

Hydro motor, Hagglund type CB400-360 SA0N0, with splines

 

4

0785007

rev.C

8

Shaft locking device

   

1

3001-B-Shaft locking device

9

Hydraulic jack for sprocket

   

1

701-1 rev.A

10

Hydraulic system

   

1

2-0147 ed.0; 2-0147-1 ed.0 2-0147-2 ed.0; 2-0147-3 ed.0

   

Spec-Marinvest-450

11

Electrical system

   

1

Draw.no’s beginning with:

   

no. 5474513

13

Pneumatic Torque Multiplier

   

1

Norbar Art.no. 18028 MTS

14

Manual Torque Multiplier

   

1

Norbar Art.no. 18008