Heavy Lift Carrier Oktober 2005 SCHOTTEL \ Operating Instructions Controllable Pitch Propeller SCP 1094 XG Heavy Lift Carrier ID-No. 1154424 SCHOTTEL- Schiffsmaschinen GmbH KanalstraBe 18 D - 23970 Wismar Telefon: +49 (03841) 20 4-0 Fax: +49 (03841) 20 43 33 ‘Woon ovptianbusrtinnf 2006an EbanntaeghlSCPIOBCHeRyMENTSU 6 Be undFurksosterheting VP Aap Hany Lit Cosi 1Heavy Lift Carrier Oktober 2005 Foreword In this description you will find details on the design of and how to operate the SCHOTTEL - controllable pitch propeller plant. ‘Any components and essential parts of the equipment are described in such a way so that it will be possible to get a clear idea on the design and operation of the c.p. propeller plant. ‘The full functionability of the c.p. propeller requires to operate and to service the equipment properly. ‘Any questions arising during the operation and maintenance work and not being covered in the operating instructions may be directed to and handled by our after-sales service department, Any requests for improving and making the operating instructions more complete will be welcome any time. Damages to the equipment having occurred due to inadequate operation shall exclude any guarantee claims. Further development of our products may cause variations from the illustrations and technical specifications, Modifications concerning the function shall be notified to the customer by way of customer information. Claims whatsever may not be deduced from this operating instructions. Any inquiries relating to the c.p. propeller plant and to spare parts service shall be addressed to: SCHOTTEL- Schiffsmaschinen GmbH Kanalstrasse 18 D-23970 Wismar Phone: +49 (03841) 20 4-0 Fax: +49 (03841) 20 43 33 Unauthorized reprint and any other reproduction of the contents of this operating instructions, passing on and disclosing the technical documentation to third parties as well as any application not authorized by the author is prohibited and is liable for compensation. ‘wo gaupiananecarhanth 205m SbantatgenSCPIONHARYYREN TSUDA Funkerabenabng VE Ape Hea itHeavy Lift Carrier Oktober 2005 Table of contents Page 1. General description 5 Es Technical specification 6 24. Particulars of the assembly units 6 24.4 Propeller blades 6 2.1.2. Hub 6 241.3, Line shatting 6 2.1.4. Gear hydraulic 6 215. Hydraulic system 6 22. Combinator mode and constant speed mode 7 23, List of measuring points 8 24. lls and lubricants 9 3. Description of the working principle of the assemblies "1 34. Hub with controllable pitch unit "1 32. Line shafting 13 3.3. Gear hydraulic, 15 34. Hydraulic system 18 3.6. Remote control unit 19 4 Operating instructions of the controllable pitch propeller plant 19 4A, Commissioning 19 42 Normal mode of operation 20 43 ‘Stopping of the controllable pitch propeller 20 5. Emergency operation 2 5A Failure of pitch adjustment oil pressure 2 52. Failure of remote contro! unit 2 6 Maintenance instructions 22 64 General 22 62. Hub 22 63. Hydraulic system 22 wscon grupo 205en_EebauntasginSCPICBONGHanyHMEN 164424doc Bay ing Fuktontectabing VO rape Hany Lit caer 3‘Oktober 2005 Heavy Lift Carrier _sonerupevandoherienyth 200m, ErtourerapriSCPIOOIXGHeNGIRENTISH24 fee Ba uné Fronsescromun VP Ange aay LM 4Heavy Lift Carrier Oktober 2005 General description The SCHOTTEL - controllable pitch propeller plant consists of the following assembly units (fig.1) - hub with propeller blades (3.1.) - line shafting (3.2.) - gear hydraulic (3.3.) - hydraulic system (3.4.) ~ remote control unit (3.5.) ‘The plant allows stepless adjustment of the propeller to any pitch between .maximum ahead” and maximum astern" without necessity to stop or to reverse the main engine. ‘The desired value for propeller pitch adjusted at the control panel of the remote control will be transmitted as an electrical signal to a directional control valve. ‘Through this directional control valve the hydraulic oil flows through pipe lines, the oil distribution box ‘and the oil line in the gear shaft and the line shafting respectively to the controllable pitch unit of the hub. “The motion of the hydraulic piston is transmitted to the setting mechanism of the hub. “The actual pitch value is taken up via feedback rod with pitch transmitter, indicated and fed as electric signal to the remote control unit. ‘We recommend to keep an operational log-book for the c.p. propeller plant where malfunctions and revisions of all kinds are to be entered. wrceteupevanuecerHenit.200han EnbauntraganSCPIOBIXGHHDHIRENTISUAdoc Say un Furlonbesrebng VPage Hes Lit core 5Heavy Lift Carrier (Oktober 2005 2. Technical specification ‘The Heavy Lift Carrier is equiped with a propulsion plant having one diesel engine (5.400 kW) which drives a controllable pitch propeller through a gear (150 rpm). 2.1. Particulars of the assembly units 2.1.1. Propeller blades Number of blades: Diameter: ‘Area ratio: rection of rotation: Controllable range: -18,13° bis +30,56° (within the mechanical stops) Material: G-CuAI10Ni F650 DIN 1714 Weight of one blade: 1225 kgs 2.4.2. Hub Type: NV 109/4-X left-hand Diameter: 4135 mm Diameter of cylinder: 680mm Material: G-CuAIIONi F650 DIN 1714 Weight: 4800 kgs, thereof hub housing 2264 kgs Oil quantity 5001 Line shafting Material: Ckas Weight: 10200 kgs il quantity: 101 2.1.4. Gear hydraulic Type: HYG 112 Weight of oil distributor: 70 kgs Setting path: 481mm Fixed pitch propeller mode: at < 25,47° (Emergency operation) Reversing time from ahead to astern: ats50s il quantity 231 2.4.5. Hydraulic system Pump capacity 112 min Elektric motor: 380 V; 50 Hz; 15 kW Nominal oil pressure: 80 +5 bar Oil temperature: max. 50°C Oil quantity in tank: 250! Gil quantity in gravity tank: 601 wc gauetndtuncnet 20ton EnbaurtegeSCPIODINGHeaMNEN HZ Bay und Frktoratecrentng VP ape Hey Lit con 6Heavy Lift Carrier 22. Combinator Mode and Constant Speed Mode Oktober 2005 Constant Speed HEAVYLIFT 228-233' SCP 109/4 XG 6 1 — 7 = a nn 5600, 90 Wate # 0.67; Tan = 6.5m: Thon = 6.5m ‘S000 wien | oR evn rate a 2272 eS 2 r= PHOT | 4000 i bece E as | |-+ Powers 3500 a= an H : | 7 I 4 ++ et + + 2000 } + pet oe ei | = = 7 es | —— 7 to Sao Combiatr Mode MEAVYLIT 28238 SCP 1014 XG ————— — Deeaalmase Lat n 00 Saree | na te Rm omnrmcan Reni tos | / + PhO. 4000 = Spood 4 ‘+ Ship Speed = ‘3800 = Power PB. _— z - * eee ae +2500 a ao ee fi 2000 Ve 2 4 _ : = _ ; - = : . 5 ao bo _ o (oer Pete cor yraupevenciectannaryh 20H etalon SCPORGHaby MENT ISU2A coe Ba rt Fundoranarcraing VP. rage Hey I 7Heavy Lift Carrier 2.3, List of measuring points Oktober 2005 — —_ E| 2 3 g e alg z 8 = ~| | 3/4 5 g z al 2 \3 |e 3/8) 3/4 & £ z 8 |é 3] §| 3] FI 8g 2 2 g |2 2| S18) 9 i : 5 2 | 8/8 Ja Zlglzla x 3 e z 3 E |g Slalsi3 oF 2 5 8 | 2| 8/3/35 5 E i i § | ilale ei Sls|q & stand-by | pressure | Herion. ‘ON- 80 | 8:02 }bar |X X | atthe vaive unit sendy |oecor” oseatas [Ope working [pressure |redon [ON 2100 ]bar | |x x] stmeinet wee, (fact fossa Ope ‘oiter iter diterentss | EPE on. | 80 |s42|bar | |x x | tine mer Miscure [reese |Fazcwo200" | opr ee Sach hydraulic oi! | temperature | Trafag ON- 60 |>e5 |°c |x x cream [sensor [row 085 ope atthe HyTank thermometer x teveiswich |eansislo oy. sev | x x ot level min, txeva’ — [ON: atte Hy-Tank din stick x stand-by pressure Herion ON- 80 6:03 |bar |X X | pressure line mao Swen” lasestes he min toca! iNess- x pressure | sytem mmeasure- ment wcongraipivenctunowrinwth. 2cDgan_EroaantwogeSCPOS4NOHoayEN aHz6.doc Band Funkorbervebng VP- Aone ee Lit 8Heavy Lift Carrier Oktober 2005 2.4. Oils and lubricants All oils must have anti-oxidant, anti-foaming and anti-corrosive properties. They must be free from impurities. Olls for the hydraulic and lubrication system ‘Attention: For the hydraulic and lubrication system must be used one kind of oil The following parameters must be observed: Kinematic viscosity at 40°C: 32 - 80 mm‘/s Pour setting point: below - 15°C Flash point above 150°C Water content: below 0,1 by vol. ‘The shipowner has to define a hydraulic oil with the designation HLP 32 or HVLP 32 upto HLP 68 or HVLP 68 according DIN 51502 or HM 32 upto HM 68 according ISO 6743/4 and the corresponding minimum standard according DIN 51524 according to the above mentioned characteristic values for the use in the c.9.p. plant. wn gamma, rear SPm OREN Hee Ofte tnOktober 2005 Heavy Lift Carrier 10 congaussandtuneianit 206 EobauntanganiSCPIOBOxGtearMENT S442 doe Ba nt Frktontescvaing VP frag Hay iHeavy Lift Carrier Oktober 2005 3. Description of the working principle of the assemblies 3.1. Hub with controllable pitch unit (fig. 2 and 3) ‘The hub of the controllable pitch propeller consists of a one-piece hub casing (1) which is bolted to the flange of the propeller shaft (45). ‘The hub housing has a cast-on hydraulic cylinder. The hydraulic cylinder works as a servomotor in connection with the hub bottom, the cylinder cover (3) and the piston (21). ‘The seal between hydraulic cylinder and cylinder cover consists of an seal ring (28). The seal between piston rod and hub bottom consists of an rod packing (26). At the piston a piston packing (25) ensures the sealing between cylinder spaces (k) and (0). To ensure complete charging of the cylinder spaces with hydraulic oll a screwed pressure limitation valve (5) is provided for deairing the piston In the piston (21) two unlockable non-return valves (34) are arranged for blocking the pitch in the ‘event of a breakdown of the hydraulic system. The piston (21) is connected to the setting yoke (20) by means of a nut (6) via the piston rod. ‘The nut (6) is connected to the piston rod by a pin and secured against turning. ‘The pins of the setting yoke (20) with the slide-pieces (4) and the radial guide grooves in the bearing plates (2) act as crank-quide which converts the longitudinal motion of the setting yoke into a rotary ‘mation of the bearing plate and the propeller blade (14) attached thereon. This transmission system guarantees optimal force relations in the cotrollable pitch mechanism for the whole adjustment range. ‘The bearing plates (2) are seated in the hub housing in such a way that they can rotate, The propeller blades (14) are bolted to the bearing plates by 6 blade fastening bolts (8) each and with 2 blade precision bolts (9) each, having a positive fit Each blade fastening bolt is provided with an seal ring (27) preventing the penetration of hub oil through the blade fastening. The blade fastening bolts are secured by means of welded locking plates (15) which are connected with each other by 2 bolt heads each. ‘The sealing between propeller blade and hub housing is effected a seal ring (19). The inner space of the hub is filled with cil. ‘The screw plug (36) closes the oil discharge hole of the hub. This oil discharge hole allows to discharge the air from the hub outside the water when filing oil into or discharging oil from the system consisting of stern tube - hub - stern tube seal, ‘To compensate unbalances of the propeller masses (10) are arranged in the bearing plates. ‘wearer 2 nmdenagrcrrcaeN te Sar nrontnnary YP a etOktober 2005 Heavy Lift Carrier 2 wncongeigitontuecterHan 206 SroaurtetageiSCPIODINHeaIMENTISHH24 do Gay und Frktonectebag VPage Hay itHeavy Lift Carrier Oktober 2005 3.2. Lineshafting (fig. 2 and 3) ‘The propeller shaft (45) is made of forged steel with an axial hollow bore. Pipes, consisting of an outside and an inside oil pipe, run through the bore to deliver the hydraulic oil the. cylinder spaces (k) and (0) of the cast-on hydraulic cylinder of the hub (1). Attention: The position of the inside oil pipe is fixed in the outside oil pipe and it is impossible to pull it out. ‘The flange forged to the rear end of the propeller shaft (45) is bolted to the propeller hub (1) by fastening bolts (60). Hub precision bolts (61) transfer the torque. The coupling (51) at the forward end of the propeller shaft is bolted to the gear shaft by precision bolts (68) and hexagon nuts (80). The cover flange (57) consisting of seawater-proof cast bronze covers the flange of propeller shaft. The jointis sealed by a seal ring (58). The cover flange (57) is fastened to the flange of the propeller shaft by means of filister-head screws (54) which are provided with seal rings (73). ‘werent en tanec HB fuknHeavy Lift Carrier Oktober 2005Heavy Lift Carrier ‘Oktober 2005 3.3. Gearhydraulic (fig. 2, 3 and 4) The Oil Distributor (OD) box is arranged at the free end of the shaft of the reduction gear. It delivers the hydraulic oil for adjustment of the propeller blades from the hydraulic power pack in the engine room through the oil line of the OD box (gear hydraulic) and the ol line ofthe propeller shaft into the hhydraulie cylinder in the hub. The OD box indicates the actual values of propeller pitch and transmits this electrically to the remote control system and to the pitch indicator. ‘The OD box consists of the two housing parts (132 and 133). The housing part (132) is flanged to the gear. In the housing part (132) the forced oil supply unit (134) is arranged which is supported by the shaft butt (135) and prevented from rotating by means of screwed-in sockets (137), ‘The shaft butt (135) is fastened with filister head screws (138) to the gear shaft In the axial bore of the shaft butt two gasket flanges (128 and 129) carry the tail rod (168). The oil line of the OD box is directly connected with the hydraulic pitch control unit in the hub by the pipes and transmits mechanically the actual value of the propeller pitch to a slide-piece guideway (164) rotating by means of anti-riction bearings. A pitch transmitter (127) is connected to the shaft (111) transmitting the actual value to the remote control unit. Leakage oil which may emerge at the oil supply unit is discharged by the connection (158). ‘The OD box is discharged via connection (167). ‘The spacer sleeve (68) is used to adjust the length of the oil line, ‘Two non-retum valves (34) in the piston of the hub block the pitch in case of breakdown of the hydraulic system. In the normal mode the propeller pitch is adjusted by means of an electrical remote control system. The desired pitch is set at the remote control stands and is transformed to an assigned pressure-oil fiow in the control unit of the hydraulic system (section 3.4.) co gateaentuecartayt. 20690 SroaartedaenSCO1ODNGHeayMMENTIS2A oe Say un Furtanbeeabng VP- Aap Hoa it cori 15Heavy Lift Carrier Oktober 2005 Ifa pitch adjusting manoeuvre has been initiated for “ahead!” by the remote control system the following processes will start: ‘The oil flow released by the control unit of the hydraulic system enters the screwed-in socket (137) of the forced-oil supply unit (134) and, consequently, into the annular channel (e). Then the oil passes through radial bores in the rotating shaft butt (135) into the space (f. From here the oil flows via radial and axial bores in the oil line of gear hydraulic into the inside oil ine of the propeller shaft and via the non-return valve (34) in the piston (21) into the cylinder space (k) of the hub, The piston (21) moves into direction “ahead” and forces the oil out of the cylinder space (o) via the piston rod into the outside oil lines of the propeller shaft and gear hydraulic into the bores (m) of the shaft butt (136), From the bores (m) the oil enters via radial bores into the space (!) ofthe oil supply unit (134) and from there via the screwed-in socket (137) into the control unit ofthe hydraulic system. ‘The longitudinal motion of the piston (21) is transferred to the setting yoke (20). By means of setting pins with slide-pieces (4) sliding in the guide grooves of the bearing plates (2) the longitudinal motion ofthe setting yoke (20) is transformed into rotary motion of the bearing plates (2) carried in the hub housing (1) and of the propeller blades (14) fastened thereon The longitudinal motion of the piston (21) is simultaneously transferred via the oil lines of the line shafting and gear hydraulic to the guide-way (164) of the slide-piece and from there via slide-pieces (110) and forked piece (163) into a rotary motion of the shaft (111). ‘The indicator (159) indicates on the scale (148) the current actual value of the propeller pitch. ‘The pitch transmitter (127) transmits an electrical signal to the remote control system and the control unit of the hydraulic system, In case a pitch adjustment manoeuvre is being performe effected in opposite direction as described above. to the direction “astern” the procedure is In the event of failure of hydraulic pressure in the hydraulic system the non-retum valves in the piston (34) prevent uncontrolled self-acting adjustment of the propeller blades by blocking the oil flow. The piston and, consequently, the propeller blades are kept approximately in the actual position at the moment of pressure failure. we group Hardin 205 en EbauntagiiSCPIOBOGHeRrIMEN! 142k de Band Furktonneurg VP Aap ey A comet 16Oktober 2005 Heavy Lift Carrier wsc0paupsannuscerHoayi. 208m. roaurteaenSC>IOHXGhEayOMENTTSH24 coe Sau und Furkonbeecratang VP. laps Hes Lat 7Heavy Lift Carrier Oktober 2005 3.4. Hydraulic system (fig. 5) The hydraulic oll pressure required for pitch adjustment is generated by one of the two pump units ‘One pump is the master pump and the other one is the stand-by pump. ‘The pump unit sucks the oil from the tank and forces it via the non-return valves and the switchable high-pressure filter to the control unit. If the pressure rises to an impermissible high level, e.g. when adjusting the plant towards mechanical stop, the max. permissible pressure will be ensured by the pressure control valve. In the normal mode the oil passes to the electrically-actuated proportional control valve and to the return via the differential pressure valve in the case when no pitch adjustment is performed. ‘The differential pressure valve is actuated by pressure pipes to the servo-motor. If no pitch adjustment of the propeller blades is performed the pressure drops behind the proportional control valve. This pressure controls the differential pressure valve. The lower the control pressure is, the more opens the differential pressure valve, the lower is the feed pressure. The oil which flows through the differential pressure vaive into the return line passes through the cooler into the tank. ‘The proportional control valve pilots the oil to the servo-motor and, thus, the pitch adjustment of the propeller blades, ‘When displacing the pilot piston of the control valve, the pump delivers the oil into a relatively closed space of the oil supply unit, the pressure in the supply line and to the servo-motor respectively increases. The differential pressure valve closes so that further pressure increase is possible in the supply line causing the adjustment of the propeller pitch. ‘After the pitch has been adjusted (proportional control valve is in central position) the pressure drops in the control line of the differential pressure valve and consequently does the supply pressure. The position of the propeller blades is retained because two non-return (34) valves which are arranged in the piston (21) isolate the lines coming from the cylinder spaces. The propeller pitch can be directly changed manually at proportional control valve.Heavy Lift Carrier ‘Oktober 2005 3.5. Remote control unit See the individual instructions for operating the remote control system. 4. Operating instructions of the controllable pitch propeller plant 4.1. Commissioning Before first commissioning of the plant and with each change of oil the hydraulic system must be thoroughly flushed with fresh hydraulic oi The new oil has to be filled up only after the drainage of this oil and cleaning of all ol filters and, if necessary, also the tank, Further use of the flush oil as useful oil is permissible provided sufficient cleanliness of the pipe system and of the c.p. propeller plant will be ensured before flushing and an oil analysis be carried out after flushing, The analysis of the flush oil must show results which meet the requirements on the permissible limits with regard to the contents of dirt and water in the fresh cil After prolonged periods of standstill or repairs the following has to be checked before commissioning of the plant: - oil level in the tank - correct switch position of all fittings in the hydraulic circuit The remote control unit and then the pump set are to be started. Care must be taken that = pump causes normal noise - pressures indicated reach normal values = oil cooler is operating, After having achieved a steady pressure build-up in the hydraulic system the plant is to be reversed ‘approximately 5 times by means of a manually operated control valve (VWP) in order to eliminate possible inclusions of air. Then the propeller pitch is to be adjusted for 0°. If all above instructions have been followed, the plant's serviceability has been stated and the safety regulations been observed, the main engine can be started. wtorgcunsandecharHnnp 20 EebaantegenSCPIINGNenn REN KAKA: Band Funktoretereaing VP-Arage Hee it corer 19Heavy Lift Carrier ‘Oktober 2005 4.2. Normal mode of operation All operations are shown in the operating instructions of the remote control unit. Parameters (section 2,3.) which are essential to the controllable pitch propeller plant are automatically monitored by the engine control system. In case of pressure failure in the hydraulic system the non-return valves (34) close in the piston (21). ‘The propeller blades are then kept in the position given at the time of pressure failure. 4.3. Stopping of the controllable pitch propeller plant Before stopping the plant the propeller blades are to be adjusted for zero pitch. Then - stop the main engine : stop the pump unit - switch off the remote unit. All fitings of the hydraulic system are to be kept in the position which is provided for the normal mode of operation. wot gourds 2c05er_EhbnuntatagiiSCPIOBGHeayNTENT 542460 Ra undFuktanbendubng VO tage Hey it co 20Heavy Lift Carrier (Oktober 2005 5. Emergency operation 5.1. Fi ure of pitch adjustment oil pressure ‘Two non-retum valves (34) are located in the piston (21) of the hub. During the adjustment process they are constantly kept open when hydraulic pressure is applied. In case of pressure failure (< 10 bar) the lockable non-return valves close the two cylinder spaces. The currently given pitch will be maintained 5.2, Failure of the remote control unit For manual operation a way valve is arranged in the control unit at the proportional way valve WP. This way valve allows direct changes of the propeller pitch. The actual propeller pitch is indicated by the system including a pointer and a scale at the pitch indicator. oor gausvanitcenriaiyth 20pm SroaantatienSCPIOSannARENTTSzKdoc San Furkerebarowmburg YP: Age Hany at cone 2Heavy Lift Carrier ‘Oktober 2005 tenance instructions The following instructions are to be adhered to for the maintenance of the controllable pitch propeller plant 6.1. General When dismantiing work is being performed to the assemblies the packing elements are to be replaced, ‘After a 4 years period of operation the equipment is to be dismantled and the bearing clearances in the hub, the propeller shaft, of the piston/cylinder - complex as well as in the oil distributor are to be checked. {A visual inspection is to be carried out. The hydraulic oil is to be replaced. 6.2. Hub While the vessel is in the dock, a visual inspection of the hub is to be carried out (screwed connection with lockings, blade surface with regard to wear, roughenings and damages). If required, repairs are to be carried out. ‘The hub oil is to be drained and to be checked for contents of water. 6.3. Hydraulic system Inthe hydraulic system are to be regulary inspected: all pipe, flange and hose connections as well as hose lines for tightness. - il level approx. after every 500 running hours = fiter cartridges quarterly or after every 1700 running hours. After every ref of oll the time intervals for filter inspections are to be shortened. - oil samples for water contents annually or after every 6800 running hours = pressure control valve, pressure switch, pump set annually or after every 6800 running hours wo waigstantuererHeswy. 20 ErosarieiegniSCPIOINGhearMMENTISHDE oe Sua Fuktontartatng VP. ape Hey Lit ceria 22