Steerprop Azimuth Propulsor SP 35 D

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Gilbert Blake
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1 SP 35 D W / 14 1 Project data Steerprop Azimuth Propulsor SP 35 D Reference job number(s)... W0164- Yard... Yard project / NB... Owner.... Type of vessel... Classification... ABS Certificates... ABS 2 Supply Specification 2.1 Basic Scope of the supply 2 Steerprop Azimuth Propulsors, each including: - Dual input at 180 degrees Power transmission with top and bottom right angle gears, shafts, and bearings - Large rotary ring integrating slewing bearing and tooth rim for azimuth - Sturdy housing to contain power train and azimuth elements - Seal assemblies on azimuth tube and propeller shaft to seal-off seawater - Tank for maintaining the static pressure of seal fluid - Four-bladed, fixed pitch type NiAl-bronze propeller. - Steerprop HJ3 high performance nozzle - Stainless steel inner surface for nozzle. - Electric azimuthing device with two electric motors, planetary gears and pinions - Electric driven hydraulic system for cooling and filtering of the lubrication oil. - Steering feedback device with double transmitters - Independent mechanical azimuth indicating device with transmitter - Alarm transducers, to be incorporated to alarm system - Large mounting can for pull-through dismounting. - Outer hull mounting flange 2.2 Controls: Electric steering system AC-AC motor controllers to position and regulate the azimuth motors AC Brake resistors Motor control units 2.3 Remote Controls system 2 Main control stations in the wheelhouse, each including 2 Drop-in control panels for each steering station comprising: - Synchronized Steerrprop azimuth and prime mover speed control levers - Indicator units for azimuth and propeller RPM - Deices for hardwired azimuth and prime mover RPM back-up controls (main station only) Control mode selection and indication device 2.4 Steerprop Control Unit 2 Steerprop Control Units in the machinery space, each including - Programmable Logic Controller for the main control for azimuth

2 SP 35 D W / 14 - Prime mover interlocks - Control voltage and local control switches - AC/ DC converter for 24 VDC control system with auto switchover to back-up 24 VDC supply with circuit breakers and filters - Control system alarms contacts, to be incorporated with alarm system 2.5 Miscellaneous control equipment and interfaces to other systems 2.6 Miscellaneous - Steerprop ECR non-follow-up control with indicators - Autopilot interface - DP-interface 1 Set of onboard spare parts 1 Set of standard hand-tools 3 Set of instruction manuals in English language 3 Set of classification certificates: ABS 2.7 Exclusions The following list of exclusions contain items that are necessary to complete the propulsion system and make it operational but are not included in the scope of Steerprop delivery: - Installation onboard - Prime movers (main drive motors) - Any auxiliaries for the prime movers, if not specified - 24 VDC electric supply for the control equipment - Cooling water supply for the heat exchangers - Cables and pipes with armaments - Electric cabling work - Central alarm system - Consoles and desks for control panels - External piping - Autopilot system - Switch for DP/Manual-mode selection - Oil fillings - Flexible couplings for absorbing torsion vibrations The following list of exclusions contain optional items that are not included in the scope of this offer: - Model test, cavitation test - Training of the crew or shipyard personnel - Alarm unit - Shaft line - Prime mover controls 3 Technical Specification 3.1 The Content of the Technical Specification The technical specification describes the technical design and the system features of Steerprop propulsors mounted on board of the subject vessels. It does not define the scope of supply which is done in the Supply Specification above. As there is

3 SP 35 D W / Performance controversy between the Supply Specification and the Technical Specification the Supply Specification prevails. The propulsors are designed and constructed in compliance with the rules and regulations of the Classification Societies and are delivered with certificate(s). The propulsors are used for propulsion and manoeuvring of the subject vessel. 3.3 Technical data of SP35D The following data pertains to a single Steerprop propulsor if not otherwise stated Propulsor main data Input Power Steering Gear - Propeller diameter... max 2800 mm 4 bladed - Nozzle... Steerprop HJ3-5 High Performance Nozzle - Propeller speed... about 239 RPM - Reduction ratio... according to ME speed - Direction of rotation 1 of input shafts... clockwise - Direction of rotating propeller 2 of propeller shafts... clockwise - Prime mover... electric motor - Input power kw - Input speed rpm The steering gear consists of electric motors connected via planetary gears to the slewing ring Lubrication 3.4 Dimensions and weight Dimensions - Type... electric steering gear - Steering drives... 2 pcs. Frequency converters - Steering motor... 2 pcs. AC electric motors connected to planetary gear - Steering speed... 18sec/180 deg - Emergency/ service... 1 pcs built on hand reel - Internal circulation... combined immersion and spray method - External circulation... 1 pcs. electrically driven lubrication pump - Cooling... 1 pcs. sea water resistant tube type cooler - Filtration... 1 pcs. filter with changeable insert - Emergency/ service... 1 pcs built on hand pump - SP 35 D installation drawing... P B 1 Looking at propulsors input shaft 2 Looking from aft

4 SP 35 D W / Weight - Weight, SP35 D... ca. 28,000 kg - Weight of auxiliaries... ca kg 3.5 Propeller 3.6 Nozzle - Type... fixed pitch, mono-block - Propeller material / Finish... NiAl bronze / Class II - Number of blades Moderate skew for low noise and vibration - Nozzle material... Mild steel grade D - Nozzle inside material... Stainless steel Interface and filling data Oil volumes - Lubrication oil volume litres - Seal oil tank litres Cooling water < 32 degree C 3.8 Electric Data - Cooling water for lubrication l/min Power demand 440 V, 60 Hz The defined power for the inverter is the maximum power, which is needed only when the propulsor is steering with large angle movements. In position keeping the power is only one tenth of the maximum. - Steering gear 1 inverter kw - Steering gear 2 inverter kw - Lubrication pump kw Control voltage main supply 220 VAC per propulsor - Control system ( V), one station system W Control voltage main supply 24 VDC per propulsor - Back-up control system ( VDC) W - Indication system ( VDC) W Alarms, Electric Steering Gear - Steering gear 1 failure... voltage free breaking contact - Steering gear 2 failure... voltage free breaking contact - Lubrication oil pressure low... voltage free breaking contact - Lubrication start oil level low... voltage free breaking contact - Lubrication run oil level low... voltage free breaking contact 3 Stainless steel inside material is an option

5 SP 35 D W / 14 - Lubrication oil temperature high... voltage free breaking contact - Lubrication oil filter clogged*... voltage free breaking contact - Seal oil level high/low... voltage free breaking contact - Seal oil tank pressure low... voltage free breaking contact - Control system alarm... voltage free breaking contact - Control system voltage supply... voltage free breaking contact - Wrong way or low steering speed... voltage free breaking contact *All filters can be connected to a single alarm point 3.9 Control System Interfaces Prime Mover Controls 4 20 ma Autopilot - Engine control ma - Other controls... voltage free making contact - Autopilot interface -45º +45º ma - Autopilot selection... voltage free making contact 4 Features of Steerprop SP35 D 4.1 General Notes, Z-drive with nozzle The following information pertains to a single azimuth propulsor unless otherwise mentioned. The design criteria and engineering objectives of Steerprop Azimuth Propulsors are reliability and consistency that provide efficient propulsion device, easy and simple installation procedures, and trouble free, economic operation cycle. The number of the proprietary components is minimized. The majority of the parts and components of a Steerprop Azimuth Propulsor are available in public domain. 4.2 Transmission Input shaft Input shaft is supplied with suitable flange to fit counter flange of the intermediate shaft Sequential Strength The power transmission is exploits the sequential principle. The selected relatively weaker parts protect valuable and hard access components of the power train. Consequently the weakest component is a blade of the propeller Shafts Shafts are made of high tensile carbon steel complying with the requirements for the strength and those of the regulatory agents.

6 SP 35 D W / 14 The propeller shaft has liners for the shaft seal. The vertical shaft is split with the tooth coupling for two reasons: it enables the installation of the propulsor in two portions and works as a safety fuse in case of accident. The lower part of the vertical shaft makes up a pinion to the lower bevel gear. The gear wheels and the propeller are mounted on the shafts with shrink fit joints. Consequently there are no keyways in the entire Steerprop unit Right Angle Gears The gears are designed and manufactured according to Klingelnberg cyclopalloid method. The material is a special alloy steel for sufficient strength. The engineering of the gears is accomplished by Steerprop Ltd. paying attention to the distinctive requirements imposed by the azimuth propulsion. In the HPG method the finishing cutting is done after the case hardening resulting in accurate tooth form. The gears are made to the Accuracy Grade 6 according to DIN 3965 (equivalent with AGMA 12) Bearings 4.3 Housing The final approval of the Steerprop gear assemblies takes place in the full torque test at the factory before accepting a propulsor for delivery. Each tooth contact is tested to assure the correctness of the assembly. This method is a comprehensive and unforgiving quality assurance revealing flaws in the gear geometry, shaft assemblies and even abnormal deflection of the gear housing. All of the bearings are roller bearings. They are dimensioned according to the recommendations of the maritime regulatory agencies, manufacturers, and the pertinent standards. The life cycle L 10h is minimum 40,000 hours. The housings and casings encapsulating the transmission and azimuth system are fabricated of Fe 52-steel plate. Special attention is paid in engineering the shapes, and material thickness not only to provide the appropriate hydrodynamic attributes but also to be sturdy having ample strength and rigidity for harsh dynamic conditions an azimuth propulsor operates in. After welding the body parts are annealed for obliterating the welding stresses Safety Feature 4.4 Seal Systems Besides the overall strength of the housing structures the particular attention is paid to the safety: The bolted flange in the azimuth tube above the propeller is carefully dimensioned to break in controlled manner in case of overwhelming impact, such as hard grounding Shaft seal condition monitoring Steerprop has Flush Fluid Seal Secure system for providing head pressure, seal lubrication and means for heat dissipation of the seals.

7 SP 35 D W / 14 To protect the propeller shaft seal a rope guard is assembled with cutters. The seals can be monitored with a new method: the head fluid in between the sequentially located seal elements is connected to the head tank with the loop that leads the fluid through the space between the azimuthing tube seals to propeller shaft seal and returning to the head tank. This feature is used for monitoring the condition of the seals and detecting leaks in the early phase of failure. The sealing tank is preferably a gravity tank. The following picture defines the head needed. If the head is not attainable the tank must be pressurized. The shipyard has to determine in early stage whether the needed head is obtainable and duly advise Steerprop Ltd Azimuthing Seals The number of the azimuth tube seals is three in series.

8 SP 35 D W / Propeller shaft Seals The propeller shaft seal asembly consists of four seal elements in sequence. The rope guard with line cutters are furnished. The liner on the shaft is made of special chrome steel alloy. 4.5 Oil coolers The heat exchangers provided by Steerprop Ltd are for Lubrication The heat balance, water capacity, and pressure difference will be advised promptly. 4.6 Surface treatment Surface Preparation Submerged Section Layers - Sand blasting... SA Epoxy primer m - Inerta 165 TM102 epoxy coat (black) m Dry Outside Surfaces - Epoxy primer m

9 SP 35 D W / Inside Surfaces - Epoxy primer m - Epoxy finish (green RAL 6019) m - Epoxy primer m 4.7 Corrosion control Cathode protection Zinc anodes for four (4) years operation 5 Installation into vessel 5.1 Large mounting can The propulsor can be arranged with a large mounting can for removal afloat. 6 Control system 6.1 Control system layout - Block diagram... C B 6.2 AC/ DC converter pcs 220VAC/24VDC converter per propulsor 6.3 Alarm display 220VAC / 24VDC converter including automatic switchover to emergency batteries in case of loss of AC supply Alarms are indicated in Steerprop display system in ECR panel 6.4 Service and Diagnostic Functions Intelligent Self Diagnostic System The control system has as inbuilt an intelligent self-diagnostic system, which is monitoring the operation condition of the control system, setting and feedback transmitters and steering speed.

SP 35 D W0164-10 / 14 Possible alarm indications are displayed through the panel indication lamps indicating also the accurate position of malfunctioning component. 6.4.2 Maintenance Support Tools Control system display showing data for the preventive maintenance: 6.

10 SP 35 D W / 14 Possible alarm indications are displayed through the panel indication lamps indicating also the accurate position of malfunctioning component Maintenance Support Tools Control system display showing data for the preventive maintenance: 6.5 ECR control panels ECR station - Running hours - Load profile - Counted rpm - Number of turnings below and over 5 degrees - Number of supply voltage drops below 18 volts - 10 last alarms with time stamp - Summary of alarms Figure 1 Steerprop control panel for machinery space. The panel has display unit /propulsor, for: azimuth indication, propeller rpm indication, alarms and service analysis. Push button controls for azimuth and motor rpm, control station selection between wheelhouse and machinery space. - Dimensions (WxH) x 250 mm - The protection class... IP44 - Material... 5 mm black anodised aluminium plate - Both Steerprop units have a common ECR control panel Control station selection/indication - Selection switch and indication lamps for Bridge / ECR control station selection Controls - Secondary steering push buttons for propulsor turning CW / CCW - Prime mover rpm control push buttons

SP 35 D W0164-11 / 14 6.5.1.3 Lamp test - Lamp test push button. - Dimmer 6.5.1.4 Display unit 6.5.1.5 Alarm buzzer Buzzer with push button - Propulsor direction indication 180 (PS) 0 180 (SB) - Propeller rpm indication -20 120 % - alarm display - 6.

11 SP 35 D W / Lamp test - Lamp test push button. - Dimmer Display unit Alarm buzzer Buzzer with push button - Propulsor direction indication 180 (PS) (SB) - Propeller rpm indication % - alarm display Steerprop control unit The Steerprop control unit comprises PLC for main control (upper part) and control relays and signal converters (right side) for main and back-up controls. At the left side of the module there are supply protection and connection switches. Also on the left there is the local remote control selection switch. The terminal block for external cabling has equipped with spring clamp type connection elements. They are vibration tolerant construction Control electronics - The protection class... IP44 - Dimensions (WxHxD) x760x210 mm - Material... Sheet steel, 1.25 mm, powder coated RAL Each Steerprop unit has own control cabinet. - Follow-up steering control - Non-follow-up steering - Propeller motor interlocking - Local-remote control selection - Control voltage on/off selection - Control voltage distribution and protection - AC/DC coverter With auto switcover to Vessel s emergency battery supply

SP 35 D W0164-12 / 14-6.6 Steerprop propulsor feed-back unit Double safety! The propulsor is equipped with two separate and different type of feedback transmitters for control system.

12 SP 35 D W / Steerprop propulsor feed-back unit Double safety! The propulsor is equipped with two separate and different type of feedback transmitters for control system. The control system can operate with one transmitter. 6.7 Protection class for electric components 6.8 Cabling - Control space... IP 22 - Machinery / Propulsor space... IP Wiring and terminals The internal wiring is wired-up to terminal strip or equal. All terminal are spring loaded Plugs The Steerprop propulsor and its auxiliary systems like hydraulics are equipped with Harting type of plugs Cable glands There are no cable glands on electronic units except on terminal boxes of propulsor and hydraulic power unit for their internal wiring. 6.9 Electric Motors (electric steering only) 7 Spare Parts - Voltage... max 480 V - Supply... 3 phase alternating current - Temperature class... F to F The following standard spares are delivered with the units:

13 SP 35 D W / Mechanical spares 7.2 Hydraulic spares 1 set of o-rings for inspection hatches and covers on upper assembly 1 off input shaft seal 1 off sealing glue 1 off screw locking compound 1 set of seals for pipe and hose joints 1 set of filter elements 1 off hydraulic fitting locking compound 7.3 Control system spares Control unit: 1 off circuit breaker 1 off relay 1 off fuse 1 off reference voltage source Panels: 1 off lamp set 1 off plastic lens (clear) 1 off plastic lens (blue) 1 off push button 8 Tools 8.1 Mechanical tools 8.2 Hydraulic tools 8.3 Control system tools 1 off adapter for press on joints 1 off hydraulic hand pump for press on joints 1 off drain hose for lubrication oil draining 1 off wrench for clutch emergency locking (optional) 1 off pressure measuring device 1 off oil sample connection 1 off lens remover 1 off lamp remover 1 off dismantling tool 9 Documents and calculations 9.1 Torsional vibration calculation analysis Steerprop will supply needed mass elastic shafting data for torsional analysis calculation to engine maker.

14 SP 35 D W / Documents All documents are in English language. Paper documents are mainly A4 size. Installation drawings Instruction and operation manual Spare parts manuals 10 Installation onboard and supervision 10.1 Installation Installation onboard is carried out by shipyard. Steerprop provides: Installation manual

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