SCHOTTEL STT 004 FP User manual

SERVICE MANUAL
No. 14300235 – 1
________________________________________________________
Key Word IMR 1 BOW
_________________________ ______________________________
Order No. 14300235
_________________________ ______________________________
Type of Product STT 004 FP
_________________________ ______________________________
Number of Units 2
_________________________ ______________________________
Serial Numbers STT-171949 / STT-171950
_________________________ ______________________________
Classification Society BV
_________________________ ______________________________
Input Power (KW) 843
_________________________ ______________________________
Input Speed (rpm) 1040
_________________________ ______________________________
Min. Operating Speed (rpm) 0
________________________________________________________
Date: 05 Nov. 2009
SCHOTTEL GmbH
Mainzer Str. 99
D-56322 Spay/Rhein
Germany
Telephone: [phone] / 61-0
Telefax : +49 (0) 2628 / 61-300 and 61-345
E-Mail: [email protected]
Internet: www.schottel.de

en STD-fs Table of Contents 14300235-1 05 Nov. 2009 1/1
Table of Contents
1 Table of Contents
2 Installation Instructions
Technical Specification.................................................................................Rev. 9, 04.11.2009...VB4-71108_3
3 Operating, Mounting and Maintenance Instructions
Information on How to Order Spare Parts ....................................................................... 347/98...........1099241
Safety and Environmental Protection Regulation "SV 1" ................................................ 348/98...........1099236
Screw Connections, Filling of Gaps, Sealing Material and Product
Recommendations......................................................................................................... 08/0075...........1099235
Piping Systems for Hydraulic, Lubrication and Similar Systems................................... 07/3110...........1099237
Preservation Instructions ................................................................................................. 641/02...........1104097
Coating Specifications for Underwater Components Made of Ferrous Castings.......... 08/1834...........1098053
Coating Specifications for Underwater Components Made of Steel ............................. 08/1833 ...........1098071
Painting-Specification BELZONA-Ceramic "S" ........................................................ 15.06.2004...........1146917
Mounting Instructions for SCHOTTEL Transverse Thrusters ........................................08/April...........1167644
Operating Instructions STT 001 FP to STT 004 FP ...................................................... 07/3028...........1148439
Lubrication Oil Recommendation and Manufacturers for STT
with Fixed-Pitch Propeller and Pitch Control................................................................. 09/1657...........1145140
Mounting of the Propeller STT 001 to STT 004 ............................................................ 07/3048...........1150744
Fitting Instructions for CENTAFLEX-Couplings with Highly Elastic
Rubber Elements M-CF-A-E-14-06 ........................................................................................... .............CENTA
Screw Connections, Preparation and Tightening Torques..............................................Rev.: 3.............CENTA
4 Spare Parts Catalogue
Information on How to Order Spare Parts ......................................................................April 97 ...........1101039
Order ............................................................................................List ..................... 05.11.2009 .........14300235
Transverse Thruster STT 004 FP................................................. List .......................... 09/1178...........1170155
Transverse Thruster STT 004 FP................................................. Drawing................... 09/1178...........1170155
Lower Gearbox ............................................................................List .......................... 08/1821...........1158217
Lower Gearbox ............................................................................Drawing................... 08/2842...........1158217
Oil Tank, cpl.................................................................................. List .......................... 08/2478...........1165363
Oil Tank, cpl.................................................................................. Drawing................... 09/0678...........1165363
Spare Parts FP Standard .............................................................List .......................... 07/2705 ...........1158089
5 SCHOTTEL Agencies
Distribution List Language Copy CD-ROM
Customer en 5 1
Yard
Agency en 1

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 1/7
2
2 – – S SC CH HO OT TT TE EL L T TU UN NN NE EL L T TH HR RU US ST TE ER R( (S S) )
T
TY YP PE E S ST TT T 4 4 F FP P
Shipowner : Bourbon Offshore
Shipyard : Zhejiang Shipbuilding Co. Ltd. (2)
Building No: ZJ 2001 to ZJ 2010 (5)
Vessel Type : IMR Vessel
Operation area : WW
Classification : BV
Class notation : Offshore Supply Vessel, Oil recovery Ship,
Special Service/Standby Rescue Vessel (150
Survivors in tropical area) + Hull, +MACH,
Unrestricted Navigation AUT-UMS, +ALM,
+DYNAPOS AM/AT-RS, SDS, FiFi 1 WITH
WATER SPRAYING COMF-NOISE 3, COMF-
VIB 3, CLEANSHIP SUPER 7+
SCHOTTEL Project : MER-071067-01/ -10
SCHOTTEL Order :
14300235/243/261/266/270/279/282/285/288/291 (6)
SCHOTTEL Codeword : IMR 1 BOW – IMR 10 BOW
( GPA 696 BOW 1 to 10 ) (2)
Rev. Issue Issue Descri
p
tion Ori
g
inator/D
p
t.
0 8.11.07 Project issue R. Schwandt/ VB4
1 03.01.08 Projekt and Order No.’s added C. Wahl/VB4
2 28.01.08 CHN – Vers. Inserted W.Eggemann/VB4
3 26.02.08 Order No. inserted W.Eggemann/VB4
4 30.05.08 Tunnel dimensionen added W.Eggemann/VB4
5 04.06.08 Shipyard and building No. added W.Eggemann/VB4
6 16.06.08 Order No, number of blades, tunnel length changes. W.Eggemann/VB4
7 06.11.08 Anode material inserted W.Eggemann/VB4
8 02.03.09 Angle of frame and waterline corrected W.Eggemann/VB4
9 04.11.09 Headline order number corrected W.Eggemann/VB2
Sinopacific Shipbuilding Group Co., Ltd Shanghai Design Associates
Schottel GmbH

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 2/7
MAIN PARTICULARS (EACH UNIT)
Nominal input power : 843 kW
Nominal input speed : 1040 rpm +/- 3%
Gear reduction : 3.786 : 1
Propeller diameter : 1990 mm
Propeller material : GS-CUAl10Fe5Ni5-C
Number of blades : 4 (2, 6)
Manufacturing standard : ISO 484/2-1981 (E). Tolerance Class II
Wearing ring in path of propeller : stainless steel, 5mm
Delivered tunnel length : 2000 mm
Wall thickness of tunnel : 25 mm
Wall thickness of hull : XXXX mm (to be issued to SCHOTTEL)
Weight incl. propeller, oil header tank
Please note that the indicated delivery time only starts after receipt of the hull thickness in
the area of the tunnel. If the wall thickness of the tunnel has to be increased following
classification rules, SCHOTTEL reserves the right to ask for an additional price.
KIND OF INSTALLATION
The unit will be delivered in SCHOTTEL standard tunnel length. It will be welded into the
hull of the vessel with a vertical power input shaft arrangement. The thruster with its direct
connection to the vessel could be defined as a part of the vessels hull.
DESIGN & CONSTRUCTION
TRANSVERSE TUNNEL:
The transverse tunnel is a welded construction made of shipbuilding steel grade A
As protection against corrosion anodes are mounted on the tunnel wall and on the (2)
cover of the lower gearbox. The anodes are fixed to the thruster with small metal feet
leaving a gap between anode and tunnel for sufficient final coating by the shipyard. If there
is not enough space for the anodes, the not mountable anodes will be supplied loose and
have to be mounted by the shipyard after installation of the bow thruster. Anode protection
for the tunnel parts which are not scope of supply of SCHOTTEL is not delivered.
Aluminium anodes are required by the customer. (7)
Important Remark to be respected by the Shipyard
To ensure sufficient protection we recommend adding adequate anode protection fixed as
described above on the tunnel parts which are built by the shipyard. Furthermore sufficient

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 3/7
anodes have to be installed on the fore ship to protect the hull. If these anodes to protect
fore ship and tunnel are missing, then the anodes delivered with the tunnel thruster serve
as only protection for the complete fore ship. This means that these anodes will disappear
within only a few months and the thruster itself will serve as anode which can lead in short
time to severe damage of the transverse thruster unit. In regular inspections, the anode
mass should be examined and replaced when necessary.
Taking account to the anode mass supplied by SCHOTTEL a specialist for anode
protection should determine how much anode mass has to be added to achieve the
desired years of protection (at least two years).
In the section of the propeller a stainless steel ring is welded into the tunnel against wear
of the tunnel.
The tunnel is equipped with 2 outer stiffening rings and one central supporting ring. The
outer stiffening rings are flat on the bottom side which allows easy welding to the frame
structure and reduces deformations. In addition, the foundation of the electric motor is
stabilized by the supporting rings.
BOW THRUSTER GEAR UNIT:
The housing of the lower gearbox is manufactured using high quality cast iron GGG 40
and contains the bevel gear transmission.
The propeller shaft is made of steel with high tensile strength and is seated in roller
bearings. Shaft sealing is achieved through radial shaft sealing rings. High grade special
stainless steel rings are used for rings which are in contact with seawater.
The HPG precision bevel gears are made from high quality steel, case-hardened and re-
cut after hardening. This results in a highly accurate tooth profile which ensures perfect
matching of the bevel gear set and a high safety factor against contact stress.
The support arm of the underwater gear housing to the tunnel is welded in. It is part of
SCHOTTEL scope of supply.
All running surfaces of shafts, flanges etc. are coated with wear and corrosion resistant
material.
Attached to the propeller shaft a fixed pitch propeller is mounted by hydraulic connection.

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 4/7
LUBRICATION:
Lubrication is ensured by oil bath lubrication. Cooling of the oil is achieved by heat
dissipation in the lower gearbox to the running water.
The separate oil header tank with level gauge is equipped with a sensor (24V DC) for the
alarm indication 'oil level to low'.
Note : This oil header tank has to be installed by the yard approx. 1 meter above the
loaded waterline.
Connections between oil header tank and lower thruster unit are not scope of SCHOTTEL
supply.
Counter connection on Schottel components are to be supplied by Schottel. (2)
( Bolts and Washers for the E-Motor ) (2)
PROPELLER BLADE LAYOUT:
(4)
As basis for our propeller layout the following data is necessary.
Please countercheck if the data is correct:
The data has to be issued to SCHOTTEL latest 3 weeks after order:
−angle of frame in bow thruster area: No.1 39,5 °
(8)
No.2 59,4 °
(8)
−angle of waterline in bow thruster area: No.1 60,2 °
(8)
−No.2 67,2 °
(8)
−distance between centreline of tunnel
and keel: 1800 mm
(recommendation: 1.5 x D of propeller)
−distance between centreline of tunnel
and waterline: 4200 mm
(recommendation: 1.5 x D of propeller)
−distance of propeller to middle of tunnel: XX mm
−Effective tunnel length at centre line of tunnel: No.1 7197 mm
−No.2 4636 mm
(6)
−inlet of tunnel conical, cone depth: XX mm
−inlet of tunnel rounded, radius: XX mm
−with inlet protection grid (delivered by the shipyard) / without grid
(A lines plan should be submitted to SCHOTTEL in order to verify the figures.)

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 5/7
Protection grids on tunnel ends have to be installed if vessel is ice classed (yard supply) In
addition, the tunnel has to be below the ice belt of the vessel (the thruster unit itself has no
ice-class).
POWER TRANSMISSION
ELASTIC COUPLING:
An elastic coupling (SCHOTTEL supply) is fitted between the power input shaft of the
tunnel thruster and the electric prime mover (form of construction: V1, not SCHOTTEL
supply) which is mounted directly vertical on the thruster unit.
PRIME MOVER
ELECTRIC PRIME MOVER (NOT SCHOTTEL SUPPLY)
A frequency controlled asynchronous motor will be used as prime mover.
ELECTRONIC CONTROL SYSTEM
Not in SCHOTTEL scope of supply.
ALARM SYSTEM
The following alarm contacts of the mechanical system will be provided and can be
connected to the ship’s alarm system:
•Oil level too low
INTERFACES ELECTRIC SYSTEM
None
TOOLS
If special tools are required for standard service of the unit they are in our scope of supply.
SPARES
Spares will be supplied according to requirements of the classification society.

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 6/7
COATING AND PAINT STRUCTURE
The thruster tunnel will be sandblasted and coated with anticorrosive primer. The lower
gearbox will be sandblasted and coated with BELZONA 1321 (Ceramic S-metal), with
extremely high resistance against abrasion, cavitations and electrolytic corrosion:
Lower gearbox: sand blasting SA 2 1/2 DIN 55928
2 layers BELZONA 1321 (Ceramic S-metal) coating each
approx. 270 µm
Tunnel: sand blasting SA 2 1/2 DIN 55928
1 x 2K Epoxy-resin-primer approx. 40 μm
(final coating by shipyard as tunnel is welded
into the vessel and is therefore part of the hull)
QUALITY ASSURANCE
SCHOTTEL provides a quality assurance system in accordance with DIN ISO 9001
certified by GL, ABS, BV and DNV. The thruster system will be supplied with a
SCHOTTEL works certificate.
CLASSIFICATION
The transverse thruster unit and the electrical equipment will be supplied with a certificate
of: BV
Class notation: see cover page
DOCUMENTATION
•Thruster / drawing with all important dimensions of the tunnel thruster (CAD version)
•Dimensional drawings of all equipment delivered loose (CAD version)
•Installation and mounting instructions of bow thruster unit
•Drawing of tunnel grid (recommendation) (CAD version)
•Lubricating oil diagrams
•Spare parts list
•Operation and maintenance instructions in English language
•Approval drawings 8 sets (2)
•Working drawings 8 sets (2)
•Final drawings 5 sets + 1CD (2)

TECHNICAL SPECIFICATION
MER-071067-01/-10 IMR 1-10 / 14300235-243-261-266-270-279-282-285-288-291
Rev 8
08.11.07 R. Schwandt VB4 TS-71108_3 Page 7/7
COMMISSIONING
As per commercial contract
CONSERVATION
The bow thruster is supplied in preserved condition (effective up to 6 months) and without
oil.
EXCLUSIONS
•Electric motor as prime mover with control equipment
•Starting equipment and alarms for electrically driven motors or hy-pumps.
•Control Panels
•Protection grids for tunnel ends
•Protection of all moving parts
•Installation and coupling of the system
•Electrical and hydraulic connections between SCHOTTEL-components and ship's
sources
•Oil filling of all aggregates
•Alarm system (other than mentioned alarm switches)
•All parts not specifically indicated in the above specification as being part of our scope
of supply.

JOIN FORCES WITH THE BEST
SCHOTTEL
FOR PROGRESSIVE PROPULSION
Operating, Mounting and
Maintenance Instructions

Information on How to Order Spare Parts 347/98 1099241en STD--Ge 1/2
Information on How to Order Spare Parts
Only the use of
ORIGINAL SCHOTTEL SPARE PARTS
guarantees the trouble--free operation of the installa-
tion.
In order to avoid incorrect supplies we ask you to in-
clude the following details in your order:
order number
building number
project number
type of unit
manual number
assembly number
part number
designation
quantity
mode of shipment (by mail, truck, railway, . . .)
shipping address
Orders for spare parts should be in writing.
Acceptance and handling of orders by phone are ex-
clusively at the customer’s risk and on his account.

Operating, Mounting and Maintenance Instructions
enSTD--Ge
2/ 2Information on How to Order Spare Parts 347/98 1099241
Preliminary Remark
These operating, maintenance and mounting in-
structions are meant to offer information and help to
operate SCHOTTEL installations and perform main-
tenance works. Therefore it is required that these
documents are read, understood and observed.
It has to be ensured that these instructions are made
available to anyone involved in operation and main-
tenance.
We cannot be liable for damage and breakdowns re-
sulting from disregard of these instructions.
It is a prerequisite that users are familiar with the
installations and have been instructed with respect to
possible dangers.
Information referring to numbers in illustrations and
diagrams are indicated in the text in brackets.
Important information referring to technical and op-
erational safety is identified by the following symbols:
ATTENTION
!
This symbol refers to operating processes and meth-
ods to avoid damage to or destruction of the material.
NOTE
This symbol indicates particularities in the process
requiring attention.
!CAUTION
This symbol is used for operating processes and
methods requiring strict adherence to prevent the
staff from being exposed to hazards.
The ”Safety and Environmental Protection Regula-
tion SV1” as well as all relevant laws being in force
in situ shall be applicable to all works on SCHOTTEL
installations.
We reserve the right of technical alterations due to
the continued development SCHOTTEL installations
are subjected to.

en TDO--Ge 1/8
Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Safety and Environmental Protection Regulation ”SV 1”
Table of Contents
Preliminary remark 2.........................................................
1 Safety regulations 3.........................................................
2 Transport and storage 3.....................................................
Transport 3.................................................................
Storage 4...................................................................
3 Installation, Starting--up and Operation 4.....................................
Installation of SCHOTTEL Products 4..........................................
Starting--up and operation (general) 4..........................................
Starting--up and operation of control systems 5..................................
4 Maintenance and installation 5...............................................
5 Removing the underwater gears of SRP 7....................................
6 Welding 8..................................................................
7 Noise protection 8..........................................................
8 Use of appliances causing noise fields 8.....................................
9 Environmental protection regulations 8......................................

Operating, Mounting and Maintenance Instructions
en
TDO--Ge
2/
8Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Preliminary remark
These ”Safety and Environmental Protection Regu-
lations” shall provide the operator or technician re-
sponsible for operating, servicing, installing or re-
placing SCHOTTEL products, with information and
assistance. For this purpose, these regulations and
the accompanying operating and installation instruc-
tions must be read, understood and observed.
It must be ensured that the relevant regulations and
instructions are readily available to everyone en-
gaged in operation, maintenance and installation.
We assume no liability for damages and breakdowns
in operation which result from the failure to com-
ply with these regulations and the accompanying
operating and installation instructions.
It is assumed that the user and/or technician is famil-
iar with the product in question and has been
instructed on any possible risks involved.
As SCHOTTEL products are subject to further devel-
opment, we reserve the right to make any technical
alterations.
Where deviations between the German text and the
foreign language text occur for idiomatic reasons, the
German text is authoritative.
The regulations and instructions quoted in this vol-
ume apply within the area of the Federal Republic of
Germany.
In other countries, the statutory provisions applicable
there shall be observed.
Observe protection mark in accordance to DIN 34!
”The passing on or copying of these documents, their
utilization and the disclosure of their contents is pro-
hibited, unless explicitly granted. All acts contrary to
this entitle us to claim for compensation. All rights re-
served in the case of a patent being granted or a de-
sign being registered.
References to pictorial illustrations in the text appear
in brackets.

en TDO--Ge 3/8
Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
1 Safety regulations
The safety regulations must always be used in com-
bination with the relevant operating and installation
instructions.
SCHOTTEL products are to be employed only for the
use stipulated in the delivery cope.
Any use other than this is considered contrary to reg-
ulations. The SCHOTTEL--Werft is not liable for dam-
ages resulting from this. The risk, in this instance, is
borne solely by the user.
The operator or technician is obliged to refuse to
carry out any work on SCHOTTEL products which
does not comply with the regulations.
In the event of a fault, the cause must be established
immediately. If the fault cannot be defined or rectified
in a correct and competent manner, it must be elimi-
nated by qualified personnel.
To prevent accidents caused by slipping, negotiable
parts must be kept free of oil and grease.
In addition to the safety and environmental regula-
tions listed in these provisions, the safety regulations
of the trade association as well as the relevant regu-
lations for the prevention of accidents must be obser-
ved.
2 Transport and storage
Transport
SCHOTTEL products which, due to their weight, can-
not be lifted without the use of auxiliary equipment,
must be fixed to a raising harness only at the lifting
points provided. If necessary, ask about possible lift-
ing points at the SCHOTTEL--Werft.
Both raising harness and hoist must be selected in
accordance to the load to be lifted.
Do not walk or stand below raised loads.
To prevent damage to bearings and gearwheels,
gears must be braced.
Example
The SRP should be braced against the direction of
rotation of operation with a pretension of 5000 to
6000 N (1/1).
Use wooden edge protection for the propeller.
Figure 1
1

Operating, Mounting and Maintenance Instructions
en
TDO--Ge
4/
8Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Storage
The interior areas of the SCHOTTEL products in
question are preserved, following the trial run on the
test stand. Corrosion protection is sufficient for
approx. 6 months, when stored in dry environments
(no sea climate).
Prior to launching y prior to every intial start--up it is
necessary to top up oil
To this effect it is necessary to observe the different
operating instructions.
If a SCHOTTEL unit is put out of operation or re-
moved due to damage, then the unit must be filled
with fresh oil during the storage period, in order to
prevent damage through corrosion.
When storing in the open and/or with considerable
changes in ambient temperature, pressure relief
must be maintained for oil--filled units, as well as for
empty units (e.g new units).
This means:
In the case of units equipped with a vent valve,
the same be opened.
In case of units equipped with a mushroom--type
vent, pressure compensation is already main-
tained.
In the case of units which are only preas-
sembled, a provisional pressure compensation
device with dust protection must be installed at
a pipe connection.
ATTENTION
The storage of electric components, for instance in-
strument panels, switch cabinets etc. in the open is
prohibited.
3 Installation, Starting--up and Operation
Installation of SCHOTTEL Products
Before commencing installation, check that the
delivery is complete. All parts must be installed
and/or removed in a competent manner.
The installation of SCHOTTEL products requires
that:
Only those personnel who possess sufficient
technical expertise and the required equipment
shall be employed.
The installation proposals of SCHOTTEL--Werft
shall be observed, and/or requested as necess-
ary.
The relevant technical regulations shall be ob-
served.
Regulations of acceptance authorities under pri-
vate law and/or public law shall be complied
with.
Starting--up and operation (general)
The operating instructions of the relevant provisions
must be observed.
Before putting SCHOTTEL products into operation,
a check must be made for obvious defects and to en-
sure that all protection devices (e.g. cover plates) are
installed soundly. Defective units may not be put into
operation.
Units with defective instruments, pilot lamps and/or
control elements may not be put into operation.
The operator must make absolutely sure that no one
is located within the danger zone of the unit before
putting this into operation.
The indicating instruments must be checked for cor-
rect functioning directly after starting--up, if neces-
sary the unit must be switched off again.