InstallationManual TunnelThruster CP RRM300028923 925 931 933

INSTALLATION MANUAL
DMN300005384
Rolls-Royce Tunnel Thruster

Tunnel Thruster
Mechanical and Hydraulic system
Yard and hull no. : Alianca S/A AL 020

ERP no. : 13S000410_411
Unit no. : RRM300028923, RRM300028925,
RRM300028931, RRM300028933
Date : 26 September 2013
Contract manager for this project:

Arild Hanken
Arild.hanken@rolls-royce.com
+47 70235277
Rolls-Royce Tunnel Thruster Installation manual Page 1 of 159

Revision history
Rev. Date Sign Changes at page Description

A 26.09.2013 TIE - First issue
Page 2 of 159 Installation manual Rolls-Royce Tunnel Thruster

TABLE OF CONTENTS
1. INTRODUCTION ......................................................................................5
1.1 Purpose .............................................................................................................................5
1.2 Warranty ............................................................................................................................5
1.3 Structure of this Installation Manual ..................................................................................5
1.4 Abbreviations .....................................................................................................................6
2. SAFETY ...................................................................................................7
2.1 General statement .............................................................................................................7
2.2 Safety Annotations ............................................................................................................8
2.3 Declaration of Conformity ..................................................................................................8
3. SYSTEM DESCRIPTION .........................................................................9

3.1 System Overview...............................................................................................................9
3.2 Design............................................................................................................................. 10
3.2.1 Tunnel ............................................................................................................................. 12
3.2.2 Thruster unit ................................................................................................................... 12
3.2.3 Gravity tank .................................................................................................................... 13
3.2.4 Seal tank ......................................................................................................................... 13
3.2.5 Hydraulic module ............................................................................................................ 13
3.2.6 Oil cooler ........................................................................................................................ 14
3.2.7 Drain pump unit .............................................................................................................. 14
3.2.8 Drain pump ..................................................................................................................... 15
3.2.9 Pitch feedback device..................................................................................................... 15
4. DELIVERY SPECIFICATION ................................................................. 17
5. TECHNICAL DATA ................................................................................ 19

5.1 Oil recommendations...................................................................................................... 19
5.1.1 Approved lubrication oil .................................................................................................. 19
5.1.2 Grease for Couplings...................................................................................................... 20
5.2 Standard painting specifications ..................................................................................... 20
6. HANDLING AND PRESERVATION ....................................................... 23

6.1 Delivery check ................................................................................................................ 23
6.2 Storage ........................................................................................................................... 23
6.3 Recommendations for long time storage (more than 6 months) .................................... 24
6.4 Recommendations at long fitting out period ................................................................... 24
7. INSTALLATION ..................................................................................... 25
7.1 Installation overview ....................................................................................................... 26
7.2 Installation of tunnel........................................................................................................ 28
7.2.1 Tunnel extension ............................................................................................................ 29
7.2.2 Connection to hull structure ............................................................................................ 29
7.2.3 Welding procedure ......................................................................................................... 29
7.3 Installation of thruster unit using jig ................................................................................ 30
7.3.1 Preparations ................................................................................................................... 31
7.3.2 Mounting, propeller unit .................................................................................................. 32
7.3.3 Verification/adjustment ................................................................................................... 33
7.4 Measurement of propeller clearing ................................................................................. 34
7.5 Welding of stay ............................................................................................................... 36

7.6 Oil filling .......................................................................................................................... 38
7.6.1 Hub, high pressure chamber .......................................................................................... 39
7.6.2 Hub, low pressure chamber ............................................................................................ 39
7.7 Installation of tooth coupling ........................................................................................... 41
7.8 Installation of motor foundation ...................................................................................... 45
7.9 Control of motor foundation alignment ........................................................................... 46
7.10 Placing of anodes ........................................................................................................... 48
7.11 Flushing of pipes ............................................................................................................. 50
7.11.1 Flushing sequence.......................................................................................................... 51
7.12 Placing of hydraulic module and tanks ........................................................................... 52
7.12.1 Location of Gravity tank .................................................................................................. 52
7.12.2 Pressure setting of Gravity tank ..................................................................................... 53
7.12.3 Location of Drain pump................................................................................................... 53
7.12.4 Location of Seal tank ...................................................................................................... 53
7.12.5 Location of hydraulic module .......................................................................................... 53
7.13 Installation of pipes ......................................................................................................... 54
7.14 Installation of the feedback device ................................................................................. 55
7.15 Air venting of pitch system .............................................................................................. 56
8. COMMISSIONING ................................................................................. 59
8.1 Precautions before start-up ............................................................................................ 59
8.1 Installation checklist ........................................................................................................ 60
8.1.1 Activities performed by the shipyard personnel .............................................................. 60
8.1.2 Activities supervised by Rolls-Royce Marine engineers ................................................. 62
9. CONTACT INFORMATION ................................................................... 65
10. FINAL INSPECTION ............................................................................. 67

10.1 At quay before trials ........................................................................................................ 67
10.2 Function test ................................................................................................................... 67
10.3 Harbour acceptance test................................................................................................. 67
10.4 Sea acceptance test ....................................................................................................... 67
10.5 Sea trial report ................................................................................................................ 68
11. TOOLS .................................................................................................. 73
12. DESIGN DRAWINGS ............................................................................ 75

12.1 Mechanic and Hydraulic ................................................................................................. 75
12.2 Electric ............................................................................................................................ 75

1. INTRODUCTION
1.1 Purpose
The Installation manual provides the information necessary to plan and install the delivered system
safely and correctly. It also enables you to verify the functionality of the equipment.
Also included are instructions for handling of the goods after they have been received at the yard. It
is important that the instructions be followed carefully to avoid problems during outfitting and
commissioning. This manual also provides instructions for all activities essential for commissioning.
1.2 Warranty
The product has a limited warranty. Please note that the warranty will be void if the equipment is
misused or not handled in accordance to prescribed standards, for example dismantling the
equipment to a level greater than described.
1.3 Structure of this Installation Manual

The first part of this manual describes the Rolls-Royce Tunnel Thruster. This helps in
understanding the installation procedures that are specified in the subsequent chapters.
 Chapters 1, 2 and 3 provide general Tunnel Thruster information.
 Chapters 4, 5, 11, 12 and 13 provide project specific information.
 Chapter 5 provides technical data.
 Chapter 7 includes all installation procedures.
 Chapters 8 and 10 provide all information related to commissioning and sea trial.
Note!
All pictures used in this manual are for illustration only.

1.4 Abbreviations
Abbreviation Description
CP Controllable pitch (propeller)
FP Fixed pitch (propeller)
cSt Centistoke (oil viscosity)
Hz Hertz (frequency)
ºC Centigrade (temperature)
kg Kilogram (weight)
kW Kilowatt (power)
l/min Liters per minute (flow)
MCR Maximum continuous rating (power rating)
mm Millimeters (lengths and diameters)
RPM Revolutions per minute (rotation speed)
V Volt (voltage)

2. SAFETY
Please take the time to read this chapter carefully, as it concerns your safety.
2.1 General statement

"UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR
INDIRECTLY CREATE RISKS TO:
[1] THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING THE WORK OR,
[2] THE PRODUCT AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS

AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK
ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY, LEGAL
AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE
PERSONS UNDERTAKING THE WORK.
IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS

AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED
BY THIS DOCUMENT TO PROTECT AGAINST RISKS TO THE ROLLS-ROYCE REDUCTION
GEAR AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM THEIR
RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND PRECAUTION REFERRED TO
ABOVE ARE IMPLEMENTED.
IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME
AWARE OF ANY ROLLS-ROYCE MARINE PRODUCT DESIGN RELATED FEATURE WHICH
COULD CREATE RISK TO A PERSON UNDERTAKING WORK OR TO THE PRODUCT AND/OR
ITS COMPONENTS PLEASE CONTACT THE RESPECTIVE TECHNICAL PRODUCT MANAGER
AT ROLLS-ROYCE MARINE AS IMMEDIATELY."

2.2 Safety Annotations
All safety directions must be respected in order to avoid damage to personnel, environment and
equipment.
The annotations used in this manual and the significance of each are listed below:
Warning
Indicates hazardous or unsafe practices, which COULD result in fatal or severe

personnel injuries and/or substantial product or property damage, if the required
precautions are not taken.
CAUTION!
Indicates hazardous or unsafe practices, which COULD result in minor personnel injuries and/or
property damage, if the requisite precautions are not taken.
Note
Draws attention to specific information of technical significance that might not be immediately
obvious to the specialist personnel, or points to important information in the procedures to follow.
2.3 Declaration of Conformity

Rolls-Royce Products are designed and built as per one of the following standards:
 Det Norske Veritas (DNV)
 American Bureau of Shipping (ABS)
 Lloyds Register (LR)
 Germanisher Lloyds (GL)
 Bureau Veritas (BV)
 RINA
 Russian Maritime Register of Shipping (RS)
 Korean Register of Shipping (KR)
 Nippon Kaiji Kyokai (NK)
A Class Certificate is issued for each product in accordance with the Class of the vessel.

3. SYSTEM DESCRIPTION
This section provides detailed information about the system to ensure safe and efficient operations.
Refer to Chapter 12 for the project specific assembly drawings from Rolls-Royce Marine.
3.1 System Overview

The Rolls-Royce Tunnel Thruster is mounted in a separate tunnel that is welded to the ship’s hull.
There are two propeller types available of Rolls-Royce Tunnel Thrusters: Controllable Pitch (CP)
and Fixed Pitch (FP). The main difference in function is that the CP thruster has remotely
adjustable propeller blades, while the FP thruster has fixed blades.
Auxiliary versions are designed with standard hydraulic system. Normal draft versions are designed
with a standard hydraulic system, including flushing of the seal box. Deep draft versions are
delivered with a deep drain arrangement, including an extra drain tank unit and an extra sealing at
the pinion.
The main versions of Rolls-Royce Tunnel Thrusters
Dynamic Positioning (DP) Auxilliary (AUX) Ice class duty (Ice)

The DP-thrusters have been The AUX thruster is the The ICE thrusters have been
designed for continuous standard design Rolls-Royce designed to withstand the ice
running operation and are Tunnel Thruster optimized for conditions required for ICE 1A
derated compared to the AUX maximum power and with Super and are derated
thruster. The DP thrusters are intermittent running profile and compared to the AUX thruster.
also equipped with a heavy limited running hours/year. The The ICE thrusters are also
duty wear resistant propeller thruster is equipped with designed for limited running
hub and skewed propeller skewed propeller blades for hours/year. The ice thrusters
blades for high efficiency/low high efficiency and low noise. are equipped with stainless
noise. A shaft seal with Viton steel propeller hub and kaplan
superlip seal rings running on a blades for increased strength.
ceramic coated liner and with a
separate lubrication system is
installed to withstand longer
running hours.
CP or FP CP or FP CP
Normal draft or deep draft Normal draft or deep draft Normal draft
Super Silent (TT2200 , TT2400 NA NA
and TT2800)

3.2 Design
A typical CP thruster configuration is shown in the figure below. Refer to the table on the next page
for component names and reference.
= Hydraulic
= Control
= Mechanical

Components not included in the standard Rolls-Royce Tunnel Thruster delivery are colored light
blue and may be ordered separately.
Pos. Component TT version Comment Chapter

1 Tunnel A 3.2.1
2 Thruster unit A 3.2.2
3 Shaft seal A
4 Propeller A
5 Pitch feedback CP 3.2.9
6 Tooth coupling A
7 Drive motor From Rolls-Royce Marine or
A
external supplier.
8 Gravity tank A 3.2.3
9 Drain pump (hand pump) A 3.2.8
10 Hydraulic module A 3.2.5
11 Hydraulic pump A
12 Pitch control CP
13 Oil cooler DP (AUX) 3.2.6
14 Drain pump unit A Only deep draught. 3.2.7
15 Seal tank DP 3.2.4
16 Drive motor starter Option.
A
cabinet.
17 DOL starter (hydraulic
A
pump).
18 DOL starter (drain Only deep draught.
A
pump).
19 Drive motor starter. From Rolls-Royce Marine or
A
external supplier.
20 Remote control A
A = Available on all TT versions, CP = only available on CP thrusters, DP = only available on DP
systems.

3.2.1 Tunnel
The thruster unit (3.2.2) is mounted into a transverse tunnel in the

hull, normally with the standard single wall design.
The Rolls-Royce Super Silent Tunnel Thruster is designed for

exceptionally low noise operation and is ideal for offshore vessels
where low noise and vibration levels are vital. It has double walls
for the full tunnel length and a flexible mounted inner tunnel. It is
equipped with leakage detectors between the walls. To further
decrease noise levels, Super Silent thrusters have reduced
propeller tip speed.
If required, the tunnels can have a stainless steel layer in the

propeller area for erosion protection.
3.2.2 Thruster unit
The thrusters are designed to give a transverse thrust to the port

and starboard sides, to move the hull sideways.
The Rolls-Royce Tunnel Thruster consists of a propeller hub with
blades and a propeller shaft, one spherical roller bearing, and two
axial roller bearings that support the shaft. A shaft seal prevents
water penetration and oil leakage. The propeller is driven by a
bevel gear, through a vertical shaft, extending into the ship’s hull.
There are two alternative propeller configurations:
 Controllable pitch (CP): The direction of thrust is regulated by
the pitch of the propeller blades.
 Fixed pitch (FP): The direction of thrust is regulated by

running the propeller in alternate directions.

3.2.3 Gravity tank
The oil tank will work both as a main oil tank and a gravity tank
and must be installed according to specifications by Rolls-Royce
Marine.
The gravity tank may also be delivered as a pressurized gravity
tank. It is then possible to pressurize the tank with air to
compensate for a lower placement in the ship.
The tank is equipped with a level switch (LS51 at Hydraulic
system diagram) for "low level alarm" and “high level alarm”. The
switch can be easily dismantled at testing.
A temperature switch (TS51) for "alarm, high oil temperature" is
installed in the oil tank.
The gravity tank is also equipped with a valve for shutting off the
oil flow.
3.2.4 Seal tank
Only for DP thrusters (TT>1100)

The purpose of this tank is to maintain oil pressure inside the
shaft seal. It is equipped with a level switch for high and low level
alarm.
3.2.5 Hydraulic module
It is important to maintain the system in such a way that it is

always in the best condition. Remember to follow the oil
recommendations, as well as the instructions given in the
maintenance chapter.
The pumps (1 or 2 in number) are vertically mounted on the
module, and driven by an electric motor.
An oil filter is mounted on the module and is equipped with an

indicator that provides a warning when the element needs to be
replaced. The filter is also provided with a by-pass valve, in case
of extreme clogging, or a cold start.

Some installations (standard DP, optional on AUX) may be equipped with a duplex filter, allowing
for a change of filter element in one of the filter bowls, while the other runs normally.
Note!
The indicator can show "red" on operation with cold oil. This does not necessarily mean that the
filter element is clogged, but may be caused by the high viscosity of the cold oil.
The hydraulic module is equipped with 3 different pressure switches (5 in the case of 2 pumps)
indicating either:
 Alarm, low pressure.
 Interlock, stop drive.
 Alarm, high pressure.
 (Autostart, pump I and pump II)
3.2.6 Oil cooler
Check the technical specification for clarification of scope of

supply.
The oil cooler is located between the hydraulic module (3.2.4)

and the thruster unit (3.2.2). Its main purpose is to cool the
hydraulic oil, using sea water or fresh water.
The cooler is equipped with a thermostatic valve for constant oil

temperature, two thermometers for the visual inspection of
temperature, and a spring loaded check valve for protecting the
oil cooler against pressure peaks.
3.2.7 Drain pump unit
Check the technical specification for clarification of scope of

supply.
The drain tank is connected to the flushing of the input shaft seal
and bearing arrangement.
A level switch will control the motor running the pump, pumping
the oil from the tank back into the system gravity tank.

3.2.8 Drain pump
A hand pump is provided for draining of oil and for oil sampling.
3.2.9 Pitch feedback device
CP thrusters only.
The pitch feedback device monitors the pitch of the propeller.
The feedback pick-up device is placed on the top flange of the
thruster unit, and is bolted to the propeller unit. The mechanical
movement is transmitted by means of a link and lever to the
potentiometer that is electrically connected to the remote control
system.

4. DELIVERY SPECIFICATION
This chapter contains the delivery specification defined by the Rolls-Royce Marine sales
representative in consultation with the customer.

5. TECHNICAL DATA
5.1 Oil recommendations

Warning
 Using oil other than that specified by Rolls-Royce Marine may cause
. malfunctions when manoeuvring the vessel. This may cause personal
injury and equipment damage.
5.1.1 Approved lubrication oil
The following lubrication oils are approved and recommended by Rolls-Royce Marine:
Manufacturer Type
BP ENERGOL GR-XP 68
CALTEX REGAL MARINE 500
CASTROL ALPHA SP 68
CHEVRON NL GEAR COMPOUND 68
ELF EPONA-Z 68
ELF VISGA 68
FRANCE PETROLEUM TOTAL CARTER EP 100
MOBIL MOBIL GEAR 600 XP 68
SHELL OMALA OIL 68
TEXACO MEROPA 68
Caution!
Do not mix motor oil with other types of oil. Even very small amounts of motor oil in the hydraulic
oil, will considerably lower the quality of these oils.
Change the oil when laboratory tests show:
 High neutralising number
 Low remaining amount of EP-additives
 High amounts of insoluble particles in the oil
 The viscosity is not within limits.

5.1.2 Grease for Couplings
The preferred greases are:
Manufacturer Type
AMOCO Coupling grease
ESSO-EXXON Mobilith SHC 460
KLÜBER Klüberplex GE 11-680
MOBIL Mobilgrease XTC
TEXACO Coupling grease Multifak 0/1
These greases are to be used under the following conditions:
 Angular misalignment less than 35 degrees.
 Coupling surface temperature lower than 70ºC.
 Speed not too high. (< 3000 rpm)
 Speed not too low. (> 200 rpm)
 No shocks, no big reversing loads.
 Good sealing conditions and no severe environment.
5.2 Standard painting specifications

 The paint coating offers protection against corrosion under normal transportation, in storage
and during outfitting periods.
 The yard carries out the final treatment according to the total painting system for the ship.
Preparation before coating:
Specification Applies to
ISO 8501-1 Surface preparation.
ISO 8501-3 Visual assessment of surface cleanliness (Grade P3)
ISO 8503-1 Steel roughness. (Medium (G) Ry 50-80 micron.)
ISO 8502-3 Dust-free testing before painting.
ISO 8502-4 Climatic conditions during painting.
Note!
Air temperature and steel temperature must at a minimum be +10°C or 3°C above dew point,
whichever is higher.

The components are delivered according to the following specification:
Sandblasting and Primer Amount

Sandblasting to SA 2,5 Strip coating before one layer of Epoxy Primer 40 – 80 microns
Interguard 269 EGA 088/089 (Red)
Parts
Tunnel
Motor foundation
Stay
Thruster unit
Oil tank
Hydraulic module
Paint Amount
One layer Intershield 300 (Bronze). min. 150 microns
One layer Intershield 300 (Alu). min. 150 microns
Part
Tunnel, non-accessible areas after mounting (Dwg. K141514)
TT Super Silent ; area between inner and outer tunnel
Paint Amount
Interprime 198 (Grey) 40 - 80 micron
One layer Interlack DQE322, RAL 6019 (Green) 40 - 80 micron
Part
Oil tank
Hydraulic module
Electronic equipment Paint

Control panel RAL 9011, black
Electronic cabinet and Starter cabinet RAL 7032, grey

6. HANDLING AND PRESERVATION
Note!
Work such as sandblasting close to the thruster unit, will create a risk of getting sand or dirt onto
the thruster blade and propeller shaft seal. In such circumstances, the thruster needs to be properly
protected, especially the blade seal and the propeller shaft seal.
6.1 Delivery check

Immediately upon arrival, the equipment must be unpacked and inspected. If there are any
complaints, you must inform Rolls-Royce Marine as soon as possible.
Immediately fill the propeller unit with the prescribed oil. During the testing before delivery, the unit
has been filled with oil and then drained. The residual oil film protects against corrosion for a
maximum period of 3 months.
The oil should meet the requirements stated in chapter 5.1.
6.2 Storage
The equipment is packed and conserved for shipment and storage for 3 months - unless otherwise
agreed in writing. Storage days are counted as delivery date to first start-up.
During storage, it is important to protect the equipment against corrosion as well as moisture and
dust.
At the shipyard, store all goods indoors. Temporary built shelters with good ventilation can be used
for some heavy components. Dust free environment is necessary for storing electrical equipment.
However, assembled machinery and electric motors must be stored in an area without ground
excitation.
Immediately after installation, the thruster system needs to be filled with oil. Before the launch of
the vessel, connect the gravity/expansion tank as shown in the hydraulic system drawing. Without a
permanent tank, a temporary arrangement has to be provided, to ensure oil pressure inside to be
0.3 bar above outside sea water pressure at all times.
In case of severely corrosive water conditions, arrangements to inhibit corrosion of the

propeller/nozzle must be carried out. It can be bubbling of air, extra temporary anodes, or
impressed current.
Regarding the top of thruster and the hydraulic system, all openings are to be sealed off at all
times. Fill the pipes with oil to inhibit rust. Preferably use oil specified by Rolls-Royce Marine.
The gear must be rotated at intervals if installed or stored in an area close to working machinery
which causes ground excitations.
Electronic equipment should be protected from excessive dust and humidity.

6.3 Recommendations for long time storage (more than 6
months)
Propeller unit, Coupling:
 These parts must be kept in an indoor warehouse.
 Outside surfaces must be protected against corrosion. We recommend the use of Dinitrol 33,
Tectyl 502, or equivalent products.
 The equipment shall be inspected and the propeller shall be rotated (by hand) at evenly spaced
short intervals.
 The propeller unit shall immediately be filled with oil. During inspection, check for any oil
leakage. For oil type, see Rolls-Royce Marine recommendation, chapter 5.1.
Hydraulic units:
 These parts must be kept in an indoor warehouse.
 Temperature must be above freezing point.
 Humidity must not exceed 80 %.
 Machine finished surfaces to be protected by oil treatment (Tectyl 258 or similar product).
Rubber sealings:
 To be kept in a dark area. In addition, all conditions that apply to the hydraulic units, are also
applicable.
6.4 Recommendations at long fitting out period

 Check the oil level in the tank every day, or connect the level switch to the alarm system.
 Rotate the propeller a few times once a week or at least once a month.
 Check the cathode protection system every 3 months.
 Inspect and clean (if necessary) before putting the propeller into operation.
 Prior to start up; have the complete system inspected by a Rolls-Royce Marine engineer.
The Thruster is equipped with anodes. The anodes must remain in place during the whole fitting-
out period. After launching, properly earth the vessel to the welding equipment so that leakage
currents do not go through the propeller.
Rolls-Royce Marine guarantee does not cover galvanic erosion damages that occur during the
outfitting time of the ship because of insufficient precautions taken by the shipyard.

7. INSTALLATION
Warning
 Never work alone when installing heavy components, even when using
secure lifting equipment such as lockable block and tackle. Most lifting
devices require two people, one to operate the lifting device and another
to ensure that the components do not get caught and damaged.
 Using hydraulic oil other than that specified in this manual may cause
malfunctions when maneuvering the vessel. This may cause injuries to the
personnel and damage to equipment.
 Always wear protective goggles if there is a risk of splinters, grinding

sparks and splashes from acids or other chemicals. Eyes are extremely
sensitive and an injury to them can result in loss of sight.
Caution!
 Plan in advance so that you have enough room for safe installation and (future) dismantling.
Plan the compartments such that all service points are accessible. Ensure that contact with
rotating components, hot surfaces or sharp edges when servicing and inspecting the propeller
system is not possible.
 Protect all parts in the Rolls-Royce Tunnel Thruster delivery such as the propeller unit,
hydraulic components and control system components during installation. In particular,
transmitters, sensors and sensitive bearings must be fully protected to avoid damage.
 Immediately on arrival, fill the propeller unit with oil of prescribed quality.
 Prior to welding, ensure that the electric system of the vessel is disconnected.
 Ensure that the warning or information decals on the product are always visible. Replace
decals that are damaged or painted over.
 Most chemicals intended for the product (engine and gearbox oils, glycol, gasoline and diesel),
or chemicals intended for the workshop (degreasing agent, paints and solvents) are harmful to
your health. Read the instructions on the packaging carefully. Always follow requisite protective
measures such as using protective masks, goggles, gloves etc. Ensure that other personnel
are not unknowingly exposed to harmful substances in the air that they breathe; for example,
ensure adequate ventilation. Deal with used and excess chemicals as directed.

7.1 Installation overview
Note!
It is highly recommended to read this entire chapter BEFORE starting any installation work.
Component Seq. Procedure Tools Reference doc. Cpt.

Tunnel and 1 Installation of  Welding “Arr. tunnel 7.2
stay tunnel. equipment mounting”
 Non-alloyed “Location of tunnel
electrodes in hull”
3 Measurement of  Measuring 7.4

propeller clearing. equipment
4 Welding of stay.  Welding “Arr. tunnel 7.5

equipment mounting”
 Non-alloyed
electrodes
9 Placing of anodes.  Welding “Recommendation 7.10

equipment for location of
anodes”
 Non-alloyed
electrodes
Motor and 6 Installation of motor “Motor foundation 7.8

motor found foundation. assembly”
7 Installation of tooth  Hydraulic “Gear coupling” 7.7
coupling. injector
 Special
wrench
 Equipment for
heating
 Dial gauge
8 Control of motor  Dial gauge “Motor foundation 7.9

foundation assembly”
alignment.
Thruster (2) Installation of  I-beams or 7.3
Unit thruster unit using similar.
jig.
 Lifting eyes
 Lifting tackles
 Flat lifting
straps
 Sealing

Component Seq. Procedure Tools Reference doc. Cpt.
compound
 Padeye
5 Oil filling.  Pump with “Hydraulic system 7.6

filter diagram”
Hydraulic 10/ Flushing of pipes.  Cleaning “Hydraulic system 7.11

system plugs diagram”
16
 Pump with
filter
11 Placing of hydraulic “Hydraulic system 7.12

module and tanks. diagram”
12 Installation of pipes.  Bending “Hydraulic system 7.13
machine diagram”
Feedback 13 Installation of “Feedback device 7.14

ass. feedback device. assembly”
14 Air venting of pitch “Hydraulic system 7.15
system. diagram”

7.2 Installation of tunnel
Spare parts Ref. no Special tools and test equipment Qty
Welding equipment
Reference documents Consumables Qty
Welding procedure PS 026.204 According to welding procedure
“Arr. tunnel mounting”
“Location of tunnel in hull”
Warning
 For welding the tunnel into the hull, the yard must use skilled welders and
. follow our enclosed guidelines. Yard must submit actual welding
procedure to Rolls-Royce Marine for approval before the welding starts.
 Before welding, the blade tip

clearance is measured and
noted. The clearance is then
observed and measured
continuously during the
welding procedure.
 After welding, the propeller

blade tip clearance must be
checked and recorded.
 Subsequent to the final

welding, blade tip clearance
should be between 6 and 25
mm.
 Weld according to WPS, and rules of the actual classification society.

Weld using the back-step method and with outmost care.
 Note that no welding is allowed on top of the standard propeller tunnel. Refer to the figure
above.
 For installations with the drive motor installed on the thruster unit via a motor foundation, the
stiffness of the tunnel structure must be considered, based on motor weight, height and other
parameters.

7.2.1 Tunnel extension
 Place the tunnel extensions against the ends of the propeller tunnel and block them up. During
welding, the propeller, and especially the blade feet and seats, must be protected against
welding spatter.
 When the joint to tunnel extensions has been filled, it shall be ground even on the "wet” side.
The porosities, which might exist, shall be removed, and the joint shall be reweld and ground.
 Exercise caution to ensure that the stainless steel layer (optional) in the way of the blade tip
area of the propeller tunnel is not damaged.
 Weld using the back-step method using electrodes according to welding procedure.
7.2.2 Connection to hull structure

 For some installations, it is necessary to connect the tunnel shell plate to webs, frames, tank
top etc. To facilitate the connection to the hull structure, it can sometimes be advantageous to
provide the tunnel with connection bars before installation.
 Note that no welding is allowed on top of the standard propeller tunnel. Refer to the illustration
above.
 After welding, check and record the propeller blade tip clearance. Also refer to the General”
section.
7.2.3 Welding procedure
When welding the tunnel to the hull, use the following welding procedure:
WPS
PS 026.204

7.3 Installation of thruster unit using jig
Lifting tackles
Flat lifting straps
Welding equipment
Welding procedure PS 026.089 L-beams or similar. 2
Drawing “Operating Principle, Installation Lifting eyes 2

Jig”
Lubrication
Padeye
Sealing compound
If the thruster unit is delivered separately, this procedure illustrates an suggestion of how to install
the thruster unit. The installation jig is not part of the Rolls-Royce Marine delivery. The thruster unit
can also be installed by using lifting eyes, lifting tackles and lifting straps.
Warning
 BEFORE committing the propeller unit to the beams, make sure the
. beams are properly supported by scaffolding or other support structure
and that no personnel is present underneath the working area.
Caution!
Before inserting the propeller unit into the tunnel, check the mounting flange in the tunnel for any
distortion that might have occurred during the welding of the tunnel into the hull. If the measured
dimensions are outside the tolerance limits, contact Rolls Royce Marine for advice.
Note!
 If the tunnel is fitted with a stainless steel erosion ring, the propeller unit should be entered from
opposite the propeller side. If the tunnel has no erosion ring, the propeller unit should be
entered from the propeller side.
 Before inserting the propeller unit into the tunnel, the mounting flange in the tunnel must be
checked for any distortion that might have occurred during the welding of the tunnel into the
hull. If the measured dimensions are outside the tolerance limits, contact Rolls Royce Marine
for advice.

7.3.1 Preparations
1. Prepare two I-beams or similar for welding onto the tunnel edge. The beams serve as
temporary landing for the mounting jig as it is hoisted into position for rolling into the tunnel. The
beams are to be of proper dimension to carry the load of the propeller unit. Refer to table 1 for
propeller unit weights.
2. Align the beams with the tunnel edge such that the mounting jig can be rolled from the initial
position on the beams and into the tunnel without obstructions.
3. Arrange fences on beams; for example, by means of flat bar welded to I-beam flanges. The
fences ensure that the installation jig stays securely on the support beams.
4. Arrange proper lateral support for beams; for example, by means of cross bracing with a flat
bar or other suitable material.
5. Arrange the beams as indicated in the following figure. The beams must protrude enough
beyond the upper tunnel edge to allow the propeller unit to land unobstructed on the beams.
The beams should be spaced to match the installation jig and angled to match the tunnel inner
surface. Refer to the assembly drawing for the mounting jig size in question for alignment
details.
6. Weld or otherwise attach two lifting eyes in approximately 5 and 7 O’clock positions in the
tunnel opposite to the support beams. Do not weld onto the stainless steel erosion ring, if
present.
7. Prepare the installation jig by mounting the wheel fork and wheel assembly onto the jig. To fix
the wheel forks:
a. Insert grub screws (2 pcs. per fork – 8 totals) fully, and then unscrew ½ turn to allow fork to
rotate freely.
b. Use a grease gun to lubricate the wheels and the wheel forks through the supplied grease
nipples. Apply grease liberally to reduce friction.
8. Mount the installation jig under the propeller unit, maintaining the correct orientation.
Thruster unit weight [kg]

Thruster size Weight with blades Weight without blades Blade weight
TT1100 910 814 24
TT1300 1200 1040 41
TT1650 2000 1685 79
TT1850 2500 2095 102
TT2000 3600 3035 142
TT2200 4500 3760 185
TT2400 6200 5340 216
TT2650 8000 6760 309
TT2800 9400 7940 390
TT3000 12000 9940 516
TT3300 14500 11980 630
These weights are for guidance. There can be some variations based on type of thruster.

7.3.2 Mounting, propeller unit
1. Attach lifting straps to the

propeller hub and below the
propeller unit flange. When
attaching straps, be
cautious not to damage the
rope guard covers or the
feedback shaft.
2. Position the propeller unit

carefully onto the support
beams using a crane.
3. Attach the straps and tackle Figure 1

arrangement between the
lifting eyes welded onto the
tunnel and the attachment
point on the installation jig.
4. Start operating the horizontal tackles and thereby, pulling the propeller unit into the tunnel as
shown in figure 2 below. Ensure that there is no damage to the propeller blades (if fitted)
during this operation, and check clearances to the tunnel wall while proceeding.
5. Continue this operation until the propeller unit is placed under the mounting flange.
6. Clean the tunnel flange and the propeller unit flange carefully. Ensure that the bolt holes are
not filled with anti corrosion paint.
7. Fit the O-ring and apply the sealing compound to the

flange area, to prevent rust and water ingress.
8. Fit the guide pins to the propeller unit flange.
9. Insert a padeye in the drive shaft.
10. Attach a lifting tackle to this padeye, and start pulling

upwards until the propeller unit is in the horizontal
position.
Figure 2
Note!
 In case the tunnel is short relative to the thruster length,
ensure that the propeller blades (if fitted) do not protrude
beyond the tunnel edge and get caught on the tunnel
edge, as this may cause damage to the blades.
Figure 3

 Use jacks under the installation jig to assist in lifting of
the propeller unit. Observe the deflection of the tunnel
wall under jacks, taking care not to damage the tunnel
wall or cause any permanent deformation to the tunnel.
11. Ensure that the O-ring is properly seated in the groove.
12. Pull the propeller unit up until the mating faces are in
contact. Be careful not to damage the pitch feedback rod
when entering through the bore in the tunnel flange
during this operation.
Figure 4
13. Insert the flange bolts, when the propeller unit is in position. Make sure that the propeller unit
is centered (by measuring the clearance between the propeller blades and the tunnel plate).
14. Tighten the bolts to the correct torque. If the propeller blades are not fitted at this stage, then
measure the distance from the propeller hub to the tunnel plate with 90° increments.
15. After tightening all the flange bolts, remove the installation jig from the propeller unit. Do not
forget to remove any attachment points welded into the tunnel during mounting.
Thruster Size Torque Bolt reference

TT1100 Torque 150 Nm M16 x 60
TT2400 Torque 1020 Nm M30 x 100
TT2650 Torque 1020 Nm M30 x 110
TT2800 Torque 1650 Nm M36 x 120
TT3000 Torque 2800 Nm M42 x 150
TT3300 Torque 2800 Nm M42 x 150
7.3.3 Verification/adjustment
Recheck the propeller clearance to the tunnel. If necessary:
1. Loosen the upper flange propeller unit bolts and adjust the clearance by moving the propeller
unit carefully.
2. Retighten the upper flange bolts as specified.
3. Secure the upper flange bolts by welding a bar across the bolt heads (refer to the propeller unit
assembly drawing).

7.4 Measurement of propeller clearing
Measuring of thruster not mounted in tunnel:
1. Measure the radius of each blade
2. Record the radius in table 3.
Measuring of thruster mounted in the tunnel:
1. Each propeller blade must be marked with numbers 1 – 4.
2. Measure clearance between tunnel and blade at all four

positions (A – D).
3. Record the clearance in table 1, below.
4. Rotate the blade with the smallest gap according to table

1.
5. Identify the location of minimum clearance and mark this

clearly on the illustration to the right. Also, record this
measurement in table 2.
Position A Position B Position C Position D

Blade 1 mm mm mm mm
Blade 2 mm mm mm mm
Blade 3 mm mm mm mm
Blade 4 mm mm mm mm
Table 1 Inspection of clearance
Blade number
Clearance
Table 2 Minimum clearance

Radius
Blade 1
Blade 2
Blade 3
Blade 4
Table 3 Radius of blades
Thruster size Clearance

1100 4 – 22
1300 6 – 23
1650 6 – 25
1850 6 – 25
2000 6 – 25
2200 6 – 26
2400 6 – 26
2650 8 – 26
2800 8 – 33
3000 8 – 33
3300 8 – 33
Table 4 Nominal clearance between blade tip and tunnel
Acceptance criteria:
 Clearance between blades and tunnel acc. to table 4.
 Radius of the propeller blades according to drawing.

7.5 Welding of stay
Welding equipment
“Arr. Tunnel mounting” According to welding procedure
1. Install the thruster unit into the tunnel according to chapter 7.3
2. Trim the length of the stay, as follow (See supporting sketch below):
 Use a straight bar that is chamfered at one end to measure the length from the thruster unit
center to the tunnel wall. The measurements will vary due to acceptable tolerances and
distortions in the tunnel.
 Carry out this measurement at the bolt PCD both port / starboard and fore / aft.
 Compensate for the actual thickness of the stay to get the final measurement.
 Transfer the measurement to the stay by drawing a line between the 2 points that will be
the line where to cut the stay.
3. Bolt the stay in position according to drawing.
4. Weld the stay according to welding procedure for the actual joint.
Pos. Description
1 Tunnel
2 Stay
3 Actual cutting length,
when compensating
for the thickness of the
stay.

Pos. Description
1 Tunnel
2 Stay
3 Illustration of how to cut
the stay. See welding
procedure.
Pos. Description
1 Area for measuring
length of stay.
2 Tunnel
3 Redundant stay.
When welding the stay into the tunnel, use the following welding procedure:
WPS
PS 026.265

7.6 Oil filling
Test hose 1
Pump with filter 1
“Hydraulic system diagram”
 Immediately upon arrival, fill the propeller unit with oil and air vent according to the instructions
as specified in this chapter.
 The oil type and viscosity used must follow the Rolls-Royce Marine instructions.
 The cleanliness of the oil should adhere to ISO 4406, Grade 16/13 or better.
 For filling up, use a pump with a filter of 10 micron, or finer, in the discharge line.
Pos.
1 Connection for oil filling.
2 Connection for venting.

7.6.1 Hub, high pressure chamber
1. Turn the propeller so that the hub venting holes are in the upward direction.
2. Loosen the two plugs [1] / [3], located in the hub cylinder and the coupling flange.
3. Fill the oil slowly through connections AA and BB at the top of the propeller unit. Air is vented
via the two holes [1] / [3].
Note!
 The high pressure chambers are filled and vented when air free oil appears at the holes. The
plugs are to be mounted and secured by welding as per separate instruction.
 If the piping is installed at this stage, filling must be carried out through connections A and B at
the pump unit.
 During fitting of pipes at a later stage, fill oil into these pipes and vent the air at the connections
AA and BB respectively, before the final tightening of these pipe connections to the propeller
unit.
7.6.2 Hub, low pressure chamber
See illustration above.
1. Fill oil through the connection FF and vent the air through the connection VV. One of the plugs
[2] for the hub low pressure sphere is to be in the upward position. Loosen the plug for air
venting.
Note!
These plugs are diametrically positioned in the spherical part of the hub body.
2. The hub is air-vented when air free oil appears at the hole.
3. When the thruster is horizontal mounted in hull, additional ventilation to be performed through
plugs on gear housing or bearing housing, i.e. see enclosed sketch.

If the hydraulic system is installed, use the following instructions:
16. Connect the filling device to connection V53 (FF).
17. Close the shut off valve V54, open the valves V53 and V56 and connect a test hose to PT4 on
the hydraulic pump unit. Loosen the air-venting plug in the hub low pressure sphere.
18. Start to fill oil into the propeller unit.
19. When the thruster is horizontal mounted in hull additional ventilation to be performed through
plugs on gear housing or bearing housing, i.e. see enclosed sketch.
20. When air free oil appears in PT4, V56 and in the hole in the hub low pressure sphere, close the
air venting hole in the hub and disconnect the test hose at PT4 and open the shut off valve V54
and close the shut of valve V56.
21. Continue to fill oil into the system until the oil tank is filled up.
The above given instruction is valid for new installations and for installations after reconditioning.
22. When topping up the oil tank from a low level (not empty), the oil can be filled via connection
V53 at the FF line.

7.7 Installation of tooth coupling
Dial gauge 1
“Gear coupling” Non-alloyed electrodes
Pos. Name
1 Hub
2 Sleeve
3 O-ring
4 O-ring or
Paper gasket
5 Bolt
6 Self-locking
nut
7 Support plate
8 Oil plug
9 Pivot
Note!
Some shaft couplings are delivered with paper gaskets instead of o-rings (see Pos.4). When shaft
coupling are delivered without O-ring groves, enclosed paper gaskets must be used.
Installation of keyed hubs:
1. Parts forming the coupling shall be cleaned carefully before mounting. This shall be applied to
teeth specially.
2. Place the sleeves [2] on the shafts.
3. Insert hubs [1] on shafts. To help mounting slightly grease with molibden bisulfure on cleaned
seats.
4. Hubs can be mounted by pressing, heating with burner or preferably in an oil bath not above
100ºC.

5. With support plate outside, place
shaft ends with the gap “a”
according the figure. Gap “a”
must be taken from the table
below according the type and
size of coupling.
6. Procede to shafts alignment

performed by means of a
straight edge and a thickness
gauge, or using an inside
caliper, as in the figure. An
accurate alignment result is
obtained using a dial indicator.
See tolerances for alignment
below.
7. Insert center support plate within

the gap “a”. Do not forget that
crowned pivot must be in contact with lower shaft end.
8. Once the coupling is mounted, it must be filled with a lubricant. See chapter 5.
9. There a two oil plugs per each half for the lubrication.
TT size 1100 1300 1650 1850 2000 2200 2400 2650 2800 3000 3300
Coupling HCCV 25 30 35 35 40 45 50 55 60 65 70
‘a’ [mm] 8 8 11 11 11 13 13 14 14 18
Lub. [kg] 0.12 0.18 0.25 0.25 0.35 0.65 0.875 1.1 1.4 2.25
Note!
Take care to fill in the lubricant in both half couplings as they are separated by the central support
plate. The upper halves of the coupling to be filled (before assembly) with 90% of grease, i.e. 10%
air. If the coupling is filled 100%, i.e. with a grease gun or simmilar the temperature rise will cause
increased pressure (axial force) and temporary grease leakages.
Remove and change the grease every 3.000 hours.

Angular alignment:
 Check either through a

gage or clock that GAP is within
permissible value.
 Maximum GAP (Y – Z)
= 0.2 mm
Radial alignment:
Check either through a gage or clock that

SAG is within permissible value.
Maximum SAG = 0.15 mm
Axial alignment:
Check appropriate distance between

shaft ends as per the approved drawings.
Nominal space ± 2 mm
Bolt up the sleeves with the recommended tightening torque:
TT size 1100 1300 1650 1850 2000 2200 2400 2650 2800 3000 3300
Coupling HCCV 25 30 35 35 40 45 50 55 60 65 70
Torque [Nm] 108 108 230 230 230 230 325 325 325 325 565

7.8 Installation of motor foundation
Dial gauge 1
“Motor foundation assembly” Split pins 2
Note!
This procedure is valid only for TT sizes 1100 – 2200, where foundation is delivered separately.
1. Place the motor foundation on top of the thruster.
2. Put the lower flange bolts in place, but do not tighten them.
3. Fix a dial gauge to the pinion shaft and measure the deviation
on the guide edge of the top flange.
4. Measure the deviation at 4 quadrants B1 – B4; each point at

90 degrees to the previous point by rotating the pinion shaft.
Record the deviation.
5. Adjust the foundation, if values are outside the acceptable

range.
6. Tighten down the flange bolts to the specified bolt torque.
7. Drill holes for the two split pins at approximately 180º to each
other, through the lower motor foundation flange and the
tunnel flange.
Fill in the following details:
Measuring point Gauge value Radial offset Gauge value/2

B1
B2
B3
B4
Acceptable deviation B/2 = 0.2 mm

7.9 Control of motor foundation alignment
Dial gauge 1
“Motor foundation assembly”
Note!
This procedure is valid only for TT sizes 1100 – 2200, where foundation is delivered separately.
1. Dial gauge is to be located on pinion shaft.
2. Rotate the pinion shaft with the dial gauge on the flange and record the deviation.
3. Rotate the pinion shaft with the dial gauge on “guide edge”, and record the deviation.
4. Measure and record distance to bed.
5. Fill in the following tables, and keep them available at commissioning.
Note!
If recorded values are out of acceptable/tolerated range, Rolls-Royce Marine needs to confirm the
results.
Measuring point Gauge value Axis value (Gauge/2)

A1
A2
A3
A4
Acceptable deviation A/2 = 0.2 mm

Measuring point Gauge value Axis value (Gauge/2)
B1
B2
B3
B4
Acceptable deviation B/2 = 0.1 mm
X Y-Z
Actual value
Acceptable deviation X = MAX 0.15 mm
Acceptable deviation Y - Z = MAX 0.20 mm

7.10 Placing of anodes
Welding equipment 1
Non-alloyed electrodes
Low profile anodes
Yards need to correctly fit the anodes in the tunnel.

Design TT-Size L1 min. L2 min. L3 min.
A 1100 300 300 800
B 1300 325 350 1000
C 1650 370 450 1200
D 1850 385 500 1350
E 2000 400 550 1450
F 2200 440 600 1550
G 2400 480 650 1700
H 2650 530 720 1900
I 2800 560 760 2000
J 3000 610 830 2200
J 3300 660 900 2400
 The tunnel towards the hull plating shall be equipped

with anodes at each end.
 Do not place the anodes closer to the propeller

centre line than measures L1 and L2.
 The anodes shall be dimensioned to give about 150

mA/m² of unpainted area.
 The anodes which cannot be installed in the tunnel

ends may be placed in the middle of the propeller unit
as per section A-A (L2).
 The anodes shall also remain there during the entire

fitting out period.

7.11 Flushing of pipes
External oil pump 1
This procedure aims to ensure that the pollution level in the hydraulic system meets the standard
specified in the NAS and ISO classifications.
Minimum flushing time: T = Vtank x 10/Q, where: Vtank = The tank volume of the HPU
+ the tank volume of the external
pump unit.
Q = The capacity of the circulation

pump in liter/minute.
Minimal total time of flushing = Vtank x 25/Qf, where: Vtank = The tank volume of the HPU
+ the tank volume of the external
pump unit.
Qf = circulated oil quantity by flushing,
in l/min.
1. Clean every pipe before mounting. This can be done by shooting minimum two cleaning plugs
through the pipe (ref. MI 2.403 / NS 5910).
2. Fill hydraulic high pressure units (HPU) with a filtration unit with high filtering quality. (Beta ratio
75 (200). 3 micron absolute or better). This applies to all tanks in the system.
3. Flush using an external circulation pump unit. During the flushing, use Beat ratio 75(200), 3
micron absolute filters. Flush until the ISO code 15/12 is met.
4. Maintain a high value for the Reynolds numbers during the flushing. To achieve this, reduce the
number of bends to obtain an acceptable oil velocity. It is also important to limit the oil
temperature to 45ºC to 55 ºC in the pipe system.
5. Connect the consumers when all bows are flushed, and the purity of the oil system meets the
ISO 4406 16/13 (NAS 7) standard. When the consumers are connected, you have to count the
increase of the particles in the system. This will have to be stabilized to the ISO 4406 16/13
standard within some weeks of normal operation.
6. Mount standard filters after flushing.
0.

7.11.1 Flushing sequence
Step 1, flushing of pitch pipes. Red lines are piping / hoses to be connected:
Step 2, flushing of lubrication pipes. Red lines are piping / hoses to be connected:
Step 3:
Pump 2-3 strokes with the hand pump.

7.12 Placing of hydraulic module and tanks
Pos.
1 Location of gravity tank
2 Max. draught
3 Min. draught
4 Location of seal tank
5 Centre of propeller hub
6 Location of pressurized
gravity tank
7.12.1 Location of Gravity tank
Use as short and straight a pipe as possible between the thruster top, the hydraulic module and the
tank. It is required to have a minimum of 10° slope on the piping.
Locate the gravity tank according to the following formula within a tolerance of 0/+1 meter:
Height_Gravity_Tank [Pos 1] = Max_Draught [Pos 2] x 1.15 + 3.3 (meter)

7.12.2 Pressure setting of Gravity tank
Pressurize the gravity tank according to the following formula:
Air_Pressure = ( Height_Gravity_Tank [Pos 1]* - Height_Pressurized_Tank [Pos 6] ) x 0.089(bar)

* Theoretical height calculated according to the formula above.
Adjust the safety valve on the gravity tank to a maximum of 0.5 bars above the set-point for
Air_Pressure.
Note!
When the difference between “maximum water level” and “minimum water level” exceeds 6 meters;
consider an arrangement with pressurized gravity tank with controllable air pressure depending on
the operation duty and the operation time in different draughts.
7.12.3 Location of Drain pump

Position the drain pump at a maximum level of 3 meters above the thruster center.
7.12.4 Location of Seal tank
Height_Seal_Tank [4] = 1 meter above tunnel flange to bottom of seal tank.
The shaft seal tank has to be located close to the thruster’s top.
Use short and straight pipe between thruster top, hydraulic module and the tank. It is required to
have a minimum of 10° slope on the piping.
Shut off valve:
 Shut off valve on the seal tank V57 must be open.
 When the line (level) is less than 8 m: The shut off valve on the seal tank V80 must be closed.
 When the line (level) is higher than 8 m: The shut off valve on the seal tank V80 must be open.
 Shut off valve on the thruster top V81 (yard supply) must be closed.
Note!
For ships with minimum water line (level) lower than 8 meters, the seal tank has to be located with
a tolerance of 0/-0.2 meters.
7.12.5 Location of hydraulic module
Position the hydraulic module close to the thruster unit (maximum distance 5 m). The pipes should
be as straight as possible with a minimum of bends (max. 4 places are 90° elbows accepted).

7.13 Installation of pipes
CAUTION!
For thrusters installed ‘opposite way’, with the propeller facing starboard, the AA and BB
connections must interchanged to make the remote control having standard connections to suit the
Danfoss proportional valve.
Note!
Pipe from gravity tank to thruster unit to be laid with “slope down”, minimum 10 º. Avoid “air locks”.
 Rolls-Royce Marine equipment has been delivered in a clean condition and has been test run
in the workshop. The utmost care must therefore be taken to avoid introduction of impurities
into the system by careless pipe laying or handling.
 Preferably, no welded pipes, welded bends or fittings must be used in the hydraulic system. If
welded pipes have to be used, the welds must be thoroughly cleaned and pickled in 20%
sulphuric acid for at least four hours, next flushed thoroughly with water, and then filled with hot
solution of sodium carbonate, which is to be left in for one hour. Then, the pipes are to be
flushed once more with hot water, then dried and the inside pipe surface must be covered with
oil.
 After cutting the pipe, properly clean the pipe ends. Remove all sharp edges on fittings, flanges
and tubes. Do not apply thread sealant or soft joint packing. For flanged pipes, use oil
resistance rubber packing. Use Loctite or Permatex Loctite or Permatex is the manufacturer‘s
recommendation for liquid seals.
 All pipes must be well shaped and installed as short and straight as possible, with minimum
bends. Do not use filler material and heat when bending pipes. Bend in the cold condition using
suitable tube bending equipment.
 Always ensure that all pipes (and other openings) are sealed off. Plastic plugs and rags in pipe
ends are not considered as adequate precaution for preventing dirt and moisture from entering
the system.
 Do not permanently connect the pipes before the system has been flushed or manually
cleaned. Refer to the flushing procedure.
 Care should be taken to fit all pipes free from stress.
 Pipes are to be made of steel, with a minimum diameter as stated at the ‘Hydraulic system
diagram’ drawing, and dimensioned to meet the requirements of the classification society.
 The maximum pipe length is 15m.
 Completed piping to be pressure tested to 1.5 x maximum working pressure or according to

requirements of the classification society.
7.14 Installation of the feedback device
Wrench 1
“Feedback device assembly”
Install after that the tunnel is finally painted and welded to the hull structure and/or that the motor
foundation (optional) is installed.
1. Bolt the feedback device to the propeller unit during the

installation at the yard.
2. Place the device on the top flange of the tunnel. Refer to the
enclosed "Feedback device assembly” drawing.
3. Provide the device with protection covers, if necessary. It

shall be accessible for adjustment and maintenance.
4. Protect the indicating rod (to tunnel) from paint and dirt to
avoid problems with feedback movement.
5. Inspect the installation of the feedback device as per the

Rolls-Royce Marine checklist before starting up.
Caution!
The feedback device/arrangement must not be painted.

7.15 Air venting of pitch system
Oil pump 1
Hose 1
Reference documents Page Consumables Qty
“Hydraulic system diagram” Oil, see chapter 5.
1. Remove ventilation plugs [4].
2. Adjust the zero-pitch on the feedback device. Set the remote

control system to the local control mode.
3. Start the hydraulic pump and set the pitch in the end position by
means of local manual control of the control valve on the pump
unit.
4. Adjust relief valve setting value (V64) [1] to 6 MPa.
5. Maneuver the pitch 10 times to each end position. Keep the relief
valve pressure for 5 seconds at each end position.
6. Set the relief valve pressure to the value stated on the Hydraulic
system diagram. Set the pitch to zero-pitch.
7. Make sure to fit the ventilation plugs [4] on the propeller hub.
8. Fill the oil tank up to the maximum oil level, when the air venting
procedure is finished.
9. Close the shut-off valve (V56) and disconnect the filling pump.
(Connection ZZ can, alternatively, be permanently connected to
an oil filling system).
10. Secure Valve V54 in fully open position.
11. Set the control in remote control position.

Location of ventilation plugs [4] on Propeller hub.

8. COMMISSIONING
8.1 Precautions before start-up

Warning
 In the event of a malfunction during the test program for the control system
and the hydraulic system, investigate and remedy the malfunction
immediately. Operating a vessel with a malfunction in the control system
or in the hydraulic system may cause personal injury and equipment
damage.
 Before rotating the propeller, inform the yard representative that the
propeller will run so he can warn all personnel of the start up.
Caution!
 Check that there are no foreign objects in the tunnel or in the water around the ship.
 Check oil level in the hydraulic tank and that the valve (V54 on Hydraulic system diagram)
between the hydraulic tank and the propeller unit is secured in the open position.
 Check that valves V56 and V53 are closed.
 Check that valve V57 is open and V80 and V81 closed on the seal tank system before
commissioning the system. Note! Keep V57 closed till after the vessel is launced to avoil leak
from the shaft seal due to pressure acting from the “wrong side” of the sealing rings!
 Check that the direction of rotation on the drive motor is as specified.
 Check that all monitoring and warning systems are connected and in service.
 Carry out visual inspections prior to sea trial; ensure that there are no oil or water leaks.
 Carry out a visual inspection to ensure that all tools or other mounting devices connected to
rotating parts are disconnected before running the shaft.
 Ensure that all mechanic and hydraulic components are mounted as specified (in case of any
alterations since the installation period) and that nothing is missing.
 Ensure that all electrical connections are complete.
 Check that all cabinet earthings are made properly.
 Ensure that all electric power is available (but do not power up).
 Ensure that the testing of other machinery or painting does not hamper the work.
 Keep oil (of correct type) available for topping up.
When depending on service from other company to run the prime mover, make the necessary
arrangement to organize it.

8.1 Installation checklist
The checklist can be used as a tool for examining the installation of the tunnel thruster. The list is
not specific for the variants of tunnel thrusters and some of the items may therefore not be
applicable.
Date
Order No.
TT size/type
Shipyard
Yard/Newb Nr.
Issuer/Signature
8.1.1 Activities performed by the shipyard personnel
Items to be checked out before the launching Checked Sign.

Welding of the tunnel into the hull.
Measurement of roundness of the tunnel and blade tip clearances after
welding. Data sent to Rolls Royce Marine for approval.
All screws and plugs tightened and locked with Loctite or stainless steel
bar. Refer to the drawing tunnel with thruster unit.
Corrosion protection, painting, anodes, etc.
Hydraulic piping completed. Each pipe section to be thoroughly cleaned
before being installed into the system!
Observe that servo cylinder connections A-AA and B-BB as showed in
the hydraulic diagram applies when the propeller is facing to port side
seen from aft or top.
When the propeller is facing starboard side seen from aft or top, the
pipes to be connected A-BB and B-AA!
Before filling the system, ensure that pipes and tanks are thoroughly
cleaned.
Thruster system filled with suitable oil. Refer to Rolls Royce
specification oil requirements.
Hub space vented for air.
Fill the seal tank. Make sure valve V80 is closed!
Check all sealings and plugs for leakage.
If sea level does not reach the thruster unit after launching, it is not a
requirement to complete the hydraulic system, but recommended.
Fill the gear housing and vent the hub space before launching.
The same requirements applies with regards to observing cleanliness of
piping system before filling oil and other matters listed above.
If drive motor is included, see separate instruction.

Items to be checked out after the launching Checked Sign.
Installation of the hydraulic components, gravity tank, seal tank and
piping (Before sea level reaches the thruster unint. See above).
Mounting of the drive motor, drive the shaft coupling, etc.
Lining up of the shafting (motor, intermediate shaft, if any). Secure the
aligneded position by pins. Recorded data to be sent UPR.
Fill correct volume of grease inside each half of the gear coupling.
Mounting of the actuator and/or feedback arrangement for the remote
control system.
Arrangement of the electric components and the installation of electric
cables according to the diagram.
Flushing of the hydraulic pipes installed by the shipyard according to
Rolls Royce Marine‘s flushing diagram. By-pass the critical
components.
This can be cancelled provided each pipe section is cleaned and sealed
properly before being installed into the piping system.
Refilling oil according to the oil filling instructions. Re-assure that tooth
couplings (and bearings and bulkhead glands, if any) are filled with
correct type and quantity of grease.
Open valve V81, V80 and V57 on the seal tank system. Make the oil
flow by natural gravity from the seal tank through the seal and collect
the oil at V81.
Close valves V80 and V81 after completing the flushing of the seal.
Items to be checked out before startup Checked Sign.

All equipment relatede to the thruster installation is mounted.
Hydraulic system is clean and made ready to commission.
All the external cabling is completed and the cable is according to
specification. This includes the control system, alarm system and drive
control.
All connections are checked according to cable lists and that all terminal
blocks are properly tightened. All cables to be labeled according to
standard.
Electric power sources are available. (Do not switch on).
The RRM system complete is ready for testing. Any external systems
connected to the RRM system to be disconnected if not cheked out with
the supplier of those systems.
Access to all equipments during tests.
The draft of ship is sufficient for testing the thruster. (Top of tunnel is
equal to the half the tunnel diameter submerged. (Minimum 0.75 m.)
Gear coupling/shaft line alignment and assembly are recorded and
accepted.

Gear coupling halves confirmed filled with suitable grease type and
quantity.
Feedback arrangement is installed and arms and linkages adjusted to
give correct readings. Tention spring adjusted to give slight torque when
feedback is going extreme CCW movement.
8.1.2 Activities supervised by Rolls-Royce Marine engineers
Items to be checked out before and during start-up Checked Sign.

Checking of the installation work made by the shipyard (as far as
practically possible without demounting).
Checking of the hydraulic system installed by the shipyard.
Like location of components, piping lay out, cleanness of pipes (make
random check if not filled with oil).
Starting up the servo pump(s). Check direction of rotation immediately!
Check for leakages in the entire hydraulic system.
Operate the pitch locally. Carefully set the pitch to maximum travel in
both directions. Observe the feedback arrangement follows the movent
and not getting jammed. Adjust if needed to avoid damage.
Checking and adjustment of the relief valve to specified pressure
according to the hydraulic diagram. Operate the pitch to maximum
travel and make the relief valv open for about 10 seconds at end stop.
Repeat at least 3 times to each side to vent the servo cylinder for air.
Turn the input shaft to make the propeller make one whole revolution
when the pitch is set to maximum travel in each direction to ensure
there are no obstructions in the tunnel.
Checking of the electric cabling for the remote control system, control
transfer, etc.
Checking the set-point for pressure- and temperature switches.
Checking of the functions for pressure- and temperature alarms,
interlock functions and possible auto-start of servo pump(s). (Together
with the shipyard / classification society.)
Test for earth faults against ships structure.
Supply voltages: Correct polarity. No earth fault.
Cable check: Supply, solenoids, potentiometer etc. correctly connected.
REMOTE CONTROL system: Follow the recommendation for the
actual type of remote control system installed.
Switching on the electric power and starting up the remote control
system. Preliminary adjustments
Eliminate any alarms showing up on the entire TT-thruster system.
Run the pitch locally. Measure the total stroke of the movement to find
out the middle position. Set pitch feedback to 20.0 mA at the
mechanical end position Starboard. Check that the mechanical end
position Port is not below 4.0 mA. Port and Starboard direction must be
determined. For thrust direction, refer the "Main Data” sheet included in
Items to be checked out before and during start-up Checked Sign.
chapter 2 (”Main Data”) in the installation diagram.
Note the way the propeller is facing to determine which way is starboard
and port movement of the feedback!
Calibrate the pitch feedback to 105% at the mechanical end positions.
Calibrate the drive motor current feedback to “zero” with stopped motor.
Calibrate the DM voltage or RPM feedback to “zero” with stopped motor
(cabling is the Yard’s responsibility).
Simulate the drive motor running.
Test the “Start” and “Emergency Stop” from all panels having these
functions during this simulation.
Check the functions from the Engine Control Room panel (Option).
Check for calibrations and parameter settings according to Rolls Royce
Marine specification / calibration list.
Items to be checked out while running alongside quay Checked Sign.

Arrange a megger test of the drive motor. Do not start if the resistance
is less than 10 mega-ohm.
Starting of the drive motor and checking direction of rotation.
Checking of pressures, temperatures, filters, oil level, and possible
leakages while doing the initial first run.
Drain the interlock pressure switch to simulate pressure loss. Confirm
the Auto Stop is working.
Re-start the drive motor.
Confirm / adjust the Zero pitch in the remote control.
Make small manouvers to confirm correct fuction from all panels.
Function test of the systems for the shipyard / classification society as
part of the wharf / sea trial tests.
Load up the drive motor gradually according to the running in procedure
for the gearwheels. The maximum load to be set up in “bollard pull”
condition which means the ship is not moving.
Final Maximum load hence has to be set during sea trial in open sea.
(If the arrangement allows, the loading up of the drive motor may be
done anlongside according to procedures agreed to between RRM and
the actual shipyard in charge.
Completion of Rolls Royce Marine "Sea Trial Report" (or at sea trial).
Preparation for the sea trial (filters, oil level, etc.).
Acceptance of the installation(s).
Tunnel thruster running in procedure:
25 % pitch: 1 hour (Auxiliary 0.5 hours)

Items to be checked out while running alongside quay Checked Sign.
Increase from 80 to 100 over a periode of 1 hour
The final setting of 100% is to be done in bollard pull condition with the
ship having no movement in the water. Set the pitch for both directions.
After the sea trial is finished, make notes of all parameters and
calibration values that have been changed during the commissioning.
One copy must be left on board and the other copy must be brought to
Rolls Royce Marine AS for filing.
Items to be checked out during sea trial Checked Sign.

Testing of the Rolls-Royce Tunnel Thrusters can in some cases be
almost completed quayside. However the following activities should be
performed:
Observation of temperatures, pressures, filters, oil level / any leakages
Necessary adjustments and corrections to be made.
Final setting of remote control adjustments.
Manoeuver tests for classification society.
Maneuver tests for completion of Rolls Royce Marine "Sea Trial Report".
(If not carried out before).
Acceptance of installations and filling in the Sea Trial Report.
Remarks:

9. CONTACT INFORMATION
Country Address Telephone Fax
Rolls-Royce Marine AS + 47 815 20 070 +47 70 01 40 12
Propulsion - Ulsteinvik Mob:
Sjøgata 98 +47 900 10 997*
Norway
N-6065 ULSTEINVIK, NORWAY
service.propulsion.ulstein@rolls-
royce.com
* 24 hr emergency

10. FINAL INSPECTION
10.1 At quay before trials

 Check and preliminary set up of the control system before starting drive motor.
 Start up of drive motor. Check direction. Check interlocks. Set the propeller at zero pitch.
 If possible, run the propeller for some time and observe pressures and temperatures.
10.2 Function test

 Make sure that the “Installation checklist”, chapter 8, has been thoroughly run through.
 Carry out the various tests and preliminary adjustments as far as possible .
 Run through the tests to be verified by Class and owner, and confirm that it is working before
showing them.
 Ensure that any external connections to other systems are checked and confirmed working.
10.3 Harbour acceptance test

 Start the prime mover and verify the direction of rotation. Check the auto stop and low oil
pressure function.
 Restart and adjust the practical “zero” pitch. Watch the temperatures and pressures running at
no load. Check for leaks, watch oil levels in systems and pressures.
 If the depth is sufficient and arrangement is made with the yard, increase the load gradually
and gently up to approximately 25% load. Keep this load for minimum one hour. In some cases
it may be possible to load up the system partly or fully. Please confirm with the project.
 Perform the acceptance test for the shipyard/classification/owner, if required, and prepare for
sea trials. Always keeping an eye on the filter conditions, oil levels, pressures and
temperatures.
10.4 Sea acceptance test

When at sea, gradually and gently increase the load according to the following procedure:
1. Increase load from 25% to 50% (provided the unit has been running at least one hour at 25%)
and keep it for minimum one hour (Auxiliary 0.5 hours).
2. Increase load from 50% to 80% and keep it for minimum one hour (Auxiliary 0.5 hours).
3. Increase load from 80% to 100% during a one hour period.
4. Keep 100% load for a period specified by the classification society, minimum one hour.
5. Keep the load as even as possible during the test. For example, avoid unnecessary crash stops
or hard turn manoeuvres.
6. Continuously watch the power consumption and oil temperature.

7. Setting and limiting of the output. Setting the overload protection system.
8. Turning tests according to requirements / yard sea trial programme.
9. Steering test (Zigzagging tests) in the direction ahead if a part of the sea trial programme.
10. Observe the vibration and noise levels on all equipment during the tests. The engineer on duty
must be informed of any alarms.
11. Ensure that all interfaces towards external systems are working according to the specifications
and to customer’s satisfaction.
10.5 Sea trial report

The Sea trial report is described in the following four pages.
The Sea trial report should be returned to Rolls Royce Marine AS when completed.
Warning
 During the sea trial, it is in the responsibility of the captain or the ship
operator to ensure that the water around the ship is free from people and
objects.
 Before a sea trial is carried out, ensure that system is functioning as

specified; the propeller pitch positions must have been adjusted and the
control system should have been fully tested.
 Stop the shafts before making any adjustment that are close to the shafts.

Sea trial report, page 1/4
Date: Issuer: Sea trial date: File No:
TT size/type: Hub size/type: Unit No: Yard/yard No:
Motor: Material, hub: Class society: Owner:
Motor power/rev.: Propeller rev.: Type of Vessel: Name of Vessel:
Port Starboard
Power [kw]
Revolutions [rpm]
Pitch (if applicable) [P/D]
Thrust [kN]
FWD AFT
Draught [meter]
Propeller noise [db]

Propeller vibrations
Remarks:

Propeller unit’s position in hull.

Direction of rotation, propeller.
Direction of rotation, input shaft.
Observation of max servo pressures Nominal Actual

Pitch 0, max RPM. Observation [bar]
Full pitch starboard. Observation [bar]
Full pitch port. Observation [bar]
Max obs. pressure when making Observation [bar]
maneuvers.
Observation and adjustments of valves Nominal Actual

Relief valve pitch oil (V64). 120 bar [bar]
Gravity tank pressure, gear housing. Observation [bar]
Shaft seal pressure. Observation [bar]
Temperatures Nominal Actual

Oil temperature. max: [°C]
Oil cooler, lub. oil in/out. max: [°C]
Oil cooler, water in/out. max: [°C]
Sealing housing input shaft. max: [°C]
Alarms Nominal Actual

Alarm low pitch pressure. 7 bar [bar]
Interlock start drive motor. 3 bar [bar]
Alarms high pressure. 120 bar [bar]
Autostart stand-by pump I. (project See project [bar]
dep.)
Autostart stand-by pump II. (Project See project [bar]
dep.

Drive motor
Load at full pitch.
Load at zero pitch.
Pitch Nominal Actual

100% pitch starboard. Measured: [mm]
Zero pitch. Measured: [mm]
100% pitch port. Measured: [mm]
End position starboard. Measured: [mm]
End position port. Measured: [mm]
Make a sketch at this report’s last page, and mark where the measurements are made.
Pitch maneuvering speed Nominal Actual

Full pitch starboard to port. 15-20 sec [sec]
Full pitch port to starboard. 15-20 sec [sec]
Data for vessel (one thruster) Nominal Actual

(where applicable)
Turning time 360° to starboard, 0 knots. Observation [sec]
Turning time 360° to port, 0 knots. Observation [sec]
Turning time 360° to starboard, 3 knots. Observation [sec]
Turning time 360° to port, 3 knots. Observation [sec]
When two or more thrusters work in unison, record turning time for combination of these on a
separate page.
Oil/grease filled Type Volume

Gear housing. [liters]
Tooth coupling. [liters]

Remarks/Sketch:
This installation is tested and adjusted according to this "Sea trial report" and "General terms".
For Rolls Royce Marine For Customer:
dep. Propulsion Ulstein:
Date: Date:
Sign: Sign

11. TOOLS
The following tools are delivered with the Rolls-Royce Tunnel Thrusters:
Art. no. TT Size Description Qty. Comment

91787 1650 - 3300 Injector 1
87313 1650 - 3300 Adapter 1 Tools for
dismounting/pumping the
87314 1650 - 3300 High pressure tube 1 gear coupling of the pinion
83181 1650 - 3300 Plug 1
K141153 1650
216844 1850
Tool for mounting the gear
K141409 2000 Mounting tool 1
coupling to the pinion
K141467 2200
K141231 2400
For Tunnel Thrusters size TT1100 – TT1300 no tools are delivered.

12. DESIGN DRAWINGS
12.1 Mechanic and Hydraulic

Drawing / document Drawing number
Dimension drawing DMN300006234/A
Tunnel and propeller unit 108240/A
Tunnel thruster mounting 108562/D
Propeller unit 108473/F
Propeller hub 108500/F
Motor foundation 216470/A
Toothed coupling 107734/B
Feedback device K141995.3/E
Tunnel installation requirement 312148/-
Location of tunnel in hull 216841/A
Hydraulic system diagram 109889/E
Alarmlist 416909/B
Hydraulic connections on thruster top 218306/-
Arrangement pump unit 312520/B
Filter arrangement 312536/B
Gravity tank 217271/F
Seal tank 216918/E
Hydraulic module 217213/D
Arrangement vibration damper 312588/D
Arrangement hoses 312582/-
12.2 Electric
Drawing / document Drawing number

Drive motor See remote control man.
Drive motor starter See remote control man.

108240/A - THRUSTER LOWER MODULE
Pos no. Item id. Item name No.
1 K986658/D Stay 1.000000
2 ./- Tool 0
3 108473/G Thruster Lower Gear Module 1.000000
4 108500/F Propeller Hub 1.000000
5 551567/A Propeller Blade 4.000000
6 108476/C Pinion Shaft 1.000000
7 216884/C Bevel Gear 1.000000
8 108562/E Tunnel Thruster Mounting 1.000000
9 K141995.3/F Feedback Unit 1.000000
108562/D - TUNNEL THRUSTER MOUNTING
1 K983598/B Washer 12.000000
2 K983597/C Sleeve 12.000000
3 90362/- Hexagon Head Screw 12.000000
5 90268/- O-Ring 1.000000
6 96848/- Round Bar 0.730000
7 900713/- Lubricant 1.000000
8 82099/- Locking Compound 1.000000
9 413247/D Sign 1.000000
10 K983125/E Dowel Pin 4.000000
108473/F - THRUSTER LOWER GEAR MODULE
01 K141172/D Gear Housing 1.000000
02 K141124/E Bearing Housing 1.000000
03 K983493/E Cover 1.000000
04 ./- Tool 0
05 ../- Tool 0
06 107829/A Propeller Shaft 1.000000
07 K141130/B Bearing Housing 1.000000
08 K141131/D Bearing Cover 1.000000
09 107821/D Propeller Hub Coupling 1.000000
10 216509/A Pitch Control Pipe 1.000000
11 K983673/D Bushing 1.000000
12 216647/B Feedback Unit 1.000000
13 K983663/F Oil Distribution Ring 1.000000
14 K983666/B Plate 1.000000
15 K141174/A Lever 1.000000
16 K141147/B Lever 1.000000
17 K983875/B Rod 1.000000
18 109324/B Rope Guard 1.000000
19 K983838/B Plate 1.000000
20 K986774/B Connector 2.000000
21 K141143/A Connector 1.000000
22 K983927/B Washer 1.000000
23 K983617/D Cover 1.000000
24 K141169/B Bushing 1.000000
25 K141177/A Washer 1.000000
26 .../- NOT CATEGORIZED 0
27 K983587/B Sleeve 1.000000
28 83179/- Plug 1.000000
29 K983678/E Tube 1.000000
30 K983679/E Plug 2.000000
31 K112177/B Connector 1.000000
32 K983625/D Distance Ring 6.000000
33 991387/- Pipe Clamp 4.000000
34 K954022/C Plug 1.000000
35 991397/- Plate 4.000000
36 K141163/A Locking Plate 1.000000
38 991390/- Pipe Clamp 6.000000
39 991398/- Plate 3.000000
40 312032/A Stern Tube Seal 1.000000
42 86003/- Roller Bearing 1.000000
43 99373/- Roller Bearing 1.000000
44 992251/- Roller Bearing 1.000000
45 992252/- Roller Bearing 1.000000
46 91295/- Roller Bearing 1.000000
47 96610/- Roller Bearing 1.000000
48 992253/- Lock Nut 1.000000
49 992254/- Lock Nut 1.000000
50 992035/- Bearing 1.000000
53 992038/- Piston Ring 1.000000
54 992039/- Piston Ring 1.000000
55 992255/- Seal Ring 1.000000
56 992041/- Stripper 1.000000
58 82444/- Seal Ring 1.000000
59 93045/- Seal Washer 6.000000
60 94562/- Seal Washer 2.000000
63 992042/A O-Ring 1.000000
64 82233/- O-Ring 1.000000
65 992043/- O-Ring 2.000000
66 992044/- O-Ring 1.000000
67 93628/- O-Ring 2.000000
69 92625/- O-Ring 1.000000
70 90029/- O-Ring 2.000000
71 992258/- O-Ring 1.000000
72 992259/- O-Ring 1.000000
75 93751/- Retaining Ring 1.000000
76 90036/- Retaining Ring 1.000000
78 84958/- Set Screw 1.000000
79 84988/- Set Screw 3.000000
80 92346/- Set Screw 2.000000
81 94195/- Set Screw 6.000000
88 90957/- Socket Head Screw 11.000000
91 91905-UL/- Socket Head Screw 2.000000
97 90411/A Socket Head Screw 6.000000
103 85179/- Washer 3.000000
104 93920/- Hexagon Nut 1.000000
105 90067/- Lock Wire 0.5
106 95347/- Continuous Thread Rod 0.135000
108 992048/- Ball Joint 2.000000
110 93822/- Pipe Coupling 4.000000
111 83374/- Pipe Coupling 4.000000
112 992127/- Hose 2.000000
113 992128/- Hose 1.000000
114 900283/- Hose 1.000000
115 900284/- Hose 1.000000
116 92263/- Plug 2.000000
117 83181/- Plug 3.000000
118 90509/- Plug 3.000000
119 90189/- Plug 1.000000
120 992049/- Plug 3.000000
122 902667/- Pipe Clamp 4.000000
124 992440/- Plug 1.000000
125 992235/- Plug 1.000000
126 992006/A Locking Compound 0
127 992051/- Locking Compound 0
131 93415/- Sealing Compound 0
108500/F - PROPELLER HUB
1 108501/D Propeller Hub Body 1.000000
2 108778/B Propeller Piston Rod 1.000000
3 216911/- Crank Pin Ring 4.000000
4 85203/- Washer 24.000000
5 312126/- Sliding Shoe 4.000000
6 312127/B Shear Joint Bolt 24.000000
7 416554/A Dowel Pin 4.000000
8 416555/- Dowel Pin 4.000000
9 312128/- Connector 1.000000
10 K954022/C Plug 3.000000
11 312129/- Sliding Bar 1.000000
12 312130/- Spring Retainer 1.000000
13 416672/A Nozzle 2.000000
14 85199/- Washer 12.000000
17 992024/- Guide Ring 1.000000
18 992000/- Piston Ring 2.000000
19 992042/A O-Ring 3.000000
20 416473/A Seal Ring 4.000000
21 992002/- O-Ring 1.000000
23 90601/A Socket Head Screw 4.000000
24 992003/- Spring 3.000000
25 96848/- Round Bar 1.9
28 992006/A Locking Compound 0
29 992007/- Locking Compound 0
30 93415/- Sealing Compound 0
31 992009/- Grease 0
32 992010/- Lubricant 0
216470/A - FOUNDATION
1 107863/C Foundation 1.000000
4 93914/- Hexagon Nut 8.000000
5 90334/- Plain Washer 8.000000
6 85678/- Dowel Pin 2.000000
107734/B - TOOTHED COUPLING
1 992473/- Toothed Coupling Hub 1.000000
2 900000/- Toothed Coupling Hub 1.000000
3 992476/- Toothed Coupling Sleeve 1.000000
4 992477/- Disc 1.000000
5 992475/- Fitted Bolt 1.000000
6 992478/- Lock Nut 1.000000
7 K141155/- Locking Plate 1.000000
8 992483/- Spacer 1.000000
10 992479/- O-Ring 2.000000
11 992480/- O-Ring 2.000000
12 992481/- Transport Bracket 1.000000
K141995.3/E - FEEDBACK UNIT
1 K993764/C Bracket 1.000000
2 K993766/A Lever 1.000000
3 K993765/B Lever 1.000000
4 900458/- Continuous Thread Rod 1.000000
8 93462/- Hexagon Nut 2.000000
9 992048/- Ball Joint 2.000000
10 K984664/- Transmitter Box 1.000000
11 901001/- Locking Compound 1.000000
12 93537-UL/- Hexagon Head Screw 1.000000
13 K145092/A Lever 1.000000
15 K145093/A Indicator 1.000000
16 K145091/- Scale 1.000000
17 99977/- Rivet 2.000000
18 313670/B Spring 1.000000
19 313672/C Spring Retainer 1.000000
20 903383/- Cover 1.000000
312148/- - INSTRUCTION, INSTALLATION
10 K141138/E Flange
218306/- - PIPE CONNECTION ARRANGEMENT
1 312662/B Mounting Plate 1.000000
2 312663/B Mounting Plate 1.000000
3 91028/- Pipe Coupling 2.000000
4 87499/- Pipe Coupling 2.000000
5 95140/- Pipe Coupling 2.000000
6 901381/- Fluid Sample Point 2.000000
7 83422/- Pipe Coupling 2.000000
8 990784/- Pipe Coupling 1.000000
9 92998/- Pipe Coupling 3.000000
11 94366/- Non Return Valve 1.000000
12 90006/- Pipe Coupling 3.000000
13 990935/- Pipe Coupling 2.000000
15 90082/- Pipe Coupling 1.000000
16 991107/- Pipe Coupling 4.000000
17 991109/- Pipe Coupling 6.000000
18 991123/- Pipe Coupling 3.000000
19 91904/- Pipe 0.500000
20 990936/- Pipe 2.000000
21 90987/- Pipe 2.000000
22 91043/- Pipe 2.000000
23 93824/- Pipe Coupling 2.000000
24 93767/- Pipe Coupling 1.000000
25 84144/- Ball Valve 2.000000
26 94244/- Pipe Coupling 2.000000
29 93845/- Pipe Coupling 2.000000
32 990508/- Pipe Coupling 1.000000
33 991111/- Pipe Coupling 4.000000
34 991103/- Pipe Coupling 4.000000
312520/B - PUMP UNIT
1 901837/- Electrical Motor 1.000000
2 901838/- Pump 1.000000
3 901751/- Bell Housing 1.000000
4 96962/- Flexible Coupling Hub 1.000000
5 96960/- Flexible Coupling Element 1.000000
6 901752/- Flexible Coupling Hub 1.000000
7 416714/- Adapter Plate 1.000000
8 80311/- Pipe 0.500000
9 312473/A Hose 1.000000
10 84135/- Ball Valve 1.000000
11 901121/- Non Return Valve 1.000000
12 95140/- Pipe Coupling 1.000000
13 990409/- Pipe Coupling 1.000000
14 90599/- Pipe Coupling 1.000000
15 94698/- Pipe Coupling 1.000000
16 900613/- Pipe Coupling 1.000000
17 91479/- Pipe Coupling 1.000000
18 90286/- Pipe Coupling 2.000000
19 83554/A Pipe Coupling 2.000000
20 83374/- Pipe Coupling 1.000000
21 83421/- Pipe Coupling 1.000000
23 991428/- Plug 1.000000
24 991099/- Pipe Coupling 1.000000
25 991123/- Pipe Coupling 5.000000
27 90869/- Spring Washer 4.000000
28 94902/- Plain Washer 4.000000
29 991081/- Pipe Coupling 1.000000
312536/B - FILTER
1 901453/A Filter 2.000000
2 901308/- Indicator 1.000000
3 992200/- Filter Cartridge 2.000000
4 91406/- Pipe Coupling 2.000000
5 83423/- Pipe Coupling 1.000000
6 83554/A Pipe Coupling 1.000000
8 991113/- Pipe Coupling 1.000000
10 91081-UL/- Spring Washer 4.000000
11 417479/A Bracket 1.000000
217271/F - GRAVITY TANK
1 992735/- Tank 1.000000
2 903066/A Oil Gauge Tube 3.000000
3 900701/- Level Switch 1.000000
4 992387/- Temperature Switch 1.000000
5 83181/- Plug 1.000000
6 83182/- Plug 3.000000
7 83179/- Plug 1.000000
8 413247TT/- Sign 1.000000
9 90082/- Pipe Coupling 1.000000
10 90097/- Pipe Coupling 1.000000
11 84145/- Ball Valve 1.000000
12 84122/- Ball Valve 2.000000
13 90605/- Pipe Coupling 7.000000
14 90316/- Pipe Coupling 3.000000
15 903321/- Pressure Maintaining Valve 1.000000
16 903325/A Filter 1.000000
17 903322/- Manometer 1.000000
18 992733/- Non Return Valve 1.000000
19 992737/- Safety Valve 1.000000
20 90599/- Pipe Coupling 3.000000
21 991123/- Pipe Coupling 3.000000
22 90683/- Pipe Coupling 1.000000
23 991093/- Pipe Coupling 4.000000
24 94256/A Pipe 1.000000
25 901359/- Pressure Switch 1.000000
26 92273/- Pipe Coupling 1.000000
27 903358/- Bracket 1.000000
28 99014/- Thermometer 1.000000
216918/E - TANK
1 992611/- Tank 1.000000
2 992392/- Cap 1.000000
3 900701/- Level Switch 1.000000
5 992609/- Blind Flange 1.000000
7 90426/- Spring Washer 4.000000
8 90006/- Pipe Coupling 2.000000
9 93767/- Pipe Coupling 2.000000
10 84144/- Ball Valve 2.000000
11 83181/- Plug 1.000000
12 413247/D Sign 1.000000
13 98077/- Pipe Coupling 2.000000
14 991107/- Pipe Coupling 3
15 991431/- Plug 1
217213/D - HYDRAULIC POWER PACK
1 312024/E Foundation 1.000000
4 312481/C Proportional Valve 1.000000
5 312480/- Pressure Sensor Block 1.000000
6 901321/- Manometer 1.000000
8 901344/- Hose 1.000000
9 312575/- Hose 1.000000
10 98967/- Pipe 1.000000
11 80311/- Pipe 0.500000
12 903210/- Screw 3.000000
13 312599/- Junction Box 1.000000
14 413247TT/- Sign 1.000000
15 409438/- Sign 1.000000
16 83179/- Plug 1.000000
312588/D - VIBRATION DAMPER
1 902269/- U-Section 13.800000
2 901207/- Elastic Element 4.000000
3 901208/- Mounting Plate 4.000000
4 901209/- Mounting Plate 4.000000
7 93462/- Hexagon Nut 8.000000
8 94415/- Hexagon Nut 4.000000
9 91341/- Spring Washer 8.000000
10 90408/- Spring Washer 4.000000
312582/- - HOSE CONNECTION ARRANGEMENT
1 312585/- Hose 1.000000
2 312586/A Hose 4.000000
3 312587/A Hose 5.000000

InstallationManual TunnelThruster CP RRM300028923 925 931 933

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InstallationManual TunnelThruster CP RRM300028923 925 931 933

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INSTALLATION MANUAL

Rolls-Royce Tunnel Thruster

Yard and hull no. : Alianca S/A AL 020

Contract manager for this project:

Rolls-Royce Tunnel Thruster Installation manual Page 1 of 159

Rev. Date Sign Changes at page Description

Page 2 of 159 Installation manual Rolls-Royce Tunnel Thruster

3. SYSTEM DESCRIPTION .........................................................................9

4. DELIVERY SPECIFICATION ................................................................. 17

5. TECHNICAL DATA ................................................................................ 19

6. HANDLING AND PRESERVATION ....................................................... 23

Rolls-Royce Tunnel Thruster Installation manual Page 3 of 159

9. CONTACT INFORMATION ................................................................... 65

10. FINAL INSPECTION ............................................................................. 67

11. TOOLS .................................................................................................. 73

12. DESIGN DRAWINGS ............................................................................ 75

Page 4 of 159 Installation manual Rolls-Royce Tunnel Thruster

1.3 Structure of this Installation Manual

 Chapters 1, 2 and 3 provide general Tunnel Thruster information.

 Chapters 4, 5, 11, 12 and 13 provide project specific information.

 Chapter 5 provides technical data.

 Chapter 7 includes all installation procedures.

Rolls-Royce Tunnel Thruster Installation manual Page 5 of 159

Page 6 of 159 Installation manual Rolls-Royce Tunnel Thruster

2.1 General statement

IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS

IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS

Rolls-Royce Tunnel Thruster Installation manual Page 7 of 159

Indicates hazardous or unsafe practices, which COULD result in fatal or severe

2.3 Declaration of Conformity

 Det Norske Veritas (DNV)

 American Bureau of Shipping (ABS)

 Lloyds Register (LR)

 Germanisher Lloyds (GL)

 Bureau Veritas (BV)

 Russian Maritime Register of Shipping (RS)

 Korean Register of Shipping (KR)

 Nippon Kaiji Kyokai (NK)

Page 8 of 159 Installation manual Rolls-Royce Tunnel Thruster

3.1 System Overview

The main versions of Rolls-Royce Tunnel Thrusters

Dynamic Positioning (DP) Auxilliary (AUX) Ice class duty (Ice)

Rolls-Royce Tunnel Thruster Installation manual Page 9 of 159

Page 10 of 159 Installation manual Rolls-Royce Tunnel Thruster

Pos. Component TT version Comment Chapter

Rolls-Royce Tunnel Thruster Installation manual Page 11 of 159

The thruster unit (3.2.2) is mounted into a transverse tunnel in the

The Rolls-Royce Super Silent Tunnel Thruster is designed for

If required, the tunnels can have a stainless steel layer in the

3.2.2 Thruster unit

The thrusters are designed to give a transverse thrust to the port

 Fixed pitch (FP): The direction of thrust is regulated by

Page 12 of 159 Installation manual Rolls-Royce Tunnel Thruster

3.2.4 Seal tank

Only for DP thrusters (TT>1100)

3.2.5 Hydraulic module

It is important to maintain the system in such a way that it is

An oil filter is mounted on the module and is equipped with an

Rolls-Royce Tunnel Thruster Installation manual Page 13 of 159

 Alarm, low pressure.

 Interlock, stop drive.

 Alarm, high pressure.

 (Autostart, pump I and pump II)