Operating Instruction

1 General ......................................................................................................... 3
1.1 Before Anchor Handling Operation ................................................................ 3
2 Operate the Water Cooling System ........................................................... 4
2.1 Selection of Operation Mode ......................................................................... 5
2.2 Operate the Pump ......................................................................................... 5
2.3 Emergency Stop ............................................................................................ 5

Copyright © 2007 Rolls-Royce plc

The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or
Doc. No.: 428-729
used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine plc.
This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation
Revision: A
is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon
Rolls-Royce plc or any of its subsidiary or associated companies.
Doc. No.: 428-729 Copyright © 2007 Rolls-Royce plc
The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or
Revision: A used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine plc.
This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation
is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon
Rolls-Royce plc or any of its subsidiary or associated companies.
Operating Instructions

1 General
Due to the continuous development of our constructions and to some customer specific
requirements, the descriptions and instructions in this chapter are made in general terms
and may in details diverge from the delivered system.
For specific details regarding your stern roller, see chapter “4 Delivery Specification”,
“5 Technical Data”, “12 Design Drawings” and “14 Subsuppliers Manuals”.

1.1 Before Anchor Handling Operation

Warning: During anchor handling operations, make sure that no personnel is

located in hazardous areas on deck.

Caution: Heavy use of the stern roller must stop immediately if the flow of cooling
water stops!

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 Operating Instructions

2 Operate the Water Cooling System

The stern roller system is a passive system, i.e. the roll of the drum is dependant on the
forces that are applied to the drum by wires, ropes or chains when hoisting or lowering
anchors.
The only equipment that is actively operated is the water cooling system, which is used
for cooling of the slide bearings and the shaft.
The starter cabinet for the water cooling system is displayed in figure 1.

5
2

1 6

7
8

Figure 1 Starter Cabinet for the Water Cooling System.

1. Flow alarm indicator
2. System running indicator
3. Emergency stop button
4. Temperature alarm indicator (Only applicable for Twin and Triple Stern Roller)
5. Level alarm indicator (Only applicable for Twin and Triple Stern Roller)
6. Control mode switch (Local / Off / Remote)
7. Stop button
8. Start button

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Operating Instructions

2.1 Selection of Operation Mode

In most deliveries it is possible to control the water cooling system for the stern roller
from both the starter cabinet and the bridge. The control mode switch (6) is located on
the starter cabinet. Its function is described in the following table:

State Function

LOCAL The water cooling system is controlled from the starter cabinet. The controls on the
bridge are disabled.

OFF The water cooling system is turned off. The ‘START’ and ‘STOP’ buttons on both
the starter cabinet and the bridge are disabled.

REMOTE The water cooling system is controlled from controls on the bridge. The ‘START’
and ‘STOP’ buttons on the starter cabinet are disabled.

Note! The emergency closing button (3) is enabled in ‘REMOTE’ mode, see
figure 1.

2.2 Operate the Pump

To start the water pump of the water cooling system from the starter cabinet (see
figure 1), proceed as follows:
1. Make sure the control mode switch (6) position is set to ‘LOCAL’.
2. Press the ‘START’ button (8).
To stop the water pump from the starter cabinet, proceed as follows:
1. Make sure the control mode switch (6) position is set to ‘LOCAL’.
2. Press the ‘STOP’ button (7).

2.3 Emergency Stop

Caution: In case of emergency, stop the pump by pressing the emergency stop
button (3).

The emergency stop button is enabled irrespecive of the position of the control mode
switch (6).
The water cooling system is disabled until the emergency stop button is released. This
is achieved by turning the emergency stop button clockwise.

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 Operating Instructions

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Revision: A
 Maintenance Instruction

1 General ......................................................................................................... 3
2 Preventive Maintenance .............................................................................. 4
2.1 Maintenance List ........................................................................................... 4
3 Corrective Maintenance .............................................................................. 5
3.1 Internal Inspection of the Bearings ................................................................ 5
3.2 Repair Skin Deformations .............................................................................. 6
3.3 Repair Cone Deformation .............................................................................. 6
3.4 Replace Sacrificial Anodes ............................................................................ 7
3.4.1 Outer Sides of the Drums ................................................................... 7
3.4.2 Inner Sides of the Drums .................................................................... 7
3.5 Replace the Pump ......................................................................................... 8
3.6 Clean the Filter .............................................................................................. 8
3.7 Refill the Tank ................................................................................................ 8

Copyright © 2007 Rolls-Royce plc

The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or
Doc. No.: 429-697
used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine plc.
This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation
Revision: B
is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon
Rolls-Royce plc or any of its subsidiary or associated companies.
Doc. No.: 429-697 Copyright © 2007 Rolls-Royce plc
The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or
Revision: B used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine plc.
This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation
is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon
Rolls-Royce plc or any of its subsidiary or associated companies.
Maintenance Instructions

1 General
Due to the continuous development of our constructions and to some customer specific
requirements, the descriptions and instructions in this chapter are made in general terms
and may in details diverge from the delivered system.
For specific details regarding this delivery, see chapters “4 Delivery Specification“,
“5 Technical Data“, and “12 Design Drawings“.
In order to give the delivered equipment a long and trouble-free service life, it is
important that strict inspections and maintenance work are performed periodically.

Warning: Read chapter “2 Safety” in this manual prior to performing any

maintenance work on the equipment.

Warning: Risk of personal injury. Make sure that all anchor handling operations are
stopped prior to any maintenance work on the stern roller is performed.

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 Maintenance Instructions

2 Preventive Maintenance
2.1 Maintenance List
Frequency Component / Action
System
After first month of Bearing Inspect the Orkot main bearing wear. A wear of < 10 mm is
operation acceptable.

Study the following drawing in chapter “12 Design Drawings”,

section “Test Drawings” carefully in order to measure the bearing
wear properly:

399-443GB ”Suggested Wear Control Procedure”

The drawing shows a method for monitoring any bearing/ shaft

wear. Since the towing cable can cause a lot of wear on the stern
roller and stern plating, it is recommended to machine down a
groove on both stern roller cones and on the stern plating on both
sides of the stern roller. These grooves will form reference
surfaces for regular monitoring of any bearing / shaft wear. The
drawing shows how to make the grooves and how to measure. By
measuring any increase, it is possible to record any signs and
quantity of wear. Use a Vernier calliper.

Note! Make sure there are no deformations of the stern plating or

stern roller cones that may influence the results.
Every 6 months Bearing Inspect the Orkot main bearing wear. See details under “After first
month of operation”, component “Bearing”.
Anually Drum The drums should be washed down to prevent build-up of dirt,
sand and marine growth.

Use a high pressure cleaner with a mild cleaning agent.

Fresh-Water Clean the filter.
Cooling System
Sacrificial Anodes Inspect the sacrificial anodes, four on each end of each drum, for
corrosion. When an anode is completely corroded, it should be
replaced with a new one, see ”3.4 Replace Sacrificial Anodes”.

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Maintenance Instructions

3 Corrective Maintenance
3.1 Internal Inspection of the Bearings
The shaft water seals are designed with extra long lips to function even if the bearings
should wear down significantly. In case excessive cooling water leaks should happen,
the seals must be checked, and replaced if necessary. Until the seals are replaced, the
amount of lost fresh-water, has to be refilled in the tank.

Note: The water inside between the drums and the shaft (approximately 700 l)
must be drained prior to the inspection of the bearings.

For internal inspection of the condition and wear of the bearings, continue as follows:
1. Make sure the pump is not running.
2. Close the ball valve that is mounted on the tank and connected to the filter inlet.
3. Disconnect the feed line of water and pump out the water inside the stern roller
through the water return line.
4. When the water inside the drums is drained and the pump is stopped, enter through
an access hatch on either side of the stern roller to access the bearing areas of both
drums.
5. Remove one of the 2” inspection hole plugs and inspect the bearing wear. Use an
inspection mirror and a torch for the inspection.
6. Check the wear of the other bearings on both drums.
7. Exit through the access hatch when the inspection is completed.
8. Re-assemble the cooling system and refill the drums and the tank with fresh-water.

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 Maintenance Instructions

3.2 Repair Skin Deformations

The stern rollers are built with a strong, thick skin. Since the skin is self-supporting, any
point load will be taken up by a large area, causing less tension in skin and thus less
damage.
To repair skin deformations, proceed as follows:
1. Cut out the damaged part of the skin, using a cutting torch.
2. Shape a new steel piece that matches the cut out part.
3. Weld the new piece onto the skin with an appropriate welding seam.
4. Paint the repaired area according to the paint instructions, see the “Installation
Manual“ for a detailed instruction.
Alternatively (for minor deformations):
1. Grind and clean the damaged area.
2. Fill the deformed area with weld.
3. Grind to smooth the surface.
4. Paint the repaired area according to the paint instructions, see the “Installation
Manual“ for a detailed instruction.

Note: The steel quality of any repair welding must be same as the skin, i.e. NVE
36 – RE min. 335 N/mm2.

3.3 Repair Cone Deformation

If the steel material on the cones is deformed and rolled outwards by the intense pressure
against the drums from the mooring cable, it may touch the stern plating. To repair this,
proceed as follows:
1. Cut off the protruded steel on the cone by means of a large angle grinder with a cut-
off disc.
2. Grind to smooth the surface.

Note: Be careful not to damage the stern plating while cutting off the extruding
steel from the cone.

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Maintenance Instructions

3.4 Replace Sacrificial Anodes

The sacrificial anodes must be replaced when worn out.

Warning: Risk of crushing! Do not access the areas between the stern hull and the
stern roller prior to any ongoing anchor handling operations are stopped.

Note: Replacing the sacrificial anodes is typically a two man operation; one
technician replacing the anodes and one technician on deck operating the
working winch and turning the drum.

Use a communication radio or similar for safe maintenance work.

3.4.1 Outer Sides of the Drums

1. Access the end of one of the drums from below deck.
2. Use a working winch to turn the drum for easy access to the sacrificial anode to be
replaced. See drawing 403-755GB in chapter “12 Design Drawings”, section “Test
Drawings” to understand how to turn the stern roller drum.
3. Remove the two screws that hold the worn out sacrificial anodes to the drum.
4. Replace the worn out sacrificial anode with a new one and fasten it to the drum.
5. Repeat step 2 to 4 in this instruction to replace the other worn out sacrificial anodes.
6. Repeat this instruction to replace the worn out sacrificial anodes on the other side
of the stern roller.

3.4.2 Inner Sides of the Drums

Warning: Risk of crushing! Always stay inside one drum while the other drum is
turned.

1. From below deck, preferably enter through the access hatch on the drum which is
not subject to replacement of sacrificial anodes.
2. Climb through the drum to the other side of the drum and open the access hatch
from the inside.
3. Use a working winch to turn the other drum for easy access to the sacrificial anode
to be replaced. See drawing 403-755GB in chapter “12 Design Drawings”, section
“Test Drawings” to understand how to turn the stern roller drum.
4. Remove the two screws that hold the worn out sacrificial anode to the drum.

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 Maintenance Instructions

5. Replace the worn out sacrificial anode with a new one and fasten it to the drum.
6. Repeat step 3 through 5 in this instruction to replace the other worn out sacrificial
anodes.
7. Repeat this instruction to replace the sacrificial anodes on the inside of the other
drum.

3.5 Replace the Pump

Warning: Risk of electric shock. Always turn off the power prior to working with
electric equipment.

To replace the pump of the water cooling system, proceed as follows:

1. Turn off the power to the pump on the starter cabinet.
2. Close the ball valve that is mounted on the tank and connected to the filter inlet.
3. Close the ball valve on the pump outlet.
4. Disconnect the power cables to the pump.
5. Remove the four M8 screws that hold the pump to its foundation.
6. Replace the pump and install the new pump in the reverse order.

3.6 Clean the Filter

To clean the filter, proceed as follows:
1. Make sure the power to the pump is turned off.
2. Close the ball valve that is mounted on the tank and connected to the filter inlet.
3. Close the ball valve on the pump outlet.
4. Open the lid on the filter.
5. Remove the round perforated steel plate that is mounted inside the filter.
6. Clean and fit the round perforated steel plate in the filter.
7. Fit the lid on the filter.
8. Open the ball valves on the tank and on the pump outlet.

3.7 Refill the Tank

To fill the tank with additional fresh-water, proceed as follows:
1. Loosen the overflow plug on the tank.
2. Remove the blind plug and connect a fresh-water hose to the tank refill pipe fitting.
3. Open the valve to the fresh-water hose to start filling the tank.
Fill the tank until water leaks from the overflow plug.

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Maintenance Instructions

4. Remove the fresh-water hose and fit the blind plug.

5. Fit the overflow plug.

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