KEM EL AIR SEAL

Type AX

INSTRUCTION MANUAL
•

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-hobooide!.readhsi'tdirnMal>.at>r KEMEL COM'ACT SEAI. T)l)eCX. DX& lv(

Kl:MELCOMPANY
~ division of EAGLEINDUSTRYCO.,IJ"D.
hltp~lwww.kernel.com
Contents
-------P.2
1. Outline
1.1 Construction
1.2 Air Control Unit (MU)
1.3A FTS eal
1.4 SIT L. 0. Tank Unit (TU)
1.5 Oil Pressure Unit (OU)
1.6 Drain Collection Unit (CU)

2. Oil Filling & Oil Pressure Test -------P.5

3. Operation of Air Seal -------P.5

3.1 Start-up Air Control Unit (MU)
3.2 Operation of Air Seal

4. Daily Maintenance --------P. 8

4.1 Stem Tube System
4.2 Air Control Unit & Drain Collection Unit

5. Trouble Sho oting

--------P.10
5.1 Abnormalities of Air Pressures/Air Flow & Actio
ns
5.2 Alarms & Actions
5.3 Other abnormal_
ities & Actions

6. Swit ch-o ver to normal Oil Seal System for

em erg enc y-- -- P. 13

7. Operation for Dry-docking, Undocking and

La yin g-u p-- -- P. 14
7.1 Dry dock ing & Und ocki ng
7.2 Layi ng-u p

-1-
 1. OUTLINE
1.1 Construction
Air Seal keeps seawater out by blowing air into sea through an air chamber (Air Chamber) provided at the space
between the #2. & 3 seal rings in AFT seal, and it keeps oil tight by controlling stem tube oil pressure to follow
change of ship's draft. Segregation of seawater and stem tube oil by Air Chamber minimize the risk of seawater
contamination. Besides, a drain line provided at the bottom of Air Chamber collects and recovers leaking oil and
water in engine room in case of leakage. At the same time, the system automatically optimizes the oil pressure
based on draft pressure detected at Air Chamber and remarkably reduces the pressure load given on AFT seal at
all draft levels. The construction of Type DX seal with a stand-by spare seal ring is employed on AFT seal, which
enables switching-over to the spare at any time by simple valve operation. FWD seal has a same construction as
existing models. The schematic diagram and the components for the system are shown in the sketch below.

---+-- Air Line

AIR SEAL - Schematic Diagram Air Control Unit
4 Lub. Oil Line
~ ·----+----- Drain Line D0 (S) Air Source
, Air Blow Line ' o_
,---------+-------------- _
I' Ps/t
Safety Valve
.,.J.-_.___._,
-7 ~~~~::-,
7 ' 1' W
Ii
fI

I' -c- 0
T
;
S T Oil Line
·· A- t----====
-
I, L- !' L-+
I FWD Seal L. 0. 1--+-~
' __--- ... . ··-· . Gire. Unit ~~~k \i~~ \Air Pressure Line
Stern Tube "B"
..., Oil Pressure Pd
_ _ _.____, FWD Seal Unit (Pump) /
I
I
Flow Controller
I
I L--4,--f) , < l , - - L . - - - - - 4 - - - - - , FC /
l
I
--o-- r----M--$
I ,----,
r- -C--
' '
I I
'------------------+---------------------------------------
Drain Collection
Drain Line
Unit H-f--=====_===-"""1-lM-

Component Function
BLOW Supply air to AFT seal
Regulate supply air pressure
TER
Air Control Unit
Regulate air flow
(MU)
Pressurize SIT L. 0 . Tank
Clean air pipe by fresh water

SIT L 0. Tank Unit Supply oil to Pump

(TU) Pressurize stem tube
Oil Pressure Unit
Circulate stem tube oil - Pump
(OU)
Drain Collection Unit Recover leaking oil/water
(CU) Recover cleaning fresh water
FWD seal L. 0.
Circulate FWD seal L. 0 .
Circulation Unit

-2 -
 1,2 AIR CONTROL UNIT (MU)
Air Con trol Uni t (MU) regulates supp
lied compressed air at the pressure*)
flow rate*) set by Air Flo w Controller set by Air Reg ulat or (R1) anc:1 th
(FC1) after passing_Air Fi~ rs (F1 &
Chamber~ AFT seal is blown into sea, cale F2). i:,e n
d />Jr BloW Lone which has a branch hne_ the regulated air lea d: ~
called TU Line, to pressurize it. MU to SIT L 0. Tank Untt Air
has a spare Air Reg ulat or (R2) and
SU ~ ~INE for ~i ng over from R1 a spare Air Flo w Con trol ler (FC r)
& FC1 on MAIN Ll~ E by C1 .Lever. ),
periochcal deaning of air purging pipe Also MU h:38 Fre sh Water Line on
and has an Alarm Switch for /J,Jr Pre
have pressure gauges P2 and P3 for ssure Low. Air Regulators R1 nd for
1 Set values of Air Regulators and Air setting air pressure.
Flow Controllers are shoWn in "Rnis
hed Plan - a R2
Piping Diagram Fig. 1".

Piping Diagram in MU
Alarm Switch P2
Air Pressure Low
Air
P4 Source
Branched
-~ V6
; y~
: r--1:><>\--t----+-.......1-- ll'
u._
<C V7 P3
OUT 1 .8
Air Blow
Line
3-W ay
Valve
OUT 3 SUB LINE Change Lever C1
'
FC2 Fresh Water
F/W Cleaning Line
VB V9
TU Line

OUT 2
!The diagram shows Air Seal operati
on using MAIN LINE. I
Air Sour ce
~
7
■· "' ' i!l!r
1 -··
Air Flow Controlle r - Pres sure P1 .
MAIN FC1 ~ 1¢)" ·• .«½ ~ BlowingAir
Air Flow f i ~ ' · ·~ c:-:;.~; Pressure P4
mete r FM1
:~fu-1• • -\ I Air Flow Controller

,~ r FC2
MAIN/SUB
Change Leve r C1 •
A. .~ LIL Air Regulator SUB
Air Filters R2& P3 ~
F1 • F2 I

MU Fron t View
Air Regulator
MAIN R1 & P2 I
~\

MU Side View Righ t

MU Side View Left

Air Blow line OUT 1

Test Line OUT 3
.....,..._....,::......._ TU line OUT 2
Fres h Wate r Line F/W

A ir Fitter Drain Dra in Air Source IN

-3 -
I
1.3AFTSeal Cross Section Air Seal
Air supplied from MU to AFT Seal blows out underwater 0 Air IN
through Air Chamber with the pressure set by Air 0 Air Blowing :;:
Regulator. The effects of air blow are explained below; ".!..
,rr.:~ ~
0 r=fllT-niii-iwilU~ Oil OUT

1) When the pressure in Air Chamber slightly exceeds

the tension forces from the #1 & #2 seal rings +
seawater pressure from the draft, the air lifts up the
#1 & #2 seal lips and starts blowing into sea through
the gap, fonned by the lift, with the constant flow
rate set by Air Flow Controller.
2) The gap by constant air blow makes Air Chamber
Seawater
being kept opened in-water all the time.
3) By this, Air Chamber pressure is equalized to the level
of tension forces from the #1 & #2. seal rings + seawater pressure from the draft or slightly above.
Because of the opening underwater, Air Chamber pressure does not go higher up to the pressure set by Air
Regulator, and also continual air blowing prevents seawater penetration into Air Chamber. Air Flow Controller
keeps constant flow and maintains the gaps under all draft level of the ship. Therefore the pressure in Air
Chamber follows water pressure from draft change with no time-delay. In addition, air from MU partly returning to
Drain Collection Unit (CU) with slight ventilation in E/R generates low speed air flow to remove leaking oil or
water from Air Chamber, through a drain hole provided at the bottom lead into CU.

The #3 & #3S seal rings can be switched over by valve operation in E/R. (Valve "C" & "D" shown in the piping
diagram P. 6.) Open these valves for the #3 in use and dose them for the #3S in use.

1.4 SIT L. 0. Tank Unit (TU)

TU is an air-tight oil tank having 100 - 200L capacity and is installed to give oil head pressure in stem tube with 2
- 2.SM of the oil height above shaft ~ter1ine. In addition, TU is connected with an air pipe comes out from Air
Blow Line to transmit the pressure in Air Chamber. By the arrangement, stem tube is pressurized at the level of
oil head pressure + Air Chamber Pressure which is loaded onto the #3 seal ring supported at the same time by
Air Chamber Pressure from seawater side while air blows out as described in Artide 1.3. Because of Air
Chamber Pressure at the front face and the back of the #3 seal ring, it counteracts each other cancelling the force.
As a result, the actual load remains on the #3 seal ring is oil head pressure of TU constant at all draft. Same
effect is available on the #3S seal ring when it is in use. TU is provided with Safety Relief Valve to avoid excessive
pressure, and Alann Switches for Oil Level High & Low. TU is also connected with Oil Pressure Unit (Oil
pumps) to circulate stem tube oil.

Oil Level High/Low

Safety Relief
Alann switches
Valve

Oil level TU Line

gauge connection ----+-,

Drain Valve
(N. C.)

TU Front View TU Top View

-4-
 1.5 Oil Pressure Unit (OU - Oil Pump) be ·i ·
OU circulates lubrication oil via "OU ➔ Stem Tube ➔ TU ➔ OU" · Stem.tu 01 pressure .
Is measu
rec1 at the
. _,... ressure is calculated by adding (or deduction on some ca~)
return hne from stem tube to TU. The co,,t:\.,l P . ~ Oil
head pressure from the gauge height to the reading value. (See calculatio~ example in P.7.) P~riodically exarnine
0 ·,1 suction & d'sch
I arge pressures on the pumps, and clean strainers for maintenanc e whenever 1s necessary•

1.6 Drain Collection Unit (CU) Joint for

Air Flow Controller FC
CU is an air-tight tank with 10L capacity and is located AFT seal
drain pipe •
below the shaft level. CU is connected to a drain pipe from
Air Vent
Air Chamber in AFT seal. Flow Controller (FC) fitted on
CU gives air-flow at a low speed (about 5 Umin.) from Air
High Level
Chamber towards CU to removes leaking seawater and oil Alarm SWitct,
into CU through the pipe. Drain recovered can be
discharged by the air pressure in CU, through Drain Valve.
(Discharge drain while M/E is stopped.) CU is fitted with
Level
Gauge
....E-_ Drain Valve
(N. C.)
Level Gauge and High Level Alarm Switch.

2. Oil Filling and Oil Pressure Test

Procedures for oil filling to stem tube and oil pressure test for Air Seal is described in P. 6. Confirm actual valve
operation for oil filling, circulation, draining & etc. in ship's piping diagram available in finished plan.

3. Operatio n of Air Seal

3.1 Start-up Air Control Unit (MU)
When air supply to Air Seal become available, start-up MU after filling oil in stem tube by the procedures below,
1) Put valve positions in MU for blowing air as per Finished Plan - ~iping Diagram Fig. 1.
2) Close Air Vent on TU and Drain Valve on CU.
3) Put valve positions for oil circulation via "TU ➔ OU ➔ Stem Tube ➔ TU", then start-up OU.
4) Open air source valve for MU.
5) Adjust settings for Air Regulator R1 and Air Flow Controller FC1 if necessary.
6) Confirm air blowing at AFT seal in dry-dock, or at sea surface in stem area after launching.
?) Record all data by using the form shown in P. 7, and examine the system is working right
8) Adjust stem tube oil pressure Ps/t by operating bypass valve on OU if necessary.
9 ) Put Change Lever C1 on SUB and examine all pressures. (FM1 does not work with SUB in use.)
j 10) Put Change Lever C1 on MAIN for normal operation.
In case of launching a new ship VJith no air blowing, examine CU periodically for possible water penetration after floatation.

3.2 Operation of Air Seal .

Air Seal System is in operation when blowing air into sea is started. The system automatically controls stem tube oil
pressure at the optimum level responding to changes of ship's draft. Keep blowing air and operating OU all the time
while the ship at sea as well as at berth ~r anchor. OU may be stopped for maintenance etc. while M/E is stopped- In
case air source is shut off, stem tube oil pressure stays at the level of oil head pressure from TU. Closely watch

t
seawaerpe netration into CU in such an event, and recover
.
or establish air supply as soon as possible Maintenance
.
• m MU and CU is done as per the artide 4 1n P. B. ·
of stem tube sys.e ,

-5 -
 -.::
i a2x.t ILS I t itGtiiMAL H1811,4.S@li{ftM J@it6 &• m
Test
TYPICAL DIAGRAM· Confirm valve no.s & details In Finished Plan Procedure
Orde l Rln,

procedure au Fllllna Leak test via "X"-Une 1) FIii stern tube and TU with oil. - See left " Procedure OIi Flllln('.
1) Close valves "A" & "B".
2) Keep valve " G" opened. Keep valves "C" & " D" closed. 2) Keep valves "C" & "D" closed.
1) FIii Sump tank, - Open Valve "I".
3) Operate OU 3) Apply oil pressure In stern tube.
2) Close air source valve for MU, and open air vent on TU.
4) Circulate oil via SumpTk.,.5/T.,." X"•llne.,.Sump Tkfor t est.
3) Close valves •c• & "D", and open valve "G". 4) Remove bottom plu1 between #3 & 35 seal rinss on AFT seal casin1.
4) Keep valves "A" & "H" open. and close valve "B". 1 #3S S) Clean up seal casing/liner/oil holes to remove oil wet.
5) Fill stem tube 1nd T\J with oil by operatlns OU.
Leak test by applyln1 air prem ure In MV
1) Close valve "G" on oll llne. 6) Leave the plus opened for more than 3 hours.
6) Stop OU after TU fllled up with half level. 2) Open valves "A", "B" & "H" on oil line.
7) Confirm no oil lea kins through the bottom hole.
7) Close air vent on TU. 3) Keep valves "C" & "D" closed.
8) Carry out Test Order "1" & "2", either by uslns; 4) Close air vent on TU. 8) Confirm no oil leaking at other area, I. e. sheet packing, "O" rin1 & etc.
a) "X"-llne, or S) Operate OU, and circulate oil via TU.,.5/T.,.TU for test.
b) Air pressure 6) Set valve positions In MU are for Air Blow.
1) Same procedures as 1) & 2) for testing #35 above.
9) Flll oll In ll3/3S by Test Order "3" after "1" & "2". 7) Reduce Resulator setting (0.2 - 0.4MPa) on "MU" to 0.lMPa.
8) B) Close valve "E", or V4 valve In MU. 2) Remove bottom plug between #4 & S seal rings on FWD seal casing.
10) Fill oil #4/5 by Test Order "6" after "3", "4" & "5".
9) Check Ps/t shows about 0.lMPa and proceed for the test. # I3) Clean up seal casing/liner/oil holes to remove oil wet.
2 4 4) Leave the plug opened for more than 3 hours.
Apply oil pressure In stern tube either by X-llne or by air pressure, and carry out
the test In accordance with the procedure shown In the table. S) Confirm no oil leaking through the bottom hole.
6) Confirm no oil leaking at other area, I. e. sheet packing, "O" ring & etc.

1) Plug all oil holes/drain holes between #3 & 35 on AFT seal casing.
Switching #3 & #3S seal rings "MU" 2) Open valves " C" & "D", to apply pressure In #3/35 chamber.
3) Close valve "H" for about 30 sec. to direct o il flows into #3/35 chamber.
Valve CIValve DI Air Source #l I4) Keep valve "H" open again for the test.
3 5) Remove bottom plug between #2 & 3 on AFT seal casing.
valve
11 ~ ~ Ir-+r----,Safety
"G" .A. l
I Air Vent, 6) Clean up seal casing/liner/oil holes to remove oil wet.
Close Close
7) Leave the plug opened for more than 3 hours.
0) Ps/t 8) Confirm no oil leaking through the bottom hole.
L
._JI
tt ,+t ± ±
,, c"
~ -----J
1) Leave bottom plug between #2 & 3 opened.
"TU" 2) Plug bottom hole between #1 & 2.
"E" t #Z 3) Remove two plugs on top between #1 & 2, for filling and air venting.
I
4
------l><}--J I 4) Fill #1/2 chamber with "Fresh Water" through the top hole.
.)J(,
I- S) Clean up seal casing/liner/filling holes to remove wet.
FWD seal Tk ~ 6) Confirm no water leaking through the bottom hole between #2 & 3.
bl)
IV
... 1) Same procedures 1) - S) for testing #2 seal ring above.
...,0
#l 12) Confirm no water leaking out.
l __
- - ~ I s 3) Drain out Fresh Water after the test.
0
Pd _j 4) Confirm all holes for fllllng, draining & air venting on AFT seal pluged.
"ou" 1) Plug all holes between #4 & Son FWD seal casing.
2) Fill #4/5 chamber with oil.
"F" s ~
#5
- ----IX!- I 6
I3) Clean up seal casing/liner to remove oil wet.
11 ?. 4) Confirm no oil lea king out.
'T'l o~
#
I~ S) Confirm all oil holes on FWD seal plugged after the test.

Sump Tk

@@@ G) Oil Line

-+--- Air Line
J: REMARKS
I. Carry out leak test after completion of flushing pipes.
2. Talee wear-down rcadin~ before and after overhauling AFT seal, for repair ship.
3. Protect seals from sand blasting, painting. welding, chemicals, excessive heat & etc.
4. Use stainless steel fitting bolts (SUS 316 or equivalent) for AFT seal installation.
S. Secure all the fitting bolts and plu~ for AFT seal by using stainless steel wire.
1. Valve positions shown above are for " Normal Operatlns Condition" of Air Seal System. 6. Put all valves (and regulator setting) back to "Normal Operating Condition" after the test
2. "X"-line is for oil circulation via the gravity llne, not In use during operation of Air Seal System. 7. Check P2 pressure indication for Regulator on the green mark.
8. Oil level may suddenly reduce when air-locking dissolved. Fill oil in such an event
 RECORD FORM - KEMEL Air Seal System ~ mm
M/V
Air Control Unit Drain Collection Unit (1 0L) SIT LO. Tank Unit Oil Pressure Unit
I
Pl P2 ! P3 I P4 DP Fl F2 ! FM1 Cl Pd FC Level 1aue:e Level gauge ! Ps/t sue. DISC.
• I
AFT !
Date Draft Air Reg. air
. 1i Reg. air
. i: Bl. Level
Oil level M/ E S/T B'r&
I
: i ow air Diff. air Air flow Air Level from S/ T oil Oil Oil FWD seal Temp. Remar1<
(M) source press. i press. i Oil mist Change Air flow Liquid in from Tk rpm
press. Air filter meter press. Tk bottom press. press. press.
in Use Tk (L) (Deg.. C)
press. Main iSub press.I filter lever control tank bottom
(MPa) (Umin.) (MPa) (cm) (MPa) (MPa) (MPa)
(MPa) (MPa) (MPa) j (MPa)
I (cm)
I . i !
1 10.4 0.7 0.3 I 0 ! 0.11 0 .01 Clean Clean 40 Main 0.09 flow ! emotv 0 43 i 0.11 0.11 0.17 #1 7 0 32 Samole
i I Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/sw #1/#2
! Clean/ Dirty! Clean/ Dirt/ Main/ Sub flow/ no !empty/ oil/ sw #1/#2
i Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no iempty/ oil/ sw #1/#2
i ! Clean/ Dirty\Clean/ Dirt/ Main/ Sub flow/ no !empty/ oil/ sw #1 / #2
: i #1 /#2
Clean/ Dirt/ Clean/ Dirt/ Main/ Sub flow/ no !empty/ oil/sw
' i Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/ sw #1/#2
! Clean/ Dirt/ Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/sw #1/#2
i Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no iempty/oil/sw #1/#2
Clean/Dirty! Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/sw #1/#2
Clean/ Dirt/ Clean/ Dirty! Main/ Sub flow/ no iempty/ oil/sw #1 / #2
Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no iempty/ oil/ sw #1 /#2
l Clean/ Dirt/ Clean/ Dirty! Main/Sub flow/ no lempty/ oil/sw #1/#2
-:i
Clean/ Dirt/ Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/sw #1/#2
: Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/sw #1/#2
Clean/ Dirty/ Clean/ Dirt/ Main/ Sub flow/ no !empty/ oil/ sw #1/#2
' Clean/ Dirty! Clean/ Dirty! Main/ Sub flow/ no !empty/ oil/ sw #1 / #2
!
1. Recordinit intervals: Once a day
2. P4, Pd & Ps/t pressures automatically follow change of water pressure from the draft.
3. Clean filters in case of pressure rise in DP gauge.
4. Clean pump strainers in case of suction pressure drop on Oil Pressure Unit.
5. Put air vent pipe of FC on in a water cup to check air flowing at Drain Collection Unit.
6. Use this form in operating the system wh ile the vessel at sea, at berth or in sea trials.
Cal f diff • I haft
Initial Setti·••n --·--·--·-·· - · -···-- ------- r-· ----- - -- - - ---- ------·····-

Symbol Standard setting Check point 1. Symbol Value Remark Example I

DP Green range (less than 0.1 MPa) Gauge height above shaft C/L (m) h Ps/t gauge 1.5 I
40 or SOL/min. Head pressure (MPa) Ps/t gauge * Hp Gauge height x 0 .009 0.0135 I
FM1 ···-·· ----- ***
·-
Pl More than 0.4MPa * Fill (-) minus value in case the gau_ge located below shaft level
P2 0 .25 - 0.35MPa on MAIN, OMPa on SUB *** Check point 2. Symbol MPa Remark Example
P3 0MPa on MAIN, 0.25 - 0.35MPa on SUB *** Stem tube oil pressure Ps/ t Variable by draft. Pd shows 0.11
*** Ac/just settings shown in Finishied Plan - Piping Diagram Fig. 1. Press. in Drain Collection Unit Pd nearly draft pressure. 0.09
Differential Pressure Ps/t - Pd t.P - 0 .02
Hp by calculation 0 .0135 j
Hei_ght of shaft centerline above keel (m) Head Pressure Ps/t gauge *
t.P + Hp below 0.05MPa 0 .0335 I
Differential pressure compensated

_, ... C
 4. Daily Maintenance
4.1 Stem Tube System
Record and monitor operation f A'
Operating Guideline shown inoKE,r Seal as per the form in P. 7. Also monitor stem tube system as per
In case of questions on the d t MEL C~MPACT Seal Type CX, DX & AX INSTRUCTION MANUAL.
"techservice@kemel c ,, fa a or operating condition, send the record to Technical Service Dept. at
· om or examination and comments.

4.2 Air Control Unit & Drain Collection Unit

Table below shows maintenance 0 f MU
and on CU. Also refer to photo manual in P. 9.

Unit Devices Symbol Standard

setting Maintenance
Nr Source 4
o. MPa Min. Fully open air source valve and keep the pressure above 0.4MPa all the time.
Differential Less than In red zone ... Cleanorrenewfilters. Pl DP
0 _1MPa
Pressure DP (D Open V10 and close V1 & V2 in MJ.
® Open V3 to release air in the line. -r-i>Q-t_,_-Q ~Fl...1..1':ld-.-<~
Gauge @ Rem0\18 filter covers. (Secure O-ring fitted)
© Rem0\18 filters. V2
in green
F1 @ Clean & re-set filters, or renew filters.
Nr Filter zone @ Close VJ. Open V1 & V2, then close V10.
F2
Pressure setting (Set value is shown in Finish .Qaiw.fl

Set Value
Plan - Piping Diagram Fig.1)
© Pull-oown the knob to unlock.
® Turn the knob for pressure setting.
IN 2L! tL ·
-E--·

R1/P2 See Note*)

Nr
&
@ Push-up the knob to lock.
Check positions of Green Markers in P2 & P3 cf::! m il. I.... MatiDc
-·~~-- '-·
Regulator (- ) . JIIW
R2/P3 Allowance gauges for indication of the set value.
MU ±0.0SMPa Note: Initial setting is made for Rl & R2 at
the time of delivery.
~1' (+ )
CAotml Knnh: Pull Down-Unlock, Up·Lock

Flow setting ( the value shown in Finished Plan-

Piping Diagram Fig.1.)
FC1 Set Value <D Pull-up the knob to unlock.
Nr Flow
& See Note*) ® Check air flow rate at FM1 .
Controller @Turn the knob for flow setting.
FC2
Allowance
© Push-down the knob to lock.
±5LJmin. Note: Initial setting is made for FC1 & FC2 at
NrFlow the tirm of delivery.
Control Kngb: Pull Up-Unlock, Down·Loclt
FM1
Meter
(D On MAit /w blows into sea via R1-+P2-+FC1-+FM1 .
Change ® On Sl.13: /w blows into sea via R2-+ P3-+ FC2, bypassing FM1 .
C1 on MAIN @ SUB is only for temporally use. (FM1 does not work.)
Lever
© Recover MAN to replace SUB as soon as possible.
(D Check ventilation through the vent, with low ai'-speed.
® Turn the knob to adjust flow speed after the lock nut loose, if necessary.
Air Flow @ Tighten the lock nut after setting air flow.
FC Slight Open
Controller Note: Initial setting is made for FC at the tirm of de live~
cu Put air-vent pipe in a water cup to check ventilation bubbles.

(D Remove drain in case of high level alarm activated.

Level @ Slight-open drain valve for discharge by air pressure in CU.
Gauge @Discharge while M'E stopped. ( Do not open the valve when M'E in operation.)

Note *) Aciust settings shown in Finished Plan - Piping Diagram Fig. l .

-8-
 ~ J
OPERATION of AIR CONTROL UNIT and DRAIN COLLECTION UNIT
'hoto 2. AirFlowControllerFCI (Sim Vie w- Left)
Photo 1. AirControl Unit (MU) -,-

Pl• .,, ·P4 1. Pull up the knob for unlock.

Press. Gauge 'd P ress. Gauge 2. Tum the knob for setting airflow.
~ 3. Check the rate by Flow Meter.
,· . Air
BloWlI18
4. Push down the knob for locking.
AkS= /4~ • Cl
Fl\1.1- FCl·
Air Flow Meter Main-Sub Air F1ow Controller
Change Lever
Fl\H-
Air F1ow Meter

Photo 4. Rerrowl Filter Elements NOTE: Do not open filters before isolating them
Photo 3. Air Regulator& Air Filtera
r from air pressure line!
Procedure for isolating filters
F!e~;:'5~ ltif Q -· ~ ~ - (DOpen Vl0 to keep bypassing airline.
I ® Clooe Vl & V2 for isolation..
~
rl[~).!)7.~;n: @Open V3 for air release .
F2• @Open filters.
CD O~l Mist - c 11"1&1
Filter Procedure for re- activating filters
Fl• <DI n.stall filters.
Air Fi.It.er • Fl ® ClooeV3.
Air F1it.er E lement @ Open Vl & V2.
® Turnthecover. ·F2 @Clooe Vl0. I V2
@ Pull down the cover. Oil !\fat Filter
P2 & Rl: Air Regulator Main O..Ower) (Rotate to detatch them.)
P3 & RZ: Air Regulat.or Sub (Upper)
(Pull down the knob and turn, to set the pressure on the green mark.)

Photo 5. Drain Collection Unit (CU) Photo 6. AirFlowConboller FC2 on SUB (Side View-Right)

from Air ;:;ssure

Chamber Gauge
1. FC2 works with change lever Cl on SUB.
2.The initial setting is made at 40 or 501Jmin.
,~
~ 3. Change flow rate as same manner as FCl.
4. Flow meter FM 1 does not work with FC2.
•FC o.SUB is used only for temporally operation.
Air F1ow 6.Recover :MAIN at the earliest opportunity
Controller Discharge Drain (with stop MIE)
(D Open drain valve
• Drain Valve ®Discharge by e.ir pressure
(N. C.) @Close drain valve

.., "'
•
 -
5. Trouble Shooting
5.1 Abnormallt fes of Air Pressures/A ir Flow & Actions
Possible Cause Action
Unit Gauge Abnormality
Air source valve closed . Open air source valve.
Low, or "Zero" pressure. Air source pressure low. Keep the pressure above 0.4MPa.
P1
(Minimum 0.4MPa required.) P1 gauge malfunction. Replace P1 gauge.

Change Lever C1 is on SUB. Put C1 on MAIN, if it works.

Air Regulator R1 setting changed. Re-adjust R1 setting.
P2 Low, or ·zero" pressure. Replace P2 gauge
P2 gauge malfunction.
Air regulator R1 malfunction. Put C1 on Sub. Replace R1.

Change Lever C1 is on MAIN. No action required.

Air Regulator R2 setting changed. Keep C1 on MAIN.
P3 Low, or ·zero" pressure. Re-adjust R2 setting.
P3 gauge malfunction.
MU Air regulator R2 malfunction. Replace P3 gaugeReplace R2.
Valves on Air Blow Line are closed. Open the valves.
Rises up to R1 (or R2) set pressure. 3-way valve on Air Blow Line in direction F/W cleaning. Put 3-way valve in direction of Air Blowing.
Clean pipe by using fresh water line in MU, while MIE
P4 Gets higher pressure in same draft level before. Blockade proceeding in Air Blow Line.
Gets larger deviation from Pd than ever before. stoooed.
0
- Low, or "Zero· pressure. Air leakage from air pipes Check pipes by sprayjnq soap water, and repair.
The pressure does not follow chanqe of draft. P4 qauqe malfunction Replace P4 qauQe.
Indicator needle in "Red Zone". Dirty filters F1 & F2. Clean or replace filters.
DP
Air Flow Controller FC1 setting changed. Re-adjust FC1 setting.
Air Flow Controller FC1 malfunction. Put C1on SUB. Replace FC1.
FM1 Out of setting range.
Air Flow Meter FM1 malfunction. Put C1on SUB. Replace FM1 .
Drain valve or Air Flow Controller FC fully opened. Close drain valve or re-adjust FC slight open.
Pressure low. Blockage or air leakaqe at drain pipe lead to CU. Clean pipe by fresh water line in MU, repair pipe.
Pd
Pd qauqe malfunction Replace Pd gauge
cu Does not follow chanqe of draft.
Seawater leakage through the #1 & 2 seal rings. Remove water. Record daily amount and report.
Level Filled with seawater.
Oil leakage through the #3 seal ring. Remove oil. Record daily amount and report.
Gauge Filled with oil.
Air vent valve on TU is opened. Close air vent valve.
Ps/t stays at head pressure of TU, or does not Air leakage at the pipe lead to TU or TU itself. Check pipes by spraying soap water, and repair.
TU rise. Ps/t gauqe malfunction. Replace Ps/t gauge
. Ps/t Fully open valve •A", shown in P. 2 diagram.
OU "Ps/t - Pd" value is greater than 0.05 MPa, with Valve "Pi on return line to TU is not fully opened. Re-adjust the bypass valve.
compensation of Ps/t gauge height. Bypass valve on OU is fully closed. Set R1 & FC1 lower, at the minimum values.
 a ------.. •·

5.2 Alarm s & Action s

ALAR M I Unit Check Point

Abnormal Condition Report to
Possible Cause Action
KEMEL
.~~.~ c1.~g·~··················.I.I.~~.!~.~!!?.c1~.i:lr..i~.. B~~.%.l:l~.~. . E:i.>_<~E:i.~~.i11.
!
9 .0.1MP a ....................... Dirty filters .............................................
J.q.\~.a.11..i:l.~.r.E:!p\c1.~E:l..~!~.~r..E:l.l.~~.n.t:5.:.................................
P2 Gauge P2 indicat es below the minimum set pressure. R1 setting changed. Re-adjust R1 setting .
(see Finishe d Plan - Piping Diagra m Fig. 1) Malfunction R1 . Put C1 on SUB.
MU Replace R1 .
Malfunction P2.
......, Replace .P2 ........................... .............................................. .
A1 FM1 Flow Meter Flow rate is below the minimum value. Re-adjust FC1 setting .
(MU) I FM 1 setting changed
(see Finishe d Plan - Piping Diagram Fig. 1) Put C1 on SUB.
········································· Malfunction FM1 .
Air
Valve positio ns ········································· ···························· ····················································1
·········· ··················•················! Replac e .FC1_. ..........................................
pressu re Wrong positio n. (see Finished Plan - Piping Diagram Fig. 1)
-
............................ ......
I Correc t valve positio ns.
Low Safety relief valve The relief
valve activates at lower pressure.
TU Air pipe joints I Malfunction valve. Repair/Repla ce the relief valve.
Ajr leakag e. (Check by spraying liquid soap.)
Air vent Loose joints etc. Repair leaking joints/pipes.
Air vent valve opened .
Close the valve.
Flow Controll er FC Excess ive air flow at FC.
CU IAir pipe joints \Setting changed. Re-adj ust FC with 2-3 air bubble s/sec.
Air leakag e. (Check by spraying liquid soap.)
Drain Valve Loose joints etc. Repair leaking joints/p ipes.
Drain valve left opened.
Air Sourc e ILoss of air source p ressure. Close drain valve.
I-' Take actions in P. 13. Recovery of air
I-' Pressu re gauge Negati ve pressu re at pump suction, causes air sucking.
! Dirty straine r
OU IStraine r Dirty straine r.
Particles in SIT oi Clean straine rs.
Oil color Air bubble s { Increased oil volume by air inclusion.)
A2 Air inclusion
TU ILevel gauge I
Level increas e in shallow draft and decrea se in deep draft
(TU) I Air-poc ket in SIT. Dissolv e air-poc ket.
SIT IStern .tube.drain .......1 Sign .of.seawa ter penetr ation .............. Yes
Oil Level ...............................................'. Increas e air flow rate at 60-80 Umin.
High CU ILevel gauge Filled with seawa ter immediately after draining. AFT seal damag e Condu ct diver inspec tion. Yes
Repair AFT seal.
FWD Decrea se oil level in FWD seal tank, and increas e
Levelg auge the Increase SIT oil pressure. ***
sea1 level in TU with same amount. (Pump ing effect.)
IPressure fluctuation in SIT . Re-fill oil in FWD seal, whene ver is necess ary. Yes
A2 TU Oil pipe joint Oil leakag e Loose joint Repair pipe joints.
(TU) cu Level gauge Oil level increas es over 2Uday.
Leakag e from the #3 seal ring Activat e the #3S seal ring .
Oil Level FWD Yes
Low Level Igauge Oil level increa ses over 2Uday.
sea1 Leakag e from the #4 seal ring Recovery. Repair the #4 seal ring. Yes
A3
(CU) Contin uous seawa ter recove ry. Increase air flow rate at 60 - BO Umin.
Liquid CU Lev~I Gauge
I I Filled with seawa ter in a day. Damag e of the #1 & 2 seal rings Condu ct diver inspec I tion. Yes
Level Dram Repair AFT seal.
High Recov ery of oil over 2Uday Damag e of the #3 seal ring Activat e the #3S seal ring. Yes I
*** Increase oil pressure by operat ing bypass valve on OU or valve "A" on return line.
The differti al pressu re "Ps/t- Pd" should not exceed 0.05M
Pa. (See P. 7 Calcula tion of pressu res)
 5.3 Other abnormalftfes & Actions

Abnormalities Check Point Report to

Possible Cause Actions
KEMEL
Seawater penetration into stern tube Air pressure in CU. Increase air flow rate at 60- BOUmin.
with no seawater collected in CU. Stern tube oil condition. Blockade in drain pipe. Clean pipe by using Fresh Water Line in MU. Yes
Conduct diver inspection, if necessary.
Stem tube oil leak with no collection Pressure in CU.
Broken pipe in stern tube Activate the #3S seal ring and keep monitoring.
of oil in CU. Oil level in TU. Yes
Blockage in drain pipe. Cleaning Air pipe by Fresh Water.
Air pressure high alarm (Option) from Valve position on Air Blow Line. Valves remain closed. Open the valves.
A1. P4 pressure on MU.
Yes
Blockade in Air Blow Line. Clean pipe by using Fresh Water Line in MU.
,...,..,, .
,;._·~.._ ~ __./
Cleaning Air Pipe by Fresh Water
·,. ·,# ~' .,..

In case P4 pressure become higher than Pd over 0.03MPa difference, it is possible -, ::.; _; it~
2~i N '
• I
..
that air flow pipes started to have blockage due to extraction of salt etc. MU has a
fresh water line to dissolve the blockage and to clean the pipe. It is recommended that
...... the ship clean the pipe by using the line with 6months intervals .
N>

U, ' .. /
, "l l ·, . - .
Procedure for Fresh Water Cleaning (To be done while M/E stopped or on turning gear.)
1) Open drain valve on CU. \ \~ ··-
'\, -
' . .
. •. ' .
/ •·
·• •• ·--

- Note 1
I- . ···:_•· '
2) Turn 3-Way Valve in MU, to the direction of Fresh Water Line.
3) Open the valve and start supply fresh water.
\ ,, \ : ~
\;_.,_;. - "/
\ . . . ' ' '
4) Clean the air pipe till fresh water coming out from the drain valve on CU. - Note 2 ~' ' •; IFlow Control ValveI
'
5) Stop fresh water supply. :'• ' ., . _:_\. .,,- '
\ \ .·~•,.- ....
6) Turn 3-Way Valve in MU, to the direction of Air Blow Line.
7) Close the drain valve on CU after blowing out water by the air.
\ ' ', -
' ~r.
8) Examine all pressures and air flow being in normal condition. !3-Way Valve
I
L _ _ _ _ _ __ _ -

11111111 Bottom Panel

Note1. When 3-way Valve is turned to the direction of Fresh Water, Air Blow line is shut off and air pressure set by R1 is directly given to TU. This may cause activation of Safety Relief
Valve on TU, which is not harmful. The activation of Safety Relief Valve may be stopped by reducing R1 setting during Fresh Water Cleaning. However, do not reduce R1 setting in
case of continual seawater leakage into CU. Also make sure R1 should be back to the set value after the cleaning.
Note2. It takes a time to have cleaning water coming out at CU drain. (Flow Control Valve on fresh water line is initially set and locked at very slow speed so that the water does not
penetrate into stem tube by sudden rise of water pressure. In case the initial setting is lost, fully close the control valve then tum the wheel 180 degree, half-tum, for re-setting.
 ncy
6. Switch-over to Oil Seal System for emerge _vessel is at sea,
drop in stem tube. In case of air lost ~ile th~
Losing air supply to AFT seal causes oil pressure if no ~t er is
It is possible to operate the system without_a,r
immediately examine seawater penetration in CU. During
observed in CU. Air supply, however, should be
recovered to raise the oil pressure at the earfiest poss,ble.
ly to MU may
the operation with no air, keep monitoring cu by
trequent examination of the drain. in case no air supp
down or stop M/E till air supply is recovered .
oontinue for a long period, study possibilities of slow-
ater by switching
uct protection of stem tube bearing from seaw
seawater oontinuously fills CU in a short time, oond
If _
per the procedures below,
Air Seal system over to normal oil seal system as
stop air supply.
1) Switch-off all alarms on MU, TU and CU and
.
2) Stop OU, and then take action 3) with no delay
ge oil cirrulation via X-line as per 'Valv e Oper ation for switching to X-line" below.
3) Chan
~) Re-start OU with no delay. which minimizes the
all the time to maintain the oil head pressure
While operation with X-line, keep OU running and remove
Strengthen examination of stem tube oil drain
chance_ of seawater penetration into stem tube. same tim
er air source failure as soon as possible. At the
• necessary to reoov
inves
.
.oontamrna
tigate poss ibility f
· iound. 1t rs
ted oil when ·t' rs
ea, ,,er
... ·
inspe •
ction and repai r of AFT seal for seawater leakage.
e, f
Va ve O

Oioer atio n for swit chin e: to X line X-lin e-

I
MU CU
TU
OU
I G
-
B Air Ven t
Valve VB I E F A
Close Ooen Ooe n Ooen
Close I Close Close Close
Oper ation
line to ressu rize
Note 1. VB valve is located in MU , on the TU.Diagr am F1'g 2
. . . ed PPlan - Piping
. in Finish
Note 2. Confi rm deta·,1 va Ive opera tion
· ·
· Sea l
V alve O erat ron for sw itch in back to Air cu MU
X-lin e OU TU
F E VB
G I Air Vent B
Valv e
Close 0 en
Ope ration Close Close

X- Line to
Sump Tk
u P1 o_
P4 sce
'II. 0 © r_A ir Sour
1 afety Valve
" G" ~~1 Pe1;...:.i : f--- --l Air Vent
1 I
1I I
Ps/ t •-JI II
"T-.. ..,_;.- .J _ ......__ ,_
,, c'' L. ____ _ ,

___...,._JI"E"
,,A''
"B''
FWD seal Tk

,, I,,

Sump Tk
Oil Line
--- Ai r Line

· 13 -
 ng and Laying-up
~r at io n for Dry-docking, Undocki
o,y,docking & Undocking as the manners below,
71 shut-down and re-start Air Seal system
· In case of dry-docking and undocking, ring dock.
air supply to CU to shut-dovvfl before ente
) Stop all alarms on MU, TU and CU, and then stop
1 seal for seal repair after dry-up.
) Disc harg e oil in stem tube, AFT seal and FWD
2 as necessary.
) Carr y out inspection or repair of the seal un~
3 filling and pressure test)
sure test as necessary. (See P. 6 for oil
4) Fill stern tube and cany out oil pres res.)
ng. (See artides 2 & 3 for the procedu
5) Re-start the system before undocki

7l Laying-up as the manners below,

er and no air, shut-down Air Seal system
In case of laying-up the ship with no pow
1) Stop all alarms on MU, TU and CU.
2) Stop OU to shut-down the system.
CU through the drain valve.
3) Examine existence of seawater in r the shut-down.
carry out drain check once a week afte
4) In case of no seawater observed, seawater by S'Mfching Air
wate r fills CU in a short time , conduct protection of stern tube bearing from
5) In case sea
em using X-line as per article 6.
Seal system over to normal oil seal syst
operating OU.
6) Circulate stern tube oil via X-line by
7) Check oil pressure at Ps/t gauge.
8) Stop OU to shut-down the system.
9) Confinn the oil head is maintained.
tube drain.
10) Examine Pslt once a week and stem
res 6)- 9), if necessary.
11) Recover the pressure by the procedu

d as the manners below,

Re-start Air Seal after the laying-up perio l".
e operation for switching back to Air Sea
1) Operate the valves as per article 6 'Valv
2) Confirm drain valve on CU is closed.
3) Operate OU.
s on MU, TU and CU to re-start.
4) Supply air to MU and activate all alarm
the system.
5) Examine all pressures and air flow of cause reduction of seal lightness. Recommend deaning
AFT seal area during laying-up period may
It is possi>le that marine gl'OIMhs around
earliest opportunity after re-activation of
the system.
and overhaul inspection of the seal at the

- 14 -