Section 5 Integration Survey & Approval

5.1 General

5.1.1 The full process implemented for the Integration Survey & Approval is given in Figure 1.5.1 Pictorial representation of Integration Survey & Approval process. The relevant Sections are also highlighted.

Figure 1.5.1 Pictorial representation of Integration Survey & Approval process

5.2 Installation

5.2.1 Mechanical Appraisal

Required Submissions
- Diagrams and details of any additional and modified piping systems
- Arrangements of machinery and equipment (for reference)
- Drawings and details of any hydraulic actuating mechanisms (Pipe design pressure, inner and outer diameters, thickness, material, design and working temperature, etc.,)
- Harbour Acceptance Test (HAT) schedule
- Sea trials schedule
Applicable Rules (Existing)
Provisional Rules for Sail-Assisted Ships, January 2008
Rules and Regulations for the Classification of Ships
- Pt 5, Ch 12 Piping Design Requirements
- Pt 5, Ch 14 Machinery Piping Systems
Additional Verification
No additional requirements.
Deliverables
The DAD will be issued at the end of the design approval process.

5.2.2 Structural Appraisal

Required Submissions
- Document explaining the design concept of the full system
- Revised Watertight Bulkhead (WT BHD) plan showing the integration of rotor column including welding details
- Wind force calculations
- Calculations of deck forces due to the rotor
- Full information regarding design parameters, including relevant environmental data and limiting operating conditions, lift and drag coefficients and resulting force variations and distributions throughout the range of operating angle of the rotor systems. These data should be supported by results from appropriate testing.
- Scantling calculations of rotor column demonstrating that the strength is equivalent to that of WT BHD including the flooding strength as per IACS UR S18 and grab reinforcement.
- 3D FEA structural analysis of rotor column integration to WT BHD
- Access arrangement plan to rotor column and to inner bottom
- Revised trim, stability and longitudinal strength calculations with installation of rotor system
- Revised final loading manual after installation of the full system
- Operation manual of the full system (for reference)
- It is a feature specific to Flettner rotors that ‘conventional load’ or ‘proof load’ tests defined in LAME Ch 12 Testing, Marking and Surveys of the Rules (as applicable) can’t be performed. Therefore, the designer and manufacturer are to prepare a detailed FAT and ship board operational test program, covering a simulation of all operational and non-operational loads and events of the rotors through their designed life.
- Test schedules/programs (for both works testing and sea trials) that are to include the methods of testing and the test facilities provided.
Applicable Rules (Existing)
Provisional Rules for Sail-Assisted Ships, January 2008
- Ch 1, 1.2 Design considerations 1.2.1
Evidence will be required to ensure that the vessel has appropriate stability when the rotor is integrated to the hull.
- Ch 1, 1.2 Design considerations 1.2.2
Evidence will be required to ensure that the propulsive machinery fitted to the ship is of sufficient power to ensure adequate manoeuvrability of the vessel in all conditions, including inoperative rotor systems. In general the propulsion machinery should be capable of operating in all conditions of heel and trim which may result from operation of the rotor systems.
- Ch 1, 1.2 Design considerations 1.2.5
If the maximum service speed with combined wind-assisted propulsion exceeds initial design service speeds, modifications to rudder and stern frame scantling might be necessary. The service speed, V, used in the derivation of rudder and stern frame scantling in the Rules for Ships, is to be taken as the maximum estimated speed, in knots, with the ship in the loaded condition with any possible combination of sail and propulsion systems.
- Ch 1, 1.4 Structural arrangements 1.4.2
It is envisioned that the main sail supporting masts will be carried through the main strength deck and extended below to a second deck or equivalent structure. Hull structure is to be reinforced and stiffened locally to ensure adequate strength and resistance to plate buckling.
- Ch 1, 1.4 Structural arrangements 1.4.3
Suitable materials should be used for ships carrying dangerous goods. Steel used within the structure or associated to the sailing system should be in compliance with the Rules for Ships, Pt 3, Ch 2 Materials.
LR Code for Lifting Appliances in a Marine Environment (LAME) (2013)
- Ch 4, 2 Shipboard cranes
- Ch 4, 3 Offshore cranes
Additional Verification
Evidence that the anchoring arrangements installed on board the ship are adequate for the increased windage area the rotors provide.
Deliverables
The DAD will be issued at the end of the design approval process.

5.2.3 Electrotechnical Systems Appraisal

Required Submissions
- Revised power tables
- Revised short circuit calculations
- Single line diagram
- Cable installation practice
- Control philosophy
- Navigation bridge visibility
- Navigation lights arrangements
- HAT schedule
Applicable Rules (Existing)
Rules and Regulations for the Classification of Ships
Provisional Rules for Sail-Assisted Ships, January 2008
- Ch 1, 1.2 Design considerations 1.2.3
A control system is to be provided so that the setting and trimming of sails may be carried out from the bridge, and is to be such that, once established, the desired settings and trimming may be automatically maintained. The control system is to provide adequate speed of response to automatically neutralise the sail system in the event of wind conditions which may damage the sail system and endanger the ship.
Additional Verification
No additional requirements.
Deliverables
The DAD will be issued at the end of the design approval process.

5.3 Survey, Inspection, Testing & Trials

5.3.1 Survey & Inspection. The survey and inspection of the rotor and foundation structure during its installation/integration are to ensure that the relevant Rule requirements stated in these Guidance Notes have been complied and any conditions given in DAD are addressed. It has to be conducted in accordance with Ch 1, 1.6 Survey requirements for sail systemsof Provisional Rules for Sail-Assisted Ships, January 2008 and LAME (2013), Ch 12, 3 Survey requirements as applicable.

5.3.2 Testing & Trials. The testing during the Flettner rotor installation/integration and under working conditions after installation/integration has to be carried out according to the requirements given in Ch 1, 1.6 Survey requirements for sail systems of Provisional Rules for Sail-Assisted Ships, January 2008 and LAME (2013), Ch 12, 3 Survey requirements as applicable.

5.3.3 Sea trials for control engineering aspects are to be carried out according to Ship Rules Pt 6, Ch 1 Control Engineering Systems, Pt 6, Ch 1, 7.1 General and Pt 6, Ch 1, 7.4 Record of trials, and for electrical engineering aspects, Ship Rules Pt 6, Ch 2 Electrical Engineering, Pt 6, Ch 2, 21 Testing and trials are to be implemented.