C102019 B W0064 PERIODIC (1)

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DOC-1017-1

Steerprop Propulsor

SP20LFD (Center)

Periodic Safety Test

Program and Instructions

Revision history:

REV. DATE MODIFIER DESCRIPTION

0 28.3.2006

AANI CREATED

A 16.5.2006

AaNi Added

run

oil

test

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DOC-1017-1

SAFETY PRECAUTIONS..................................................................................................................... 4

1.1

ENERAL

.......................................................................................................................................... 4

1.2

ARNINGS

....................................................................................................................................... 4

1.2.1

Thrust at propulsor ...................................................................................................................... 4

1.2.2

Hydraulic pressure ...................................................................................................................... 4

1.2.3

Oil leakage................................................................................................................................... 4

1.2.4

Hot water ..................................................................................................................................... 4

1.2.5

Rotating or moving machinery .................................................................................................... 4

1.2.6

AC and auxiliary power circuits .................................................................................................. 4

1.2.7

Low voltage control circuits ........................................................................................................ 4

SAFETY INSTRUCTIONS ................................................................................................................... 5

2.1

NSTALLATION

.................................................................................................................................. 5

2.2

ONNECTION

.................................................................................................................................... 5

2.3

EASUREMENTS

.............................................................................................................................. 5

2.4

ARTHING

........................................................................................................................................ 5

TERMINOLOGY ................................................................................................................................... 6

APPARATUS NECESSARY TO PERFORM THE TEST................................................................. 7

4.1.1

Referred documents ..................................................................................................................... 7

4.1.2

Needed tools................................................................................................................................. 7

SERVICE DISPLAY .............................................................................................................................. 9

5.1

LARMS

........................................................................................................................................... 9

5.1.1

Main alarms................................................................................................................................. 9

5.2

TATUS

............................................................................................................................................. 9

5.2.1

Control......................................................................................................................................... 9

5.2.2

Lubrication .................................................................................................................................. 9

5.2.3

Prime mover................................................................................................................................. 9

5.3

EASUREMENTS

.............................................................................................................................. 9

5.3.1

Meters in the status displays........................................................................................................ 9

ALARM SYSTEM ALARMS...............................................................................................................10

6.1

OLTAGE SUPPLY FAILURE

.............................................................................................................10

6.2

ONTROL SYSTEM FAILURE

............................................................................................................10

6.3

UBRICATION SYSTEM WARNING

....................................................................................................10

6.4

UBRICATION SYSTEM FAILURE

......................................................................................................10

6.5

LIMITATION

............................................................................................................................10

6.6

EALING SYSTEM FAILURE

..............................................................................................................10

ALARM AND AUXILIARY FUNCTION TESTS .............................................................................11

7.1

ENERAL

.........................................................................................................................................11

7.2

QUIPMENT STATUS

........................................................................................................................11

7.3

ONTROL VOLTAGE ALARM TEST

...................................................................................................12

7.3.1

Starting .......................................................................................................................................12

7.3.2

Main control voltage alarm F1 circuit breaker ..........................................................................12

7.3.3

Automatic change-over to back-up supply..................................................................................12

7.3.4

Back-up control voltage alarm F2 circuit breaker .....................................................................12

7.3.5

Automatic change-over to back-up supply back to main supply.................................................12

LUBRICATION SYSTEM ...................................................................................................................13

8.1

UBRICATION OIL PUMP MOTOR STARTER

......................................................................................13

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8.1.1

Local start...................................................................................................................................13

8.1.2

Lubrication pump alarm .............................................................................................................13

8.1.3

Local stop....................................................................................................................................13

8.1.4

Lubrication oil pressure alarm ...................................................................................................13

8.1.5

Lubrication oil filter alarm .........................................................................................................13

8.1.6

Lubrication oil filter alarm test end............................................................................................14

8.2

UBRICATION OIL TEMPERATURE ALARM TEST

..............................................................................15

8.2.1

Test procedure ............................................................................................................................15

8.2.2

Ending the test ............................................................................................................................15

8.3

UBRICATION OIL LEVEL ALARM TEST

...........................................................................................16

8.3.1

Start oil level...............................................................................................................................16

8.3.2

Lubrication run oil level alarm test ............................................................................................16

8.3.3

Ending the test ............................................................................................................................16

8.4

EAL OIL TANK ALARM TESTS

.........................................................................................................17

8.4.1

Seal oil tank air pressure low alarm test ....................................................................................17

8.4.2

Seal oil level alarm test...............................................................................................................17

8.4.3

Ending the test ............................................................................................................................17

LOCAL CONTROL ..............................................................................................................................18

9.1

ENERAL

.........................................................................................................................................18

9.2

QUIPMENT STATUS

........................................................................................................................18

9.3

AFETY PRECAUTIONS

.....................................................................................................................18

9.4

OCAL STEERING

.............................................................................................................................18

9.4.1

Starting .......................................................................................................................................18

9.5

RPM

CONTROL

................................................................................................................................18

DP CONTROL.......................................................................................................................................19

10.1

ENERAL

.........................................................................................................................................19

10.2

QUIPMENT STATUS

........................................................................................................................19

10.3

AFETY PRECAUTIONS

.....................................................................................................................19

10.4

EST PROCEDURE

............................................................................................................................19

10.4.1

Starting Propulsor ..................................................................................................................19

10.4.2

Stopping Propulsor.................................................................................................................19

TEST PROGRAM AND REPORT......................................................................................................20

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DOC-1017-1

1 S

AFETY

RECAUTIONS

1.1 G

ENERAL

Only competent electrician may carry out the electric work

Only competent engineer may carry out the machinery work

Only competent vessel operator may carry the vessel operation work

1.2 W

ARNINGS

1.2.1 T

HRUST AT PROPULSOR

During this test can propulsor give thrust.

1.2.2 H

YDRAULIC PRESSURE

There can be pressure at propulsor lubrication system. Give the pressure come out
before you open plugs totally.

1.2.3 O

IL LEAKAGE

Do not open the protection tube, because then the oil can come out from propulsor.

1.2.4 H

OT WATER

Be careful with hot water.

1.2.5 R

OTATING OR MOVING MACHINERY

Coming into contact with this machinery is extremely dangerous and may cause
death or severe injury.

1.2.6 AC

AND AUXILIARY POWER CIRCUITS

The components of the AC and power circuits and terminals are live, when the
equipment is connected to supply potential. Coming into contact with this
voltage is extremely dangerous and may cause death or severe injury.

The motor control unit SMU has one motor supply.

The motor terminals and brake terminals are live when the frequency converter
is connected to mains, even if the motor is not running.

The frequency converter has a large capacitive leakage current.

1.2.7 L

OW VOLTAGE CONTROL CIRCUITS

The control I/O terminals are isolated from the AC control or power circuits.
However, the relay outputs and other I/O terminals may have a dangerous
control voltage present even the equipment is disconnected from the AC control
or power supply.

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2 S

AFETY INSTRUCTIONS

2.1 I

NSTALLATION

The equipment and machinery is meant for fixed installation.

2.2 C

ONNECTION

Do all connections only when there is no voltage supply on!

Do not do any temporary connections!

Before connecting the supply voltage on, be sure the units are clean and dry!

Take care that nobody is working or touching the electric connections, when
you connect the supply voltage, open the circuit breakers before you connect
the shipside supply!

2.3 M

EASUREMENTS

Do not perform any measurements when the equipment is connected to AC
control or power circuits supply potential.

After disconnecting the frequency converter from the mains, wait until the fan
stops and indicators on the keypad go out. Wait 5 more minutes before doing
any work on power or AC side connections. Do not even open the cover before
this time has expired.

Do not perform any voltage withstand tests on any part of the frequency
converter. This test should be made special procedure.

Prior to measurements on the motor or the motor cable, disconnect the motor
cable from frequency converter.

Do not touch the IC or other electronic circuits on circuit boards. Static voltage
discharge may damage the components.

Before connecting the AC control or power circuits supply potential, make sure,
that all covers and cabinet doors are closed.

2.4 E

ARTHING

All equipment bodies or frames should be always earthed with an earthing
conductor connected to the earthing terminal.

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3 T

ERMINOLOGY

AP02

Control voltage supply converter inside SMU

BR01

Encoder at steering motor

Dynamic positioning system

Main control voltage circuit breaker inside SCU

Indication control voltage circuit breaker inside SCU

FP1

Lubrication pump motor protection switch inside SMU

HI41

Remote control selected at SMU

HI43

Failure indication at SMU

HI48

Lubrication pump supply on

KM1

Supply voltage change-over switch

Propulsor motor system

SAP

Steerprop azimuth propulsor

SC01

Remote / Local control switch inside SCU

SC02

Local steering switch at LCR

SC11

Lubrication pump local stop at SMU

SED

Steerprop service display

SH52

Running indication at SMU

SH52

Lubrication pump local start at SMU

SMU

Steerprop motor control unit

Steerprop azimuth propulsor

SS01

Control voltage switch inside SCU

XP01

Connector at SAP

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DOC-1017-1

4 A

PPARATUS NECESSARY TO PERFORM THE TEST

4.1.1 R

EFERRED DOCUMENTS

Service Manual

4.1.2 N

EEDED TOOLS

Digital multimeter

Hand tools

Thermometer up to 100 degree C (212 F)

Water at 80 degree C (176 F) at 1 litre can

Lubrication oil test tool according drawing P000156-A

Seal oil test tool according drawing P000157-A

Adjustable pressure air connection with M20x1.5 adapter, up to 7 bar

32 mm hex wrench

10 mm hex wrench

2 pc 27 mm key

1 pc 22 mm key

1 pc 19 mm key

Test Tool P000156 for lubrication oil level test. Made out 3 mm steel wire.

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Test Tool P000157 for seal oil level test. Made out 3 mm steel wire.

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5 S

ERVICE DISPLAY

At the door of the SCU unit is service display, which is giving
service, alarm and fault finding information from service and
operation personnel.

The SED panel will inform different alarm and system status
during the test.

Service display is called later SED.

5.1 A

LARMS

5.1.1 M

AIN ALARMS

Start oil level low

Run oil level low

Lubrication pressure low

Lubrication temperature high

Lubrication oil filter

Lubrication oil pump

Seal oil level

Seal oil pressure

5.2 S

TATUS

5.2.1 C

ONTROL

DP status, fail

Feedback status, fail

SAP running

SAP control system

70 % limitation

5.2.2 L

UBRICATION

SMU status, stopped, fail

Remote control selection

5.2.3 P

RIME MOVER

Starting allowed/not

Start oil level low

Remote control selection

5.3 M

EASUREMENTS

5.3.1 M

ETERS IN THE STATUS DISPLAYS

Lubrication pressure

Lubrication temperature

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6 A

LARM SYSTEM ALARMS

6.1 V

OLTAGE SUPPLY FAILURE

Main control voltage circuit breaker

Back-up control voltage circuit breaker

Automatic change-over to back-up supply

6.2 C

ONTROL SYSTEM FAILURE

PLC failure

6.3 L

UBRICATION SYSTEM WARNING

Filter clogged

Lubrication cooling and circulation pump alarm

Lubrication pressure alarm

6.4 L

UBRICATION SYSTEM FAILURE

Lubrication start oil level

Lubrication temperature

6.5 70

LIMITATION

Lubrication oil temperature

6.6 S

EALING SYSTEM FAILURE

Seal oil pressure

Seal oil level

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7 A

LARM AND

UXILIARY

UNCTION

ESTS

7.1 G

ENERAL

This test procedure includes alarm and auxiliary function tests for propulsor

7.2 E

QUIPMENT STATUS

This test will be started with a propulsor, which is in running condition.

Supply switch SS01 on, control voltage is ON

Main control voltage circuit breaker F1 ON

Back-up control voltage circuit breaker F2 ON

Supplies on vessel switchboards are ON.

Connect steering gear and pump supplies ON.

Local control SC01 switch is at remote position.

Control is at wheelhouse

Propeller motor is ready

Pump is ready

Vessel alarm and automation systems are running

DP system is running and ready for operation

PM control is running and ready for operation

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7.3 C

ONTROL VOLTAGE ALARM TEST

This test procedure includes all control voltages supplies for propulsor

Main control voltage 24 VDC, circuit breaker F1

Back-up control voltage 24 VDC, circuit breaker F2

7.3.1 S

TARTING

Supply switch SS01 OFF

7.3.2 M

AIN CONTROL VOLTAGE ALARM

CIRCUIT BREAKER

Switch OFF the circuit breaker F1 from SCU.

Control voltage alarm will appear.

Control system alarm will appear.

Lubrication warning will appear.

Lubrication failure will appear.

Switch circuit breaker F1 ON.

Main control starts and remote control is operational.

Alarms will disappear.

7.3.3 A

UTOMATIC CHANGE

OVER TO BACK

UP SUPPLY

Switch OFF the main 24 VDC from vessel switchboard.

The control voltage supply goes automatically to back-up supply.

The relay KM1 change the supply to back-up

You can verify the voltage level between terminals 222 and 223. It should
be over 22 VDC.

Remote control is still operational.

Control voltage alarm will appear.

7.3.4 B

ACK

UP CONTROL VOLTAGE ALARM

CIRCUIT BREAKER

Switch OFF the circuit breaker F1 from SMU.

Verify the voltage level between terminals 200 and 201. It should be over
22 VDC.

You can verify the voltage level between terminals 200 and 201. It should
be over 22 VDC.

Switch OFF the circuit breaker F2 from SMU.

Control voltage alarm will appear.

Switch circuit breaker F2 ON.

Alarm will disappear.

Switch circuit breaker F1 ON.

7.3.5 A

UTOMATIC CHANGE

OVER TO BACK

UP SUPPLY BACK TO MAIN SUPPLY

Switch ON the main 24 VDC from vessel switchboard.

The relay KM1 changes the supply to main supply.

You can verify the voltage level between terminals 222 and 223. It should
be over 22 VDC.

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8 L

UBRICATION SYSTEM

8.1 L

UBRICATION OIL PUMP MOTOR STARTER

The lubrication pump motor is controlled by DOL starter at SMU unit. There are local
control push buttons at door of the SMU unit.

This test will be started with a propulsor, which voltage supplies are on, then the
voltage supply switch SS01 is on.

The vessel alarm and automation systems are running.

8.1.1 L

OCAL START

Start lubrication pump with SC11

Indication at SED will give indication

Pump is running

8.1.2 L

UBRICATION PUMP ALARM

Turn the switch at FP1 to 0

The lubrication pump will stop

Pump failure alarm will appear

Turn the switch at FP1 to 1

Pump failure alarm will disappear

Pump should start automatically

8.1.3 L

OCAL STOP

Stop the pump with SC11

Indication at SED does not indicate

Pump is not running

8.1.4 L

UBRICATION OIL PRESSURE ALARM

Lubrication oil pressure alarm will appear

Start the pump with push button SC11

Lubrication oil pressure alarm will disappear

You can follow the pressure at SED

8.1.5 L

UBRICATION OIL FILTER ALARM

Open the plug at filter head

Start the pump with push button SC10

Lubrication oil filter alarm will appear

Open the plug at filter head

Lubrication oil filter alarm will disappear

You can follow the pressure at SED

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DOC-1017-1

8.1.6 L

UBRICATION OIL FILTER ALARM TEST END

Stop the lubrication pump with SC11

Disconnect the electric connector from filter contamination indicator

Release the seger-ring from contamination indicator

Remove the contamination indicator from the filter head with 30 mm key

Connect the contamination indicator to the air pressure supply G1/2
adapter

Connect the electric connector to contamination filter indicator

Adjust the pressure up to 6 bars

Lubrication oil filter alarm will appear at ca 5 bar

You can follow the alarm at SED

Depressurize the air supply

Lubrication oil filter alarm will disappear at ca 5 bar

Disconnect the electric connector from filter contamination indicator

Disconnect the contamination indicator from the air pressure supply G1/2
adapter

Install the contamination indicator to the filter head with 30 mm key

Put the seger-ring to contamination indicator

Connect the electric connector to contamination filter indicator

Start the pump with push button SC10

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DOC-1017-1

8.2 L

UBRICATION OIL TEMPERATURE ALARM TEST

This test will be started with a propulsor, which voltage supplies are on, then the
voltage supply switch SS01 is on and local control SC01 is switched to remote control
also electric supplies for pumps and steering gears are on.

The vessel alarm and automation systems are running.

8.2.1 T

EST PROCEDURE

Open the transmitter element fastening nut
from protection tube with pairs of 27 mm key.

Draw the temperature element out from tube.

Put the element into can of hot water (>75
deg C) (do not put the cable into can,
because it can disturb). Or use separate
heater to heat the sensor over 75 deg C.

Oil temperature alarm will appear.

Let the water (heater) cool down slowly and
follow the meter.

At 70…75 deg C the alarm will disappear.

You can follow the temperature at SED

8.2.2 E

NDING THE TEST

Dry the sensor and put it back to protection tube and tight the nut.

Stroke the element lightly with grease

Put the element back to protection tube

Tighten the nuts smoothly with pairs of 27 mm key

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8.3 L

UBRICATION OIL LEVEL ALARM TEST

The user is responsible for periodically carrying out a functional test or a visual check.
The function of the contacts can be tested with the unit in situ or removed, by moving
the float manually or by filling the container. Care must be taken to ensure that the
functional test does not trigger any process operations.

A visual check is made of components in the unit that are exposed to the liquid stored
in the tank, its vapors or condensate to ascertain whether any signs of corrosion exist.
This inspection can only be carried out from inside the storage tank or after the unit has
been removed.

This test will be started with a propulsor, which voltage
supplies are on, then the voltage supply switch SS01 is on
and local control SC01 is switched to remote control also
electric supplies for pumps are on.

The vessel alarm and automation systems are running.

This test procedure includes lubrication oil level alarm tests
for propulsor. The lubrication oil level switch is located on
the rear end of the propulsor. The oil control unit has plug
for testing the level switches.

Upper for start oil level

Lower for run oil level

Level switch principle

8.3.1 S

TART OIL LEVEL

Open the test plug with 10 mm hex wrench

Thread the test tool carefully through the hole

Push the upper float carefully down (do not
break the float and its fastening by pushing it
hard).

Start oil level alarm will appear

Release the float up

Start oil level alarm will disappear

8.3.2 L

UBRICATION RUN OIL LEVEL ALARM TEST

Turn the tool so that you can go to beside of the upper float

Push the lower float carefully down (do not break the float and its fastening
by pushing it hard)

Run oil level alarm will appear

Release the float up

Run oil level alarm will disappear

8.3.3 E

NDING THE TEST

Pull the test tool carefully out

Close the test plug with 10 mm hex wrench

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8.4 S

EAL OIL TANK ALARM TESTS

The vessel alarm and automation systems are running.

This test procedure includes oil level alarm and seal oil pressure alarm tests for seal oil
tank.

8.4.1 S

EAL OIL TANK AIR PRESSURE LOW ALARM TEST

Close the air valve.

Release the pressure by pulling the ring at relief
valve.

Seal oil pressure alarm will appear, the alarm is
adjusted to 0.1 bar.

Open the air valve.

Alarm will disappear.

8.4.2 S

EAL OIL LEVEL ALARM TEST

Open the dip stick with 32 mm hex wrench.

Thread the test tool carefully through the hole.

Pull the upper float carefully up (do not break the
float and its fastening by pulling it hard).

Seal oil level alarm will appear.

Release the float

Seal oil level alarm will disappear.

Push the lower float carefully down (do not break
the float and its fastening by pushing it hard).

Seal oil level alarm will appear.

Release the float.

Seal oil level alarm will disappear.

8.4.3 E

NDING THE TEST

Continue from the previous section

Pull the test tool carefully out

Close the test plug with 32 mm hex wrench

Open the air valve

Seal oil pressure alarm will disappear

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9 L

OCAL

ONTROL

9.1 G

ENERAL

This test procedure includes propulsor local control.

9.2 E

QUIPMENT STATUS

This test will be started with a propulsor, which voltage supplies are on, then the
voltage supply switch SS01 is on and local control SC01 is selected also electric
supplies for pumps are on.

9.3 S

AFETY PRECAUTIONS

During this test will the propeller have power and the vessel has thrust and it will move.

9.4 L

OCAL STEERING

9.4.1 S

TARTING

Start lubrication pump locally.

9.5 RPM

CONTROL

The RPM control is carried out with engine local control

The engine RPM and propulsor input rpm is indicated from engine.

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10 DP

CONTROL

10.1 G

ENERAL

This test procedure includes propulsor main control for steering.

10.2 E

QUIPMENT STATUS

10.3 S

AFETY PRECAUTIONS

During this test will the propeller have power and the vessel has thrust and it will move.

10.4 T

EST PROCEDURE

10.4.1 S

TARTING

ROPULSOR

Start propulsor from DP

Steerprop control system starts

Lubrication pump starts

Indication lamp HI42 is lit on SMU door

Propulsor is ready for DP and under DP control

10.4.2 S

TOPPING

ROPULSOR

Stop propulsor from DP

Indication lamp HI42 is not lit on SMU door

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11 T

EST PROGRAM AND REPORT

DESCRIPTION

INSTR,

SAP

LOCAL

SED

ALARM

REMARK

Main control voltage circuit breaker

7.3.2

Back-up control voltage supply

7.3.4

Automatic change to back-up supply

7.3.3

5 Lubrication

pump

8.1

Lubrication pump alarm

8.1.2

Lubrication oil pressure

8.1.4

Lubrication oil filter alarm

8.1.5

9 Lubrication

oil

temperature

8.2

10 Lubrication

oil

level

Error!

Referen

ce
source

not

found.

11 Seal

oil

pressure

8.4.1

12 Seal

oil

level

8.4.2

13 Local

starting

9.4

14 Local

RPM

control

9.5

DP selection and control

DP Propulsor start

10.4.1

DP Propulsor stop

10.4.2

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