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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
B
C
D
E
F
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DOC-1017-1
1
SAFETY PRECAUTIONS..................................................................................................................... 4
1.1
G
ENERAL
.......................................................................................................................................... 4
1.2
W
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
2
SAFETY INSTRUCTIONS ................................................................................................................... 5
2.1
I
NSTALLATION
.................................................................................................................................. 5
2.2
C
ONNECTION
.................................................................................................................................... 5
2.3
M
EASUREMENTS
.............................................................................................................................. 5
2.4
E
ARTHING
........................................................................................................................................ 5
3
TERMINOLOGY ................................................................................................................................... 6
4
APPARATUS NECESSARY TO PERFORM THE TEST................................................................. 7
4.1.1
Referred documents ..................................................................................................................... 7
4.1.2
Needed tools................................................................................................................................. 7
5
SERVICE DISPLAY .............................................................................................................................. 9
5.1
A
LARMS
........................................................................................................................................... 9
5.1.1
Main alarms................................................................................................................................. 9
5.2
S
TATUS
............................................................................................................................................. 9
5.2.1
Control......................................................................................................................................... 9
5.2.2
Lubrication .................................................................................................................................. 9
5.2.3
Prime mover................................................................................................................................. 9
5.3
M
EASUREMENTS
.............................................................................................................................. 9
5.3.1
Meters in the status displays........................................................................................................ 9
6
ALARM SYSTEM ALARMS...............................................................................................................10
6.1
V
OLTAGE SUPPLY FAILURE
.............................................................................................................10
6.2
C
ONTROL SYSTEM FAILURE
............................................................................................................10
6.3
L
UBRICATION SYSTEM WARNING
....................................................................................................10
6.4
L
UBRICATION SYSTEM FAILURE
......................................................................................................10
6.5
70
%
LIMITATION
............................................................................................................................10
6.6
S
EALING SYSTEM FAILURE
..............................................................................................................10
7
ALARM AND AUXILIARY FUNCTION TESTS .............................................................................11
7.1
G
ENERAL
.........................................................................................................................................11
7.2
E
QUIPMENT STATUS
........................................................................................................................11
7.3
C
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
8
LUBRICATION SYSTEM ...................................................................................................................13
8.1
L
UBRICATION OIL PUMP MOTOR STARTER
......................................................................................13
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DOC-1017-1
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
L
UBRICATION OIL TEMPERATURE ALARM TEST
..............................................................................15
8.2.1
Test procedure ............................................................................................................................15
8.2.2
Ending the test ............................................................................................................................15
8.3
L
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
S
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
9
LOCAL CONTROL ..............................................................................................................................18
9.1
G
ENERAL
.........................................................................................................................................18
9.2
E
QUIPMENT STATUS
........................................................................................................................18
9.3
S
AFETY PRECAUTIONS
.....................................................................................................................18
9.4
L
OCAL STEERING
.............................................................................................................................18
9.4.1
Starting .......................................................................................................................................18
9.5
RPM
CONTROL
................................................................................................................................18
10
DP CONTROL.......................................................................................................................................19
10.1
G
ENERAL
.........................................................................................................................................19
10.2
E
QUIPMENT STATUS
........................................................................................................................19
10.3
S
AFETY PRECAUTIONS
.....................................................................................................................19
10.4
T
EST PROCEDURE
............................................................................................................................19
10.4.1
Starting Propulsor ..................................................................................................................19
10.4.2
Stopping Propulsor.................................................................................................................19
11
TEST PROGRAM AND REPORT......................................................................................................20
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DOC-1017-1
1 S
AFETY
P
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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DOC-1017-1
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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DOC-1017-1
3 T
ERMINOLOGY
AP02
Control voltage supply converter inside SMU
BR01
Encoder at steering motor
DP
Dynamic positioning system
F1
Main control voltage circuit breaker inside SCU
F2
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
PM
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
SP
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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DOC-1017-1
Test Tool P000157 for seal oil level test. Made out 3 mm steel wire.
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DOC-1017-1
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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DOC-1017-1
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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DOC-1017-1
7 A
LARM AND
A
UXILIARY
F
UNCTION
T
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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DOC-1017-1
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
F1
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
F2
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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DOC-1017-1
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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DOC-1017-1
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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DOC-1017-1
8.4 S
EAL OIL TANK ALARM TESTS
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.
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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DOC-1017-1
9 L
OCAL
C
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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DOC-1017-1
10 DP
CONTROL
10.1 G
ENERAL
This test procedure includes propulsor main control for steering.
10.2 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 switched to remote control
also electric supplies for pumps on. Indication lamp HI41 is lit on SMU door. The vessel
alarm and automation systems are running.
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
P
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
P
ROPULSOR
Stop propulsor from DP
Indication lamp HI42 is not lit on SMU door
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DOC-1017-1
11 T
EST PROGRAM AND REPORT
ID
DESCRIPTION
INSTR,
SAP
LOCAL
SED
DP
ALARM
REMARK
1
Main control voltage circuit breaker
7.3.2
2
Back-up control voltage supply
7.3.4
3
Automatic change to back-up supply
7.3.3
5 Lubrication
pump
8.1
6
Lubrication pump alarm
8.1.2
7
Lubrication oil pressure
8.1.4
8
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
15
DP selection and control
10
16
DP Propulsor start
10.4.1
17
DP Propulsor stop
10.4.2