So0650c1 Mc90 III Sat Docum

KMSS Doc.no.
: SO-0650-C1 / 30-Jan-03
System Acceptance Test Engine Room Simulator

ERS MAN B&W 5L90MC-VLCC Ver. MC90-III
Department/Author: ___________________ <Tor H.Kristoffersen> Approved by: ____________________ <Alv Smith Johansen>
2003 KONGSBERG MARITIME SHIP SYSTEMS AS All rights reserved No part of this work covered by the copyright hereon may be reproduced or otherwise copied without prior permission from KONGSBERG MARITIME SHIP SYSTEMS AS
System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III
KMSS Doc.no.: SO-0650-C1 / 30-Jan-03
DOCUMENT STATUS Issue No. SO-0650-A SO-0650-B SO-0650-C SO-0650-C1 Date/Year 13-May-97 14-Oct-97 19-Jan-98 30-Jan-03 Inc. by ASJ/beba THK/beba THK/beba BEBA Issue No. Date/Year Inc. by
CHANGES IN DOCUMENT Issue No. A B C C1 ECO No. MP-1131 MP-1154 Paragraph No. 6 6/7 All Paragraph Heading/ Description of Change First Issue Added Inert Gas & ALCAP Separator + PTI/PTO tests. 6.4 moved to 7.2.16. Changed logo and layout
TABLE OF CONTENT
Section 1. 2. 2.1 2.2 2.3 3. 3.1 4. 4.1 4.2 5. 5.1 5.2 5.3 5.4 6. 6.1 6.2 6.3 6.4 7. 7.1 7.2 7.3 8. 8.1 8.2 8.3 Page INTRODUCTION................................................................ 1 OPERATIONAL T ESTING ..................................................... 2 Operational Tests.......................................................... 2 Operational Testing Procedure......................................... 2 Data To Be Recorded and Retained .................................. 2 PHYSICAL INVENTORY (APPENDIX A).................................... 3 Physical Inventory Check-Off Lists ................................... 3 SYSTEM ACCEPTANCE T ESTS (APPENDIX B) ............................ 4 Factory Acceptance Test ................................................. 4 Site Acceptance Test ..................................................... 4 OPERATIONAL TEST #1 ............................................... 5 Title: Scenario #1-Dead Ship Start ................................... 5 Data Sheet #1 .............................................................. 6 Data Sheet #2 .............................................................14 Data Sheet #3 .............................................................31 OPERATIONAL TEST #2 ............................................. 33 Title: Scenario #2-Dock To Full Power At Sea ...................33 Data Sheet #1 .............................................................34 Data Sheet #2 .............................................................36 Data Sheet #3 Test of PTI/PTO ......................................44 OPERATIONAL TEST #4 ............................................. 46 Title: Scenario #3-Full Sea Speed To Anchoring ................46 Data sheet #1 .............................................................47 Data sheet #2 Test of Inert Gas Plant.............................54 INSERTING FAULTS ......................................................... 56 Title: Scenario # 4-Inserting Faults.................................56 Inserting Faults ...........................................................57 Data Sheet #1 .............................................................62
INVENTORY LIST ...............................................................Appendix A SYSTEM ACCEPTANCE TEST ..................................................Appendix B
ii
INTRODUCTION
This document is a draft Factory and Site Acceptance Test Document submitted for Customer. The tests outlined are intended to accomplish the following objectives: * Verify, by physical inventory, the presence of all deliverable hardware, software and documentation as set forth in the Contract, and the Design Review meeting. On the unit level demonstrate the units capability to perform its specified functions. On the system level demonstrate the capability of the system to perform its specified functions. Record and document the conduct of the acceptance tests and the status of deliverables with respect to their conformance with the requirements of the specification.
* *
OPERATIONAL TESTING
Operational testing will demonstrate and verify that items listed in the Physical Inventory will have been tested to assure that all functional requirements contained in the contract documents have been met.
2.1
Operational Tests
These tests will consist of scenarios designed to demonstrate the contractually required functional capabilities of items listed in the previously generated Physical Inventory. Tests are designed to demonstrate capabilities on the unit level and the system level as well. The individual tests will be presented in a format similar to the test of the Physical Inventory. Each functional capability is identified, and a step by step procedure to be followed is presented along with an observation to be noted by the two observers.
2.2
Operational Testing Procedure
The outlined step by step procedure must be followed precisely. Acceptable performance is attested to by the KMSS and Customer observers signing in the space provided. Any deviations from expected performance, are to be noted in the column provided. Deviations will be discussed at the conclusion of the test. Final acceptance is accomplished after both the Physical Inventory and the Operational Testing has been satisfactorily completed.
2.3
Data To Be Recorded and Retained
The following shall be recorded and retained from each operational test; * * Alarm log and event log. Snapshot at end of scenario (stored in Initial Condition)
PHYSICAL INVENTORY (APPENDIX A)
The physical Inventory of the FAT verifies that the items specified in the several Extents of Delivery (Scope of Supply) documents included in the contract are in fact present. The description and number of individual items of hardware, software and documentation will be listed under the major system components' deliverable under the contract.
3.1
Physical Inventory Check-Off Lists
The same format will be used throughout the FAT. Each item in the delivery will be listed under its respective major component. The first column will identify the Item by its No. The adjacent column will provide the item name and a brief description or specification of that item. A third column will list the quantity of those items while a fourth will provide a space for the Kongsberg Maritime Ship Systems a.s. and the Customer's observer to place their initials indicating the presence of the item. Physical dimensions of items may be checked if specified in the contract. Space for notes is available in the fifth and last column in the event that deficiencies are noted. These notes will be used to develop a deficiency or hit list upon completion of the FAT.
4
4.1
SYSTEM ACCEPTANCE TESTS (APPENDIX B)

Factory Acceptance Test
In order to fulfill the objectives set forth in the Introduction the Factory Acceptance Test (FAT) will consist of separate and distinct parts as below: * * A physical inventory of all deliverable hardware, software and documentation. Operational tests on the unit level of hardware and software as a part of total system operational tests of hardware and software.
The physical inventory will verify that all hardware, software and documentation material have been delivered as required by the contract, including the System Design Specification. The operational testing on unit and system level will verify that hardware and software perform functionally as required by the contract, including the System Design Specification. The FAT will be conducted at Kongsberg Maritime Ship Systems a.s., Horten, Norway. The FAT will be conducted under the direction and control of the Kongsberg Maritime Ship Systems a.s. appointed Test Director. Other participants in the FAT may include authorized representatives of Kongsberg Maritime Ship Systems a.s. and the Customer. Designated representatives of the Customer and the Supplier will be authorized to sign off on satisfactory completion of the individual tests as well as the physical inventory line items.
4.2
Site Acceptance Test
The objective of the Site Acceptance Test (SAT) is to assure that the total system hardware, software and documentation have been delivered and installed at the Customer facilities and continue to function as proven in the FAT. The SAT will involve a procedure similar to the FAT. * * A Physical Inventory will be taken and attested to by Customer and KMSS observer. Operational testing will once again demonstrate the capability of the system to perform functional requirements, according to Contract.
5
5.1
OPERATIONAL TEST #1
Title: Scenario #1-Dead Ship Start
The ship has been at the dock or anchorage for a week and no equipment is running nor is shore power available. Prior to shutting down, the engineers had purified adequate HFO to fill HFO service tank. They had also filled the DO service tank. The Fresh Water Expansion Tank(s) was left filled 50%. Lube oil sumps were left 50% full with freshly purified oil. Both starting air tanks were pressed up to 30 bar (485 psig). Service Air Receiver was pressed up to 7 bar (102 psig). The ship is in a tropical Gulf port. Air temp. is 30 deg.C (86 deg.F), and sea water is 30 deg.C (86 deg.F). Vessel is in ballast. All other parameters are set at normal condition. The control will be in the ME Local Control Mode. The Test Director (TD) will follow the steps necessary to bring the engine room to the point where the engine is ready to respond to the remote control. At this point the TD will create INIT CONDITION #2 READY FOR DEPARTURE. Initial Condition #2 will be used to set the initial conditions for future scenarios. No faults will be inserted in this scenario.
5.2
Step No. 5.2.1
Data Sheet #1
Test Director Action At the start of Init. Condition #1, Dead Ship Start, all ambients, hull condition, ship load etc., are set at default values. No power is available. Power up the simulator by supplying 24V to all Control Consoles, operating panels, Main Switchboard sections and ME Local Operating Console. Load Initial Condition #1 DEAD SHIP START: Press all lamp test pushbuttons and take printout of selected model drawings. Verify that all lamps representing valves, pumps and controllers are lit. Random selection of pumps and valves are illuminated. Observation Observer Notes KMSS Customer
5.2.2
5.2.3
Step No.
Test Director Action Select various sub-system displays for verifying the Dead Ship Condition.
Observation -No steam pressure. -No machinery running. -No el power. -All generators disconnected and stopped. All Controllers are in Local Control.
Observer Notes KMSS Customer Ref. sub-systems MD19; MD20; MD56; MD70; MD71; MD72, or Boiler Console, Main Switchboard and Control Room Console
5.2.4
Check Control Room Console and Engine Room equipment to be certain that all controls are in the correct position for the initial conditions of OP Test #1. Start simulation by pressing Running
RUNNING at TEC2000 is lit, i.e., Simulation is on. Ref.. sub-system Electric Power Plant' (MD 70) Note: Emergency Gen. is battery started
5.2.5
Start Emergency Generator in MANUAL from the Main Switchboard in local Connect Emergency Generator from the same location.
Voltage, on emergency bus bar (440V)
Step No. 5.2.6
Test Director Action Line up Compressed Air System, by: Draining all Air Coolers and Receivers. Close when Water Content is zero Open valves for LTFW Cooling to Air Coolers Open inlet valves to Air Receivers. Open outlet valves from Air Receivers.
Observation
Water Content decreases to zero
Observer Notes KMSS Customer Ref. sub-system 'Compressed Air System' (MD 60) V04440, V0442 and V04444
(The corresponding valves is lit.) (The corresponding valves is lit.)
V04460, V04461 V04462, V04463
Open Service Air Receiver Inlet and Outlet Valve, and Control Air Drier/press Reduction Valve 5.2.7 Open for LTFW cooling of Compressor Air Coolers: Line up the LTFW system by opening valves allowing flow through the Air Compressor Cooler.
V04464, V04465 and V04466
Ref. sub-system: 'Main SW System' (MD 01) Ref. sub-system (MD10) V1135, V1123.
Step No.
Test Director Action
Observation
Observer Notes KMSS Customer Ref. sub-system (MD10)
Check ME FW Expansion Tank level Start Aux. LTFW pump
Min 1.0 meter Aux LTFW pump starts LTFW Discharge Pressure. LTFW starts flowing
Ref. sub-system (MD10) P1001, G1075
5.2.8
Set LTFW controller in AUTO, and setpoint to 34 deg C. Line up SW system: Open Sea Chest 1 inlet valve, and FW Cooler 1 SW Shut Off Valve. Open SW overboard Shut Off Valve and SW Recirc Line Shut Off Valve Start Aux SW Pump
Controller changes to new output value
V700 and V0670
SW Discharge Pressure. SW starts flowing
Ref. sub-system (MD1) G063, P0632
Step No.
Test Director Action Set SW Controller in Auto, and Setpoint to 20 deg C.
Observation Controller changes to new output value. Observe the flow in overboard and recirc lines DG1 Oil Sump 50% full LO pump starts and runs till normal LO press is obtained and then stops. Start Air Press to DG1
Observer Notes KMSS Customer Ref. sub-system (MD 01)
5.2.9
Prepare DG1 for start-up: - Line up DG1 LO system - Set DG1 El. LO Pump in Auto
Ref. sub-system 'Diesel Generator 1' (MD 71) and or Hardware delivered.
- Line up DG1 Start Air Line - Line up DG1 DO System - Check DO Service Tank Level (MD 03) - Check FW Exp. Tank Level - Line up DG1 SW System
4,0 meter 50% full
10
Step No.
Test Director Action - Reset DG1 trips if any - Set DG1 in Local Control Mode Press start button DG1.
Observation
Observer Notes KMSS Customer
DG1 accelerating to approx 1200 RPM Ref. sub-system: 'Electrical Power Plant' (MD 70) and Main Switchboard.
5.2.10
Raise speed to frequency 60Hz
Adjust voltage to 440V Connect DG1 to Main Bus Bar Emergency Generator Circuit Breaker is automatically disconnected. Observe that the AUTO and Ready and Prior 1 are lit at PowerChief. Em'gy Gen. stops after a while
Set DG1 in Remote Control mode. When all alarms are removed, the Ready Lamp will light. Select AUTO- mode at Power, and select Priority 1 Set Emergency Generator in AUTO
11
Step No. 5.2.11
Test Director Action Start Air Compressors:
Observation
Observer Notes KMSS Customer Ref. sub-system 'Compressed Air System' (MD 60) and on Hardware if delivered.
Set Start Air Compressor #2 in Auto at PowerChief.
Compressor No.2 Auto lamp at Control Console on Service Air Compressor, Auto lamp at Control Console on DG2 Oil Sump 50% full
Set Service Air Compressor in AUTO
5.2.12
Prepare DG2 for stand-by: - Line up DG2 LO System - Set DG2 El. LO Pump in Auto
LO Pump starts and runs till normal LO press is obtained and then stops.
12
Step No.
Test Director Action - Line up DG2 Start Air Line
Observation Start Air Press to DG2
- Line up DG2 DO System - Check DO Service Tank Level (MD 03) - Check FW Exp. Tank Level - Line up DG2 SW System - Reset DG2 trips if any - Set DG2 in Remote Control mode - Set DG2 in AUTO READY lamp turns on Ref. subsystem Pump & Compr. Panel (MD101) 4,0 meter 50% full Ref. subsystem Diesel Generator no.2 (MD72)
13
5.3
Step No. 5.3.1
Data Sheet #2
Test Director Action Light off oil fired boiler on DO. Check level in DO Service Tank Open supply valves from HFO and DO service tanks to boiler. Observation Observer Notes KMSS Customer Ref Subsystem Fuel oil service tanks (MD03) Ref Subsystem Fuel oil service tanks (MD03) V327, and V367 DO Pump starts, DO/HFO Select Valve in DO The valve turns green, indicating open valve Ref Subsystem Oil fired Boiler (MD 83) and Boiler Console R 05634, V05654
4 meter
Start DO pump and select DO.
5.3.2
Open Primary Steam Drum Vent Valve.
Open Superheater vent and drain valves Check water level in Primary Drum Refill if necessary 0 mm Ref Sub-system Oil fired Boiler (MD 83) and Boiler Console
14
Step No. 5.3.3
Test Director Action Install burner with small tip (DO) Start Combustion Air Fan. RESET any tripping functions on boiler if present. Set all controllers in MANUAL; Master Controller, FO flow controller, Air Flow Controller and Excess Air Controller. Burner Management is also out of AUTO Open FO Flow controller to approx. 30%, Open Air Flow controller to maximum, otherwise purging will not be completed
Observation
Ref Sub-system Boiler Combustion (MD 84) and Boiler Console
5.3.4
Press purge START
The Purging process is in progress
When purging is completed, adjust Air Flow Controller to 15%
15
Step No.
Test Director Action Start burner 1 by pressing burner no 1 ON Adjust air and oil to obtain burning with as little smoke as possible, and as little oxygen content as possible. by adding more FO If the burner by any reason fails to ignite, purge again and repeat procedure. Put Air Flow Controller, Fuel Oil Controller and Oxygen controller on AUTO, and increase the rate of burning by manually increasing the output from the Master Controller Adjust the Master output to 15%
Observation Fire is present in Burner no. 1 Increase in Man output form FO controller
All Controllers except Master Controller in AUTO.
Automatic control of oxygen controller Observe increase in temp in oil fired boiler
Close vent valves when drum pressure has reached 1 bar (14 psig). Increase the firing rate by manual increase of the master controller.
16
Step No. 5.3.5
Test Director Action Line up the Steam Generator system
Observation
Observer Notes KMSS Customer Ref Sub-system Steam Generator (MD 82) and Boiler Console
Check water level in Steam Generator. Adjust if necessary Set level controller to Man, and output to 0% Open Steam Generator Vent Valve Check Feed water Tank level Start Main Feed Water Pump
0.0 meter
Output changes accordingly Pressure is 1 bar (14,2 psig) 2 meter The Feed Water Pump starts Vent flow shuts
V5103
Close Steam Generator Vent Valve, when press is above1 bar (14.2 psig) Set Steam Generator level Controller in AUTO, set point 0.0 meter
AUTO is lit
17
Step No.
Test Director Action Open main steam supply valve providing steam for HFO to oil fired Boiler. Put steam on HFO settling and service tanks.
Observation Observe rise in Boiler HFO Heater Outlet Temp Observe temps. rise.
Observer Notes KMSS Customer Ref Sub-system Steam Generator (MD 82) and Boiler Console
5.3.6
Open for supply of steam to primary water heating. As the pressure increases above 8 bar (113,6 psig) stop the burner, Open for Atomizing Steam Shut Off Valve Change over to HFO; Boiler DO Select Valve to HFO Start Boiler HFO pump Change Burner type to HFO Set all controllers in MANUAL, Master Controller, FO flow controller, Air Flow Controller and Excess Air Controller. Burner Management is also out of AUTO Boiler DO Select Valve turns off Ref Sub-system Boiler Combustion (MD 84) and Boiler Console V5640 V5654
Ref Sub-system Boiler Combustion (MD 84) and Boiler Console
18
Step No.
Test Director Action Open FO Flow controller to approx. 10%, Open Air Flow controller to maximum, otherwise purging will not be completed
Observation
5.3.7
Press purge START When purging is completed, adjust Air Flow Controller to 10% Start burner 1 by pressing burner no 1 ON Put Air Flow Controller, Fuel Oil Controller and Oxygen controller on AUTO, Perform the same for Oxygen and Master Controllers Set Master Controller to 14 bar(199 psig)
The Purging process is in progress
Fire is present in Burner no. 1 All Controllers in AUTO.
Observe change in oil output from the controllers Observe that Burner Management is ready for automatic control of both burners. Ref Sub-system Boiler Combustion (MD 84) and Boiler Console
19
Step No. 5.3.8
Test Director Action Put Burner Management Control in AUTO
Observation AUTO is lit. If pressure is above the Master Controller setpoint, the burner(s) will automatically stop. Approx. 0.0 meter in Steam Generator drum
Observer Notes KMSS Customer Ref Sub-system Boiler Combustion (MD 84) and Boiler Console
Observe proper Control of Steam Generator level Controller
5.3.9
Line up LO Purifier: LO Purifier Supply and return valves to be opened Apply for Steam to LO purifier Heater LO temp Controller on AUTO, setpoint 88 deg C. Start LO feed Pump, adjust speed to 20% Steam flow present. increase in LO temp inlet purifier Ref Sub-system Lub Oil Purifier
(MD08)
20
Step No.
Test Director Action Start LO Purifier Check Operating Water Tank. Adjust Gravity Ring to 25% Put LO Purifier on AUTO
Observation
Min. 0.5 meter
Observe Automatic shooting sequence. If the control logic fails to establish normal automatic condition, it will try once more.
Ref Sub-system Lub Oil Purifier

(MD09)
5.3.10
Preparation for start of ME. Line up ME Fresh Water System by Open ME Preheater Inlet Valve Valve V1140 turns green Valve V1141 turns dark Ref Sub-system ME Fresh Water System MD10).
Close Preheater bypass Valve
21
Step No.
Test Director Action Open ME Preheater steam Valve FW Gen Bypass valve to be 100% Start HTFW Pump no. 1
Observation
The pump starts, disch press and cooling flow is present.
Ref Sub-system ME Fresh Water System (MD10).
Set Temp Controller in AUTO, Setpoint 80 deg C. Set HTFW Pump no.2 in AUTO Ref Sub-system PowerChiefPump/ Compr (MD102), or Main Control Console HTFW pump disch. press reaches normal . value.
When HTFW temp inlet ME is above 60 deg C, shut steam supply to ME preheater, and open bypass Valve.
22
Step No. 5.3.11
Test Director Action Change over to Main LTFW no 1 Set LTFW Pump no.2 in AUTO
Observation FW flow and disch. press increase
Observer KMSS
Notes
Customer
Ref Sub-system PowerChiefPump/ Compr (MD102), or Main Control Console Increase in SW flow and disch. press. Ref Sub-system PowerChiefPump/ Compr (MD102), or Main Control Console
5.3.12
Change over to Main SW Pump no.1
Set SW pump no 2 in AUTO
5.3.13
Line up ME Lub Oil System: Check ME Lub Oil Service tank Open LO Cooler no. 1 Open LO Filter no. 1 Open Main Bearing Supply Valve Check FW flow available. V1367 turns open (lamp green) Minimum 1 meter Ref Sub-system ME Lub Oil System (MD12).
23
Step No.
Test Director Action Start Main LO pump no 1.
Observation Disc. press and LO flow is present
Observer KMSS
Notes
Customer
Ref Sub-system PowerChiefPump/ Compr (MD102), or Main Control Console Ref Sub-system ME Lub Oil System (MD12).
Set Lub Oil Controller on Auto, set point 45 deg C
Change in Output in order to reach normal condition
Put LO Pump no.2 on AUTO 5.3.14 Check Cam Shaft LO System. Refill if necessary Line up Cam Shaft LO system Start Cam Shaft LO Pump No.1 Put Cam Shaft LO Pump no.2 on AUTO Disc. press and LO flow is present Ref Sub-system PowerChiefPump/ Compr. (MD102), or Main Control Console Ref Sub-system ME Lub Oil System (MD12). Min 0.7 meter
Adjust Cam Shaft LO temp controller to set point 45 deg C
Change in Output in order to reach normal condition
24
Step No.
Test Director Action Check level in Cyl LO Tank. Refill if required Open for LTFW through Cam Shaft and Main LO coolers
Observation Min 0.7 meter
Ref Sub-system ME Fresh Water System (MD10). When vessel is deep laden the high tank is used. When lube oil flows through the stern tube bearing to the sump tank, it is automatically pumped back to the gravity tank in use. Ref Stern Tube system (MD54)
5.3.15
Line up Stern Tube system:
Select the appropriate LO Gravity Tank. In Ballast, line up inlet and outlet valves for low Gravity Tanks Check LO Sump Tank Level min 50% L3450
25
Step No.
Test Director Action Set LO Pump 1 on AUTO
Observation Pump starts, Lo Flow and Disch. press present Flow through LO Cooler.
Observer Notes KMSS Customer G3477, P3463 on MD 54
Apply cooling flow through Stern Tube LO Cooler. Open Stern Tube Lub Oil Cooler Inlet Valve 5.3.16 Line up FO Supply System. Open DO Supply valve to ME
V3571, G3570
Ref Sub-system Fuel Oil Service Tank (MD03). V0366
Open HFO Supply valve to ME V0326 Open DO/HFO mixing Valve to 100% DO/HFO mixing valve position 100% Pump starts, FO supply Pump disch. press and flow present Ref Sub-system ME Fuel Oil System (MD 02).
Start FO Supply Pump no.1
26
Step No.
Test Director Action Set FO Supply pump no 2 in AUTO
Observation
Open for Fuel Oil to FO Heater no. 1 Open for FO through FO filter no. 1 Ensure that FO Emergency Shut off valve is open. Select ME FO Return Select Valve to Vent Tank. 5.3.17 Start FO Booster Pump 1 Increased disch. press and presence of FO flow at MD 02.
Observer Notes KMSS Customer Ref Sub-system PowerChief Pump/Compr Control (MD102), or Main Control Console V105 V114
P0020, and G0026
Put FO Booster Pump no 2 on AUTO
Ref Sub-system PowerChief Pump/Compr Control (MD102), or Main Control Console
Apply steam for heating of FO Adjust FO Viscosity Controller to 13 CentiStoke
27
Step No.
Test Director Action Set Viscosity Controller in AUTO
Observation Change in FO Viscosity controller position. Pump Starts, Alarm message disappears
Observer Notes KMSS Customer Ref Sub system ME Fuel Oil System (MD 02). Ref Sub system Ship Propulsion System (MD56) or Main Control Console Ref Sub-system PowerChief Pump/Compr Control (MD102), or Main Control Console
5.3.18
Start Steering Gear Servo Pump no.1
Set Steering gear pump no. 2 on AUTO
5.3.19
Start Engine Room Fan no.1 and no. 2
R0764 starts
Ref Model Variable Page 5800 Ship Ventilation System or Electrical consumers (MD 74)
Activate Engine Control Room Aircondition by -Open Air Condition SW supply valve V672 opens, SW flow through Air Condition cooler present. R0763 turns on, and the temps change accordingly Ref Sub SW System (MD01),
-Start Air Condition
Ref Model Variable Page 5800 Ship Ventilation System or Electrical consumers (MD 74).
28
Step No. 5.3.20
Test Director Action Start ME Aux. Blower No 1 locally Set Blowers on AUTO
Observation Blower No 1 starts Blower No 2 starts automatically if required Flow through Air Coolers are present. G1070, G1071.
Observer Notes KMSS Customer Ref Sub ME Power (MD20).
5.3.21
Open for LTFW to ME Air Cooler 1 and 2.
V1130 & V1131. Ref Subsystem Fresh Water System (MD10).
5.3.22
Prepare start of Main Engine: Line up ME start Air System, by opening ME start air valve V4511. Notify bridge of intention to turn engine. Check that ME Control is in Local and Stop. Camshaft position to Ahead Reset ME Fail, Slow Down, or Shut downs if any activated Trip lamps turn dark. Ref Subsystem ME Power (MD19)or Main Control Console, AC sect. Start air press to ME is available
29
Step No.
Test Director Action Open indicator cocks. Engage Turning gear. Rotate engine several turns.
Observation
5.3.23
Attempt to turn engine on air.
Engine will not turn due to ENGAGED TURNING GEAR interlock logic. Shut Down appears
30
5.4
Step No. 5.4.1
Data Sheet #3
Test Director Action Disengage turning gear. Observation ENGAGED TURNING GEAR light is turned off Observer Notes KMSS Customer Ref Sub system ME Power (MD19), or ME local Console.
Turn Engine on Slow turning Air Shut indicator cocks. Fifteen minutes prior to stand by, Start engine Dead Slow Ahead. Note sound and rpm and other parameter changes.
Stop Engine. Start engine Dead Slow Astern. Increase ME speed . Stop engine. Start Steering Gear Pump #1 Set Rudder Control in MANUAL. Note turbocharger speed. Ref Sub system ME Power (MD19), or ME local Console. Ref. sub-system: 'Ship Propulsion System' (MD 56)
5.4.2
31
Step No.
Test Director Action Change Rudder Set Point: -15 degrees, port & starboard Set Rudder Set Point in Neutral. Transfer Steering Gear to Auto Pilot.
Observation
Change in rudder pos. accordingly.
5.4.3
Store the Initial Condition # 2 READY FOR DEPART. Take alarm and event logs. Stop the simulation by pressing FREEZE.
Freeze is lit.
32
6
6.1
OPERATIONAL TEST #2
Title: Scenario #2-Dock To Full Power At Sea
This test will start out with the scenario 'Ready For Departure' and end with the condition 'Full Power at Sea, HFO'. Changing over from DO to HFO will be incorporated in this exercise. The test will also address the capabilities of the malfunction system. Furthermore the effect of changing in operational conditions (e.g., weather condition and fuel quality) is demonstrated. The initial conditions for OP Test #2 will be Init Condition #2 READY FOR DEPARTURE. The scenario will terminate after taking Initial Condition #3 FULL POWER AT SEA HFO which will serve to set the initial conditions for Operational Test #3 and other future scenarios.
33
Operational Test #2 starts with vessel at dock with engine prepared to respond to Order Telegraph and steering engine tested.
6.2
Step No. 6.2.1
Data Sheet #1
Test Director Action Power up the simulator by supplying 24V to all Control Consoles, Main and Switchboard sections ME Local Operating Console Load Initial Condition #2 READY FOR DEPARTURE: Check Control Room Console and Local Control Panel to be certain all controls are in correct position for the initial conditions of #2 ME in Stop position lined up for Diesel Oil, LO Purif is running. Temp's and levels are normal Compressors are stopped, and in Manual. Press: above 30 bar Ref Sub system : (MD 20, MD 101 - 104) Observation Random selection of pumps and valves are illuminated. Observer Notes KMSS Customer
6.2.2
Shut down both starting air compressors. Stop Start Air Comp. No 1 and 2, and put them in Manual
Ref Sub system Start Air and Compressor (MD60), or Main Control Console (MD102)
34
Step No. 6.2.3
Test Director Action Isolate Starting Air Tank #2: Close Start Air Receiver 2 Inlet and Outlet Valves.
Observation Note starting air supply available limited to Start Air tank #1 with no make up. Note number of engine starts and drop in pressure in Start. Air Tank #1 Observe Low Start Air Press.
Observer Notes KMSS Customer Ref Sub system Start Air and Compressor (MD60). V4461 and V4463
Alternate turning engine ahead and astern in process of bringing all components up to temperature without undue stress.
Recognize engine had previously been Prepared to Get underway as per Init Condition #2.
6.2.4
Check steam to HFO fuel heater and supply for steam tracing,.
35
6.3
Step No. 6.3.1
Data Sheet #2
Test Director Action Open Start Air Receiver 2 Inlet and Outlet Valves. Observation Observer Notes KMSS Customer Ref Sub system Start Air and Compressor (MD60). V4461 and V4463
Start Air Compressors on AUTO. Observe Auto start of Air Compressors
Compressors starts, and stops automatically according to Start/Stop set point approx.30 bar Note rise in air outlet temp, high outlet temp alarm, Comp #1 shut down, Comp #2 start. Start Air Pressure reaches normal values.
Ref Sub system Start Air and Compressor (MD60), or Main Control Console (MD102)
6.3.2
Shut off cooling water to Start Air Comp.#1. Continue to manoeuver engine as proceeding toward departure.
At Instructor Station (Bridge) restore starting air pressure to default value. Set P4300 at Variable Page 6000 to 30 bar.
To save time unless it is desired to witness time required to recover.
36
Step No. 6.3.3
Test Director Action Move Instructor Station (Bridge) Engine Order Telegraph to Stand By. Respond on Control Room Console Order Telegraphs to Stand By.
Observation Stand By Telegraph at Instructor Station (Bridge). Indicated a flashing lamp. Acknowledge from Control Room by resetting the flashing lamp to steady light (Stand By). Observe engine response, ME rpm and sound for realism.
Observer Notes KMSS Customer Variable page 9010, model Variable X07541
6.3.4
Move Instructor Stations (Bridge) Emergency Order Telegraph to Dead Slow Astern. Respond on the Control Room Console Emergency Order Telegraph. Move engine control lever to Dead Slow Astern. Reset Telegraph alarm
Ref Sub system (MD104), or AutoChief section at Main Control Console
37
Step No. 6.3.5
Test Director Action At Instructor Station (Bridge) move the Order Telegraph to Slow Ahead. Respond on the Control Room Console Start of Engine, Slow Ahead.
Observation
Observe rpm of Turbo chargers, exhaust temperatures and FO flow G0027 indicates net flow to ME Pump starts, alarm disappears Ref. sub-system 'ME Fuel Oil System' (MD 02). Ref. sub-system 'Steam generation Plant' (MD 80), or Boiler Console Ref. sub-system 'Exhaust Boiler' (MD 81) or Boiler Console
Departure. Take fuel meter readings.
6.3.6
Start Exhaust Boiler Circulation pump
6.3.7
Set Exhaust Boiler Controller on Auto, and adjust set point to 14 bar
38
Step No. 6.3.8
Test Director Action Check the FO viscosity control
Observation Viscosity Control in single control mode Steam flow available, increased temperature in Bunker Tanks V0112 turns open Controller output signal adjusts accordingly During a period there is no HFO flow due to clogged HFO pipe line from Service tank
Observer Notes KMSS Customer Ref. sub-system 'ME Fuel Oil System' (MD 02). V0206, V0222, V0236 and V0252. Ref Sub system Fuel Oil Transfer System (MD05)
Open Steam Supply valves to 100% for Bunker Tanks
Open ME FO Steam Tracing Valve Set FO Viscosity Controller on AUTO, and set point to 13 CentiStoke
Ref. sub-system 'ME Fuel Oil System' (MD 02) or viscosity meter. G0040
Gradually change the HFO/DO Mixing Valve to HFO.
Shut off steam tracing.
39
Step No. 6.3.9
Test Director Action Increase engine speed to full speed from Instructor Station (Bridge) by moveing the Order Telegraph to Full Ahead.
Observation Throttle to 100% Load at AutoChief Console. Observe activation of Thermal Limit at AutoChief control Panel. Note oil firing ceases and Exhaust boiler damper is under PID control to maintain steam pressure
Observer Notes KMSS Customer Ref Sub system (MD104), or AutoChief section at Main Control Console. Ref Sub system (MD84 and 81)
6.3.10
Line up the Condenser System : Start the Condenser Vacuum Pump Open Steam Condenser SW supply Valve Start Main Condensate Pump Flow through cooler is present Level in Condenser decreases V0673 Ref Sub-system SW System (MD 01) L4703 Ref Sub-system Steam Condenser System (MD 85)
40
Step No. 6.3.11
Test Director Action Line up the turbogenerator. Open valve for drain of ME superheater
Observation
Ref. sub-system 'Exhaust Boiler (MD 81) Valve opens. TG pipeline Water index decreases Min 50% Ref. sub-system 'Steam Turbines' (MD 86)
Open TG steam line drain valve. Close when pipeline is empty of water.
6.3.12
Check TG LO tank level Line up the TG LO system Set TG LO Priming pump on AUTO
The electrical LO pump starts and stops in sequence
Ref. sub-system 'Steam Turbines (MD 86)
41
Step No. 6.3.13
Test Director Action Apply sealing Steam to TG, by open the TG sealing steam outlet valve and TG sealing steam supply valve Open TG Steam Outlet Shut Off Valve Reset trips if any
Observation
Observer Notes KMSS Customer V4655 and V4656.
V4660
6.3.14
Turn on the TG exitation voltage
Exitation Voltage turns on Ref. sub-system 'Steam Turbines (MD 86). The attached LO pump starts and after a while the electrically driven LO pump stops
Start the turbo generator by slowly opening the emergency stop valve Let the turbo generator run for about 2 minutes at low speed ( about 1000 rpm.)
42
Step No.
Test Director Action Increase slowly until normal speed is obtained, i.e., 6400 rpm
Observation The TG's governor will take control as speed is close to 6400 rpm Cooling flow is present
Open TG Emergency stop valve to 100% Open for LTFW cooling water to TG LO system 6.3.15 Adjust Frequency and Voltage for synchronisation to Main Bus Bar. Connect TG to Main Bus Bar, and perform loadsharing. Adjust the magnetisation if necessary From the PowerChief Panel, set DG1 and TG in AUTO. DG1 in priority 1 (less important). DG2 to be set in priority 2. 6.3.16 Store the Initial Condition # 3 FULL SPEED ON HFO. Take alarm and event logs. Stop the simulation by pressing FREEZE.
Ref. sub-system 'Steam Turbines (MD 86)/ Fresh Water system (MD10). Ref. sub-system 'Electrical Power plant (MD 70) and Main Switchboard
TG takes load
Ref. sub-system 'PowerChief generator Control (MD 101) or PowerChief panel, Main Control Console
Freeze is lit.
43
6.4
Step No. 6.4.1
Data Sheet #3 Test of PTI/PTO

Test Director Action Load INIT CONDITION #3 'FULL SPEED ON HFO' Select various sub-system displays, Start simulation by pressing RUNNING. Prepare Shaft Generator for operation. Connect bus tie on busbar 2. Connect the clutch to the ME locally and transfer to REMOTE. Start Synchronous Condenser 'Simulation Running' lamp turns on. Ref. sub-systems: MD 02; MD 20; MD 70; MD 103; MD 104 ME running approximately 70 rpm. The speed on shaft generator and compensate motor will increase. Observation Observer Notes KMSS Customer
6.4.2
6.4.3
6.4.4
Increase of Cond. Motor speed up to 1800 rpm. The Shaft Generator will take load. Load will be sheared between the generators The PowerChief will equalize the load between the other generators and the shaft generator.
6.4.5
Connect Shaft Generator (PTO) activate CONN on PowerChief panel. Set Shaft Generator in AUTO Set Shaft Generator on DataChief console in AUTO and priority. Take DG 2 out of AUTO and disconnected. Set DG2 in AUTO after it has been disconnected.
6.4.6
6.4.7
44
Step No. 6.4.8 6.4.9
Test Director Action Take Shaft Generator out of AUTO. Switch mode from PTO to PTI on MD73 SG Power take In / Power take OFF
Observation
Observer Notes KMSS Customer DG 2 will start on request and connected. Shaft Generator power will be reduced and now take electric load and supply the ME shaft. The FO consumption and regulator output on ME will be reduced.
6.4.10
Change the load setting on PTI to maximum load and supply the ME shaft.
6.4.11
Stop the simulation by pressing FREEZE.
45
7
7.1
OPERATIONAL TEST #4
Title: Scenario #3-Full Sea Speed To Anchoring
This operational test will simulate the changes in conditions from steady steaming to arrival at harbor and manoeuvring to anchoring area. Changing over from HFO to DO will be incorporated in this exercise. The Test will be initiated by introducing INIT CONDITION #3- FULL SPEED ON HFO. As previously all functions will work correctly as no faults will be introduced deliberately. The only alarms will result from operator error. OPERATIONAL TEST #3 will be terminated by generating INIT CONDITION #4: 'AT ANCHOR' This will be used as initial scenario for later exercise illustrating faults. A printout of selected parameters will be taken and recorded for future checking of conditions.
46
7.2
Step No. 7.2.1
Data sheet #1
Test Director Action Load INIT CONDITION #3 'FULL SPEED ON HFO' Select various sub-system displays, Start simulation by pressing RUNNING. Same parameter values as from operational test #2 'Simulation Running' lamp turns on. Ref. sub-systems 'Fuel Oil Settling Tanks' (MD 04) and 'Fuel Oil Service System' (MD 03) Ref. sub-systems: MD 01; MD 10; MD 20; MD 56; MD 70; MD 71. Observation Observer Notes KMSS Customer
7.2.2
7.2.3
Press RUNNING button to start simulation
7.2.4
Line up HFO Separator 2 for transfer of HFO from HFO Settling Tank No. 1 to HFO Service Tank. Open HFO Settling Tank 1 Outlet Valve Open HFO Settling Tank 1 Inlet Valve Open HFO Separator 2 suction valve Open HFO Separator 2 discharge valve Open HFO Service Tank 1 Inlet Valve
47
Step No. 7.2.5
Test Director Action Supply Steam to HFO Separator 2 Heater HFO temp. Controller on AUTO, setpoint 98 deg C. Start HFO feed Pump, adjust the Flow Control valve to 100% open. Start HFO Separator 2 motor. Open water supply valve Check Operating Water Tank.
Observation
Steam flow present. increase in HFO temp inlet purifier Observe recirculation flow to settling tank. Elmotor current will increase and stabilize and waiting for speed light, until decrease of current and cut of centrifuge clutch. Min. 0.5 meter Observe the barograph on the water transm. Pop up window the increase of water cont. During separation and shooting process.
7.2.6
Start the HFO Separator 2.
When HFO Service Tank is close to full, reduce the separation of HFO volume to the ships HFO consumption.
48
Step No. 7.2.7
Test Director Action Line up for transfer from Fore Bunker FO Tank to HFO Settling Tank No.1.Start and run FO Transfer Pump untill HFO Settling Tank No.1 is filled up. Reduce ME Throttle Setting from FULL AHEAD to HALF AHEAD from the Instructor Station (Bridge).
Observation
Observer Notes KMSS Customer Ref. sub-systems 'Fuel Oil Transfer Tanks' (MD 05) and 'Fuel oil Settling Tanks' (MD 04)
7.2.8
Gradual reduction in - RPM - exhaust temp - FO consumption - ships speed Gradual reduction in Steam Contr. Valve to FO Heaters Throttle setting HALF AHEAD Speed ME Approx. 60 rpm
Ref. sub-system (MD 103), or Main Control Console
7.2.9
Change the HFO/DO Mixing Valve from HFO position to DO position.
Ref. sub-system 'Fuel Oil Supply System' (MD 02) or Main Control Console Ref. sub-system MD 104
49
Step No.
Observation
As Oil Fired Boiler is on AUTO, burner will ignite due to lack of ME Exhaust gas 7.2.10 Give command from Main Control Console, PowerChief to disconnect TG in Semi AUTO AUTO out, and disconnect command noticed Autostart of DG2 if not already connected 7.2.11 Shut down the TG Gradually close the Emergency Stop Valve Valve position of V4652 to zero. Auto start of TG LO pump Ref. sub-system 'Steam Turbines' (MD 86) or appropriate location in Engine room Ref. sub-system MD 101, or Main Control Console, PowerChief
Turn off the TG Exitation Voltage Shut TG Sealing Steam outlet valve and supply valve
50
Step No.
Observation
Shut TG Steam outlet shut off valve Set TG LO pump in Manual and Stop the Pump Close FW supply to TG 7.2.12 Set ME Throttle to SLOW AHEAD from the Instructor Station (Bridge). Further reduction in - RPM - exhaust temp - FO consump. - ships speed Throttle to 30% Load at AutoChief Console. Ref. sub-system MD 103, or Main Control Console, AutoChief Indicator panel
7.2.13
Decrease engine speed to Dead Slow Ahead from Instructor Station (Bridge) by moving the Order Telegraph to DEAD SLOW AHEAD. Acknowledge the Command from Bridge at Emergency Telegraph
Ref Sub system (MD104), or AutoChief section at Main Control Console.
Steady light at Telegraph DEAD SLOW AHEAD
51
Step No. 7.2.14
Test Director Action Decrease engine speed to Dead Slow Astern from Instructor Station (Bridge) by moving the Order Telegraph to DEAD SLOW ASTERN.
Observation Throttle to 30% Astern at AutoChief Console. Engine starts ASTERN, Ship Speed decreases Steady light at Telegraph DEAD SLOW ASTERN Throttle to 0% at AutoChief Console. Engine stops, Ship Speed 0
Observer Notes KMSS Customer Ref Sub system (MD104), or AutoChief section at Main Control Console.
Acknowledge the Command from Bridge at Emergency Telegraph
7.2.15
At Ship Speed at 0 set ME stop Command from Instructor Station (Bridge) by moving the Order Telegraph to STOP.
52
Step No. 7.2.16
Test Director Action Stop FO Transfer pump and close the suction and discharge valves Change HFO suction from Settling Tank no 1 to suction from HFO service tank Shut down the ME FO Supply system: -stop the FO pumps and put them in Manual. Close the valves Shut down the ME LO Supply system: - Stop the pump(s) and put them in MAN -Close the valves Shut down the Stern Tube System. Set Pumps in local and stop the pump(s) running. Stop the Steering Gear. Put them out of AUTO Store INIT CONDITION #4 AT ANCHOR
Observation
7.2.17
7.2.18
7.2.19
7.2.20 7.2.21
53
7.3
Step No. 7.3.1
Data sheet #2 Test of Inert Gas Plant

Test Director Action Load INIT CONDITION #4 AT ANCHOR Observation Observer Notes KMSS Customer
7.3.2
Select various sub-system displays, Start simulation by pressing RUNNING.
Same parameter values as from operational test #2 'Simulation Running' lamp turns on.
Ref. sub-systems: MD 1; MD 10; MD 20; MD 56; MD 70; MD 71.
7.3.3
Press RUNNING button to start simulation
7.3.4
Line up all systems required for start of 2 cargo turbines, #1 - 100%, #2 - 75%. Inert Gas Plant Open valve Inert Gas Scrubber Sea Chest & discharge valve Start Inert Gas Scrubber pump Open drain to scrubber when sufficient level in scrubber is obtained Open Valve Inert Gas fan Suction & discharge Set press Contr. in Manual, open 100% to funnel Open Valve 23577 Inert Gas supply line Start Fan 1
7.3.5
V 23572, V 23574
V 23543, V 23541 V 23577 Boiler line temp. 54
Step No.
Test Director Action Open valve Deck Seal Sea Chest & discharge Start deck water seal pump Open Main deck line valve Set pressure controller in AUTO Set O2 analyzer to ON Open Inert Gas Main Control Valve
Observation
Observer Notes KMSS Customer V 23530, V 23531 V 23554
Observe
V 23538
7.3.6
Check that the oil fired Boiler functions properly - on HFO - Large nozzles - Atomizing Steam present - All controllers in AUTO at Boiler Console. - Aux. Condenser Pump running - Aux. Feed water Pump is running Stop the simulation by pressing FREEZE.
If delivered, or MD84
7.3.7
55
8
8.1
INSERTING FAULTS
Title: Scenario # 4-Inserting Faults
This operational test will demonstrate steaming at normal full sea speed while experiencing numerous faults. The scenario will be initiated using INITIAL CONDITION #3 The test includes demonstration of pre-programmed fault insertion. In addition to preprogrammed faults it will be demonstrated the introduction of faults on line from the INSTRUCTOR STATION (BRIDGE). Several faults will be introduced in order to demonstrate cascading of abnormal conditions. It will be obvious that time will not permit all faults to be demonstrated. It is also obvious that simultaneous or multiple faults mask the effects of each other. These two facts will influence this scenario. The ramp effect will be demonstrated to show its use in testing the alertness of the student.
56
8.2
Step No. 8.2.1
Inserting Faults
Test Director Action Load INIT CONDITION #3 'FULL SPEED ON HFO' Prepare pre-programmed malfunctions as follows: 5 min: FO Booster Pump #1 Motor Failure (M1303) 10 min: FO Viscosity Controller Failure (M1312) 15 min: Cyl 1 Injection Valve Nozzle Wear Ramp = 0-100% during 18 minutes (M2503). Set to RUN. Observation Observer Notes KMSS Customer
8.2.2
Pre-programmed fault: 5 min after start ME FO Pump #1 fails Reset fault on ME FO Pump #1
ME FO Pump #2 auto start. Fault removed.
Ref. sub-system 'Fuel Oil Supply System' (MD 02) Fault: M0203
57
Step No. 8.2.3
Test Director Action Pre-programmed fault: 10 min after start FO Viscosity Controller fails, i.e., output control signal locked
Observation Fuel temp out of control. Viscosity changes accordingly.
Observer Notes KMSS Customer Ref. sub-system 'Fuel Oil Supply System' (MD 02) Fault: M0206
Transfer FO Viscosity Control to Manual Operation. Restore normal viscosity. After viscosity stabilized, reset malfunction. 8.2.4 Pre-programmed fault: 15 min after start ME1 Cyl.1 Injector Pump starts to detoriate from normal (0) to worn (50) in 18 minutes. Remote Control incr. Fuel Link Pos. to compensate for detoriation. Cyl.#1 Temp. Dev. increasing, giving alarm. Reset fault after 20 minutes. Variable Parameters return to normal values Ref. sub-system 'ME 1 Power' (MD19 and 20)Fault: M1302
58
Step No. 8.2.5
Test Director Action Insert fault: Water leakage into Aft Bilge Well (M4601) to 2%
Observation Increasing Aft Bilge Level. Aft Bilge Level High alarm at 50%. Horn off. Flashing light goes steady. Alarm light turns off. The heater is switched off as temp reaches 80oC
Observer Notes KMSS Customer Ref. sub-system 'Bilge Wells' (MD 62) Fault: M4601
Acknowledge alarm. Line up Bilge Well System.
Turn Bilge separator heating on.
Turn Bilge Separator in automatic operation Start Bilge Separator Pump Repair fault: 'Leakage into Aft Bilge Well'. Bilge Level decreases.
59
Step No. 8.2.6
Observation Main Engine is running at full speed.
Change SW temp to 15 degC and Air temp to 20 degC Let SW Controller reach steady condition Put SW pumps in Manual Set SW Temp. Controller in MANUAL, and output signal according to output signal as when controller was in Auto 8.2.7 Record readings of FW cooler no.1 outlet temp Steam Condenser outlet temp Aircondition cooler outlet temp
Variable List 9002
Ref. sub-system ' SW System' (MD 01)
60
Step No. 8.2.8
Test Director Action Insert fault: 'Sea Chest Filter 1 Very Dirty'
Observation SW Pump Disch. Press decr. All Cooler Outlet Temps. of SW cooled systems higher than readings recorded during normal condition
Observer Notes KMSS Customer Fault: M0111 (high value)
Open Sea Chest 2 Inlet Valve
Ref. sub-system 'SW System' (MD01). Ref. sub-system 'SW System' (MD01). The system will establish normal values
Shut off Sea Chest 1 Inlet Valve
Reset Fault.
61
8.3
Step No. 8.3.1
Data Sheet #1
Test Director Action Load INIT CONDITION #3 'FULL SPEED ON HFO' Prepare Turbocharger #1 & #2 inlet air filter to foul on ramp from clean (0) to fouled (50%) in 20 min. (M2402 and M2412) M2402 M2412 Observation Observer Notes KMSS Customer
Take records of Exhaust temps. Start simulation by pressing RUNNING. At 450 deg C (840 deg F) HI exh. temp alarm and eng. slow down should take place.
Take new records of Exhaust temps and compare with values for clean filters Restore clean filter.
62
Step No. 8.3.2
Test Director Action Load INIT CONDITION #3 'FULL SPEED ON HFO' Start simulation by pressing RUNNING. At INSTRUCTOR STATION introduce change in HFO specification.
Observation
(BRIDGE), Note influence on viscorator and fuel temp.
(Variable Page 1129)
At INSTRUCTOR STATION (BRIDGE), Change in levels. introduce change in Weather Condition from calm weather to hurricane False alarms will 10 Beaufort (waves), Wind force: 25m/s, occur, i.e., ME FW wind direction: 90 degrees Exp Tank, HFO service Tank, DG LO sump tanks. Observe unsteady ME rpm and may be slow down
Variable List 9002.
63
Appendix A to System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver. MC90-III Inventory List
INVENTORY
Instructor's Facilities Instructor Station The Instructor's facilities comprise following main units: Item No. SC1 Item Name & Description Hewlett Packard 9000/715/100 PA RISC server/ workstation 100 MHz PA RISC Processor High Bandwidth CPU and RAM interfaces 24 MB ECC SIMM, expandable to 192 MB 64 KB instruction cache 64 KB data cache 1 GB Hard disk 2.0 GB 3.5 DDS tape (back-up medium) 1 1 Quantity 1 Observer KMSS
Customer
Notes
Instructor Station, continued Item No. Item Name & Description Integrated I/O subsystem IEEE 802.3 Ethernet LAN interface with Thinmau and BNC T connector configuration SCSI-II, RS-232 (2), Centronics Audio I/O ports HP-HIL interface 1024 x 768, 75 Hz., colour graphic interface 17 inches 1024x768, Colour Monitor Software runtime license for EMULA Software runtime license for OTISS Software runtime license for PPT2000 License-to-use HP-UX 9.0 IF1 IF2 IF3 IF4 IF5 IF6 Telephone System. Operational Keyboard Trackerball Standard Keyboard Printer Type: Epson LX-300 Audio Amplifier 1 1 1 1 1 2 Quantity Observer KMSS
Customer
Notes
Engine Room Equipment The Engine Room will be equipped with: Item No. ER M4 SND2 Item Name & Description Large Scale Interactive Mimic Loudspeakers Alarm lamp Alarm Horn Quantity 1 4 1 1 Observer KMSS
Customer
Notes
Engine Control Room Equipment The control room equipment consists of life like equipment with all necessary functions. The following will be provided: Item No. Item Name & Description ECR Engine Control Room Console comprising: Quantity Observer KMSS
Customer
Notes
ECR1 Pump-/Compr.- & El.Generator Section incl: ECR1V1 Generator Control Panel ECR1 H1 Pump- & Compressor ECR2 Alarm- & Communication-Section incl: ECR2 V2 Workstation Monitor 17 ECR2 H2 Man/Machine Comm. Panel ; TEC2000 ECR3 Remote Control Indication Section incl: ECR3 V3 Indication panel ECR3 H3 Main Engine Remote Control
1 1
1 1
1 1
Item No. Item Name & Description MSB MSB1 MSB2 MSB3 MSB4 MSB5 MSB6 MSB7 BCC Main Switchboard Comprising: Diesel Generator No. 1 Diesel Generator No. 2 Synchronising w/Shore Connection Turbo Generator Shaft Generator Emergency Generator Miscellaneous Boiler Control Console including: Boiler indicator Panel Boiler Console Control panel Printer, Epson LX-300
Quantity
Observer KMSS
Customer
Notes
1 1 1 1 1 1 1
1 1 1
ECR P1
Specification of the Interactive Workstation, included in the alarm and communication console (ECR2): Item No. Item Name & Description Quantity Observer KMSS WS1 Hewlett Packard 9000/715/100 workstation 100 MHz PA RISC Processor 1
Customer
Notes
High bandwidth CPU and RAM interfaces 16 MB ECC SIMM, expandable to 192 MB 64 KB Instruction cache 64 KB Data cache Integrated I/O Subsystem IEEE 802.3 Ethernet LAN interface w/ Thinmau and BNC T connector configuration SCSI-II, RS-232 (2), Centronics Audio I/O ports HP-HIL interface 1024x768, 75 Hz colour graphic interface 17 inches 1024x768, Colour Monitor
Item No.
Item Name & Description Software runtime license for EMULA Software runtime license for OTISS Software runtime license for PPT2000 License-to-use HP-UX 9.0
Quantity
Observer KMSS
Customer
Notes
WS1.1 WS1.2
Operational Keyboard, TEC 2000 Trackerball
1 1
Performance of the workstations delivered: 35 MIPS (million instructions pr. sec.) 8 MFLOPS (million floating point operations pr. sec.) 34 SPEC marks
Mathematical Software Models, Engine Room Subsystems. Item No. Item Name & Description
MD 01 MD 02 MD 03 MD 04 MD 05 MD 06 MD 07 MD 08 MD 09 MD 10 MD 12 MD 13 MD 19 MD 20 MD 21 MD 22 MD 23 MD 24 MD 25 MD 29 MD 53 MD 54 MD 56 MD 60 Sea Water System Fuel Oil System Fuel Oil Service Tanks Fuel Oil Settling Tanks Fuel Oil Transfer System HFO Separator 1 HFO Separator 2 DO Purifier System LO Purifier System Fresh Water System Main Engine Lubrication Oil System Main Engine Turbocharger System Main Engine Control System Main Engine Local Control Main Engine Cylinder no. 1 Main Engine Cylinder no. 2. Main Engine Cylinder no. 3 Main Engine Cylinder no. 4 Main Engine Cylinder no. 5 Main Engine Bearing System Propeller Servo Oil System Stern Tube system Ship Steering and Propulsion Start Air and Air Compressor
Quantity
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Item No.
MD 61 MD 62 MD 63 MD 64 MD 65 MD 70 MD 71 MD 72 MD 73 MD 74 MD 80 MD 81 MD 82 MD 83 MD 84 MD 85 MD 86 MD 87 MD 89 MD 101 MD 102 MD 103 MD 104 MD 110
Item Name & Description

Fresh Water Generator Bilge Wells Bilge Separator Refrigeration System Waste Heat Recovery System Electric Power Plant Diesel Generator no. 1 Diesel Generator no. 2 Shaft Generator Take In / Power Take Off Electrical Consumers Steam Generation Plant Exhaust Boiler Steam Generator Oil Fired Boiler Boiler Combustion Steam Condenser Turbo Generator Cargo Turbines Inert Gas Plant PowerChief - Generator Control PowerChief - Pump / Compr. Control AutoChief - Indicator Panel AutoChief - Main Engine Control Maine Engine - Bridge Control
Quantity
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Observer KMSS
Customer
Notes
10
Item No.
MD 111 MD 112 MD 120 MD 121 MD 122 MD 123 MD 130 MD 150
Item Name & Description

Ship - Course Control Ship Load Cylinder Indication - Press/Angle Cylinder Indication - Press/Vol Weak Spring Diagram Cyl. Indication Delta - Press/Angle Pen Recorder Description of Legends
Quantity
1 1 1 1 1 1 1 1
Observer KMSS
Customer
Notes
11
Instructor's Programs The following instructor functions (software) will be provided: Item No. Item Name & Description IP1 IP2 IP3 IP4 IP5 IP6 IP7 IP8 IP9 Changing Process Response and Behaviour Setting Fixed Conditions Setting External Conditions Setting Malfunctions Repairing/Resetting Malfunctions Training Monitoring and Recording Play-Back Facilities Online Editor for Training Scenario Generation Automatic Evaluation of Training Scenarios Quantity 1 1 1 1 1 1 1 1 1 Observer KMSS Customer Ref. 'Operating Condition Dynamic Response' Ref. 'Operating Condition -Fixed Process' Ref. 'Variable List - page 9002' Ref. 'Malfunction List - page 600' Ref. 'Malfunction List - page 600' Ref. 'Picture Directory - MD 02' Ref. 'Replay'-button Ref. 'Scenario & Time Editor' Ref. 'Evaluation Editor' Notes
12
Documentation The delivery includes the following documentation: Item No. Item Name & Description DOC1 TEC 2000 Description Instructors facilities User's Manual includes: Basic system description Description of functions and operation of the simulated process models. Technical Manuals including: Hardware Configuration and arrangement Maintenance Manual and Card Manual 2 Quantity Observer KMSS
Customer
Notes
DOC2
DOC3
DOC4
Computer and peripheral equipment includes: Manufacturers standard operating manuals
13
Appendix B to System Acceptance Test ERS MAN B&W 5L90MC90-VLCC Ver. MC90-III Acceptance Test Certificates
14
FACTORY ACCEPTANCE TEST CERTIFICATE
PURCHASER: PURCHASE ORDER NO. : P.N.O.
The Engine Room Simulator, ERS MAN B&W 5L90MC90-VLCC, MC90-III, has been tested through the System Acceptance Test prepared by KONGSBERG MARITIME SHIP SYSTEMS AS and approved by representatives of the Customer and has been found to be in accordance with the specifications of the contract.
REPRESENTATIVES FROM PURCHASER KONGSBERG MARITIME SHIP SYSTEMS as
------------------------------------
-------------------------------------
DATE__________________
15
SITE ACCEPTANCE TEST CERTIFICATE
PURCHASER : PURCHASE ORDER NO. : P.N.O.
The Engine Room Simulator, ERS MAN B&W 5L90MC90-VLCC, MC90-III, has been tested through the System Acceptance Test prepared by KONGSBERG MARITIME SHIP SYSTEMS AS and approved by representatives of the Customer and has been found to be in accordance with the specifications of the contract.
REPRESENTATIVES FROM PURCHASER KONGSBERG MARITIME SHIP SYSTEMS as
------------------------------------
-----------------------------------------
DATE_________________
16

So0650c1 Mc90 III Sat Docum

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

So0650c1 Mc90 III Sat Docum

Uploaded by

Copyright:

Available Formats

KMSS Doc.no.

System Acceptance Test Engine Room Simulator

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

INVENTORY LIST ...............................................................Appendix A SYSTEM ACCEPTANCE TEST ..................................................Appendix B

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Operational Testing Procedure

Data To Be Recorded and Retained

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

PHYSICAL INVENTORY (APPENDIX A)

Physical Inventory Check-Off Lists

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

SYSTEM ACCEPTANCE TESTS (APPENDIX B)

Site Acceptance Test

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Voltage, on emergency bus bar (440V)

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Step No. 5.2.6

Water Content decreases to zero

(The corresponding valves is lit.) (The corresponding valves is lit.)

V04460, V04461 V04462, V04463

V04464, V04465 and V04466

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Test Director Action

Observer Notes KMSS Customer Ref. sub-system (MD10)

Check ME FW Expansion Tank level Start Aux. LTFW pump

Ref. sub-system (MD10) P1001, G1075

Controller changes to new output value

V700 and V0670

SW Discharge Pressure. SW starts flowing

Ref. sub-system (MD1) G063, P0632

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Test Director Action Set SW Controller in Auto, and Setpoint to 20 deg C.

Observer Notes KMSS Customer Ref. sub-system (MD 01)

4,0 meter 50% full

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Observer Notes KMSS Customer

Raise speed to frequency 60Hz

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Step No. 5.2.11

Test Director Action Start Air Compressors:

Set Start Air Compressor #2 in Auto at PowerChief.

Set Service Air Compressor in AUTO

System Acceptance Test ERS MAN B&W 5L90MC-VLCC Ver.MC90-III

KMSS Doc.no.: SO-0650-C1 / 30-Jan-03

Test Director Action - Line up DG2 Start Air Line

Observation Start Air Press to DG2