. list vma_narr Record# vma_narr 1 0000-000-00-G-V-STW ROS Maintenance Management Plan (General Notes and Comments) Reminder: These procedures have been developed for the Western Region's State Class ROS vessels. If you should make any significant chnages to any procedure, please change the last three (3) characters of the MIC code "STA" to your vessel's unique three (3) character identifier: ST5 - Gem State ST7 - Grand Canyon State ST9 - Keystone Stae Note: Please use the f1 Help key to obtain more information about using and updating RRF-MARTS. For additional assistance please feel free to contact the following individuals: Region............: Mr. Fred Hoffmann (757:441-3731) MARAD Headquarters: F. Critelli (202:366-1883) Introduction The Maritime Administration's Reduced Operating Status (ROS) Maintenance Program Plan has been developed by the Maritime Administration, Office of Ship Operations, Division of Ship Maintenance and Repair. The Program Plan has two (2) elements: (1) the development of vessel/equipment specific inspection, test and maintenance procedures; and (2) the scheduling, implementation and performance of these procedures. Contained herein are generic inspection, test, and maintenance procedures for equipment typically found on steam and/or diesel propelled vessels in the Ready Reserve Force (RRF) - by no means is it all inclusive. These procedures are intended to serve as a baseline from which the Ship Manager and the vessel's Reduced Operating Status (ROS) crew are to develop vessel/equipment specific maintenance procedures. During the development of these generic procedures, it was recognized that each vessel and the equipment installed thereon is different and not every test, inspection or maintenance procedure may be completely applicable to a specific vessel, equipment and/or system. It is intended that these procedures provide guidance relative to what is to be achieved in inspecting, testing, or maintaining specific systems or individual equipment. Where a vessel's systems or equipment are different, the Ship Manager and the vessel's Reduced Operating Status (ROS) crew shall review technical manuals, operating procedures, ship's plans, etc., to either revise and/or edit the generic procedures contained herein OR develop new procedures to inspect, test, and maintain the specific systems and equipment. To the maximum extent possible the development of individual vessel/equipment specific test, inspection and maintenance procedures should be pursued on a "class" basis. Hence, coordination will be required between Reduced Operating Status (ROS) crews and Ship Managers of vessels of a similar class (design). The coordination of these efforts and the initial approval of the "class" and "vessel" specific procedures shall be through the appropriate Maritime Administration Region. The MARAD generic Reduced Operating Status test, inspection and maintenance procedures are stored in a database within the RRF-MARTS v2.0 Technical Database Module and are known as Retention/ROS Maintenance Actions (RMA). Each procedure (record) within the RMA database is capable of being edited and/or modified by the RRF-MARTS user. In addition, new procedures (records) may be added to the VMA database by the user. Instructions for utilizing the RMA database to develop a specific vessel's or class of vessels procedures and transferring these procedures to the Vessel Maintenance Actions (VMA) database within RRF-MARTS v2.0 are contained in the User's Guide. Each procedure (record) has its unique Maintenance Identification Code (MIC) number, a short title, a long title and a narrative description of the procedure. When developing a new procedure, the Ship Manager and/or Reduced Operating Status (ROS) crew should contact MARAD headquarters (202: 366-1883) for the assignment of the appropriate MIC number. Maintenance Plan Once the Ship Manager has developed his class/vessel/equipment specific test, inspection and maintenance procedures and they have been approved by MARAD, they can be transferred to the RRF-MARTS Vessel Maintenance Actions (VMA) database. This database will be used by the Ship Manager to develop the vessel's monthly/annual ROS Maintenance Management Plan by assigning to each procedure the specific month(s) in which it is to be performed. Once this has been accomplished, the actual documenting of the performance of the procedures will be accomplished utilizing the RRF-MARTS Scheduled/Phase Maintenance Tracking Submodule. Instructions in the use of this Submodule are described in the User's Guide for RRF-MARTS v2.0. Comments The following is provided as a sample pump list for a typical Roll-On/Roll-Off diesel (DSL) or steam (STM) propelled vessel. The Ship Manager and/or Reduced Operating Status (ROS) crew may need to develop inspection, testing, maintenance, and operating procedures for each pump. Injector Cooling (DSL) Piston Cooling (DSL) Centrifugal Bilge Reciprocating Bilge Fire Emergency Fire Salt Water Service Ballast Diesel Oil Transfer Fuel Oil Transfer Boiler Circulating (DSL) Boiler Feed Chemical Wash (DSL) In-Port Feed (STM) Main Engine Lube Oil (DSL) Crosshead Lube Oil (DSL) Sludge Lube Oil Service (STM) Lube Oil Purifier Fuel Oil Purifier Fuel Oil Service Diesel Oil Service Cylinder Oil Transfer (DSL) Lube Oil Transfer Low Temp Fresh Water (DSL) High Temp Fresh Water (DSL) Low Temp Fresh Water Booster (DSL) Evaporator Distillate Evaporator Feed Evaporator Brine Generator Pre-Lube Sterntube Lube Oil RO/RO Hydraulic Oil Transfer RO/RO Hydraulic Circulating Sewage Over Board Sewage Vacuum Windlass-Mooring Bowthruster Hydraulic Refrigeration Salt Water Cooling A/C Salt Water Cooling Potable Water Hot Water Circulating Hydraulic Valve Pack Feed Water Transfer Main Condenser Vacuum (STM) Contaminated Drain Tank Main Circulating Sea Water (STM) Main Condensate (STM) SSTG Circulating Sea Water (STM) SSTG Condensate (STM) The following items are identified as equipment, machinery, and outfitting that should be addressed when developing class/vessel specific ROS Maintenance Procedures. Not all items listed may be applicable to all vessels. Additional equipment installed aboard vessels may not be listed. A. Maintain canvas stack covers and canvas cover for fixed outside equipment and controls. B. Identify, inventory and maintain cargo lashing gear. Defective pieces to be discarded and replaced or exchanged. C. Inspection of tank pressure/vacuum vent valves. Include a random sampling for physical disassembly and internal condition inspection. D. Truck (forklift) gas oil tank stations be given same maintenance considerations as other small DO day tanks. E. Aerial system, mountings, brackets, and rigging to be inspected for physical condition. F. Emergency gear locker to be inventoried and dated products replaced (Check off list to be developed). G. Watertight doors and escape hatches to be inspected and maintained (Check off list to be developed). H. Small ventilation and exhaust fans (e.g. CO2 fans) located throughout vessel to be inspected and tested for operations with close attention given to louvers and weather cover condition (Check off list to be developed). I. Inspect outside fresh water faucets and deck air valves, to include bridge window wash system (Check off list to be developed). J. Maintain International Shore Connection and Fire Plan for local fire assistance. K. Inspection of shorepower cabling, fire and potable hoses connections and telephone wiring, maintain damage free. L. Inspection of bunkering stations, maintaining availability of flange connection adapters and scupper plugs. Keep sounding plugs and labeling tags in good order (Check off list to be developed). M. Maintain and test daylight signal lamp and station. N. Check and maintain master clock and all local readouts. O. As walkie-talkies represent, at time, a second means of communication, units and battery condition to be properly tested and maintained. P. Test "Loadmaster" computer, ensure backup nicad battery is in good condition. Q. Remote ballast station and level indication to be inspected for good working order. Verify proper operation of pump controls and valve operation. R. Mast winches to lower mast for travel under bridges. Test and inspect winches, limit switches and wire maintenance. Inspect and lubricate hinges. S. Inspect and maintain shore side auxiliary boilers. Any questions or suggestions; please forward to: U. S. Department of Transportation Maritime Administration Div. of Ship Maintenance and Repair, MAR-611 400 Seventh Street, S.W. Washington, D.C. 20590 Attention: Mr. Paul Gilmour F. X. Critelli End of Record: Last Update - 4/1/97 !!! 2 0101-001-W1-G-V-STW House Cleaning No narrative provided. 3 0101-001-W1-G-V-STW House Cleaning No narrative provided. 4 0101-001-W1-G-V-STW House Cleaning No narrative provided. 5 0101-001-W1-G-V-STW House Cleaning No narrative provided. 6 0105-001-W1-G-V-STW Maintenance Daywork No narrative provided. 7 0105-001-W1-G-V-STW Maintenance Daywork No narrative provided. 8 0105-001-W1-G-V-STW Maintenance Daywork No narrative provided. 9 0105-001-W1-G-V-STW Maintenance Daywork No narrative provided. 10 0110-001-W1-G-V-STW Administrative Requirements No narrative provided. 11 0110-001-W1-G-V-STW Administrative Requirements No narrative provided. 12 0110-001-W1-G-V-STW Administrative Requirements No narrative provided. 13 0110-001-W1-G-V-STW Administrative Requirements No narrative provided. 14 0110-002-W1-G-V-STW MARTS Data Entry/Updating No narrative provided. END OF RECORD 15 0110-002-W1-G-V-STW MARTS Data Entry/Updating No narrative provided. END OF RECORD 16 0110-002-W1-G-V-STW MARTS Data Entry/Updating No narrative provided. END OF RECORD 17 0110-002-W1-G-V-STW MARTS Data Entry/Updating No narrative provided. END OF RECORD 18 0114-001-W1-G-V-STW Mooring Lines (Tighten/Inspect) No narrative provided. 19 0114-001-W1-G-V-STW Mooring Lines (Tighten/Inspect) No narrative provided. 20 0114-001-W1-G-V-STW Mooring Lines (Tighten/Inspect) No narrative provided. 21 0114-001-W1-G-V-STW Mooring Lines (Tighten/Inspect) No narrative provided. 22 0184-001-M6-G-V-STW Lube Oil Analysis NOTE: Obtain and send out lube oil samples as per the MARAD Fleet wide Oil Analysis and Monitoring Guide. Taking representative samples or samples from a specific location in a large tank is difficult. Ship Managers shall have available a specially suited dip-in type sampler that can be lowered through an opened manhole or disconnected vent pipe should a primary inspection reveal contamination. TASK: Sample per instructions from the Chief Engineer and Ship's Manager. Power Generation Equipment and Auxiliary Equipment 1. Prior to activating these systems, take and visually inspect lube oils samples from systems, sumps and storage tanks in accordance with the clear and bright criteria. When visual examination indicates contamination, notify Port Engineer. 2. Applications include but not limited to: Anchor windlass gear box Constant Tension Winches gear boxes Capstans gear boxes Main Engine Purifier Outlet Lube oil purifier gear box SSTG's Seal Pump Crane Diesel Generators Emergency Diesel Generator Lifeboat Diesel Engines Lifeboat Davits gear boxes Accommodation ladder winches gear boxes Air Compressors Main Feed Pumps gear boxes Line shaft bearings Stern Tube Cavity Stern Tube System End of Record: Last Update - 05/15/97 23 0184-002-M6-G-V-STW Hydraulic Oil Analysis NOTE: Obtain and send out hydraulic oil samples as per the MARAD Fleet wide Oil Analysis and Monitoring Guide. Taking representative samples or samples from a specific location in a large tank is difficult. Ship Managers shall have available a specially suited dip-in type sampler that can be lowered through an opened manhole. TASK: Sample per instructions from the Chief Engineer and Ship's Manager. A. Prior to activating these systems, take and visually inspect the hydraulic oil samples from equipment, sumps and storage tanks in accordance with the clear and bright criteria. When visual examination indicates contamination, notify the port engineer. B. Applications include but are not limited to: Bow/Stern Thruster Drive and Pitch Systems Cargo Cranes Drive System Watertight Doors Drive System Steering Gear/Ram System End of Record: Last Update - 05/15/97 24 0184-003-M6-G-V-STW DO / Blended Fuels Analysis NOTE: Obtain and send out fuel oil samples as per the MARAD Fleet wide Oil Analysis and Monitoring Guide. Taking representative samples or samples from a specific location in a large tank is difficult. Ship Managers shall have available a specially suited dip-in type sampler that can be lowered through an opened manhole or disconnected vent pipe. At a later date, test kits will be provided by MARAD to the staff taking samples to determine in biological growth is present at the oil water interface. Frequency of performance of this task varies as noted below. TASK: Sample per instructions from the Chief Engineer and Ship's Manager. A. At first Phase IV Cycle after deactivation or award of Ship Manager contract, the Ship Manager shall consult records to determine if all tanks containing diesel or blended fuel were treated with a dispersant and biocide at deactivation. Record findings in the Phase IV Maintenance Report/s. If no additives were utilized, consult COTR over best method to facilitate injecting of same during lay-up. B. At first Phase IV Cycle after deactivation or award of Ship Manager contract, take benchmark samples of all tanks and submit to Region approved laboratory for analysis. At two year intervals after the first benchmark sampling, take new samples for analysis and comparison. C. Semi-annually, in conjunction with the tank gauging task, 9902-001-M6-G-V-STW, Tank Gauging, sound fuel tanks with a water finding paste and determine amount of water, if any, in each tank. D. If water is present, take samples (of the oil water interface if possible) and send to Region approved contractor for analysis to determine if any biological growth is present. Continue samples at each Phase IV Cycle until water is removed. E. Application includes but are not limited to: Fuel Storage Tanks Fuel Settlers Daily Service Tanks Cold Boiler Light-off Emergency Diesel Generator Tank Auxiliary Diesel Generator Tanks Fuel Double Bottoms Fuel Deep Tanks End of Record: Last Update - 05/15/97 25 0185-001-M3-G-V-STW Water Chemical Treatment NOTE: MARAD has instituted a Water Chemical Treatment Program to ensure proper chemical levels are maintained in water systems. ROS Chief Engineers shall be familiar with the aspects of this program as they are dictated in the RRF Fleetwide Water Chemistry and Treatment Program Technical Manual. The ROS Chief Engineer shall maintain and submit records of all water systems' chemistry and treatment per the appropriate Water Chemistry Logs. TASK: Sample and check levels as directed by the Chief Engineer. A. Through the MARAD Water Chemical Treatment Program, the Chief Engineer shall maintain proper chemical levels of all distilled and fresh water systems, active and inactive. B. Upon activating any system, the Chief Engineer shall follow the appropriate procedures to ensure the proper chemicals are acquired and proper dosing is instituted. End of Record: Last Update - 05/15/97 26 0197-001-M1-G-V-STW Log Books (Daily) TASK: Maintain Log Books on all out-ported ships as follows: A. All personnel and visitors shall log themselves on and off the ship. B. Record all draft readings and any change in vessel's position. C. Record description of all work to be performed, number of person(s) and contractor's company name. D. Record all Regulatory reports, inspections or tests, and incidents concerning safety, security and environmental issues. E. Log books shall be forwarded to Region COTR upon request. End of Record: Last Update - 05/15/97 27 0700-001-M1-G-V-STW General Ship Inspection TASK: Visually inspect entire vessel including all cargo holds, machinery spaces, accommodation spaces, steering gear room bridge, and all other spaces. The inspection shall include the following: A. Visually inspect all bilges, bilge-wells, accessible cofferdams, and accessible voids for presence of water, oily wastes, and other liquids. Report presence of same to Chief Engineer and/or Ship's Manager. Test bilge level and flooding alarms including both audio and visual indicators. Sound chain locker as required. THE DISCHARGE TO THE SEA OR OTHER WATERS OF OILS, OILY WASTES, SLUDGES, INDUSTRIAL WASTES, FOOD WASTE, TRASH, AND REFUSE COLLECTED ASHORE OR FROM SHIP IN PORT IS PROHIBITED. ALL OILY WASTES AND OILS SHALL BE STORED AND TRANSFERRED TO PROPER SHORE-SIDE FACILITY FOR PROCESSING. NOTIFY REGION'S SHIP OPERATIONS OFFICER PRIOR TO TRANSFERRING OILS, OILY WASTES, SLUDGES, AND INDUSTRIAL WASTES. B. Visually inspect all accessible sea chests, discharges, and other hull penetrations to ensure they are secured, leak free, structurally sound, and free of defects, damage, and deterioration. C. Check stern tube shaft seal packings for leakage. Check stern tube lube oil head tank for changes in level. Remove water from ship and properly dispose of same when found in shaft alley bilges. If vessel is equipped with and/ bow/thrusters also check head tank levels and quality. D. Ensure all vents, intakes, exhausts, hatches, manholes, portholes, and all other access-ways to the interior of the ship are secured and tightly sealed, unless otherwise required to be open for use BY ROS CREW. This does not apply to tanks containing fluids which expand and contract due to changes in temperature. E. Visually inspect ship's mooring lines and wires for proper arrangement in accordance with the ship's mooring plans, proper tension, proper installation of rat guards, and general condition including defects, damage, and deterioration. F. Measure and record forward and after draft readings. When noticeable change has occurred, inspect all spaces and sound all tanks to determine cause of draft change. Ensure all flooding marks are clearly visible on both port and starboard sides of hull. G. Visually inspect gangway to ensure it is safe and properly secured. H. Visually inspect interior and exterior of vessel for general cleanliness. Remove trash and debris. Clean exterior and interior spaces as required. I. Visually inspect shore power connection. Ensure proper connection of same. Measure and record shore power readings on monthly basis. J. When applicable, visually inspect all stores lockers, valuable lockers, and slop chest to ensure seals are not disturbed and broken. When seals are found to be disturbed or broken, immediately notify COTR. K. Ensure all drains and scuppers are free of debris and all other foreign materials. Remove all standing water as required. L. Check all fire fighting equipment and safety equipment for proper stowage and visually inspect for good operating condition. Fire Control Plan shall be readily visible and posted near gangway. *** This check is to be cursory. Complete inspection per 8101-001-M6-H-V-STW, Fire Fighting Equipment. M. Ensure all heaters used in electrical equipment outside of dehumidified zones and in boilers are functioning. N. Visually inspect all non-sealed exterior watertight doors and gaskets for deterioration and watertight integrity. O. Ship Managers shall conduct and record the general inspection results bi-weekly on all out-ported ships. End of Record: Last Update - 05/15/97 28 0705-001-Y1-G-V-STW Protective Coatings (Hull/Decks/Topsides) TASK: Inspect all painted surfaces of exterior decks, foundations and topside surfaces, for spot corrosion. Prepare and paint all surfaces found to be deteriorated. Wire brush area and utilize coatings suitable for spot work on non-blasted surfaces. Assume approximately 500 sq. ft to be spot repaired annually. End of Record: Last Update - 05/15/97 29 0705-002-Y1-G-V-STW Wood Surfaces Preservation TASK: Inspect all non-painted wood surfaces throughout the vessel for condition. Apply wood oiling/preserving solution to all non-painted wood decks and rails. End of Record: Last Update - 05/15/97 30 1203-001-M6-H-V-STW Hawse Pipe Covers TASK: Visually inspect for defects, damage, and deterioration. Lubricate dogs as required. End of Record: Last Update - 05/15/97 31 1204-001-M6-H-V-STW Chain Pipe Covers TASK: Visually inspect for defects, damage, and deterioration. Lubricate dogs as required. End of Record: Last Update - 05/15/97 32 1255-001-Y1-H-V-STW Sea Sheds TASK: Visually inspect, clean, lubricate, and test all of the onboard sea sheds. A. Clean, lubricate, and free-up all D-rings. B. Clean, lubricate, and free-up all twist locks. C. Megger test winch motors. D. Check oil levels of all winches. E. Power up all winches and operationally test. Grease winch and slush all wires. Inspect wires and winch during operational tests and note all deficiencies. F. Inventory and ensure proper number of lifelines and stanchions are included with each sea shed. G. Clean, lubricate, and free-up all access trunk covers. End of Record: Last Update - 05/15/97 33 1404-001-M1-H-V-STW Toilet and Shower Areas NOTES: 01. ALL DECKS TO CLEAN AND DRY. 02. TO BE PERFORMED ONCE A CYCLE. TASK: Visually inspect, test and maintain decking as follows: A. Inspect tile and grout for damage or deterioration. B. Inspect underlayment in way of any loose or missing tiles. C. Test underlayment by walking and observing any soft areas. D. Inspect and repair, when necessary, any caulked areas with silicone caulking. E. Flush all toilets F. Run water from sinks and showers End of Record: Last Update - 05/15/97 34 1605-001-M6-H-V-STW Hydraulic Watertight Doors TASK: Visually inspect, test, and maintain the forward hydraulic hatch covers: A. Visually inspect all components for excessive wear, defects, and damage. Clean all seating and sealing surfaces, dogs, and wedges free of rust, scale & hardened/dried grease. B. Visually inspect all fasteners for damage, deterioration, and defects. Ensure fasteners are properly and securely fastened. Replace with new, fasteners equal to original as required. Apply proper preservation compound to fasteners as required. Inspect dog linkages, fasteners, pins, etc. to ensure they are connected properly. C. Ensure proper lubrication of all moving parts. Replace with new, all broken and missing grease fittings. Lubricate as required, and hand exercise all mechanical controls and linkages to ensure free and proper operation of same. D. Check hydraulic oil tanks for proper fluid level and quality. Replenish with new oil as required. Prior to operating hand pump, verify hoses and tubing is connected and intact. Ensure doors are free of obstructions. E. Undog/unlock hatch. Exercise door from full closed to full open position, and back to full closed position a total of two (2) cycles. While fully open inspect seals for damage, defects, and deterioration. While exercising door, prove entire hydraulic systems leak free. While doors are open, inspect gasket, seating surfaces and knife edges. Clean rust, scale and dried grease from surfaces. Preserve with fresh grease. F. After completing tests and inspections, grease gasket and close hatch. Ensure tight seals. Lubricate dogs as necessary. G. Secure all components of the hatch and its systems in properly stowed position and condition. Clean area free of oil, grease and debris upon completion. End of Record: Last Update - 05/15/97 35 1612-001-M6-H-V-STW Side Ports - Hydraulic Operated TASK: Visually inspect, test and maintain the hydraulically operated side ports as follows: A. Visually inspect all components for excessive wear, defects, damage, and deterioration. Clean all seating surfaces on dogs and wedges free of rust, scale and dried grease. B. Visually inspect all fasteners for damage, defects, and deterioration. Ensure fasteners are properly and securely fastened. Replace with new, fasteners equal to original, as required. Inspect dog linkages, fasteners, pins, etc. to ensure they are connected properly. Apply proper preservation compound to fasteners as required. C. Ensure proper lubrication of all moving parts. Replace with new, all broken and missing grease fittings. Lubricate as required, and hand exercise all mechanical controls and linkages to ensure free and proper operation of same. D. Check hydraulic oil tanks for proper fluid level and quality. Replenish with new oil as required. Prior to operating hand pump, verify hoses and tubing are connected and intact. Ensure doors are free of obstructions. E. Undog/unlock side ports. Exercise the ports from full closed to full open position, and back to full closed position a total of two (2) cycles. While fully open, inspect the seals for damage, defects, and deterioration. While exercising the door, prove entire hydraulic system is leak free. While doors are open, inspect gasket, seating surfaces and knife edges. Clean rust, scale and dried grease from surfaces. Preserve with fresh grease. F. After completing tests and inspections, grease gasket and close side port. Ensure tight seals. Lubricate dogs as necessary. G. Secure all components of the side port and its systems in properly stowed position and condition. Lock side port in its properly stowed position. Clean area of oil, grease, and debris upon completion. End of Record: Last Update - 05/15/97 36 2030-001-M1-H-V-STW Accommodation Ladder Winches (Operate) TASK: Operationally test the accommodation ladders. Completely cycle the ladder up and down. Re-stow ladder which is not being used to board the vessel. End of Record: Last Update - 05/15/97 37 2030-002-M6-H-V-STW Accommodation Ladder Winches (Inspect/Test) TASK: Visually inspect, test, and maintain the accommodation ladder winches as follows: A. Visually inspect all components of the accommodation ladder winches for excessive wear, damage, deterioration, and other defects. B. Visually inspect all foundation fasteners for damage, deterioration and defects. Ensure fasteners are properly and securely fastened. Replace with new fasteners equal to original as required. Apply proper preservation compound to fasteners as required. C. Lubricate all components as necessary. Check gear sump(s) for proper fluid levels. Replenish with new oil as necessary using Chevron RPM Heavy Duty Motor 15W-40 or equivalent. D. Visually inspect, test, and maintain motor controller(s) as per 6401-001-M6-E-V-STW, Motor Controllers/Control Panels. Megger test electric motor(s). Record megger test results on Megger Report Form. E. Attach weight to bridle or utilize the accommodation ladder. Exercise sheaves by lowering weight to water's edge. Prove satisfactory operation of winch brakes. Hoist weight and repeat process. While performing this task, visually inspect wire rope for excessive wear and defects. Slush wire rope as necessary using proper preservation compound. F. Using the winches, lower and hoist ladders (when ladders are not stowed away). G. Secure accommodation ladder and winches in properly stowed position and condition. End of Record: Last Update - 05/15/97 38 2201-001-M3-H-V-STW Main Steering Gear (Operate) TASK: Operationally test the main steering gear in all modes of operation. A. Energize steering unit. Activate steering control system and rudder angle indicators. Using each steering station, order rudder from hard over to hard over, and back to amidships. Test each steering station using all operating modes. Ensure rudder angle indicators function properly and indicate true position of the rudder. Check helm and rudder angle indicators for proper synchronization. Switch over power to alternate / auxiliary steering unit. Repeat all tests using same. While testing steering gear, prove entire hydraulic systems leak free. B. NFU Controller, move rudder from zero (0) to thirty (30) degrees over on one side, back to zero (0) degrees, and from zero (0) to thirty (30) degrees on the opposite side. Return rudder to amidships position. Note: Steering Gear should be capable of moving the rudder from 35o hardover on one side through 30o on the other side within 27.9 seconds. Note the time it takes to move the rudder in both directions. C. Align steering gear hydraulic system for emergency manual operation using the hand pump. Using hand pump, move rudder from five (5) degrees over on one side to five (5) degrees over on the opposite side. Return rudder to center position. Realign system for normal operation. D. Return entire steering controls, stations, units, circuits, and all other components of the steering systems to "as found" condition. Secure same. End of Record: Last Update - 05/15/97 39 2201-002-M6-H-V-STW Main Steering Gear (Inspect/Test) NOTE: ENSURE AREA IN WAY OF RUDDER IS CLEAR OF ALL DEBRIS AND FLOATING OBJECTS. TASK: Visually inspect and test main steering gear as follows: A. Visually inspect all components of the steering gear, steering systems, and steering controls for excessive wear, damage, deterioration, and other defects. B. Visually inspect all foundation fasteners for damage, deterioration, and defects. Ensure fasteners are properly and securely fastened. Where required, replace with new fasteners equal to original as required. Note: All control linkage fasteners are to be self locking, double nut or drilled and cotter pin installed to prevent the accidental removal of same due to vibration or other causes. Apply proper preservation compound to fasteners as required. C. Lubricate all valve stems as necessary. Operate all valves associated with the steering gear from original position to full open or closed position, and back to original position. D. Check hydraulic oil sumps for proper fluid levels. Draw oil sample. Replenish with new oil as required. Hydraulic Oil: Chevron Turbine Oil GST 68 or equivalent. E. Visually inspect, test, and maintain motor controllers as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels, Motor Controllers/Control Panels.. F. Hand rotate (if possible) and megger test electric motors. Record all megger test results on Megger Report Form. G. Test steering gear failure alarm system. H. Pressure grease lubricate rudder stock as required using proper compound. Chevron Dura-Lith Grease EP 2 or equivalent. I. Energize steering unit. Activate steering control system and rudder angle indicators. Using each steering station, order rudder from hard over to hard over, and back to amidships. Test each steering station using all operating modes. Ensure rudder angle indicators function properly and indicate true position of the rudder. Check helm and rudder angle indicators for proper synchronization. Switch over power to alternate / auxiliary steering unit. Repeat all tests using same. While testing steering gear, prove entire hydraulic systems leak free. J. NFU Controller, move rudder from zero (0) to thirty (30) degrees over on one side, back to zero (0) degrees, and from zero (0) to thirty (30) degrees on the opposite side. Return rudder to amidships position. Note: Steering Gear should be capable of moving the rudder from 35o hardover on one side through 30o on the other side within 27.9 seconds. Note the time it takes to move the rudder in both directions. K. Align steering gear hydraulic system for emergency manual operation using the hand pump. Using hand pump, move rudder from five (5) degrees over on one side to five (5) degrees over on the opposite side. Return rudder to center position. Realign system for normal operation. L. Return entire steering controls, stations, units, circuits, and all other components of the steering systems to "as found" condition. Secure same. M. Apply to rams and follow up gear new preservative equal to original. N. Test means of communication between wheel house and steering gear room in accordance with 6505-001-Y1-E-V-STW, Sound-Powered Telephone System. O. Grease motor coupling as required (if applicable). P. Examine rams for signs of surface rusting. Clean and lubricate with a film of oil as necessary. End of Record: Last Update - 05/15/97 40 2405-001-Y1-H-V-STW Lift Off/Lift On Hatch Covers TASK: Visually inspect all components of the hatch covers for excessive wear, defects, and deterioration. A. Lift each hatch cover using the ship's cranes in order to visually check the hatch cover gaskets, channels, and knife edges. Note all discrepancies. B. Visually check all dogging devices. Inspect the threads on all dogging devices. Rotate the nuts on all dogging devices to ensure the units are not seized. Note all discrepancies. C. Reinstall all hatches and properly secure using all dogging devices. Adjust dogs as necessary to ensure watertight integrity of the hatch covers. D. Enter each cargo hold while the cargo hatches have been installed and secured. With all lights out in the cargo hold, visually inspect the hatch covers to ensure no daylight passes through the hatch cover sealing areas. If light can be seen, attempt to re-adjust the dogging devices. Note all discrepancies which cannot be remedied by simple adjustments of the dogging devices. End of Record: Last Update - 05/15/97 41 2601-001-M6-H-V-STW Mooring Chocks / Roller Fairleads TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect all components of the mooring chocks and roller fairleads for excessive wear, damage, deterioration, and other defects. B. Test each roller chock and roller fairlead for freedom of movement. Free up and lubricate using Chevron Dura-Lith Grease EP 2 or equivalent. Replace with new, all broken and missing grease fittings. End of Record: Last Update - 05/15/97 42 2610-001-M3-H-V-STW Anchor Windlass - Electric Motor (Operate) TASK: Operationally test the anchor windlass. A. Engage windlass and walk anchor and chain out to berth bottom and hoist in. Engage brakes, disengage clutch, cautiously drop using brakes, engage clutch and hoist in. B. Secure all components of the anchor windlass and anchor windlass systems in properly stowed position and condition. De-energize all circuits. Ensure correct operating instructions are posted at each control station. Inspect controls protective covering for weather tightness. End of Record: Last Update - 05/15/97 43 2610-002-M6-H-V-STW Anchor Windlass - Electric Motor (Inspect/Test) TASK: Visually inspect, test, and maintain the combined electric anchor windlass and warping winch as follows: A. Visually inspect all components of the combined anchor windlass and warping winch, including brake bands, adjusting screws and nuts, and brake drums for defects, damage, and deterioration. B. Open electric brake cover and inspect the brake lining and drum for wear. Check magnetic operation and brake adjustment. Check stuffing box and re-seal brake cover. C. Visually inspect all foundation fasteners for damage, deterioration, and defects. Ensure fasteners are properly and securely fastened. Replace with new fasteners equal to original as required. Apply proper preservation compound to fasteners as required. D. Check gear sump for proper lubrication oil level. Replenish with new oil using Chevron Gear Compound EP 220 or equivalent as necessary. E. Replace with new, all missing and broken grease fittings. Lubricate all windlass bearings Using Chevron Dura-Lith Grease EP 2 or equivalent. Ensure proper lubrication of entire anchor windlass in accordance with manufacturer's instructions. F. Lubricate all hand wheels. Operate all hand wheels associated with the anchor windlass from original position to full open or closed position, and back to original position. G. Visually inspect, test, and maintain motor controller(s) as per 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. Megger test electric motors. H. Engage and disengage the wildcat locking devices. I. Set brakes and ensure chain stoppers are in place. Disengage clutches. Energize anchor windlass electric circuits. Test operate the windlass free in each direction for ten (10) minutes. Test operate warping winch for ten (10) minutes in each direction. J. Secure all components of the anchor windlass and anchor windlass systems in properly stowed position and condition. De-energize all circuits. Ensure correct operating instructions are posted at each control station. Inspect controls protective covering for weather tightness. End of Record: Last Update - 05/15/97 44 2614-001-M6-H-V-STW Stern Anchor Jack-Up Mooring Winch TASK: Visually inspect, test, and maintain Stern Anchor Jack-Up Mooring Winch as follows: A. Visually inspect all components of the winch for damage, defects, and deterioration. B. Visually inspect all components of the remote control stand for damage, defects, and deterioration. Clean all components of the remote control stand free of all dirt, debris, and other foreign materials. Lubricate remote control stand shaft and cam as required. (When fitted) C. Visually inspect all foundation fasteners for damage, defects, and deterioration. Ensure fasteners are properly and securely fastened. Replace with new fasteners equal to original as required. Apply proper preservation compound to fasteners as required. D. Visually inspect brake bands, and brake drum for excessive wear, damage, defects, and deterioration. E. Check gear box for proper oil level and quality. Replenish with new oil as necessary. F. Replace with new, all broken and missing grease fittings. Ensure proper lubrication of entire winch, including bearings, couplings, and bushings, in accordance with manufacturer's instructions. G. Visually inspect and check solenoid air Gap and connections for proper tightness. Adjust and tighten same as required in accordance with manufacturer's instructions. H. Visually inspect and check couplings for proper tightness. Adjust and tighten same as required in accordance with manufacturer's instructions. I. Visually inspect, test, and maintain motor controller as 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. Megger test electric motor. J. Operationally test winch in forward and reverse directions, for ten (10) minutes in each direction. K. Payout and visually inspect wire rope for deterioration, damage, and defects. Slush wire rope as necessary using proper preservation compound. Report quantity and type of preservation compound used. L. Secure all components of the winch in properly stowed position and condition. M. Activate winch heater and ensure proper operation of same (When fitted). End of Record: Last Update - 05/15/97 45 2615-001-M6-H-V-STW CT Mooring Winches - Electric (Inspect/Test) TASK: Visually inspect, test, and maintain constant tension winch as follows: A. Visually inspect all components of the constant tension winch for damage, defects, and deterioration. Ensure correct operating instructions are posted at each control station. Inspect controls protective covering for weather tightness. B. Visually inspect all foundation fasteners for damage, deterioration, and defects. Ensure fasteners are properly and securely fastened. Replace with new fasteners equal to original as required. Apply proper preservation compound to fasteners as required. C. Check gear box for proper oil level. Draw oil sample. Replenish with new oil using Chevron Gear Compound 220 or equivalent as necessary. D. Replace with new, all broken and missing grease fittings. Ensure proper lubrication of entire winch, including bearings, in accordance with manufacturer's instructions. E. Visually inspect and test M/G set as per 6101-01-M6-E. F. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels. Megger test direct current electric motor. Record all Megger test results on the Megger Report Form. G. Operationally test mooring winch in forward and reverse directions for ten (10) minutes in each direction. H. Visually inspect wire rope for deterioration, damage, and defects. Slush wire rope as necessary using proper preservation compound. I. Secure all components of the constant tension mooring winches in properly stowed position and condition. End of Record: Last Update - 05/15/97 46 2615-002-M6-H-V-STW CT Mooring Winches - Electric (Operate) TASK: Operationally test the constant tension mooring winches. A. Operationally test mooring winch in forward and reverse directions for ten (10) minutes in each direction. B. Visually inspect wire rope for deterioration, damage, and defects. C. Secure all components of the constant tension mooring winches in properly stowed position and condition. End of Record: Last Update - 05/15/97 47 2620-001-M3-H-V-STW Capstans - Electric (Operate) TASK: Operationally test the capstans. A. Operationally test each capstan in forward and reverse directions for ten (10) minutes in each direction. B. Secure all components of each capstan in properly stowed position and condition. End of Record: Last Update - 05/15/97 48 2620-002-M6-H-V-STW Capstans - Electric (Inspect/Test) TASK: Visually inspect, test, and maintain each capstan as follows: A. Visually inspect all components of the capstans for damage, defects, and deterioration. Ensure correct operating instructions are posted at each control station. Inspect controls protective covering for weather tightness. B. Visually inspect all foundation fasteners for damage, deterioration, and defects. Ensure fasteners are properly and securely fastened. Replace with new fasteners equal to original as required. Apply proper preservation compound to fasteners as required. C. Check gear box for proper oil level. Draw oil sample. Replenish using new oil using Chevron Gear Compound EP 220 or equivalent as necessary. D. Replace with new, all missing and broken grease fittings. Ensure proper lubrication of entire capstan, including all bearings, using Chevron Dura-Lith Grease EP 2 or equivalent. E. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. Hand rotate motor (if possible) and megger test electric motor. Record all megger test results on the Megger Report Form. F. Operationally test each capstan in forward and reverse directions for ten (10) minutes in each direction. G. Secure all components of each capstan in properly stowed position and condition. End of Record: Last Update - 05/15/97 49 2705-001-M3-H-V-STW Pedestal Cranes (Operate) TASK: Operationally test all of the vessel's cargo cranes. CRANES SHALL BE TESTED AND OPERATED IN ACCORDANCE WITH MANUFACTURER'S SAFETY PRECAUTIONS, PROCEDURES, AND INSTRUCTIONS. CRANES SHALL BE OPERATED ONLY BY QUALIFIED AND PROPERLY TRAINED PERSONNEL. A. Test operate cranes through entire range of operating conditions. Test all brakes to ensure safe and free operation of same. Ensure boom is clear of all obstructions. Rotate crane at slew speed through entire operating circle in both clockwise and counterclockwise directions. Slowly raise and lower boom from zero (0) degrees to maximum working boom angle. Use a test load if necessary. CAUTION: DO NOT EXCEED SAFE WORKING LOAD WHEN TESTING CRANES. Check load cells for proper operation. Calibrate same as required. Swing boom outboard of ship. Lower and raise load to and from water's edge. Test brakes while lowering and raising test load. Remove test load. Return cranes to original position and operating condition. B. De-energize and secure all components of the cranes. Preserve and leave cranes in properly stowed position. Ensure cranes are properly sealed, and D/H equipment is installed and operating properly. End of Record: Last Update - 05/15/97 50 2705-002-M3-H-V-STW Pedestal Cranes (Inspect) NOTE: Read and be familiar with equipment technical manuals and Deck Operating Manual (if applicable) prior to operating. The following procedures are provided for initial guidance. Test cranes in conjunction with Auxiliary Diesel Generators (6105-04-M3-E-V-STW, Auxiliary Diesel Generators). For vessels with ROS crews, Ship Manager personnel shall perform the light-off procedures once every three months. TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect all components of the cranes for excessive wear, defects, damage, and deterioration to ensure safe and satisfactory operation before energizing same. Report condition of crane and all deficiencies. Inspection shall include but not be limited to the following: 1. Hoisting hook assemblies. 2. Wire ropes. 3. Boom and hook block pulley assemblies. 4. Boom foot pins. 5. Boom framework. 6. Ladder and guard rails. 7. Hinges and latching mechanisms. 8. Foundation bolts, including crane slew ring bolts, turntable slew ring bolts, and all mounting bolts. 9. Limit switch connections and actuators. 10. Hydraulic hose assemblies. 11. Machine space and boom work lights, fixtures, and brackets. 12. Cabin control and cabin indicator lights. 13. Electrical enclosure heaters. (Ensure heaters are functioning properly). 14. Electrical controls and connections. 15. Window wiper blades. 16. Cab window and air vent latches and hinges. 17. Weathertight door hinges, latching surfaces, and seals. 18. Machine space cooling fans, cab exhaust fan and window wipers. 19. Electrical cables in Crane Machinery Bases and Turntable. 20. Turntable Slew Load Brake and Linings. 21. Crane Slew Load Brake and Linings 22. Rider Block Load Brake and Linings 23. Tagline Load Brake and Linings 24. Hoist Load Brake and Linings 25. Luff Load Brake and Linings 26. Lights and Indicators. 27. Load Cell 28. Slack Line Switch End of Record: Last Update - 05/15/97 51 2705-003-M6-H-V-STW Pedestal Cranes (Lubricate) A. Ensure proper lubrication of entire cranes in accordance with manufacturer's instructions and as follows: NOTE: Refer to Maintenance Chapters of the Manufacturer's Instruction Manual. 1. Lubricate Boom Foot Pin 2. Lubricate Foot Keep 3. Lubricate Turntable Slew Bearing 4. Lubricate Turntable Slew Gearbox Bearings 5. Lubricate Crane Slew Gearbox Bearings 6. Lubricate Crane Slew Bearings 7. Lubricate Slackline Switch Rollers 8. Lubricate Swivel Beam Pulleys 9. Lubricate Rider Block Rollers 10. Lubricate Power Swivel Beam Pins 11. Lubricate Hook Swivel Pin 12. Lubricate Hook Pin and Hook Pin Safety Pin 13. Lubricate Hook Block Swivel Gear Set 14. Lubricate Rider Block Pulley 15. Lubricate Wire Rope Dead End Pivot 16. Lubricate Wire Rope Socket Pivot 17. Lubricate Rope Access Cover Hinges 18. Lubricate Rider Block Drum Shaft 19. Lubricate Tagline Drum Shaft 20. Lubricate Tagline Winch Sheaves 21. Lubricate Tagline Winch Guide Rollers 22. Lubricate Turntable Pinion Gear Teeth 23. Lubricate Turntable Trap Door Hinges 24. Lubricate Turntable Trap Door Handles 25. Lubricate Machinery Base Trap Door Hinges 26. Check Cab A/C Unit for proper operation 27. Lubricate Luff/Slew/Turntable Level Trap Door Hinges 28. Lubricate Crane Slew Ring Teeth 29. Lubricate Crane Slew Pinion Teeth 30. Lubricate Cab Access Door Hinges 31. Lubricate Cab Access Door Latches 32. Lubricate Luff Wire Rope 33. Lubricate Hoist Wire Rope 34. Lubricate Tagline Wire Rope 35. Lubricate Luff/Slew Master Switch 36. Lubricate Hoist Master Switch 37. Lubricate RBTS Foot Switches 38. Lubricate Hoist Winch Bearings 39. Check Turntable Slew Hydraulic Motors for proper operation 40. Check Crane Slew hydraulic motor for proper operation 41. Lubricate Luff Winch Bearings 42. Lubricate Luff End Bracket Bearing 43. Lubricate Flood Light Pivot, Hinges, and Latches 44. Lubricate Equalizing Beam Pivot Pins 45. Lubricate Equalizing Beam Hook Thrust Bearing 46. Lubricate Tagline Motor 47. Lubricate Tagline Support Arm Rod Ends 48. Check oil level in Hoist, Luff, and Slew Hydraulic power unit (74-76) are applicable for electro-Hyd cranes) 49. Check oil cooler and hydraulic hoses 50. Renew lubricant in Crane and Turnable Slew Gear boxes (77-81 are applicable for Electric cranes) 51. Lubricate Window Wiper Arm Shaft, Bushings, and Bearings 52. Lubricate Window Latches and Hinges 53. Lubricate Vent Latches and Hinges 54. Lubricate Window Wiper Ball Bearing B. Replace with new, all broken and missing grease fittings. Clean grease fittings and apply lubricant until visible between faying surfaces. C. Remove and set aside trap door in the center of the turntable which provides one access to turntable slew pinion and slew gear. Visually inspect turntable slew pinion and slew gear for damage, defects, and deterioration. Report all deficiencies. Using a brush or swab, apply lubricant to slew gear and pinion teeth. Rotate twin crane sufficient to cover all working surfaces. Remove excess lubricant. Reinstall trap. D. Lubricate slew gear and pinion as follows: Enter mast through turntable. Using a brush or swab, apply lubricant sufficient to cover all meshing surfaces. Remove excess lubricant. E. Free up and lubricate all access doors, trap doors, windows, hinges, and latches. F. Check hoist, luff, and slew hydraulic units (or if applicable) for proper oil levels and quality. Check RBTS hydraulic power unit for proper oil level (if applicable). Ensure oil is contamination free. Replenish with new oil as required. Report quantity and type of oil used. G. Hand exercise slack wire limit switches (if possible). Prove satisfactory mechanical and electrical operation of same. H. Lubricate as required and hand exercise all mechanical controls and linkages to ensure free and proper operation. I. Visually inspect all rope sheaves for excessive wear, damage, and defects. Report all deficiencies. J. Remove and set aside brake covers. Visually inspect brake linings, discs, shoes, pads, linkages, pivot pins, and all other components of the brakes for irregular and excessive wear, damage, and defects. Check, adjust, and test same in accordance with manufacturer's instructions. K. Visually inspect and test all control circuits in accordance with manufacturer's instructions. Replace with new, all lights and indicators found to be defective and burnt out. Visually inspect, test, and maintain motor controllers in accordance with 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. Megger test electric motors in accordance with manufacturer's guidance. Report all meger test results on the Megger Report Form. CRANES SHALL BE TESTED AND OPERATED IN ACCORDANCE WITH MANUFACTURER'S SAFETY PRECAUTIONS, PROCEDURES, AND INSTRUCTIONS. CRANES SHALL BE OPERATED ONLY BY QUALIFIED AND PROPERLY TRAINED PERSONNEL. L. Payout and visually inspect wire ropes for damage, defects, frays, fishhooks, nicks, corrosion, and other defects. Slush wire ropes as necessary using proper preservation compound. End of Record: Last Update - 05/15/97 52 3401-001-M6-H-V-STW Galley Equipment TASK: Visually inspect and test all galley equipment every 6 months as necessary to ensure proper operation. If ROS Crew is feeding onboard the vessel, only inspect the equipment which is not used on regular basis. Steward shall report all malfunctioning equipment to the Chief Engineer. A. Visually inspect all equipment for damage, defects, and deterioration. Megger test applicable galley equipment. Record all meger test results on the Megger Report Form. B. Test all switches to ensure free and proper operation. C. Open and close doors to ranges and ovens to ensure free and proper operation of hinges. D. Apply electric power to all heating elements. Ensure proper operation of same. E. Operationally test mixer, peeler, slicer, and all other equipment. Ensure proper operation of same. End of Record: Last Update - 05/15/97 53 3407-001-Y1-H-V-STW Refrigerators TASK: Operationally test refrigerators and ice machines in the galley, crew, and officer pantries. Ensure proper operation of same. After completing tests, secure same. Leave refrigerator doors blocked open and supported underneath. Blow out condenser coils with compressed air. Note: If ROS Crew is feeding onboard the vessel, only inspect the equipment which is not used on regular basis. Steward shall report all malfunctioning equipment to the Chief Engineer. End of Record: Last Update - 05/15/97 54 3411-001-M6-H-V-STW Laundry Equipment TASK: Megger test all washer and dryer motors. Record all megger test results on the Megger Report Form. Operationally test and ensure proper operation of laundry equipment. End of Record: Last Update - 05/15/97 55 3801-001-M6-H-V-STW Ventilation Fans NOTE: DO NOT BREAK ANY DEHUMIDIFICATION SEALS OR SEALING MATERIAL TO PERFORM THIS TASK. DO NOT PERFORM THIS TASK WHERE IT REQUIRES BREAKING OF SEALS/SEALING MATERIAL IN ORDER TO BE PERFORMED. IF THE VESSEL IS AN ROS SHIP, DEHUMIDIFICATION SEALS MAY NOT EXIST ON ALL VENTILATION OPENINGS. TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect all components of the ventilation fans for excessive wear, damage, defects, and deterioration. B. Lubricate all components as required. C. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. D. Hand rotate (if possible) and megger test electric motor. Record all megger test results on the Megger Report Form. E. Activate each fan motor for time period sufficient to cycle through controller speeds and not to exceed five (5) seconds. F. Inspect all evaporator coils and preheater units. Check all dampers and any corresponding controls. G. Report to COTR all fans (location, service, etc.) where the foregoing cannot be carried out. End of Record: Last Update - 05/15/97 56 3820-001-M6-H-V-STW Intake and Exhaust Ducts/Openings TASK: Visually inspect all intake and exhaust openings for defective, damaged, and deteriorated covers, gaskets, and securements. Lubricate wing nuts and dogs as applicable. End of Record: Last Update - 05/15/97 57 3831-001-M6-H-V-STW Fire Dampers NOTE: DO NOT BREAK ANY SEALS OR SEALING MATERIAL TO PERFORM THIS TASK. FIRE DAMPERS LOCATED IN LOCATIONS AND VENTILATION SYSTEMS SECURED AND SEALED FOR DEHUMIDIFICATION PURPOSES SHALL NOT BE EXERCISED. TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect all fire dampers for excessive wear, damage, defects, and deterioration. B. Lubricate as required and hand exercise all fire dampers. C. Ensure fire dampers are properly labeled in accordance with the requirements of the regulatory bodies. D. Report to COTR all fire dampers (location, service, etc.) where the foregoing cannot be carried out. End of Record: Last Update - 05/15/97 58 4020-001-M1-E-V-STW Emergency Diesel Generator (Operate) TASK: Operationally test the emergency diesel generator. ROS crew shall operationally test the emergency diesel generator under load for approximately two hours. Shut down and secure the generator upon completion of test. End of Record: Last Update - 05/15/97 59 4020-002-M6-E-V-STW Emergency Diesel Generator (Inspect/Test) NOTE: EMERGENCY DIESEL GENERATOR SET SHALL BE MAINTAINED OPERABLE, AND LEFT IN READY TO USE CONDITION AT ALL TIMES. ENSURE THAT SHORE POWER AND BUS TIE BREAKERS ARE OPEN BEFORE STWRTING GENERATOR. TASK: Visually inspect, test and maintain this equipment as follows: A. Lubricate diesel engine and generator as per the lubrication and service requirements as specified in the manufacturer's maintenance manual. Check oil in sump For proper fluid level and quality. Replenish with new oil as required using Chevron Delo 6170 Oil 40 ore equivalent. B. Ensure sufficient quantity and quality of fuel is available in emergency diesel generator tank to test generator as required and to maintain fuel system in a primed condition. When storing fuel, provide and add an approved additive to fuel to inhibit biological growth. Follow manufacturer's instructions when adding same to fuel. C. Ensure sufficient quantity and quality of coolant is available in engine and coolant system to safely and properly operate engine. Ensure coolant contains proper quality and quantity of anti freeze and corrosion inhibitor as recommended by the engine manufacturer for the geographical area in which the vessel is moored. Place tag on engine cooling system with the following information: Date coolant/anti freeze replenished, type (Name of brand), quantity used, and replenished by whom. D. Ensure emergency generator room is adequately ventilated. Remove and set aside ventilation system seals and blanks as required. After completing tests, reinstall and renew as necessary emergency generator room ventilation blanks and seals. E. Visually inspect, test, and maintain starting batteries (if applicable). F. Remove and set aside exhaust and air intake duct blanks (when fitted). G. Remove and set aside engine exhaust pipe plug and cover (when fitted). H. Clean fuel, oil, and air filters as per manufacturer's recommendations and recommended time intervals. Replace with new fuel, oil, and air filters as required. I. Test operate inlet and exhaust cooling air louvers using both manual and automatic modes (when fitted). J. Megger test electric generator using manufacturer's guidelines. Ensure solid state devices are isolated from high voltage generated during megger test. Record all megger test results on the Megger Report Form. K. Inspect hydraulic start system. Maintain hydraulic oil levels and quality. Replenish with new oil as necessary. L. Start diesel engine manually; allow diesel engine to reach steady state operating conditions prior to additional testing and loading. Provide power to emergency switchboard for 1/2 hour. Stop diesel engine. M. Start diesel engine using automatic mode and ensure automatic transfer of power to emergency switchboard properly occurs. Place load on emergency generator and emergency switchboard. Secure load. N. Operationally test overspeed trip with hand held tachometer using extreme caution. Be ready to manually shutdown engine if necessary. Operationally test manual trips and emergency alarms where feasible. O. Ensure all gauges and thermocouple function properly. Visually inspect gauges for damage and defects. P. Secure diesel engine. Reinstall all plugs and covers. Use new sealant as required. Q. Enter into ships log the time and date the emergency diesel generator was operated. Note any deficiencies. End of Record: Last Update - 05/15/97 60 4035-001-M6-E-V-STW Auxiliary Diesel Generators NOTE: THIS TASK IS FOR SELECT VESSELS WITH DIESEL GENERATOR SETS LEFT IN AN OPERABLE, READY TO USE CONDITION AND COOLING SYSTEM AVAILABLE. READ AND BE FAMILIAR WITH TECHNICAL MANUAL PRIOR TO OPERATING. TASK: Visually inspect, test and maintain this equipment as follows: A. Lubricate diesel engine and generator as per the lubrication and service requirements as specified in the manufacturer's maintenance manual. Check oil in sump for proper fluid level and quality. Replenish with new oil as necessary using Chevron Delo 6170 Oil 40 or equivalent. B. Ensure sufficient quantity of purified fuel is available in diesel generator tank to test generator as required and to maintain fuel system in a primed condition. When storing fuel, provide and add approved additive to fuel to inhibit biological growth. Follow manufacturer's instructions when adding same to fuel. C. Ensure sufficient quantity of coolant is available in engine and coolant system to safely and properly operate engine. Ensure coolant contains proper quantity and quality of anti-freeze and corrosion inhibitor as recommended by the engine manufacturer for the geographical area at which the vessel is moored. Place a tag on the engine cooling system with the following information: Date coolant/anti-freeze replenished, type {name of brand}, quantity used, and replenished by whom. D. Remove and set aside exhaust and air intake duct blanks (when fitted). E. Remove and set aside engine exhaust pipe plug and cover. F. Clean fuel, oil, and air filters as per manufacturer's recommendations and recommended time intervals. Replace with new fuel, oil, and air filters as required. G. Test operate inlet and exhaust cooling air louvers using both manual and automatic modes (when fitted). H. Visually inspect, test, and maintain pre-lube pump and crankcase blower motor controllers. Hand rotate (if possible) and megger test electric motors. Record all megger test results on the Megger Report Form. I. Ensure engine room is properly ventilated to supply engine combustion air and safely operate engine. J. Activate pre-lube and pre-heat system. Activate crankcase blower (if applicable), fuel and cooling systems (if applicable). Visually inspect engine components for proper lubrication. K. Start diesel engine using starting air system. Allow diesel engine to reach steady state operating conditions prior to additional testing and loading. Test operate engine and generator for one-half (1/2) hour using no load. Ensure all circuit breakers connecting switchboard to all machinery, circuits, and controls are open/off. Place load on engine and generator using ship's lighting system or other load. L. Test over-speed trip (using extreme caution) and test manual trips. Test emergency alarms where feasible. Test all control circuits, remote starting systems, and remote shut-off systems. M. Ensure all gauges and thermocouples function properly. Visually inspect gauges for damage and defects. N. Secure diesel engine. Secure pre-lube pump, crankcase blower, and cooling system. Re-install all plugs and covers. Use new sealant as required. Secure ventilation systems and seals as necessary. Drain all secondary cooling water systems and leave open. Clean fuel and lube oil filters. End of Record: Last Update - 05/15/97 61 4101-001-M6-M-V-STW Main Propulsion Turbines NOTE: BEFORE ROTATING THE SHAFT, ENSURE AREA IN WAY OF PROPELLER IS FREE AND CLEAR OF ALL DEBRIS AND FLOATING OBJECTS. Accomplish this task in conjunction with inspection and testing of lube oil pumps, lube oil systems, and 4405-001-M6-M-V-STW, Propellers- Solid/Fixed Pitch as applicable. Prior to rotating main engines, gears, and shafting, test operate lube oil system and circulate lube oil through system while bypassing main engine, gears, and shafting. Ensure lubricant quality is within allowable use limits as determined by main propulsion equipment manufacturers. ALL BEARING OIL SIGHTS/BUBBLERS MUST BE CHECKED FOR SUFFICIENT OIL FLOW PRIOR TO PROCEEDING WITH THIS TASK. DO NOT ACCOMPLISH THIS TASK IF LUBE OIL TEMPERATURE IS BELOW 45 DEGREES (F). IF LUBE OIL TEMPERATURE IS BELOW 45 DEGREES, HEAT THE OIL UTILIZING THE INSTWLLED ELECTRIC LUBE OIL HEATER OR ELECTRIC PURIFIER HEATER. Draw oil samples for all lube oil systems affected by this task. TASK: Visually inspect, test and maintain this equipment as follows: A. Disconnect, remove, and set aside tailshaft locks which are fitted in shaft alley. Leave tailshaft lock disconnected. Before towing ship, ensure lock is reinstalled. B. Remove and set aside all lube oil systems strainer covers. Visually inspect strainers for damage, defects, and deterioration. Clean strainers, removing all dirt, debris, lint, and other foreign materials. Reinstall strainers and reassemble strainers equal to original. Align strainers for normal and proper operation. C. Check oil level in main sump tanks for proper fluid level and quality. Ensure oil level is just below rim of bull gear to prevent oil foaming. Activate the main lube oil systems. Ensure adequate supply of lube oil to turbines, bearings and gears. Check sight flows and pressure gages to ensure proper oil flow to each bearing. D. Drain one-half (1/2) gallon of lube oil from sump of each line shaft bearing. Lubricate shaft in each bearing housing with same. Replenish line shaft bearing sumps oil as necessary. While rotating shafting, visually inspect bearing surfaces for defects, damage, and deterioration. E. Visually inspect, test, and maintain turning gear motor controllers as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. Hand rotate (if possible) and megger test electric motors. Record all megger test results on the Megger Report Form. F. Check stern tube oil supply and sump tanks for proper fluid levels and quality. Replenish with new oil using Chevron Turbine Oil GST 100 or equivalent as necessary. G. Visually inspect, test and maintain stern lube oil pump as per 6301-01-M6-E-V-STW, Electric Motors. Hand rotate (If applicable) and megger test motor. Record all megger test results on the Megger Report Form. H. Activate stern tube lube oil system. I. Disengage lock on turning gear. Engage turning gear motors and start same. Rotate main shafts one and one-fourth (1-1/4) revolutions. J. De-energize and disengage shaft turning gear motors. K. Secure main lube oil systems equal to original. End of Record: Last Update - 05/15/97 62 4201-001-M6-M-V-STW Main Propulsion Reduction Gears TASK: Prepare and operate in accordance with 4001-01-M6-M, 4002-01-M6-M or 4101-01-M6-M-V-STW as applicable. End of Record: Last Update - 05/15/97 63 4301-001-M6-M-V-STW Line Shafting and Bearings TASK: Prepare and operate in accordance with 4001-01-M6-M, 4002-01-M6-M or 4101-01-M6-M-V-STW as applicable. End of Record: Last Update - 05/15/97 64 4405-001-M6-M-V-STW Propellers - Solid / Fixed Pitch NOTE: Perform this task in conjunction with 4001-01-M6-M, 4002-01-M6-M or 4101-01-M6-M-V-STW as applicable. TASK: When rotating shafting and when blade(s) become visible above water, visually inspect propeller blades for defects and damage. Report condition of propeller to the port engineer. End of Record: Last Update - 05/15/97 65 4705-001-W2-M-V-STW Pump, Fire (Operate) UNIT(S): As directed by Chief Engineer. NOTE: Pumps with mechanical seals must not be activated without containing system fluid. TASK: Once every two weeks, in conjunction with fire and boat drill, visually inspect, test, and maintain Fire pumps as follows: A. Visually inspect, test, and maintain motor controller as scheduled per ROS RMA Item 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. Inspect, test, and maintain motor as scheduled per ROS RMA Item 6301-001-M6-E-V-STW, Electric Motors. For vessels outfitted with diesel powered fire pumps, refer to ROS RMA Items 4020-001-M6-V-STW, Emergency Diesel Generator for applicable diesel engine maintenance and testing. B. Ensure all plugs are in pump. Lubricate valve stems as required and manually operate all valves associated with pumps from original position to full open, to full closed position and return to original position. Cycle valves one (1) complete cycle. C. Ensure suction and discharge valves are opened. Line up discharge to fire main. Take suction from sea water manifold. Ensure "bleeder" stations are open on deck fire stations. D. Start pump from all local and remote locations. Inspect for proper operation. Ensure vacuum is pulled with pump and that discharge pressure is built up. Listen for abnormal bearing sounds. Visually inspect all gauges for damage and defects. Ensure run/stop indicator lights function properly. E. At completion, close all valves and secure sealing water to Pumps. Secure Power to Controller. F. Note - If the ship is outfitted with more than one fire pump, a different fire pump will be used for each test cycle; the idea being to regularly start and test all of the ship's fire pumps. End of Record: Last Update - 05/15/97 66 4705-001-W2-M-V-STW Pump, Fire (Operate) UNIT(S): As directed by Chief Engineer. NOTE: Pumps with mechanical seals must not be activated without containing system fluid. TASK: Once every two weeks, in conjunction with fire and boat drill, visually inspect, test, and maintain Fire pumps as follows: A. Visually inspect, test, and maintain motor controller as scheduled per ROS RMA Item 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. Inspect, test, and maintain motor as scheduled per ROS RMA Item 6301-001-M6-E-V-STW, Electric Motors. For vessels outfitted with diesel powered fire pumps, refer to ROS RMA Items 4020-001-M6-V-STW, Emergency Diesel Generator for applicable diesel engine maintenance and testing. B. Ensure all plugs are in pump. Lubricate valve stems as required and manually operate all valves associated with pumps from original position to full open, to full closed position and return to original position. Cycle valves one (1) complete cycle. C. Ensure suction and discharge valves are opened. Line up discharge to fire main. Take suction from sea water manifold. Ensure "bleeder" stations are open on deck fire stations. D. Start pump from all local and remote locations. Inspect for proper operation. Ensure vacuum is pulled with pump and that discharge pressure is built up. Listen for abnormal bearing sounds. Visually inspect all gauges for damage and defects. Ensure run/stop indicator lights function properly. E. At completion, close all valves and secure sealing water to Pumps. Secure Power to Controller. F. Note - If the ship is outfitted with more than one fire pump, a different fire pump will be used for each test cycle; the idea being to regularly start and test all of the ship's fire pumps. End of Record: Last Update - 05/15/97 67 4705-002-M6-M-V-STW Centrifugal Pumps - Motor Driven NOTE: PUMPS WITH MECHANICAL SEALS MUST NOT BE ACTIVATED WITHOUT CONTAINING SYSTEM FLUID. TASK: Visually inspect, test, and maintain all motor driven pumps (AS SPECIFIED BY CHIEF ENGINEER) as follows: A. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. B. Hand rotate pumps and motors to ensure free operation. C. Megger test electric motors. Record all megger test results on the Megger Report Form. D. If pump/motor couplings are connected and no operating fluid is in system do not run. E. If pump/motor couplings are disconnected, activate motors, and run motors for period of time sufficient to ensure proper operation. Ensure run/stop indicator lights function properly. F. Visually inspect all gauges for damage and defects. G. Lubricate valve stems as required and manually operate all valves associated with pumps from original position to full open or full closed position and return to original position. Cycle valves one (1) complete cycle. End of Record: Last Update - 05/15/97 68 4705-003-M6-M-V-STW Pump, Main Feed - Turbine Driven (Inspect) UNIT(S): MAIN FEED PUMPS TASK: At LEAST every six months, visually inspect Main Feed Pumps as follows: A. Check oil sump for proper fluid level. Draw oil from sump drain to check for water. Replenish with new oil as necessary per manufacturer's specifications. B. Covers are left open on the Turbine end of units. Operate electric Oil pumps on each unit, if applicable. Hand rotate the turbine and pump shaft sufficiently to ensure free operation. C. Lubricate as required, and hand rotate the hand wheels of all manually operated suction, discharge, supply, exhaust, and drain valves from original position to full open, to full closed position, and back to original position. D. Inspect seals on the pump and turbine. E. Visually inspect gauges for defects, damage, and deterioration. End of Record: Last Update - 05/15/97 69 4710-001-M6-M-V-STW Rotary Pumps - Motor Driven NOTE: PUMPS WITH MECHANICAL SEALS MUST NOT BE ACTIVATED WITHOUT CONTAINING SYSTEM FLUID. TASK: Visually inspect, test, and maintain all motor driven pumps (AS SPECIFIED BY CHIEF ENGINEER) as follows: A. Visually inspect, test, and maintain motor controllers as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. B. Hand rotate pumps and motors to ensure free operation. C. Megger test electric motors. Record all megger test results on the Megger Report Form. D. If pump/motor couplings are connected do not run. E. If pump/motor couplings are disconnected, activate motors, and run motors for period of time sufficient to ensure proper operation. Ensure run/stop indicator lights function properly. F. Visually inspect all gauges for damage and defects. G. Lubricate valve stems as required and manually operate all valves associated with pumps from original position to full open or full closed position and return to original position. Cycle valves one (1) complete cycle. End of Record: Last Update - 05/15/97 70 4730-001-M6-M-V-STW Reciprocating Pumps TASK: Visually inspect and maintain pumps SPECIFIED BY CHIEF ENGINEER (including liquid and steam or air ends) as follows: A. Visually inspect all components for excessive wear, damage, and defects. B. Replace with new, all broken and missing grease fittings. C. Ensure proper lubrication of entire pump as per manufacturer's instructions. D. Replace with new piston and valve packing if necessary. E. Open all drain valves. Lightly spray lubricant into steam and pump cylinders through drain openings. Leave drains open. Open cylinder heads and lubricate from there if drains will not provide adequate lubricating access. Reinstall head covers and gaskets. F. Ensure all pistons move freely. Using suitable method, move pistons one stroke. Provide and install as necessary: wooden blocks under cross-heads to prevent pistons and rods from falling to bottom position. Fabricate four (4) additional 2" by 4" wooden blocks of various lengths. Use blocks to leave pistons in different positions after each test and inspection. CAUTION: WHEN USING AIR TO DISPLACE PUMP PISTONS, DO NOT EXCEED NORMAL STEAM OPERATING PRESSURE. NOTE: Use moisture separator between air compressor and pump when using air to displace pistons. G. Lubricate as required, and manually operate all pump valves. Operate valves from full closed to full open, and then back to original position. End of Record: Last Update - 05/15/97 71 4806-001-Y1-M-V-STW Flexible Rubber Expansion Joints Task: Visually inspect all flexible rubber pipe joints and expansion joints for signs of dry-rot, external damage or deterioration. Note date stamp on flexible joints, ensure less than ten years, ensure no painting, and ensure correct bonding straps. Report any deficiencies to the port engineer. End of Record: Last Update - 05/15/97 72 4820-001-M6-M-V-STW Manually Operated Valves NOTE: VALVES THAT ARE WIRED CLOSED AND VALVES THAT ARE CHAINED CLOSED SHALL NOT BE EXERCISED. TASK: Visually inspect, test and maintain this equipment as follows: A. Inspect the valves not otherwise specified in these instructions for damage or defects (except those in the locked hotel spaces). Lubricate valves as required and hand rotate from full closed to full open and back to original position. All weather deck valves and all main steam, auxiliary steam, exhaust steam, and bleed steam valves shall be exercised at each phase IV period. Valves locally associated with pumps or specific pieces of equipment mentioned in this manual shall be exercised in conjunction with that equipment. Hydraulic system valves shall be exercised with their respective hydraulic systems. Defective valves shall be corrected or tagged and recorded, including system and shipboard location. Survey all valve label plates and record deficiencies accordingly. End of Record: Last Update - 05/15/97 73 4827-001-M6-M-V-STW Motor Operated Valves NOTE: VALVES THAT ARE WIRED CLOSED AND VALVES THAT ARE CHAINED CLOSED SHALL NOT BE EXERCISED. TASK: Visually inspect, test and maintain this equipment as follows: A. Exercise all valves from full open to full closed, and back to original position using local manual operator. Lubricate valve stems as required. B. Visually inspect, test, and maintain motor controllers as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. C. Hand rotate (if possible) and megger test electric motors. D. Ensure gear limit switch is properly adjusted for motorized operation. Energize all valve control systems and cycle all valves from full closed to full open, and back to original position. Ensure valve position indicators and indicator lights function properly. Secure all control systems equal to original. Also exercise valves from remote actuators if applicable. End of Record: Last Update - 05/15/97 74 4905-001-M1-M-V-STW Air Compressors, Start Air (Inspect /Test) UNIT(S): CRANE DIESELS NOTES: Conduct this maintenance action in conjunction with ROS RMA Item 4005-(001 through 004), as applicable. TASK: Once every month, or as noted, visually inspect, test and maintain this equipment as follows: A. Inspect and maintain compressor and air tank drain separator traps for proper function. B. Visually inspect, test, and maintain motor controller as scheduled per ROS RMA Item 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. Inspect, test, and maintain motors as scheduled per ROS RMA Item 6301-001-M6-E-V-STW, Electric Motors. C. Inspect couplings or drive belts for cracks, deterioration, uneven, or excessive wear. Ensure belts are aligned per manufacturers specifications. Replace all belts in a set if one is worn. Ensure guards are properly in place. D. Inspect unloader solenoids, pressure switches, wiring, and fittings for proper operation and good order. Ensure compressor discharge line check valve is in good order. Sample compressor oil using "clear and bright" method. E. Maintain cooling water side as per manufacturers recommendations. F. Activate air systems. Ensure automatic and standby start functions perform properly. Prove satisfactory operation of entire air system. Operate systems using all modes. Ensure gauges function properly, noting normal operating pressures and temperatures. Adjust pneumatic controls as necessary. G. Every 200 Hours of service, or as manufacturer specifies, complete the following: 1. Secure and tagout power to the compressor. Drain oil from the compressor crankcase. 2. Open crankcase covers and wipe sump clean. If crankcase is inaccessible, flush unit. 3. Visually inspect condition of oil intake filter. Clean or replace as necessary. Use only lint-free cloth when servicing air compressor. 4. Inspect condition of crankcase cover gasket and replace as necessary. Replace crankcase cover. 5. Refill crankcase with oil per manufacture's specifications. 6. Clean and inspect air filter. Replace as necessary. End of Record: Last Update - 05/15/97 75 4905-002-M6-M-V-STW SS Air Compressors / Systems TASK: Visually inspect, test and maintain this equipment as follows: A. If applicable, close all valves, piping, fittings, and inspection covers in the ship service air system, which were opened for draining and D/H purposes. B. Check filters and filter/dehydrators. Replace with new filters as required. Check system lubricators and add oil as required. C. If compressor requires water for cooling, perform one time decoupling and just run motor. Place removed fasteners in bag and attach to compressor. If compressor does not require water for cooling or sealing, proceed with following: Recouple non-water cooled compressor if previously de-coupled. Check compressor oil level and fill as required. D. Visually inspect, test, and maintain motor controller(s) as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. E. Hand rotate (if possible) and megger test electric motor(s). Record all megger test results on the Megger Report Form. F. Hand rotate air compressor at flywheel (If possible) to ensure free operation. G. Visually inspect control air receiver and clean out any debris. Temporarily close receiver manhole and ensure entire air system is ready for operation. Open control air system valves necessary to place receiver in service. H. Activate air systems. Ensure automatic and standby start functions perform properly. Prove satisfactory operation of entire air system. Operate systems using all modes. Ensure gauges function properly. Adjust pneumatic controls as necessary. Exercise system valves in accordance with 4820-01-M6-M-V-STW, Manually Operated Valves. I. Secure all components of the compressed air systems including air compressors, valves, controls, and all other components of the air systems. For non-ROS ships, re-open all system drains and fittings and re-open receiver manhole for DH purposes. End of Record: Last Update - 05/15/97 76 4905-003-M6-M-V-STW Control Air Compressors / Systems TASK: Visually inspect, test and maintain this equipment as follows: A. If applicable, close all necessary valves, piping, fittings, and inspection covers in the control air system, which were opened for draining and D/H purposes. B. Check control air refrigerant filter type dehydrator. If air cooled, provide power and operationally test. If water cooled, do not activate. C. If compressor does not require water for cooling or sealing, proceed with following: Recouple non-water cooled compressor if previously de-coupled. Check compressor oil level and fill as required using Chevron Delo 1000 Marine 30 or equivalent. D. Replace system filters (including branch lines) and filter/dryers with new filters as required. Inspect oil coalescer filter, if installed. E. Visually inspect, test, and maintain motor controller(s) as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW, Motor Controllers/Control Panels.. F. Hand rotate (if possible) and megger test electric motor(s). Record all megger test results on the Megger Report Form. G. Hand rotate air compressor at flywheel, if possible, to ensure free operation. H. Visually inspect control air receiver and clean out any debris. Temporarily close receiver manhole and ensure entire air system is ready for operation. Open control air system valves necessary to place receiver in service. I. Activate air system and commence pumping of receiver. Ensure automatic and standby start functions function properly. Prove satisfactory operation. Ensure gauges function properly. Adjust pneumatic controls and as necessary. J. Exercise system valves in accordance with 4820-001-M6-M-V-STW, Manually Operated Valves. K. Secure all components of the compressed air systems including air compressors, valves, controls, and all other components of the air systems. For non-ROS ships, Re-open system drains and fittings for DH purposes and re-open receiver manhole. Drain condensate from refrigi-filter. L. Report all deficiencies to port engineer. End of Record: Last Update - 05/15/97 77 4905-004-M6-M-V-STW Emergency Air Compressors/Systems TASK: Visually inspect, test and maintain this equipment as follows: A. Close all valves, piping, fittings, and inspection covers in the ship service air system, which were opened for draining and D/H purposes. B. Check filters and filter/dehydrators. Replace with new filters as required. Check system lubricators and add oil as required. C. Recouple compressor if previously de-coupled. Check compressor oil level and fill as required. D. Visually inspect, test, and maintain motor controller(s) as per 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. E. Hand rotate (if possible) and megger test electric motor(s). F. Hand rotate air compressor at flywheel (If possible) to ensure free operation. G. Visually inspect control air receiver and clean out any debris. Temporarily close receiver manhole and ensure entire air system is ready for operation. Open control air system valves necessary to place receiver in service. H. Activate air systems. Ensure automatic and standby start functions perform properly. Prove satisfactory operation of entire air system. Operate systems using all modes. Ensure gauges function properly. Adjust pneumatic controls as necessary. Exercise system valves in accordance with 4820-001-M6-M-V-STW, Manually Operated Valves.. I. Secure all components of the compressed air systems including air compressors, valves, controls, and all other components of the air systems. Re-open all system drains and fittings and re-open receiver manhole for DH purposes. J. Report all deficiencies to Chief Engineer and/or Ship's Manager. End of Record: Last Update - 05/15/97 78 5005-001-Y1-E-V-STW Ship's Service Turbine Generators NOTE: Be familiar with technical manuals prior to exercising. TASK: Visually inspect, test and maintain this equipment as follows: A. Remove and set aside all lube oil systems strainer covers. Visually inspect strainers for damage, defects, and deterioration. Clean strainers, removing all dirt, debris, lint, and other foreign materials. Reinstall strainers and reassemble strainers equal to original. Align strainers for normal and proper operation. B. Activate and ensure proper lubrication of entire SSTG set. Check oil sump for proper fluid level. Draw oil sample. Replenish with new oil as required using Chevron Turbine Oil GST 100 or equivalent. C. Hand rotate generator and turbine using suitable method. While performing this step, ensure adequate lubrication of generator and turbine. D. Test operate oil failure throttle trip and emergency shutdown trips to ensure proper operation. E. Rotate all associated valves (except Lube Oil Sump Drain Valve) from "as found" position to full open position, to full closed, and back to original position. End of Record: Last Update - 05/15/97 79 5101-001-M6-M-V-STW Propulsion Boilers (Wet Lay-Up) TASK: Temporarily remove (and later reinstall) covers and inspect boiler firesides to the extent that would ensure safe, reliable, and proper operation. Inspection shall include, but not be limited to the following: ECONOMIZERS SUPERHEATERS SOOT BLOWERS FIRESIDES (INCLUDING BRICKWORK) CASINGS REFRACTORY AIR HEATERS HEADERS AIR REGISTERS A. Measure and record relative humidity values in the furnace and superheater cavities. B. Hand exercise air registers. C. Inspect and test operate installed lay-up heaters and fans. D. Ensure proper lubrication of all soot blowers. Check "oilers" (bubblers) for proper fluid level. Replenish with new oil as required. E. Using Ship's Service Air, operate all soot blowers through entire blowing cycle. F. If possible: Open, close, and return to "as found" position: all primary and secondary valves associated with the boiler. Lubricate valve stems as required using high temperature lubricant. G. (If applicable) Visually inspect, test, and maintain air heater motor controllers as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels-V-STW. Megger test air heater motors. Test motors for proper operation. Ensure adequate lubrication. H. Inspect drums and headers to the extent to determine if any external leakage is occurring. I. Inspect casings and windboxes for rust and failing paint or debris. J. Inspect stack cover to determine if in place and intact. K. Check uptakes and smoke pipes for moisture, rust and soot. Ensure access covers are resealed after inspection. L. Check and ensure all air exit and inlet adapters are in place. M. Check that hoses and duct work from the heater to the boiler are intact. N. Check and clean heater inlet filters. O. Clean the heater fan and heater element. P. If installed, check all safety valve seals. If not installed verify that valves are stored and protected from moisture. Q. Inspect furnace linings and refractories for cracking and moisture. R. Open inner and outer casing doors as necessary to check the external condition of tubes, drums, and headers. Remove and loose soot accumulations that may have collected. If firesides have been treated with a fireside conditioning compound, it may be tacky to the touch. Inspect tube ends for any sign of increased fireside corrosion. S. Verify that fireside and waterside conditions are stable and corrosion or deterioration of metal surfaces is not progressing. T. Restore wet lay-up as original. End of Record: Last Update - 05/15/97 80 5140-001-M3-M-V-STW Soot Blowers (Inspect/Test) UNIT(S): All blowers on both boilers. TASK: Once every three months, operate and inspect all soot blowers in accordance with the manufacturers maintenance manual. A. Operate and inspect all soot blowers to the maximum extent possible without steam. Ensure all oil lubricators are full and operating. Inspect all air lines for leaks. Test from each console board for remote operation. B. Ensure rollers on retractable units are turning and are well lubricated. Note any items that need service. End of Record: Last Update - 05/15/97 81 5310-001-M6-M-V-STW Forced Draft Blowers Motor Driven TASK: Visually inspect, test, and maintain forced draft fans as follows: A. Ensure proper lubrication of entire forced draft fan and motor. B. Hand rotate fans and motors to ensure free operation. C. Open and close fan dampers and crossover dampers in fan discharge duct. Lubricate dampers as required (when fitted). D. Visually inspect, test, and maintain motor controllers as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. Megger test electric motors. Record all megger test results on the Megger Report Form. E. Activate the blower motors and test run at all speeds for ten minutes to ensure proper operation, no vibration and no unusual noise. F. Secure all components of the forced draft fans and motors as original. End of Record: Last Update - 05/15/97 82 5315-001-M6-M-V-STW Gland Exhaust Fan TASK: Visually inspect, test, and maintain gland exhaust fans as follows: A. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. B. Hand rotate (if possible) and megger test electric motor. Record all megger test results on the Megger Report Form. C. Activate fan motor for time period sufficient to ensure proper operation. End of Record: Last Update - 05/15/97 83 5406-001-Y1-M-V-STW Air Receivers (Test) SYSTEM(S): As directed by the Chief Engineer. TASK: Once every year, in conjunction with the ABS/USCG mid-term or biennial COI inspection, air receivers will be opened, cleaned, inspected, and tested. Relief valves will be tested. End of Record: Last Update - 05/15/97 84 5701-001-M3-M-V-STW Lube Oil Purifiers (Test) UNIT(S): Lube oil purifier TASK: Once every month, operate lube oil purifier(s) to accomplish periodic purification of engine room lube oil sumps, as follows: NOTE: Operation of the lube oil purifiers and purification of engine room machinery sumps, ROS RMA Item 5701-001-W1-M, shall be recorded in the ship's Lube Oil Purification Log by the ROS Chief Engineer. Refer to ROS RMA Item 0702-001-DY-G A. Visually inspect, test, and maintain motor controller as scheduled per ROS RMA Item 6401-001-M6-E. Inspect, test, and maintain motors as scheduled per ROS RMA Item 6301-001-M6-E. B. Check oil level in purifier gear box. Sample oil using "clear and bright" method. Lube Oil Purifiers shall be maintained per manufacturer's recommended scheduled maintenance practices. C. Ensure control air and potable water are lined up to purifier. Ensure steam is available for steam heater, if applicable. D. Line up oil system to take suction from main engine sump. Operate purifier, assuring proper start up sequence and operation. List any defects in operation, or leaks in system. E. Operate purifier for sufficient time necessary to ensure proper operation. Inspect for proper operation, sequencing, unit is "shooting" properly, leakage, correct balance, vibrations, etc. F. Consideration for sludge and oily water from purifier cycling should be anticipated and appropriate disposal line-up (to sludge tank). G. When securing unit several manual self-cleanings ("shooting") of unit should be done before shutdown End of Record: Last Update - 05/15/97 85 5720-001-M6-M-V-STW Oily Water Separator TASK: Visually inspect and test oil/water separator as follows: A. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. B. Hands rotate (if possible) and megger test electric motor. Record all megger test results on the Megger Report Form. C. Discharged/cleaned sludge/water must be captured and removed from vessel. Separator shall be left cleaned and in good order. End of Record: Last Update - 05/15/97 86 5805-001-Y1-M-V-STW Fresh Water Distiller(s) (Inspect) UNIT(S): As directed by the Chief Engineer. NOTE: The period between cleanings of the distilling plant will vary with operating conditions. NIREX units need only to be inspected once every year. The interval of this task may be adjusted based upon the operating parameters of the ROS ship. Ensure that system is properly secured and tagged before performing any maintenance action. Ensure dump is open and valves to potable water and distillate tanks are closed. Waste water will be pumped into the bilge and processed. CAUTION: DO NOT CLEAN DISTILLATE SIDE OF UNIT WITH CHEMICAL ACID SOLUTION. ALWAYS ENSURE THAT THE DISTILLER HAS BEEN FLUSHED THOROUGHLY WITH FRESH WATER BEFORE ATTEMPTING TO PLACE IN SERVICE. TASK: Once every six months, inspect, clean, test and operate the fresh water distilling unit as follows: A. Inspect dump valve packing for leakage. Add or replace packing if necessary. Oil pins periodically with appropriate lubricant. After oiling, the valve should be exercised. B. Inspect zinc electrodes on the inlet and outlet side of the heat exchanger. Clean the electrodes with a wire brush, or if worn excessively (more than 50% deterioration), replace with new electrodes. C. Clean shell, tubes, demister, and other internal parts of evaporator using appropriate methods and tools, as necessary. Verify coating systems are intact. D. Visually inspect, test, and maintain motor controllers as per ROS RMA Item 6401-001-M6-E-V-STW, Motor Controllers/Control Panels.. Inspect, test, and maintain distillate, circulating, chemical feed, and other applicable motors per ROS RMA Item 6301-001-M6-E-V-STW, Electric Motors. E. Allow seawater to flow from salt water circulating pump into the feed heater and 1st and 2nd stages of the distiller. Test operate chemical feed pump. Fill distiller and pressurize to 2 - 3 psig to ensure no leaks. Pump down with brine pump. F. Again, ensure dump is open and valves to potable water and distillate tanks are closed. Water will be pumped into the bilge and processed. Align fresh water to flow into distillate chamber of the second stage through the air ejector. Once a level is attained, operate the distillate pump to ensure proper pumping capacities. G. All areas will be flushed with fresh water and drained upon completion of tests. Drains will be left open until next test period. End of Record: Last Update - 05/15/97 87 5813-001-Y1-M-V-STW Salinity Indicators (Inspect) UNIT(S): As directed by the Chief Engineer. LOCATION(S): As directed by the Chief Engineer. TASK: Once every six months, inspect, clean, and maintain salinity indicators as follows: A. Inspect salinity meter for loose connections. Verify cover seal is intact and tight. B. Remove individual cells from the system. Inspect each cell for damage, discoloration, corrosion, or fouling. Change out "O"-ring if necessary. C. Using manufacturer's suggested solvent, clean individual electrodes. D. Test each cell and calibrate as required. Ensure solenoid dump valve and alarms are operating at required PPM (or GPG) as required. E. Reinstall cells per manufacturer's specifications. End of Record: Last Update: 05/15/97 88 5901-001-M6-M-V-STW Refrigeration Systems (Inspect/Test) UNIT(S): #1 and #2 main refrigeration units. NOTE: All maintenance to the ship's refrigeration systems, particularly maintenance that involves the replenishment of refrigerants or detection of leaks, shall be recorded by the ROS Chief Engineer in the ship's Refrigeration Systems Maintenance Log. Refer to ROS RMA Item 0702-001-DY-G. TASK: Once every month, visually inspect, test and maintain active and inactive equipment as follows: A. Visually inspect, test, and maintain motor controller as scheduled per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. B. Check compressor sight glass on unit. Maintain oil level and quality per manufacturers specifications. C. Test compressor suction and discharge valves. D. Inspect receivers to ensure a level of refrigerant remains in standby unit. Ensure that the control air compressor is operational. Clean and inspect the suction strainer and control oil strainer. Inspect dehydrator, filter, and/or dryer cartridge and replace if necessary (minimally once per year). E. Open, inspect, and clean cooling water suction strainers. Restore to original. Ensure the salt water service pump is operating, with supply open to refrigeration units. Purge the condenser, if necessary. F. Inspect the compressor foundation bolts for signs of deterioration and looseness. Replace or tighten fasteners as necessary. G. Start unit. Closely monitor oil and refrigerant levels in compressors and receivers. H. Inspect/test compressor mechanical seal for any leakage. I. Operate the unit and place the system in service for a period of time sufficient to complete the required inspections and ensure proper operation. Secure the other unit. End of Record: Last Update - 05/15/97 89 5903-001-Y1-M-V-STW Air Conditioning Compressors NOTE: Disregard sections C, D & E from the below procedures if the system has not been deactivated and is operated daily by the ROS crew. IF THE SYSTEM HAS BEEN DEACTIVATED, DO NOT ACTIVATE MOTOR WITH COUPLING CONNECTED TO COMPRESSOR AS THIS WILL CAUSE SERIOUS DAMAGE TO THE COMPRESSOR. TASK: Visually inspect, test and maintain this equipment as follows: A. Check compressor sight glass for proper oil level and quality. Maintain oil level above shaft seals. B. Visually inspect, test, and maintain motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. C. Uncouple compressor from motor (one time only after deactivation). D. Hand rotate motor to ensure free operation. Megger test electric motor. E. Activate the motor for period of time sufficient to ensure proper operation. End of Record: Last Update - 05/15/97 90 6105-001-M3-E-V-STW Auxiliary Diesel Generators NOTE: THIS TASK IS FOR SELECT VESSELS WITH DIESEL GENERATOR SETS LEFT IN AN OPERABLE, READY TO USE CONDITION AND COOLING SYSTEM AVAILABLE. READ AND BE FAMILIAR WITH TECHNICAL MANUAL PRIOR TO OPERATING. PERFORMANCE OF THIS TASK AND COOLING SYSTEM SET UP MUST BE ACCOMPLISHED IN CONSULTATION WITH MARAD COTR AND UNDER THE DIRECT SUPERVISION OF A MARAD SURVEYOR OR SHIP MANAGERS PORT ENGINEER. FOR VESSELS WITH RETENTION CREWS, THIS TASK SHALL BE PERFORMED ONCE EVERY THREE MONTHS IN CONJUNCTION WITH CARGO GEAR LIGHT-OFF. UNITS: As Directed by the Chief Engineer and/or the Ship's Manager. TASK: Visually inspect, test and maintain this equipment as follows: A. Lubricate diesel engine and generator as per the lubrication and service requirements as specified in the manufacturer's maintenance manual. Check oil in sump for proper fluid level and quality. Replenish with new oil as necessary. B. Ensure sufficient quantity of purified fuel is available in diesel generator tank to test generator as required and to maintain fuel system in a primed condition. When storing fuel, provide and add approved additive to fuel to inhibit biological growth. Follow manufacturer's instructions when adding same to fuel. C. Ensure sufficient quantity and quantity of coolant is available in engine and coolant system to safely and properly operate engine. Ensure coolant contains proper quantity and quality of anti-freeze and corrosion inhibitor. as recommended by the engine manufacturer for the geographical area at which the vessel is moored. Place a tag on the engine cooling system with the following information: Date coolant/anti-freeze replenished, type {name of brand}, quantity used, and replenished by whom. D. Remove and set aside exhaust and air intake duct blanks (when fitted). E. Remove and set aside engine exhaust pipe plug and cover. F. Clean fuel, oil, and air filters as per manufacturer' recommendations and recommended time intervals. Replace with new fuel, oil, and air filters as required. G. Test operate inlet and exhaust cooling air louvers using both manual and automatic modes (when fitted). H. Visually inspect, test, and maintain pre-lube pump and crankcase blower motor controllers. Hand rotate (if possible) and megger test electric motors. I. Megger test generator using manufacturer's guidelines. Ensure solid state devices are isolated from high voltage generated during megger test. J. Ensure engine room is properly ventilated to supply engine combustion air and safely operate engine. K. Activate pre-lube and pre-heat system. Activate crankcase blower (if applicable), fuel and cooling systems (if applicable). Visually inspect engine components for proper lubrication. L. Ensure indicator cocks are opened. Blow down engine using start air. Start diesel engine using starting air system. Allow diesel engine to reach steady state operating conditions prior to additional testing and loading. Test operate engine and generator for one-half (1/2) hour using no load. M. Ensure all circuit breakers connecting switchboards to all machinery, circuits, and controls are open/off. Place load on engine and generator using ship's lighting system or other load. N. Test over-speed trip (using extreme caution) with hand held tachometer. Record and report overspeed trip RPM. Test manual trips, low lube oil trips, high temperature alarm and low voltage trip. Test other emergency alarms where feasible. Test all control circuits remote starting systems, and remote shut-off systems. O. Ensure all gauges and thermocouples function properly. Visually inspect gauges for damage and defects. P. Secure diesel engine. Secure pre-lube pump, crankcase blower, and cooling system. Re-install all plugs and covers. Use new sealant as required. Secure ventilation systems and seals as necessary. Drain all secondary cooling water systems and leave open. Clean fuel and lube oil filters. End of Record: Last Update - 05/15/97 91 6201-001-Y1-E-V-STW Switchboards / Distribution Panels NOTE: SWITCHBOARDS AND CONTROLLERS MUST NOT BE ENERGIZED WHILE PERFORMING THIS TASK. SECURE SHORE POWER. AFTER COMPLETING TESTS, RE-CONNECT AND ENERGIZE SHORE POWER. TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect for damage and defects and manually exercise all circuit breakers on the ship's service, emergency, deck machinery, steering gear, I.C., anchor windlass, and all other switchboards/ distribution panels located throughout the vessel. Ensure proper operation of same. After completing tests and inspections, ensure all circuit breakers are in the off/open position. B. Visually inspect and vacuum as necessary all dust, dirt, and foreign materials from all electrical components of switchboards and adjacent areas. {Annually). C. Visually inspect to ensure all electrical connections and mechanical fastenings are securely fastened. Secure fasteners as required. (Annually) D. Measure and record insulation resistance readings of switchboard feeders and distribution feeders. (At time of vessel's deactivation and on an as required basis for troubleshooting purposes thereafter). E. Verify as correct all circuit breaker panel labels. End of Record: Last Update - 05/15/97 92 6235-001-M1-E-V-STW Batteries and Chargers TASK: Ensure all batteries used to power radio equipment, gyrocompass, I.C. circuits, start diesel engines, activate general alarm system and any other battery operated system are in usable condition. A. Check and maintain proper level of electrolyte in cells. Add distilled water as necessary. Maintain terminals free of corrosion, and coat same with protective coating. Charge as necessary. Proper safety goggles shall be worn when checking and testing electrolyte in batteries. B. Provide and utilize a test battery as necessary for the testing of any required battery operated shipboard components. End of Record: Last Update - 05/15/97 93 6301-001-M6-E-V-STW Electric Motors NOTE: Only grease motor bearing when definitely necessary. Otherwise grease will get into and ground windings TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect motor casings, pot heads, gaskets, screens and foundations for deterioration or damage. Test insulation reading. Hand rotate motor if possible. Record all megger test results on the Megger Report Form. B. Test in accordance with all other Phase IV Procedures where required. Run all motors as necessary to ensure proper operation at all speeds and ensure respective controls and indicator lights function. End of Record: Last Update - 05/15/97 94 6401-001-M6-E-V-STW Motor Controllers / Control Panels NOTE: At the time that each individual motor is inspected and tested, perform this task prior to electrically operating the individual motor. Visual inspection and testing of motor controllers and control panels shall be performed prior to electrically operating motors, however maintenance items as specified in this task shall be performed only as required to ensure proper operation of same. (Troubleshoot and perform maintenance as required). TASK: Visually inspect, test and maintain this equipment as follows: A. Open motor controller/control panel and visually inspect all components for excessive wear and defects. Clean and remove all dirt debris and water. Spray with drying/cleaning solvent as needed. Ensure all electrical connections and mechanical fastenings are securely fastened. Visually inspect all contacts for burned surfaces, pitting, and oxide film. If burnt or corroded, clean contacts by lightly sanding. Renew contacts when found defective and deteriorated beyond repair. Visually inspect control wiring for insulation cracks, frays, nicks, overheated Insulation, and any other defects. Ensure overload relays are in good mechanical condition and all parts are complete and securely fastened. Check relay sizes to ensure they are sized in accordance with their motor nameplate data and heater rating table. Check cable packing to all exterior controllers and replace if loose. With controller disengaged, measure insulation resistance of all control wiring from motor to switch. Lubricate controller / control panel case hinges as required. Secure controller / control panel, ensuring tight seal. Replace controller door gasket as needed to ensure watertight integrity of exterior controllers. Test control circuits for proper operation. B. Ensure all controllers are disengaged, preventing inadvertent operation of equipment. C. Verify controller nameplate is attached and legible. End of Record: Last Update - 05/15/97 95 6504-001-M6-E-V-STW Engine Telegraph System TASK: Energize the engine order telegraph system. Station one person in the engine room and one person on the bridge. Test the telegraph, ordering and acknowledging receipt of all engine speed orders. Test wrong direction alarm, if applicable. End of Record: Last Update - 05/15/97 96 6505-001-M3-E-V-STW Sound-Powered Telephone System TASK: Visually inspect and test entire sound powered telephone system{s}. Ensure proper operation of same including selector switches, magnets, wires, call bells, indicator lights, and hand cranks {when fitted}. Voice communicate between all stations. End of Record: Last Update - 05/15/97 97 6521-001-M6-E-V-STW Rudder Angle Indicators TASK: Visually inspect and test rudder angle indicator system including; rudder angle transmitter and repeaters in conjunction with 2201-001-M6-H-V-STW, Main Steering Gear (Inspect/Test). Test all related alarms, i.e. steering failure, etc. End of Record: Last Update - 05/15/97 98 6550-001-W2-E-V-STW Flooding Alarm System TASK: Activate each float switch to ensure the alarm and warning light function properly. End of Record: Last Update - 05/15/97 99 6550-001-W2-E-V-STW Flooding Alarm System TASK: Activate each float switch to ensure the alarm and warning light function properly. End of Record: Last Update - 05/15/97 100 6551-001-M6-E-V-STW ER/Bridge Alarm / Indicator Panels TASK: Energize alarm and indicating circuits using test button and acknowledge button. Replace lamps and fuses when necessary for proper operation of circuits. End of Record: Last Update - 05/15/97 101 6551-002-M6-E-V-STW ER Alarm and Indicator Panels NOTE: This task may be performed in conjunction with other tasks requiring activation of the above listed equipment, components, and circuits. TASK: Visually inspect and test all components of the centralized engine control console or general alarm panel as applicable, including: Motor control switches (test in conjunction with 4705-02-M6-M-V-STW, 4710-01-M6-M-V-STW or 4715-01-M6-M-V-STW as applicable), selector switches, engineer's emergency call system, watch reporting system, watertight door controls, temperature and lamp test push-buttons, alarm indicating lights, alarms, push-buttons, throttle control section, generator sections, control switches, and rheostats. End of Record: Last Update - 05/15/97 102 6552-001-M6-E-V-STW General Alarm System TASK: Test the general alarm system from all stations and ensure all bells operate satisfactorily. Walk through all zones to ensure that all bells and lights are functional. End of Record: Last Update - 05/15/97 103 6553-001-M6-E-V-STW Bridge Alarm and Indicator Panels TASK: Visually inspect and test all components of the wheel house consoles and/or panels as practical, including radar systems, whistle controls, throttle controls (if applicable), lamp dimmer, alarm lights, alarm horn, smoke detection system, running lights, Deck and Steward's Call System, ventilation motor controls, Christmas tree lights, and failure alarm announcing systems, etc. Replace lamps and fuses as necessary to ensure proper operation. Perform this task in conjunction with those tasks specified in this instruction requiring activation of the above listed equipment, components, and circuits. End of Record: Last Update - 05/15/97 104 6554-001-M1-E-V-STW Intruder Alarm System (Test) UNIT(S): As directed by the Chief Engineer and/or the Ship's Manager. TASK: Once every three months, test-operate all components of the Intruder Alarm System. Ensure all alarm enunciators, bells, lamps and all other components of the system function properly. A. Unit will be tested from each alarm station to prove proper operation. End of Record: Last Update - 05/15/97 105 6561-001-Y1-E-V-STW Smoke Detection System TASK: Test operate all components of the Smoke Detection System. Ensure all alarm enunciators, bells, lamps, and all other components of the system function properly. A. Ensure all smoke detection sampling lines are clear. B. Test all spaces served by the smoke detection system. Using smoke cans, or other methods, trigger the smoke alarms for each zone. One at a time. End of Record: Last Update - 05/15/97 106 6601-001-Y1-E-V-STW Radio Equipment NOTE: All radio emissions will be conducted by an operator suitably licensed for the equipment being tested, serviced or operated in accordance with the Rules and Regulations of the Federal Communications Commission (FCC) TASK: Unless otherwise directed by the COTR, the Ship Manager shall provide a radio operator to visually inspect, power up, conduct "on the air" tests, and repair as required: the ship's radio equipment, including all transmitters, receivers, and items required by the FCC Ship Radio License as well as relevant navigation and bridge equipment that have not been locked in storage. Record all test activities in the ships log. End of Record: Last Update - 05/15/97 107 6701-001-M6-E-V-STW Navigation Equipment TASK: Visually inspect, power up, operate to extent practical and perform minor servicing, on the ship's navigation equipment that has not been locked in storage. Equipment may include but shall not be limited to the following: Alarms Course Recorder Doppler Speed Log Engine Order Telegraph Fog Signaling Devices INMARSAT Satellite Navigator/Global Positioning System Loran Omega Radar and Automatic Radar Plotting Aids Fathometer Radio Direction Finder Gyro and Magnetic Compasses (including steering station and all repeaters) Storm Wipers and/or Rotating Clear View Windows Phones Ship's Whistle Navigation Lights Radios End of Record: Last Update - 05/15/97 108 6801-001-M6-E-V-STW Ship's Lighting Systems TASK: Individually activate each lighting circuit. Observe ground detecting lamps for indication of grounded and shorted circuits. Troubleshoot and remove all improper grounds from circuits. Replace with new, all light bulbs found to be defective and burnt out (Utilize G.E. Survivor 130V-75W or equal for incandescence). Verify as correct all circuit breaker labels. De-energize circuits upon completion. End of Record: Last Update - 05/15/97 109 6801-002-M6-E-V-STW Emergency Lighting System TASK: Visually inspect and test same as follows: A. Visually inspect each emergency light for missing lamp, globe and/or guards. Replace with new, all light bulbs found to be defective and burnt out. B. Ensure all globes and guards are free of dirt, paint, and other foreign materials. Ensure each fixture is marked with a red "E" for emergency. End of Record: Last Update - 05/15/97 110 6813-001-M6-E-V-STW Navigation Lights TASK: Activate the running light indicator and the navigation light panel located on the bridge. Place all switches in the "ON" position. Ensure indicator lights are functioning properly. Test both filaments. Visually inspect the running lights and boxes located at port and starboard bridge wings. Lubricate and free up hinges and latching device on access doors. Ensure masthead lights, range light, stern light, forward and after anchor lights, and not-under-command lights function properly. End of Record: Last Update - 05/15/97 111 6901-001-M1-E-V-STW Cathodic Protection System NOTE: ROS Crew shall be responsible for ensuring proper operation and monitoring of the Cathodic protection system. Refer to manufacturer's instructions for proper operation, testing, inspections, and maintenance. Cathodic protection system should not be left on in mode of operation that may cause the hull to be over impressed with current resulting in damage to hull coatings. Cathodic system shall be properly adjusted and set to prevent damage to underwater paint system. TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect system. Ensure system is functioning properly. Adjust controls and rheostats as required to ensure hull potential is within the manufacturer's recommended range. B. Measure and record readings including rheostat and control indicators. Take voltage readings at nine different locations in the water surrounding the ship. Take readings at each location at two foot depth intervals until the water bottom is reached. Also test and record the water salinity. (If ship has a permanently installed system with a hull potential recorder included, record voltage readings from this unit in lieu of the nine locations.) C. Clean power supply free of all dirt, rust, and other foreign materials. (Annually) D. Ship Manager shall submit a Cathodic inspection report bi-weekly. End of Record: Last Update - 05/15/97 112 8101-001-M6-H-V-STW Fire Fighting Equipment NOTE: Regardless which staff performs the below listed task, the Ship Manager is reminded of his additional Coast Guard COI Firefighting equipment inspection responsibilities. TASK: Check fire stations for correct markings and presence of all equipment as per the fire control plan. The ship has a total of 32 fire stations. Inspect station valves for damage to threads and handwheels. Ensure valves operate properly. End of Record: Last Update - 05/15/97 113 8105-001-M6-H-V-STW Portable Fire Extinguishers (Inspect) LOCATIONS: Inspection Check-off List Required UNIT(S): As directed by the Chief Engineer and/or the Ship's Manager. NOTE: The Ship Manager will develop a check-off list of the location and type of all portable and semi-portable fire extinguishers. TASK: Once every three months, visually inspect the condition of the ship's portable fire extinguishers. A. Ensure that each extinguisher is securely stowed in its bracket. B. Ensure that the locking pin is in place, properly sealed and that it cannot be removed without breaking the seal wire. C. Check to see that each fire extinguisher has a tag affixed to it, showing the last date of annual servicing by a shoreside contractor. D. Check extinguisher gauges. Gauges should read in the green section. Note gauges reading in the red section. Readings in the red section of the gauge means that the unit will have to be refilled and/or replaced. 1. CO-2 Fire Extinguishers: a. Inspect the hose and horn for damage, deterioration and tightness of fittings. b. Inspect band and clamp assembly to ensure that the horn can be properly secured. 2. Dry Chemical Fire Extinguishers: a. Inspect the nozzle opening and nozzle stowage post of holder. Ensure that the post and holder are intact and can be secured in the stowed position. E. Properly fill out the inspection checklist, noting the material condition of each fire extinguisher. Return completed list to the ROS Chief Engineer or Chief Mate for action. End of Record: Last Update: 05/15/97 114 8205-001-M3-H-V-STW Engine Powered Lifeboat (Operate) TASK: Operationally test the engine of the lifeboats. A. For water cooled engines with water un-available, start until engine comes up to speed, then shut down. Do not let engine overheat. Cooling water should be provided by hose if available. Drain water upon completion. Air cooled engines shall be operated for a minimum of five minutes. Test propelling gear in neutral, ahead, and astern modes. B. After testing lifeboats davits and winches, secure all components of the lifeboat and stow lifeboat in properly stowed position and condition. End of Record: Last Update - 05/15/97 115 8205-002-M6-H-V-STW Engine Powered Lifeboat (Inspect) NOTE: Regardless which staff performs the below listed task, the Ship Manager is reminded the lifeboat is to be inspected, tested, and maintained in accordance with 46 CFR and SOLAS. TASK: Visually inspect, test and maintain this equipment as follows: A. Check watertight integrity of all through hull fittings and lubricate all shafting and linkages as required, giving particular attention to the safe operating condition of propeller stern tube, stuffing box, propeller unit/reversing gear, releasing gear universal joints/bearings/hooks (if installed), and drain plug seals. B. Inspect condition of hull, air tanks, provision tanks, thwarts, benches, footings, rudder, and tiller fittings for signs of corrosion or damage and service accordingly. Operate rudder in both directions. Ensure standing water is not allowed to collect in bilges by checking clearance of limber holes and drains. Clear bilges of all loose tools/debris and record any deficient coatings. C. Lubricate and service engine as per lubrication and service requirements as specified in the manufacturer's maintenance manual. Check oil sump for proper fluid level. Draw oil sample. Replenish with new oil as necessary. D. Ensure sufficient quantity of fuel is available in fuel tank to test and operate engine as required. Replace with new fuel as required and at each USCG COI renewal period. When storing fuel, provide and add approved additive to inhibit biological growth. Follow manufacturer's instructions when adding same to fuel. E. Replace with new fuel filter, oil filter, and air filter if required. F. Manually turn the engine over one and one half (1 1/2) revolutions. G. For water cooled engines with water un-available, start until engine comes up to speed, then shut down. Do not let engine overheat. Cooling water should be provided by hose if available. Drain water upon completion. Air cooled engines shall be operated for a minimum of five minutes. Test propelling gear in neutral, ahead, and astern modes. H. After testing lifeboats davits and winches, secure all components of the lifeboat and stow lifeboat in properly stowed position and condition. End of Record: Last Update - 05/15/97 116 8206-001-M6-H-V-STW Gravity Davits / Winches (Inspect/Test) BEFORE INSPECTING AND TESTING BOAT DAVIT BRAKES, ENSURE ALL DAVIT AND BOAT SAFETY DEVICES ARE IN PROPER WORKING ORDER AND ARE IN PLACE. NO ONE SHALL BE ALLOWED IN LIFEBOAT WHILE IT IS BEING LOWERED. TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect davits, davit rollers, brakes, brake linings, brake drums, blocks, sheaves, and releasing gear for excessive wear, defects, and other deterioration. B. Visually inspect, test, and maintain winch motor controller as per 6401-001-M6-E-V-STW, Motor Controllers / Control Panels. Megger test lifeboat winch electric motor. Record all megger test results on the Megger Report Form. C. Test out all limit switches before lowering boat. Grease all rollers, blocks, and sheaves as necessary. D. ENSURE THAT RELEASING GEAR IS PROPERLY SECURED AND IN PLACE, ENSURING PROPER SECUREMENT OF LIFEBOAT. E. Release gripes. Place same in boat. F. Ensure winch brake is in safe and proper working order. G. Using the brake to control the speed of the boat, lower the boat to the embarkation deck. Stop same by use of the counterweight brake. H. Energize hoist winch motors. Using winch, hoist boat. While hoisting boat, test satisfactory mechanical and electrical operation of limit switches. Continue hoisting boat to position just before limit switches deactivate winch. Using hand crank, return boat completely to its original stowed position. While raising boat/I-beam, visually inspect wire rope for frays, nicks, excessive wear, defects, deterioration, and other damage. Slush wire rope as necessary using proper preservation compound. I. Secure all components of boat, davits, and winches in properly stowed condition and position. Record test in vessel log book. End of Record: Last Update - 05/15/97 117 8206-002-M6-H-V-STW Gravity Davits / Winches (Operate) TASK: Operationally test the lifeboat davits. A. Using the brake to control the speed of the boat, lower the boat to the embarkation deck. Stop same by use of the counterweight brake. B. Energize hoist winch motors. Using winch, hoist boat. While hoisting boat, test satisfactory mechanical and electrical operation of limit switches. Continue hoisting boat to position just before limit switches deactivate winch. Using hand crank, return boat completely to its original stowed position. While raising boat/I-beam, visually inspect wire rope for frays, nicks, excessive wear, defects, deterioration, and other damage. Slush wire rope as necessary using proper preservation compound. C. Secure all components of boat, davits, and winches in properly stowed condition and position. Record test in vessel log book. End of Record: Last Update - 05/15/97 118 8501-001-M6-H-V-STW Workshop Equipment TASK: Visually inspect, test and maintain this equipment as follows: A. Visually inspect all workshop equipment for damage and defects. Test run motors for period of time sufficient to ensure satisfactory operation. Equipment shall include lathe, drill press, grinder, etc. B. All workshops utilized for the accomplishment of the Phase IV shall be left in a clean condition and all respective workshop equipment/tools shall be left in neatly stowed positions. End of Record: Last Update - 05/15/97 119 9565-001-Y1-H-V-STW Emergency Remote Stops NOTE: Systems that can not be tested under actual operating conditions shall be simulated where possible. The method of simulation shall be noted in the general inspection comments section of the maintenance report. TASK: Inspect all manual pull wires and linkages, electrical contacts, pneumatic tubes, fittings, and motors. Operate and test all remote actuated shut downs including but not limited to the below. Cycle each stop to the fully closed or shut down position, and return to original position. End of Record: Last Update - 05/15/97 120 9570-001-M6-M-V-STW Reach Rods and Remote Operators TASK: Lubricate as required, and visually inspect all accessible reach rods, universal joints, and bushings for damage, defects, and deterioration. Cycle reach rods one (1) complete cycle and return to "as found" position. Perform this task in conjunction with 4820-01-M6-M-E-V-STW through 8820-01-M6-M-E-V-STW as applicable. End of Record: Last Update - 05/15/97 121 9902-001-M6-G-V-STW Tank Gauging NOTE: This item is required on all tanks on out-ported ships and on all fuel tanks on Fleet located ships. TASK: Sound all double bottom tanks, diesel fuel tanks, settling tanks, storage, cofferdams, voids, peak, wing, and deep tanks. Water finding paste or other suitable means shall be used to determine the amount of water found in the bottom of fuel tanks. Measure and record the amount and identify type of liquid found in each tank. Record readings and identity of liquid on Tank Gauging Report. Post one copy of readings in Chief Engineer's Office aboard ship. End of Record: Last Update - 05/15/97 !!! . set alte off