. List VMA_NARR Record# VMA_NARR 1 0000-000-00-G-V-KKK General Notes and Comments NOTE: THIS DATABASE FILE APPLIES TO THE CAPE K CLASS VESSELS. WHEN UPDATING ANY SPECIFIC PROCEDURE WITH THE RRF-MARTS, PLEASE CHANGE THE VESSEL (CLASS) IDENTIFIER (KKK) IN THE MIC CODE OF THE PROCEDURE TO YOUR SPECIFIC VESSELS' IDENTIFIER: CAPE KENNEDY: KK1 CAPE KNOX: KK2 PREAMBLE: THESE INSTRUCTIONS ARE INTENDED TO PROVIDE CORE MAINTENANCE PROCEDURES FOR THE CAPE "K" CLASS VESSELS IN ROS STATUS. THEY ARE AN INTEGRAL PART OF THE ROS MAINTENANCE MANAGEMENT PLAN. UPDATES/REVISIONS ARE REQUIRED TO BE SUBMITTED ANNUALLY TO THE MARAD COTR. ALL INSPECTIONS, TESTS, AND TASKS AS SPECIFIED BY THESE INSTRUCTIONS SHALL BE PERFORMED IN ACCORDANCE WITH GOOD MARINE PRACTICE. ALL EXERCISING AND TESTING OF EQUIPMENT AND MACHINERY SHALL BE PERFORMED IN ACCORDANCE WITH THE INDIVIDUAL EQUIPMENT/MACHINERY MANUFACTURER'S PROCEDURES, GUIDELINES, SAFETY PRECAUTIONS, AND INSTRUCTIONS. PRIOR TO TESTING ALL EQUIPMENT AND MACHINERY AS SPECIFIED IN THESE INSTRUCTIONS AND GUIDELINES ENSURE PROPER LUBRICATION AND PROPER FLUID LEVELS. PRIOR TO TESTING AND EXERCISING EQUIPMENT, ENSURE FLUID/LUBRICANT IS CONTAMINATION FREE AND IS WITHIN QUALITY LIMITS AS SPECIFIED BY THE INDIVIDUAL EQUIPMENT'S MANUFACTURER AND LUBRICANT/FLUID MANUFACTURER. CONSULT TECHNICAL MANUALS FOR ALL PARAMETERS AND PARTICULARS CONCERNING EQUIPMENT, I.E., LUBRICATION POINTS, FILTERS, INSPECTION PORTS, ETC. WHEN REPLENISHING FLUIDS USE NEW FLUID AS RECOMMENDED BY THE EQUIPMENT'S MANUFACTURER OR SHIP'S LUBRICATION/ FLUID CHART. WHILE PERFORMING VISUAL INSPECTIONS, VISUALLY INSPECT ALL MACHINERY FASTENERS FOR DAMAGE, DEFECTS, AND DETERIORATION. REPLACE FASTENERS WITH NEW FASTENERS EQUAL TO ORIGINAL AS REQUIRED. ENSURE FASTENERS ARE PROPERLY AND SECURELY FASTENED. COAT NEW FASTENERS WITH PROPER PRESERVATION COMPOUND. THE SHIP MANAGER IS RESPONSIBLE FOR ENSURING THAT THE READY RESERVE FORCE (RRF) EQUIPMENT CONFIGURATION AND SPARE PARTS MANAGEMENT INFORMATION SYSTEM (ECSMIS) IS PROMPTLY AND ACCURATELY UPDATED WHENEVER PARTS ARE ISSUED OR RECEIVED. SHIP MANAGER WILL REQUEST THE REGION COTR TO UPDATE ECSMIS WHEN THE SHIP MANAGER DOES NOT HAVE THIS CAPABILITY. THIS MAY BE ACCOMPLISHED BY PROVIDING THE REGION COTR WITH A COPY OF FORM MA-973. UPDATE OF RRF-ECSMIS MUST BE ACCOMPLISHED WITHIN 24 HOURS OF THE TRANSACTION ACTIVITY. MEGGER TEST ALL MOTORS (INCLUDING LAUNDRY AND GALLEY EQUIPMENT) AND GENERATORS, TO ENSURE SAFE AND SATISFACTORY OPERATION PRIOR TO TESTING AND ENERGIZING SAME. HAND ROTATE ALL MOTORS TO ENSURE FREE OPERATION OF SAME. SUBMIT REPORT (SEE GENERAL NOTE L) OF ALL INSULATION RESISTANCE READINGS. ENSURE INSULATION RESISTANCE IS WITHIN ACCEPTABLE RANGE AS DETERMINED BY EQUIPMENT'S NAMEPLATE DATA. ALL ELECTRICAL EQUIPMENT TESTED SHALL HAVE A MINIMUM INSULATION RESISTANCE OF ONE (1) MEG-OHM TO ENSURE SAFE AND SATISFACTORY OPERATION WHEN ENERGIZED. ANY ELECTRICAL EQUIPMENT THAT COULD BE HARMED BY INSULATION TESTING (I.E., ELECTRONIC EQUIPMENT, TRANSFORMERS, VOLTAGE REGULATORS, ETC.) SHALL NOT BE TESTED. SHIP MANAGER SHALL ENSURE THAT ADEQUATE FIRE FIGHTING CAPABILITY IS AVAILABLE ABOARD OUTPORTED SHIP. ADDITIONAL REQUIREMENTS AS DEEMED NECESSARY AS A RESULT OF THE TESTS AND INSPECTIONS AS SPECIFIED IN THESE INSTRUCTIONS SHALL BE PROVIDED. FIRE FIGHTING EQUIPMENT AND REQUIREMENTS SHALL AT LEAST MEET THE REQUIREMENTS OF THE REGULATORY BODIES, STATE, AND LOCAL AUTHORITIES OF THE PORT/BERTH WHERE THE VESSEL IS MOORED. SHIP MANAGER SHALL DERIVE PLANS FOR FIGHTING FIRES ABOARD THE VESSEL. ADEQUATE TRAINING SHALL BE PROVIDED TO ALL PERSONNEL. FIRE CONTROL PLANS SHALL BE READILY VISIBLE AND POSTED NEAR GANGWAY. SUBMIT COPY OF PLAN TO COTR WITHIN SIX MONTHS OF CONTRACT AWARD. SEA VALVES FOR SEA CHESTS WHICH ARE NOT BLANKED OFF SHALL NOT BE EXERCISED. SHIP MANAGER SHALL ENSURE SEA VALVES EXPOSED TO THE SEA ARE TAGGED INDICATING THE SAME, DISABLE (IF REQUIRED), AND WIRE CLOSED. POST CLEARLY VISIBLE SIGN LISTING LOCATION, SERVICE, TYPE, AND QUANTITY OF SEA VALVES. SIGN SHALL BE POSTED ON INTERIOR NEAR MAIN ACCESS TO SHIP. FUEL OIL, DIESEL OIL, AND LUBE OIL TANK/SUMP ISOLATION VALVES SHALL NOT BE EXERCISED (INCLUDING DRAIN VALVES) UNLESS OTHERWISE REQUIRED FOR THE OPERATION OF SPECIFIC MACHINERY (I.E. EMERGENCY GENERATOR, MAIN LUBE OIL SYSTEM, ETC.). THOSE TANK/SUMP ISOLATION VALVES NOT REQUIRED TO BE EXERCISED BY THESE INSTRUCTIONS AND GUIDELINES SHALL BE TAGGED BY SHIP MANAGER, AND WIRED CLOSED. AFTER COMPLETING TESTS AND EXERCISING AS REQUIRED, ENSURE ALL OTHER FUEL OIL, DIESEL OIL, AND LUBE OIL SYSTEMS VALVES ARE CLOSED. AFTER COMPLETING ALL TESTS AND INSPECTIONS AS SPECIFIED IN THESE INSTRUCTIONS, RECORD ALL VESSEL DEFICIENCIES IN THE RRF MAINTENANCE AND REPAIR TRACKING SYSTEM (RRF MARTS). SEND A FLOPPY DISK CONTAINING THE RECORDED DEFICIENCIES TO THE APPLICABLE CONTRACTING OFFICER'S TECHNICAL REPRESENTATIVE (COTR) OR HIS DESIGNATED ASSISTANT CONTRACTING OFFICER'S TECHNICAL REPRESENTATIVE (ACOTR) FOR THAT PARTICULAR VESSEL. INCLUDE WITH THE FLOPPY DISK, A HARD COPY PRINT-OUT OF THE DEFICIENCIES. FOR ANY PREVIOUSLY RECORDED DEFICIENCIES THAT WERE CORRECTED DURING THE LATEST PHASE IV CYCLE, MARK UP A HARD COPY PRINTOUT OF THE EXISTING DEFICIENCY AND FORWARD IT TO THE COTR FOR UPDATE OF THE RRF MARTS SYSTEM. ALL DEFICIENCIES THAT WERE FOUND AND CORRECTED DURING THE SAME PHASE IV CYCLE SHALL NOT BE INCLUDED IN RRF MARTS, BUT SHALL BE RECORDED IN A STANDARD TYPE WRITTEN FORM AND FORWARDED TO THE COTR FOR HIS INFORMATION. ALSO DEVELOP AND SUBMIT TO THE COTR THE DEHUMIDIFICATION SYSTEM REPORT, INSULATION RESISTANCE READINGS REPORT, GENERAL INSPECTION COMMENTS, DRAFT READINGS, TANK GAUGING REPORT, CATHODIC PROTECTION SYSTEM REPORT, AND ALL OTHER REPORTS AND FORMS REQUIRED BY THESE INSTRUCTIONS. A PHASE IV MAINTENANCE CYCLE CERTIFICATION AND CHECK-OFF SHEET SHALL ALSO BE FORWARDED TO THE COTR. THE COTR WILL SUBMIT A COPY OF THE CHECK-OFF SHEET TO MARAD HEADQUARTERS' DIVISION OF SHIP MAINTENANCE AND REPAIR WITH THE QUARTERLY RRF MARTS UPDATE. ANY REPAIRS THAT AFFECT THE STATUS OF THE VESSEL SHALL NOT BE ACCOMPLISHED WITHOUT PRIOR APPROVAL FROM THE COTR. STRICTLY ADHERE TO ALL APPLICABLE FEDERAL, STATE AND LOCAL SAFETY RULES WHEN HANDLING OR DISPOSING OF HAZARDOUS WASTE. AS NOTED HEREIN, SHIP MANAGERS WHO ARE CONTRACTED TO PROVIDE A RETENTION CREW FOR SPECIFIC VESSEL/S SHALL ENSURE THAT ALL MAJOR CARGO HANDLING EQUIPMENT (except OPDS equipment and SEABEE barge elevator) IS TESTED OUT ONCE EVERY THREE MONTHS AS OPPOSED TO THE USUAL SEMI-ANNUAL TASKING. NOTE: THE CODIFICATION OF THE "MARAD PHASE IV MAINTENANCE PROCEDURES FOR GENERAL CLASS VESSELS" FOR USE IN RRF-MARTS HAS NECESSITATED SOME MINOR CHANGES TO SOME OF THE CODE NUMBERS AND THEIR SEQUENCING ORDER TO THOSE CONTAINED IN THE TECHNICAL EXHIBIT (TE-8) OF THE CONTRACT. END OF RECORD 2 0105-001-DY-G-V-KKK RRF ROS M&R Daily Inspection Monitor all operating machinery and systems to insure integrity of their operation and safety. Check the machinery spaces and other remote areas on the vessel for safety and seaworthiness. Record the results of the inspection in the attached DUTY ENGINEER DAILY INSPECTION Watch Log Sheet. Record any alarms, including machinery alarms or ROS alarm system alarms, and the time or their occurrences during each watch. List actions taken as appropriate. END OF RECORD 3 0105-002-DY-G-V-KKK Duty Engineer's Daily Inspection M/V CAPE __________ DATE_____________________ WATCH LOG SHEET TIME_____________________ ENGINEER _________________ GENERATOR # OR SHORE POWER ________ D/G ready for immediate use # ________ VOLTS ________ AMPS ________ LO Pressure ________ LO Level ________ KW ________ Rocker Arm Pressure _____ FO Pressure ________ FV CW Pressure ________ LO Temp ________ JW Temp ________ 24V Battery System _______ Expansion Tank Level________ Aux SW Pump # __________ Suction ________ Discharge _______ SS Reefer CW Pump ______ Suction ________ Discharge _______ AC CW PUMP # __________ Suction ________ Discharge _______ ME JW Heater Temp ______ Suction ________ Discharge _______ DG 1&2 JW Htr Temp _____ Suction ________ Discharge _______ DG 3&4 JW Htr Temp _____ Suction ________ Discharge _______ Air Compressor # ______ HP________ LP______ OP______ Air Receiver # 1_____ #2________ Control______ Marine Sanitation Device Compressor # _____ Pump #____ HTH check____ Port Fresh Water Tank Tons _____in Service? _____ Stbd Fresh Water Tank Tons _____in Service? _____ Potable Water Pump # _____Tank Pressure _____ Hot Water Recirc Pump suction _____Discharge _____ Hot Water Tank Pressure _____ Console A/C LP _____ HP _____OP ____ SS Refrigeration LP _____ HP _____OP ____ Dom. Reefer Unit _____ Suct _____ Dis. _____ Oil _____ Boxes Freeze_____ Meat _____Veg____ Air Conditioning Unit _____ Suct._____ Dis.______ Oil_______ House A/C LP _____ HP _____OP_____ Fans check _____ Cooling Water _____ Machinery Spaces ________ Stabilizer Rooms ________ Bow Thruster Rooms ________ Tank Top Hold ________ Bilge Level ________ Alarm List Time __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ Signature ________________________________ END OF RECORD 4 0105-003-W1-G-V-KKK RRF ROS M&R Weekly Inspections Conduct a thorough inspection of all spaces throughout the vessel to insure integrity of safety, operation and appearance of the vessel. Record the results of the inspection in the attached WEEKLY SHIP INSPECTION REPORT. 1. Ship's Exterior Hull, Decks, Houses and Cargo Spaces. Check drafts and flooding marks. Inspect the general appearance and integrity of the external hull. Inspect the accommodation ladders for general safety and lighting. Ascertain that a fire control plan and other pertinent emergency information is provided near the gangway. Inspect the mooring lines. Check arrangement, proper slackness, rat guards and general condition of the lines. Inspect mooring fenders. Take chain locker soundings. Inspect the main deck for general appearance and cleanliness. Insure that all drains and scuppers are clear. Inspect the center ramp way door. Inspect all superstructures and deck houses. Insure that the drains and scuppers are clear and that there is no standing water. Inspect storeroom interiors for general appearance, cleanliness and lighting. Ascertain that storerooms are secured and locked. Inspect the holds for general appearance, cleanliness and safety (including lighting). Ascertain that all watertight doors are secured. Check hold bilge wells and insure that upper hold drains are clear. Inspect voids. Check for signs of rats. 2. Cleanliness, Order and Sanitation. Make a thorough inspection of the interior accommodations, including but not limited to the galley, messrooms, refrigeration spaces, living quarters, passageways, heads and washrooms, wheelhouse and chart and radio spaces, gyro room and offices. Inspect for general appearance, cleanliness and safety. 3. Machinery / Electrical Spaces and Equipment. Inspect the general appearance, cleanliness and safety of all machinery spaces, machinery and electrical equipment. Inspect the tank top and bilges. Insure that the flooding alarms are tested and working satisfactorily. Inspect the shaft alley and stern tube seal. When applicable, check the integrity of the shaft and rudder locks. Check the turning gear. Ascertain that all doors and skylights are closed and that all storerooms are secured and locked. END OF RECORD 5 0105-003-W1-G-V-KKK RRF ROS M&R Weekly Inspections Conduct a thorough inspection of all spaces throughout the vessel to insure integrity of safety, operation and appearance of the vessel. Record the results of the inspection in the attached WEEKLY SHIP INSPECTION REPORT. 1. Ship's Exterior Hull, Decks, Houses and Cargo Spaces. Check drafts and flooding marks. Inspect the general appearance and integrity of the external hull. Inspect the accommodation ladders for general safety and lighting. Ascertain that a fire control plan and other pertinent emergency information is provided near the gangway. Inspect the mooring lines. Check arrangement, proper slackness, rat guards and general condition of the lines. Inspect mooring fenders. Take chain locker soundings. Inspect the main deck for general appearance and cleanliness. Insure that all drains and scuppers are clear. Inspect the center ramp way door. Inspect all superstructures and deck houses. Insure that the drains and scuppers are clear and that there is no standing water. Inspect storeroom interiors for general appearance, cleanliness and lighting. Ascertain that storerooms are secured and locked. Inspect the holds for general appearance, cleanliness and safety (including lighting). Ascertain that all watertight doors are secured. Check hold bilge wells and insure that upper hold drains are clear. Inspect voids. Check for signs of rats. 2. Cleanliness, Order and Sanitation. Make a thorough inspection of the interior accommodations, including but not limited to the galley, messrooms, refrigeration spaces, living quarters, passageways, heads and washrooms, wheelhouse and chart and radio spaces, gyro room and offices. Inspect for general appearance, cleanliness and safety. 3. Machinery / Electrical Spaces and Equipment. Inspect the general appearance, cleanliness and safety of all machinery spaces, machinery and electrical equipment. Inspect the tank top and bilges. Insure that the flooding alarms are tested and working satisfactorily. Inspect the shaft alley and stern tube seal. When applicable, check the integrity of the shaft and rudder locks. Check the turning gear. Ascertain that all doors and skylights are closed and that all storerooms are secured and locked. END OF RECORD 6 0105-003-W1-G-V-KKK RRF ROS M&R Weekly Inspections Conduct a thorough inspection of all spaces throughout the vessel to insure integrity of safety, operation and appearance of the vessel. Record the results of the inspection in the attached WEEKLY SHIP INSPECTION REPORT. 1. Ship's Exterior Hull, Decks, Houses and Cargo Spaces. Check drafts and flooding marks. Inspect the general appearance and integrity of the external hull. Inspect the accommodation ladders for general safety and lighting. Ascertain that a fire control plan and other pertinent emergency information is provided near the gangway. Inspect the mooring lines. Check arrangement, proper slackness, rat guards and general condition of the lines. Inspect mooring fenders. Take chain locker soundings. Inspect the main deck for general appearance and cleanliness. Insure that all drains and scuppers are clear. Inspect the center ramp way door. Inspect all superstructures and deck houses. Insure that the drains and scuppers are clear and that there is no standing water. Inspect storeroom interiors for general appearance, cleanliness and lighting. Ascertain that storerooms are secured and locked. Inspect the holds for general appearance, cleanliness and safety (including lighting). Ascertain that all watertight doors are secured. Check hold bilge wells and insure that upper hold drains are clear. Inspect voids. Check for signs of rats. 2. Cleanliness, Order and Sanitation. Make a thorough inspection of the interior accommodations, including but not limited to the galley, messrooms, refrigeration spaces, living quarters, passageways, heads and washrooms, wheelhouse and chart and radio spaces, gyro room and offices. Inspect for general appearance, cleanliness and safety. 3. Machinery / Electrical Spaces and Equipment. Inspect the general appearance, cleanliness and safety of all machinery spaces, machinery and electrical equipment. Inspect the tank top and bilges. Insure that the flooding alarms are tested and working satisfactorily. Inspect the shaft alley and stern tube seal. When applicable, check the integrity of the shaft and rudder locks. Check the turning gear. Ascertain that all doors and skylights are closed and that all storerooms are secured and locked. END OF RECORD 7 0105-003-W1-G-V-KKK RRF ROS M&R Weekly Inspections Conduct a thorough inspection of all spaces throughout the vessel to insure integrity of safety, operation and appearance of the vessel. Record the results of the inspection in the attached WEEKLY SHIP INSPECTION REPORT. 1. Ship's Exterior Hull, Decks, Houses and Cargo Spaces. Check drafts and flooding marks. Inspect the general appearance and integrity of the external hull. Inspect the accommodation ladders for general safety and lighting. Ascertain that a fire control plan and other pertinent emergency information is provided near the gangway. Inspect the mooring lines. Check arrangement, proper slackness, rat guards and general condition of the lines. Inspect mooring fenders. Take chain locker soundings. Inspect the main deck for general appearance and cleanliness. Insure that all drains and scuppers are clear. Inspect the center ramp way door. Inspect all superstructures and deck houses. Insure that the drains and scuppers are clear and that there is no standing water. Inspect storeroom interiors for general appearance, cleanliness and lighting. Ascertain that storerooms are secured and locked. Inspect the holds for general appearance, cleanliness and safety (including lighting). Ascertain that all watertight doors are secured. Check hold bilge wells and insure that upper hold drains are clear. Inspect voids. Check for signs of rats. 2. Cleanliness, Order and Sanitation. Make a thorough inspection of the interior accommodations, including but not limited to the galley, messrooms, refrigeration spaces, living quarters, passageways, heads and washrooms, wheelhouse and chart and radio spaces, gyro room and offices. Inspect for general appearance, cleanliness and safety. 3. Machinery / Electrical Spaces and Equipment. Inspect the general appearance, cleanliness and safety of all machinery spaces, machinery and electrical equipment. Inspect the tank top and bilges. Insure that the flooding alarms are tested and working satisfactorily. Inspect the shaft alley and stern tube seal. When applicable, check the integrity of the shaft and rudder locks. Check the turning gear. Ascertain that all doors and skylights are closed and that all storerooms are secured and locked. END OF RECORD 8 0105-004-W1-G-V-KKK Weekly Ship Inspection Report VESSEL: LOCATION: INSPECTOR(S): DATE: SHIP'S EXTERIOR HULL, DECKS, HOUSES AND CARGO SPACES. a. Draft Marks: Draft Forward Meters Draft Aft Meters Mean Draft Meters b. Flooding Mark:.......................Sat Unsat c. General appearance of external hull.. G F P d. Accommodation ladder.................Sat Unsat e. Fire Control Plan and pertinent emergency information provided on ship near gangway..Yes No f. Mooring Lines: Arrangement..........Sat Unsat Proper Slackness......Yes No Rat Guards............Yes No General Condition.....G F P g. Fenders..............................Sat Unsat h. Chain Locker Soundings Port FT IN Stbd FT IN i. Main Deck......Rust: Yes No ......G F P j. Drains and Scuppers.....................Sat Unsat k. Upper Deck Center Rampway Door..........G F P l. Mast House Tops Standing Water:....Yes No m. Deck or Mast Houses Secured............ Yes No n. Deck or Mast House Interiors............G F P o. General appearance of superstructures / deck houses................................. G F P p. Doors/Access Hatches/Manholes Secured and Locked................................... Yes No q. Deck Store Rooms Secured?................ Yes No r. Holds.........Rust: Yes No ........Sat Unsat s. Tween Deck Hatch Covers Closes........... Yes No t. Hold Bilgewells.......................... G F P u. Voids.................................... G F P v. Evidence of rats?.........................Yes No CLEANLINESS, ORDER AND SANITATION a. Galley.................................. G F P b. Messrooms............................... G F P c. Refrigeration Spaces/Boxes.............. G F P d. Living Quarters......................... G F P e. Passageways............................. G F P f. Heads and washrooms..................... G F P g. Wheelhouse.............................. G F P h. Chartroom............................... G F P i. Radio Room....Secured: Yes No .... G F P j. Gyro Room............................... G F P k. Offices................................. G F P l. Trash and debris removed from above spaces............................... Yes No m. Cleaned or left above spaces in clean condition............................ Yes No MACHINERY / ELECTRICAL SPACES AND EQUIPMENT a. General appearance of machinery spaces.... G F P b. General appearance of machinery........... G F P c. General appearance of electrical equipment.G F P d. General appearance of Tank Top and Bilges..G F P e. Oil in Bilges / Bilge Wells............... Yes No f. Water in Bilges / Bilge Wells..............Yes No g. Flooding Alarm Tested.................. Sat Unsat h. General appearance of Shaft Alley......... G F P i. Seachests................................. G F P j. Stern tube seal.........................Sat Unsat k. Main Shaft Locked......................... Yes No l. Jacking Gear Engaged...................... Yes No m. Hatches / manholes closed..................Yes No n. Doors and Skylights closed.................Yes No o. General appearance of steering gear room.. G F P p. Rudder Locked............................. Yes No q. Engine Room Storerooms secured?............Yes No Notes and comments: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ END OF RECORD 9 0105-004-W1-G-V-KKK Weekly Ship Inspection Report VESSEL: LOCATION: INSPECTOR(S): DATE: SHIP'S EXTERIOR HULL, DECKS, HOUSES AND CARGO SPACES. a. Draft Marks: Draft Forward Meters Draft Aft Meters Mean Draft Meters b. Flooding Mark:.......................Sat Unsat c. General appearance of external hull.. G F P d. Accommodation ladder.................Sat Unsat e. Fire Control Plan and pertinent emergency information provided on ship near gangway..Yes No f. Mooring Lines: Arrangement..........Sat Unsat Proper Slackness......Yes No Rat Guards............Yes No General Condition.....G F P g. Fenders..............................Sat Unsat h. Chain Locker Soundings Port FT IN Stbd FT IN i. Main Deck......Rust: Yes No ......G F P j. Drains and Scuppers.....................Sat Unsat k. Upper Deck Center Rampway Door..........G F P l. Mast House Tops Standing Water:....Yes No m. Deck or Mast Houses Secured............ Yes No n. Deck or Mast House Interiors............G F P o. General appearance of superstructures / deck houses................................. G F P p. Doors/Access Hatches/Manholes Secured and Locked................................... Yes No q. Deck Store Rooms Secured?................ Yes No r. Holds.........Rust: Yes No ........Sat Unsat s. Tween Deck Hatch Covers Closes........... Yes No t. Hold Bilgewells.......................... G F P u. Voids.................................... G F P v. Evidence of rats?.........................Yes No CLEANLINESS, ORDER AND SANITATION a. Galley.................................. G F P b. Messrooms............................... G F P c. Refrigeration Spaces/Boxes.............. G F P d. Living Quarters......................... G F P e. Passageways............................. G F P f. Heads and washrooms..................... G F P g. Wheelhouse.............................. G F P h. Chartroom............................... G F P i. Radio Room....Secured: Yes No .... G F P j. Gyro Room............................... G F P k. Offices................................. G F P l. Trash and debris removed from above spaces............................... Yes No m. Cleaned or left above spaces in clean condition............................ Yes No MACHINERY / ELECTRICAL SPACES AND EQUIPMENT a. General appearance of machinery spaces.... G F P b. General appearance of machinery........... G F P c. General appearance of electrical equipment.G F P d. General appearance of Tank Top and Bilges..G F P e. Oil in Bilges / Bilge Wells............... Yes No f. Water in Bilges / Bilge Wells..............Yes No g. Flooding Alarm Tested.................. Sat Unsat h. General appearance of Shaft Alley......... G F P i. Seachests................................. G F P j. Stern tube seal.........................Sat Unsat k. Main Shaft Locked......................... Yes No l. Jacking Gear Engaged...................... Yes No m. Hatches / manholes closed..................Yes No n. Doors and Skylights closed.................Yes No o. General appearance of steering gear room.. G F P p. Rudder Locked............................. Yes No q. Engine Room Storerooms secured?............Yes No Notes and comments: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ END OF RECORD 10 0105-004-W1-G-V-KKK Weekly Ship Inspection Report VESSEL: LOCATION: INSPECTOR(S): DATE: SHIP'S EXTERIOR HULL, DECKS, HOUSES AND CARGO SPACES. a. Draft Marks: Draft Forward Meters Draft Aft Meters Mean Draft Meters b. Flooding Mark:.......................Sat Unsat c. General appearance of external hull.. G F P d. Accommodation ladder.................Sat Unsat e. Fire Control Plan and pertinent emergency information provided on ship near gangway..Yes No f. Mooring Lines: Arrangement..........Sat Unsat Proper Slackness......Yes No Rat Guards............Yes No General Condition.....G F P g. Fenders..............................Sat Unsat h. Chain Locker Soundings Port FT IN Stbd FT IN i. Main Deck......Rust: Yes No ......G F P j. Drains and Scuppers.....................Sat Unsat k. Upper Deck Center Rampway Door..........G F P l. Mast House Tops Standing Water:....Yes No m. Deck or Mast Houses Secured............ Yes No n. Deck or Mast House Interiors............G F P o. General appearance of superstructures / deck houses................................. G F P p. Doors/Access Hatches/Manholes Secured and Locked................................... Yes No q. Deck Store Rooms Secured?................ Yes No r. Holds.........Rust: Yes No ........Sat Unsat s. Tween Deck Hatch Covers Closes........... Yes No t. Hold Bilgewells.......................... G F P u. Voids.................................... G F P v. Evidence of rats?.........................Yes No CLEANLINESS, ORDER AND SANITATION a. Galley.................................. G F P b. Messrooms............................... G F P c. Refrigeration Spaces/Boxes.............. G F P d. Living Quarters......................... G F P e. Passageways............................. G F P f. Heads and washrooms..................... G F P g. Wheelhouse.............................. G F P h. Chartroom............................... G F P i. Radio Room....Secured: Yes No .... G F P j. Gyro Room............................... G F P k. Offices................................. G F P l. Trash and debris removed from above spaces............................... Yes No m. Cleaned or left above spaces in clean condition............................ Yes No MACHINERY / ELECTRICAL SPACES AND EQUIPMENT a. General appearance of machinery spaces.... G F P b. General appearance of machinery........... G F P c. General appearance of electrical equipment.G F P d. General appearance of Tank Top and Bilges..G F P e. Oil in Bilges / Bilge Wells............... Yes No f. Water in Bilges / Bilge Wells..............Yes No g. Flooding Alarm Tested.................. Sat Unsat h. General appearance of Shaft Alley......... G F P i. Seachests................................. G F P j. Stern tube seal.........................Sat Unsat k. Main Shaft Locked......................... Yes No l. Jacking Gear Engaged...................... Yes No m. Hatches / manholes closed..................Yes No n. Doors and Skylights closed.................Yes No o. General appearance of steering gear room.. G F P p. Rudder Locked............................. Yes No q. Engine Room Storerooms secured?............Yes No Notes and comments: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ END OF RECORD 11 0105-004-W1-G-V-KKK Weekly Ship Inspection Report VESSEL: LOCATION: INSPECTOR(S): DATE: SHIP'S EXTERIOR HULL, DECKS, HOUSES AND CARGO SPACES. a. Draft Marks: Draft Forward Meters Draft Aft Meters Mean Draft Meters b. Flooding Mark:.......................Sat Unsat c. General appearance of external hull.. G F P d. Accommodation ladder.................Sat Unsat e. Fire Control Plan and pertinent emergency information provided on ship near gangway..Yes No f. Mooring Lines: Arrangement..........Sat Unsat Proper Slackness......Yes No Rat Guards............Yes No General Condition.....G F P g. Fenders..............................Sat Unsat h. Chain Locker Soundings Port FT IN Stbd FT IN i. Main Deck......Rust: Yes No ......G F P j. Drains and Scuppers.....................Sat Unsat k. Upper Deck Center Rampway Door..........G F P l. Mast House Tops Standing Water:....Yes No m. Deck or Mast Houses Secured............ Yes No n. Deck or Mast House Interiors............G F P o. General appearance of superstructures / deck houses................................. G F P p. Doors/Access Hatches/Manholes Secured and Locked................................... Yes No q. Deck Store Rooms Secured?................ Yes No r. Holds.........Rust: Yes No ........Sat Unsat s. Tween Deck Hatch Covers Closes........... Yes No t. Hold Bilgewells.......................... G F P u. Voids.................................... G F P v. Evidence of rats?.........................Yes No CLEANLINESS, ORDER AND SANITATION a. Galley.................................. G F P b. Messrooms............................... G F P c. Refrigeration Spaces/Boxes.............. G F P d. Living Quarters......................... G F P e. Passageways............................. G F P f. Heads and washrooms..................... G F P g. Wheelhouse.............................. G F P h. Chartroom............................... G F P i. Radio Room....Secured: Yes No .... G F P j. Gyro Room............................... G F P k. Offices................................. G F P l. Trash and debris removed from above spaces............................... Yes No m. Cleaned or left above spaces in clean condition............................ Yes No MACHINERY / ELECTRICAL SPACES AND EQUIPMENT a. General appearance of machinery spaces.... G F P b. General appearance of machinery........... G F P c. General appearance of electrical equipment.G F P d. General appearance of Tank Top and Bilges..G F P e. Oil in Bilges / Bilge Wells............... Yes No f. Water in Bilges / Bilge Wells..............Yes No g. Flooding Alarm Tested.................. Sat Unsat h. General appearance of Shaft Alley......... G F P i. Seachests................................. G F P j. Stern tube seal.........................Sat Unsat k. Main Shaft Locked......................... Yes No l. Jacking Gear Engaged...................... Yes No m. Hatches / manholes closed..................Yes No n. Doors and Skylights closed.................Yes No o. General appearance of steering gear room.. G F P p. Rudder Locked............................. Yes No q. Engine Room Storerooms secured?............Yes No Notes and comments: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ END OF RECORD 12 0105-005-Y1-G-V-KKK RRF ROS M&R Phase IV Inspection Conduct a thorough inspection of all spaces throughout the vessel to insure integrity of safety, operation and appearance of the vessel. Record the results of the inspection in the attached PHASE IV CYCLE SHIP INSPECTION REPORT. 1. Ship's Exterior Hull. Check drafts and flooding marks. Inspect the general appearance and integrity of the coating of the freeboard, boot top, underwater hull (as visible at waterline) and stern ramp. Look for evidence of oil contamination around the stern ramp. Check all mooring lines for arrangement, proper slackness, rat guards and general condition. Inspect fenders. Inspect the pilot doors for general safety and lighting. If the pilot door is open to the dock, insure that a Fire Control Plan is present at the pilot door. Inspect the starboard gangway for general safety and lighting. Insure that a Fire Control Plan and any other pertinent emergency information is present at the gangway. Insure that the port gangway is stowed and secured properly. 2. Upper Deck. Inspect coating and cleanliness of decks. Insure that deck drains and scuppers are clear. Inspect general appearance of the center rampway door and check for evidence of contamination. Insure that escape hatches are unlocked and adequately illuminated. 3. Focsle Deck. Inspect coating and cleanliness of decks. Insure that deck drains and scuppers are clear. Insure that the anchor chains and windlasses are secured. Inspect general appearance of mooring winches and anchor windlasses and check for evidence of oil leakage. Inspect above the deck house. Insure that deck drains and scuppers are clear. Insure that mast lights are working properly. Inspect deck house storerooms for general appearance and insure that they are locked. 4. Bosun Storeroom. Insure adequate lighting throughout the space. Inspect coating and cleanliness of decks. Check stowage of gear and supplies. Inspect port and stbd bilge wells. Take soundings of the chain lockers. Inspect the hydraulic pump room for general safety, including lighting, and cleanliness. 5. Cargo Holds & Ladder Wells. Make a thorough inspection of the upper tween deck (UTD), lower tween deck (LTD), tank top hold and threshold/rampway areas. Inspect coating and cleanliness of decks. Check hold bilge wells and insure upper hold drain systems are clear. Inspect holds for general safety, including lighting and markings. Inspect hold escapes for general safety, including lighting and markings. Check stowage of gear and supplies. Inspect the general appearance of the starboard gastight door to the UTD, port gastight door to the LTD, watertight ramp cover to the tank top hold, and watertight center rampway door and stern door. Make a thorough inspection of the forward ladder well from the focsle to the bosun storeroom, UTD, LTD and bow thruster room; center ladder well from the upper deck to the UTD, LTD and tank top; and threshold ladder well from the poop deck to the threshold space in way of the traffic control room, talley office and batter charger space. Check for general appearance and cleanliness and adequate lighting. Inspect the traffic control room, talley office, emergency gear locker and battery room for general condition and appearance. 6. Provision Spaces. Inspect the refrigeration machinery space, reefer handling room, vegetable box, meat box, deep freeze box, refrigerated store box, dry provision store room and bonded store room for general cleanliness and lighting. Check safety of the arrangement of the deck gratings in the refrigeration boxes. 7. Accommodation Spaces. Make a thorough inspection of all of the accommodation spaces, including the poop deck, first deck, second deck, third deck and navigation deck. Inspect all spaces for general appearance, cleanliness and lighting. Insure that all storerooms are locked. Make a thorough inspection of all exterior accommodation spaces. Check for general appearance, cleanliness and lighting. Inspect coating of decks. Insure that all deck drains and scuppers are clear. Inspect general appearance of stern ramp winches and after mooring winches. Check for evidence of oil leakage around all winches. Inspect the gyro room, battery room, engine room supply fan room, emergency generator room and all deck store rooms for general appearance, cleanliness and lighting. 8. Machinery Spaces. Make a thorough inspection of all machinery spaces, including the main engine flat, generator flat, mid flat, lower level, tank top and bilges, shaft alley, control room and change room, machine shop and electrical shop, mooring winch hydraulic pump room, cargo gear hydraulic pump room, steering gear room, boiler spaces and fidley and air conditioning room. Check for general appearance, cleanliness and safety, including lighting. Inspect the bilge wells. Insure that the flooding alarms work properly. Check the stern tube seal. When installed, check the shaft lock and rudder lock. Insure that all hatches, manholes, doors and skylights are closed and storerooms are locked. END OF RECORD 13 0112-001-M1-H-V-KKK Dehumidification Visually inspect and test all dehumidification system. Insure proper and continuous operation of the dehumidification systems including dehumidifiers, air distribution systems and automatic control stations. Record the results of the inspection, maintenance and repairs on the attached DEHUMIDIFICATION INSPECTION REPORT. NOTE: Ship Manager shall possess a psychrometer and know the correct methods for determining relative humidity. A. Maintain relative humidity in all D/H zones within the range of thirty-five percent to forty-five percent (35% to 45%). Adjust hygrosensor controls and flow dampers as necessary to achieve same. Adjust air flow to maintain a uniform relative humidity within the desired range throughout all entire zones. B. Measure and record psychrometer and hygrosensor readings at each zone. C. When the relative humidity is found to be outside of the desired range, additional readings shall be measured and recorded until such time as the values stabilize within the desired range. Identify cause of improper values, perform tasks necessary to correct the deficiency, and adjust the station control settings and dry air flow as necessary. D. While performing visual inspection, ensure proper operation of D/H machine by engaging manual control switch (when machine is not running). Routine inspection and maintenance of D/H Machine shall be performed in accordance with manufacturer's instructions and include: 1. Visually inspect D/H machine electric heater for evidence of overheating. Measure resistance of heating element if it appears to be defective. 2. Visually inspect all drive belts for defects, damage, and deterioration. Replace belts as necessary. Check drive belts for proper tension. Adjust same as necessary. 3. Clean air filters as necessary. 4. Lubricate all components as necessary. 5. Inspect all hoses and ducting throughout vessel and ensure all connections are tight. E. Read and record elapsed running time as indicated on elapsed running time meter. Compare reading with vessel's meter average monthly readings and last several monthly readings. When running time appears to be excessive, refer to Step C. Also refer to technical manual. Excessive running time indicates a possibility of the following: -Faulty D/H Machine -Air and/or water leaks into D/H Zones -Faulty Hygrosensor Controls F. Replace chart paper on hygrometer's chart recorder as required. Review marked chart for any unusual readings. Properly label and submit the dehumidification reports to the chief engineer for review and distribution. G. Test operate fire detectors located at D/H machines (if applicable) to ensure proper operation of same. Reset same after test, if applicable. H. Seals and sealing material. 1. Visually inspect all sealing material for deterioration, damage, and defects. Repair and replace with new as necessary. 2. When high relative humidity readings are measured, a careful search shall be made for air and water leaks around and throughout the zones. Eliminate all leaks. Utilize ventilation system in pulling vacuum as needed in checking for leaks. Reseal ventilation system after usage. END OF RECORD 14 0112-002-M1-H-V-KKK DH Inspection Report DEHUMIDIFICATION SYSTEMS A. Verified relative humidity in all D/H zones to be within range of thirty-seven percent to forty percent 37% to 40%)................... Yes No B. Relative Humidity Readings: a. Pilot House b. Engine Control Room c. Main Engine d. Boiler Furnace e. f. g. C. D/H machines, air distribution systems and automatic controls functioning properly........................ Yes No D. Elapsed Running Time: Hours Minutes Previous Reading Hours Minutes Difference in Readings Hours Minutes Within Acceptable Range................ Yes No E. Renew chart paper and submit original to Chief, Division of Ship Management; submit copy to Ship Operations Officer; and file a copy in the Chief Engineer's Office...................... Yes No F. Inspected D/H zone seals and sealing materials........................ Sat Unsat END OF RECORD 15 0114-001-AR-H-V-KKK Vessel Mooring This item is reserved to charge ROS manpower requirements necessary for adding, removing, moving or adjusting the vessel's mooring lines and wires as required due to river stage or tidal changes, stern ramp operations, shifting of vessel, dock and/or sea trials, etc. END OF RECORD 16 0115-001-W1-G-V-KKK Fire/Flood/Entry Protection The ROS alarm system consists of four (4) zones, namely fire, flood, intrusion and CSI. It also alarms when there is a power failure. Power failure is independent of the four main zones. The alarm panel is located in the starboard side passageway leading down from the upper deck to the lower tween deck. The panel contains a voice/pager dialer capable of dialing out to three (3) phone numbers and one (1) pager. The panel also contains a control box with relays, terminal blocks, transformers and indicator lights. The control box was installed because of the limited ampere capability of the alarm panel due to the added lights and siren on the flying bridge. On the flying bridge there is a panel with four (4) weather proof lights (red for fire; green for flood; yellow for intrusion; and white to indicate power available to the system) and one (1) weather proof siren. The light/siren panel is provided with sufficient cable so it can be moved to the port or stbd side. It is also fitted with a junction box so it can be disconnected when the vessel is activated. The NDRF fire alarm circuit consists of four (4) zones with ionization detectors strategically located where dehumidification machines may be present. The four (4) locations are engine control room (ECR), engine lower level port side near the aft end of the main engine, engine room lower level stbd side above the purifiers, and in the wheelhouse. Junction boxes are also located in the engine room and third deck passageway for possible future addition of additional detectors. During ROS, the NDRF fire alarm circuit is disconnected at the main alarm panel. The vessel=s main fire detection system is connected to the ROS alarm system instead of the NDRF fire alarm system. Any fire alarm from the ship's fire detection system will also activate the ROS alarm system. The ROS flood alarm circuit consists of six (6) zones with Gems float switches strategically located where flooding is most likely. The float switches are located in the forward engine room bilges, aft engine room bilges (shaft alley), bow thruster room, port and stbd stabilizer rooms and lower (tank top) cargo hold. The intrusion alarm was installed for use when the vessel is not manned and all access to the vessel is secured and locked. The intrusion alarm circuit consists of three (3) limit switches, one each at the stbd Upper Deck door and port and stbd forward Poop Deck doors. Each location also contains a keypad to allow programming of the entire ROS alarm system from either location. The entire ROS alarm system is capable of being acknowledged or armed from either keypad. The system can only be alarmed if there are no alarm inputs. Independent zones can be bypassed. During ROS, the intrusion alarm zone and CSI zone are normally bypassed. The engine room control console CSI annunciation panel has been connected to the ROS alarm system as Zone 4. When the CSI panel is up and running and Zone 4 is energized, any CSI alarm will also activate the ROS alarm system. On a weekly basis, a random sample of flood floats and fire detectors shall be activated to test the integrity of the floats and detectors as well as to test the voice/pager dialer. Each week, a different random sample of flood floats and fire detectors shall be tested. In addition, the power failure alarm shall also be tested on a weekly basis. The message shall be received from any telephones called and the code shall be received from the duty engineer=s pager to verify each test. During testing of the ROS alarm system, verify that the independent keypads at the three (3) doors function properly. Also, verify that the appropriate lights on the flying bridge illuminate. END OF RECORD 17 0115-001-W1-G-V-KKK Fire/Flood/Entry Protection The ROS alarm system consists of four (4) zones, namely fire, flood, intrusion and CSI. It also alarms when there is a power failure. Power failure is independent of the four main zones. The alarm panel is located in the starboard side passageway leading down from the upper deck to the lower tween deck. The panel contains a voice/pager dialer capable of dialing out to three (3) phone numbers and one (1) pager. The panel also contains a control box with relays, terminal blocks, transformers and indicator lights. The control box was installed because of the limited ampere capability of the alarm panel due to the added lights and siren on the flying bridge. On the flying bridge there is a panel with four (4) weather proof lights (red for fire; green for flood; yellow for intrusion; and white to indicate power available to the system) and one (1) weather proof siren. The light/siren panel is provided with sufficient cable so it can be moved to the port or stbd side. It is also fitted with a junction box so it can be disconnected when the vessel is activated. The NDRF fire alarm circuit consists of four (4) zones with ionization detectors strategically located where dehumidification machines may be present. The four (4) locations are engine control room (ECR), engine lower level port side near the aft end of the main engine, engine room lower level stbd side above the purifiers, and in the wheelhouse. Junction boxes are also located in the engine room and third deck passageway for possible future addition of additional detectors. During ROS, the NDRF fire alarm circuit is disconnected at the main alarm panel. The vessel=s main fire detection system is connected to the ROS alarm system instead of the NDRF fire alarm system. Any fire alarm from the ship's fire detection system will also activate the ROS alarm system. The ROS flood alarm circuit consists of six (6) zones with Gems float switches strategically located where flooding is most likely. The float switches are located in the forward engine room bilges, aft engine room bilges (shaft alley), bow thruster room, port and stbd stabilizer rooms and lower (tank top) cargo hold. The intrusion alarm was installed for use when the vessel is not manned and all access to the vessel is secured and locked. The intrusion alarm circuit consists of three (3) limit switches, one each at the stbd Upper Deck door and port and stbd forward Poop Deck doors. Each location also contains a keypad to allow programming of the entire ROS alarm system from either location. The entire ROS alarm system is capable of being acknowledged or armed from either keypad. The system can only be alarmed if there are no alarm inputs. Independent zones can be bypassed. During ROS, the intrusion alarm zone and CSI zone are normally bypassed. The engine room control console CSI annunciation panel has been connected to the ROS alarm system as Zone 4. When the CSI panel is up and running and Zone 4 is energized, any CSI alarm will also activate the ROS alarm system. On a weekly basis, a random sample of flood floats and fire detectors shall be activated to test the integrity of the floats and detectors as well as to test the voice/pager dialer. Each week, a different random sample of flood floats and fire detectors shall be tested. In addition, the power failure alarm shall also be tested on a weekly basis. The message shall be received from any telephones called and the code shall be received from the duty engineer=s pager to verify each test. During testing of the ROS alarm system, verify that the independent keypads at the three (3) doors function properly. Also, verify that the appropriate lights on the flying bridge illuminate. END OF RECORD 18 0115-001-W1-G-V-KKK Fire/Flood/Entry Protection The ROS alarm system consists of four (4) zones, namely fire, flood, intrusion and CSI. It also alarms when there is a power failure. Power failure is independent of the four main zones. The alarm panel is located in the starboard side passageway leading down from the upper deck to the lower tween deck. The panel contains a voice/pager dialer capable of dialing out to three (3) phone numbers and one (1) pager. The panel also contains a control box with relays, terminal blocks, transformers and indicator lights. The control box was installed because of the limited ampere capability of the alarm panel due to the added lights and siren on the flying bridge. On the flying bridge there is a panel with four (4) weather proof lights (red for fire; green for flood; yellow for intrusion; and white to indicate power available to the system) and one (1) weather proof siren. The light/siren panel is provided with sufficient cable so it can be moved to the port or stbd side. It is also fitted with a junction box so it can be disconnected when the vessel is activated. The NDRF fire alarm circuit consists of four (4) zones with ionization detectors strategically located where dehumidification machines may be present. The four (4) locations are engine control room (ECR), engine lower level port side near the aft end of the main engine, engine room lower level stbd side above the purifiers, and in the wheelhouse. Junction boxes are also located in the engine room and third deck passageway for possible future addition of additional detectors. During ROS, the NDRF fire alarm circuit is disconnected at the main alarm panel. The vessel=s main fire detection system is connected to the ROS alarm system instead of the NDRF fire alarm system. Any fire alarm from the ship's fire detection system will also activate the ROS alarm system. The ROS flood alarm circuit consists of six (6) zones with Gems float switches strategically located where flooding is most likely. The float switches are located in the forward engine room bilges, aft engine room bilges (shaft alley), bow thruster room, port and stbd stabilizer rooms and lower (tank top) cargo hold. The intrusion alarm was installed for use when the vessel is not manned and all access to the vessel is secured and locked. The intrusion alarm circuit consists of three (3) limit switches, one each at the stbd Upper Deck door and port and stbd forward Poop Deck doors. Each location also contains a keypad to allow programming of the entire ROS alarm system from either location. The entire ROS alarm system is capable of being acknowledged or armed from either keypad. The system can only be alarmed if there are no alarm inputs. Independent zones can be bypassed. During ROS, the intrusion alarm zone and CSI zone are normally bypassed. The engine room control console CSI annunciation panel has been connected to the ROS alarm system as Zone 4. When the CSI panel is up and running and Zone 4 is energized, any CSI alarm will also activate the ROS alarm system. On a weekly basis, a random sample of flood floats and fire detectors shall be activated to test the integrity of the floats and detectors as well as to test the voice/pager dialer. Each week, a different random sample of flood floats and fire detectors shall be tested. In addition, the power failure alarm shall also be tested on a weekly basis. The message shall be received from any telephones called and the code shall be received from the duty engineer=s pager to verify each test. During testing of the ROS alarm system, verify that the independent keypads at the three (3) doors function properly. Also, verify that the appropriate lights on the flying bridge illuminate. END OF RECORD 19 0115-001-W1-G-V-KKK Fire/Flood/Entry Protection The ROS alarm system consists of four (4) zones, namely fire, flood, intrusion and CSI. It also alarms when there is a power failure. Power failure is independent of the four main zones. The alarm panel is located in the starboard side passageway leading down from the upper deck to the lower tween deck. The panel contains a voice/pager dialer capable of dialing out to three (3) phone numbers and one (1) pager. The panel also contains a control box with relays, terminal blocks, transformers and indicator lights. The control box was installed because of the limited ampere capability of the alarm panel due to the added lights and siren on the flying bridge. On the flying bridge there is a panel with four (4) weather proof lights (red for fire; green for flood; yellow for intrusion; and white to indicate power available to the system) and one (1) weather proof siren. The light/siren panel is provided with sufficient cable so it can be moved to the port or stbd side. It is also fitted with a junction box so it can be disconnected when the vessel is activated. The NDRF fire alarm circuit consists of four (4) zones with ionization detectors strategically located where dehumidification machines may be present. The four (4) locations are engine control room (ECR), engine lower level port side near the aft end of the main engine, engine room lower level stbd side above the purifiers, and in the wheelhouse. Junction boxes are also located in the engine room and third deck passageway for possible future addition of additional detectors. During ROS, the NDRF fire alarm circuit is disconnected at the main alarm panel. The vessel=s main fire detection system is connected to the ROS alarm system instead of the NDRF fire alarm system. Any fire alarm from the ship's fire detection system will also activate the ROS alarm system. The ROS flood alarm circuit consists of six (6) zones with Gems float switches strategically located where flooding is most likely. The float switches are located in the forward engine room bilges, aft engine room bilges (shaft alley), bow thruster room, port and stbd stabilizer rooms and lower (tank top) cargo hold. The intrusion alarm was installed for use when the vessel is not manned and all access to the vessel is secured and locked. The intrusion alarm circuit consists of three (3) limit switches, one each at the stbd Upper Deck door and port and stbd forward Poop Deck doors. Each location also contains a keypad to allow programming of the entire ROS alarm system from either location. The entire ROS alarm system is capable of being acknowledged or armed from either keypad. The system can only be alarmed if there are no alarm inputs. Independent zones can be bypassed. During ROS, the intrusion alarm zone and CSI zone are normally bypassed. The engine room control console CSI annunciation panel has been connected to the ROS alarm system as Zone 4. When the CSI panel is up and running and Zone 4 is energized, any CSI alarm will also activate the ROS alarm system. On a weekly basis, a random sample of flood floats and fire detectors shall be activated to test the integrity of the floats and detectors as well as to test the voice/pager dialer. Each week, a different random sample of flood floats and fire detectors shall be tested. In addition, the power failure alarm shall also be tested on a weekly basis. The message shall be received from any telephones called and the code shall be received from the duty engineer=s pager to verify each test. During testing of the ROS alarm system, verify that the independent keypads at the three (3) doors function properly. Also, verify that the appropriate lights on the flying bridge illuminate. END OF RECORD 20 0118-001-AR-G-V-KKK Trash/Waste Disposal This item is reserved to charge ROS manpower requirements necessary for routine trash and waste disposal. END OF RECORD 21 0128-001-AR-G-V-KKK Crane/Material Handling This item is reserved to charge ROS manpower requirements necessary for routine crane and forklift handling and other material handling for stores deliveries and contractor support. END OF RECORD 22 0143-001-AR-M-V-KKK Operational Tests (Non-Reg) Plant Start Up/Operate Following are procedures for plant start up and other operations under various conditions. It should be understood that these are only intended to be guidelines for operations. Common sense and good marine engineering practice should take precedence over these guidelines. How to Start up the Engine Room Installation, without Shore Power Ship in a total A black out situation: - Check emergency generator cooling water, lube oil and fuel oil. - Pump up the hydraulic starter, 75 strokes by hand. - Start emergency generator and put on ear protection. - Close the main circuit breaker from emergency generator on ESB. Situation: Emergency generator is feeding the emergency switchboard (ESB). - Close the main circuit breaker from MSB on ESB. - Check whether the 24 volt batteries are connected and charger panel in Gyro Room (3rd Deck) is switched on. - Go to the main switchboard (MSB) and reset the ABus Tie Breaker@ on the bus tie breaker panel (to Aoff@ position) - Switch on the bus tie breaker by switch ACOS-52@ and selector switch AESB / Thrusters@ on ESB. Situation: Emergency generator is feeding the ESB and the MSB - Reset the breakers on the MSB with a ANon Preferential function. - Start the Engine Room Ventilation. - Replace all drain plugs and close all air vents on all coolers. - Start and auxiliary cooling water pump and an air compressor. - Pump up one (1) main air vessel until approximately 18 bar. - Open air valve on main air vessel to auxiliaries. - Start hydraulic power unit for valves. - Switch on Engine Room monitoring system on 220 volt feeder panel and accept all incoming alarms. - Now an auxiliary engine can be started. When shore power is available: - Start an auxiliary cooling water pump and an air compressor. - Pump up one main air vessel until approximately 18 bar. - Open air valves on main air vessel to auxiliaries. - Check 24 volt system - Switch off as many systems as possible: pumps, AC accommodation, etc. - Go to the emergency generator room, check the emergency generator and start it. Starting air and 24 volt are available. Selector switch on manual, push start and generator will start. Put on ear protection because the generator is noisy. - Switch off the shore power, Ablack out situation@. - Close the main circuit breaker from emergency generator on ESB. The following procedure is as above in a total black out situation. To start an auxiliary engine - Turn the engine at least one turn by hand. - Close the indicator cocks. - Check the expansion tank and replenish. - Check lube oil level in sump tank. - Start pre-lube oil pump. When the pump selector switch is on automatic, the pump will start when the Astop@ button from the engine on the MSB is pressed. - Open diesel oil valve to auxiliary engines on tank. - Open diesel oil valve before and after diesel oil meter. - Open diesel oil valve inlet and return on each engine. Make sure the blended oil valves are closed. - Open diesel oil valve to fuel valve cooling oil system. (Near diesel oil meter.) - Make sure the turning gear is disengage and the turning handle bar is in its holder. - Open starting air to the engine and start engine. There are three locations to start and auxiliary engine. On the engine: Remove the protection cap on top of the air starting air solenoid and operate solenoid by hand. On the local control panel near the engines: Check if the blue Aready@ lamp is on. If not: Check if the turning handle bar is in its holder. Check if the fuel lever is in Astarting position@ Check if the blue Aready@ light on MSB is on. Press the start button on the engine control panel on MSB. Situation: The auxiliary engine is running idle. The emergency generator is feeding the ESB and the MSB. Synchronize the main generator with the MSC (emergency generator) Hold the selector switch of the synchroscope to automatic and the generator will switch on the main bus bar. The design of the installation is such that the main generator can run synchronously with the emergency generator for a few seconds, after that the circuit breaker from the emergency generator on the ESB will open automatically. Go to the emergency generator room and stop the emergency generator. Put the selector switch on the engine control panel to automatic. Reset the main circuit breaker from the emergency generator on the ESB. (should be in Aoff@ position) Situation: The main generator is feeding the MSB and the ESB. Switch all motor controllers on MC1 and MC2 to remote and start up the machinery as required. Cylinder Cooling Water System Main Engine Drawing M-22132 Valves normally open: 8 cylinder inlet butterfly valves. (Marked on cylinder 8) 8 cylinder outlet butterfly valves. 8 deaeration hoses with self closing quick coupling 3 inlet butterfly valves turbo chargers.(Marked on turbo 3) 3 outlet butterfly valves turbo chargers. 1 valve from cooling water expansion tank to system, near cylinder cooling water cooler. 1 general air vent main engine, near turbo 2 2 suction valves cylinder cooling water pumps. 2 discharge valves cylinder cooling water pumps. Valves normally closed: 16 drain valves cylinder cooling water, two each cylinder. 3 drain valves cooling water turbo chargers Before starting up one of the pumps, check level in the cylinder cooling water expansion tank on first deck near boiler, should be approximately half full. Do not over fill otherwise the tank will overflow when the engine is warming up. Then start a cylinder cooling water pump and switch on the heating. ATTN: Do not close the cooling water valves from turbo charge 2, because this will interfere in the cooling water flow through the main engine. ATTN: When starting up the evaporator, open the cylinder cooling water valves, especially the inlet butterfly valve, slowly . To prevent possible Atrip @ main engine. Piston Cooling Water System Main Engine Drawing M-22132 Valves normally open: 2 Discharge valves piston cooling water pumps. 1 Drain valve from piston cooling water chest to separating tank. 1 Overflow valve from separating to drain tank. 4 valves near boiler water circulating pumps (on 1st deck) to/from gland cooling, to cool these glands with piston cooling water. 1 inlet valve cooling spiral in fuel valve cooling water tank. 1 outlet valve cooling spiral in fuel valve cooling water tank Before starting the piston cooling water pumps check level in piston cooling water drain tank. After starting the pump check the flow in sight glasses on port aide of the main engine. ATTN: When the piston cooling water temperature exceeds 70 degrees C a Ano flow@ alarm will be triggered. The sensor for this alarm is a heating element cooled by the cooling water flow. When the flow stops the element will arm up and an alarm will sound when this element reaches a temperature of 70 degrees C. So when the piston cooling water outlet temperature is too high this will result in a false Ano flow@ alarm. If this occurs, check flow through sight- glasses immediately and lower piston cooling water temperature. Fuel Valve Cooling Water System Main Engine Drawing M-22132 Valves normally open: 8 inlet valves on cylinder head main engine 8 outlet valves on cylinder head main engine 2 suction valves on fuel valve cooling water pumps 2 discharge valves on fuel valve cooling water pumps Before starting one of the pumps check level in expansion tank. This tank is divided in two (2) compartment, the pump suction is from the compartment with gauge glass (at port side). After starting the pump open steam to steam coil in the tank. On SB side of the tank is a drain pan with valve, this valve is normally closed. Auxiliary Engine Cooling Water System Drawing M-22132 Valves normally open: 4 Supply valves from expansion tank to engines, under the floor plating of the generator deck. 4 Deaeration valves on the top of the engines. 4 Preheating valves, port front side of generator Before starting the auxiliary engine, check level in expansion tank, situated in spiral stair case. This tank has two compartments, port side compartment for engine 1 and 2, SB side compartment for engine 3 and 4. These two compartments will overflow into each other. Fresh Cooling Water System Air Compressors Drawing M-22132 Valves normally open: 3 Supply valves from expansion tank to compressors 3 Deaeration Valves 3 Cooler inlet valves 3 Cooler outlet valves Before starting an air compressor check level in expansion tank, situated on generator deck at SB side of auxiliary engine #3. Main Sea Cooling Water System Drawing M-21133 Valves normally open: 1 Main suction Valve from Sea Chest 2 Pump suction Valves 2 Pump Discharge Valves 2 Inlet Valves Air Coolers 2 Outlet Valves Air Coolers (Keep these valves throttles to regulate scavenging air temperature 1 Outlet valve lube oil cooler 1 Outlet valve piston cooling water cooler 1 Overboard valve main circulating water 1 Inlet valve shaft bearing cooling water 1 Overboard valve shaft bearing cooling water. Valve normally closed: Emergency bilge suction valve ATTN: Before starting a main sea cooling water pump, after a dry dock period, it is wise to put the temperature regulating 3-way valve in such a position that the recirculating line is closed and all sea water is pumped directly overboard. Then deaerate pumps thoroughly and start one of the pumps. Probably some water will come out of the air vent from the suction filters situated in top of the engine room. Let the pump run for a few minutes until all the air is pushed out of the system, then put the recirculating 3-way valve in normal position. If the pumps are started without closing the recirculating line, a lot of water will spray into the engine room top out of the suction filter air vent., Once this is done, the pumps can be stopped and started without any problems. Air Conditioning Cooling Water System Drawing M-22133 Valves normally open; 1 Suction valve from sea chest 2 Suction valves from pumps 2 Discharge valves from pumps 2 Inlet valves from condensers on 2nd deck in AC Room 2 Outlet valves from condensers on 2nd deck in AC Room. 1 Overboard valve in Engine Room Valves normally closed: 1 Suction cross-over valve from main sea inlet 1 Discharge cross-over valve to domestic reefer installation 1 Discharge valve from fire line to AC Condensers on 2nd Deck in AC Room Air Conditioning Cooling Water System Drawing M-22133 Valves normally open: 1 Suction valve from sea chest 2 Suction Valves from pumps 2 Discharge valves from pumps 2 Inlet valves from condensers on 2nd Deck in AC Room 2 Outlet valves from condensers in 2nd Deck in AC Room 1 Overboard valve in Engine Room Valves normally closed: 1 Suction cross-over valve from main sea inlet 1 Discharge cross-over valve to domestic reefer installation 1 Discharge valve from fire line to AC condensers on 2nd Deck in AC Room. Domestic Cooling Water System Drawing M-22132 Valves normally open: 1 Suction Valve form Sea Chest 2 Suction Valves from Cooling Water Pumps 2 Discharge Valves from Cooling Water Pumps 2 Inlet Valves from condensers in domestic reefer room 2 Outlet valves from condensers in domestic reefer room 1 Overboard valve in Engine Room Valves normally closed: 1 Discharge Cross-over Valve from AC Cooling Water System Auxiliary Sea Cooling Water System Drawing M-22133 Valves normally open: 2 Suction Valves from sea chest 3 Suction Valves from pumps 3 Discharge valves from pumps 4 Inlet valves auxiliary engines 4 Outlet valves auxiliary engines 1 Overboard valve 3 Inlet Valves air compressor coolers 3 Outlet Valves air compressor coolers 1 General inlet valve air compressor coolers 1 General outlet valve air compressor coolers 1 Inlet valve atmospheric condenser 1 Outlet valve atmospheric condenser 1 Inlet valve drain cooler 1 Outlet valve drain cooler 2 Inlet valves AC unit engine control room 2 Inlet valves AC Unit engine control room ATTN: Before starting an auxiliary sea cooling water pump, after a dry docking period, deaerate pumps first then close the recirculating (temperature control) valve by closing the control air. Then start the pumps and let them run for approximately half and hour to get rid of all the air out of the system. Then open the control air to temp control valve and keep an eye on the circulating water temperature for an hour or so. ATTN: The coolers from auxiliary engines, air compressor and AC ECR, always collect a lot of sea shells. The best remedy is to back flush these coolers as soon as there is an indication that the temperature are starting to rise. To discharge sludge to shore facilities with the fuel oil transfer pump, First make sure that all the valves in the fuel oil transfer system are closed. NOTE: The hand operated suction and discharge valves (marked 405 and 407 on trim desk ) are normally kept open. Valves to be opened: 1 Direct Suction from DWT SB (hand operated). This valve is situated in from of the fuel oil trim pump under the floor plating and is clearly marked. 1 Hydraulic pump discharge valve (313) on trim desk 1 Hydraulic valve (309) to bunker line 1 Hand operated valve (401 or 402) at bunker station Connect a proper fuel oil bunker hose to bunker connection. Preferably discharge sludge into a barge which can hold a least 30 tons. The transfer pump is pumping the sludge out real quick. (25 to 30 tons per hour) be aware of this. Pump pressure approximately 6 bar. ATTN: There is an emergency stop button near the bunker stations on deck. This emergency stop can either be used for the transfer pump or the sludge pump. There is a selector switch on the sludge pump motor controller in the engine room. Make sure this witch is in the right position. Always test the emergency stop at the beginning of the sludge discharge. When the DWT is empty, stop the transfer pump and close the hand operated direct suction valve from DWT SB. Open hydraulic pump suction valve (312) and a valve from one of the oil storage tanks and pump some clean oil through the bunker lines until all lines are free of sludge. Stop the pump and close all valves and clean the suction filter from the transfer pump. To pump bilge water from bilge to dirty water tank port: Open the suction valves as required Discharge valves to be opened: 1 Discharge valve of the pump (BS121V) 1 By-Pass Valve from oily water separator BS122V) 1 Discharge valve to dirty water tank port BS130V) Make sure the following discharge valves are closed: 1 Inlet valve oily water separator (BS124V) 1 Outlet valve 3rd Stage oily water separator 2 Overboard valves (BS129V and B161V) To pump down the bilges with the main bilge/ballast pumps directly overboard. This is normally only done with the bilges in the cargo hold. All valves are hydraulically operated from the ballast console in the TCR, just follow the lines on the desk. ATTN: To prevent the bilge/ballast pump from running dry it is wise to open the sea inlet and throttle the discharge from the pump that is not in use and open the suction valve so the running pump has a little bit sea suction via the other pump. NOTE: It is also possible to pump down the cargo hold bilges, or for instance, the duct keel with the ballast stripping educator. See also Drawing M-22134. To do this, open the following hand-operated valves in the Engine Room (valves all marked): 1 Educator suction valve from port ballast line (WB212V) 1 Educator suction valve from SB ballast line (WB213V) 1 Suction valve educator (WB214V) 1 Overboard valve educator (W115V) 1 Feedwater valve on manifold from fire main pump 1 or 2 to educator. (WB301V or WB302V) Start the fire pump and open the required hydraulic valves in the TCR. Sludge Transfer System in Engine Room Drawing M-22135 Dirty water tank Port (DWT Port ) is only as a bilge water collecting tank and coastal waters. Dirty water tank SB (DWT SB) is used as a sludge collecting tank; from this tank the sludge can be discharged to shore facilities. The oil from the fuel oil sludge tank, the lube oil sludge tank and the piston gland residue tank is pumped to the DWT SB. The oil from the oily water separator drains into DWT SB as well. The oil from the oil drain tank is pumped to the FO Settling Tank. Water from the above mentioned tanks can be pumped overboard via the oily water separator with the engine room bilge pump. There is a suction valve from the sludge tank next to the suction manifold of the engine room bilge pump. To pump oil from sludge tanks to DWT SB, use the sludge pump. First make sure all valves in the system are closed, then; Valves to open: 1 Suction valve from required tank (all marked) 1 Discharge valve to DWT SB (marked) To pump oil from the oil drain tank to settling tank, use sludge pump First make sure all valves in the system are closed, then; Valves to open: 1 Suction valve from oil drain tank 1 Discharge to deck and settling tank near sludge pump 1 Discharge valve to settling tank marked (37), behind the ECR on SB side. ATTN: Make sure the sludge discharge valves on deck near bunker stations are closed. How to pump down the bilges overboard with the Engine Room Bilge Pump via Main Bilge Line First make sure that all valves in the system are closed, also the hydraulic valves, operated in the TCR. Suction valves to open: 1 Suction valve from port or Starboard forward bilge, locally operated by hand. OR the suction valve from the aft bilge (hydraulic valve) This valve, however is only used in case of emergency, to prevent oil contamination of the main bilge line. 1 Suction valve (BS120V) on pump manifold form main bilge line. Discharge valves to open: 1 Discharge valve on pump (BS124V) 1 Inlet valve oily water separator (BS124V) 1 Outlet valve 3rd stage oily water separator (BS127V) 2 Overboard valves (BS129V and B160V) 2 Small valves to 15ppm monitor Open control air to automatic oil discharge valve and switch on the electric control box to Aautomatic@. First fill up the oily water separator with sea water, open the suction from the sea chest on the pump manifold and start the pump. NOTE: There is a sea suction valve on the sea chest next to aux. sea cooling water pump 1, which is normally open. When the oily water separator is filled up with sea water, slowly close the sea suction valve on the pump manifold. To pump down the aft bilge open the following suction valves: 1 Suction valve from aft bilge (BS108V) locally hand operated 1 Suction valve on pump manifold from aft bilge (B119V) The discharge valves to be opened as required. NOTE: Make sure the suction valves from both the dirty water tanks are closed because they are on the same suction line as the after bilge. To pump water from the dirty water tank Port or Stbd overboard, close the suction valve from the after bilge and open the suction (under the floor plating) from the dirty water tank required. Bilge Pumping System in Machinery Space Drawing M-22135 There are three (3) bilges in the Engine Room, each bilge has a level alarm (Mobrey float switch) There is one AEngine Room Flooding@ alarm, the float for this alarm is situated just in from of the aft bilge. All these three (3) bilges can be pumped down through the oily water separator and the 15 ppm equipment overboard, with the engine room bilge via the Amain bilge line@. Normally this main bilge line is only used to pump down the two forward bilges. (The bilge suction lines from the cargo holds are also connected to the same Amain bilge line@). The aft bilge has a separate suction line which is also used to pump down the dirty water tanks with the engine room bilge pump. NOTE: A Wilden pump is installed , parallel to the electrical bilge pump, to obtain a better suction when there is a lot of air in the system. The main bilge and ballast pumps or the ballast educator can be used to pump down the bilge via the Amain bilge line. In this case, the water is not pumped via the oily water separator, but directly overboard. So this system is only to be used in case of an emergency, or when only clean water is pumped out. There is also a direct suction on the main bilge and ballast pumps from Port and Starboard forward bilge. There is a large emergency suction on the main sea cooling water pump forward; this suction valve can be manually opened just on forward side of the main sea cooling water pumps against the bulkhead. Fuel Oil Purifier System Drawing 22144-20 How to run FO Sep 1 or 2 on heavy fuel oil. When separator 1 has been separating diesel oil, make sure the parameter settings are set for fuel oil. NOTE: The temperature in the fuel oil settling tank has to be kept as constant as possible, because the ALCAP separator with it electronic devices is sensitive to temperature fluctuations. Therefore it is wise to pump only small amounts of oil into this tank. When the ship is at sea, running at full speed, pump at least three times a day. The separator suction from the settling tank is very close tot he transfer pump discharge into this tank, so a too large quantity of relatively cold oil pumped into the settling tank will effect the operation of the separator immediately. NOTE: A sludge conditioning set is mounted on these separators. After each discharge cycle, a small amount of water is injected in the bowl to keep the sludge, formed in the bowl, soft. This way the sludge will be discharged easier and a partial discharge is prevented. The separator can destroy itself and a dangerous situation occurs, when a hard lump of sludge breaks off and is left in the bowl after a sludge discharge causing imbalance of the bowl. Valves to open: 1 Suction Valve from the settling tank on the tank. 1 Suction from FO System near separator 1 Discharge to clean FO Tank near separator Valves to close: 1 Suction valve from the Anon running@ separator 1 Discharge valve from the Anon running@ separator When separator 1 is separating fuel oil, make sure that the valves to and from the DO tanks are closed. Note: It is possible to separate diesel oil from tank 2SB directly to the clean diesel oil tank. Valve to close: 1 Hydraulic valve (318 or 319) on diesel oil settling tank port or stbd (operated on trim desk in ECR) Valve to open: 1 Hydraulic valve (302) from tank 2SB 1 Valve (2) near drinking water pumps. All other valves stay in the same position as in the first situation. NOTE: It is possible to recirculate clean oil from clean DO tank to the separator by opening the drain valve to DO transfer system. (Close valves on settling tanks and/or tank 2 SB first, otherwise clean oil will flow back to these tanks. Valves in fuel oil system normally closed: 1 By-pass valve FO Meter 1 By-pass valve Feeder Unit 1 By-pass valve Automatic B&K filter All valves on mixing pipe (no longer in use) 1 Return valve to clean oil tank from mixing pipe 1 FO Inlet valve steam heater 1 1 FO outlet valve steam heater 1 1 By-pass valve electric heater 1 By-pass valve viscorator 1 Former inlet valve automatic B&K filter 1 Former outlet valve automatic B&K filter 1 Recirculating valve main engine Diesel Oil Purifier System Drawing 22144-20 NOTE: The original two MAPX-210 fuel oil purifiers have been replaced by two FOPX (ALCAP) separators. FO Sep #1: Separates diesel oil or fuel oil. (Parameter settings on MARST control box have to be changed for fuel or diesel operation, see instruction book) FO Sep #2: Separates fuel oil only NOTE: Parameter settings on MARST control box FO Sep #1 have to be changed for fuel or diesel operation as follows: For fuel oil operation For diesel oil P-14: 24 P-14: 15 P-15: 120 P-15: 0 P-17: 34 P-17: 50 All other parameter values stay unchanged. NOTE: Fuel oil tank 2 SB has been altered from fuel oil tank to diesel tank. How to run FO Sep. 1 on diesel oil, from DO settling tank to clean oil tank: Valves to open: 1 Hydraulic valve (318 or 319) on diesel oil settling tank Port or Stbd. (Operated on trim desk in ECR) 1 Suction valve from DO System, near separator 1 Discharge valve to clean DO tank, near separator 1 Discharge valve to clean DO tank (311), near tank Valves to close: All valves in DO Transfer System 1 Suction valve separator from FO System 1 Discharge valve separator to clean FO tank 1 Suction valve DO filter pump (313) 1 Discharge valve DO filter pump (315) Start separator as a separator is normally started. Start feeder pump from separator. The capacity, from this pump, can be regulated by the thyristor regulating unit on the tween deck above the separators. - For diesel oil approximately 25Hz - For fuel oil approximately 40 hz with main engine running at full speed Fuel Oil System Main Engine This system has been modified a few times, so the diagram M-22143 is not accurate any more, see for the present situation the diagram on the reverse of the plastified diagram in ECR. The fuel oil feeder unit was installed in 1985, this feeder unit replaced the mixing pipe. The automatic fuel oil filter B&K was originally situated after the fuel oil heaters. The high oil temperature caused a lot of problems with these filters. Now this filter is placed in the Alow temperature@ area in the feeder unit circulating system. What used to be the by-pass filter from the automatic filter is now in sue as a last filter before the HP fuel pumps. The electrical heater was installed in 1994, electrical switch and control box of this heater is situated in engine control room. Valves in fuel oil system normally open: 1 Valve on clean diesel oil tank (S.O.S. Valve) 1 Valve on clean fuel oil tank (S.O.S. Valve) 3 Way Valve to be kept in FO or DO position 1 Valve before fuel oil meter 1 Valve after fuel oil meter 1 Feeder unit inlet valve 2 Suction valves feeder unit pumps 2 Discharge valves feeder unit pumps 1 Inlet valve FO B&K filter (automatic fuel oil filter) 1 Outlet valve FO B&K filter 1 Deaeration valve on deaeration tank feeder unit 1 Outlet valve deaeration tank feeder unit 1 Return valve from Main Engine to deaeration tank 1 Outlet valve feeder unit 2 Suction valves FO circulating pumps 2 Discharge valves FO circulating pumps 2 valves in recirc. line from the FO circulating pumps 1 FO inlet steam heater #1 1 Series cross-over valve (Heaters normally in series) 1 FO outlet valve steam heater #2 1 Inlet valve electrical heater 1 Outlet valve electrical heater 1 Inlet valve viscorator 1 Outlet valve viscorator 1 Inlet valve Aby-pass@ filter 1 Outlet valve Aby-pass@ filter Lube Oil System Auxiliary Engines Drawing M-22141 The electrically driven pre-lube oil pump (one for each engine) has to be started before a diesel generator is started, by pressing the Astop@ button from the engine in the ECR. Check lube oil pressure on monitor in control room The main lube oil pump from the diesel generators is driven by the engine. There is a separate lube oil system for the rocker arms, with a separate tank on SB side of each engine. ATTN: The duplex lube oil filters from a running engine have to be cleaned weekly. It is wise to start another engine and only change over these filters when the engine is idling or stopped. The safety devices are very sensitive and could stop the engine when filters are changed over with a running engine. ATTN: The large CJC filters are no linger in use since 1983. Description Main Engine Lube Oil Purifier System Drawing M-22142 Suction valves to open: 1 Purifier manifold (middle valve from Main Engine Sump Tank. 1 On the Purifier Discharge valves to open: 1 On purifier manifold (middle valve) to Main Engine Sump Tank 1 On purifier, throttled as required, back pressure just above the alarm set point. On the Cape Knox: The capacity of the purifier is regulated by throttling the suction valve of the built - on pump. On the Cape Kennedy: The purifier has a recirculating line to regulate the capacity. ATTN: The lube oil renovating tank is kept empty ATTN: The lube oil separator is started a few hours before the main lube oil pump is started and is not stopped until the main engine is shut off for a linger period. Lubricating Oil System Main Engine Drawing M-22141 Valves normally open: 2 Suction valves main lube oil pumps 2 Discharge valves main lube oil pumps 2 Suction valves cross head lube oil pumps 2 Discharge valves cross head lube oil pumps 1 N.R. valve from main lube oil system to cross head bearings 1 Regulating valve from main lube oil system to bearings. ATTN: Always start main lube oil pump first, before starting cross head bearing lube oil pump. ATTN: The N.R. valve from main engine system to cross heads is to be kept open at all times, to ensure minimum amount of oil flow to cross heads in case of cross head lube oil pump failure. This valve is now secured in Aopen@ position. ATTN: With the manually operated pressure regulating valve the bearing oil pressure is reduced from approximately 6 bar in main lube oil system to 3.5 bar (on local manometer). This valve is situated on SB Fore side of the main engine. The Cylinder Oil Day Tank Drawing M-22142 With the engine running at full speed this tank had to be filled up at least twice a day. On the Cape Kennedy this system has been altered, see drawing M-22142. The tank in front of the old measuring tank is in use now. This tank has three floats. Pump Stop Pump Start Low Level Alarm So once the valves on the tank are open and the selector switch on the pump controller is set to automatic, the measuring tank will be kept full. ATTN: Make sure there is sufficient oil in the storage tank in use, otherwise fill up the measuring tank manually or switch over to the other storage tank, to prevent the pump from running dry. Valves to open: 1 Suction valve from storage tank 1 or 2 1 Suction valve on pump 1 Discharge valve on pump 1 Supply valve to Main engine lubricators under measuring tank 5 Supply valves on Main Engine lubricators ATTN: Valves to cylinder oil lubricators are kept open at all times, to prevent air coming into the system. This air will accumulate in the lubricators and they will run dry, resulting in possible engine damage. There is a ANo Flow: alarm on every lubricator. Various Lube Oil Systems Drawing M-22142 How to load the lube oil storage tanks Lube Oil Storage Tanks - Main Engine Connect the filling hose to marked flange at filling station upper deck Port or Stbd. Valves to open: Valve marked A1@ to storage tank 1 Valve marked A2@ to storage tank 2 Block valve to storage tank marked A3@ Cylinder Lube Oil Storage Tanks Connect the filling hose to marked flange at filling station upper deck Port or Stbd. Valves to open: Filling valve to cylinder oil tank 1 Filling valve to cylinder oil tank 2 Lube Oil Tank Auxiliary Engine Connect the filling hose to marked flange at filling station upper deck Port or Stbd. Valves to open: Filling valve to lube oil storage tank aux. engine Hydraulic Oil Storage Tanks for Ramp Power Pack Unit These two tanks are situated above the traffic control room. Connect the filling hose to marked flange at filling station upper deck Port or Stbd. Valves to open: Filling valve at filling station Filling valve on tanks, one each tank Make sure other valves on tanks are closed. Lube Oil Day Tanks for Air Compressors etc. on Mid Flat Port There is a filling connection on the rampway to deck 3 half way down. Various Lube Oil Systems Drawing M-22142 How to fill up: The Sump Tank of the Main Engine: Valves to open: Valve on lube oil storage tank 1 or 2 to main engine. Marked vale to sump tank under floor plating on port side of main engine. Make sure that the valves to stern tube and stern tube drain tank are closed. The Sump Tank of the Auxiliary Engines: These tanks are filled up by means of the lube oil transfer pump, E.R. floor SB near sludge pump, only when large quantities of oil have to be supplied. Valves to open: Various on lube oil storage tank aux. engine to transfer pump Suction valve on manifold transfer pump Discharge valve to auxiliary engines on manifold transfer pump Marked valve to sump tank aux. engine under floor plating generator deck. Make sure the valves to the other auxiliary engines are closed and that the valve to the measuring tank is closed. To replenish the sump tanks with smaller quantities of oil, it is wise to use the measuring tank. Fill up this measuring tank with the transfer pump (approximately 450 liters), then fill up the sump from this tank. END OF RECORD 23 0171-001-AR-G-V-KKK Equipment Validation Surveys This item is reserved to charge ROS manpower requirements required to carry out equipment validation surveys in support of the Ready Reserve Force (RRF) Equipment Configuration & Spare Parts Management Information System (ECSMIS). Reference the Ready Reserve Force (RRF) Logistics Management Manual, with particular attention to Section II: Shipboard Supply Management Program, and Section III: Configuration Management Program. END OF RECORD 24 0172-001-AR-G-V-KKK Spare Parts Inventories This item is reserved to charge ROS manpower requirements necessary to maintain the Personal Computer Shipboard Allowance List (PC-SAL). It shall be a goal to maintain all stock inventories and stock records with an accuracy rate of 98% or better. For tracking purposes, note related MEI codes below as applicable: 0173 Shipboard Spare Parts Reference the Ready Reserve Force (RRF) Logistics Management Manual, with particular attention to Section II: Shipboard Supply Management Program. END OF RECORD 25 0172-002-M6-G-V-KKK Controlled Equipage Inventory All controlled equipage and high dollar value items shall be inventoried to verify accuracy of the current controlled material inventory. The crew shall ascertain that the appropriate MA-Forms are submitted when controlled equipage and high dollar value items are placed aboard and/or removed from the vessel. Reference the Ready Reserve Force (RRF) Logistics Management Manual, with particular attention to Section II: Shipboard Supply Management Program. An updated controlled material inventory shall be submitted annually. END OF RECORD 26 0184-001-Y1-G-V-KKK Fuel / Lube / Waste / Hazmat Analysis NOTE: Read and be familiar with test procedures as indicated in the MarAd provided test kit. Refer to the RRF Fleetwide Oil Monitoring and Analysis Program schedule. HFO and MDO: Test fuels on board for the following. 1. Density 2. Viscosity 3. Water content 4. Stability 5. Presence of salt water in oil. DIESEL LUBES: Test main and aux. diesel engine lubes on board for the following. 1. Density 2. Viscosity 3. Water content 4. Insolubles 5. TBN OTHER LUBES: Test stern tube lube oil system for the following. 1. Density 2. Viscosity 3. Water content 4. TAN 5. Presence of salt water in oil HYDRAULICS: Test all hydraulic systems oil on board for the following. 1. Density 2. Viscosity 3. Water content 4. TAN END OF RECORD 27 0185-001-M1-G-V-KKK Water Treatment Analysis Draw samples from the below listed systems at designated sampling points. Visually inspect samples noting debris, sediment, oil or any other abnormal characteristic. Using RRF Fleetwide Water Chemistry and Treatment Program Technical Manual Vols. I and II as guidance, test samples. Record results in water chemistry log. Dose any deficient systems with Drew Liquid Dewt or AGK 100 as applicable. END OF RECORD 28 0189-001-Y1-E-V-KKK Megger / Electrical Resistance During the course of each Phase IV cycle, insulation resistance readings shall be taken of all motors, lighting circuits, power distribution feeders and motor feeders. Insure that insulation resistance readings are within equipment=s nameplate data. All electrical equipment tested shall have a minimum insulation resistance of one (1) megohm to ensure safe and satisfactory operation when energized. Any electrical equipment that could be harmed by insulation testing (i.e. electronic equipment, transformers, voltage regulators, etc.) shall not be megger tested. If insulation resistance readings are below the minimum acceptable range, action shall be taken to attempt to bring up the resistance by energizing the motor winding heaters or space heaters fitted or by installation of temporary infrared heat lamps or strip heaters. Motors can be megger tested from the feeders at their respective controllers; however, if megger readings are below the minimum acceptable range, they shall be tested at the potheads to determine if the fault is in the motor or between the controller and motor. Record all insulation resistance readings and the date each reading was taken and the ambient temperatures in the attached Insulation Resistance Report. At the completion of each Phase IV cycle, the Insulation Resistance Report shall be submitted to the Port Engineer for distribution to the COTR and applicable regulatory bodies for the record and file. END OF RECORD 29 0190-001-AR-G-V-KKK Documentation Support This item is reserved to charge ROS manpower requirements necessary for the preparation of routine and unanticipated (accident, casualty, oil spill, etc.) reports and documents as required by MarAd and company policies and directives. END OF RECORD 30 0194-001-AR-H-V-KKK Navigation Publications This item is reserved to charge ROS manpower requirements necessary for taking inventory of and updating Navigation publications. END OF RECORD 31 0195-001-AR-G-V-KKK Safety Publications / Notices This item is reserved to charge ROS manpower requirements necessary for posting and updating safety publications, instructions and notices. END OF RECORD 32 0196-001-AR-G-V-KKK Training Publications / Materials This item is reserved to charge ROS manpower requirements necessary for posting and/or distribution of training publications and for showing of training videos and/or demonstration of other training materials during safety meetings. END OF RECORD 33 0197-001-AR-G-V-KKK Log Books (Maintain Daily) This item is reserved to charge ROS manpower requirements necessary for maintaining daily log books, including MARTS MSN and RSN modules, and for preparation of daily, weekly, monthly, quarterly, semi-annual and annual reports. 1. Vessel log books shall be maintained and updated daily and available for review upon request. Log books shall include, but not be limited to draft readings and any change in vessel=s position, record description of all work to be performed, number of contractors on board, record of regulatory inspections and tests, incidents concerning safety, security and environmental issues, all parameters of operating machinery, running hours of pertinent machinery operated each day, and record of condition of water around the ship. 2. A personnel log shall be kept at the gangway. All personnel and visitors shall log themselves on and off the ship. 3. A Maintenance Action Report shall be submitted weekly. 4. A crew list shall be maintained, updated and submitted on a monthly basis. 5. A hazmat inventory shall be maintained, updated and submitted on a monthly basis. 6. A seal log shall be maintained, updated and submitted on a monthly basis. 7. Soundings shall be taken, recorded and submitted on a monthly basis. 8. A record or spare parts usage shall be maintained, updated and submitted on a monthly basis. 9. A vessel inspection shall be conducted on a weekly basis and followed up with the appropriate vessel inspection reports. 10. Worklists shall be maintained, updated and submitted as required. END OF RECORD 34 0714-001-AR-H-V-KKK Fuel / Ballast Tanks This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of fuel, diesel, lube oil, ballast, fresh water, feed water and other miscellaneous tanks and voids. END OF RECORD 35 0715-001-AR-H-V-KKK Stern Tube This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the stern tube and related components and systems, including stern tube seals and stern tube lube oil system. END OF RECORD 36 0716-001-AR-H-V-KKK Rudder This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the rudder, including taking of clearance readings to satisfy regulatory requirements. END OF RECORD 37 0720-001-AR-M-V-KKK Machinery This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of miscellaneous machinery not otherwise covered by 0722-001-AR-M-V (AUXILIARIES) or other specific items in the 0700 (REGULATORY SURVEYS AND INSPECTIONS) series of items. END OF RECORD 38 0721-001-AR-M-V-KKK Propulsion This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the main engine and other propulsion related machinery. END OF RECORD 39 0722-001-AR-M-V-KKK Auxiliaries This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of auxiliary machinery. END OF RECORD 40 0723-001-AR-M-V-KKK Refrigeration This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections or operational tests of the domestic refrigeration and accommodation air conditioning systems. END OF RECORD 41 0730-001-AR-E-V-KKK Electrical This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of miscellaneous electrical systems and components. END OF RECORD 42 0731-001-AR-E-V-KKK Automation This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the vessel=s automation systems as described in the Periodic Safety Test Procedure. END OF RECORD 43 0732-001-AR-E-V-KKK Controls This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of miscellaneous controls and control systems. END OF RECORD 44 0740-001-AR-H-V-KKK Cargo Gear This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of machinery and systems that support the stern ramp and cargo doors. END OF RECORD 45 0743-001-AR-H-V-KKK Cranes This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the provision crane (i.e. quadrennial testing), and other cranes, hoists and lift machinery. END OF RECORD 46 0745-001-AR-H-V-KKK Ramps - Stern / Interior This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the stern ramp (i.e. structural inspection, operational testing, quadrennial, etc.), and stern door, port and starboard gastight doors, watertight center rampway door and watertight rampway cover (i.e. operational testing, hose tests, etc.). END OF RECORD 47 0750-001-AR-E-V-KKK Navigation Communications This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of all navigation and communication equipment and systems. END OF RECORD 48 0755-001-AR-M-V-KKK Steering Gear This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the steering gear. END OF RECORD 49 0760-001-AR-H-V-KKK Vessel / Personnel Safety This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of miscellaneous vessel and personnel safety equipment and features. END OF RECORD 50 0761-001-AR-H-V-KKK Safety Equipment This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of miscellaneous safety equipment. END OF RECORD 51 0762-001-AR-H-V-KKK Fixed Firefighting Systems This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of the main CO2 system and the independent CO2 systems for the paint locker and emergency generator room, as well as the firemain. END OF RECORD 52 0763-001-AR-H-V-KKK Portable Firefighting Equipment This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of portable and semi-portable firefighting equipment (i.e. fire extinguishers, fire station equipment, firemen=s outfits, emergency gear lockers, etc.). END OF RECORD 53 0765-001-AR-H-V-KKK Lifeboats Davits and Winches This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of lifeboats, davits and gear. END OF RECORD 54 0766-001-AR-H-V-KKK Portable Lifesaving Gear This item is reserved to charge ROS manpower requirements required to support and carry out regulatory surveys and inspections of portable lifesaving gear (i.e. liferafts, ring buoys, SCBA and OBA apparatus, etc.). END OF RECORD 55 1202-001-Y1-H-V-KKK Mooring Bits and Foundations Visually inspect mooring bits and their foundations for defects, damage, wear and deterioration. Pay special attention to chaffing wear and foundation welds. END OF RECORD 56 1203-001-Y1-H-V-KKK Hawse Pipes Visually inspect the hawse pipes for defects, damage, wear and deterioration. Pay special attention to chaffing wear. END OF RECORD 57 1204-001-Y1-H-V-KKK Chain Pipes Visually inspect the chain pipes for defects, damage, wear and deterioration. Pay special attention to chaffing wear. Insure that the chain pipe covers are present and installed in good order when anchor tackle is idle. END OF RECORD 58 1205-001-M6-H-V-KKK Pawls Visually inspect the anchor chain pawls for defects, damage and deterioration. Lubricate mechanical parts as required. END OF RECORD 59 1206-001-M6-H-V-KKK Chain Stoppers Visually inspect the anchor chain stoppers for defects, damage and deterioration. Lubricate mechanical parts as required. END OF RECORD 60 1223-001-Y1-H-V-KKK Windows Visually inspect all accommodation space windows for damage and defects. Insure that all escape windows aren=t missing any securing dogs. Lubricate the dogs and hinges on all escape windows. Test all escape windows by opening and closing to insure freedom of movement. Insure that all escape windows are fitted with instruction placards. END OF RECORD 61 1224-001-Y1-H-V-KKK Windows - Wheelhouse Visually inspect the wheelhouse windows windows for damage and defects. Test the window wipers (3) to prove satisfactory operation. END OF RECORD 62 1260-001-M6-H-V-KKK Fire Station Boxes (Inspect) 1. Conduct a complete inspection and inventory of each fire station throughout the vessel. Refer to the attached FIRE STATION INVENTORY for guidance. 2. Where fitted, check the condition of the hose box or fire station box. Check the condition of the hose box or fire station box door hinges where doors are fitted. 3. Insure that the fire station is properly numbered in accordance with the attached FIRE STATION INVENTORY, which is complete in accordance with the vessel=s fire control plan. 4. Exercise the valves by fully opening and closing the valves. Lubricate the valve stems with anti-seize compound. Tighten any loose or leaking packing glands. 5. Insure that all valves and gated wyes are fitted with caps attached with keeper chains. 6. Check the first aid fresh water valves in each fire station within the accommodations. 7. Insure that all spanners and nozzles are in place. 8. Visually inspect the hoses for damage, deterioration or defects. 9. Insure that applicators are in place in accordance with the fire control plan. END OF RECORD 63 1317-001-Y1-H-V-KKK Packing Gland Visually inspect the rudder packing gland for signs of leakage. Adjust gland when required. END OF RECORD 64 1330-001-Y1-H-V-KKK Tools - Rudder Handling Tools Visually examine the following tools for unshipping and replacing rudder. Confirm that tools are present, secured and protected from corrosion. Check tightness of securing fasteners and as necessary maintain same. Touch up any deficiencies in corrosion protection using approved protectant. Report any uncorrected deficiencies. 1 ea. Lifting Rod for after part 120 mm OD x 1,220 mm long, threaded ends 1 ea. Lifting Rod for fwd part 120 mm OD x 1,140 mm long, threaded ends 4 ea. Eye Nut for Lifting Rod 200 mm ID eye x 400 mm 2 ea. Adjusting Ring after part Tapered Ring 130 mm ID x 320 mm OD x 47 mm thick 2 ea. Adjusting Ring fwd part Tapered Ring 130 mm ID x 320 mm OD x 62 mm thick 4 ea. Eye Bolt for Lifting Rods 72 mm OD x 40 mm ID eye bolt with 35 mm thread END OF RECORD 65 1400-001-Y1-H-V-KKK Deck Covering For tracking purposes, note related MEI codes below as applicable: 1401 Accommodation spaces 1402 Working spaces 1403 Commissary spaces 1404 Toilet/shower areas 1410 Reefer spaces 1415 Weather decks 1421 Portable gratings 1430 Deck treads 1431 Ladder treads Visually inspect all deck coverings throughout the vessel for damage, deterioration and wear. Note all deficiencies found during the inspection and suggested remedies for repair. Insure that all vinyl composite tile (VCT) decks and decks with other tile or deck covering are intact. Check for loose tiles or signs of moisture under the deck covering. Insure that all decks in working spaces are clean and safe, particularly in passageways, commissary spaces, toilet and shower areas and reefer spaces. Inspect coating of weather decks and other steel decks for signs of coating breakdown and steel deterioration. Insure that all portable gratings are safely secured. Check deck treads and ladder treads for wear. END OF RECORD 66 1601-001-Y1-H-V-KKK Watertight Doors Make a thorough inspection of all watertight and weathertight doors, hatches and scuttles throughout the vessel. For tracking purposes, note related MEI codes below as applicable: 1603 Watertight scuttles 1604 Watertight hatches - non cargo hand 1606 Watertight door operators 1626 Suez Canal light access door For each watertight door, hatch and scuttle, check the following as applicable: 1. Visually inspect for defects, damage and deterioration. 2. Clean all gasket seating and sealing surfaces free of rust, scale, paint and hardened/dry grease. Lubricate sealing and seating surfaces as required. 3. Check hinge adjustments. 4. Check tightness of securing dogs and tighten as required. 5. Replace grease nipples on dogs and hinges, when fitted and as required and lubricate hinges and dogs. 6. Check for presence of dog pipes on either side of each door. Check for presence of the strongbacks for the port and stbd pilot doors and the port entrance from the upper deck to the refrigeration spaces and stbd entrance from the upper deck to the upper deck accommodation spaces. 7. For the watertight guillotine door between the bow thruster room and lower tween deck, operate the hand wheel from fully closed to fully open and back to fully closed. Apply anti-seize compound to the threads of the shaft. 8. Chalk test each door, hatch and scuttle. The impression of the knife edge shall be continuous around the closure and should be centered on the gasket. Note: Neither hammers, mauls, materials of like intent nor cheater pipes more than one foot in length shall be used to operate the dogs for securing the closure for testing. Use of force greater than that normally expected from one man utilizing a one foot cheater pipe shall be grounds for rejecting the test. 9. Watertight doors located on weather decks or exterior bulkheads shall be hose tested. A 1-1/2 inch hose with approximately 70 psi water pressure shall be directed all around the door from a distance of not more than ten feet. The water shall be applied from the weather deck side of the door. The stream of water shall be moved slowly to insure that the entire sealing surface, particularly the butt joint, is subjected to the full force of the water. No leakage shall be allowed. 10. Watertight doors located within the vessel=s interior shall be soap and air tested in lieu of being hose tested. Compressed air of approximately 90 psi shall be directed all around the door from a distance of not more than one foot. From the opposite side of the door, a soapy water solution or a commercially available leak indicating solution shall be liberally applied to the gasket to indicate leaks. the stream of air shall be moved slowly to insure that the entire sealing surface, particularly the butt joint, is subjected to the full force of air. No leakage shall be allowed. The following doors, hatches and scuttles shall be dealt with: 1. Watertight bow door for Suez Canal light, approx 1100 mm x 1400 mm (6). 2. FR 259 on centerline of foc=sle deck; weathertight hatch down to bos=n storeroom; approx 1100 mm x 1100 mm (H1). 3. FR 247 port side of foc=sle deck; weathertight scuttle down to rope locker; approx 600 mm diameter (H2). 4. FR 247 starboard side of foc=sle deck; weathertight scuttle down to rope locker; approx 600 mm diameter (H2). 5. FR 242 port side of foc=sle deck; weathertight entrance to NO. 3 DECK STORE; approx 650 mm wide x 1650 mm high (D9). 6. FR 242 on centerline of foc=sle deck; watertight ENTRANCE to bow thruster room; approx 750 mm wide x 1600 mm high (D1). 7. FR 242 starboard side of foc=sle deck; weathertight entrance to NO. 4 DECK STORE; approx 650 mm wide x 1650 mm high (D9). 8. FR 229 port upper deck; watertight entrance to BOS=N STORE ROOM; approx 750 mm wide x 1600 high (D1). 9. FR 229 starboard upper deck; watertight entrance to BOS=N STORE ROOM; approx 750 mm wide x 1600 mm high (D1). 10. FR 189 port side upper deck; watertight ENTRANCE from weather deck down to upper tween deck; approx 650 mm wide x 1650 mm high (D9). 11. FR 189 starboard side upper deck; watertight ENTRANCE from weather deck down to upper tween deck; approx 650 mm wide x 1650 mm high (D9). 12. FR 107 port side upper deck; watertight ENTRANCE from weather deck down to upper tween deck, port fin stabilizer room and port pilot access; approx 625 mm wide x 1650 mm high (D14). 13. FR 107 starboard side upper deck; watertight ENTRANCE from weather deck down to upper tween deck, stbd fin stabilizer room and stbd pilot access; approx 625 mm wide x 1650 mm high (D14). 14. FR 67 to starboard off centerline on upper deck; small watertight door on center rampway door to upper deck; approx 400 mm wide x 600 mm high (D18). 15. FR 51 port upper deck; weathertight ENTRANCE from weather deck to port side upper deck accommodations; approx 900 mm wide x 1650 mm high (D13). 16. FR 51 starboard upper deck; weathertight ENTRANCE from weather deck to starboard side upper deck accommodations; approx 750 mm wide x 1650 mm high (D3). 17. FR 57-60 fwd of first deck over center rampway, approx nine feet x eleven feet (9= X 11=) weathertight hatch to center rampway. 18. FR 18, aft, to starboard of centerline; approx three feet x four feet (3= x 4=) weathertight hatch down to lazarette. 19. FR 107-109 port side upper tween deck, watertight pilot door, approx 625 mm x 1700 mm (D6). 20. FR 106 port side upper tween deck; weathertight hatch from upper tween deck down to port FIN STABILIZER ROOM; approx 600 mm x 600 mm (H5). 21. FR 106-108 port side UTD, weathertight door to pilot vestibule and stabilizer room; approx 600 mm x 1600 mm (D5). 22. FR 107-109 stbd side upper tween deck, watertight pilot door, approx 625 mm x 1700 mm (D6). 23. FR 106 starboard side upper tween deck; weathertight hatch from upper tween deck down to starboard FIN STABILIZER ROOM; approx 600 mm x 600 mm (H5). 24. FR 106-108 stbd side UTD, weathertight door to pilot vestibule and stabilizer room; approx 600 mm x 1600 mm (D5). 25. FR 241 on centerline on lower tween deck; watertight guillotine door from hold to BOW THRUSTER ROOM; approx 600 mm wide x 1550 mm high (5). END OF RECORD 67 1615-001-Y1-H-V-KKK Non-Watertight Doors Make a thorough inspection of all non watertight doors throughout the vessel. For each door, check the following as applicable: 1. Visually inspect for defects, damage and deterioration. 2. Clean all gasket seating and sealing surfaces free of rust, scale, paint and hardened/dry grease. Lubricate sealing and seating surfaces as required. 3. Check hinge adjustments. 4. Check tightness of securing dogs and tighten as required. 5. Replace grease nipples on dogs and hinges, when fitted and as required and lubricate hinges and dogs. 6. Check for presence of dog cheater pipes where required. 7. Test door self-closing devices, when fitted. Adjust and lubricate self-closing devices as necessary for proper operation. 8. Chalk test each door, when applicable. The impression of the knife edge shall be continuous around the closure and should be centered on the gasket. Note: Neither hammers, mauls, materials of like intent nor cheater pipes more than one foot in length shall be used to operate the dogs for securing the closure for testing. Use of force greater than that normally expected from one man utilizing a one foot cheater pipe shall be grounds for rejecting the test. The following doors shall be dealt with: 1. FR AP+ cage door in foc=sle space bos=n storeroom to Suez Canal light. 2. FR 243 door from fwd hydraulic pump room to foc=sle stairtower down to bow thruster room. 3. FR 242-243, port door from foc=sle space bos=n storeroom to fwd hydraulic pump room. 4. FR 242-243, stbd door from foc=sle space bos=n storeroom to fwd hydraulic pump room. 5. FR 20 aft starboard, poop deck; entrance to SHORE CONNECTION BOX. 6. FR 20 aft starboard, poop deck; entrance to NO. 2 DECK STORE. 7. FR 13 aft port, poop deck; entrance to PAINT STORE ROOM. 8. FR AP, port side poop deck; oval ENTRANCE to threshold space. 9. FR 13 aft port, 1st deck; entrance to EMERGENCY DIESEL GENERATOR room. 10. FR 19 aft off centerline on 2nd deck; entrance to A/C ROOM. 11. FR 33 port side 3rd deck; entrance to GYRO & CONVERTER ROOM. 12. FR 28 port side 3rd deck; entrance to BATTERY ROOM. 13. FR 26 port side 3rd deck; entrance to engine room supply FAN ROOM. 14. FR 27 port side 3rd deck; entrance from engine room supply fan room to fidley spaces. 15. FR 33 starboard side 3rd deck; entrance to NO. 1 DECK STORE ROOM. 16. FR 31 port side of stack on navigation bridge deck; entrance to stack funnel/fidley spaces. 17. FR 243 door from UTD to foc=sle stairtower down to bow thruster room (D4). 18. FR 201 centerline gastight door in escape pillar from lower holds. 19. FR 181 centerline gastight door in escape pillar from lower holds. 20. FR 121 centerline gastight door in escape pillar from lower holds. 21. FR 67 stbd off centerline, gastight door from UTD to machinery space. 22. FR 64 stbd, 750 mm x 1600 mm door from corridor between upper deck and hold stairtower (D19). 23. FR 67 stbd off centerline, 750 mm x 1600 mm gastight door from UTD to hold stairtower (D12). 24. FR 69 stbd off centerline, 750 mm x 1600 mm gastight door from LTD to hold stairtower. 25. FR 69 stbd off centerline, 750 mm x 1600 mm gastight door from tank top hold to hold stairtower. 26. FR 42 door from center rampway to elevator. 27. FR 57-60 gastight 3000 x 2040 hatch from center rampway to engine room main engine flat (H7). 28. FR 24-27 gastight 1500 mm x 2040 mm hatch from center rampway to engine room generator flat (H8). 29. FR 67 starboard side on upper tween deck; small door on stbd gastight door to upper tween deck; approx 400 mm wide x 600 mm high (D17). 30. FR 27 port side at upper tween deck level; small door on port gastight door to lower tween deck; approx 400 mm wide x 600 mm high (D17). 31. FR 65 escape hatch from engine control room to UTD. 32. FR 67 centerline gastight hatch in machinery space from pipe tunnel. 33. FR 20 door to engine store room. 34. FR 20 door to aft hydraulic pump rooms. 35. FR 10 door to aft lazarette from aft hydraulic pump room. 36. Machine shop door. 37. Electrical shop door. 38. Bow/stern thruster transformer room doors ( qty 2). END OF RECORD 68 1616-001-Y1-H-V-KKK Joiner Doors Visually inspect all joiner doors throughout the accommodations for damage or defects. Ascertain that all joiners on Class A divisions have self-closing devices and that all self-closing devices are in proper working order. END OF RECORD 69 1617-001-Y1-H-V-KKK Exterior Doors Visually inspect all exterior doors throughout the accommodations for damage or defects. Check door sills and jambs for signs of deterioration. Inspect all door gaskets and sealing surfaces. Chalk test the exterior doors to prove their weathertight integrity. Ascertain that all self-closing devices are in proper working order. END OF RECORD 70 1618-001-Y1-H-V-KKK Wheelhouse Doors Visually inspect the port and starboard bridge wing doors for damage or defects. Check door sills and jambs for signs of deterioration. Inspect all door gaskets and sealing surfaces. Chalk test the exterior doors to prove their weathertight integrity. Clean and lubricate guides and rollers as required. END OF RECORD 71 1621-001-M1-H-V-KKK Cargo Doors (Maintain) For tracking purposes, note the following related MEI codes as applicable: 1622 Casing Doors 1672 Ramp Covers Accomplish the following monthly maintenance to the starboard gastight door between the threshold and the upper tween deck, port gastight door between the threshold and the lower tween deck, center rampway watertight casing door to the upper deck, and watertight ramp cover for access from the lower tween deck to the tank top hold. Visually inspect each door or cover for defects. Check the hydraulic cylinders for signs of leaks. Check hydraulic hoses for signs of damage or deterioration. Check the door and cover gaskets for damage or defects. Where fitted, check the door lock gangbars. Inspect the dogs for signs of damage. Inspect all limit switches for signs of damage or defects to the switch or electrical cables. Grease all grease points as required. Remember grease points on the sheaves for the port and starboard gastight doors and on all pivoting points on the door locking gangbar assemblies. Also, some pivoting cylinders are fitted with grease points on their swivel pins. Lubricate the guides and rollers for the tank top rampway cover as required. Inspect each control station for defects. Lamp up indicator lights as required. Conduct an operational test of each door and ramp cover in both the automatic and manual modes. NOTE: The operator shall be familiar with the sequence of events when a casing door or ramp cover is opened or closed before attempting to operating the doors or covers manually. Note: The following guidelines are assuming that the hydraulic system is up and running. For opening in automatic mode: 1. Turn on the power to the control station with the power on/off switch on the station. Note: Only one control station can be powered up at any one time. If another station is powered, that station being used will get the Anot in use@ flashing indicator light. 2. Switch the auto/manual switch to auto. 3. Depress the Aopening start@ button to start the opening sequence. For closing in automatic mode: 1. Turn on the power to the control station with the power on/off switch on the station. Note: Only one control station can be powered up at any one time. If another station is powered, that station being used will get the Anot in use@ flashing indicator light. 2. Switch the auto/manual switch to auto. 3. Depress the Aclosing start@ button to start the closing sequence. For opening in manual mode: 1. Turn on the power to the control station with the power on/off switch on the station. Note: Only one control station can be powered up at any one time. If another station is powered, that station being used will get the Anot in use@ flashing indicator light. 2. Switch the auto/manual switch to manual. 3. For each individual sequence of operation in the manual mode, the buttons must be depressed continuously until the sequences are completed. 4. Unlock cleats (doors) or locks (ramp cover) by depressing the Acleat unlock@ button. Check that the Alock@ light extinguishes when the cleats or locks begin to unlock and that the Aunlock@ light illuminates after the cleats or locks are completely unlocked. Visually check all cleats or locks in any case of uncertainty. 5. Open the door or ramp cover by depressing the Aopen@ button. The Aclose@ light shall extinguish when the door starts to open and the Aopen@ light shall illuminate when the door or cover is completely open. 6. For the casing doors, after the doors are completely open, lock the stoppers by depressing the Astopper lock@ button. The Aunlock@ light shall extinguish when the stoppers start to lock in the door and the Alock@ light shall illuminate after the stoppers are completely extended or locked in. For closing in manual mode: 1. Turn on the power to the control station with the power on/off switch on the station. Note: Only one control station can be powered up at any one time. If another station is powered, that station being used will get the Anot in use@ flashing indicator light. 2. Switch the auto/manual switch to manual. 3. For each individual sequence of operation in the manual mode, the buttons must be depressed continuously until the sequences are completed. 4. For the casing doors, depress the Aopen@ button momentarily to lift the weight of the doors off their stoppers. 5. For the casing doors, unlock the stoppers by depressing the Astopper unlock@ button. The Alock@ light shall extinguish when the stoppers start to unlock and the Aunlock@ light shall illuminate after the stoppers are completely unlocked. 6. Close the door or ramp cover by depressing the Aclose@ button. The Aopen@ light shall extinguish after the door starts closing and the Aclose@ light shall illuminate after the door is completely closed. 7. Lock the cleats or locks by depressing the Acleat lock@ button. The Aunlock@ light shall extinguish after the cleats or locks start locking and the Alock@ light shall illuminate when the cleats or locks are locked. END OF RECORD 72 1621-002-Y1-H-V-KKK Cargo Doors (Chalk/Hose Test) For tracking purposes, note the following related MEI codes as applicable: 1622 Casing Doors 1672 Ramp Covers Conduct a chalk test of the starboard gastight door between the threshold and the upper tween deck and the port gastight door between the threshold and the lower tween deck. Conduct a hose test of the watertight center rampway door to the upper deck and the watertight rampway cover over the tank top hold. If any areas around the gastight doors fail to make contact during the chalk testing or any areas around the watertight door and cover leak, mark the areas sufficiently and submit a report detailing deficient areas where repairs must be made. END OF RECORD 73 1630-001-Y1-H-V-KKK Refrigeration Doors NOTE: If the refrigeration system is shut down, ascertain that all refrigerated space doors are left open to prevent mildew from forming in the boxes. The doors shall be blocked up so they don=t warp on their hinges while left open. Inspect all refrigerated space doors for damage and defects. Insure the doors to the handling room, vegetable room, meat room, deep freeze room and refrigerated stores room (ex. beer locker). Check the condition of the gaskets on the doors and the sealing surface of the door sills. Test the door latches to insure that they latch the doors tight. Ascertain that the doors can be opened properly from inside the refrigerated spaces. Test the Alocked in@ alarm for each refrigerated space. Insure that the Alocked in@ alarms work properly. END OF RECORD 74 1631-001-M6-H-V-KKK Pilot Ladders Visually inspect the port and starboard pilot ladders as well as similar embarkation ladders for the lifeboats and liferafts for damage, deterioration or defects. Note: Replacement steps are available for Comar Mark I type ladders. Note: Ladders should be kept under cover while not in use to prevent deterioration from the sunlight and weather. Inspect the pneumatic reels for the pilot ladders. Check air motor gear oil quantity and quality and replenish or replace oil as required. Check condition of securements for the tops of the ladders. Check the securing pins for the reels. Grease all points as required. Hand turn the stowage reel to insure movement. Test the pneumatic reels to insure proper operation by lowering and raising each ladder completely. END OF RECORD 75 1635-001-M6-H-V-KKK Accommodation Ladders Visually inspect the port and starboard accommodation ladders for damage and defects. Check for cracks in the ladders. Check condition of handrails and insure that all pins are in satisfactory condition. Replace all damaged, defective or missing fasteners, pins, etc. with equal replacements. Inspect condition of stowage tie rods. Lubricate all components as necessary. Inspect gear case oil; replace as necessary. Grease all grease points on all sheaves and turntable platforms. Slush wires as necessary. Apply anti-seize compound to the threads on all stowage tie rods. Inspect limit switches for damage and defects. Inspect limit switch cables for signs of damage or deterioration. Hand test all limit switches to prove satisfactory operation. Megger test the motors and controllers. Test each accommodation ladder to insure proper operation. Lower ladders to the water=s edge or dock. Watch for freedom of movement of all sheaves and drums. Prove satisfactory operation of the winch brakes. While lowering the ladders, visually inspect the wire ropes for wear and defects. Slush wires as required. Raise ladders after testing and stow and secure ladders in good order. END OF RECORD 76 1637-001-Y1-H-V-KKK Fixed Vertical Ladders Visually inspect all fixed ladders for damage and deterioration. Ascertain that handrails are not wasted to where they have sharp knife edges that could cut the hands. Check the tightness and condition of all fasteners. Replace wasted or missing fasteners as necessary. Insure that the top and bottom step of all fixed vertical ladders in the weather have non-slip steps in accordance with MarAd Logistics safety and personal protection equipment (PPE) policies. END OF RECORD 77 1638-001-Y1-H-V-KKK Fixed Inclined Ladders Visually inspect all fixed inclined ladders for damage and deterioration. Ascertain that handrails are not wasted to where they have sharp knife edges that could cut the hands. Check the tightness and condition of all fasteners. Replace wasted or missing fasteners as necessary. Insure that the top and bottom of each ladder is painted yellow for safety. Insure that the top and bottom step of each ladder in the weather has an non-slip treads in accordance with MarAd Logistics safety and personal protection equipment (PPE) policies. END OF RECORD 78 1650-001-Y1-H-V-KKK Gratings and Supports Visually inspect all gratings and supports for damage and deterioration. In the engine room, check gratings around machinery (ie. purifiers, steering gear, etc.). Outside, check the operator platform gratings on the mooring winches and anchor windlasses in way of the controls and brakes. In the refrigerated spaces, check the floor gratings in each refrigerated box. Where fitted, check the condition of all fasteners and clips. Tighten all loose fasteners and clips. Replace missing fasteners and clips. Where loose gratings are fitted together, such as in the refrigerated boxes, insure that the gratings fit together tight to prevent tripping hazards. END OF RECORD 79 1651-001-Y1-H-V-KKK Floor Plates and Supports Visually inspect all floor plates and supports in the engine room and all other machinery spaces for damage and defects. Where fitted, check the condition of all fasteners and/or clips. Tighten all loose fasteners and clips. Replace missing fasteners and clips. Insure that non-slip strips are installed in areas designated by the MarAd Logistics safety and personal protection equipment (PPE) policies. Areas include around the emergency diesel generator and inside the entrance to the space; in the electrical shop; in the operator area of all boom and windlass operating stations; inside and outside of all entrances to the steering gear room; and at the top and bottom of all ladders with the engine casing where the decking is neither diamond tread nor grating. END OF RECORD 80 1660-001-Y1-H-V-KKK Safety Gates Visually inspect all safety gates. Areas include openings in the bulwarks on the upper deck; openings in the handrails around the accommodations for liferaft and lifeboat embarkation; tops of stern ramp kingposts; etc. Check the condition of u-staples for safety chains. Insure that all safety gates have their required safety chains. Safety chains should be secured at one end with a shackle and fitted with a snap hook at the other end for easy connect/disconnect. Replace all missing or deteriorated safety chains. As a guideline, safety chains should be of 3/16@ galvanized or stainless steel chain. Shackles and snap hooks should also be of galvanized or stainless steel. END OF RECORD 81 1670-001-M1-H-V-KKK Stern Door (Maintain) Visually inspect the stern door for defects. Check the hydraulic cylinders for signs of leaks. Check hydraulic hoses for signs of damage or deterioration. Check the door and cover gaskets for damage or defects. Check the door lock gangbars. Inspect the dogs for signs of damage. Inspect all limit switches for signs of damage or defects to the switches or electrical cables. Grease all grease points as required, including all pivoting points on the door locking gangbar assemblies. Inspect the control station for defects. Lamp up indicator lights as required. If possible (when the ramp is down) conduct an operational test of the stern door in both the automatic and manual modes. NOTE: The operator shall be familiar with the sequence of events when the stern door is opening or closing before attempting to operate the door. Note: The following guidelines are assuming that the hydraulic system is up and running and control power is on at the first deck stern ramp control station. For opening in automatic mode: 1. Switch the auto/manual switch to auto. 2. Depress the Aopen@ button to start the opening sequence. For closing in automatic mode: 1. Switch the auto/manual switch to auto. 2. Depress the Aclose@ button to start the closing sequence. For opening in manual mode: 1. Switch the auto/manual switch to manual. 2. For each individual sequence of operation in the manual mode, the buttons must be depressed continuously until the sequences are completed. 3. Unlock the cleats by depressing the Acleat unlock@ button. Check that the Alock@ light extinguishes when the cleats begin to unlock and that the Aunlock@ light illuminates after the cleats are completely unlocked. Visually check all cleats in any case of uncertainty. 4. Open the door by depressing the Aopen@ button. The Aclose@ light shall extinguish when the door starts to open and the Aopen@ light shall illuminate when the door is completely open. 5. After the door is completely open, lock the stoppers by depressing the Astopper lock@ button. The Aunlock@ light shall extinguish when the stoppers start to lock in the door and the Alock@ light shall illuminate after the stoppers are completely extended or locked in. For closing in manual mode: 1. Switch the auto/manual switch to manual. 2. For each individual sequence of operation in the manual mode, the buttons must be depressed continuously until the sequences are completed. 3. Depress the Aopen@ button momentarily to lift the weight of the door off its stoppers. 4. Unlock the stoppers by depressing the Astopper unlock@ button. The Alock@ light shall extinguish when the stoppers start to unlock and the Aunlock@ light shall illuminate after the stoppers are completely unlocked. 5. Close the door by depressing the Aclose@ button. The Aopen@ light shall extinguish after the door starts closing and the Aclose@ light shall illuminate after the door is completely closed. 6. Lock the cleats by depressing the Acleat lock@ button. The Aunlock@ light shall extinguish after the cleats or locks start locking and the Alock@ light shall illuminate when the cleats are locked. END OF RECORD 82 1670-002-Y1-H-V-KKK Stern Door (Hose Test) Conduct a hose test of the watertight stern door. If any areas around the watertight door leak, mark the areas sufficiently and submit a report detailing deficient areas where repairs must be made. END OF RECORD 83 1671-001-M1-H-V-KKK Stern Ramp (Maintain/Test) Accomplish the following monthly maintenance to the stern ramp. Visually inspect the stern ramp and all components, including but not limited to hydraulic pumps, valves and piping in the hydraulic pump room; hydraulic motors and winches on the first deck; and stern ramp control station on the first deck. Check the hydraulic cylinders for signs of leaks. Check hydraulic hoses for signs of damage or deterioration. Inspect all limit switches for signs of damage or defects to the switch or electrical cables. Inspect the port and starboard W1 and W2 winches for excessive scale on the brake drums and wear on the brake linings. Grease all grease points on the winches, sheaves, etc. as required. Lubricate all guides and rollers for the wires. Inspect the control station for defects. Lamp up indicator lights as required. Check the hydraulic oil level in the sump. Replenish oil as necessary. Put a generator on line and transfer the electric load from shore to ships power. Turn on the control power at the stern ramp control station. Start the No. 1 and No. 2 hydraulic pumps and allow them to run for approximately one hour to warm up the hydraulic system. After hydraulic system has been allowed to warm up, start the remaining four pumps. Excercise the port/stbd W1 and W2 winches in manual mode to ascertain proper operation and freedom of the brakes. Test the main W1 winches individually (uncoupled) and together (coupled) to insure proper operation of the clutch. Unlock and relock the securing locks. Verify that both section 1 locks and both section 2 to section 1 locks work properly. Check indicator lights. Extend and retract the buttress cylinders to insure proper operation. Check indicator lights. Lock and unlock the buttress cylinder locks to insure proper operation. Check indicator lights. For the inboard vessel, assuming tidal/river stage conditions are normal and safe, conduct an operational test of the stern ramp in automatic mode. Refer to manufacturers operating instructions as necessary. Remember the following guidelines and precautions: 1. Partially lift the accommodation ladder to prevent damage to same. 2. Provide adequate oil spill pollution prevention gear in case of emergency. 3. Transfer water in the heeling tanks for proper as necessary. Place the heeling system in automatic. 4. Mate and bosn shall monitor mooring lines during ramp operation. 5. Land plywood dunnage ashore to place under the section 3 flaps. During raising and lowering of the stern ramp, inspect the wires for defects. Slush the wires as necessary. Also, apply lubricant to the winch gears as necessary. Verify properation of all sequences of operation during lowering and raising of the stern ramp. Insure proper operation of the ramp operating sirens and beacons and alarm buzzer. Insure proper operation of the quay sensor and rotating beacon at the end of the stbd side of section 1. When possible, test the ramp auto-tension mode. Insure proper operation of the touch quay (auto- tension) sensor and rotating beacon and siren. END OF RECORD 84 1845-001-M1-H-V-KKK Fenders Visually inspect the three (3) Yokohama fenders between the two vessels. Check condition of the fenders and integrity of the wire rope rigging and tightness of cable clamps. Check for signs of chaffing of the bulwarks by the wire ropes. END OF RECORD 85 1850-001-Y1-H-V-KKK Lanyards and Halyards Visually inspect the halyards on the jack staff, forward mast, after mast and ensign staff. Replace halyards as necessary. Check condition of blocks, cleats, etc. for damage or deterioration. Replace as necessary. END OF RECORD 86 2002-001-M1-H-V-KKK Stern Ramp Winches Refer to the following procedure for maintenance to the stern ramp winches: 1671-001-M1-M-V-KKK Stern Ramp Monthly Maintenance and Operational Test END OF RECORD 87 2030-001-M6-H-V-KKK Accommodation/Pilot Ladder Winches For pilot ladder winches, please refer to the following procedure: 1631-001-M6-G-V-KKK Pilot Ladders. For accommodation ladders, please refer to the following procedure: 1635-001-M6-G-V-KKK Accommodation Ladders. END OF RECORD 88 2201-001-M1-H-V-KKK Steering Gear (Test) Manufacturer John Hastie & Co., Ltd. Greenock, Scotland Type Four Ram Electric Hydraulic Ram Diameter 13@ Radius of Action 3=6@ Design Torque 270 MT Specified Shock Valve Pressure 1910 psi (133 kg/sq cm_ Motor BHP 75 (55.93 KW) Motor RPM 576 Motor Enclosure E.V.D.P. Motor Bearings Pre-loaded ball bearing Motor Insulation Class B Starters N/Q Electrical Supply 440/3/60 Gear Working Angle 70 degrees Gear Time (2 pumps operating) 65 degrees in 28 seconds Tiller Type Solid Boss / Trunnion Type Gear Weight : incl rudder carrier) 36 tons (approx) 1. From the dock examine area about rudder as far as practicable and ascertain ARUDDER CLEARANCE.@ 2. Test sound powered phone communication between steering gear room, wheelhouse and machinery space console. 3. Check oil level in main hydraulic unit and port and starboard telemotors. Add oil as required. 4. Clean and examine all guide and slide rails. 5. Clean and examine rapson slides. 6. Clean and wipe any machinery and deck of all oil and grease. 7. Megger check motor and record readings. 8. Confirm that main pump motors are free by hand rotating against normal direction of rotation. 9. Check level in rudder stock grease pump reservoir and top up as required. 10. Start rudder stock grease pump and confirm operation by loosening (2) ea. grease capillaries noting discharge. Tighten any other leaking capillary fittings. 11. Visually examine steering gear to ensure no obstruction to movement. 12. Coordinate Chief Officer on bridge and test steering gear through full range of movement to include port and starboard pumps, wheelhouse control, non-follow up local control, and trickwheel control. 13. Run both pumps simultaneously and test the steering gear over the 65 degree range from 30 degrees on one side to 35 degrees on the other side, and vice versa. Record time elapsed to complete 65 degrees each way. USCG requires that the full range of 65 degrees shall be accomplished in 28 seconds. END OF RECORD 89 2305-001-M1-H-V-KKK Stabilizers - Retractable Type (Check) Mfg (Control System): Sperry Marine Systems Division Mfg (Gyrofin Hydraulics and Heavy Machinery): Sasebo Heavy Industries, Ltd (SSD Ltd) Type of system: Remote R1 440V 60Hz Fin Size: 3R (12.6= x 6=) Type of hydraulics: Dupar 60Hz Fin location: Centered on Fr. 105 For tracking purposes, note related MEI codes as applicable: 2306 Fins/Fin Shafts 2307 Outboard Bearings 2308 Inboard Bearings/Lubrication 2309 Electro-hydraulic Drive System 2310 Automatic Sevo-control System 2311 Gyro Sensing Unit 2312 Tilting Mechanism 2313 Fin Boxes/Sea Gland 2314 Bridge Console 2315-001-M6-M-V-KKK Apparatus Board / Instrumentation 2340 List Control System Check the bearing oil and seal oil head tank levels for both the port and starboard stabilizers. Replenish oil as necessary. Note: It is important to maintain the seal oil level even during periods of lay up to maintain the integrity of the seal and prevent ingress of sea water into the fin shaft housing in case of seal failure. Check for ingress of sea water in the fin shaft housing by taking a sample of the oil from the test cock or valve on the housing. Check the hydraulic power unit for problems or signs of oil leakage. Check the hydraulic power unit oil sump level and replenish as required. Power up the control power and port and starboard stabilizers from the engine control room and check indicator lights in the stabilizer room as well as at the control cabinet in the engine control room and at the control console in the wheelhouse. Note: The outboard vessels outboard stabilizer may be tested from the local control panel by switching the local/remote switch to local. Depress the Arig out@ button to extend the stabilizer. After the fin is completely out, check indicator lights at all locations. Depress the Arig in@ button to retract the fin back in its housing. Check indicator lights. Note: Before operating the outboard stabilizer, check for clearance outside the vessel. END OF RECORD 90 2305-002-Y1-H-V-KKK Stabilizers - Retractable Type (Test) Mfg (Control System): Sperry Marine Systems Division Mfg (Gyrofin Hydraulics and Heavy Machinery): Sasebo Heavy Industries, Ltd (SSD Ltd) Type of system: Remote R1 440V 60Hz Fin Size: 3R (12.6= x 6=) Type of hydraulics: Dupar 60Hz Fin location: Centered on Fr. 105 For tracking purposes, note related MEI codes as applicable: 2306 Fins/Fin Shafts 2307 Outboard Bearings 2308 Inboard Bearings/Lubrication 2309 Electro-hydraulic Drive System 2310 Automatic Sevo-control System 2311 Gyro Sensing Unit 2312 Tilting Mechanism 2313 Fin Boxes/Sea Gland 2314 Bridge Console 2315-001-M6-M-V-KKK Apparatus Board / Instrumentation 2340 List Control System Note: Read and become familiar with manufacturers instruction manual 1-109A. This test will be conducted at annual sea trial. STARTING AND RIGGING OUT FROM BRIDGE CONTROL PANEL 1. Turn POWER keyswitch ON. Both FIN IN indicators will light. LOW SPEED indicator will light regardless of speed setting. (Control must be in AUTOMATIC not LOCAL for P/S units) 2. Press SEQUENCE START switch. A) Port PUMP ON indicators will light. (Release SEQUENCE START when Port pump motor starts). B) LOW SPEED indicator will go out if manual or automatic speed input is more than half design speed. C) Port FIN ANGLE meter will go to zero. D) Port FIN IN indicator will go out after a few seconds. (If Port FIN IN indicator stays on, fin may not have gone to zero angle). E) Starboard PUMP ON indicator will light in about ten seconds. F) Starboard FIN ANGLE meter will go to zero. G) Starboard FIN IN indicator will go out in a few seconds after Starboard PUMP ON indicator lights. H) After one or two minutes, FIN OUT and STANDBY indicators will light. STABILIZING (BRIDGE CONTROL PANEL) 1. Ensure that STANDBY indicator is lit. 2. Set up SPEED and SENSITIVITY. (This may be done while fins are rigging.) A) Speed: Select AUTO or MAN. If MAN, set SHIP SPEED control to present speed. (If LOW SPEED indicator lights, ship speed is less than 1/2 design speed and will have reduced effectiveness. No harm will be done, however, if the Stabilizer is used in this condition.) B) Sensitivity: Select AUTO or MAN. If MAN, set sensitivity to 1, (or , if you know by experience where it should be for present sea conditions, set it to that value). 3. Press STABILIZE. (It is preferable to do this when the ORDERED LIFT meter is at about zero). Both fins will begin to move to stabilize the ship. STABILIZE indicator will light. STANDBY indicator will go out. 4. Readjust SENSITIVITY if in MAN. Keep the sensitivity as high as possible without producing saturated ordered lift for more than 10 or 20 per cent of the time. NOTE: ORDERED LIFT meter saturates at about 100% at the design speed. At lower speeds this value will be less. In AUTO, sensitivity will start low and gradually increase until it is optimum. It will require two or three minutes for this to occur. 5. Periodic Adjustments: A) Periodically check sensitivity setting if in MAN. B) Keep SHIP SPEED up-to-date if in MAN. C) If the ship operates at low speed for a short time, the fins may be put in STANDBY or may be left in STABILIZE with the understanding that they are only 1/4 as effective at half design speed. For STARTING AND RIGGING OUT FROM CONTROL AND MONITOR PANEL and STARTING AND RIGGING OUT FROM LOCAL CONTROL UNIT, refer to operating manual 1-109A. RIGGING IN AND STOPPING FROM BRIDGE CONTROL PANEL 1. Press STANDBY switch. (STABILIZE indicator will go out. STANDBY indicator will light. FIN ANGLE and FIN LIFT meters will go to zero. 2. Press SEQUENCE STOP switch. A) STANDBY indicator will go out. B) After a few seconds, both FIN OUT indicators will go out. (If either FIN OUT indicator stays on, fin may not have gone to zero angle.) C) After one or two minutes, both FIN IN indicators will light, not necessarily at the same time nor in any particular order. D) As each fin reaches the rigged-IN position, its PUMP ON indicator will go out. E) When both pumps are off, power will be shut down. (There is no indication of this on Bridge Control Panel.) 3. Turn POWER keyswitch to off (when both PUMP ON indicators have gone out and FIN IN indicators are lit, FIN IN indicators will go out). Panel illumination (if on) will go out. For RIGGING IN AND STOPPING FROM CONTROL AND MONITOR PANEL and RIGGING IN AND STOPPING FROM LOCAL CONTROL UNIT, refer to operating manual 1-109A. END OF RECORD 91 2315-001-M6-E-V-KKK Stabilizers - Instrumentation Board CLEANING: A vacuum cleaner can be used for removing dust and dirt from the interior of Control System units but care must be taken not to damage or disturb components. Grease and oil can be removed from system with suitable solvent. LAMPING: Lamp test control consoles and replace defective lamps with proper lamps. Refer to lamp chart TABLE 3-1 of manual 109-A. ALARM TEST: Test alarm circuits in the Control and Monitor Panel. Press the PORT ALARM TEST and STBD. ALARM TEST switches on the Control and Monitor Panel. Verify that each active indicator comes on (spare indicators will not come on) and that the audible alarm sounds. Verify that the ALARM MUTE switch will silence the audible alarm so that the alarm remains silenced when the ALARM MUTE switch is released. END OF RECORD 92 2503-001-M1-H-V-KKK Passenger Elevator (Inspect/Maintain) Mfg. Nippon Elevator Ind. Co., Ltd. Type: Single lap traction geared type Operation system: AC2-speed automatic Capacity: 500 kg or 7 persons Speed: 60 m/min Traveling stroke: 22 m Service floors: 7 stops Alarms: Emergency bell, overload, CO2, General Power supply: AC 3 phase, 440 V 60 Hz Motor: 7.5 kW, 6-pole, 1150 rpm, totally enclosed For tracking purposes, note related MEI codes below as applicable: 2512 Elevator machinery 2513 Elevator rigging Conduct the following monthly inspections and maintenance on the passenger elevator in accordance with the manufacturer=s instructions. 1. Inspect and test the telephone on the operating panel in the car. 2. Test all indicator and emergency lamps. Relamp as necessary. Note: Lamps can be tested by turning on and of the change over switch inside the panel. 3. Test the emergency light inside the car. Turn off the lamp circuit breaker inside the control panel in the machinery room and confirm that the emergency light is lit. 4. Test the emergency stop push-button inside the car. While ascending and descending, push the emergency stop button and confirm that the elevator stops. 5. Inspect the cage door and interlocks. a. Test the safety switch (edge). b. Test the door interlocks. With the cage door opened, push ascending or descending push buttons to confirm that the elevator does not operate. c. Clean the cage door sealing edge groove. d. Lubricate the door sliding grooves. 6. Inspect the photo switches and tighten any loose mechanical or electrical connections. 7. Inspect the governor safety device and insure tightness of fasteners and fittings. 8. Inspect the car guide shoes for tightness and wear. 9. Check the guide rail lubricators and fill with oil as required. 10. Test the interlock switches at each floor. Open one door at a time and assure that the elevator does not operate. Insure that the Adoor open@ indicator illuminates when each door is opened. 11. Inspect all limit switches. Verify tightness of mechanical and electrical connections. 12. Inspect the counterweight for tightness of fasteners and adequate lubrication. 13. Inspect inside the elevator pit. Check the final limit switch and cage guide shoes. END OF RECORD 93 2503-002-M3-H-V-KKK Passenger Elevator (Inspect/Maintain) Mfg. Nippon Elevator Ind. Co., Ltd. Type: Single lap traction geared type Operation system: AC2-speed automatic Capacity: 500 kg or 7 persons Speed: 60 m/min Traveling stroke: 22 m Service floors: 7 stops Alarms: Emergency bell, overload, CO2, General Power supply: AC 3 phase, 440 V 60 Hz Motor: 7.5 kW, 6-pole, 1150 rpm, totally enclosed For tracking purposes, note related MEI codes below as applicable: 2512 Elevator machinery 2513 Elevator rigging Conduct the following quarterly inspections and maintenance on the passenger elevator in accordance with the manufacturer=s instructions. 1. Inspect and test the emergency exit on the top of the car. a. Open the emergency exit door (push-up type). b. Pushing either an ascending or descending push button, confirm that the car does not operate. c. While the car is in motion, insure that opening of the emergency exit door breaks the operating circuit and stops the elevator. 2. Test the manual operation of the car. a. Climb out the car to the top of the car through the emergency escape in the overhead. b. Light the operating lamp. c. Switch the change-over switch from AUTO to MAN. d. Close the emergency escape completely. e. Test the manual operation by using the UP and DOWN pushbuttons. 3. Inspect and clean the manual operating panel. a. Switch the ON switch to OFF. b. Open the panel. Clean inside the panel and verify tightness of all components and wiring. 4. Inspect the wire ropes and check their tension. To check tension, operate the car by means of the operating panel on top of the car and stop it at the position that the counterweight and cage are adjoining. Pull the wire ropes one after another confirm whether or not force is applied uniformly to each rope. If not, adjust the ropes the adjusting nuts as required. 5. Inspect the traveling cable. Clean cable free of dirt and grease. Repair chaffed areas with tape. 6. Inspect the guide rail and verify tightness of all fasteners. 7. Check the governor wire rope and rope tension. Adjust tension as required. 8. Inspect the counterweight and car buffer springs in the pit. 9. Inspect the traction machine. Clean the machine free of oil and grease. 10. Inspect and clean the controller and all components. Verify tightness of all components and wiring. 11. Inspect and clean the motor. Check for signs of bearing failure. END OF RECORD 94 2503-003-Y1-H-V-KKK Passenger Elevator (Certify) Mfg. Nippon Elevator Ind. Co., Ltd. Type: Single lap traction geared type Operation system: AC2-speed automatic Capacity: 500 kg or 7 persons Speed: 60 m/min Traveling stroke: 22 m Service floors: 7 stops Alarms: Emergency bell, overload, CO2, General Power supply: AC 3 phase, 440 V 60 Hz Motor: 7.5 kW, 6-pole, 1150 rpm, totally enclosed Annually, the passenger elevator shall be inspected, operationally tested and weight tested by a recognized elevator repair facility service technician in accordance with the applicable edition of ASNI/ASME A17.2 - 1982 Inspectors Manual for Elevators (1982 or latest revision) and USCG regulations. The repair facility shall issue a certificate which shall state the following: a. That the elevator has been thoroughly inspected in accordance with requirements of ASNI/ASME A17.2 - 1982 Inspectors Manual for Elevators and Escalators. b. That repairs, replacements and corrections have been made. These shall be described in detail. c. That all repairs are in conformity with all requirements of the applicable edition of ASNI/ASME A17.2 - 1982 Inspectors Manual for Elevators and Escalators. END OF RECORD 95 2505-001-M3-H-V-KKK Dumbwaiters (Inspect/Maintain) Mfg.: Nippon Elevator Ind. Co., Ltd. Conduct the following inspections and maintenance on the ship=s elevator on a quarterly basis, or more frequently depending on amount of use. 1. Open the cover of the control panel and floor panels and for cleaning and maintenance. a. Clean the panels free of dirt and debris. b. Check tightness of all electrical components and wiring. c. Relamp indicator lights as necessary. 2. Operationally test the dumbwaiter between all floors (upper deck, poop deck, first deck and second deck). Test the dumbwaiter from each floor=s operator panel. Verify proper operating order of the relays inside the control panel. 3. Test the dumbwaiter door interlocks. Insure that the dumbwaiter does not operate if door(s) are open. 4. Test the intercom system between all floors. END OF RECORD 96 2505-002-Y1-H-V-KKK Dumbwaiters (Certify) Mfg.: Nippon Elevator Ind. Co., Ltd. Annually, the dumbwaiter shall be inspected, operationally tested and weight tested by a recognized elevator repair facility service technician in accordance with the applicable edition of ASNI/ASME A17.2 - 1982 Inspectors Manual for Elevators (1982 or latest revision) and USCG regulations. The repair facility shall issue a certificate which shall state the following: a. That the dumbwaiter has been thoroughly inspected in accordance with requirements of ASNI/ASME A17.2 - 1982 Inspectors Manual for Elevators and Escalators. b. That repairs, replacements and corrections have been made. These shall be described in detail. c. That all repairs are in conformity with all requirements of the applicable edition of ASNI/ASME A17.2 - 1982 Inspectors Manual for Elevators and Escalators. END OF RECORD 97 2544-001-DY-H-V-KKK Power Sweepers (Inspect Daily) Mfg: Tennant Model: 355D Engine: Diesel The following maintenance shall be performed on the vessel=s street sweeper every day of use. 1. Check the engine air filter indicator. Empty the filter dust cap. 2. Check engine oil level. 3. Check brush compartment skirts for damage, wear and adjustment. 4. Check the hopper lip skirts for damage, wear and adjustment. 5. Check the hopper side skirt for damage and wear. 6. Check the main brush for damage, wear and adjustment. Check brush pattern. 7. Check the side brush for damage, wear and adjustment. Check brush pattern. END OF RECORD 98 2544-002-HR-H-V-KKK Power Sweeper M&I (50 Hr) Mfg: Tennant Model: 355D Engine: Diesel The following maintenance shall be performed on the vessel=s street sweeper every 50 hours. 1. Rotate the main brush end-for-end. 2. Check the fuel pipes and clamps for tightness and wear. END OF RECORD 99 2544-003-HR-H-V-KKK Power Sweepers M&I (100 Hr) Mfg: Tennant Model: 355D Engine: Diesel The following maintenance shall be performed on the vessel=s street sweeper every 100 hours. 1. Change engine oil and filter. 2. Check engine fan belt tension. 3. Check the hopper dust filter for damage. Clean or replace as required. 4. Clean the radiator core exterior. Check coolant level. 5. Check the hydraulic fluid reservoir level. 6. Check rear tire pressure. 7. Check the main brush and hopper seals for damage or wear. END OF RECORD 100 2544-004-HR-H-V-KKK Power Sweeper M&I (200 Hr) Mfg: Tennant Model: 355D Engine: Diesel The following maintenance shall be performed on the vessel=s street sweeper every 200 hours. 1. Check radiator hoses and clamps for tightness and wear. 2. Check parking brake adjustment. 3. Check and adjust brake pedal travel. 4. Lubricate rear wheel support bearings. 5. Rotate the side brush guard 90 degrees. END OF RECORD 101 2544-005-HR-H-V-KKK Power Sweeper M&I (400 Hr) Mfg: Tennant Model: 355D Engine: Diesel The following maintenance shall be performed on the vessel=s street sweeper every 400 hours. 1. Check, lubricate and adjust the front wheel bearings. 2. Replace the fuel filter cartridge. 3. Remove any sediment from the fuel tank. 4. Flush the cooling system. END OF RECORD 102 2544-006-HR-H-V-KKK Power Sweeper M&I (800 Hr) Mfg: Tennant Model: 355D Engine: Diesel The following maintenance shall be performed on the vessel=s street sweeper every 800 hours. 1. Replace hydraulic reservoir breather and suction strainer. Change hydraulic fluid. 2. Change the hydraulic fluid filter element. 3. Check the hydraulic hoses for wear and damage. 4. Torque the propelling motor shaft nut. 5. Torque the rear wheel nuts. 6. Clean and tighten the battery cable connection. END OF RECORD 103 2570-001-DY-H-V-KKK Forklift/Pallet Trucks (Inspect Daily) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm On a daily basis or on each day or each shift in which the forklift will be used, the forklift shall be inspected by the truck operator to comply with OSHA regulations. The truck operator shall complete a LIFT TRUCK OPERATOR=S DAILY/WEEKLY INSPECTION REPORT - INTERNAL COMBUSTION LIFT TRUCKS. 1. Check engine oil level. When oil must be added, record number of quarts. 2. Inspect the fuel system for leaks. 3. Inspect coolant level in the radiator. 4. Inspect tires for foreign particles, gouges and cuts. Check pneumatic tire pressure. 5. Inspect the mast, carriage, fork and attachment for loose or missing bolts and damage. Inspect the chain. Check adjustments and operation. 6. Check for oil and water leaks. 7. Inspect the general condition of the forklift truck. 8. Inspect the operator=s compartment for general cleanliness. 9. Check engine oil pressure at the gauge. 10. Check the fuel level. 11. Check the ammeter for battery charging rate. 12. Check operation of all safety equipment, including rotating lights, back-up alarms, etc. 13. Check operation of the steering system. 14. Check the brakes and brake pedal travel. Check parking brake adjustment. 15. Inspect overall condition and operation of the forklift truck. END OF RECORD 104 2570-002-W1-H-V-KKK Forklift/Pallet Trucks (Inspect) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm On a weekly basis, in addition to carrying out the daily forklift inspection, the forklift truck operator shall perform the weekly check to comply with OSHA regulations. The truck operator shall complete a LIFT TRUCK OPERATOR=S DAILY/WEEKLY INSPECTION REPORT - INTERNAL COMBUSTION LIFT TRUCKS, and ascertain that the AWeekly Check@ endorsement is completed. 1. Clean the air cleaner as required. 2. Check the hydraulic oil level. 3. Check the clutch oil level. 4. Check the transmission oil level. 5. Inspect all oil lines for leaks. 6. Inspect the battery compartment and check electrolyte level. 7. Check the power steering oil level. 8. Check the lift chain adjustment. END OF RECORD 105 2570-002-W1-H-V-KKK Forklift/Pallet Trucks (Inspect) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm On a weekly basis, in addition to carrying out the daily forklift inspection, the forklift truck operator shall perform the weekly check to comply with OSHA regulations. The truck operator shall complete a LIFT TRUCK OPERATOR=S DAILY/WEEKLY INSPECTION REPORT - INTERNAL COMBUSTION LIFT TRUCKS, and ascertain that the AWeekly Check@ endorsement is completed. 1. Clean the air cleaner as required. 2. Check the hydraulic oil level. 3. Check the clutch oil level. 4. Check the transmission oil level. 5. Inspect all oil lines for leaks. 6. Inspect the battery compartment and check electrolyte level. 7. Check the power steering oil level. 8. Check the lift chain adjustment. END OF RECORD 106 2570-002-W1-H-V-KKK Forklift/Pallet Trucks (Inspect) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm On a weekly basis, in addition to carrying out the daily forklift inspection, the forklift truck operator shall perform the weekly check to comply with OSHA regulations. The truck operator shall complete a LIFT TRUCK OPERATOR=S DAILY/WEEKLY INSPECTION REPORT - INTERNAL COMBUSTION LIFT TRUCKS, and ascertain that the AWeekly Check@ endorsement is completed. 1. Clean the air cleaner as required. 2. Check the hydraulic oil level. 3. Check the clutch oil level. 4. Check the transmission oil level. 5. Inspect all oil lines for leaks. 6. Inspect the battery compartment and check electrolyte level. 7. Check the power steering oil level. 8. Check the lift chain adjustment. END OF RECORD 107 2570-002-W1-H-V-KKK Forklift/Pallet Trucks (Inspect) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm On a weekly basis, in addition to carrying out the daily forklift inspection, the forklift truck operator shall perform the weekly check to comply with OSHA regulations. The truck operator shall complete a LIFT TRUCK OPERATOR=S DAILY/WEEKLY INSPECTION REPORT - INTERNAL COMBUSTION LIFT TRUCKS, and ascertain that the AWeekly Check@ endorsement is completed. 1. Clean the air cleaner as required. 2. Check the hydraulic oil level. 3. Check the clutch oil level. 4. Check the transmission oil level. 5. Inspect all oil lines for leaks. 6. Inspect the battery compartment and check electrolyte level. 7. Check the power steering oil level. 8. Check the lift chain adjustment. END OF RECORD 108 2570-003-HR-H-V-KKK Forklift/Pallet Trucks (500 Hr) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm The following maintenance shall be performed on the vessel=s forklift every six months or 500 hours. 1. Change the powershift transmission oil. 2. Change the powershift transmission oil filter. 3. Change the differential oil (powershift). 4. Change the hydraulic tank oil filter. 5. Change the fuel filter. 6. Change the air cleaner element. 7. Change the engine coolant. 8. Adjust the lift chains. END OF RECORD 109 2570-004-HR-H-V-KKK Forklft/Pallet Trucks (2000 Hr) Mfg: Caterpiller Model: DP40 Engine: Diesel Transmission: Powershift 2-speed Rated Capacity/Load Center: 8,000 lb./24 in. or 4000 kg/500 mm The following maintenance shall be performed on the vessel=s forklift every twelve months or 2000 hours. 1. Change the hydraulic oil and filter. 2. Change the brake fluid. 3. Inspect the brakes. 4. Replace rubber parts of the brake master cylinder. 5. Replace the rubber parts of the brake wheel cylinder. 6. Replace hydraulic system high pressure hoses. 7. Replace spark plugs and tune engine. 8. Magnaflux test the forks. 9. Repack the drive and steer wheel bearings. END OF RECORD 110 2575-001-DY-H-V-KKK Strato Lift (Inspect Daily) Mfg: Strato-Lift & Boom, Inc. 1 Thoroughly inspect the entire machine for physical damage and wear. Complete the Awalk-around inspection@ detailed in AOperation and Safety Manual@. Repair any defects before operating the machine. 2. Check the batteries condition - electrolyte level; sign of corrosion. 3. Check hydraulic fluid level (2-1/2@ below top of reservoir at breather). 4. Check brake operation. 5. Check lug nuts for tightness. END OF RECORD 111 2575-002-W1-H-V-KKK Strato Lift (Inspect) Mfg: Strato-Lift & Boom, Inc. 1. Inspect the pivot points for signs of wear. 2. Inspect the tie rod and front spindle assemblies for signs of wear. END OF RECORD 112 2575-002-W1-H-V-KKK Strato Lift (Inspect) Mfg: Strato-Lift & Boom, Inc. 1. Inspect the pivot points for signs of wear. 2. Inspect the tie rod and front spindle assemblies for signs of wear. END OF RECORD 113 2575-002-W1-H-V-KKK Strato Lift (Inspect) Mfg: Strato-Lift & Boom, Inc. 1. Inspect the pivot points for signs of wear. 2. Inspect the tie rod and front spindle assemblies for signs of wear. END OF RECORD 114 2575-002-W1-H-V-KKK Strato Lift (Inspect) Mfg: Strato-Lift & Boom, Inc. 1. Inspect the pivot points for signs of wear. 2. Inspect the tie rod and front spindle assemblies for signs of wear. END OF RECORD 115 2575-003-M1-H-V-KKK Strato Lift (Inspect/Maintain) Mfg: Strato-Lift & Boom, Inc. 1. Check gears for signs of wear. Lubricate the gears with Lubriplate 1200-2 or equal. END OF RECORD 116 2575-004-HR-H-V-KKK Strato Lift (500 Hr) Mfg: Strato-Lift & Boom, Inc. 1. Change the hydraulic oil. 2. Clean the oil filter screen inside the hydraulic reservoir; replace if it is damaged. END OF RECORD 117 2601-001-Y1-H-V-KKK Mooring Equipment Once annually, prior to sea trials, inventory mooring equipment and insure that there is an adequate supply of safe equipment on board. As a guideline, minimum quantities should be two (2) 300= 1-inch messengers, six (6) heaving lines, four (4) spare pennants, two (2) spare mandel shackles, six (6) rope stoppers, four (4) chain stoppers, and two (2) cheater bars. Also insure there are adequate anchor chain stoppers aboard. These items should be split fore and aft. END OF RECORD 118 2605-001-M1-H-V-KKK Anchor Windlass (Exercise) Note: When operating an anchor windlass, personnel should wear safety goggles. Also insure adequate gear oil in bull gear reservoir. Grease all points as required. Each anchor windlass shall be powered up and operated in heaving and veering mode while disengaged. With anchor pawl down, operate brake wheel. With brake on, lift pawl. With brake on and pawl down, operate clutch. END OF RECORD 119 2605-002-M3-H-V-KKK Anchor Windlass (Test) Note: When operating an anchor windlass, personnel should wear safety goggles. Also insure adequate gear oil in bull gear reservoir. Once quarterly, remove the anchor chain stoppers and lower and raise each anchor to and from the water=s edge. With anchors secured back in their housings after the test, apply the brakes and re-install the chain stoppers. END OF RECORD 120 2605-003-Y1-H-V-KKK Anchor Windlass (Sea Trial Tests) Note: When operating an anchor windlass, personnel should wear safety goggles. Also insure adequate gear oil in bull gear reservoir. Each anchor windlass shall be powered up and operated in heaving and veering mode while disengaged. With anchor pawl down, operate brake wheel. With brake on, lift pawl. With brake on and pawl down, operate clutch. Remove the chain stoppers and weigh out each anchor from their housings. Drop each anchor approximately two (2) or three (3) fathoms and test the windlass brakes. Lower each anchor until the first shot mark is at the water=s edge. Retrieve each anchor and record time elapsed to raise one shot. END OF RECORD 121 2614-001-W2-H-V-KKK Mooring Winches (Operate) Note: When operating winches, personnel should wear safety goggles. Insure adequate gear oil in bull gear reservoirs. Grease all points as required. Twice monthly, each mooring winch hydraulic pump (four (4) fwd and four (4) aft) shall be powered up and the winches shall be operated locally while disengaged in heaving and veering mode. END OF RECORD 122 2614-001-W2-H-V-KKK Mooring Winches (Operate) Note: When operating winches, personnel should wear safety goggles. Insure adequate gear oil in bull gear reservoirs. Grease all points as required. Twice monthly, each mooring winch hydraulic pump (four (4) fwd and four (4) aft) shall be powered up and the winches shall be operated locally while disengaged in heaving and veering mode. END OF RECORD 123 2614-002-M3-H-V-KKK Mooring Winches (Operate) Note: When operating winches, personnel should wear safety goggles. Insure adequate gear oil in bull gear reservoirs. Grease all points as required. Once quarterly, each mooring winch hydraulic pump (four (4) fwd and four (4) aft) shall be powered up and the winches shall be operated under load. END OF RECORD 124 2617-001-M3-H-V-KKK Mooring Winch - Remote Controls Note: When operating winches, personnel should wear safety goggles. Insure adequate gear oil in winch bull gear reservoirs. Grease all points as required. Once Quarterly, each mooring winch hydraulic pump (four (4) fwd and four (4) aft) hydraulic pump and the remote control hydraulic pumps (one (1) fwd and one (1) aft) shall be powered up and the winches shall be operated while disengaged in heaving and veering mode from the remote control stations. END OF RECORD 125 2660-001-Y1-H-V-KKK Mooring Lines Once annually prior to sea trials, inventory mooring lines and check for weathering. Insure adequate supply of safe lines on hand for sea voyage. Minimum complement shall be three (3) forward and three (3) aft. END OF RECORD 126 2701-001-DY-H-V-KKK 3T Stores Crane (Maintain Daily) 1. Winch Lubricate bearings with grease via the grease nipples. 2. Oil Supply Before each use of the crane, grease is to be filled so that it almost overflows through the seals in the internal gears and slewing rim. 3. Swivel Hook Inspect the swivel hook for damage or defects. Check for freedom of movement. END OF RECORD 127 2701-002-M1-H-V-KKK 3T Stores Crane (Maintain) 1. Electric Motor Lubricate bearings via the grease nipples. 2. Pipelines Inspect for signs of oil leakage in hydraulic pipelines. Inspect the flanges for oil leaks and tighten as required. 3. Brake Gear Lubricate the brake links and threads with grease to prevent rust. 4. Wire Cable Inspection of breaking of wire element and diameter of wire. Inspection of rust and grease on the surface of wire should be once a month. In the case that more then 10% of elements are cut in one strand of wire cable, or that the diameter of wire is reduced to less than 7%, replace the wire cable with a new one. Since the rust is a cause of the breaking of wire, replace the wire rope by a new one. Coat the wire sufficiently with grease. 5. Slewing Rim The connecting bolts for the slewing rim and turn table should be checked to see if they are loose. Accordingly, the periodical inspection should be always carried out. Note: Welding operations are to be avoided in the vicinity of the slewing rim because a strain due to a rise of temperature will be generated. If the welding is unavoidable, inform the Port Engineer / Chief Engineer for an approval. 6. Changing of the hydraulic fluid Sample of the oil shall be taken once a month for observation. If the oil is not clean and becomes cloudy, or if there is clear evidence of containing foreign matter, then it is advised to send a sample of the oil out for analysis and then proper measures be taken in accordance with the test results. Note: At the time of changing oil, flushing of the entire system is recommended. END OF RECORD 128 2701-003-M3-H-V-KKK 3T Stores Crane (Maintain) 1. Sheaves Inspect the sheaves for freedom of movement and signs of bearing wear. Listen for abnormal noises. 2. Pin at the base Jib Move the jib and inspect the pin at the base for freedom of movement and bearing wear. Listen for abnormal noises. Lubricate pin with oil as required. 3. Limit Switches Inspect the limit switches and wiring for signs of damage or defects. Test switches to prove proper operation. END OF RECORD 129 2701-004-M6-H-V-KKK 3T Stores Crane (Maintain) 1. Chain Coupling Inspect of greasing and centering of chain coupling. Remove the cover and full up the grease in the chain coupling. Correct the centering of the chain coupling; the maximum reading on a dial indicator should not exceed 0.1 mm (refer to mfg. instructions for details). END OF RECORD 130 2701-005-Y1-H-V-KKK 3T Stores Crane (Maintain) 1. Fastening Bolt Check the tightness of all fasteners and tighten any loose fasteners. 2. Gearing of Internal Gears Inspect the condition of the internal gears for wear. The backlash between gears should be 0.5 - 0.7 mm. 3. Painting The durability of the crane will depend on the annual inspection of the machinery parts, maintenance and handling and proper maintenance of the painted surfaces. Since rust will reduce the strength of the steel it is necessary to periodically check for rust spots. Special attention is required for the painting crane surfaces. END OF RECORD 131 2709-001-M6-H-V-KKK Hoist Machinery For each of the following pneumatic hoists, accomplish the inspections and maintenance outlined below. Forward Machinery Spaces Access Hoist Aft Machinery Space Access Hoist Port/Stbd Bunker Station Hoists Port/Stbd Pilot Ladder Hoists Visually examine the hoists. Check all hydraulic fluids and gear oils. Add appropriate lubricants. See lube schedule for proper lubricant. Check all air connections and electrical connections. Grease all lubrication points. Operate each hoist through its full range of motion noting and recording any deficiencies. Pay particular attention to condition of purchase wire, rotating sheaves, purchase hook and/or traveling block. END OF RECORD 132 2709-002-M6-H-V-KKK 6T ER Hoist Machinery Crane Lubricate the hoist regularly. Follow the instructions under the heading ALubrication@ in the instruction manual. Check the air motor oil level with the dipstick. Fill the motor casing as required through the lubricating hole on the upper side of the motor casing Note: The motor, except the main valve, is splash lubricated. The main valve is lubricated from a special cast-reservoir in the upper part of the crankcase. From this reservoir, which is kept filled by splash from the crankshaft, oil is fed by gravity to the moving parts of the main valve. Check that the gear case is full of oil. The gears are lubricated by pouring oil through the lubricating hole on the upper side of the gear casing. Note: On the under side of both the gear casing and the crank case there are oil drain plugs. The oil in both the crankcase and gear casing should be drained and changed at least twice a year during normal use. Operationally test the hoist in its full range of movement: forward and aft; side to side; and up and down on the hook. Note: The hoist is designed for operating at a gauge pressure of 7 kg/sq cm. The brake is not fully released if the pressure drops below 4.5 kg/sq cm. Therefore, it is important that the air line pressure during operation never falls below this pressure as excessive wear of the brake may result Note: Take care that the ropes are always loaded by the weight of the hook. Never lower so far that the hook block rests on the ground and the ropes become slack, as there is a risk that in this case they may become coiled or wedded in the drum. Note: If the air supply is moist, there is a risk in cold weather that the moving parts of the hoist will operate sluggishly or freeze up. This applies especially to the throttle which is not lubricated from the central splash lubrication in the crankcase. Inspect the condition of the purchase wire, rotating sheaves, purchase hook and traveling block. END OF RECORD 133 2910-001-Y1-H-V-KKK Securing Points Annually, all cargo lashing securing points shall be cleaned and inspected. Using a shop vacuum and/or other means, remove all debris and standing water from the recessed securing points. Inspect securing points for structural cracks and deterioration. Report any deficiencies. END OF RECORD 134 2960-001-Y1-H-V-KKK RO/RO Equipment Annually, visually inspect all cargo lashing gear for signs of damage or deterioration. Review and update the lashing gear inventory as required utilizing the existing inventory and the ALASHING GEAR Field Identification and Inventory Guide. END OF RECORD 135 3316-001-W1-H-V-KKK Toilet and Shower Spaces Obtain a master key from the chief engineer. Test operate all sinks, showers, toilets and faucets in all staterooms, general toilets and other spaces throughout the accommodations, including the Poop Deck, First Deck, Second Deck, Third Deck and Navigation Bridge Deck. Test all outside hose bibs (faucets) fore and aft. Note and record any deficiencies. Return the master key to the chief engineer after completion of this task. END OF RECORD 136 3316-001-W1-H-V-KKK Toilet and Shower Spaces Obtain a master key from the chief engineer. Test operate all sinks, showers, toilets and faucets in all staterooms, general toilets and other spaces throughout the accommodations, including the Poop Deck, First Deck, Second Deck, Third Deck and Navigation Bridge Deck. Test all outside hose bibs (faucets) fore and aft. Note and record any deficiencies. Return the master key to the chief engineer after completion of this task. END OF RECORD 137 3316-001-W1-H-V-KKK Toilet and Shower Spaces Obtain a master key from the chief engineer. Test operate all sinks, showers, toilets and faucets in all staterooms, general toilets and other spaces throughout the accommodations, including the Poop Deck, First Deck, Second Deck, Third Deck and Navigation Bridge Deck. Test all outside hose bibs (faucets) fore and aft. Note and record any deficiencies. Return the master key to the chief engineer after completion of this task. END OF RECORD 138 3316-001-W1-H-V-KKK Toilet and Shower Spaces Obtain a master key from the chief engineer. Test operate all sinks, showers, toilets and faucets in all staterooms, general toilets and other spaces throughout the accommodations, including the Poop Deck, First Deck, Second Deck, Third Deck and Navigation Bridge Deck. Test all outside hose bibs (faucets) fore and aft. Note and record any deficiencies. Return the master key to the chief engineer after completion of this task. END OF RECORD 139 3330-001-Y1-H-V-KKK Nameplates / Notices / Markings Visually inspect all nameplates, notices and markings throughout the vessel and insure that they are legible and in good order. Update or replace nameplates, notices and markings as required to maintain a high level of safety and awareness throughout the vessel. END OF RECORD 140 3401-001-M1-H-V-KKK Commissary Equipment For tracking purposes, note related MEI codes as applicable: 3402 Mixers 3403 Vegetable/meat processors 3404 Kettles/egg boilers/steamers/food warmers 3405 Range/oven/broiler/griddle 3406 Garbage disposals/compactor 3407 Refrigerators/ice cube makers/drinking water fountains 3408 Dishwasher 3409 Toasters/coffee makers 3415 Comm. equip. (other than commissary spaces) 3416 Dispensers (beverage/cleansers) 3420 Filters 3422 Sanitizer, sink 3438 Ventilation hoods Visually inspect and test all commissary equipment to insure proper operation. Report all deficiencies. END OF RECORD 141 3406-001-Y1-H-V-KKK Garbage Disposals / Compactor Mfg: International Compactor, Inc. Model: MP-6S Insure that the two bolts on the chute door support arm are tight. Hand wash or hose out the stainless steel compaction chamber as required. Ascertain that the hydraulic oil level is at the proper level. Note: Hydraulic oil level should be inspected ONLY when the compaction plate is in the uppermost position. Note: The hydraulic oil filter should be changed once a year or after an equivalent amount of hours of operation when the trash compactor is in continuous use. a. Unplug the machine. b. Remove the filter by turning in a counter- clockwise direction. c. Install a new filter element, model MPS-50- P25-A. Using an incorrect filter will result in damage the hydraulic system. d. Run the compactor through one cycle. e. With the compaction plate in the full up position refill the hydraulic tank. 4. Test the garbage compactor to insure satisfactory operation. END OF RECORD 142 3410-001-M1-H-V-KKK Laundry Spaces For tracking purposes, note related MEI codes as applicable: 3411 Laundry equipment 3412 Washing machines 3413 Dryers Visually inspect and test all laundry equipment to insure proper operation. Report all deficiencies. END OF RECORD 143 3500-001-Y1-H-V-KKK Controlled Substances Inventory In accordance with 21 CFR 1301.28(h), the Master shall prepare a report for each calendar year which will give in detail an accounting for all controlled substances received, dispensed and disposed of during that year. The Master shall file this report with the Corporate Medical Officer employed by the owner or operator of the vessel. At the end of each year the Master shall compile an up- to-date inventory of all narcotics/controlled substances. The Master shall maintain a copy of the correspondence on board for the vessel=s files. Once the inventory is completed with the Master=s final signature, the Master is legally responsible for the exact contents. Note: Other procedures as outlined in Quality Manual QMED-411 regarding disposal procedures of narcotics/controlled substances shall remain in effect. END OF RECORD 144 3801-001-M1-H-V-KKK HVAC Systems For tracking purposes, note related MEI codes as applicable: 3804 Steam or hot water heaters 3805 Electric heaters 3811 Air mixing units 3815 Preheaters 3816 Reheaters 3817 Coolers 3820 Ducts and supports 3821 Cowls 3831 Dampers 3832 Filters 3840 Thermostatic & humidity control 3841 Pneumatic temperature controls 3842 Temperature control system Visually inspect the accommodation HVAC machinery and associated components for damage or defects. Inspect vent ducts and cowls for damaged and deterioration. Inspect condition of insulation and lagging. During summer months when the air conditioning system is in operation, test the steam and electric preheaters and reheaters to insure proper operation in preparation for winter. During winter months when the steam or electric heating system is in operation, test the air conditioning system to insure proper operation in preparation for summer. Insure that all controls for the heating and air conditioning systems function properly. END OF RECORD 145 3822-001-M6-H-V-KKK Mushrooms Visually inspect all mushroom vents for all tanks throughout the vessel, including but not limited to ballast, fuel, diesel, lube oil, dirty water and fresh water tanks. Inspect vents for signs of damage or deterioration. Exercise the closures for gravity type closures for all water tank vents (ballast, fresh water, feed water, etc.). Insure freedom of movement of the closure. Apply anti-seize on the closure shaft as required. Exercise the valve type (handwheel) closures for all oil tank vents (fuel, diesel, lube oil, etc.) to insure freedom of movement. Apply anti-seize compound to all valve stems. Insure that all oil tank vents are fitted with stainless steel wire mesh / screen in accordance with USCG regulations. Check that all tank mushroom vents are fitted with label plates to identify their respective tanks. Insure that they are labeled properly in accordance with applicable drawings. END OF RECORD 146 3832-001-M1-H-V-KKK Filters Visually inspect all ventilation fan intake filters, including but not limited to main engine and auxiliary generator engine turbochargers, engine room supply fan room intake filters, emergency generator room intake filters and air conditioning air handler filters. Clean or replace filter media as required. END OF RECORD 147 4005-001-W1-M-V-KKK Main Propulsion Diesel - MPDE (Rotate) Examine area in way of propeller and ascertain as far as possible that propeller is clear and free to turn. Visually examine main engine checking all fluids including cylinder, piston and fuel valve cooling water levels, LO circulating tank level, cylinder oil day tank level, turning gear motor and turning gear. Turn on main LO pump and allow to run for at least 10 minutes noting local and remote pressure gauges. Open all main engine indicator cocks. Hand crank cylinder lubricators 100 turns each. Engage jacking gear and install securing pin. Jack main engine over a minimum of 1-1/4 turns. Note: Do not stop engine in the same position as original. Remove pin, disengage jacking gear and install securing pin to lock gear in disengaged position. Secure main LO pump. Close main engine indicator cocks. End of Record 148 4005-001-W1-M-V-KKK Main Propulsion Diesel - MPDE (Rotate) Examine area in way of propeller and ascertain as far as possible that propeller is clear and free to turn. Visually examine main engine checking all fluids including cylinder, piston and fuel valve cooling water levels, LO circulating tank level, cylinder oil day tank level, turning gear motor and turning gear. Turn on main LO pump and allow to run for at least 10 minutes noting local and remote pressure gauges. Open all main engine indicator cocks. Hand crank cylinder lubricators 100 turns each. Engage jacking gear and install securing pin. Jack main engine over a minimum of 1-1/4 turns. Note: Do not stop engine in the same position as original. Remove pin, disengage jacking gear and install securing pin to lock gear in disengaged position. Secure main LO pump. Close main engine indicator cocks. End of Record 149 4005-001-W1-M-V-KKK Main Propulsion Diesel - MPDE (Rotate) Examine area in way of propeller and ascertain as far as possible that propeller is clear and free to turn. Visually examine main engine checking all fluids including cylinder, piston and fuel valve cooling water levels, LO circulating tank level, cylinder oil day tank level, turning gear motor and turning gear. Turn on main LO pump and allow to run for at least 10 minutes noting local and remote pressure gauges. Open all main engine indicator cocks. Hand crank cylinder lubricators 100 turns each. Engage jacking gear and install securing pin. Jack main engine over a minimum of 1-1/4 turns. Note: Do not stop engine in the same position as original. Remove pin, disengage jacking gear and install securing pin to lock gear in disengaged position. Secure main LO pump. Close main engine indicator cocks. End of Record 150 4005-001-W1-M-V-KKK Main Propulsion Diesel - MPDE (Rotate) Examine area in way of propeller and ascertain as far as possible that propeller is clear and free to turn. Visually examine main engine checking all fluids including cylinder, piston and fuel valve cooling water levels, LO circulating tank level, cylinder oil day tank level, turning gear motor and turning gear. Turn on main LO pump and allow to run for at least 10 minutes noting local and remote pressure gauges. Open all main engine indicator cocks. Hand crank cylinder lubricators 100 turns each. Engage jacking gear and install securing pin. Jack main engine over a minimum of 1-1/4 turns. Note: Do not stop engine in the same position as original. Remove pin, disengage jacking gear and install securing pin to lock gear in disengaged position. Secure main LO pump. Close main engine indicator cocks. End of Record 151 4005-002-M1-M-V-KKK Main Propulsion Diesel - MPDE (Operate) Note: This task is to be completed in conjunction with the following additional tasks: 4035-001-M1-M-V-KK1/KK2 Auxiliary Diesel Engines Auxiliary Diesel Engine Rollover 0185-001-M1-M-V-KK1/KK2 Water Treatment Analysis Also, see 0143-001-AR-M-V-KK1/KK2 Operation Tests (Non-Reg) Plant Start Up and Operating Procedures Remove all applicable stack covers and replace on completion. Light off aux boiler and raise steam pressure. Secure shore power and put designated aux diesel generator on line. Maintain watch on all machinery and systems. Check all LO levels to include main circulating tank, stern tube, line shaft, turning gear, turning gear motor, main engine governor and turbocharger. Check all CW levels to include cylinder CW, piston CW and fuel valve CW. Report any abnormal conditions. Start and maintain CW pumps. Raise cylinder CW temp to 55-60 deg C. From dock examine area about propeller as far as practicable and issue AWheel Clearance.@ Start and maintain main and crosshead LO pumps. Confirm that cylinder indicator cocks are open. Engage turning gear. Hand lubricate cylinder liners 100 turns. Rotate engine on turning gear for approximately 1 hour. Line up and start main engine fuel booster and fuel circulating pumps recording main engine fuel meter. With Chief Mate on bridge, wheelhouse main engine key in Aon@ position and main engine in engine control room control, test EOT, automatic telephone, sound powered telephone and general alarm. Stop turning gear, disengage and secure same. Confirm turning gear engage/disengage indicators on engine room and bridge consoles operational. Remove turbocharger silencer covers and afterwards replace. With all main engine and aux parameters normal, open main start air valves and open automatic starting air valve to >automatic=. Hand crank cylinder lubricators an additional 50 turns. Notify bridge and roll main engine on air only ( no fuel) fwd and astern from both engine control room and engine side locations. ( 4 starts). Confirm proper lubrication for line shaft bearings and turbocharger rotors. Take necessary measure to block Fuel to engine, transfer to > Bridge Control= and roll engine on air only, forward and astern ( 2 starts). Transfer control back to engine room control and confirm all indicating lights. Close main air start valves and close automatic air starting valve. On completion of main engine rollover, return wheelhouse main engine key to Chief Engineer, return all equipment and valves to original. Report any abnormal conditions. End of Record 152 4005-003-HR-M-V-KKK MPDE Foundation Bolts (Check Pretension - 6000 HR) Check the pretension of the bedplate foundation bolts every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 110, sheet 1. END OF RECORD 153 4005-004-HR-M-V-KKK MPDE Main Bearing (Check Clearances - 6000 HR) Measure main bearing wear and check vertical bearing clearance (reduce clearance if necessary) every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 117, sheet 1. END OF RECORD 154 4005-005-HR-M-V-KKK MPDE Main Bearing Thrust Bolts (Check Pretension - 15000 HR) Check pretension of main bearing thrust bolts and retighten if necessary every 15,000 to 20,000 hours of engine operation in accordance with Sulzer RND-D Maintenance Manual worksheet Group 117, sheet 2. END OF RECORD 155 4005-006-HR-M-V-KKK MPDE Tie Rods Pretension (Check Pretension - 6000 HR) Check pretension of tie rods and retighten if necessary every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 197, sheet 1. END OF RECORD 156 4005-007-HR-M-V-KKK MPDE Cylinder Head Safety Valves (Inspect/Test - 6000 HR) Remove the cylinder head safety valves for testing, dismantling for inspection, assembling, after inspection and/or repairs and adjustments after reassembly every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 277, sheet 1. END OF RECORD 157 4005-008-HR-M-V-KKK MPDE Crankshaft Deflections (Measure - 3000 HR) Measure crankshaft deflection every 3000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 310, sheet 1. END OF RECORD 158 4005-009-HR-M-V-KKK MPDE Connecting Rod Bearings (Check Clearances - 3000 HR) Check upper and lower connecting rod bearing clearances and reduce the clearances of the lower bearings if necessary every 3000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 330, sheet 1. END OF RECORD 159 4005-010-HR-M-V-KKK MPDE Connecting Rod Bearings (Inspect - 15000 HR) Inspect the upper and lower connecting rod bearings and replace as necessary every 15,000 to 20,000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 330, sheets 2,4,5, and 6. END OF RECORD 160 4005-011-HR-M-V-KKK MPDE Crossheads (Check Clearances - 6000 HR) Check running clearnances every 6000 to 8000 hours of engine operations in accordance with Sulzer RND-M Maintenance Manual Worksheet Group 337, sheet 1. END OF RECORD 161 4005-012-HR-M-V-KKK MPDE Unit Inspection (Remove/Inspect/Check - 6000 HR) Remove pistons for inspections, cleaning and measurement of grooves every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 340, sheets 1-4. Check cooling space and clean if necessary in accordance with worksheet Group 340, sheet 5. Check tightness of piston after reassembly in accordance with worksheet Group 340, sheet 6. Check for possible burnings onthe piston crown in accordance with worksheet Group 340, sheet 7. Align piston cooling telescopic pipes in accordance with worksheet Group 340, sheet 8. Remove piston rings for clenaing and isnpection for wear; fit new rings if necessary in accordance with worksheet Group 344, sheet 1. Dismantle glands of piston cooling elscopic pipes and clean and inspect for wear in accordance with worksheet group 360, sheet 1. Remove standpipes and check condition of guide bushes in accordance with worksheet Group 360, sheet 2. At each piston withdrawal, measure the cylinder liner bore in accordance with worksheet Group 214, sheet 1. Remove the ridge in the bore, round off edges of scavenging and exhaust ports and remachine lubricating grooves in accordancewith worksheet Group 214, sheet 2. At each piston withdrawal, check the lubricating quills for function and tightness in accordance with worksheet group 215, sheet 1. At each piston withdrawal, clean the piston rod gland rings and measure wear in accordance with worksheet Group 231, sheet 1. At each piston withdrawal, inspect the cylinder cover combustion space in accordance with worksheet Group 271, sheet 1-3. Clean the sealing face of the fuel injector seat or replace if necessary in accordance with worksheet Group 271, sheet 4. END OF RECORD 162 4005-013-HR-M-V-KKK MPDE Running Direction Safeguard (Operational Test - 15000 HR) Operationally test the running direction safeguard every 15000 to 20000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 453, sheet 1. END OF RECORD 163 4007-001-HR-M-V-KKK MPDE Woodward Governor (Drain/Replace Oil - 3000 HR) Drain the governor oil, rub out the casing and replace the oil with new every 3000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 511, sheet 1. END OF RECORD 164 4009-001-M1-M-V-KKK MPDE Turning Gear Visually inspect, test and maintain this equipment as follows: NOTE: Main Engine shall be in a stopped position and secured while testing the turning gear. Main Engine indicator cocks shall be opened to avoid overloading the turning gear and the lube oil pump shall be operated during the testing of the turning gear. A. Verify the oil level is normal in the turning gear sump. B. Visually inspect the open gears for defects, damage and deterioration. Grease open gears as required. C. Operationally test the engaging and disengaging functions of the turning gear. END OF RECORD 165 4010-001-Y1-M-V-KKK MPDE Tools Visually inspect all special main engine tools for damage, defects and deterioration. Conduct a complete inventory of all tools against the inventory in PC-SAL. Carry out preventative maintenance as required to preserve tools in safe working condition. END OF RECORD 166 4011-001-HR-M-V-KKK MPDE Camshaft Driving Gearwheels (Check Backlash - 1500 HR) Check the backlash and condition of the teeth on the camshaft driving gearwheels every 1500 hours of engine operation in accordance with RND-M Maintenance Manual worksheet Group 411, sheet 1. END OF RECORD 167 4011-002-HR-M-V-KKK MPDE Camshaft Driving Gearwheels (Check Clearances - 6000 HR) Check the bearing clearances of the intermediate camshaft driving gearwheels every 6000 to 8000 hours of engine operations in accordance with Sulzer RND-M Maintenance Manual worksheet 411, sheet 1. END OF RECORD 168 4011-003-HR-M-V-KKK MPDE Camshaft Bearings (Check Clearances - 6000 HR) Check the camshaft bearing clearances every 6000 to 8000 hours of engine operations in accordance with Sulzer RND-M Maintenance Manual schedules of clearances Group 012, sheet 10. END OF RECORD 169 4011-004-HR-M-V-KKK MPDE Fuel Cams Running Surface (Inspect - 1500 HR) Inspect the running surface of the fuel cams every 1500 hours of engine operation. END OF RECORD 170 4011-005-HR-M-V-KKK MPDE Fuel Cams Cam Nuts (Retighten - 6000 HR) Retighten fuel cam nuts every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 421, sheet 1. END OF RECORD 171 4011-006-HR-M-V-KKK MPDE Fuel Pump Cut-Out (Clean/Inspect - 15000 HR) Dismantle, clean and inspect the pneumatic fuel pump cut-out device and replace the slide ring and Viton if necessary every 15000 to 20000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual Worksheet Group 530, sheet 1. END OF RECORD 172 4011-007-HR-M-V-KKK MPDE Fuel Injection Pumps (Clean/Inspect - 6000 HR) Clean, remove and inspect the fuel injection pump valves every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 551, sheet 1. Check the distribution and adjust if necessary in accordance with worksheet Group 551, sheet 1. Lap the sealinf faces for the valve covers as required in accordnace with worksheet Group 551, sheet 2. Check and adjust the safety valves in accordance with worksheet Group 551, sheet 1. END OF RECORD 173 4012-001-HR-M-V-KKK MPDE Integral Lube Oil System (Spot Test - 500 HR) Conduct a spot test of the lubricating oil every 500 hours of engine operation in accordance with sulzer RND-M Maintenance Manual, worksheet Group 042, sheet 1. END OF RECORD 174 4012-002-HR-M-V-KKK MPDE Integral Lube Oil System (Oil Analysis - 3000 HR) Draw lubriating oil samples every 3000 hours of engine operation and submit same to a recognized laboratory for analysis in accordance with Sulzer RND-M Maintenance Manual worksheet, Group 042, sheet 2. END OF RECORD 175 4012-003-HR-M-V-KKK MPDE Cylinder Lube Oil Pumps (Drain/Wash Out - 6000 HR) Drain and wash out the housing of the cylinder lubricating pumps every 6000 to 8000 hours of engine operation. END OF RECORD 176 4013-001-HR-M-V-KKK MPDE Exhaust Manifold Inlet Grids (Clean/Renew - 8000 HR) Clean the protections grids at the inlets of the turbochargers or fit new grids if necessary every 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 810, sheet 1. END OF RECORD 177 4014-001-HR-M-V-KKK MPDE Starting Air Valves (Inspect/Grind Seats - 6000 HR) Dismantle the starting air valves for inspection and grind in seats if necessary every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 274, sheet 1. END OF RECORD 178 4014-002-HR-M-V-KKK MPDE Starting Air Pilot Valve (Claen/Inspect - 15000 HR) Dismantle, clean and inspect the starting air pilot valve and check slide valve for ease of movement every 15000 to 20000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 431, sheet 1. END OF RECORD 179 4014-003-HR-M-V-KKK MPDE Starting Air Control Valve (Clean/Inspect - 15000 HR) Dismantle, clean and inspect the starting air control valve every 15000 to 20000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 431, sheet 1. END OF RECORD 180 4014-004-HR-M-V-KKK MPDE Automatic Start Air ShutOff (Clean/Inspect - 6000 HR) Dismantle, clean and inspect the automatic starting air shut-off valve (particularly the seat and springs) every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 436, sheet 1. END OF RECORD 181 4015-001-M1-M-V-KKK MPE Charge Air System Auxiliary Blower (Inspect/Test) Visually inspect, test and maintain this equipment as follows: A. Visually inspect all components of the main engine auxiliary scavenge blower for excessive wear, damage, defects, and deterioration. B. Lubricate all components as required. C. Visually inspect, test, and maintain motor controller in accordance with: 6401-001-M6-E-V-KK1/KK2 Electric Motor Controllers. D. Hand rotate (if possible) and megger test electric motor. E. Verify proper operation of auxiliary blower while the main engine is operational. END OF RECORD 182 4015-001-M1-M-V-KKK MPDE Auxiliary Blower Visually inspect, test and maintain this equipment as follows: A. Visually inspect all components of the main engine auxiliary scavenge blower for excessive wear, damage, defects, and deterioration. B. Lubricate all components as required. C. Visually inspect, test, and maintain motor controller in accordance with: 6401-001-Y1-E-V-KK1/KK2 Electric Motor Controllers. D. Hand rotate (if possible) and megger test electric motor. E. Verify proper operation of auxiliary blower while the main engine is operational. END OF RECORD 183 4015-002-HR-M-V-KKK MPDE Charge Air Receiver (Clean/Inspect - 3000 HR) Inspect, clean, and recondition the non-return valves every 3000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet, Group 646, sheet 1. END OF RECORD 184 4015-003-HR-M-V-KKK MPDE Charge Air Receiver (Clean - 6000 HR) Clean the charge air receiver every 6000 to 8000 hours of engine operation or as required in accordance with Sulzer RND-M Maintenance Manual worksheet, Group 646, sheet 1. END OF RECORD 185 4015-004-HR-M-V-KKK MPDE Auxiliary Blower (Clean - 6000 HR) Clean the impeller and casing of the auxiliary blower every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 656, sheet 1. END OF RECORD 186 4016-001-HR-M-V-KKK MPDE Control Air Pressure Reducing Unit (Clean Filter - 6000 HR) Remove and clean the filter in the control air pressure reducing unit every 6000 to 8000 hours of engine operation in accordance with Sulzer RND-M Maintenance Manual worksheet Group 404, sheet 1. END OF RECORD 187 4020-001-W1-M-V-KKK Emergency Diesel - EDG (Inspect/Test) Carry out the weekly checks as follows: A. Check the crankcase oil level. The oil level should be between the "Low" and "High" marks o the dipstick. B. Check the coolant level. The coolant level should be to the bottom of the fill neck in the radiator. NOTE: Check the coolant level only when the engine is stopped. Do not remove the radiator cap from a hot engine. Remove the radiator cap slowly to relieve coolant system pressure. Do not add cold coolant to a hot engine. Add coolant additive or antifreeze as required. C. Visually inspect the cooling fan. Check for cracks, loose rivets, and bent or loose blades. Check the fan mountings. NOTE: Check the cooling fan only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. D. Visually inspect the belts. Check for cracks and fraying. NOTE: Check the belts only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. E. Report all deficiencies Operationally test the emergency generator. Allow the emergency generator engine to run for at least 30 minutes continuously each week. Observe operating parameters. END OF RECORD 188 4020-001-W1-M-V-KKK Emergency Diesel - EDG (Inspect/Test) Carry out the weekly checks as follows: A. Check the crankcase oil level. The oil level should be between the "Low" and "High" marks o the dipstick. B. Check the coolant level. The coolant level should be to the bottom of the fill neck in the radiator. NOTE: Check the coolant level only when the engine is stopped. Do not remove the radiator cap from a hot engine. Remove the radiator cap slowly to relieve coolant system pressure. Do not add cold coolant to a hot engine. Add coolant additive or antifreeze as required. C. Visually inspect the cooling fan. Check for cracks, loose rivets, and bent or loose blades. Check the fan mountings. NOTE: Check the cooling fan only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. D. Visually inspect the belts. Check for cracks and fraying. NOTE: Check the belts only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. E. Report all deficiencies Operationally test the emergency generator. Allow the emergency generator engine to run for at least 30 minutes continuously each week. Observe operating parameters. END OF RECORD 189 4020-001-W1-M-V-KKK Emergency Diesel - EDG (Inspect/Test) Carry out the weekly checks as follows: A. Check the crankcase oil level. The oil level should be between the "Low" and "High" marks o the dipstick. B. Check the coolant level. The coolant level should be to the bottom of the fill neck in the radiator. NOTE: Check the coolant level only when the engine is stopped. Do not remove the radiator cap from a hot engine. Remove the radiator cap slowly to relieve coolant system pressure. Do not add cold coolant to a hot engine. Add coolant additive or antifreeze as required. C. Visually inspect the cooling fan. Check for cracks, loose rivets, and bent or loose blades. Check the fan mountings. NOTE: Check the cooling fan only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. D. Visually inspect the belts. Check for cracks and fraying. NOTE: Check the belts only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. E. Report all deficiencies Operationally test the emergency generator. Allow the emergency generator engine to run for at least 30 minutes continuously each week. Observe operating parameters. END OF RECORD 190 4020-001-W1-M-V-KKK Emergency Diesel - EDG (Inspect/Test) Carry out the weekly checks as follows: A. Check the crankcase oil level. The oil level should be between the "Low" and "High" marks o the dipstick. B. Check the coolant level. The coolant level should be to the bottom of the fill neck in the radiator. NOTE: Check the coolant level only when the engine is stopped. Do not remove the radiator cap from a hot engine. Remove the radiator cap slowly to relieve coolant system pressure. Do not add cold coolant to a hot engine. Add coolant additive or antifreeze as required. C. Visually inspect the cooling fan. Check for cracks, loose rivets, and bent or loose blades. Check the fan mountings. NOTE: Check the cooling fan only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. D. Visually inspect the belts. Check for cracks and fraying. NOTE: Check the belts only when the engine is stopped. Rotate the crankshaft by using only the crankshaft barring techniques recommended by the engine manufacturer. E. Report all deficiencies Operationally test the emergency generator. Allow the emergency generator engine to run for at least 30 minutes continuously each week. Observe operating parameters. END OF RECORD 191 4020-002-HR-M-V-KKK EDG Engine (M&I) (Maintenance/Inspection - 10 HR) Perform the following maintenance and inspections of the emergency diesel engine every 10 hours of operation in accordance witht he maintenance schedule in the Deutz instruction manual: 1.Check motor oil level. 2.Check cooling water level (use anti-freeze when required) 3.Inspect the air cleaner for soiling. END OF RECORD 192 4020-003-HR-M-V-KKK EDG Engine (M&I) (Maintenance/Inspection - 500 HR) Perform the following maintenance and inspections of the emergency diesel engine every 500 hours of operation in accordance with the maintenance scheulde in the Deutz instruction manual: 1. Change motor oil (engine unde normal operating conditions). 2. Check valve clearnances with feeler gauges. 3. Clean oil filter and renew paper elements. 4. Inspect fastening of manifolding. 5. Inspect injection piping. END OF RECORD 193 4020-004-HR-M-V-KKK EDG Engine (M&I) (Maintenance/Inspection - 750 HR) Perform the following maintenance and inspections of the emergency diesel engine every 750 hours of operation in accordance with the maintenance schedule in the Deutz instruction manual: 1. Inspect injection pumps 2. Inspect water pumps 3. Remove and inspect cylinder system 4. Check starting air control system 5. Inspect turbo charger END OF RECORD 194 4020-005-HR-M-V-KKK EDG Engine (Overhaul) (Overhaul - 15000 HR) Overhaul the emergency diesel engine completely, including replacemnt of the vibration damper, every 15,000 hours of operation in accordance with the maintenance schedule in the Deutz instruction manual. END OF RECORD 195 4035-001-W1-M-V-KKK SSDG (Inspect/Roll-Over) Visually inspect the four (4) generator engines and note any apparent deficiencies. Check all lube levels to include: sump, rocker arm, fresh water pump drive, turbocharger and governor. Refill all lubes to operational level. See lube chart for proper lubricants. Start prelube pump and note pressure. Visually inspect engine for oil flow and leaks. Note lube oil filter differential gauge. Check fresh water expansion tank level and check that fresh water valves are opened to each engine. Confirm that freshwater temperature is above 30 deg Centigrade. Refill expansion tank above low level alarm level as required. Open indicator cocks on each engine. Secure fuel rack to each engine to prevent engine from starting. Open starting air valve to each engine. From local control station with control switch in local position, start and roll each engine over on air sufficiently to observe discharge from indicator cocks. Report any abnormal discharges. Lamp up local control station indicator lights. Close starting air to each engine. Secure prelube pumps as original. Record any deficiencies noted. END OF RECORD 196 4035-001-W1-M-V-KKK SSDG (Inspect/Roll-Over) Visually inspect the four (4) generator engines and note any apparent deficiencies. Check all lube levels to include: sump, rocker arm, fresh water pump drive, turbocharger and governor. Refill all lubes to operational level. See lube chart for proper lubricants. Start prelube pump and note pressure. Visually inspect engine for oil flow and leaks. Note lube oil filter differential gauge. Check fresh water expansion tank level and check that fresh water valves are opened to each engine. Confirm that freshwater temperature is above 30 deg Centigrade. Refill expansion tank above low level alarm level as required. Open indicator cocks on each engine. Secure fuel rack to each engine to prevent engine from starting. Open starting air valve to each engine. From local control station with control switch in local position, start and roll each engine over on air sufficiently to observe discharge from indicator cocks. Report any abnormal discharges. Lamp up local control station indicator lights. Close starting air to each engine. Secure prelube pumps as original. Record any deficiencies noted. END OF RECORD 197 4035-001-W1-M-V-KKK SSDG (Inspect/Roll-Over) Visually inspect the four (4) generator engines and note any apparent deficiencies. Check all lube levels to include: sump, rocker arm, fresh water pump drive, turbocharger and governor. Refill all lubes to operational level. See lube chart for proper lubricants. Start prelube pump and note pressure. Visually inspect engine for oil flow and leaks. Note lube oil filter differential gauge. Check fresh water expansion tank level and check that fresh water valves are opened to each engine. Confirm that freshwater temperature is above 30 deg Centigrade. Refill expansion tank above low level alarm level as required. Open indicator cocks on each engine. Secure fuel rack to each engine to prevent engine from starting. Open starting air valve to each engine. From local control station with control switch in local position, start and roll each engine over on air sufficiently to observe discharge from indicator cocks. Report any abnormal discharges. Lamp up local control station indicator lights. Close starting air to each engine. Secure prelube pumps as original. Record any deficiencies noted. END OF RECORD 198 4035-001-W1-M-V-KKK SSDG (Inspect/Roll-Over) Visually inspect the four (4) generator engines and note any apparent deficiencies. Check all lube levels to include: sump, rocker arm, fresh water pump drive, turbocharger and governor. Refill all lubes to operational level. See lube chart for proper lubricants. Start prelube pump and note pressure. Visually inspect engine for oil flow and leaks. Note lube oil filter differential gauge. Check fresh water expansion tank level and check that fresh water valves are opened to each engine. Confirm that freshwater temperature is above 30 deg Centigrade. Refill expansion tank above low level alarm level as required. Open indicator cocks on each engine. Secure fuel rack to each engine to prevent engine from starting. Open starting air valve to each engine. From local control station with control switch in local position, start and roll each engine over on air sufficiently to observe discharge from indicator cocks. Report any abnormal discharges. Lamp up local control station indicator lights. Close starting air to each engine. Secure prelube pumps as original. Record any deficiencies noted. END OF RECORD 199 4035-002-HR-M-V-KKK SSDG (M&I) (Maintenance/Inspection - 12 HR) Conduct the following maintenance and inspections on the auxiliary generator engines every 12 to 24 hours of operation in accordance with the standard intervals for disassembling and clenaing in the Daihatsu instruction manual: 1. Inspect engine for loosening, oil leakage & wate leakage. 2. Check oil quantity and replenish oil as required. END OF RECORD 200 4038-001-HR-M-V-KKK SSDG Fuel Injection System Timing (Check Timing - 1200 HR) Check injeciton timing and adjust maximum pressure as required every 1200 to 2400 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 201 4038-002-HR-M-V-KKK SSDG Fuel Injection System Rebuild (Rebuild/Test - 4000 HR) Disassemble, inspect rebuild, test and adjust the fuel injection pumps and inspect the oil seal and bearings on the fuel feed pump every 4000 to 7000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 202 4039-001-HR-M-V-KKK SSDG Oil Cooler Overhaul (Inspect/Clean - 8000 HR) Open oil cooler for overhaul inspection and cleaning every 8000 to 14000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. Replace zincs if necessary. END OF RECORD 203 4042-001-Y1-M-V-KKK SSDG Tools - Generator Engine Visually inspect all generator engine tools for damage, defects and deterioration. Conduct a complete inventory of all tools against the inventory in PC-SAL. Carry out preventative maintenance as required to preserve tools in a safe working condition. END OF RECORD 204 4042-001-Y1-M-V-KKK Tools - Generator Engine Tools Visually inspect all generator engine tools for damage, defects and deterioration. Conduct a complete inventory of all tools against the inventory in PC-SAL. Carry out preventative maintenance as required to preserve tools in a safe working condition. END OF RECORD 205 4043-001-HR-M-V-KKK SSDG Governor Oil (Replace Oil - 2000 HR) Replace the governor oil every 2000 to 3600 hours in accordance with recommendations in the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 206 4060-001-HR-M-V-KKK SSDG Intercooler (Overhaul - 2000 HR) Open the intercooler for overhaul inspection every 2000 to 3600 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. Replace zincs as necessary. END OF RECORD 207 4060-002-HR-M-V-KKK SSDG Turbocharger (Replace Oil - 350 HR) Replace the lube oil in the turbocharger every 350 to 500 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual END OF RECORD 208 4060-003-HR-M-V-KKK SSDG Turbocharger Air Cleaner (Clean - 1200 HR) Clean the turbocharger air cleaner every 1200 to 2000 hours in accordance with the Standard Intervals for Disassembling and Clenaing in the Daihatsu instruction manual. END OF RECORD 209 4060-004-HR-M-V-KKK SSDG Turbocharger Internals (Clean - 2000 HR) Disassemble the turbocharger for internal cleaning and inspection of jacket sections every 2000 to 3600 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 210 4060-005-HR-M-V-KKK SSDG Turbocharger Bearings (Replace - 4000 HR) Replce turbocharger bearings every 4000 to 7000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 211 4062-001-HR-M-V-KKK SSDG Crankshaft Main Bearing (Inspect/Measure - 8000 HR) Inspect inside and rear impact surface and measure wear of main bearing shells every 8000 to 14000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 212 4063-001-HR-M-V-KKK SSDG Unit Overhaul (Remove/Inspect/Check - 4000 HR) Remove pistons for inspection every 4000 to 7000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. Insect piston rings. Inspect inside and rear impact surface of connecting rod bearing shells and measure wear. Inspect liners and measure wear. Measure wear of crank pins and piston pins. END OF RECORD 213 4064-001-HR-M-V-KKK SSDG Camshaft/Valve Train Rollers (Inspect - 350 HR) Inspect the camshaft and rollers every 350 to 500 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 214 4064-002-HR-M-V-KKK SSDG Camshaft/Valve Train Tappets (Check/Measure - 8000 HR) Check tappet wear and measure bushings every 8000 to 14000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 215 4064-003-HR-M-V-KKK SSDG Camshaft/Valve Train Bearing (Measure - 16000 HR) Measure camshaft bearing shell wear every 16000 to 26000 hours in accordance with the Standard Intervals for Disasssembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 216 4065-001-HR-M-V-KKK SSDG Timing Gear (Check/Measure - 8000 HR) Check for tightness of bolts, measure gear contact and rack lash and measure bearing bushing wear every 8000 to 14000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 217 4066-001-HR-M-V-KKK SSDG Cylinder Heads/Nozzle (Check - 1200 HR) Check injection state of nozzles every 1200 to 2000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 218 4066-002-HR-M-V-KKK SSDG Cylinder Heads/Exhaust Valves (Lap-In - 1200 HR) Lap in exhaust valves every 1200 to 2000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 219 4066-003-HR-M-V-KKK SSDG Cylinder Heads/Intake Valves (Lap-In - 4000 HR) Lap in intake vavles every 4000 to 7000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 220 4066-004-HR-M-V-KKK SSDG Cylinder Heads/Starting Valves (Lap-In - 4000 HR) Lap in starting air valves every 4000 to 7000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 221 4066-005-HR-M-V-KKK SSDG Cylinder Heads/Safety Valves (Lap-In - 4000 HR) Lap in cylinder safety vavles every 4000 to 7000 hours in accordance with the Standard Intervals for Disassembling and Cleaning in the Daihatsu instruction manual. END OF RECORD 222 4080-001-W2-M-V-KKK Lifeboat Diesel Engines For each port and starboard lifeboat, conduct the following inspection and operational test of the lifeboat propulsion diesel engine. 1. Visually examine the engine, checking engine oil, fuel and transmission fluid. Bring fluids to operating level as required. 2. Open fuel valve to route fuel to engine. Note: After testing engines, close the fuel valves. 3. Open engine valves by pushing compression levers all the way aft. 4. Use engine crank and fit onto overhead shaft. Test racheting device by turning engine crank in counterclockwise direction facing aft. 5. If racheting device is satisfactory, rotate crank in clockwise direction to turn over engine. Build up sufficient engine RPM=s and close valves by flipping compression levers to start engine. 6. Allow engine to run, noting a rise in temperature. 7. Test engine transmission ahead and astern, but do not run in ahead or astern for extended periods of time since stern bearing is water lubricated. END OF RECORD 223 4080-001-W2-M-V-KKK Lifeboat Diesel Engines For each port and starboard lifeboat, conduct the following inspection and operational test of the lifeboat propulsion diesel engine. 1. Visually examine the engine, checking engine oil, fuel and transmission fluid. Bring fluids to operating level as required. 2. Open fuel valve to route fuel to engine. Note: After testing engines, close the fuel valves. 3. Open engine valves by pushing compression levers all the way aft. 4. Use engine crank and fit onto overhead shaft. Test racheting device by turning engine crank in counterclockwise direction facing aft. 5. If racheting device is satisfactory, rotate crank in clockwise direction to turn over engine. Build up sufficient engine RPM=s and close valves by flipping compression levers to start engine. 6. Allow engine to run, noting a rise in temperature. 7. Test engine transmission ahead and astern, but do not run in ahead or astern for extended periods of time since stern bearing is water lubricated. END OF RECORD 224 4201-001-Y1-M-V-KKK MPE Bull and Turning Gear (Inspect) Disconnect and rig aside the bull gear cover. Clean the bull gear and turning gear teeth as required to facilitate inspection. Engage the turning gear and turn the main engine through one complete cycle to turn the bull gear 360 degrees to facilitate a complete inspection of all teeth. Note: Main engine LO pump and stern tube LO pump should be running and main engine cylinder lubricators should be hand cranked as required before and while the turning gear is engaged and running. Note condition of bull gear and turning gear teeth as appropriate. If necessary, thoroughly clean the bull gear and turning gear teeth free of preservation compound and dye check the teeth to check teeth contact. After inspections, liberally apply preservation compound on bull gear and turning gear teeth. Rig the bull gear cover back to place and reconnect in good order. END OF RECORD 225 4460-001-Y1-M-V-KKK Bow / Stern Thrusters For tracking purposes, note related MEI codes as applicable: 4465 Controllable pitch type 4469 Drive mechanism 4470 Control mechanism 4471 Instrumentation Read and become familiar with manufactures instruction manual 1-127-B. This operation and inspection shall be conducted at annual sea trial. Prior to leaving dock, divers should determine that the propellers are free of any obstruction. START-UP Note: Three SSDG=s should be parallel to operate thrusters. 1. Check the oil level and condition in the sump tank and the gravity tank. 2. Confirm that the power switch is ON at the main switchboard. (Lighting of the source lamp.) 3. Confirm that the start up and stopping position change-over switch on the starter for the maneuvering oil pump motor is set to the remote control side. 4. Confirm that the remote control panel power switch is ON. 5. Confirm that suction and discharge valves are open for maneuvering oil pump and start pump. Confirm pump ON light is lit. 6. Observe neutral blade angle of the blade angle indicator. (Within 2 degrees for both left and right) Drive motor will not start if pitch angle is greater than 2 degrees. 7. Start drive motor. Note: The drive motor will not start unless the discharge pressure of the maneuvering oil pump is greater than the pressure set by the pressure switch and the propeller blade angle is in neutral position. DURING OPERATION: 1. By the control lever on the remote control panel, instructions shall be given to the revolving bow or stern on the port or starboard pitch indicator lamps. 2. In case the maneuvering oil pump is overloaded, the motor will stop; and if the pressure remains below the pre-set value for more than 10 seconds the main motor will stop. 3. To prevent overload of the main motor, a load control system is equipped. 4. Inspect for leakage, vibration, abnormal noises, and working pressures. 5. Check oil level the sump tank and gravity tank. STOPPING: 1. After finishing maneuvers, set the propeller to zero pitch. 2. Stop the drive motor and pump motor. 3. Switch off the power to all unit. END OF RECORD 226 4705-001-AR-M-V-KKK Centrifugal Pumps For each centrifugal pump, carry out the following inspection and conduct appropriate maintenance and repairs. Record results of the inspection, maintenance and repairs on the attached PUMP CHECK OFF CHART. After inspection and maintenance and repairs, test pumps in accordance with all other Phase IV procedures where required. Run pumps as necessary to ensure proper operation and ensure priming system (when fitted), controls and indicator lights function properly. Note: Pumps with mechanical seals shall not be activated without containing system fluid. For tracking purposes, not related MEI codes below as applicable: 4706 Priming system When applicable, inspect the pump=s priming system to ensure proper operation. For pumps with priming lines from the casing, inspect the tubing for defects. Ensure tubing does not have any restrictive kinks or bends. Where there is evidence of leaks, tighten fittings as required. For pumps with priming fluid head tanks, inspect integrity of tanks and piping/tubing between tanks and pumps. Note all deficiencies deferred for repair. 1. Visually inspect foundation. Note condition of coating and steel. Report coating failure and wasted steel. 2. Hammer test foundation fasteners. Tighten all loose fasteners. 3. Visually inspect pump casing. Where fitted, assure that the vibration analysis blocks are still in place. Install new blocks as necessary to replace missing blocks. 4. Visually inspect pump/motor coupling. Check tightness of fasteners. When applicable, check condition of coupling rings. 5. Inspect suction pressure gauge and isolation valve. Note condition of gauge face plate, glass window and fittings. Does gauge have a current calibration sticker? Test isolation valve. Does valve open and close freely? 6. Inspect discharge pressure gauge and isolation valve. Note condition of gauge face plate, glass window and fittings. Does gauge have a current calibration sticker? Test isolation valve. Does valve open and close freely? 7. Check piping/tubing for suction pressure gauge. Is piping/tubing intact? Is piping/tubing rigidly supported by clamps or bands to prevent vibration? Is piping/tubing free of restrictive kinks or bends? 8. Check piping/tubing for discharge pressure gauge. Is piping/tubing intact? Is piping/tubing rigidly supported by clamps or bands to prevent vibration? Is piping/tubing free of restrictive kinks or bends? 9. When applicable, insure presence of grease nipples. Replace nipples as necessary. Apply grease as required. 10. Inspect condition and tightness of packing gland, where fitted. 11. Inspect condition and tightness of gland nuts, where fitted. 12. Inspect condition of gland studs, where fitted. 13. If there is evidence of leakage through packing gland, tighten down on gland. If tightening of gland does not stop leakage, install additional packing or replace all packing as appropriate. 14. Inspect mechanical seal for visual defects and tightness of seal. 15. Inspect condition pump casing plug(s). Renew wasted plugs. When possible, remove plugs and lubricate with anti-seize compound and re-install same. 16. Hand rotate pump to ensure free operation. 17. Inspect impeller shaft in way of stuffing box or mechanical seal for wear or pitting. 18. Inspect pump nameplate. If a new nameplate is needed to replace a missing nameplate, look up nameplate data in the manufacturer=s manual and requisition a new nameplate for installation. 19. Is nameplate legible? Clean nameplate if necessary. Record nameplate data on the pump inspection form. If a new nameplate is needed to replace an illegible nameplate, look up nameplate data in the manufacturer=s manual and requisition a new nameplate for installation. 20. Inspect external coating of pump and appurtenances. Report coating deficiencies or failures. END OF RECORh%J9X.J9<5J9^4J9F-J9^ J9"J9$ J9 227 4705-001-AR-M-V-KKK Centrifugal Pumps For each centrifugal pump, carry out the following inspection and conduct appropriate maintenance and repairs. Record results of the inspection, maintenance and repairs on the attached PUMP CHECK OFF CHART. After inspection and maintenance and repairs, test pumps in accordance with all other Phase IV procedures where required. Run pumps as necessary to ensure proper operation and ensure priming system (when fitted), controls and indicator lights function properly. Note: Pumps with mechanical seals shall not be activated without containing system fluid. For tracking purposes, not related MEI codes below as applicable: 4706 Priming system When applicable, inspect the pump=s priming system to ensure proper operation. For pumps with priming lines from the casing, inspect the tubing for defects. Ensure tubing does not have any restrictive kinks or bends. Where there is evidence of leaks, tighten fittings as required. For pumps with priming fluid head tanks, inspect integrity of tanks and piping/tubing between tanks and pumps. Note all deficiencies deferred for repair. 1. Visually inspect foundation. Note condition of coating and steel. Report coating failure and wasted steel. 2. Hammer test foundation fasteners. Tighten all loose fasteners. 3. Visually inspect pump casing. Where fitted, assure that the vibration analysis blocks are still in place. Install new blocks as necessary to replace missing blocks. 4. Visually inspect pump/motor coupling. Check tightness of fasteners. When applicable, check condition of coupling rings. 5. Inspect suction pressure gauge and isolation valve. Note condition of gauge face plate, glass window and fittings. Does gauge have a current calibration sticker? Test isolation valve. Does valve open and close freely? 6. Inspect discharge pressure gauge and isolation valve. Note condition of gauge face plate, glass window and fittings. Does gauge have a current calibration sticker? Test isolation valve. Does valve open and close freely? 7. Check piping/tubing for suction pressure gauge. Is piping/tubing intact? Is piping/tubing rigidly supported by clamps or bands to prevent vibration? Is piping/tubing free of restrictive kinks or bends? 8. Check piping/tubing for discharge pressure gauge. Is piping/tubing intact? Is piping/tubing rigidly supported by clamps or bands to prevent vibration? Is piping/tubing free of restrictive kinks or bends? 9. When applicable, insure presence of grease nipples. Replace nipples as necessary. Apply grease as required. 10. Inspect condition and tightness of packing gland, where fitted. 11. Inspect condition and tightness of gland nuts, where fitted. 12. Inspect condition of gland studs, where fitted. 13. If there is evidence of leakage through packing gland, tighten down on gland. If tightening of gland does not stop leakage, install additional packing or replace all packing as appropriate. 14. Inspect mechanical seal for visual defects and tightness of seal. 15. Inspect condition pump casing plug(s). Renew wasted plugs. When possible, remove plugs and lubricate with anti-seize compound and re-install same. 16. Hand rotate pump to ensure free operation. 17. Inspect impeller shaft in way of stuffing box or mechanical seal for wear or pitting. 18. Inspect pump nameplate. If a new nameplate is needed to replace a missing nameplate, look up nameplate data in the manufacturer=s manual and requisition a new nameplate for installation. 19. Is nameplate legible? Clean nameplate if necessary. Record nameplate data on the pump inspection form. If a new nameplate is needed to replace an illegible nameplate, look up nameplate data in the manufacturer=s manual and requisition a new nameplate for installation. 20. Inspect external coating of pump and appurtenances. Report coating deficiencies or failures. END OF RECORD 228 4705-002-AR-M-V-KKK Pump Check Off Chart VESSEL: CAPE LOCATION: Poland Street Wharf - New Orleans, LA PUMP DESCRIPTION: Type: Capacity (m3/h): Total Head (m): Speed (rpm): Prime Mover: 0 - Poor; requires further attention by the crew (see Remarks below) 1 - Poor; requires contract support (see Remarks below) 2 - Requires parts for repair (see Remarks below) 3 - Deferable; needs improvement (see Remarks below) 4 - Repaired during inspection (see Remarks below) 5 - Satisfactory 0 1 2 3 4 5 N/A 1. Foundation 2. Hammer Test Foundation Nuts 3. Pump Casing 4. Coupling 5. Suct Press Gauge and isolation Valve 6. Disch Press Gauge and isolation Valve 7. Piping for Suct Gauge 8. Piping for Dis. Gauge 9. Grease Nipples 10. Gland 11. Gland Nuts 12. Gland Studs 13. Gland Packing 14. Mechanical Seal 15. Pump Casing Plug(s) 16. Free Rotation of Impeller 17. Impeller Shaft iwo stuffing box) 18. Name Plate 19. Name Plate Data Leg. 20. External Coating Remarks: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ Signature:__________________ Title:_________________ Name:___________________________ Date:_________ END OF RECORD 229 4710-001-AR-M-V-KKK Rotary Pumps For each rotary pump, carry out the following inspection and conduct appropriate maintenance and repairs. After inspection and maintenance and repairs, test pumps in accordance with all other Phase IV procedures where required. Run pumps as necessary to ensure proper operation and ensure priming system (when fitted), controls and indicator lights function properly. Note: Pumps with mechanical seals shall not be activated without containing system fluid. 1. Visually inspect foundation. Note condition of coating and steel. Report coating failure and wasted steel. 2. Hammer test foundation fasteners. Tighten all loose fasteners. 3. Visually inspect pump casing. Where fitted, assure that the vibration analysis blocks are still in place. Install new blocks as necessary to replace missing blocks. 4. Visually inspect pump/motor coupling. Check tightness of fasteners. When applicable, check condition of coupling rings. 5. Inspect suction pressure gauge and isolation valve. Note condition of gauge face plate, glass window and fittings. Does gauge have a current calibration sticker? Test isolation valve. Does valve open and close freely? 6. Inspect discharge pressure gauge and isolation valve. Note condition of gauge face plate, glass window and fittings. Does gauge have a current calibration sticker? Test isolation valve. Does valve open and close freely? 7. Check piping/tubing for suction pressure gauge. Is piping/tubing intact? Is piping/tubing rigidly supported by clamps or bands to prevent vibration? Is piping/tubing free of restrictive kinks or bends? 8. Check piping/tubing for discharge pressure gauge. Is piping/tubing intact? Is piping/tubing rigidly supported by clamps or bands to prevent vibration? Is piping/tubing free of restrictive kinks or bends? 9. When applicable, insure presence of grease nipples. Replace nipples as necessary. Apply grease as required. 10. Inspect seal for visual defects and tightness of seal. 11. Hand rotate pump to ensure free operation. 12. Inspect shaft in way of seal for wear or pitting. 13. Inspect pump nameplate. If a nameplate is needed to replace a missing nameplate, lookup nameplate data in the manufacturer's manual and requisition a new nameplate for installation. 14. Is nameplate legible? Clean nameplate if necesary. Record nameplate data on the pump inspection form. If a new nameplate is needed to replace an illegible nameplate, look up nameplate data in the manufacturer's manual and requisition a new nameplate for installation. 15. Inspect external coating of pump and appurtenances. Report coating deficiencies or failures. END OF RECORD !!! 230 4730-001-W1-M-V-KKK Bilge Pump (Maintain) Perform the following weekly maintenance to the reciprocating bilge pump in accordance with the manufacturer~s recommendations. 1. Lubricate the bearing metal. END OF RECORD 231 4730-001-W1-M-V-KKK Bilge Pump (Maintain) Perform the following weekly maintenance to the reciprocating bilge pump in accordance with the manufacturer~s recommendations. 1. Lubricate the bearing metal. END OF RECORD 232 4730-001-W1-M-V-KKK Bilge Pump (Maintain) Perform the following weekly maintenance to the reciprocating bilge pump in accordance with the manufacturer~s recommendations. 1. Lubricate the bearing metal. END OF RECORD 233 4730-001-W1-M-V-KKK Bilge Pump (Maintain) Perform the following weekly maintenance to the reciprocating bilge pump in accordance with the manufacturer~s recommendations. 1. Lubricate the bearing metal. END OF RECORD 234 4730-002-M3-M-V-KKK Bilge Pump (Inspect/Maintain) Perform the following quarterly maintenance to the reciprocating bilge pump in accordance with the manufacturers recommendations. Grease the ball and roller bearings (including the motor). Inspect the gland packing and replace as required. END OF RECORD 235 4730-003-Y1-M-V-KKK Bilge Pump (Inspect/Maintain) Perform the following annual (or 8000 hour) inspections and maintenance to the reciprocating bilge pump in accordance with the manufacturers recommendations. Note: All clearances and parts should be checked routinely when the unit is dismantled for maintenance and repairs. 1. Inspect and if necessary replace the bearing metal. 2. Inspect and if necessary replace the bucket ring. 3. Inspect and if necessary replace the pump valve and seat 4. Repaint the cast iron casting as necessary. END OF RECORD 236 4730-004-HR-M-V-KKK Bilge Pump (20,000 HR) Perform the following 20,000 hour inspections and maintenance to the reciprocating bilge pump in accordance with the manufacturers recommendations. Note: All clearances and parts should be checked routinely when the unit is dismantled for maintenance and repairs. 1. Inspect and replace if necessary the ball and roller bearings (including the motor). 2. Inspect the pump cylinder and valve box. 3. Inspect the reduction gear. END OF RECORD 237 4801-001-AR-M-V-KKK Piping and Fittings For tracking purposes, note related MEI codes as applicable: 4803 Actuators (electric/hydraulic/pneumatic) 4805 Piping/plumbing 4806 Expansion joints 4815 Pipe fittings 4816 Hydraulic hoses/fittings 4819 Miscellaneous hoses 4820 Valves 4821 Stop valves 4822 Check valves 4823 Stop-check valves 4824 Relief valves 4825 Regulating valves 4826 Thermostatic valves 4827 Motor operated valves 4828 Air operated valves 4829 Sentinel valves 4830 Safety valves 4833 Manifolds 4835 System fittings (strainers, filters, traps, etc.) 4836 Gauge glasses & assemblies 4840 Whistle 4850 Sea chests/overboard discharge connections 4852 Sea strainers (in piping) 4860 Educators For each system in the engine room and throughout the vessel, inspect all components of the system for damage, deterioration, leaks, and other defects. When possible, all valves shall be exercised fully open and fully closed to insure freedom of movement. Apply anti-seize compound to the valve stems. Check valve handwheel identification tags. Tags shall be cleaned on a wire wheel to facilitate legibility. Illegible tags shall be replaced. Refer to the attached VALVE CHECK OFF CHART for guidance. Piping shall be inspected for signs of leakage, particularly at flanged and threaded joints. Leaking gaskets shall be replaced. Leaking threaded connections shall be repaired with pipe dope or teflon. Pipe and tubing fittings, valves and all other system fittings shall be inspected for leaks or other defects. Repair all leaks or replace defective components. Strainers, filters and traps shall be opened and cleaned. Gauge glasses and assemblies shall be cleaned and repacked as required. When possible, electric/hydraulic/pneumatic actuators, regulating valves, thermostatic valves, motor operated valves, air operated valves, sentinel valves, safety valves and educators shall be tested to insure proper operation. When applicable, refer to the attached REMOTE OPERATING VALVE CHECK OFF CHART for guidance. Hoses and expansion joints shall be inspected for wear and deterioration. Replace defective hoses and expansion joints. END OF RECORD 238 4801-002-AR-M-V-KKK Piping / Fittings - Valve List VESSEL: ___________________________________ LOCATION: ___________________________________ VALVE DESCRIPTION: Application: __________ Valve Number: __________ Manufacturer: __________ Style: __________ Size: __________ Notes: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ 0 - Poor; requires further attention by the crew (see Remarks below) 1 - Poor; requires contract support (see Remarks below) 2 - Requires parts for repair (see Remarks below) 3 - Deferable; needs improvement (see Remarks below) 4 - Repaired during inspection (see Remarks below) 5 - Satisfactory INSPECTION 0 1 2 3 4 5 N/A Freedom of movement 2. Handwheel 3. Handwheel Nameplate 4. Nameplate Legible 5. Stem 6. Flanges/Gaskets 7. Flange Fasteners 8. Tightness of Packing Gland 9. Packing Gland Fasteners 10. Body MAINTENANCE Exercise the valve from fully open/closed to fully closed/open. Adequately lubricate the stem with anti- seize compound during exercise. Tighten loose flange, gland and handwheel fasteners and bonnet as applicable. Verify the correct information on the handwheel nameplate iaw Application above. If missing or incorrect, specify correct nomenclature for a new nameplate. Include size (OD) of namplate and ID of hole to fit the nameplate on the stem under the handwheel nut. If it is recommended that the valve be replaced, provide all pertinent information for ordering, including application, materials, manufacturer (if available), style, and size (ie. 5k40; 10k125). Also include flange to flange (face to face) dimensions, number of holes on the flange, bolt circle diameter and flange diameter. Remarks: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ Signature:_________________ Title:_____________________ Name:__________________________ Date:_____________ END OF RECORD 239 4801-003-AR-M-V-KKK Piping / Fittings - Remote Operator List VESSEL: ___________________________________ LOCATION: ___________________________________ VALVE DESCRIPTION: Application: __________ Valve Number: __________ Manufacturer: __________ Style: __________ Size: __________ Actuator (elect/hyd/pneu): __________ Actuator mfg: __________ Notes: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ 0 - Poor; requires further attention by the crew (see Remarks below) 1 - Poor; requires contract support (see Remarks below) 2 - Requires parts for repair (see Remarks below) 3 - Deferable; needs improvement (see Remarks below) 4 - Repaired during inspection (see Remarks below) 5 - Satisfactory INSPECTION 0 1 2 3 4 5 N/A 1. Freedom of movement 2. Handwheel 3. Nameplate 4. Nameplate Legible 5. Stem 6. Flanges/Gaskets 7. Flange Fasteners 8. Tightness of 9. Packing Gland 10. Packing Gland Fasteners 11. Body 12. Limit switches 13. Indicator Lights 14. Actuator MAINTENANCE 1. Manually exercise the valve from fully open/closed to fully closed/open. 2. Ensure limit switch(es) is (are) properly adjusted for remote operation. 3. Ensure valve position indicators and indicator lights function properly. 4. Exercise valve from its remote operating station(s) if applicable. 5. Verify the correct information on the nameplate iaw Application above. If missing or incorrect, specify correct nomenclature for a new nameplate. Remarks: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ ____ Signature:_________________________ Title:_________ Name:______________________________ Date:_________ END OF RECORD 240 4851-001-M1-M-V-KKK Sea Valves Prior to implementing this task, note any operational considerations or repair work which may be affected by opening or closing sea valves. Individually fully open and close the following sea valves. Adjust packing as necessary. Use reach rods where fitted. Report any noted deficiencies. Note: Frame Locations are approximate. # IDENTIFICATION SIZE/TYPE Location Tested Note W101V Main Sea CW Suction 400 mm B Fr 63 P ______ _____ W102V Aux Eng CW Suction 250 mm B Fr 64 S ______ _____ W103V Air Con CW Suction 200 mm B Fr 64 P ______ _____ W104V Dom Reefer CW Suction 50 mm G Fr 64 P ______ _____ W105V Main Engine CW Overboard 400 mm B Fr 61 P ______ _____ W106V Air Cond CW Overboard 200 mm B Fr 43 P ______ _____ W107V Dom Reefer CW Overboard 50 mm G Fr 43 P ______ _____ W108V Aux Eng CW Overboard 250 mm B Fr 43 S ______ _____ W109V Line Shaft Brg CW Overboard 40 mm G Fr 28 P ______ _____ W110V Bilge and Ballast Suction 300 mm B Fr 64 C ______ _____ W111V MS Fire Pump Suction 125 mm B Fr 64 P ______ _____ W112V Fire & Deck Wash Pump Suc 125 mm B Fr 64 P ______ _____ W113V Evap Ejector Pump Suction 80 mm G Fr 63 P ______ _____ W114V Bilge & Ballast Pump Ovbd 300 mm B Fr 61 P _____ _____ W115V Ballast Eductor Ovbd 150 mm B Fr 59 P _____ _____ W116V Evap Ejector Ovbd 65 mm G Fr 50 P _____ _____ W117V Port Sea Chest Vent 100 mm B Fr 63 P _____ _____ W118V Stbd Sea Chest Vent 100 mm B Fr 63 S _____ _____ W119V Aux Engine CW Suction 200 mm B Fr 64 S _____ _____ A101V Port Sea Chest Steam Out 40 mm G Fr 63 P _____ _____ A102V Stbd Sea Chest Steam Out 40 mm G Fr 63 S _____ _____ A103V Port Ovbd Chest Steam Out 40 mm G Fr 61 P _____ _____ Q101V Aux Boiler Blow 40 mm G Fr 31 S _____ _____ B101V OWS Overboard 40 mm G Fr 45 S _____ _____ B102V Aux Bilge Pump Sea Suction 50 mm G Fr 64 S _____ _____ SL1V Accommodation Soil Ovbd Port 150 mm G Fr 29 P _____ _____ SL1V Accommodation Soil Ovbd Stbd 150 mm G Fr 29 S _____ _____ ECR A/C CW Overboard 40 mm G Fr 45 S _____ _____ Gastight Door Scupper Valves 80 mm SC Fr 55 S _____ _____ Steering Gear Room Bilge Ovbd 50 mm G Fr 8 P _____ _____ Blanked Off Out of Commission Gastight Door Scupper Valves 80 mm SC Fr 12 P _____ _____ Deck CW Overboard Aft 100 mm G Fr 10 P _____ _____ Emergency Fire Pump Suc 100 mm AG Fr 245 P _____ _____ Emergency Fire Pump Stm Out 15 mm G Fr 245 P _____ _____ Deck CW Overboard Forward 65 mm G Fr 245 P _____ _____ Port Stabilizer CW Suction 100 mm G Fr 108 P _____ _____ Port Stabilizer CW Ovbd 40 mm AG Fr 108 P _____ _____ Port Stabilizer CW SC Air Out 15 mm G Fr 108 P _____ _____ Stbd Stabilizer CW Suction 100 mm G Fr 108 S _____ _____ Stbd Stabilizer CW SC Air Out 15 mm G Fr 108 S _____ _____ Stbd Stabilizer CW Ovbd 40 mm AG Fr 108 S _____ _____ Bos=n Store Bilge Eductor Ovbd 50 mm SC Fr 240P _____ _____ TCR Toilet Scupper Valve 50 mm SC Fr 5 P _____ _____ Threshold/Flaps Drain Scuppers 50 mm SC Fr 5 P _____ _____ Threshold/Flaps Drain Scuppers 50 mm SC Fr 15 S _____ _____ END OF RECORD 241 4906-001-DY-M-V-KKK Main Air Compressors (Inspect Daily) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The following inspection shall be performed on the main and topping up air compressors on a daily basis or approximately every ten (10) hours of operation (during normal continuous service) in accordance with manufacturer's instructions. 1. Visually inspect for compressors and system piping and components for defects. 2. Verify proper line up of piping, including delivery piping and salt water cooling for the cooling fresh water coolers. 3. Check level of fresh water expansion tank. 4. Check oil level in crankcase. 5. Check oil and air pressures and gauge cock and valve settings. END OF RECORD 242 4906-002-HR-M-V-KKK Main Air Compressors M&I (150 HR) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The following maintenance shall be performed on the main and topping up air compressors every 150 hours in accordance with manufacturer=s instructions. 1. Clean and inspect the automatic valves. END OF RECORD 243 4906-003-HR-M-V-KKK Main Air Compressors M&I (250 HR) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The following maintenance shall be performed on the main and topping up air compressors every 250 hours in accordance with manufacturer=s instructions. 1. Clean the air inlet filter. 2. Lift test the water jacket relief valve. END OF RECORD 244 4906-004-HR-M-V-KKK Main Air Compressors M&I (500 HR) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The following maintenance shall be performed on the main and topping up air compressors every 250 hours in accordance with manufacturer=s instructions. 1. Drain and fill the crankcase with new oil. 2. Clean and inspect the non-return (N.R.V.) delivery valve. END OF RECORD 245 4906-005-HR-M-V-KKK Main Air Compressors M&I (1000 HR) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The following maintenance shall be performed on the main and topping up air compressors every 1000 hours in accordance with manufacturer=s instructions. 1. Clean and inspect the valves, seats and o-ring seals. Replace as necessary. 2. Replace the fusible plug. 3. Replace the by-pass oil filter. END OF RECORD 246 4906-006-HR-M-V-KKK Main Air Compressors M&I (2000 HR) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The following maintenance shall be performed on the main and topping up air compressors every 2000 hours in accordance with manufacturer=s instructions. 1. Clean the first stage and second stage coolers. END OF RECORD 247 4906-007-HR-M-V-KKK Main Air Compressors M&I (4000 HR) Main Air Compressors No. 1 & 2 Mfg.: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 720 Capacity: 190 cu m/h Delivery: 30 kg/sq cm Topping Up Air Compressor Mfg: Teikoku-Hamworthy Type: Two Stage Vertical Piston Model: 2TM6 Cyl.: 2 RPM: 600 Capacity: 160 cu m/h Delivery: 30 kg/sq cm The main and topping up air compressors shall be stripped, inspected, measured and overhauled as necessary every 4000 hours in accordance with manufacturer=s instructions. END OF RECORD 248 4907-001-DY-M-V-KKK Control Air Compressor (Inspect Daily) Mfg.: Ingersoll-Rand Type: Rotary Screw Air Compressor Model: EP 40 SE The following inspection shall be performed on the control air compressors daily or every eight (8) running hours (during normal continuous use) in accordance with manufacturer=s instructions. 1. Check the coolant level. 2. Check the discharge temperature (air). 3. Check the separator element differential. 4. Check the air filter delta P (at full load). 5. Check the oil filter delta P. END OF RECORD 249 4907-002-HR-M-V-KKK Control Air Compressor M&I (500 HR) Mfg.: Ingersoll-Rand Type: Rotary Screw Air Compressor Model: EP 40 SE The following maintenance shall be performed on the control air compressor every 500 hours in accordance with manufacturer=s instructions. 1. Check the V-belt/belt tension. END OF RECORD 250 4907-003-HR-M-V-KKK Control Air Compressor M&I (1000 HR) Mfg.: Ingersoll-Rand Type: Rotary Screw Air Compressor Model: EP 40 SE The following maintenance shall be performed on the control air compressor every 1000 hours in accordance with manufacturer=s instructions. 1. Check the temperature sensor. END OF RECORD 251 4907-004-HR-M-V-KKK Control Air Compressor M&I (2000 HR) Mfg.: Ingersoll-Rand Type: Rotary Screw Air Compressor Model: EP 40 SE The following maintenance shall be performed on the control air compressor every 2000 hours in accordance with manufacturer=s instructions. 1. Replace the coolant filter. Note: In dirty environments, the coolant filter may require replacement more frequently. END OF RECORD 252 4907-005-HR-M-V-KKK Control Air Compressor M&I (4000 HR) Mfg.: Ingersoll-Rand Type: Rotary Screw Air Compressor Model: EP 40 SE The following maintenance shall be performed on the control air compressor every 4000 hours in accordance with manufacturer=s instructions. 1. Clean the separator scavenge screen and orifice. 2. Clean the cooler cores. Note: Cooler cores may require more frequent cleaning if discharge air temperature is excessive or if unit shuts down on high air temperature. 3. Replace the air filter. Note: In dirty environments, the air filter may require replacement more frequently. 4. Replace the separator element. Note: In dirty environments, the separator element may require replacement more frequently. END OF RECORD 253 4907-006-HR-M-V-KKK Control Air Compressor M&I (8000 HR) Mfg.: Ingersoll-Rand Type: Rotary Screw Air Compressor Model: EP 40 SE The following maintenance shall be performed on the control air compressor every 8000 hours in accordance with manufacturer=s instructions. 1. Replace the shaft seal. 2. Replace the coolant. Note: In dirty environments, the coolant may need to be changed more frequently. 3. Inspect the starter contactors. END OF RECORD 254 4930-001-M1-M-V-KKK Ships Service Air Dryer (Maintain) Mfg.: Pall Trinity Micro Corporation (Courtland, NY) Type: Desiccant Type HA Air Dryer Model: S1HA1 The following inspections shall be performed on the ship=s service air dryer on a monthly basis (during normal continuous use) in accordance with manufacturer=s instructions. 1. Check operating conditions: purge rate, line temperatures, line pressure, inlet flow, etc. 2. Inspect visual moisture indicator (make sure the bleed is open). The indicating gel will be BLUE when air is dry and PINK when air is wet. 3. Check pressure drop across the pre-filter and after filter. Should normally be less than 5 psig. 4. Check the dryer operating cycle for proper operation of solenoid valves, timer, etc. END OF RECORD 255 4930-002-M3-M-V-KKK Ships Service Air Dryer (Maintain) Mfg.: Pall Trinity Micro Corporation (Courtland, NY) Type: Desiccant Type HA Air Dryer Model: S1HA1 The following inspections shall be performed on the ship=s service air dryer every three (3) months (during normal continuous use) in accordance with manufacturer=s instructions. 1. Check the outlet dew point. 2. Blow down the relief valve. END OF RECORD 256 4930-003-M6-M-V-KKK Ships Service Air Dryer (Maintain) Mfg.: Pall Trinity Micro Corporation (Courtland, NY) Type: Desiccant Type HA Air Dryer Model: S1HA1 The following inspections shall be performed on the ship=s service air dryer every three (3) months (during normal continuous use) in accordance with manufacturer=s instructions. 1. Inspect and clean or replace the pilot air filter cartridges. 2. Inspect the purge exhaust mufflers and clean as required. 3. Check the stem nut on the pilot operated valves (inlet and purge). If loose, tighten per manufacturer=s instructions. END OF RECORD 257 4930-004-Y1-M-V-KKK Ships Service Air Dryer (Maintain) Mfg.: Pall Trinity Micro Corporation (Courtland, NY) Type: Desiccant Type HA Air Dryer Model: S1HA1 The following inspections shall be performed on the ship=s service air dryer annually (during normal continuous use) in accordance with manufacturer=s instructions. 1. Inspect the desiccant and replace if is badly broken up or contaminated with oil. Note: Desiccant normally is 1/8@ diameter or larger. 2. Inspect and clean or replace the seats on the check valves. 3. Inspect and clean the pilot operated valves. Replace packings if they have become worn or damaged. 4. Inspect and clean the solenoid valves. END OF RECORD 258 4930-005-DY-M-V-KKK Control Air Dryer (Inspect Daily) Mfg.: Ingersoll-Rand Type: Direct Expansion Refrigerated Air Dryer Model: DXR 140 The following inspections shall be performed on the control air dryer daily or every eight (8) hours (during normal continuous use) in accordance with manufacturer=s instructions. 1. Check the operation of the automatic drain valve. 2. Check the high evaporator temperature, refrigerant suction temperature, refrigerant discharge temperature and alarm lights on the System Operation Monitor. END OF RECORD 259 4930-006-M1-M-V-KKK Control Air Dryer (Maintain) Mfg.: Ingersoll-Rand Type: Direct Expansion Refrigerated Air Dryer Model: DXR 140 The following inspections shall be performed on the control air dryer on a monthly basis (during normal continuous use) in accordance with manufacturer=s instructions. 1. Inspect the condenser coils. Remove all dust, dirt or other particles with a soft brush or with compressed air (no more than 30 psig). If coils are coated with oil, grease or other substances that reduce the cooling efficiency, clean the coil. END OF RECORD 260 4930-007-HR-M-V-KKK Control Air Dryer M&I (4500 HR) Mfg.: Ingersoll-Rand Type: Direct Expansion Refrigerated Air Dryer Model: DXR 140 The following maintenance shall be performed on the control air dryer every 4500 hours in accordance with manufacturer=s instructions. Note: The blue SERVICE DUE indicator on the System Operation Monitor will light after 4500 hours of dryer operation. 1. Disassemble and clean the automatic drain valve. 2. Disassemble and clean separator bowl. 3. Inspect the condenser coils and clean if necessary. 4. Lubricate the fan motors with 20 wt motor oil. 5. Reset the SERVICE DUE INDICATOR. a. Turn the power switch to the OFF position. b. Hold down the PUSH TO TEST and CLOSED/OPEN buttons simultaneously. c. Turn the power switch to the ON position. d. Wait two seconds. Release the PUSH TO TEST and CLOSED/OPEN buttons. END OF RECORD 261 5120-001-Y1-M-V-KKK Waste Heat Economizer 1. Visually inspect the waste heat economizer through openings and manholes as required to insure boiler is free of debris, corrosion, cracks and other deficiencies. 2. Inspect sheathing, insulation and lagging for damage. END OF RECORD 262 5143-001-Y4-M-V-KKK Boiler Mountings Open all auxiliary oil-fired boiler and exhaust gas economizer mounts. Lap in discs to seats and blue test each mount to prove adequate seating contact to the USCG. Replace heat treated fasteners with new and close up mounts in good order after inspection. END OF RECORD 263 5143-002-Y8-M-V-KKK Boiler Mountings Disconnect and remove all auxiliary oil-fired boiler and exhaust gas economizer mounts. Lap in valves to seats as required and blue test each mount to the satisfaction of the USCG. Hydro test each mount to the satisfaction of the USCG. After tests and inspections, re-install all mounts in good order with new heat treated fasteners. END OF RECORD 264 5305-001-M1-H-V-KKK Ventilation Fans Operationally test each ventilation fan, including supply and exhaust fans for miscellaneous spaces and all cargo hold fans throughout the vessel to insure proper operation. Refer to the list of fire dampers in item: 3831-001-M3-H-V-KKK Dampers The fire damper list notes which dampers are fitted with supply and/or exhaust fans. When possible, inspect the rotating elements to damage or defects. Otherwise, listen for abnormal sounds while fans are running. END OF RECORD 265 5330-001-M1-H-V-KKK Fan Controls Prior to operational test of all ventilation fans, inspect motors when possible in accordance with: 6301-001-AR-E-V-KKK Electric Motors. Inspect and maintain fan motor controllers in accordance with: 6401-001-AR-E-V-KKK Electric Motor Controllers END OF RECORD 266 5406-001-Y3-M-V-KKK Air Receivers Open each air receiver and present to the USCG for internal inspection. No. 1 Main Engine Starting Air Receiver No. 2 Main Engine Starting Air Receiver Generator Engine Starting Air Receiver Instrument (Control) Air Receiver) Emergency Generator Engine Starting Air Receiver END OF RECORD 267 5701-001-HR-M-V-KKK LO Purifier M&I (24 HR) Perform the following inspections and maintenance every 24 hours or daily as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. Operational check the following: 1. Machine Run (speed). 2. Power Consumption. 3. Oil Level in worm gear housing. 4. Observation of discharged liquids. 5. Temperature. 6. Throughput. 7. Sludge Tank. 8. Pressure. 9. Level in operating liquid tank. 10. Automatic control device (signal lamps). END OF RECORD 268 5701-002-HR-M-V-KKK LO Purifier M&I (200 HR) Perform the following inspections and maintenance every 200 hours or weekly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Check and if necessary replenish oil in the worm gear housing. 2. Check and trace any leaks. 3. Check machinery operating speed. END OF RECORD 269 5701-003-HR-M-V-KKK LO Purifier M&I (750 HR) Perform the following inspections and maintenance every 750 hours or monthly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Dismantle the bowl and thoroughly clean the bowl inset parts. Clean and lubricate the lock rings and oil the bowl body nave bore. Check seals. 2. Power Transmission - clean and oil the bowl spindle cone. 3. Control System - Check flow of operating liquid. Check sludge discharge interval of automatic control device. 4. Strainers and filters - Check and clean. END OF RECORD 270 5701-004-HR-M-V-KKK LO Purifier M&I (1500 HR) Perform the following inspections and maintenance every 1500 hours or bi-monthly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Worm Gear Housing - Clean and change oil. 2. Bowl - Dismantle and clean sludge discharge mechanism of bowl. Check springs, seals and sludge ports. Check for erosion. END OF RECORD 271 5701-005-HR-M-V-KKK LO Purifier Overhaul (9000 HR) Perform the following thorough overhaul, cleaning and lubrication every 9000 hours or annually as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Bowl Check - Pressure in set of discs. Lock ring joint. Corrosion and other material attacks. 2. Power transmission - Dismantle bowl spindle, clutch coupling and work wheel shaft. Check particularly ball bearings and ear as well as top bearing springs and buffers. Exchange friction pads. Renew grease in nave. 3. Control system - Clean operating liquid tank and check pipes and valves. 4. Height positions - Check and adjust. 5. Frame - Renew brake lining. Touch up paint. Check elasticity of vibration dampers and mounting of machine. END OF RECORD 272 5705-001-HR-M-V-KKK DO Purifier M&I (24 HR) Perform the following inspections and maintenance every 24 hours or daily as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. Operational check the following: 1. Machine Run (speed). 2. Power Consumption. 3. Oil Level in worm gear housing. 4. Observation of discharged liquids. 5. Temperature. 6. Throughput. 7. Sludge Tank. 8. Pressure. 9. Level in operating liquid tank. 10. Automatic control device (signal lamps). END OF RECORD 273 5705-002-HR-M-V-KKK DO Purifier M&I (200 HR) Perform the following inspections and maintenance every 200 hours or weekly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Check and if necessary replenish oil in the worm gear housing. 2. Check and trace any leaks. 3. Check machinery operating speed. END OF RECORD 274 5705-003-HR-M-V-KKK DO Purifier M&I (750 HR) Perform the following inspections and maintenance every 750 hours or monthly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Dismantle the bowl and thoroughly clean the bowl inset parts. Clean and lubricate the lock rings and oil the bowl body nave bore. Check seals. 2. Power Transmission - clean and oil the bowl spindle cone. 3. Control System - Check flow of operating liquid. Check sludge discharge interval of automatic control device. 4. Strainers and filters - Check and clean. END OF RECORD 275 5705-004-HR-M-V-KKK DO Purifier M&I (1500 HR) Perform the following inspections and maintenance every 1500 hours or bi-monthly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Worm Gear Housing - Clean and change oil. 2. Bowl - Dismantle and clean sludge discharge mechanism of bowl. Check springs, seals and sludge ports. Check for erosion. END OF RECORD 276 5705-005-HR-M-V-KKK DO Purifier Overhaul (9000 HR) Perform the following thorough overhaul, cleaning and lubrication every 9000 hours or annually as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Bowl Check - Pressure in set of discs. Lock ring joint. Corrosion and other material attacks. 2. Power transmission - Dismantle bowl spindle, clutch coupling and work wheel shaft. Check particularly ball bearings and ear as well as top bearing springs and buffers. Exchange friction pads. Renew grease in nave. 3. Control system - Clean operating liquid tank and check pipes and valves. 4. Height positions - Check and adjust. 5. Frame - Renew brake lining. Touch up paint. Check elasticity of vibration dampers and mounting of machine. END OF RECORD 277 5706-001-HR-M-V-KKK FO Purifier M&I (24 HR) Perform the following inspections and maintenance every 24 hours or daily as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. Operational check the following: 1. Machine Run (speed). 2. Power Consumption. 3. Oil Level in worm gear housing. 4. Observation of discharged liquids. 5. Temperature. 6. Throughput. 7. Sludge Tank. 8. Pressure. 9. Level in operating liquid tank. 10. Automatic control device (signal lamps). END OF RECORD 278 5706-002-HR-M-V-KKK FO Purifier M&I (200 HR) Perform the following inspections and maintenance every 200 hours or weekly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Check and if necessary replenish oil in the worm gear housing. 2. Check and trace any leaks. 3. Check machinery operating speed. END OF RECORD 279 5706-003-HR-M-V-KKK FO Purifier M&I (750 HR) Perform the following inspections and maintenance every 750 hours or monthly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Dismantle the bowl and thoroughly clean the bowl inset parts. Clean and lubricate the lock rings and oil the bowl body nave bore. Check seals. 2. Power Transmission - clean and oil the bowl spindle cone. 3. Control System - Check flow of operating liquid. Check sludge discharge interval of automatic control device. 4. Strainers and filters - Check and clean. END OF RECORD 280 5706-004-HR-M-V-KKK FO Purifier M&I (1500 HR) Perform the following inspections and maintenance every 1500 hours or bi-monthly as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period , the latter can be extended. 1. Worm Gear Housing - Clean and change oil. 2. Bowl - Dismantle and clean sludge discharge mechanism of bowl. Check springs, seals and sludge ports. Check for erosion. END OF RECORD 281 5706-005-HR-M-V-KKK FO Purifier Overhaul (9000 HR) Perform the following thorough overhaul, cleaning and lubrication every 9000 hours or annually as appropriate. Note: The time intervals of maintenance relate to continuous operation. If the mentioned number of operating hours is not obtained during the period, the latter can be extended. 1. Bowl Check - Pressure in set of discs. Lock ring joint. Corrosion and other material attacks. 2. Power transmission - Dismantle bowl spindle, clutch coupling and work wheel shaft. Check particularly ball bearings and ear as well as top bearing springs and buffers. Exchange friction pads. Renew grease in nave. 3. Control system - Clean operating liquid tank and check pipes and valves. 4. Height positions - Check and adjust. 5. Frame - Renew brake lining. Touch up paint. Check elasticity of vibration dampers and mounting of machine. END OF RECORD 282 5708-001-DY-M-V-KKK Incinerator (Inspect Daily) During regular use of the incinerator, perform the following daily inspections and maintenance in accordance with manufacturer=s recommendations. 1. Check the level of fuel oil in the service tank and replenish if necessary 2. Check and if necessary empty ash box. 3. Check that liquid waste tank heater and mix are on. 4. Open ash slide and clean thoroughly with stiff brush. END OF RECORD 283 5708-002-M3-M-V-KKK Incinerator (Inspect/Maintain) During regular use of the incinerator, perform the following quarterly inspections and maintenance in accordance with manufacturer=s recommendations. 1. Check the sealing packing around the ash box door and ash slide for looseness or damage. If the packing require renewal, cut or scrape away all traces of the old packing. Clean the seal surfaces and fit new packing using an impact adhesive. 2. Remove the sludge burner and clean it with a stiff brush. 3. Remove the inspection plates and clean the wire screen with a stiff brush. END OF RECORD 284 5708-003-M6-M-V-KKK Incinerator (Inspect/Maintain) During regular use of the incinerator, perform the following semi-annual inspections and maintenance in accordance with manufacturer=s recommendations. 1. Lubricate the rotary arm chair and check tension. 2. Grease the bearing case using a grease nipple. 3. Renew the reduction gear box lubricating oil. END OF RECORD 285 5708-004-Y1-M-V-KKK Incinerator (Inspect/Maintain) During regular use of the incinerator, perform the following annual inspections and maintenance in accordance with manufacturer=s recommendations. 1. Check the interior of the combustion chamber refractory and repair any damaged areas. Local damage should be chipped back to at least one anchor and a dovetail shape formed. NOTE: Open door and insert safety bar. Switch main switch to AOFF@ before entering. 2. Check the cone diverter for serviceability and scraper bars on rotary arm. Renew if necessary. END OF RECORD 286 5717-001-DY-M-V-KKK Sterilizer - Fresh Water (Inspect Daily) Inspect the fresh water UV sterilizer on a daily basis. Check for leaks and insure proper operation. END OF RECORD 287 5717-002-Y1-M-V-KKK Sterilizer - FW (Replace Lamps) Replace the lamps for the two (2) fresh water UV sterilizers. Manufacturer recommends replacement of lamps annually, even if they still illuminate, because the light tends to loose its UV characteristics after prolonged use. END OF RECORD 288 5805-001-M6-M-V-KKK Distiller - LP Flash Type (Maintain) Manufacturer: Sasakura Engineering Co., Ltd.; Osaka, Japan Model: AFG U No. 6 (N) Capacity: 35 tonnes/day Note the following related MEI codes as applicable: 5812 Eductor 5813 Salinity indicator-solenoid dump valve 5814 Gauge board & instruments 5815 Integral piping and fittings The following maintenance shall be performed on the ship=s main evaporator every six (6) months during reduced operating status of the vessel. 1. Fill the separator shell with water to hydrostatically test the shell. 2. Clean the salinity cell. Test the salinity indicator. 3. Test the ejector pump and air and brine ejectors. 4. Circulate cooling water through the condenser and test the flow meter. 5. Visually inspect all appurtenances, including piping, valves, fittings, thermometers, pressure gauges, etc. for deficiencies. Repair all deficiencies in good order. END OF RECORD 289 5805-002-HR-M-V-KKK Distiller - LP Flash Type (2000 HR) Manufacturer: Sasakura Engineering Co., Ltd.; Osaka, Japan Model: AFG U No. 6 (N) Capacity: 35 tonnes/day Note the following related MEI codes as applicable: 5812 Eductor 5813 Salinity indicator-solenoid dump valve 5814 Gage board & instruments 5815 Integral piping and fittings The following maintenance shall be performed on the ship=s main evaporator every three (3) months or 2000 hours (during normal continuous use). 1. Check the gland packing on the air-outlet valves on the condenser and heat exchanger for wear and leakage. Repair if necessary. 2. Check the ejector pump bearing case for proper lubrication. Add more grease if necessary. 3. Check the gland packing in the ejector pump for wear and leakage. Repair if necessary. END OF RECORD 290 5805-003-HR-M-V-KKK Distiller - LP Flash Type (4000 HR) Manufacturer: Sasakura Engineering Co., Ltd.; Osaka, Japan Model: AFG U No. 6 (N) Capacity: 35 tonnes/day Note the following related MEI codes as applicable: 5812 Eductor 5813 Salinity indicator-solenoid dump valve 5814 Gage board & instruments 5815 Integral piping and fittings The following maintenance shall be performed on the ship=s main evaporator every six (6) months or 4000 hours (during normal continuous use). 1. Check the tubes in the heat exchanger for scale formations. If scale is formed, clean (descale) according to the instruction manual. 2. Check the condenser tube sheets for damage and corrosion. Repair as necessary. 3. Check the condenser corrosion plate for fit and degree of wear. Replace if necessary. 4. Inspect the water ejector (air and brine ejector) for wear and scale formations. Clean the nozzle and diffuser as necessary. Replace worn out nozzles. END OF RECORD 291 5805-004-HR-M-V-KKK Distiller - LP Flash Type (8000 HR) Manufacturer: Sasakura Engineering Co., Ltd.; Osaka, Japan Model: AFG U No. 6 (N) Capacity: 35 tonnes/day Note the following related MEI codes as applicable: 5812 Eductor 5813 Salinity indicator-solenoid dump valve 5814 Gage board & instruments 5815 Integral piping and fittings The following maintenance shall be performed on the ship=s main evaporator every twelve (12) months or 8000 hours (during normal continuous use). 1. Pressure test the outside of the heat exchanger tubes in accordance with the instruction manual. 2. Inspect the coating inside the separator shell. Repair damaged coating in accordance with the instruction manual. 3. Inspect the deflector for damage and defects. Repair as necessary. 4. Remove the condenser covers and inspect the tubes for scale formations. Clean tubes as necessary. 5. Inspect the tube ends for corrosion. 6. Clean the salinity meter. Note: During normal continuous operation, the salinity cell should be cleaned on a monthly basis. 7. Open the non-return valves. Clean valves free of scale formations. Check for freedom of movement of the valve flaps. 8. Remove and clean the strainers in front of the feed water orifice. 9. Disassemble and clean the spring loaded valve. 10. Clean the air-outlet valves on the condenser and heat exchanger. 11. Inspect the ejector pump impeller, casing rings, shaft and shaft sleeve for wear and corrosion. Overhaul pump as necessary. 12. Adjust the indicators and alarm on the control panel in accordance with the instruction manual. END OF RECORD 292 5901-001-M1-M-V-KKK Ship's Service Refrigeration System For tracking purposes, note related MEI codes as applicable: 5905 Compressors - s/s 5950 Diffusers/fans - electrical 5955 Diffusers/fans - mechanical 5965 Condensers - s/s When the vessel=s refrigeration system is in operation during ROS, visually test and maintain the refrigeration system equipment on a monthly basis as follows: 1. Change over to idle unit. Check compressor sight glass for proper oil level and quality prior to change over. Replenish with new oil as required. 2. Drain oil in compressor, clean sump, replenish oil. 3. Inspect and change as needed all zincs in condenser. Inspect and clean condenser tubes as required. 4. Inspect and clean as needed all box diffuser units. Check that defrost tray drains are clear. 5. Inspect and maintain compressor and diffuser fan motors in accordance with 6301-001-M6-E-V-KK1/KK2 Electric Motors. 6. Inspect and maintain motor controllers in accordance with 6401-001-M6-E-V-KK1/KK2 Electric Motor Controllers. END OF RECORD 293 5903-001-M1-M-V-KKK Air Conditioning System For tracking purposes, note related MEI codes as applicable: 5915 Compressors - air cond 5950 Diffusers/fans - electrical 5955 Diffusers/fans - mechanical 5975 Condensers - a/c Visually test and maintain the air conditioning system and equipment on a monthly basis as follows: 1. Change over to idle unit. Check compressor sight glass for proper oil level and quality prior to change over. Replenish oil as required. 2. Drain oil in compressor, clean sump, replenish oil. (Change oil after 2 months running time) 3. Inspect and change as needed all zincs in condenser. Inspect and clean condenser tubes as required. 4. Inspect air handler and clean intake filters. 5. Inspect and clean as needed evaporator coils. 6. Inspect and maintain compressor and fan motors in accordance with 6301-001-M6-E-V-KK1/KK2 Electric Motors. 7. Inspect and maintain motor controllers in accordance with 6401-001-M6-E-V-KK1/KK2 Electric Motor Controllers. END OF RECORD 294 6201-001-M6-E-V-KKK Electric Power Distribution For tracking purposes, refer to related MEI codes as applicable: 6205 Ship service generator switchboard 6206 Instrumentation 6207 Main/emergency switchboard 6208 Indicating lamps/panels 6210 Emergency generator switchboard 6211 Instrumentation 6215 Test panel 6216 Instrumentation 6220 Distribution panels 6221 Shore connection box 6225 Voltage regulators 6230 Transformers 6231 Rectifiers 1. Visually inspect all switchboards and distribution panels, including the shore connection box, for damage or defects. 2. When possible, manually exercise all circuit breakers to insure proper operation. 3. When possible, clean all switchboards and distribution panels free of dust, dirt and debris. 4. Inspect all electrical connections and tighten all loose connections. 5. Measure and record insulation resistance readings of switchboard feeders and distribution feeders. 6. Verify that all labels on switchboards and distribution panels are accurate. 7. Test all ground indicators and insure that all circuits are free of grounds. Insure proper operation of all ground indicator panels. 8. Inspect all instrumentation for damage or defects. 9. Relamp all indicator lights on all switchboards, distribution panels, controllers and consoles as required. END OF RECORD 295 6235-001-W1-E-V-KKK Batteries 1. Check and maintain proper level of electrolyte in cells. Note: PROPER SAFETY GOGGLES SHALL BE WORN WHEN CHECKING AND TESTING BATTERY ELECTROLYTE 2. Add distilled water as required. 3. Maintain terminals free of corrosion and coat same with protective coating. 4. Note and record any discrepancies. The following battery systems to be dealt with: Emergency Service Batteries Radio Station Batteries Fire Detection System Batteries Forklift Batteries Street Sweeper Battery Scissors Lift Batteries Fire/Flood/Entry Protection Security System Batteries END OF RECORD 296 6235-001-W1-E-V-KKK Batteries 1. Check and maintain proper level of electrolyte in cells. Note: PROPER SAFETY GOGGLES SHALL BE WORN WHEN CHECKING AND TESTING BATTERY ELECTROLYTE 2. Add distilled water as required. 3. Maintain terminals free of corrosion and coat same with protective coating. 4. Note and record any discrepancies. The following battery systems to be dealt with: Emergency Service Batteries Radio Station Batteries Fire Detection System Batteries Forklift Batteries Street Sweeper Battery Scissors Lift Batteries Fire/Flood/Entry Protection Security System Batteries END OF RECORD 297 6235-001-W1-E-V-KKK Batteries 1. Check and maintain proper level of electrolyte in cells. Note: PROPER SAFETY GOGGLES SHALL BE WORN WHEN CHECKING AND TESTING BATTERY ELECTROLYTE 2. Add distilled water as required. 3. Maintain terminals free of corrosion and coat same with protective coating. 4. Note and record any discrepancies. The following battery systems to be dealt with: Emergency Service Batteries Radio Station Batteries Fire Detection System Batteries Forklift Batteries Street Sweeper Battery Scissors Lift Batteries Fire/Flood/Entry Protection Security System Batteries END OF RECORD 298 6235-001-W1-E-V-KKK Batteries 1. Check and maintain proper level of electrolyte in cells. Note: PROPER SAFETY GOGGLES SHALL BE WORN WHEN CHECKING AND TESTING BATTERY ELECTROLYTE 2. Add distilled water as required. 3. Maintain terminals free of corrosion and coat same with protective coating. 4. Note and record any discrepancies. The following battery systems to be dealt with: Emergency Service Batteries Radio Station Batteries Fire Detection System Batteries Forklift Batteries Street Sweeper Battery Scissors Lift Batteries Fire/Flood/Entry Protection Security System Batteries END OF RECORD 299 6236-001-W1-E-V-KKK Battery Chargers During weekly battery inspection and testing, inspect the battery chargers and insure proper operation. END OF RECORD 300 6236-001-W1-E-V-KKK Battery Chargers During weekly battery inspection and testing, inspect the battery chargers and insure proper operation. END OF RECORD 301 6236-001-W1-E-V-KKK Battery Chargers During weekly battery inspection and testing, inspect the battery chargers and insure proper operation. END OF RECORD 302 6236-001-W1-E-V-KKK Battery Chargers During weekly battery inspection and testing, inspect the battery chargers and insure proper operation. END OF RECORD 303 6301-001-AR-E-V-KKK Electric Motors For each electrical motor, carry out the following inspection and conduct appropriate maintenance and repairs. Record results of the inspection, maintenance and repairs on the attached MOTOR CHECK OFF CHART. After inspection and maintenance and repairs, test motors in accordance with all other Phase IV procedures where required. Run motors as necessary to ensure proper operation and ensure brakes (when fitted), controls and indicator lights function properly. For tracking purposes, note related MEI codes below as applicable: 6302 Motor/brakes 6305 Pump motors 6310 Purifier motors 6312 Jacking gear motor 6314 Power operation valve motors 6335 Workshop equipment motors 6340 Refrig compressor/ac motors 6341 Air compressor motors 6345 Fan and blower motors 6350 Deck machinery motors 6355 Cargo winch motors & brakes 6359 Boat winch motors 6360 Accom. ladder motors & brakes 6364 Anchor windlass motor 6365 Automatic mooring winch motors 6366 Capstan motors 6368 Steering gear motors 6369 Stabilizer motors 6370 Elevator motors 6373 Dumbwaiter motors 6374 Bow & stern thruster motors 6379 Stern ramp winch motors 6397 Miscellaneous small motors 1. Visually inspect motor casing. Where fitted, assure that the vibration analysis blocks are still in place. Install new blocks as necessary to replace missing blocks. 2. Visually inspect foundation. Note condition of coating and steel. Report coating failure and wasted steel. 3. Visually inspect the external appearance of the rotor and stator. If necessary, clean rotor and stator free of dirt and debris. Note any visual defects. 4. Inspect the cooling fan, where fitted. If necessary, clean fan free of dirt and debris. 5. Check terminal box screws. Repair missing, defective or stripped screws as appropriate. 6. Inspect terminal box gaskets and cable glands. Renew gaskets and cable gland sealant as necessary. Report missing or broken gland nuts. 7. Check tightness of all connections in the terminal box. Tighten all loose connections. 8. Inspect condition of insulation on wires. If insulation resistance readings taken at controller (see 6401 ELECTRIC MOTOR CONTROLLERS) were suspect, take insulation resistance readings of the motor at each phase at the pot head. 9. Turn motor coupling by hand. 10. Where fitted, check integrity of motor heaters (strip heaters, space heaters or lights). Note: Maintenance of motor winding heaters is covered in 6401 ELECTRIC MOTOR CONTROLLERS. 11. Inspect motor nameplate. If a new nameplate is required to replace a missing nameplate, look up nameplate data in the manufacturer=s manual and requisition a new nameplate for installation. 12. Is nameplate legible? Clean nameplate if necessary. Record nameplate data on the motor inspection form. If a new nameplate is needed to replace an illegible nameplate, look up nameplate data in the manufacturer=s manual and requisition a new nameplate for installation. 13. When applicable, insure presence of grease nipples. Replace nipples as necessary. Apply grease as required. Note: Do not over grease motors as the grease could ingress into and ground the windings. 14. Visually inspect coating of motor and appurtenances. Report coating deficiencies or failure. END OF RECORD 304 6301-002-AR-E-V-KKK Electric Motor Check Off List VESSEL: CAPE LOCATION: MOTOR DESCRIPTION: Application: Manufacturer: Frame: Type: kW: Speed (rpm): Phase: 3 Cycles: 60 Volts/Amperes: Serial No.: 0 - Poor; requires further attention by the crew (see Remarks below) 1 - Poor; requires contract support (see Remarks below) 2 - Requires parts for repair (see Remarks below) 3 - Deferable; needs improvement (see Remarks below) 4 - Repaired during inspection (see Remarks below) 5 - Satisfactory INSPECTION 0 1 2 3 4 5 N/A 1. Motor Casing 2. Foundation 3. Rotor/Stator externally) 4. Cooling Fan 5. Terminal Box Screws 6. Terminal Box Gaskets /Cable Glands 7. Connection Tightness 8. Insulation of Wires 9. Turn Motor Coupling by Hand 10. Heaters (winding/space/strip) 11. Nameplate 12. Nameplate Data 13. Grease Nipples 14. External Coating MEGGER TEST, INSULATION RESISTANCE Phase A (Megaohms) Phase B (Megaohms) Phase C (Megaohms) Remarks: __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ __________________________________________________ _____ Signature:___________________ Title:__________________ Name:______________________________ Date:________ END OF RECORD 305 6401-001-AR-E-V-KKK Electric Motor Controllers For tracking purposes, not related MEI codes below as applicable: 6402 Group controls 6405 Pump motor controllers 6410 Purifier motor controllers 6412 Jacking gear motor controllers 6414 Pwr oper valve mtr controllers 6440 Refrig compressor mtr contrlrs 6441 Air compressor mtr controllers 6442 Air conditioning mtr cont. 6445 Fan & blower motor controllers 6447 Dehumidification 6450 Deck machinery mtr controllers 6455 Cargo winch motor controllers 6459 Boat winch motor controllers 6460 Accomm ladder mtr controllers 6464 Anchor windlass mtr controllrs 6465 Auto mooring winch mtr contrlr 6466 Capstan motor controllers 6468 Steering gr mtr controllers 6469 Stabilizer mtr controllers 6470 Elevator motor controllers 6473 Dumbwaiter motor controllers 6474 Bow thruster motor controllers 6475 Stern thruster 6490 Stores crane For each controller, perform the following preventative maintenance. 1. De-energize the controller. 2. Open the controller panel and inspect interior for burn damage, loose connections and cleanliness. 3. Verify tightness of all wiring and electrical components. Tighten loose connections. 4. Vacuum out all loose debris and dust. If required, clean dirty components with an evaporating solvent. 5. Relamp all indicator lights as required. END OF RECORD 306 6504-001-M1-E-V-KKK Engine Order Telegraph System Energize the engine order telegraph system. Station one person in the engine control room and one person in the wheelhouse. Test the engine order telegraph, ordering and acknowledging receipt of all engine speed orders. Verify proper operation of the telegraph recorder in the wheelhouse. END OF RECORD 307 6505-001-M1-E-V-KKK Sound Powered Telephone System 1. Visually inspect and test sound powered telephone systems. Test each phone at all stations. 2. Ensure proper operation of selector switches, magnets, wires, enunciators, indicator lights, and hand cranks. 3. Confirm clear voice communications between all stations. 4. Note any deficiencies. Emergency Circuit: Wheelhouse 1. Engine Control Room 2. Local Control Station Main Engine 3. CO2 Room 4. Safety Station 5. Stern Thruster Space 6. Bow Thruster 7. Emergency Gear 8. Traffic Control Room 9. Chief Engineer=s Day Room and Bedroom Navigation Circuit: Wheelhouse 10. Captain Day and Bedroom Foc=sle Steering Gear Room 1. Stern Ramp Control Stand END OF RECORD 308 6506-001-M1-E-V-KKK Automatic Telephone System Mfg: JRC 1. Visually inspect and test entire dial telephone system to insure proper operation of the entire system. 2. Confirm clear communication to and from all stations: a. Navigation Officer b. Engine Officer c. Recreation d. Deck Crew e. Engine Crew f. Catering g. Emergency Circuit (All Stations) 3. Note any deficiencies. END OF RECORD 309 6510-001-Y1-G-V-KKK Voice Tubes Test the voice tube from the bridge steering stand to the flying bridge magnetic compass stand. END OF RECORD 310 6511-001-M6-E-V-KKK UHF - Cargo / Portable Communications Inventory and test operation of all UHF Handsets, Motorola HT 1000. Insure each unit has a speaker/mic and holster. Inventory and test all spare batteries and battery chargers for the handheld radios. END OF RECORD 311 6521-001-M1-E-V-KKK Rudder Angle Indicator System During steering gear test. Inspect and check for correctness of all rudder angle indicators. Indicators located in following locations: Overhead, above steering stand (three-face). Wheelhouse center forward console (panel mounted). Bridge wings, port and starboard. Steering gear platform. Test the cut-out switches for the port and starboard repeaters on the bridge wings. END OF RECORD 312 6551-001-M1-E-V-KKK Engineers Signal / Alarm System In manned engine room status, activate the engineers alarm system. Walk throughout the engine room and insure that all sirens and rotating beacons are functioning properly. Switch to unmanned status and activate the alarm system. Insure that the alarm sounds in the wheelhouse. Insure that the alarm sounds by the pool. Test each duty engineer receptacle in the staterooms on the first deck, C/E and 1A/E staterooms and day rooms, officers= dining room and lounge, sport room and engineers= office. END OF RECORD 313 6552-001-M1-E-V-KKK General Alarm System Test the general alarm system from all stations. Walk through all areas of the vessel to insure that all sirens are functional and audible. END OF RECORD 314 6578-001-M6-E-V-KKK Remote Level Indicating System Ballast and FO Tanks Mfg.: Yamatake-Honeywell Co., Ltd. Conduct the following preventive maintenance to the remote level indicator systems for the ballast and fuel oil tanks. Consult the manufacturer=s manual for guidance. Tools and Equipment Item Used to Hand Syringe Dust interior of transmitting unit Soft bristle brush Clean Diaphragms Solvent Clean diaphragms and end covers (pressure chambers) Dashpot (transmitting unit) Check for excessive oil leakage. Thin film of oil in damping area is permissible and does affect operation. All piping connections between meter and primary element. Inspect for leakage. Tighten all loose connections. Interior of transmitting unit Clean out the interior of the instrument case with dry air. Clean and blow down all connecting piping, meter bodies and vent drain fittings. END OF RECORD 315 6601-001-M6-E-V-KKK Exterior Communications For tracking purposes, note related MEI codes as applicable: 6602 Receivers 6603 Transmitters 6604 Transceivers 6605 Radio telegraph equipment 6606 Antenna spares 6607 Jack/switching panels/plug 6608 Digital frequency meter 6610 Radio teletype equipment 6615 Radiotelephone equipment 6620 Lifeboat portable radio equip. 6622 Modulator 6623 Freq. shift diversity convert. 6625 Auto alarm 6626 Auto keyers 6630 Satellite communications 6635 Power supply 6640 Amplifiers/filters/exciters NOTE: All radio emissions shall 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). A radio operator shall visually inspect and test all of the ship=s radio equipment. All test activities shall be recorded in the ship=s log. END OF RECORD 316 6701-001-M6-E-V-KKK Navigation Equipment Inventory and test all navigation equipment in accordance with 33 CFR 164.25 for getting underway. END OF RECORD 317 6705-001-W2-E-V-KKK Radars and Associated Antennas For tracking purposes, note related MEI codes below as applicable: 6780 Collision avoidance system Insure no personnel are on radar mast before powering up antennae=s Power up gyro compasses as per 6715-001-W2-E-V-KK1/KK2. Power up both Raytheon M34 ARPA=s. Run both units through self test. Switch both units to stand-by and wait 5 minutes. Switch both units to Transmit. Check both masts for proper movement. Enable various functions of each unit and compare against the other. Change scales of each unit and compare. Switch antennae=s between units and compare. END OF RECORD 318 6705-001-W2-E-V-KKK Radars and Associated Antennas For tracking purposes, note related MEI codes below as applicable: 6780 Collision avoidance system Insure no personnel are on radar mast before powering up antennae=s Power up gyro compasses as per 6715-001-W2-E-V-KK1/KK2. Power up both Raytheon M34 ARPA=s. Run both units through self test. Switch both units to stand-by and wait 5 minutes. Switch both units to Transmit. Check both masts for proper movement. Enable various functions of each unit and compare against the other. Change scales of each unit and compare. Switch antennae=s between units and compare. END OF RECORD 319 6708-001-M1-E-V-KKK Echo Sounder Equipment Power up the Simrad En . Check depth under keel from chart or manual observation. Compare digital readouts of Simrad 1C and Simrad 1S Switch scales and compare readouts. Switch transponders from bow to stern. Power up recorder and compare with Simrad 1C and Simrad 1S readings. Check and replace as necessary all lights and graph paper. Insure adequate supply on hand for replacement. END OF RECORD 320 6714-001-Y1-E-V-KKK Gyro Pilot System For tracking purposes, note related MEI codes below as applicable: 6740 Elec. steering-gyro pilot sys. During sea trials in open seaway and with regards to traffic situation, Insure rudder command, course setting, and parameter settings are correct. Turn Sperry ADG 6000 system motor switch to auto. Set course and maintain for one hour. Note and indicate such on course recorder. Change course 10 degrees or more using Auto pilot course order dial. Check movement of rudder and insure rudder limit and turn rate parameter settings are adhered to. END OF RECORD 321 6715-001-M1-E-V-KKK Gyro Compass System For tracking purposes, note related MEI codes below as applicable: 6716 Master gyro compass Power up both gyro compass motors and wait at least four (4) hours. Switch on each gyro compass. Check heading against chart or aziumuth and each other for correctness. Check for proper operation of the gyro compass repeaters on the port and starboard bridge wings. Refer to 6718- 001-M1-E-V-KK1/KK2. Note: During sea trials, take azimuths hourly to check error. END OF RECORD 322 6717-001-M1-E-V-KKK Course Recorder During inspection of steering gear, power up course recorder and insure rudder positions are recorded. Check and replace as necessary all lights and graph. Insure adequate supply on hand for replacement. Note: During sea trials, check course recorder hourly to insure courses and rudder positions are adhered to. END OF RECORD 323 6718-001-M1-E-V-KKK Gyro Repeaters During Gyro compass system inspection, check all gyro repeaters for synchronization. Repeaters are in following locations: Bridge wings Port and Starboard Steering Stand Forward console of pilot house Steering Gear Room Chart table. Note: During sea trials, check repeaters for follow up. END OF RECORD 324 6725-001-M1-E-V-KKK Magnetic Compass During Gyro compass inspection check magnetic compass for change. Note: During sea trials take azimuths hourly and establish deviation card. Check magnetic compass repeater for correctness. END OF RECORD 325 6730-001-M1-E-V-KKK Radio Direction Finder Power up Plath Angulas Radio Direction Finder. From Radio Navigational Aids, select acceptable beacon and tune finder into corresponding frequency. Check bearing against charted bearing and enter into log. Note: During sea trials, select beacon that can be visually observed. Swing ship and construct bearing card for FCC certification. END OF RECORD 326 6735-001-M1-E-V-KKK Loran/Navsat Power up Trimble NT 2000 GPS and Furuno GPS Navigator GP 500. Compare position displayed against other unit and with chart location. Operate various sailing functions and check against alternate methods. END OF RECORD 327 6745-001-Y1-E-V-KKK Doppler Speed Log During sea trials check hourly SAGEM speed log read out and compare with alternate methods. END OF RECORD 328 6750-001-M1-E-V-KKK Weather Printer Power up Radio Holland Navtex 2 and select print status. Monitor for one hour to insure reception of information and then secure. END OF RECORD 329 6751-001-M1-E-V-KKK Radio Receiver GMDSS Station Power up all receivers and terminals for operation. The Radio Officer shall test for transmission annually during sea trials. END OF RECORD 330 6755-001-M1-H-V-KKK Whistle Control Insure no one is working aloft. Test forward whistle from stations as follows: Port bridge wing mooring station. Starboard bridge wing mooring station. Pilot house forward center console. Notify engineers to give you air to after whistle and operate using manual pull in pilot house overhead. END OF RECORD 331 6757-001-M1-E-V-KKK Fog Bell/Gong System Fog whistle: Power up Tyfon fog timer and operate on forward whistle for 60, 90, 120 second duration in auto mode. Repeat on after whistle. Activate in Hand mode and secure. Bell/gong system: Power up JRC recorded bell and gong player in Gyro room. Power up main unit on bridge. Operate in anchor position and audibly check fore and aft. Repeat in aground position. END OF RECORD 332 6770-001-M1-H-V-KKK Window Wipers Power up three wiper/heater units located on bridge. Insure adequate supply of blades for replacement on hand. END OF RECORD 333 6775-001-M1-G-V-KKK Portable Navigation Equipment Conduct inventory and maintain adequate supply of navigational tools onboard for activation. Dividers Triangles Parallel rule calculator correction template etc. END OF RECORD 334 6784-001-M1-H-V-KKK Load Calculator / Indicator Power up loadmax and run through self test. Boot up load program designed for vessels and run through self test. Enter weights and measurements of dockside condition and compare visual drafts with calculated drafts. END OF RECORD 335 6790-001-M1-H-V-KKK Clinometer / Inclimometer Power up clinometers in traffic control room and check for correctness. Visually check drafts and compare with clinometer. END OF RECORD 336 6801-001-W1-E-V-KKK Lighting For tracking purposes, note related MEI codes below as applicable: 6810 Exterior lighting 6811 House lighting 6812 Signal lighting 6813 Navigation lighting 6814 Searchlights 6830 Interior lighting 6832 Machinery space lighting 6833 Cargo space lighting 6834 Refrigeration space lighting 6840 Light dimmers 1. Individually activate each lighting circuit, observing ground detection system. 2. Locate and repair all grounded fixtures and circuits. 3. Visually inspect all main and emergency lights, renewing all spent bulbs, ballasts, starters and lamp holders as required. 4. Confirm satisfactory condition and proper installation of all globes, diffusers and guards. 5. Confirm that all Emergency lights are so indicated with a red >E=. 6. Verify or correct all circuit labeling. 7. Leave circuits energized or Aas found@ as applicable. 8. Note and record any uncorrected deficiencies. End of Record 337 6801-001-W1-E-V-KKK Lighting For tracking purposes, note related MEI codes below as applicable: 6810 Exterior lighting 6811 House lighting 6812 Signal lighting 6813 Navigation lighting 6814 Searchlights 6830 Interior lighting 6832 Machinery space lighting 6833 Cargo space lighting 6834 Refrigeration space lighting 6840 Light dimmers 1. Individually activate each lighting circuit, observing ground detection system. 2. Locate and repair all grounded fixtures and circuits. 3. Visually inspect all main and emergency lights, renewing all spent bulbs, ballasts, starters and lamp holders as required. 4. Confirm satisfactory condition and proper installation of all globes, diffusers and guards. 5. Confirm that all Emergency lights are so indicated with a red >E=. 6. Verify or correct all circuit labeling. 7. Leave circuits energized or Aas found@ as applicable. 8. Note and record any uncorrected deficiencies. End of Record 338 6801-001-W1-E-V-KKK Lighting For tracking purposes, note related MEI codes below as applicable: 6810 Exterior lighting 6811 House lighting 6812 Signal lighting 6813 Navigation lighting 6814 Searchlights 6830 Interior lighting 6832 Machinery space lighting 6833 Cargo space lighting 6834 Refrigeration space lighting 6840 Light dimmers 1. Individually activate each lighting circuit, observing ground detection system. 2. Locate and repair all grounded fixtures and circuits. 3. Visually inspect all main and emergency lights, renewing all spent bulbs, ballasts, starters and lamp holders as required. 4. Confirm satisfactory condition and proper installation of all globes, diffusers and guards. 5. Confirm that all Emergency lights are so indicated with a red >E=. 6. Verify or correct all circuit labeling. 7. Leave circuits energized or Aas found@ as applicable. 8. Note and record any uncorrected deficiencies. End of Record 339 6801-001-W1-E-V-KKK Lighting For tracking purposes, note related MEI codes below as applicable: 6810 Exterior lighting 6811 House lighting 6812 Signal lighting 6813 Navigation lighting 6814 Searchlights 6830 Interior lighting 6832 Machinery space lighting 6833 Cargo space lighting 6834 Refrigeration space lighting 6840 Light dimmers 1. Individually activate each lighting circuit, observing ground detection system. 2. Locate and repair all grounded fixtures and circuits. 3. Visually inspect all main and emergency lights, renewing all spent bulbs, ballasts, starters and lamp holders as required. 4. Confirm satisfactory condition and proper installation of all globes, diffusers and guards. 5. Confirm that all Emergency lights are so indicated with a red >E=. 6. Verify or correct all circuit labeling. 7. Leave circuits energized or Aas found@ as applicable. 8. Note and record any uncorrected deficiencies. End of Record 340 6812-001-M1-E-V-KKK Signal Lighting Power up maneuvering light on forward console of bridge. Check Port, Starboard, Astern, and Emergency modes. Power up morse signal light port side forward console of bridge. Check light for illumination. Relamp all console indicator lights and exterior signal lights as required. END OF RECORD 341 6813-001-W2-E-V-KKK Navigation Lighting Power up normal navigation lighting and visually inspect all running lights. Turn each light off individually and listen for failure buzzer. Power up emergency navigation lighting and visually inspect all running lights. Turn each light off individually and listen for failure buzzer. Power up navigational lights on main mast and visually inspect. Power up Not Under Command Lights and visually inspect. END OF RECORD 342 6813-001-W2-E-V-KKK Navigation Lighting Power up normal navigation lighting and visually inspect all running lights. Turn each light off individually and listen for failure buzzer. Power up emergency navigation lighting and visually inspect all running lights. Turn each light off individually and listen for failure buzzer. Power up navigational lights on main mast and visually inspect. Power up Not Under Command Lights and visually inspect. END OF RECORD 343 6814-001-M1-E-V-KKK Searchlights Check hand held signal light for operation. Insure adequate supply of lamps on hand for replacement. END OF RECORD 344 6840-001-M1-E-V-KKK Light Dimmers Check all dimmer switches on bridge consoles for operation. Insure adequate supply of bulbs on hand for replacement. END OF RECORD 345 8102-001-M6-H-V-KKK Fire Doors / Closures / Dampers Exercise all fire dampers throughout the vessel, including dampers and closures for miscellaneous spaces and dampers for cargo hold ventilation fans. Refer to the attached list of dampers for quantities and locations. In addition to the dampers on the attached list, include the new galley dampers and HVAC dampers in the accommodations. Insure freedom of movement of damper handles, hinges and closures as applicable. For weather tight and watertight dampers with gaskets, inspect the gaskets for signs of damage or deterioration. Replace damaged or deteriorated gaskets with new. Chalk test gaskets to insure proper sealing. Liberally apply anti-seize compound to all mechanical parts including hinges and securing dogs. Exercise dogs to insure freedom of movement. END OF RECORD 346 8105-001-M6-H-V-KKK Fire Extinguishers Once during each Phase IV cycle, all portable and semi- portable fire extinguishers throughout the vessel, including spares, shall be inventoried and inspected. This shall include all portable dry chemical and CO2 extinguishers as well as the four (4) semi-portable foam extinguishers and one (1) semi-portable dry chemical extinguisher. Refer to the attached fire extinguisher inventory list for guidance with the inventory and inspection. Ascertain that all numbered extinguishers are located at their correct numbered locations. Both the extinguisher and the location shall be stenciled or otherwise labeled with the proper extinguisher number in accordance with the fire plan. Visually inspect each fire extinguisher for defects and check the gauges to insure that all extinguishers are fully charged. Annually, the fire extinguisher inspections shall be conducted by a recognized fire protection service facility for the USCG mid-period or COI inspection. All portable fire extinguishers shall be inspected, weighed, powder fluffed. Extinguishers shall be left tagged and sealed and ready for immediate use. Inspection reports shall be provided by the fire protection service facility to the vessel for files. END OF RECORD 347 8106-001-Y1-H-V-KKK Fire Detection Annually, the Pyrotronics fire detection system shall be inspected and tested by a recognized fire protection service facility. Verify that there are no trouble zones or general trouble lights. Test the system to the satisfaction of the USCG for the vessel=s annual mid-period or COI inspection. The service facility shall provide an inspection report for the vessel=s files. END OF RECORD 348 8115-001-Y1-H-V-KKK CO2 Room Equipment Annually, the main and two (2) independent CO2 systems shall be inspected and tested by a recognized fire protection service facility. The main system contains five hundred three (503) 100# bottles; the emergency generator room independent CO2 system contains three (3) 100# bottles; and the paint locker independent CO2 system contains two (2) 100# bottles. All bottles shall be weighed and serial numbers shall be recorded. A function test of the main CO2 system shall be performed in the presence of the USCG. All bottles shall be disconnected from the manifolds prior to testing. All remote pulls for the engine room and cargo holds shall be tested. Using test bottles, all stop valves, control valves, sirens, time delays, pressure switches and discharge heads shall be tested in each zone location (engine room, upper tween deck, lower tween deck and tank top hold). Insure that all ventilation shutdowns work satisfactorily. After testing is completed to the satisfaction of the USCG, the system shall be re-armed, sealed, tagged and left ready for use. A function test of the emergency generator room CO2 system shall be performed in the presence of the USCG. All bottles shall be disconnected from the discharge piping prior to testing. Test the pull controls. Using a test bottle, test the siren, time delay, pressure switch and discharge heads. Insure that the engine air intake dampers close and the engine trips. After testing, the system shall be re-armed, sealed, tagged and left ready for use. A function test of the paint locker CO2 system shall be performed in the presence of the USCG. Both bottles shall be disconnected from the discharge piping prior to testing. Test the pull controls. Using a test bottle, test the time delay, siren and discharge heads. After testing, the system shall be re-armed, sealed, tagged and left ready for use. Inspection reports and bottle weight reports shall be submitted by the service facility for the vessel=s files. END OF RECORD 349 8205-001-M6-H-V-KKK Lifeboats For each lifeboat, accomplish the following maintenance and inspection procedures. Refer to the attached LIFEBOAT MAINTENANCE & INSPECTION check lists. Inspect the general appearance of the boat. As a minimum, check the tiller and rudder, hull rivets, thwarts, engine compartment, flemming gear, boat markings, side compartments, side compartments, boat cover and drains. Insure that engine operating instructions are posted. Note and record date of change of fuel and engine oil. END OF RECORD 350 8206-001-W2-H-V-KKK Lifeboat Davits For each lifeboat davit, accomplish the following maintenance and testing procedures. Refer to the attached LIFEBOAT DAVIT INSPECTION & TESTING check lists. Insure that operation and lubrication instructions are posted on or adjacent to the davit. Grease all points as required. Check the gear oil level in each davit winch gear case and refill or change as necessary. When oil is changed, the gear case shall be thoroughly cleaned with lint free rags. Inspect all rigging for wear, deterioration or defects. Release the gripes and lower the boat approximately twelve inches (12@) past the limit switches. Check all sheaves and drums for freedom of movement. Inspect the fall wires for signs of weakness or damage. Wires shall be replaced if there are any signs of weakness or damage. Note: Fall wires shall be end-for- ended every 2-1/2 years and shall be replaced every 5 years in accordance with USCG regulations. Energize the winch and raise the boat. Test each limit switch while raising the boat. After testing, stow the boat and secure the gripes. END OF RECORD 351 8206-001-W2-H-V-KKK Lifeboat Davits For each lifeboat davit, accomplish the following maintenance and testing procedures. Refer to the attached LIFEBOAT DAVIT INSPECTION & TESTING check lists. Insure that operation and lubrication instructions are posted on or adjacent to the davit. Grease all points as required. Check the gear oil level in each davit winch gear case and refill or change as necessary. When oil is changed, the gear case shall be thoroughly cleaned with lint free rags. Inspect all rigging for wear, deterioration or defects. Release the gripes and lower the boat approximately twelve inches (12@) past the limit switches. Check all sheaves and drums for freedom of movement. Inspect the fall wires for signs of weakness or damage. Wires shall be replaced if there are any signs of weakness or damage. Note: Fall wires shall be end-for- ended every 2-1/2 years and shall be replaced every 5 years in accordance with USCG regulations. Energize the winch and raise the boat. Test each limit switch while raising the boat. After testing, stow the boat and secure the gripes. END OF RECORD 352 8206-003-M6-H-V-KKK Liferaft Davits Test the operation of the port and starboard liferaft davits. Prior to testing, grease all points as required. Inspect the release hook for damage or defects. Attach a weight to the hook and lift the weight by cranking the winch. Lower the weight and test the brake by pulling the brake cable. Position the weight just slightly off the deck and test the release hook by pulling the release cable. During testing, insure freedom of movement of all sheaves and drums. Inspect wires for any weak or damaged areas. Weak or damaged wires shall be changed. END OF RECORD 353 8210-001-M6-H-V-KKK Life Ring Buoys Lifebuoys/Rings/Jackets Liferings Once during each Phase IV cycle, all life rings shall be inventoried and inspected. One of the semi-annual inspections shall be accomplished with a USCG inspector for the mid-period or COI inspection. Insure that all life rings are mounted in their correct locations in accordance with the fire control plan. Inspect each life ring for damage. Damaged rings shall be replaced. Insure that all rings are properly stenciled with the vessel=s name and hailing port. Insure that all rings are fitted with retro-reflective tape. For life rings with painters, inspect the condition of the painters. For life rings with lights, insure that the batteries are not expired. For life rings with smoke, insure that the smoke canisters are not expired. Temporarily remove the rings from the quick release racks on the bridge wings and test the quick releases. END OF RECORD 354 8210-002-M6-H-V-KKK Lifejackets - PFDs Once during each Phase IV cycle, all lifejackets shall be inventoried and inspected. One of the semi-annual inspections shall be accomplished with a USCG inspector for the mid-period or COI inspection. Insure that there are forty (40) lifejackets for crew and riders, as well as additional lifejackets on the bow and in the wheelhouse and engine room in accordance USCG regulations. Inspect each lifejacket for signs of deterioration or damage. Deteriorated or damaged jackets shall be replaced. Insure that all jackets are properly stenciled with the vessel=s name and hailing port. Insure that all jackets are fitted with approved whistles and lights. Check that the light batteries are not expired. END OF RECORD 355 8211-001-M6-H-V-KKK Self-Contained Breathing Apparatus Once during each Phase IV cycle, all SCBA units shall be inventoried and inspected. One of the semi-annual inspections shall be accomplished by a recognized service facility with a USCG inspector for the mid-period or COI inspection. Insure that there is one (1) SCBA in each emergency gear locker and two (2) SCBA each in the refrigeration machinery room and air conditioning machinery room in accordance with the fire control plan. Inspect each SCBA and ascertain that all accessories and spare bottles are present. During the inspection by the recognized service facility, the bottles shall be inspected, weighed, sealed, tagged and certified. END OF RECORD 356 8215-001-Y1-H-V-KKK Liferafts Once per year, the four (4) twenty-five person liferafts and one (1) six-person raft shall be removed from the vessel and sent to a recognized service facility for inspection, inventory of gear, presentation to a USCG inspector and certification for the mid period or COI inspection. All dated items, including batteries and beacon batteries shall be replaced. Insure that the hydrostatic release is current. If expired, it shall be replaced. Insure that launching instructions and liferaft number and capacity placards are posted adjacent to all liferafts. Inspection documents and certificates shall be provided by the service facility to the the vessel for files. END OF RECORD 357 8220-001-M6-H-V-KKK Lifeboat Equipment Once per Phase IV cycle, all of the equipment in the port and starboard lifeboats shall be inspected and inventoried. One of the semi-annual inspections shall be accomplished with a USCG inspector for the mid-period or COI inspection. Refer to the attached LIFEBOAT EQUIPMENT INVENTORY. END OF RECORD 358 8230-001-M6-H-V-KKK Survival/Exposure Suits Once during each Phase IV cycle, all exposure suits shall be inventoried and inspected. One of the semi-annual inspections shall be accomplished with a USCG inspector for the mid-period or COI inspection. Insure that there are forty (40) exposure suits for crew and riders, as well as additional suits on the bow and in the wheelhouse and engine room in accordance USCG regulations. Inspect each exposure suit for signs of deterioration or damage. Deteriorated or damaged jackets shall be replaced. Insure that all jackets are properly stenciled with the vessel=s name and hailing port. Insure that all of the suits are fitted with approved whistles and lights. Check that the light batteries are not expired. Also, check that all suits have donning instructions and wax for the zippers. END OF RECORD 359 8501-001-M1-M-V-KKK Workshop Equipment For tracking purposes, note related MEI codes as applicable: 8501 Workshop equipment 8505 Lathes 8506 Lathe attachments 8520 Drill presses 8525 Grinders 8530 Welding equipment 8560 Engine test stand 8580 High pressure cleaning equip. Visually inspect all workshop equipment for damage or defects. Test run all equipment to insure proper operation. Lubricate all shop equipment as required for preservation and operation. All workshop spaces shall be left in a clean condition and all workshop equipment and tools shall be neatly stowed. END OF RECORD 360 8701-001-AR-M-V-KKK System Instruments (Gauges) For tracking purposes, note related MEI codes as applicable: 8702 Main Gauge Board 8705 System Indicating Instruments 8706 Thermometers / Pressure Gauges 8710 System Recording Instruments Visually inspect system instrumentation including pressure gauges, thermometers, electrical instrumentation, tank level indicators and all special instrumentation throughout the engine room and all other machinery or control spaces through the vessel. Report any deficiencies. END OF RECORD 361 9501-001-Y1-M-V-KKK Automation Safety Test Test and inspect all vital machinery automation systems in accordance with the vessel=s APeriodic Safety Test Procedure@ as required by 46 CFR Sections 61. Test procedures in the Periodic Safety Test Procedure are provided in accordance with 46 CFR Sections 61.40-1, 61.40-6, 61.40-10 and applicable sections of Part 62 - Vital System Automation. All tests, except those items which are specifically agreed with the OCMI to be impractical, must be witnessed by a U.S. Coast Guard inspector. A photocopy of the test procedure should be used as a record of each test cycle. When the tests are completed, the test procedure copy should be signed by the Chief Engineer and the attending U.S. Coast Guard inspector and kept on board the vessel. All tests should be directed by persons thoroughly familiar with the operation and maintenance of the ship=s machinery systems, safety equipment and related alarm function. System and equipment operating and maintenance manuals should be reviewed prior to conducting any of the Periodic Safety Tests. General Safety Precautions: Always be aware of the possible hazards to personnel and equipment. Make certain that no dangerous conditions will result from the performance of these tests. Properly notify ship=s crew that these tests will be carried out. Make proper notification of test completion. Provide adequate communications among test team members. Properly instruct test team members of their responsibilities and performance requirements. Assure that test results are properly recorded in the Engineer=s Log. Systems should be reset to normal operating and/or ready conditions following completion of tests. END OF RECORD 362 9601-001-DY-M-V-KKK MSD (Inspect Daily) 1. Check the air compressor pressure gauge. Reading should be between 0.2 and 0.7 kg/sq cm. IF the pressure is too low, check the compressor filter assembly and piping for leakage. IF the pressure is too high, check the air diffuser and filter and clean as required. 2. Check the sludge return line to insure that the activated sludge is being returned. If not, check the air supply line for clogs or leaks and repair as necessary. 3. Check the chlorinator for level of chlorination tablets. The tube shall be filled with tablets at least up to one-fourth height from the bottom. If not, remove the top cover and fill the tube full. END OF RECORD 363 9601-002-W1-M-V-KKK MSD (Inspect/Maintain) Check the residual chlorine content of the treated water. The residual chlorine content must be between 2 ppm and 5 ppm. If the residual chloring content exceeds 5 ppm, use only one tube. If the residual chlorine content is below 2 ppm, use two tubes. END OF RECORD 364 9601-002-W1-M-V-KKK MSD (Inspect/Maintain) Check the residual chlorine content of the treated water. The residual chlorine content must be between 2 ppm and 5 ppm. If the residual chloring content exceeds 5 ppm, use only one tube. If the residual chlorine content is below 2 ppm, use two tubes. END OF RECORD 365 9601-002-W1-M-V-KKK MSD (Inspect/Maintain) Check the residual chlorine content of the treated water. The residual chlorine content must be between 2 ppm and 5 ppm. If the residual chloring content exceeds 5 ppm, use only one tube. If the residual chlorine content is below 2 ppm, use two tubes. END OF RECORD 366 9601-002-W1-M-V-KKK MSD (Inspect/Maintain) Check the residual chlorine content of the treated water. The residual chlorine content must be between 2 ppm and 5 ppm. If the residual chloring content exceeds 5 ppm, use only one tube. If the residual chlorine content is below 2 ppm, use two tubes. END OF RECORD 367 9601-003-M1-M-V-KKK MSD (Inspect/Maintain) 1. Replace the compressor in use with the stand-by compressor. Repair the compressor just taken out of service as necessary. Note: When the air compressor outlet pressure exceeds the limited figures (0.7 kg/sq cm), check the air diffuser regardless of the checking period. Replace the diffuser. 2. Check the chlorinator to insure that the tube inside is not clogged. If necessary, remove the chlorinator and clean it. Note: The cleaning period of the chlorinator depends on the conditions of use. When the ship is underway and outside of restricted territory and the chlorinator is not in use, clean the chlorinator after removing the tablets. END OF RECORD 368 9601-004-M3-M-V-KKK MSD (Inspect/Maintain) 1. Stop the flow of soil to the plant for about half an hour. Then pump out through the discharge pump about 75% of the mixed solution in the aeration compartment to rid the unit of excess sludge. Note: This operation is limited to unrestricted territory. 2. Check the interior screen of the aeration compartment for excessive sludge. If soiled or clogged, clean with fresh water or pure sea water. 3. Check the inside of the clarification compartment for excess sludge. If soiled or clogged, clean with fresh water or pure sea water. END OF RECORD 369 9601-005-M6-M-V-KKK MSD (Inspect/Maintain) Check the filter cartridge of the aeration compressor. If soiled, renew the cartridge. Note: Cleaning the cartridge with a toluene solvent will serve as an emergency remedy. END OF RECORD 370 9601-006-Y1-M-V-KKK MSD (Inspect/Maintain) For tracking purposes, not the following related MEI codes as applicable: 9602 Float switches 1. Discharge the soil from the tank and clean the inside of the tank with fresh water or clean sea water. After cleaning, inspect the interior of the tank and all accessories for defects. Note: The manufacturer recommends touch up coating inside the tank every three years. Coating condition should be inspected and noted for the record during each annual inspection. 2. While tank is opened for inspection, hand-test all float switches to insure proper and satisfactory operation. END OF RECORD !!! . set ALTE off