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ABG

EO MANUAL
FOR
DESS VESSELS
YARD 237,257,258,270-275

PREPARED BY
ABG SHIPYARD LTD
NEAR MAGDALLA PORT
DUMAS ROAD
SURAT
GUJURAT-395007
1

ABG
CONTENTS

TEST METHOD / PROCEDURE:

S.No.

Description of the test

Page nos.

1.

Maneuvering Position Change over Test

67

2.

Main engine start/stop & clutch IN / OUT Test

8-9

3.

Main Propulsion Emergency Pitch Test

10

4.

Main Engine protective system test

11-15

5.

Alarm Test for Main Engines

16-18

6.

Alarm Test for Main Propulsion

19-20

7.

Alarm Test For Main Generator Diesel Engine

21

8.

Alarm Test For Emergency Generator Diesel Engine

22

9.

Alarm Test For Bow Thruster

23

10.

Miscellaneous Tests for Other Aux. Machinery

24-28

11.

Miscellaneous test for Main Engine Pumps

12.

Miscellaneous test for Other Pumps

13.

Alarm Test for Tank Level

32

14.

Alarm Test for PMS

33-34

15.

System Alarm Test

35

16.

Fire Alarm Test

36

17.

Dead Man Alarm

37

DOCUMENT PREPARED BY ABG SHIPYARD LTD.


2

29
30-31

ABG
TEST METHOD / PROCEDURE :
CASE 1

: Pressure Alarm to be confirmed by making abnormal pressure in actual service


system with pressure calibrator or in detective line led to the pressure switch.

CASE 2

: Temp. alarm to be confirmed by putting sensor into hot liquid. However, in case of high
temp. sensor, it is to be confirmed by using dummy resistor or by RTD simulator.

CASE 3

: Level alarm to be confirmed by operating the float switch or by opening


or closing electric contact point.

CASE 4

: Alarm of oil content or salinity to be confirmed by soaking sensor into testing solution or by changing
the detectors set point manually.

CASE 5

: Over load alarm of motor to be confirmed by manual shutting of over current relay.

CASE 6

: Abnormal alarm of oil purifier to be confirmed by operating the detector manually.

CASE 7

: Running lamp of electric driven machinery to be confirmed by operating start and stop button (or
switch).

CASE 8

: Remote start and stop of electric driven machinery to be confirmed by operating remote start and
stop button (or switch).

CASE 9

: Auto start and stop of electric driven machinery to be confirmed by opening or closing electric
contact point.

CASE 10

: Confirmation by cutting off the no fuse breaker or fuse.

CASE 11

: Confirmation by opening or closing the electric contact point or by operating limit switch

CASE 12

: Confirmation by changing set point of variable resistance.

CASE 13

: Smoke to be introduced into the smoke or heat detector through test kit for detection of photocell.

CASE 14

: Main engine over speed can be perform in actual running operation.

CASE 15

: G.E. over speed can be performed by operating the simulation setting.

CASE 16

: Activate any alarm in unmanned control operation, twenty seven (27) minutes after, DEADMAN PRE-WARNING ALARM is activated and after another three (3) minutes, ENGINEERS
CALL follows.

DOCUMENT PREPARED BY ABG SHIPYARD LTD.


3

TEST METHOD / PROCEDURE :

ABG

CASE 17(1)

: Swbd. in Manual mode. Two generators connected to busbar and running in parallel. With
the governor control switch, decrease the speed of the generator to transfer full load to
other generator. Decrease the speed further.

CASE 17(2)

Swbd.in Manual mode. Increase the load on the generator.

CASE 17(3)

Swbd.in Manual mode. Increase the voltage from the AVR.

CASE 17(4)

Swbd.in Manual mode. Decrease the voltage from the AVR.

CASE 17(5)

Swbd.in Manual mode. Increase the speed of the generator.

CASE 17(6)

: Swbd.in Manual mode. Decrease the speed of the generator.

CASE 17(7)

: Swbd. In Auto mode. Generators in PMS. Change nominal frequency setting on standby generators
PPU to 60 Hz (Channel No.4011). Increase the load on running generator to more than 80%. (After
the completion of checks, revert back to the original setting)

CASE 17(8)

: Swbd. In Auto mode. Generators in PMS. Remove cable from ter.17 of standby generators PPU.
Increase the load on running generator to more than 80%.

CASE 17(9)

: Swbd. In Auto mode. Generators in PMS. Two generators connected to busbar and running in
parallel. Remove cable from ter.16 of standby generators PPU .Reduce the load on busbar to less than
20%. (After the completion of checks, connect the cable back)

CASE 17(10)

: Swbd. in Manual mode. Generator is running and connected to the busbar. Remove cable from ter.54
& 55 of connected generators PPU. (After the completion of checks, connect the cable
back).

CASE 17(11)

: Swbd. In Auto mode. Generators in PMS. Interchange cables on ter.79 & 81 of standby generators
PPU. Increase the load on running generator to more than 80%.(After the completion of checks,
connect the cable back)

CASE 17(12)

: Swbd. In Auto mode. Generators in PMS. Remove cable from ter.66 of standby generators PPU.
Increase the load on running generator to more than 80%. (After the completion of checks, connect
the cable back)

CASE 17(13)

: Decrease the power supply (24V DC) for PPU to less than 18V.

CASE 17(14)

:Select the generator to Manual mode or create any common alarm.

CASE 17(15)

: Swbd. In Auto mode. Generators in PMS. Remove cable for gen. start signal of standby generator
from terminals. Increase the load on running generator to more than 80%.(After the completion of
checks, connect the cable back)

CASE 17(16)

: Create any breaker trip alarm.

CASE 17(17)

: Create any earth fault or short terminals 1 & 3 on insulation monitor.


DOCUMENT PREPARED BY ABG SHIPYARD LTD.
4

ABG
ABBREVIATIONS USED IN TEST METHODS
W/H

Wheel House

C/R

Control Room

E/S

Engine Side (or Machine Side)

P.B.

Push Butten

White Lamp

Amber lamp

Green Lamp

Red Lamp

Yellow Lamp

Blue lamp

Orange Lamp

Alarm Buzzer

EXT.

Extended Alarm Panel

DNV
PAL

DNV Surveyor Attendance


PARTICULAR ALARM LINE

EXTENSION ALARM GROUP


1&2

M/E SHUTDOWN

3&4

M/E SLOWDOWN

5&6

M/E ALARM

MISC. ALARM

LEVEL ALARM

SYSTEM ALARM

10

THRUSTER ALARM

11

PMS ALARM

12

PROPULSION ALARM

DOCUMENT PREPARED BY ABG SHIPYARD LTD.


5

ABG
1. MANEUVERING POSITION CHANGE OVER TEST
1)
ITEM
NO :
1-1-1

CONTROL ROOM TO WHEEL HOUSE (under M/E stopping)


CONFIRMATION

TEST METHOD
OR OPERATION

ITEM

(C/R to W/H)

(C/R)
Press the maneuvering
position change over Bridge
control P.B.

(W/H)

Press Bridge control P.B.

C/R

REMARKS
W/H

C/R
G : ON

C/R
R : ON

C/R
G : ON

C/R
R : OFF

W/H
R : FLICKER

W/H
G : FLICKER

W/H
R : ON

Press The
In command P.B.
at the new station to
be in command
N.B.-It is possible
Bridge station only

FREQ. OF
TEST(Months)

DNV

W/H
G : ON

PREPARATION:
Control Position
: C/R
(W/H) Telegraph Transmitter : STOP
(C/R) Telegraph Receiver
: STOP
(C/R) Speed selection P.B.
: OFF

DOCUMENT PREPARED BY ABG SHIPYARD LTD.

ABG
1. MANEUVERING POSITION CHANGE OVER TEST
1) WHEEL HOUSE TO CONTROL ROOM (under M/E stopping)

ITEM
NO :

1-1-2

CONFIRMATION

TEST METHOD
OR OPERATION

ITEM

REMARKS
C/R

(W/H to C/R)

(W/H)
Press the maneuvering position
change over ECR control P.B.

W/H
G : ON

W/H
R : ON

W/H
G : OFF

C/R
G : FLICKER

C/R
R : FLICKER

Ditto

Ditto

C/R
G : ON

Press ECR control P.B.

DNV

Maneuvering position
change over from
W/H to C/R possible
only from aft station

W/H
R : ON

(C/R)
Turn the main telegraph to STOP
position
(C/R)

W/H

FREQ. OF
TEST(Months)

C/R
R : ON

Confirm that M/E can


be started at C/R

PREPARATION:
control Position
: W/H
(W/H) Telegraph Transmitter : STOP
(C/R) Telegraph Receiver
: Any desired division
(C/R) Speed selection P.B. : OFF

DOCUMENT PREPARED BY ABG SHIPYARD

ABG

2. MAIN ENGINE START/STOP & CLUTCH IN / OUT TEST


ITEM
NO :

ITEM

TEST METHOD
OR OPERATION

CONFIRMATION
E/S

Start Engine By pressing


engine running P.B.

ENGINE
RUNNING
G : ON
VARIABLE
RPM ;
Y: ON

ENGINE
RUNNING
G : OFF
RPM ; 00
:
ENGINE
RUNNING
G : ON
VARIABLE
RPM ;
Y: ON

Change to design RPM Press Fixed


RPM P.B.

ENGINE
RUNNING
G : ON
FIXED RPM
Y: ON

ENGINE
RUNNING
G : ON
FIXED RPM
Y: ON

Stop Engine by pressing stop PB.

STOP
R: ON

STOP
R: ON

ENGINE
RUNNING
G : OFF
RPM ; 00

2-1

C/R

M/E START & STOP


FROM E/S OR C/R

B/R

REMARKS

FREQ. OF
TEST(Months)

DNV

RPM:00

RPM: 550
CONFIRM THAT
BEFORE STARTING
THE ENGINE GEAR
BOX LUBE OIL PUMP
MUST BE ON.

RPM: 1000

RPM: 0
Confirm that at the time
of CLUTCH IN
1. no. engine speed
advisable in variable
rpm

2-2

CLUTCH IN

Press clutch in PB from in


command control station

SHAFT RPM

R:
BLINKING
G: ON

R : BLINKING
G: ON

DOCUMENT PREPARED BY ABG SHIPYARD

2. Pitch must be in zero


3. Clutch IN / OUT
possible from any in
command control station

ABG

ITEM NO
:

2-3

ITEM

CLUTCH OUT

CONFIRMATION

TEST METHOD
OR OPERATION

Press clutch out PB from in


command control station

REMARKS

E/S

C/R

B/R

SHAFT RPM

G:
BLINKING
R: ON

G:
BLINKING
R: ON

Clutch IN / OUT
possible from any in
command control station

FREQ. OF
DNV
TEST(Months)

PREPARATION:
control Position
: W/H
(W/H) Telegraph Transmitter : Desired Division
(C/R) Telegraph Receiver
: Any desired position
(C/R) Speed Control dial : Allowable speed position

DOCUMENT PREPARED BY ABG SHIPYARD

ABG
3. MAIN PROPULSION EMERGENCY PITCH TEST

ITEM
NO :

ITEM

CONFIRMATION

TEST METHOD
OR OPERATION

REMARKS

E/S

3-1

3-2

3-3

C/R

B/R

FOR MANUAL CONTROL PITCH


SWITCH TO POSITION LOCAL
ON LOCAL CONTROL BOX &
PUSH THE DIRECTIONAL
SOLENOID VALVE WHICH ARE
MOUNTED NEAR OD BOX AS PER
BRIDGE INSTRUCTION.

PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

C/R

PRESS BACK UP PB AND


OPERATE PITCH CONTROL KNOB

PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

R : ON PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

R : ON PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

W/H

PRESS BACK UP PB AND


OPERATE PITCH CONTROL
LEVER

PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

R : ON PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

R : ON PITCH
INDICATOR
NEEDLE ON
ASTERN OR
AHEAD

E/S

PREPARATION:
(W/H) Telegraph Transmitter : Desired Division
(C/R) Telegraph Receiver
: Any desired position
(C/R) Speed Control dial : Allowable speed position

GREEN------------------AHEAD
RED----------------------ASTERN

DOCUMENT PREPARED BY ABG SHIPYARD

DNV
FREQ. OF
TEST(Months)

CONFIRM THAT
1. GB LUBE OIL
STANDBY
PUMP MUST
BE ON.
2. PROPELLOR
MUST BE
CLUTCH OUT
WITH M/E

10

ABG
3. MAIN ENGINE PROTECTIVE SYSTEM TEST

1) ELECTRIC SOURCE FAILURE TEST


ITEM
NO:

4-1-1

ITEM

DESIGN
ACTUAL

CONTROL
PLC FAILURE

4-1-2

SAFETY PLC
FAILURE

4-1.3

Control
Cabinet 24V
DC FAILURE

TEST
METHOD OR
OPERATION

Put micro switch Off


mode outside control
MMC card inside control
cabinet

Put micro switch Off


mode outside Safety MMC
card inside control cabinet

Cut off the engine Maneuv.


System source.( DC supply) by
Breaker in DCDB or control
cabinet

CONFIRMATION
C/R

W/H

Reset by
microswitch
put in Run
mode

(CAUSE IND.)
CONTROL PLC
FAILURE
R : FLICKER Z :
SOUND

(CAUSE IND.)
SAFETY PLC
FAILURE
R : FLICKER Z :
SOUND

(CAUSE IND.)
POWER
FAILURE
R : FLICKER Z :
SOUND

REMARKS FREQ. OF TEST DNV


(Months)

(CAUSE IND.)
PAL:
BLINKING
Z : SOUND

Reset by
microswitch
put in Run
mode

EXT.
PAL:
BLINKING
Z: SOUND

Reset by
storing
power
24 VDC in 24
V dist. Box.

DOCUMENT PREPARED BY ABG SHIPYARD


11

ABG
4. MAIN ENGINE PROTECTIVE SYSTEM TEST
2)

ITEM
NO :

4-2-1

STARTING INTERLOCK TEST

ITEM

TURNING GEAR
Put key
/ KEY SWITCH
INTERLOCK

CONFIRMATION

TEST METHOD
OR OPERATION

REMARKS
E/S

C/R

(E/S)
Engage the turning gear slowly as far
as the START INTERLOCK lamp in
C/R & on E/S turns on.

START
INTERLOCK
R : ON

START
INTERLOCK
R : ON

(E/S)
switch off mode

START
INTERLOCK
R : ON

START
INTERLOCK
R : ON

CONFIRM THAT
STARTING AIR
CANNOT BE
SUPPLIED TO THE
ENGINE

(E/S)
Disengage the turning gear.

START
INTERLOCK
R : OFF

START
INTERLOCK
R : OFF

CONFIRM THAT
STARTING AIR CAN
BE SUPPLIED TO
THE ENGINE

START
INTERLOCK
R : ON

M/E L.O. Priming


Press. Can be override
In Emergency start
From E/S

(E/S)Put L.O.priming in manual mode START INTERLOCK R


Turn key switch ON
: ON
4-2-2

M/E L.O. Priming


Pressure Interlock

(E/S)
Put L.O.priming in Auto mode

START
INTERLOCK
R : OFF

START
NTERLOCK
R : OFF

FREQ. OF TEST
DNV
(Months)

CONFIRM THAT
STARTING AIR CAN
BE SUPPLIED TO
THE ENGINE

DOCUMENT PREPARED BY ABG SHIPYARD


12

4.

ABG

MAIN ENGINE PROTECTIVE SYSTEM TEST


2) EMERGENCY SHUT DOWN

ITEM
NO :

4-3-1

4-3-2

4-3-3

4-3-4

4-3-5

PREPARATION OR
ITEM
OVER SPEED
Preparation
1.Be sure to start L.O.
Pre Lub. Pumps.
2.Take measure that
M/E never starts.
(Possible gen.
Operation on board).
Jacket Water Temp.
(Engine Outlet)
Gear Box Low L.O.
Press.

DESIGN
(ACTUAL)

TEST METHOD OR
OPERATION
C/R

TEST : rpm
1150
SET : rpm
1000

98 C

1.0 BAR

Main Engine speed to be


increased to the testing
speed.
- Manually increasing
fuel rack position.

REMARKS

FREQ. OF
DNV
TEST(Months)

Confirm that
main engine is
stopped

W/H

(CAUSE IND.)
R : FLICKER
Z : SOUND

CASE 2
Do not start Gear box
L.O. standby pump before
starting the engine.

MAIN L.O. INLET LOW RPM<550 : 2.0 BARPre-Lub.Oil pump


PRESS:
switched Off.
(PRE LUB)
RPM<300 OR
RPM>550 :
Preparation
1.0
BAR
1.Be sure to start L.O.
Pre Lub. Pumps.
2.Take measure that
RPM>300 :
M/E never starts.
0.7BAR
(Possible gen.
Operation on board).
Manual Stop
(W/H,C/R,E/S)

CONFIRMATION

(CAUSE IND.)
PAL :
BLINKING
Z : SOUND
EXT.A :
FLICKER
Z : SOUND

Operate the manual


emergency stop switch.
DOCUMENT PREPARED BY ABG SHIPYARD
13

ABG
4. MAIN ENGINE PROTECTIVE SYSTEM TEST
3) EMERGENCY SHUT DOWN
ITEM
NO :

PREPARATION OR
ITEM

SET POINT
(DESIGN)

TEST METHOD OR
OPERATION

CONFIRMATION
REMARKS
C/R

(CAUSE IND.)
4-3-6

Oil mist connection

8%

CASE NO.11

R : FLICKER
Z : SOUND

DOCUMENT PREPARED BY ABG SHIPYARD

W/H

(CAUSE IND.)
PAL :
BLINKING
Z : SOUND
EXT.A :
FLICKER
Z : SOUND

Confirm that
main engine is
stopped

FREQ. OF
TEST
(Months)

DNV

14

ABG
Resetting of emergency shutdown state can be carried out after remedying the cause of it. By the following operations:
1) Under wheel House Maneuver
Operate Main Telegraph Transmitter lever to STOP position.
2) Under CONTROL ROOM Maneuver
Operate Speed Control Dial in the Control room to STOP position.
3) Under Engine Side Maneuver
Operate Fuel Regulating Lever at Engine side to STOP position.

Indicating lamp of emergency shutdown continue to light after removing cause. This lamp is reset by CAUSE RESET SWITCH.

DOCUMENT PREPARED BY ABG SHIPYARD

15

ABG

5. ALARM TEST FOR MAIN ENGINE


ITEM
NO.

DESCRIPTION

DESIGN
(IN BAR)

ACT
UAL

ALARM
HIGH

LOW

SHUT
DOWN

TEST
METHOD OR
OPERATION

CONFIRMATION
C/R

W/H

(CAUSE
IND.)

(CAUSE
IND.)

R
FLICKER
Z:
SOUND

PAL:
BLINKING
Z:
SOUND

REMARKS

FREQ.O
F TEST
(Months)

DNV

PRESSURE SWITCHS/TRANSMITTER
5.1
5.2
5.3

LOW L.O.PRESSURE Before


Engine < 550RPM
LOW L. O.PRESSURE Before
Engine > 550RPM

1.5

LT Water Pressure

1.7

2.5

1.0

5.6

DIFFERENTIAL LUB OIL


PRESSURE
FUEL OIL PRESSURE ON
EBGINE
F.O. DIFFERENTIAL
PRESSURE

5.7

STARTING AIR PRESSURE

15

5.8

Jacket WATER PRESSURE


Before Engine

1.5

5.9

Jacket WATER PRESSURE


Before Engine warning

1.7

5.10

M/E HIGH PRESSURE PIPE


LEAKAGE

0.5

5.4
5.5

5.11
5.12
5.13
5.14

MANOUVERE AIR PRESSURE


LO PRESSURE PRIMMING
PUMP
ROCKER ARM LO PRESSURE
NOZZLE OIL PRESSURE

1.9

1.5

O
O
O
O

BY
PRESSURE.
CALIBRATOR
OR CASE-1

O
0

EXT .
PAL:
BLINKING
Z:
SOUND

0.2

0.3

0.8

DOCUMENT PREPARED BY ABG SHIPYARD

16

ABG
5.
ITEM
NO.

ALARM TEST FOR MAIN ENGINE

DESCRIPTION

DESIGN
(IN
DEG.)

ACT
UAL

HIGH

ALARM
SHUT
LOW
DOWN

TEST
METHOD OR
OPERATION

CONFIRMATION
C/R

W/H

REMAR
KS

FREQ.OF
TEST
(Months)

DNV

TEMP. SENSOR/SWITCHES
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
5..27
5..28
5..29

JACKET WATER TEMP. AFTER


ENGINE
L.T.WATER TEMP
LO TEMPERATURE BEFORE
ENGINE
LO TEMPERATURE AFTER
ENGINE
NOZZLE OIL TEMPERATURE
EXH. GAS TEMP.CYL.1
EXH. GAS TEMP.CYL.2
EXH. GAS TEMP.CYL.3
EXH. GAS TEMP.CYL.4
EXH. GAS TEMP.CYL.5
EXH. GAS TEMP.CYL.6
EXH. GAS TEMP.CYL.7

95 DEG C
65 DEG C

O
O

68DEG C

84 DEG C

95 DEG C

465 DEG C
465 DEG C
465 DEG C
465 DEG C
465 DEG C
465 DEG C
465 DEG C

465 DEG C
EXH. GAS TEMP.CYL.8
EXH. TEMP.BEFORE TURBINE- 600 DEG C
1
EXH. TEMP. BEFORE
600 DEG C
TURBINE-2

(CAUSE
IND.)
(CAUSE
IND.)

O
O
O

RTD
SIMULATOR
OR CASE-2

O
O
O

R:
FLICKER
Z:
SOUND

PAL:
BLINKING
Z:
SOUND

EXT .
PAL:
BLINKING
Z:
SOUND

O
O
O
O

DOCUMENT PREPARED BY ABG SHIPYARD

17

ABG
5.
ITEM
NO.

ALARM TEST FOR MAIN ENGINE


DESIGN
DESCRIPTION

ACT
UAL

ALARM
HIGH LOW

SHUT
DOWN

STATUS

TEST
METHOD OR
OPERATION

CONFIRMATION
C/R

W/H

REMARKS

FREQ.OF
TEST
(Months)

DNV

MISCELLENEAOUS
5.30

TURBO CHARGER SPEED


PICK UP

5.31

LUBE OIL SUMP LEVEL

5.32

WIRE BREAK 51 x S / 52 x S
GEAR OIL
WIRE BREAK 71 EL
EMERGENCY STOP
WIRE BREAK 0.7 HT JACKET
WATER TEMPERATURE
WIRE BREAK A04 LO OIL MIST
DETECTION SIGN
WIRE BREAK 15 LO
PRESSURE AFTER FINE
FILTERBREAK 77 SA
WIRE
SHUTDOWN SOLENOID

5.38

MODULE FAILURE UN 01

5.39

MODULE FAILURE UN 02

5.40

MODULE FAILURE UN 03

5.41

MODULE FAILURE UN 04

5.42

MODULE FAILURE UN 05

5.43

MODULE FAILURE UN 07

5.33
5.34
5.35
5.36
5.37

39300 RPM
67 %

BY INCREASING
THE FUEL RACK

0
0

CASE 3

(CAUSE
IND.)

0
0
CASE-11
0
0

(CAUSE
IND.)

R:
FLICKER
Z:
SOUND

BY REMOVING
THE
RESPECTIVE
MODULE IN M/E
CONTROL
CABINET

DOCUMENT PREPARED BY ABG SHIPYARD

PAL:
BLINKING
Z : SOUND

EXT .
PAL:
BLINKING
Z : SOUND

18

ABG
6.
ITEM
NO.

ALARM TEST FOR MAIN PROPULSION

DESCRIPTION

DESIGN
(IN
DEG.)

ALARM

ACTUAL
HIGH

LOW

SHUT
DOWN

TEST METHOD
OR OPERATION

CONFIRMATION
C/R

W/H

REMARKS

FREQ.O
F TEST
(Months)

DNV

TEMP. SENSOR/SWITCHES
R/G OIL TEMP
6.1
6.2
6.3

70 DEG
C

STERN TUBE AFT BEARING 80 DEG C


TEMP.
R/G THRUST BEARING
HIGH TEMP SHUT DOWN
95 DEG C

6.4

R/G THRUST BEARING HIGH


90 DEG C
TEMP SLOW DOWN

6.5

INTER SHAFT BEARING 1


TEMP.

6..6

INTER SHAFT BEARING 2


TEMP.

6.7

INTER SHAFT BEARING 33


TEMP.

6.8

INTER SHAFT BEARING 4


TEMP.

6.9

HYDRAULIC OIL TEMP

O
O

RTD SIMULATOR
OR CASE-2

(CAUSE
IND.)

O
O

80 DEG
C

80 DEG
C

80 DEG
C

80 DEG
C

70 DEG
C

DOCUMENT PREPARED BY ABG SHIPYARD

(CAUSE IND.)

R : FLICKER
Z : SOUND

PAL:
BLINKING
Z:
SOUND

EXT .
PAL:
BLINKING
Z:
SOUND

19

ABG

6. ALARM TEST FOR MAIN PROPULSION

ITEM
NO.

DESCRIPTION

DESIGN ACTUAL
(IN BAR)
HIGH

ALARM
ALARM
LOW
STATUS

TEST METHOD
OR OPERATION

CONFIRMATION
C/R

W/H

REMAR
KS

FREQ.OF
TEST
DNV
(Months)

PRESSURE SENSOR/SWITCHES
6.10

R/G LO LOW PRESSURE

16 BAR

6.11

HTDRAULIC SYSTEM LO
LOW PRESSURE

40 BAR

CASE-2

(CAUSE
IND.)

MISCELLANEOUS
6.12
6.13
6.14
6.15
6.16
6.17

R/G OIL LEVEL

HUB LUB. GRAVITY TANK


OIL LEVEL
STERN TUBE GRAVITY
TANK LEVEL

R/G FILTER-1
CONTAMINATE
R/G FILTER-2
CONTAMINATE
CPP OIL FILTER BLOCK

(CAUSE IND.)
CASE-3

O
O
O
O
O

6.19

CPP LO FILTER BLOCK


CPP CONTROL SYSTEM
FAIL

6.20

CPP MAIN POWER FAIL

6.21

CPP BACK UP POWER FAIL

O
O

6.22

HYDRAULIC POWER PACK


PUMP FAIL

6.18

6.23

R/G STBY PUMP FAIL

CASE-11

R : FLICKER
Z : SOUND

PAL:
BLINKING
Z:
SOUND

EXT .
PAL:
BLINKING
Z:
SOUND

O
CASE-10

CASE- 9

DOCUMENT PREPARED BY ABG SHIPYARD

20

ABG
7.
ITEM
NO.

ALARM TEST FOR MAIN GENERATOR DIESEL ENGINES

DESCRIPTION

DESIGN
(IN
PSI&
DEG.)

7.1

LUB.OIL PRESSURE

35 PSI

7.2

LUB.OIL PRESSURE

30 PSI

7.3

JACKET WATER TEMP.

7.4

JACKET WATER TEMP.

7.5

OVER SPEED

7.6

EMERGENCY STOP

102
DEG C
106
DEG C
2124
RPM

ACT
UAL

ALARM
HIGH

LOW

SHUT
DOWN

O
O

TEST
METHOD OR
OPERATION

PRESSURE
CALIBRATOR
OR CASE-1

RTD
SIMULATOR
OR CASE-2

CASE 15

OPERATE THE
MANUAL EME.
STOP SWITCH

CONFIRMATION
C/R
(CAUSE
IND.)

R:
FLICKER
Z : SOUND

W/H

REMARKS

FREQ.OF
TEST
(Months)

DNV

(CAUSE
IND.)

PAL:
BLINKING
Z:
SOUND
EXT .
PAL:
BLINKING
Z:
SOUND

DOCUMENT PREPARED BY ABG SHIPYARD


21

ABG
8. ALARM TEST FOR EMERGENCY GENERATOR

ITEM
NO.

8.1
8.2
8.3
8.4
8.5
8.6

DESCRIPTION

ALARM
DESIGN
(IN PSI&DEG.
HIGH LOW

LUB OIL PRESSURE

1.38
BAR

LUB OIL PRESSURE

0.83
BAR

SHUT
DOWN

CASE 1
O

90
DEG C

JACKET WATER TEMP.

99
DEG C

2000 RPM

CASE 15

OPERATE THE
MANUAL EME.
STOP SWITCH

EMERGENCY STOP

C/R

W/H

REMARKS FREQ.OF
TEST
(Months)

DNV

JACKET WATER TEMP.

OVER SPEED TRIP

CONFIRMATION

TEST
METHOD OR
OPERATION

O
CASE 2

(CAUSE IND.) (CAUSE


IND.)
R:
FLICKER
Z:
SOUND

PAL :
BLINKING
Z:
SOUND

EXT:
PAL :
BLINKING
Z:
SOUND

DOCUMENT PREPARED BY ABG SHIPYARD


22

ABG

9. ALARM TEST FOR STERN THRUSTER


DESCRIPTION

DESIGN
IN BAR
&
DEGREE

ALARM
HIGH LOW

SHUTDOWN STATUS

TEST
METHOD OR
OPERATION

15

CASE-1,CASE
11,

HYDRAULIC OIL LEVEL LOW /


POWER PACK MOTOR OVERLOAD

CASE-3

9.11

DRIVE MOTOR TEMPERATURE TRIP

9.4

HYDRAULIC TEMP. HIGH / FILTER


CLOGGING

80

9.5

DRIVE MOTOR OVER LOAD (110%)

990A

9.1

HYDRAULIC PRESSURE LOW ALARM

9.2

9.6

TT ECU POWER FAILURE


ALARM

CASE-2

CASE-11

CONFIRMATION
C/R

FREQ.
OF
TEST
(Months)

DNV

(CAUSE
(CAUSE IND.) IND.)
R:
FLICKER
Z : SOUND

CASE-5

W/H

REMARKS

SWITCH OFF
POWER SUPPLY (AC
&DC)
IN DISTRIBUTION
BOARD

DOCUMENT PREPARED BY ABG SHIPYARD

PAL :
BLINKING
Z:
SOUND
EXT:
PAL :
BLINKING
Z::

23

ABG
10. ALARM TEST FOR STERN THRUSTER
DESCRIPTION

DESIGN
IN BAR
&
DEGREE

ALARM
HIGH LOW

SHUTDOWN STATUS

TEST
METHOD OR
OPERATION

15

CASE-1,CASE
11,

HYDRAULIC OIL LEVEL LOW /


POWER PACK MOTOR OVERLOAD

CASE-3

9.11

DRIVE MOTOR TEMPERATURE TRIP

9.4

HYDRAULIC TEMP. HIGH / FILTER


CLOGGING

80

9.5

DRIVE MOTOR OVER LOAD (110%)

990A

9.1

HYDRAULIC PRESSURE LOW ALARM

9.2

9.6

TT ECU POWER FAILURE


ALARM

CASE-2

CASE-11

CONFIRMATION
C/R

FREQ.
OF
TEST
(Months)

DNV

(CAUSE
(CAUSE IND.) IND.)
R:
FLICKER
Z : SOUND

CASE-5

W/H

REMARKS

SWITCH OFF
POWER SUPPLY (AC
&DC)
IN DISTRIBUTION
BOARD

DOCUMENT PREPARED BY ABG SHIPYARD

PAL :
BLINKING
Z:
SOUND
EXT:
PAL :
BLINKING
Z::

24

11. MISCELLANEOUS TEST FOR OTHER AUX.MACHINERY

ITEM
NO :

ITEM

DESIGN

C/R
No.1

RUNNING

CASE 7
No.2

10.1

MAIN AIR
COMPR.

AIR HIGH
TEMP.
ABNORMAL
STOP

AUTO
START

75 deg.C

No.1

Kg/cm

START
G : ON

MAIN AIR
COMPRESSOR
NO. 1~2
ABNORMAL

EXT. B :
FLICKER
Z : SOUND

Confirm Air.
Comp.
Stopped
Automatically.
6

Confirm the
change over
switch in auto
position

START G :
ON
CASE 1
CASE 9

Kg/cm2
29 or 30

FREQ OF
TEST
DNV
(Months)

W/H

21 or 22

15
PPM

Remarks
(NORMAL)

R : FLICKER
Z : SOUND

No.2

No.2
OILY
CONTENT
HIGH

CASE 2

No.2

AUTO STOP

OILY BILGE
SEPARATOR

No.1

No.1

10.2

CONFIRMATION

TEST METHOD
OR OPERATION

STOP R :
ON

CASE 4

Confirmed
Bilge pump
stop
automatically

DOCUMENT PREPARED BY ABG SHIPYARD


25

ABG
11. MISCELLANEOUS TEST FOR OTHER AUX. MACHINERY

CONFIRMATION
ITEM NO :

10.3

10.4

ITEM

DESIGN

Kg/cm
22

HP CUTOUT

L.P. CUTOUT

Kg/cm
0.8

PROV.
REFRIGERATOR

TEST METHOD
OR OPERATION

C/R

FREQ OF
TEST
(Months)

DNV

W/H

CASE 1

AC PLANT FAILURE

(CAUSE IND.)
R : FLICKER
Z : SOUND

10.5

Remarks

TRU 1 FAILURE

(CAUSE IND.)
PAL:
BLINKING
Z : SOUND
EXT.

10.6

TRU 2 FAILURE

10.7

EMERGENCY LIGHTING BATTERY


CHARGER FAILURE

10.8

DG-1 24V MAIN SUPPLY FAILURE

10.9

DG-1 24V MAIN SUPPLY FAILURE

CASE 10

DOCUMENT PREPARED BY ABG SHIPYARD

PAL:
BLINKING
Z : SOUND

26

ABG

11. MISCELLANEOUS TEST FOR OTHER AUX. MACHINERY

CONFIRMATION
ITEM NO :

ITEM

DESIGN

TEST METHOD
OR OPERATION

Remarks
C/R

10.10

10.11

EMERG.DGSTART BATT.CHARGER
FAILURE
BULK HANDLING
SYSTEM ALARM

CASE 10

(CAUSE IND.)

CASE 5

PAL:
BLINKING
Z : SOUND

No.1
No.2
(CAUSE IND.)

10.12

10.13

10.14

RADIO GMDSS BATT.CHARGER


FAILURE
GAS DETECTION POWER FAILURE

NAV.LIGHTS PANEL POWER FAILURE

W/H

CASE 10

R : FLICKER
Z : SOUND

FREQ OF
TEST
(Months)

DNV

EXT.
PAL:
BLINKING
Z : SOUND

CASE 10

10.15

FIRE ALARM PANEL POWER FAILURE

10.16

PMS MAIN SUPPLY FAILURE

10.17

CO2 SYSTEM VALVE OPEN

CASE 11

DOCUMENT PREPARED BY ABG SHIPYARD


27

ABG

11. MISCELLANEOUS TEST FOR OTHER AUX. MACHINERY


CONFIRMATION
ITEM NO :

ITEM

DESIGN

10.18

AUTO PILOT OFF COURSE ALARM

10.19

POSCON JOYSTICK FAILURE

10.20

GYRO COMPASS POWER FAIL

10.21

SEWAGE PLANT FAILURE

10.22

ENGINE ROOM
SUPPLY FAN FAILURE

TOILET
EXH.FANSTARTER
FAILURE

CASE-10

GALLEY EXH. FAN


STARTER FAILURE

OVELOAD

10.25

B.T. SUPPLY FAN


STARTER FAILURE

OVELOAD

10.26

10.27

10.28

10.29

BOSON STORE
SUPPLY FAN
STARTER
FAILURE
CEMENT ROOM
SUPPLY FAN
STARTER
FAILURE
S/GEAR ROOM
SUPPLY FAN
STARTER
FAILURE
EME.DG ROOM
SUPPLY FAN
STARTER
FAILURE

(CAUSE IND.)

(CAUSE IND.)

R : FLICKER
Z : SOUND

PAL:
BLINKING
Z : SOUND

OVELOAD

10.24

OVELOAD

OVELOAD

OVELOAD

OVELOAD

W/H

CASE-10

No.2
10.23

DNV

CASE-10
-

OVELOAD

C/R

FREQ OF
TEST
(Months)

CASE-11
-

No.1

TEST METHOD
OR OPERATION

Remarks

EXT.
PAL:
BLINKING
Z : SOUND

CASE-5

DOCUMENT PREPARED BY ABG SHIPYARD

28

ABG
11. MISCELLANEOUS TEST FOR OTHER AUX. MACHINERY

ITEM NO :

ITEM

DESIGN

CONFIRMATION

TEST METHOD
OR OPERATION

Remarks
C/R

RUNNING

No.1

No.1

CASE 7

CASE 5

No.2
10.30

STEERING
GEAR

LOW
VOLTAGE

PHASE FAIL

No.1

G : ON

(CAUSE IND.)
-

CASE 10

DISCONNECT
PHASE

CASE 3

No.2
No.1
No.2

HYD. OIL TK.


LOW LEVEL

No.1

DNV

(CAUSE IND.)

No.2
OVERLOAD

W/H

FREQ OF
TEST
(Months)

R: FLICKER
Z: SOUND

DOCUMENT PREPARED BY ABG SHIPYARD

PAL:
BLINKING
Z : SOUND
EXT.
PAL:
BLINKING
Z : SOUND

29

ABG
12. MISCELLANEOUS TEST FOR MAIN ENGINE PUMPS
1) PUMP RUNNING AND ABNORMAL TEST
CONFIRMATION

ITEM NO :

ITEM

DESIGN

TEST METHOD
OR
OPERATION

ABNORMAL STOP
STBY

RUN
C/R

11-1-1

11-1-2

11-1-3

11-1-4

11-1-5

W: ON

G: ON

No.2

W: ON

G: ON

Fuel oil P/P


Tripped
R: FLICKER
Z : SOUND

No.1

W: ON

G: ON

S.W. COOLING P/P


STOP

W: ON

G: ON

R : ON

No.1
M/E F.O
FEED PUMP
M/E SEA
WATER
COOLING
STBY PUMP

No.1
M/E PRE
LUB.PUMP

M/E F.O. OIL


BOOSTER
P/P

No.2

No.1
M/E JACKET
WATER
MODULE

No.2

No.2

CASE 5
CASE 7

W: ON

G: ON

W: ON

G: ON

W: ON

G: ON

W: ON

G: ON

M/E L.O.PRIMING
P/P.STARTER
FAILURE
R : FLICKER
Z : SOUND

W/H

FREQ
OF
REMARKS
DNV
TEST
(Months)

Fuel oil P/P


Tripped
R: FLICKER
Z : SOUND
EXT.
Z: SOUND

M/E L.O.PRIMING
P/P.STARTER
FAILURE
R : FLICKER
Z : SOUND

EXT.
Z: SOUND

Confirm
that the
motor is
stopped
in
abnorma
l stop

M/E JACKET
M/E JACKET WATER
WATER PREHEATER PREHEATER
FAILURE
FAILURE
R : FLICKER
R : FLICKER
Z : SOUND
Z : SOUND

EXT.
Z: SOUND

(P)
(S)

W: ON

G: ON

W: ON

G: ON

F.O. BOOSTER P/P


RUNNING ALARM
R : FLICKER
Z : SOUND

DOCUMENT PREPARED BY ABG SHIPYARD

F.O. BOOSTER P/P


RUNNING ALARM
R : FLICKER
Z : SOUND

EXT.
Z: SOUND

30

ABG
13.

MISCELLANEOUS TEST FOR OTHER PUMPS


1)
PUMP RUNNING AND ABNORMAL TEST
CONFIRMATION
ITEM
NO :

12-1-1

ITEM

RED.GEAR
LUB.OIL
STBY PUMP

DESIGN

CASE 5

No.1
No.2

TEST METHOD
OR
OPERATION

CASE 7

STBY

ABN.
STOP

RUN

W: ON

G: ON

W: ON

G: ON

G/B.ST-BY
LUB.OIL
P/P
G : OFF

REMARKS
W/H
Confirm that
the motor is
stopped in
abnormal
stop

FREQ OF
TEST
(Months)

DNV

DOCUMENT PREPARED BY ABG SHIPYARD


31

ABG
14.

MISCELLANEOUS TEST FOR PUMPS


2)

PUMP AUTO START & STOP TEST

ITEM NO :

12-2-1

12-2-2

12-2-3

DESIGN

ITEM

FRESH WATER
HYDROPHORE
PUMP

TEST METHOD
OR
OPERATION

CONFIRMATION
REMARKS

FREQ OF
TEST
(Months)

DNV

E/S

AUTO-START

1.8 Kg/cm

G : ON
By press. Switch of F.W.
PRESSURE SWITCH OF
TK.

3.2 Kg/cm2
AUTO-STOP

SEA WATER
HYDROPHORE
PUMP

AUTO-START

1.8 Kg/cm2

AUTO -STOP

3.2 Kg/cm2

FRESH/SEA
WATER
HYDROPHORE
PUMP

AUTO-START

1.8 Kg/cm2

AUTO -STOP

CASE 1
CASE 7

G : ON

G : ON

3.2 Kg/cm2

DOCUMENT PREPARED BY ABG SHIPYARD

32

ABG
15.

ALARM TEST FOR TANK LEVEL


ITEM
NO.

ALARM
ITEM

DESIGN
HIGH

13.1

BILGE HOLDING TANK

13.2

SEWAGE TANK

13.3

SLUDGE TANK

13.4

E.R.BILGE AFT (P)

13.5

E.R.BILGE AFT (S)

13.6

E.R.BILGE FWD (P)

13.7

E.R.BILGE FWD (S)

LOW

13.11

B/T ROOM BILGE LEVEL

13.12

M/E EXPANSION TANK

13.13

EME. GEN. F.O. DAY TK LEVEL

13.9
13.10

CONFIRMATION
C/R

W/H

(CAUSE
IND.)

(CAUSE
IND.)

R:
FLICKER
Z:
SOUND

PAL:
BLINKING
Z:
SOUND

CASE 3

STGR. ROOM BILGE


CEMENT TK.ROOM BILGE
LEVEL (S)
CEMENT TK.ROOM BILGE
LEVEL

13.8

TEST
METHOD
OR
OPERATION

DOCUMENT PREPARED BY ABG SHIPYARD

PAL:
BLINKING
Z:
SOUND

REMARKS FREQ. OF
TEST
(Months)

DNV

33

ABG
16.

ITEM
NO.

ALARM TEST FOR PMS

DESCRIPTION

DESIGN

DELAY
(SEC.)

ALARM FEEDER
TRIP

BRKR.
TRIP

TEST
METHOD
OR
OPERATION
CASE 17(1)

14.1

DG REVERSE POWER

-5%

14.2

DG PREF.TRIP (CURRENT)

95%

14.3

DG OVER CURRENT

14.4

DG OVER CURRENT INVERSE

14.5

DG VOLTAGE HIGH

110%

ALARM
TRIP

14.6

DG VOLTAGE LOW

ALARM
TRIP

14.7

DG FREQUENCY
HIGH

ALARM
TRIP

14.8

DG FREQUENCY
LOW

ALARM
TRIP

CONFIRMATION
C/R

W/H

FREQ.
OF
REMARKS TEST
(Month
s)

DNV

MSB
MSB
ABNORMAL ABNORMAL

CASE 17(2)

103%

10

105%

85%

10

75%

0.5

CASE 17(3)

CASE 17(4)

103%

10

105%

97%

10

95%

R:
FLICKER
Z : SOUND

PAL:
BLINKING
Z:
SOUND
3

CASE 17(5)

PAL:
BLINKING
Z:
SOUND

CASE 17(6)

14.9

DG OVERLOAD

110%

14.10

DG SYNCH.FAIL

60

CASE17(2)
CASE 17(7)

DOCUMENT PREPARED BY ABG SHIPYARD


34

ABG

17. ALARM TEST FOR PMS

ITEM
NO.

DESCRIPTION

DESIGN

DELAY ALARM
(SEC.)

FEEDER
TRIP

BRKR.
TEST
TRIP
METHOD OR
OPERATION

14.11

DG CB ON FAILURE

14.12

DG CB OFF FAILURE

14.13

DG CB POSITION FAILURE

CASE 17(10)

14.14

DG PHASE SEQUENCE ERROR

CASE 17(11)

14.15

DG GOV.REGULATOR FAILURE

CASE 17(12)

14.16

DG n PPU BATTERY VOLTAGE


LOW

<18V

CASE 17(13)

14.17

DG NOT READY FOR PMS

CASE 17(14)

14.18

DG START FAILURE

CASE 17(15)

14.19

DG BREAKER TRIP

CASE 17(16)

14.20

EARTH FAULT 440V

CASE 17(17)

14.21

EARTH FAULT 230V

100%

10

14.22

DG PREF.TRIP (LOAD)

CASE 17(8)

CONFIRMATION
C/R

W/H

MSB ABNORMAL

MSB
ABNORMAL

FREQ.
OF
REMAR TEST
KS
(Month
s)

DNV

CASE 17(9)

PAL:
BLINKING
Z :SOUND

(CAUSE IND.)

(CAUSE IND.)
R :FLICKER
Z :SOUND

DOCUMENT PREPARED BY ABG SHIPYARD

R : FLICKER
Z : SOUND

PREFRENTIAL
TRIP
CASE 17(2)

EXT.
PAL
BLINKING
Z :SOUND

PREFRENTIA
L TRIP
(CAUSE IND.)
PAL :
BLINKING
Z :SOUND
EXT:
PAL
BLINKING
Z :SOUND

35

ABG
18. SYSTEM ALARM TEST
ITEM
NO.

DESCRIPTION

DESIGN

DELAY
(SEC.)

ALARM FEEDER
TRIP

BRKR.
TRIP

15.1

ECR HMI COMM.ERROR

180

15.2

BRIDGE (FWD) HMI


COMM.ERROR

180

15.3

BRIDGE (AFT) HMI


COMM.ERROR

180

15.4

CH.ENGR.HMI COMM.ERROR

180

15.5

180

ND

ENGR.HMI COMM.ERROR

15.6

REC.ROOM HMI COMM.ERROR

180

15.7

MESS ROOM HMI


COMM.ERROR

180

15.8

PMS PLC COMM.ERROR

300

15.9

ECR SCADA COMM.ERROR

180

TEST
METHOD OR
OPERATION

CASE 10

CONFIRMATION
C/R

W/H

(CAUSE
IND.)

(CAUSE
IND.)

R:
FLICKER
Z:
SOUND

PAL :
BLINKING
Z:
SOUND

REMARKS

FREQ.
OF TEST
(Months)

DNV

PAL
BLINKING
Z:
SOUND

DOCUMENT PREPARED BY ABG SHIPYARD


36

ABG
19. FIRE ALARM SYSTEM TEST
ITEM
ITEM
NO.

DETECTOR
ZONE NO.

ZONE NAME

WHEEL HOUSE

2, 3

UPPER F'CLE DECK

4,5,14

F'CLE DECK

6,7,8,9

GALLEY, PASSAGE, HOSPITAL,


DKSTORE,EME. DG.ROOM,ETC.
(MAIN DECK)

11

BELLS

1
2
2+ 1 HF

MANUAL
CALL
POINTS

TEST METHOD
OR OPERATION

C/R

10

ECR

3
4
CASE 13
1) CONFIRM
WORKING OF
ALL DETECTOR
A BY
SMOKE & B by
HEAT

11,12

ENGINE ROOM

13

15

STEERING GEAR & CEMENT ROOM

2 HF

B.T. COMPARTEMENT

1 HF

NOTE : A = SMOKE DETECTOR

B = HEAT DETECTOR

3 HF

W/H

FREQ. OF
TEST DNV
(Month
s)

16.1
1HF

CONFIRMATION

(FIRE
DETECT
REPEATER ION
MAIN
PANEL
PANEL)
(ECR)

R : FLICKER R : ON
Z : SOUND Z :
SOUND

C = EXPLOSION PROOF DETECTOR

HF=HORN+FLASHER

DOCUMENT PREPARED BY ABG SHIPYARD

37

ABG
20. DEAD MAN ALARM

ITEM
NO :

ITEM

DESIGN

CONFIRMATION

TEST METHOD
OR OPERATION

REMARKS
C/R
PRE WARNING
INDICATED IN
ENGINE ROOM
+
3 MINUTES

17.1

DEAD MAN ALARM

Minutes 27

CASE 16
DEAD MAN
ALARM
R ; FLICKER
Z : SOUND

W/H

FREQ OF
TEST
DNV
(Months)

DEAD MAN ALARM


PAL : BLINKING
Z : SOUND
EXT.

Alarm sound followed


by Engineers call after
3 minutes

DEAD MAN ALARM


PAL:BLINKING
Z : SOUND

DOCUMENT PREPARED BY ABG SHIPYARD


38