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STEERING GEAR CHECK LISTS

STEERING GEAR CHECK LISTS

CHEVRON OREGON CLASS


(ARIZONA, COLORADO, WASHINGTON)

JOHN YOUNG CLASS


(ALTAIR, CAPELLA, CYGNUS, ORION, SIRIUS, VIRGO)

FRANK A. SHRONTZ CLASS


(ANTARES, GEMINI, PHOENIX, REGULUS,)

ANGELICOUSSIS CLASS
(ANTONIS I., MARIA A.)

DYNAMIC VISION CLASS


(DYNAMIC ENERGY)

NEPTUNE VOYAGER CLASS


(STELLAR, VEGA)

APPENDIX I STEERING GEAR CHECK LIST CHEVRON OREGON CLASS

STEERING GEAR CHECK LIST WATCH DUTIES AT SEA - SHIP'S CREW Wheelhouse Equipment I. 2. 3. Check the rudder angle indicator activity while on Gyro Mode. Check the ship's rate of turn indicator activity and the right direction of turn. Check the course and the rudder angle tracks on Ship's Course Recorder. (They should not be completely straight lines. Their pattern should be used to adjust the automatic pilot parameters to attain the optimum of steering performance). Check that: a. The luminous legend marking on Steering Console and Electric Steering Stand. b. The alarm lamps and light indicators are all functioning.

Steering Gear Flat Equipment 5. 6. Check the carrier bearing for unusual localized high temperature and unusual noise. Check the operating temperature of the system by feeling the casing and discharge piping of the running pump. The temperature should not exceed 160F. Check for signs of hydraulic fluid leakage from hydraulic cylinders' packing gland and cylinder body end seals, and from the whole double dual pump hydraulic power pack. Listen to pump and motor while operating for unusual localized noise. Feel motor end bell housing close to shaft for bearing heat.

7.

8.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY EACH WATCH Date _____________________ SHEET 1 OF 2

9. 15 15

Check pump and motor mounting bolts for signs of working. Check oil level in port and starboard steering pump sumps. Check for any signs of damage, looseness of lock devices on port and starboard rudder repeat back matching linkage, and for any loose or broken rudder gland studs.

NOTE: 1. Use greases, hydraulic oils and lubricating oils specified on vessel's lubrication chart.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY EACH WATCH Date _____________________ SHEET 2 OF 2

STEERING GEAR CHECK LIST PRIOR TO DEPARTURE - SHIP'S CREW Steering Gear Flat Steering Dual Pumps and Motors Test 1. With Port (EKI) and starboard (DB6) Steering Gear circuit breakers closed note that Power Available" lamp is illuminated on port and starboard pump starter. Bridge will start and test port and starboard units. Check for unusual noise from motor bearings, pump coupling, dual pump casing of both hydraulic power units. In cold weather condition, turn "ON the steering flat heating system and keep one pump running prior to departure for the time required to warm the oil to 68F/86F. Greasing required on a weekly basis.

2.

3.

4.

Wheelhouse Equipment Communication Means 1. Thoroughly test all communication systems and signals, including alternate communication methods such as radios. This also includes Gyro repeater on steering flat. Rudder Angle Indicators 2. Check the rudder angle indicators (3 in total) of the NAVIGATING BRIDGE in relation to the actual position of the rudder per mechanical rudder indicator. Also, check that the rudder angle is correctly being recorded on the ship's recorder.

Steering Console Operation 3. Check that both port and starboard control POWER AVAILABLE, MODE, SYSTEM and STATION legend markings are illuminated. Make certain that power is available at the rudder angle indicating system (switch No. 6 in Navigation Power Panel 1P1A).

4.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PRIOR DEPARTURE Date _____________________ SHEET 1 OF 4

5.

Place the STATION switch in "Console". Rotate the Mode switch through each position. Note that NFU, LVR Pilot, Gyro Pilot legend markings illuminate. Also, note feel of switch. It should snap in each detent position. Rotate the STATION switch through each position. Note that CONSOLE, PORT LEVER STR, STARBOARD LEVER STR, ELECTRIC STAND legend markings illuminate. Also, note feel of switch. It should snap in each detent position. Place the System Selector switch to Port and check that PORT, PORT PUMP ON legend markings illuminate. Position station switch in "Console" and Mode switch to NFU. Make certain the 35/45 key-operated switch is on 45 position. Operate the non-follow-up controller alternately between 45 hard-over port and 45 hard-over starboard. Observe rudder movement on the rudder angle indicator. Check that the 35/45 electrical overtravel limit switches stop the rudder at 35 and 45 respectively (a stuck open 45 limit switch, invalidates all steering modes of the affected system from the Bridge and Aft Station). With Master Gyrocompass operating, mode switch on Gyro and rudder amidships, make certain that heading pointer and lubber line are lined up. Operate the Heading Order control to select a new heading. With the ship docked check that the rudder turns in the direction that would cause the vessel to turn to the new heading. Check, also, that the rudder stops at 15 inside angle limit, set by the Rudder Limit potentiometer, in each direction (15 limit is sufficient). Restore the heading pointer in line with the lubber line. The rudder should return to amidships. Check, that the repeater heading dial is synchronized with the Master Gyro compass. (If correction is necessary, check the repeater step motor for freedom using the synchronized knob. A stuck motor at 5 degrees, for example, would prevent the OFF-COURSE ALARM set at 7 degrees from alarming while on Gyro mode). Gyro Off-Course Alarm

6.

7.

8.

9.

10.

11.

12.

With the Gyrocompass operating and the Course Order control set at Gyro- compass reading, place the Alarm Set Control in TEST to simulate an alarm condition and check that the alarm light (located under the reset switch) flashes. Then press the reset switch and note that the alarm light stops flashing, but continues to illuminate. Reset the alarm set control from TEST position to approximately 7 and note that the light goes out.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PRIOR DEPARTURE Date _____________________ SHEET 2 OF 4

13

Check that the NFU controller overrides the Gyro and Hand mode. With either mode selected, position the NFU handle as necessary to gain control of the rudder. The rudder will respond to operation of the NFU controller until the handle is held in same position. Once released, the preselected mode will automatically take over. NOTES 1. Only the NFU controller on the console overrides any mode and any station in the Wheelhouse. The two neon lamps on the directional servo-amplifier cards light up one at a time respectively for port and starboard direction. The two neon lamps on the dual flow servo-amplifier card light up simultaneously over 5 rudder order. Operating NFU controller, the two neon lamps of the directional servo-amplifier card light up simultaneously, regardless the direction.

2.

3.

4.

14.

Place the Mode switch to Lever Pilot and check the operation of the Lever Pilot both in HAND and AUTO mode: a. Lower the steering lever to the HAND position. Move the lever alternately in each side to operate the rudder in the Follow-up mode. Observe smooth response of the rudder on the rudder angle indicator. Raise lever to AUTO POSITION. Turn the COURSE TRIM control by 5 alternately in each side and check that the rudder moves in the direction that would cause the vessel to turn to the new heading. Return the rudder amidships. With the lever raised to its extreme upper position, move it alternately right and then left. Check that the rudder stops at 15 inside angle limit in each side (full throw of the lever, from amidships to the hard over left or right, represents a course change of 40 degrees). Electric Steering Stand Operation

b.

15

Place the STATION switch in ELECT STAND. Select the HAND mode on the steering stand. Check that Fort Power Available", "Starboard Power Available", Port Pump On" and "Hand" legend markings are illuminated. a. Hand Operation: With the Mode switch in HAND, insert the rudder order by the wheel to operate with FOLLOW-UP, and swing the rudder between left and right side. Observe smooth response of the rudder on the rudder angle indicator.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PRIOR DEPARTURE Date _____________________ SHEET 3 OF 4

b.

NFU Operation: Place the Mode switch in NFU. Operate the NFU controller alternately between port and starboard. Observe rudder movement on the rudder angle indicator.

NOTES: 1 This NFU is not provided with override feature.

2. While operating Mode switch and NFU lever, note feel of switch. They should snap in each detent position. Lever Steerer Operation (Port and Starboard) 16. Place station switch to Port Lever Steerer. Move lever alternately between port and starboard. The rudder will swing in the follow-up mode. check the smooth movement of the rudder in the Bridge Wing rudder indicator. Switch the Station switch to Starboard Steerer and repeat the same test.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PRIOR DEPARTURE Date _____________________ SHEET 4 OF 4

STEERING GEAR CHECK LIST PRIOR TO ARRIVAL - SHIP'S CREW

Wheelhouse Equipment 1. Check that the luminous legend markings on Steering Console and Steering Stand, and the indicator and alarm lamps on the Annunciator Panel illuminate according to the prevailing conditions both for the running and the stand-by unit. Test each steering station namely: Steering Console, Steering Stand, Port and Starboard Lever Steerer, by swinging the rudder between port and starboard on NFU and/or Followup mode as appropriate in accordance with the mode-availability of each station. In conjunction with above test No. 2, check the rudder indicators on the Bridge in relation to the actual position of the rudder per mechanical rudder indicator in the steering flat. NOTES 1. Above tests prior to arrival are to be carried out consistent with vessel safety.

2.

3.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PRIOR ARRIVAL Date _____________________ SHEET 1 OF 1

STEERING GEAR CHECK LIST 6 MONTHS - SHIP'S CREW Wheelhouse Equipment Steering Console and Steering Stand 1. Check synchros, step motor, and synchros overtravel mechanical stops for looseness of mounting screws. Check pin springs, fastening the pinions and wheels on their shafts along the gear train, are not partially dislodged. Check condition of the gear train teeth.. Listen to any,unusual localized noise while rotating the helm unit. Check wire terminals for looseness without pulling the wires. Check the five (5) fuses of the steering console for correct values: Two 5A, two 2A, one IA.

2.

3.

4. 5.

Steering Gear Flat Equipment Dual Pump Motor Starter (Port & Starboard) 6. Trip both circuit breakers, EKI and MCC "E" Board and DB6 on MCC 'D' Board. Place "Warning Tag" on each breaker. "Circuit Breaker Open" and Control Power Failure" visual and audible alarms should go on for port and starboard hydraulic power unit, in Wheelhouse, PCC and Steering Flat. Secure local isolator switch and open starter door on both controllers. Megger starter, control circuit, and motor. Port or Starboard

Date

Control Circuit

Motor

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY 6 MONTHS Date ___________________ SHEET 1 OF 3

7.

Check contactor pressure of the contacts by pushing in slowly on the armature until it bottoms. Be sure it seals against the stationary frame. Release and allow to snap back. The armature should not bind. (Excessive gap between armature and stationary frame causes the coil to draw more current due to lower impedance, which would overheat it in a short time.) Check the arc shield for burned through blowout fins, the surface of the contacts, and contacts alignment. The main contactor contacts are silver plated and should be renewed only when the silver coating has been penetrated. Do not attempt to file them. The silver oxide is self reducing. Check contact spring tension. Contact heating may draw the temper of the spring and reduce the pressure of contacts in the closed position. Check four fuses for correct value. They should be two 6A and two 8A. Check for clip tension by removing and replacing fuses in their clips. Look for discolored fuse clips and fuse and caps (poor contact pressure causes often premature blowing of fuses). Do not polish silver plated clips and caps. Inspect wires for loose connections (do this by tightening the securing devices, not by moving the wires) and for any sign of deterioration of the insulation. Look at each wire terminal for sign of excess heat particularly that of the overload heater element. Inspect mechanical parts for damage and loose screws, bolts. Select AFT STEERING STATION and assure rudder is amidships. Close the circuit breaker and the isolater of the starter being observed. Activate the controller. Watch main contactor armature. It should seal shut with no chatter or bounce. Check amperage is balanced in all three phases. Dual Pump Motor (Port & Starboard)

8.

9.

10.

11.

12.

13.

Check motor heater strip input current by the tong meter. The reading should be approximately 0.5A. Co-ordinate this test with requirement 12 of this list. Steering Dual Pump Sumps Hydraulic Oil

14.

Drain small quantity of oil from each sump tank, examine for discoloration and contamination. Carry out the Millipore test. Send a sample for analysis. Dual Pump Sumps Hydraulic Oil Reserve

15.

Check that sufficient reserve oil for the dual pump sumps is being kept in the reserve tank. Filling hose should be kept well stowed and in sound condition.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY 6 MONTHS Date ___________________ SHEET 2 OF 3

Rudder Angle Repeatback Box (Port & Starboard) 16. Check repeatback box is in full working order. Inspect for proper mesh, evidence of wear and backlash of pinion and wheel teeth. Check both gear shafts end play. Make sure pins fastening the gears to the shafts are not partially dislodged. Check the gear and cam setscrews for looseness, the micro-switches for freedom. Look for loose wire connections by tightening the securing devices, not by moving the wires, and the wire insulation for sign of deterioration. While checking the starboard repeatback box, grasp the rudder angle transmitter synchro and check for any looseness in mounting. Inspect the teeth of the synchro drive gear for sign of sear and the gear set screw for looseness. Check the Rudder Angle Repeatback box driving linkages for any lost motion. Steering Flat Housekeeping 17. The steering flat sometimes turns into a convenient place for temporary storage of material but then it becomes a storeroom. Extra spaces can be utilized as that but it must be done neatly and safely. Everything should be secured and all aisles should be open. The operating instruction board should be kept legible. Also, the deck, ladders, and platforms should be kept clean and in sound condition.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY 6 MONTHS Date ___________________ SHEET 3 OF 3

STEERING GEAR CHECK LIST 3 MONTHS - SHIP'S CREW Hand Pump Steering 1. Reduce ship's speed below 8 knots or less. Position rudder to amidships, and set the rudder 10 degrees in each direction. Record the maximum pressure reached, and the number of crankings to swing the rudder to 10 degrees (it should be a minimum of 850 psi). Date Pressure Crankings

Working Cylinders All 1&3 2&4

Valves To Be Closed A-B-C-D-G-K A-B-C-D-G-H-J A-B-C-D-E-F-K

Valves To Be Open E-F-H-J-L-M E-F-K-L-M G-H-J-L-M

Emergency Two-Cylinder-Group Operation 2. Reduce ship's speed below 8 knots or less. Position the rudder amidships prior to the test. Set up steering gear shut-off valves per following table in accordance with the selected emergency condition. Test the rudder response time.

Working Cylinders 1&3 2&4

Valves To Be Closed G-H-J-L-M E-F-K-L-M Hydraulic Piping Shut-off Valves

Valves To Be Open A-B-C-D-E-F-K A-B-C-D-G-H-J

3.

Operate all shut-off valves checking free operation from open to close. Co-ordinate this test with requirement of following test No. 25. CAUTION: Close cylinder valves J - H before exercising by-pass K and cylinder valves E - F before checking by-pass G. Close by-pass valve before opening cylinder valves.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY 3 MONTHS Date ___________________ SHEET 1 OF 2

Hydraulically Locking of Rudder 4. Reduce the speed to 8 knots or less. Position the rudder amidships prior to the test. Stop the steering pump. Check that the rudder is being held in position. If it does not, close the shut-off valves E-F-J-H. Rudder Stock Ground Wire 5. Check for effective electrical bond between rudder and ship's hull. Securing Devices and Seating Racks of Hydraulic Tubings and Main Hydraulic Lines 6. While underway, carefully examine main hydraulic lines and hydraulic tubings such as those for the hydraulic actuators, cylinder pressure gauges, cylinder air escape, sensors, drains, etc., for soundness and tightness of their supports/clamps and for any situation where tubings and/or pipes chafe or abrade each other. Concentrate on checking for pipes and tubings working in support clamps. Securing Devices of Hydraulic Cylinder Clevis and Rodeye 7. Check on each cylinder the clevis pin lock plate device for looseness of keeper screws,, and the rodeye welded steel plates in way of piston rod flats for soundness. Rudder Time Response 8. Check the response time, at 8 knts. by swinging the rudder from 35 left to 35 right and vice-versa, timing from 35 to 30. The time in any case should not exceed I second for every 2 1/3. which means it should not take more than 28 seconds from 35 left to 30 right (Minimum Average Rudder Rate 2.6/second-One Pump).

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY 3 MONTHS Date ___________________ SHEET 2 OF 2

STEERING GEAR CHECK LIST PERIODIC OVERHAUL - SHIP'S CREW Steering Gear Flat Equipment Hydraulic System Valve Handles 1. Check that plug or cock valves that have detachable handles or wrenches are supplied with an individual operating handle or wrench secured in an obvious, easily accessible location. Hydraulic System Valve Color Codings 2. Check that all valve operating wheels and top works are color coded to show normal at sea operating positions. Valves normally open at sea are to have green wheels, valves normally closed at sea are to have red wheels and valves that can be either open or closed are to have neutral color. The color code is to be posted in normal size letters on the operating instruction board. Dual Pump Motor A.C. Starter (Port & Starboard) 3. Check that a wiring diagram combined with a simplified/elementary drawing of the pump motor starter is posted on the inside of the starter box front door. Also, check that all the electrical components inside the starter box have the same designations as those shown on the wiring diagram. Hydraulic Sumps Oil Renewal 4. Drain and replace all hydraulic fluid in one sump. Clean tank before new fluid is added. The tank should be filled through a 20 micron filter. Clean or replace the suction filter. Purge the power unit of any entrapped air. Send sample for analysis. Inspect reserve tank for cleanliness condition. Port Date drained and refilled Starboard

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 1 OF 10

NOTES 1. The work in this list is to be done in addition to six months crew list during periodic overhaul. Use greases, lubricating oils and hydraulic oils specified in vessel's lubrication chart. STEERING GEAR CHECK LIST DRYDOCK - VENDOR Electronic Equipment Rudder Angle Indicators 1. Remove cover from 4 indicators in Wheelhouse, smell interior for odor of overheated insulation. Check terminals for tightness. Replace cover. Energize system and check rudder angle system at 5 intervals against mechanical rudder angle indicator in steering gear room. Rudder Angle Transmitter (In Starboard Repeatback) 2. Cut out power switch No.6 in Navigation Power Panel 1P1A Remove cover from Starboard Rudder Repeatback Box. a. b. c. d. e. f. g. h. i. j. k. Condition of slip rings and brushes. Clean as necessary. Insulation resistance. Terminal board for loose wire terminals. Supply voltage fluctuation should not be more than 10%. Bearings of the generator for feel of roughness. Gear teeth for proper mesh, evidence of wear, lack of lubrication. Gear set screws for looseness, pin springs for dislodging. Cover gasket. Renew if necessary. For any loosing in mounting by grasping the transmitter generator. Clearance between case and driving shaft. Transmission linkage for lost motion.

2.

Replace cover. Energize the system and check rudder angle system at 5 intervals against mechanical rudder angle indicator in steering gear room. VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________ FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 2 OF 10

Universal Sperry Gyropilot Computer Electronic Modules' Input and Output Tests 3. Two Simpson model 260 multimeters or equivalent are required for the following tests. Before proceeding, position the rudder amidships; select the steering console station; tag and remove the leads to terminals 3 & 4 of TB6 to disconnect the power to both port and starboard directional valve solenoids. Ascertain that ship's power (115 VAC) is supplied to terminals #1 & #2 of TBI, TE3 and TB6. Perform, in configurations except as noted:

Power Supply Module A1 Step I - Ascertain that the input voltage between terminals TP3 and TP4 of negative supply channel and TP5 and TP6 of positive supply channel is 20 VAC 10%. Step 2 - Check that the regulated output voltage is +15 VDC between terminals TP2 and TP0 and -15 VDC between TP and TPO. Adjust potentiometer R9 for a +15 volt reading and potentiometer RI0 for a -15 volt reading, if it is necessary. Seal the adjustment screw with glyptal. Pilot Watch Alarm Module A2 Step 3 - With system in Gyro mode, set the off course alarm set point at 5 and insert a course error of 10. Check that the.alarm system is being activated after a preset time delay. Test with opposite polarity error signal. Repeat the tests with the mode switch positioned to Lever Pilot. Check that the alarm system is being triggered when the alarm set point is being exceeded. Step 4 - If the required alarm response is not observed in Step 3, for both Gyro and Lever Pilot Auto position, verify the following conditions for the internal circuits of the module: a. b. c. d. e. Measure +15 volts d-c at test point TPI. Measure -15 volts d-c at test point TP2. Measure 0.2 to 1.0 volt/degree (the uncalibrated course error input) at test point TP3. Measure 10 volts d-c at test point TP4 by inserting a course error of 10 degrees (calibrated course error input voltage, 1 volt/degree). With a course error exceeding the offcourse alarm set point, measure -12 volts d-c (or greater) at the output test point TP7.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 3 OF 10

If the input voltage corresponding to 10 course error signal is present at TP3 and confirmed at TP4 whereas a positive voltage is measured at TP7, the module is faulty. Test with opposite polarity error signal. Dual Demodulator Module A3 Step 5 - Check that the reference input voltage reads 115 VAC between test points TP5-TP6. Step 6 - Check the voltage gain of channel 1 (Gyro signal). Insert a 10 error signal by the Course-Selector knob. Check that the output voltage at test points TP3-TP4 results into the ratio of .4 VDC/1 volt AC with the input signal at test points TPI-TP2. Check the Voltage gain of channel 2 (Steering Stand Helm Signal). Insert a 10 error signal by the wheel. Check that the ratio between output/input signal voltages falls within .4VDC per volt AC input, respectively at test points TP9, TPI0, TP7 and TP8. NOTE: When input signal from TPI and TP2 is in phase with reference voltage from TP5-TP6, the output voltage at TP3 is positive with respect to TP4. When input signal from TP7 to TP8 is in phase with reference voltage from TP5 to TP6, the output voltage at TP9 is positive with respect to TPI0.

Step 7 - If the required output response is not observed in Step 6, when a 10' error voltage is present at either channel 1 or channel 2 input, the module is quite probably faulty. Rudder Order Computer Module A4 Step 8 - Switch the mode selector to Gyro. Check for zero volt indication at test point TP3 when the automatic course selector pointer indicates zero course error. Step 9 - Check that the voltage reading of the input heading error, at TP2 reflects the ratio of 0.2 to 0.75 volt per degree of heading error. Step 10 - Verify that the test point TP3 monitors a calibrated heading error signal of 0.25 volt per degree, that is 2.5 volts when the automatic course selector pointer indicates 10 degrees course error, regardless of the scaling of the input signal. Step 11 - Check that the computed rudder order output signal measures 0.25 volts d-c per degree heading error at test point TP14. Step 12 - Insert a heading change and check that the rudder stops at an angle coinciding with that set by the RUDDER LIMIT potentiometer. Test with opposite polarity error signal.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 4 OF 10

Step 13 - Check that voltages for internal circuits measure +15 volts d-c at TP19 and -15 volts d-c at TP20. Step 14 - Repeat all above steps 8 through 13 with Mode Selector Switch positioned to Lever Pilot, and Lever Pilot handle raised to Auto mode. NOTES: 1. The proper settings for RATE switch S1, RATE FILTER switch S2, and INTEGRAL switch S3 depend upon the type of ship and its steering equipment. The proper settings have been determined during sea trials and should not be changed. They should be recorded so that they can be set into any replacement Rudder Order Computer module that might be installed in the future. Rudder Servo Amplifier Module A5 Step 15 - Check that the voltage to internal circuits measures +15 volt d-c at test point TPI0, 15 volts d-c at TP11. Step 16 - Check the GAIN potentiometer calibration. This is correct when output signal neon lamp DS1 for port direction lights up with +0.2 volt d-c measured at TP3, and DS2 for starboard direction illuminates with -0.2 volts at TP3 (install a multimeter on the solenoid output). Step 17 - Check the calibration of the Rudder Cal potentiometer. This is correct when 5 volts at test point TP3, produces 20 rudder. Step 18 - Check the calibration of the Helm Cal potentiometer. This is correct when inserting 20 rudder order, the rudder swings by 20. If the helm unit is uncalibrated, order full rudder travel and adjust Helm Cal potentiometer to produce full rudder travel. If lamp DSI or DS2 is not being energized in Step 16, check the .presence of following input signals, selecting the respective steering mode: a. b. c. Automatic Rudder Order signal at TP3 (should be 0.25 volt/degree minimum). Helm Rudder Order signal at TP4 (should be 0.15 volt/degree minimum). Rudder Repeatback signal at TP2 (should be 0.15 volt/degree minimum).

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 5 OF 10

Rudder Servo Amplifier Module A6 Step 19 - Check that the dual flow dump solenoid energizes when the rudder order is greater than 5 degrees. Check that the cascade output signal measures 5 VDC, with 5 degree rudder order, at test point TP6 of servo amplifier module A5. Step 20 - Check that the dual flow input signal measures 1.0 VDC per degree at test point TP2 of servo amplifier module A6. Check that the neon lamps DS1 & DS2 light up simultaneously at a rudder order greater than 5 degrees. Step 21 - Upon completion of the tests, reconnect all leads, previously removed. 4. Gyropilot Computer Visual Inspection and Cleaning a Clean interior of any accumulated dirt and dust. Remove plug-in type printed circuit modules and clean board connections and sockets. b. Check all wire terminal connections for tightness on every terminal board (do not pull the wires). c. Check all printed circuit module components for bad leads, cold solder connections, component or board discoloration, and deteriorated printed wiring. Check modules for good socket fit. d. Check all ship's wiring terminal lugs and tighten all terminal board connections. Steering Stand Order Synchro (Port & Starboard) 5. With steering system de-energized, place the Station Switch to Steering Console and the system Switch to "Starboard" position. Connect ohmmeter across R1 and R2 for the port helm order synchro. Rotate helm from 35 right to 35 left several times. Observe ohmmeter, needle should not flutter. Record resistance. Connect meter across S1 and S3. Record resistance. Place system selector switch in "Port" position. Connect- ohmmeter across R1 and R2 for starboard helm order synchro. Rotate helm as before and observe needle. Record resistance. Connect meter across S1 and S3. Record resistance. With 500V megger, megger both synchros. Check terminals for loose connections. With steering system de-energized, place the Station Switch to Steering Stand, the Console Mode switch to Lever Pilot, and the System Selector switch to Starboard". Test the order synchros using the same procedure adopted in above test No. 5.

6.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 6 OF 10

Rudder Feedback Potentiometer (Port & Starboard) 7. With the steering system energized, measure voltage across 91-93 of TB6 with a Multimeter and record. Connect the meter across 91 and 92. Switch to Pilot Lever and energize STARBOARD UNIT. Swing the Pilot Lever in the Hand Mode slowly and smoothly from H/O to H/O. The meter should show a smooth, even voltage change. Perform the same test on the alternate unit using the wire terminals 46, 47 and 48 of terminal board TB3. Lever Steerer Order Potentiometer (Port & Starboard) 8. With steering system energized connect the meter across 43 and 44 of TB3. Swing the port Lever Steerer slowly and smoothly from H/O to H/O. The meter should show a smooth, even voltage change. Perform the same test on starboard Lever Steerer connecting the meter across wires 41 and 42. Lever Pilot Steering Head 9. Perform the following tests and checks: a. Order Potentiometer (Port & Starboard): With steering system energized check that voltage between wires 4 and 6 of TB303 and record. Check for smooth voltage change between wires 4 and 5 by swinging the Lever Pilot from H/O to H/0. Repeat the same tests for starboard potentiometer R301. Check the contacts condition of operation relay K301, repeater relay K302, operation switch S302, repeater switch S303, relay R1 and relay K2. Check the gear wheel teeth for proper mesh and sign of wear along the gear train. Check the gear set screws for tightness and the gear pin springs are properly in place. Check the repeater motor B301 for sticking-free movement. Clean interior of any accumulated dirt and dust. Check all wire terminal connections for tightness on all terminal boards (do not pull the wires).

b.

c.

d. e. f.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 7 OF 10

10.

Make sure Gyrocompass is running, and "Power Available" legend markings are illuminated on the Monitoring Panel in Wheelhouse. Test each steering station, namely: Steering Console, Steering Stand, Port and Starboard Lever Steerer; by swinging the rudder between 45 hard-over port and 45 hard-over starboard on NFU and/or Follow-up mode as appropriate in accordance with the mode-availability of each station. Repeat the tests with the alternate hydraulic unit. In conjunction with above steering tests, check the rudder indicators on the Bridge in relation to the actual position of the rudder per mechanical rudder indicator in the steering flat. Check also that the 35/45 electrical overtravel switches stop the rudder at 35 and 45 respectively in each side, for port and starboard hydraulic power unit. With Master Gyrocompass operating, mode switch on Gyro and rudder amidships, make certain that heading pointer and lubber line are lined up. Operate the Heading Order control to select a new heading. With the ship docked check that the rudder turns in the direction that would cause the vessel to turn to the new headings. Check, also, that the rudder stops at 15 inside angle limit, set by the Rudder Limit potentiometer, in each direction (15 limit is sufficient). Restore the heading pointer in line with the lubber line. The rudder should return to amidships. Check that the steering console NFU controller overrides all other modes and stations. With any other mode selected position the NFU handle as necessary to gain control of the rudder until the handle is held in the same position. Once released, the preselected mode will automatically take over. Check and adjust as necessary the synchronization of both steering systems on Gyro mode for Steering Console, Hand and Auto mode for Lever Pilot, and HAND mode for Steering Hand. Switching from one system to the other. The rudder should not move. Place the System Selector Switch in Port Aft. Check that indicating lights go on. Alternate the rudder by Port NFU control between 45 hard-over port and 45 hard-over starboard. Check that the movement of the rudder is smooth and continuous. Repeat the test with the STARBOARD NFU control. Check rudder movement and correct functioning of the indicating lights. 4-Way Pilot Directional Valve (Port & Starboard)

11.

Test for the following electrical and mechanical performance to determine its good working order. Replace defective parts. Retest to prove the full working order of the equipment to Chief Engineer's satisfaction.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 8 OF 10

a.

When 115 VAC are impressed across a solenoid, the inrush current shall not exceed 3.5 amps and the steady state holding current shall not exceed 0.6 amps. All electrical circuits shall test at least 1 megoahm to ground with multimeter type ohmmeter. A maximum of 500V should be used for testing the circuitry. Solenoids should not hum when energized. Measure and record ohmic resistance of left and right direction solenoid in Dual Transfer Switchbox "A" for port hydraulic power unit, and in Dual Transfer Switchbox "B" for starboard unit (terminals 28 and 39 for left solenoid, and 26 and 40 for right solenoid). The rudder should not move when neither solenoid is energized. With hydraulic pressure available, actuate manually the 4-way valve in each direction by depressing the push pin at each solenoid end. Release the push pin before the rudder slams into the mechanical stops. CAUTION: This operation negates the electrical limit switches. g. If the valve is found sluggish in operation, inspect the interior for foreign particles, the valve spool for bindings and centering springs for reduced strength or breakage. Dump Valve Solenoid (Port & Starboard)

b.

c. d.

e. f.

12.

Check that the solenoid meets the requirements a, b, and c of above item No. 11. Measure and record ohmic resistance: Terminals 23 and 24 for port solenoid in Dual Transfer Switchbox "A", and 23 and 24 for starboard solenoid in Switchbox "B". Check that the dump valve opens to the sump when the solenoid is de-energized.

13.

Test hydrostatically the steering system to the High Pressure Relief Valve setting. Record the popping pressure and set the port and starboard relief valves as necessary at 1950 psig. Port Popping Press & Setting Adj. To. Stbd Popping Press & Setting Adj. To.

Date

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 9 OF 10

14.

Check that the dump valve solenoid is being de-energized by the pressure switch at 1100 psi. Adjust the setting as necessary. Co-ordinate this test with requirement of above test No. 13. Main Steering Pump

15.

Remove one complete in--line dual pump assembly. Overhaul unit or install shore based spare unit and return unit removed from ship for factory inspection and overhaul.

NOTES 1. Request Repair Superintendent to arrange vendors for above work prior to overhaul. Electronic vendor for above items 1-12 to submit written report of all findings. Mechanical vendor for above items 13-16 to submit written report of all findings. Vendors to check with Chief Engineer prior to opening or running any equipment.

2. 3. 4.

VESSEL CLASS CHEVRON OREGON VESSEL __________________________ INITIALS _________________________

FREQUENCY PERIODIC OVERHAUL Date ___________________ SHEET 10 OF 10

APPENDIX I STEERING GEAR CHECK LIST JOHN YOUNG CLASS

STEERING GEAR CHECK LIST PRIOR TO DEPARTURE SHIPS CREW Wheelhouse Equipment 1. 2. Check the OFF-COURSE alarm for good operation. Make sure the repeater HEADING DIAL of the CRT display and of the Alarm/Heading module, is synchronized with the Master Gyrocompass. Check the Alarm Heading Module for correct display, for Reference Heading numerical value, and for the good operation of the alarm monitoring system by depressing the Test switch. N O T E: The Alarm/Heading Module is not a back up steering means, it is only a back up coursekeeping information center. *4. Check the Upper and Lower part of the graphic-and-character-formatted CRT display for: a. Correct presentation of the three video-indicators, namely, Heading in DEG., Heading Rate in Deg./Min, Rudder Angle in Deg.. Correct presentation of the PAGE for each mode. Correct Rudder Angle Limit value, and current entry of Laden/light ship function. Making sure the Adaptive Weather Adjust is selected in Gyro mode.

3.

b. c. d. 5.

Thoroughly test all communication systems and signals, including alternate communication methods such as radios. This also, includes gyro repeater in steering flat. With the 35/45 deg. key-switch turned to 45 deg. position, alternately test run the steering gear system N. 1 and N. 2 on HAND ( Follow up ) and NFU ( Non-follow up ) mode, and check: a. The light indicators of the Status Module illuminate in correspondence to each mode and system. For loose control handle of System switch, and NFU rocker switch. Each should snap into its detent position.

6.

*b.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PRIOR DEPARTURE DATE ___________________________ SHEET 1 OF 4

c.

The rudder angle indicators of the W/H and Bridge Wings in relation to the actual position of the rudder per mechanical rudder indicator. Also, check that the rudder angle is correctly being recorded on the ships course recorder. The rudder stops at 35 deg. on each side when the 35/45 deg. key-switch is turned to 35 deg. position, and to 45 deg. when it is turned to 45 deg. position. While on Helm mode, insert zero rudder order and verify the rudder positions amidships. Note and record any misalignment. N O T E S: 1. The Non-follow up (NFU) mode is selected by pressing either Right or Left side of the NFU rocker switch on the Status Module. The Helm mode is selected by depressing the Helm switch on the Status Module. Prior to stopping the steering pump, position the rudder amidships. With one of the two steering pumps dedicated to drive the rams, the standby unit can be started up from the Watch Officer Console, and run idle only. The Steering Stand Remote and Remote Enable push buttons are not used. They are provided for eventual future installation of auxiliary steering stations (Bridge Wings).

d.

e.

2.

3. 4.

5.

Steering Flat Equipment 7. Listen for unusual noise from motor bearings, pump couplings, and pump oil sumps (coordinate this check with test N. 6 of this list). Listen to the starter of the running steering pump for humming noise (coordinate this check with test N. 6 of this list). Check and record in Steering Gear Log: (a) the main motor ampermeter reading (it should be _____ A approx.); (b) the pilot oil system pressure (it should read _____ Kg/sq. cm. approx.);

8.

*9.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PRIOR DEPARTURE DATE ___________________________ SHEET 2 OF 4

(c) the engine hydraulic pressure, while alternating between Left and Right rudder (it should be _____ kg/sq. approx.); (d) the carrier bearing weardown reading in mm _____ (coordinate this check with test N. 6 of this list ). N O T E: Shut off pressure gauge valves after each check. M10. Test the Steering Gear Power Failure alarm and the Control Power Failure alarm, by cutting out the main power switch at main and emergency switchboard, and check the visual and audible alarm is triggered in the W/H and in ECR. *11. Test the Follow up (FFU) and Non-follow up (NFU) steering mode of N. 1 and N. 2 system RCU (Rudder Control Unit), as long as necessary to show proper functioning, by switching to the Local Control on the RCU to be operated. Switch back to the Remote Control after the test. N O T E: To enable the FFU mode, the relevant knob must be depressed and released. Q12. Test the Local Emergency Control (trick-wheel) of system N. 1 and N. 2. Cut out power supply to the Control Box, jack up and lock the steering pump unloading valve of the system selected, and start up locally the steering pump of the same system. Using the Emergency Knob of the Servo-mechanism, alternately swing the rudder over each side of an angle shorter than 35 deg. N O T E: This Manual Emergency NFU mode negates the electrical limit switches. *13. Test the LOW and LOW-LOW oil level alarm and the associated hydraulic rams logic isolation of steering system N. 1 and N. 2: A. Drain the alarm Test Tube of system N.1 (starboard) down to LOW level setting and check: The LOW level visual and audible alarms go on both in W/H and ECR. The isolation valve N.1 energizes and by-passes the power cylinders N.3 and N.4, while cylinder N.1 and N.2 remain working. Drain the same alarm Test Tube down to LOW-LOW level setting and check:

B.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PRIOR DEPARTURE DATE ___________________________ SHEET 3 OF 4

The LOW-LOW visual and audible alarms go on in W/H and ECR. The isolation valve N.1 de-energizes. The isolation valve N.2 energizes and by-passes power cylinder N.1 and N.2. The steering pump N.1 stops and the N.2 start up automatically to actuate the power cylinder N.3 and N.4 only.

The alternate operations will occur when draining the alarm Test Tube of system N.2. N O T E S: 1. 2. If the isolation valve fails to operate at sea, jack it up and lock it manually. At sea, reduce ships speed to half or 7 knot, whichever is lesser, when steering with two rams only.

14.

Apply grease, as required, to the tiller Rapson slide and its roller bearing, and to the Repeatback Box linkages. In cold weather condition, turn on the steering gear flat heaters, and have one pump running before departure for the time required to warm the oil to 23/30 deg. C. N O T E S: 1. Items marked by (*) need not be performed if the last full testing was less-than seven (7) days at sea. The item marked by (M) is to be performed monthly. The item marked by (Q) qualifies as a quarterly emergency steering drill required by inspection and test records, and should be noted as completed when performed. Greasing required by item N.14 of this list may be done on a weekly basis, if required. Use grease recommended in vessels lubrication chart.

15.

2. 3.

4.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PRIOR DEPARTURE DATE ___________________________ SHEET 4 OF 4

STEERING GEAR CHECKLIST PERIODIC OVERHAULVENDOR Electronic Equipment Rudder Angle Indicators 1. Check the rudder angle indicators at 5 deg. intervals against mechanical rudder angle indicator in steering flat. Check terminals for tightness and synchros for bearing roughness, bearing lubrication, and condition of slip rings.

Rudder Angle Transmitter 2. Check the synchro for good operating condition, the synchro shaft bearing for excess clearance, the shaft driving linkage for lost motion, and the terminals for tightness.

SPR-2000 Adaptive Auto Pilot 3. The following equipment must be serviced only by a certified Tokyo Keiki Co. technician. a. b. c. d. e. f. Steering Stand RCUs Tokyo Keiki Boxes Rams Isolation Logic Box Torque Motors and related stroking servo-assembly Repeatback Units

Mechanical Equipment STEERING MACHINERY SURVEY 4. Examination of the steering machinery is to be carried out, including an operational test and checking of the relief valve settings. Further, a hydrostatic check of the steering system to the relief valve settings is to be conducted using the installed power units. The machinery may be required to be opened for further examination as considered necessary by the surveyor.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PERIODIC OVERHAUL DATE ___________________________ SHEET 1 OF 2

MAIN STEERING GEAR PUMP N.1 AND N.2 (Kawasaki) 5. Remove one complete in-line pump assembly (submerged in oil sump), as designated by the Repair Superintendent/Chief Engineer. Overhaul unit or install shore-based spare unit and return unit removed from ship for factory inspection and overhaul.

SAFETY VALVES OF STEERING SYSTEM N.1 AND N.2 6. Hydrostatically test the steering system N.1 and N.2 to the safety valve setting of 295 kg/sq. cm. Disconnect power supply to Control box N.1, jack and lock by lock-nut the related solenoid unloading valve. Stroke the steering pump N.1 to the mechanical stop alternately in each direction and make sure each safety valve pops at 295 kg/sq. cm. Adjust the setting if necessary. Operate in the same way to test the safety valves of system N.2. N O T E: The time of each safety valve test shall not exceed 30 sec, because the electric motor can burn.

SERVO-PUMP SYSTEM RELIEF VALVES 7. Test hydrostatically the relief valve of servo-pump system N.1 and N.2. Record the popping pressure. Adjust the valve setting, if necessary, at 18-20 kg/sq. cm. N O T E S: 1. Request Repair Superintendent to arrange vendors for above work prior to overhaul. Electronic vendor for above items 1-2-3, to submit written report of all findings. Mechanical vendor for above items 4-5-6-7 to submit report of all findings. Vendors to check with Chief Engineer prior to opening or running any equipment.

2. 3. 4.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PERIODIC OVERHAUL DATE ___________________________ SHEET 2 OF 2

STEERING GEAR CHECK LIST PRIOR TO ARRIVAL SHIPS CREW Wheelhouse Equipment 1. Thoroughly test all communication systems and signals, including alternate communication methods such as radios. This also, includes gyro repeater in steering flat. With the 35/45 deg. key-switch turned to 45 deg. position, alternately test run the steering gear system N.1 and N.2 on HAND (Follow up) and NFU (Non-follow up) mode, and check: a. The rudder angle indicators of the W/H and Bridge Wings in relation to the actual position of the rudder per mechanical rudder indicator. Also, check that the rudder angle is correctly being recorded on the ships course recorder. The rudder stops at 35 deg. on each side when the 35/45 deg. key-switch is turned to 35 deg. position, and to 45 deg. when it is turned to 45 deg. position. N O T E: A stuck-open 45 deg. rudder angle limit switch invalidates all steering modes from the Bridge

2.

b.

Steering Flat Equipment 3. Listen for unusual noise from motor bearings, pump couplings, and pump oil sumps (coordinate this check with test N. 6 of this list). Listen to the starter of the running steering pump for humming noise (coordinate this check with test N.6 of this list). Test the LOW and LOW-LOW oil level alarm and the associated hydraulic rams logic isolation of steering system N.1 and N.2: A. Drain the alarm Test Tube of system N.1 (starboard) down to LOW level setting and check: The LOW level visual and audible alarms go on both in W/H and ECR. The isolation valve N.1 energizes and by-passes the power cylinders N.3 and N.4, while cylinder N.1 and N.2 remain working.

4.

*5.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PRIOR ARRIVAL DATE ______________________ SHEET 1 OF 2

B.

Drain the same alarm Test Tube down to LOW-LOW level setting and check: The LOW-LOW visual and audible alarms go on in W/H and ECR. The isolation valve N.1 de-energizes. The isolation valve N.2 energizes and by-passes power cylinder N.1 and N.2. The steering pump N.1 stops and the N.2 start up automatically to actuate the power cylinder N.3 and N.4 only.

The alternate operations will occur when draining the alarm Test Tube of system N.2.

N 0 T E S: 1. 2. If the isolation valve fails to operate at sea, jack it up and lock it manually. At sea, reduce ships speed to half or 7 knots, whichever is lesser, when steering with two rams only. Items marked by (*) need not be performed if the last full testing was less than seven (7) days at sea.

3.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PRIOR ARRIVAL DATE ______________________ SHEET 2 OF 2

STEERING GEAR CHECKLIST PERIODIC OVERHAULSHIPS CREW Mechanical Equipment SOLENOID/MANUAL ACTUATED VALVES 1. Check the valve spool of the following valves shifts from the rest to the operation position and vice versa without binding. If the valve spool proves sluggish in shifting from one position to the other, check the valve interior for presence of foreign particles, the spool for binding, the return spring for softness and/or breakage. Replace defective parts. Retest to prove the full working order of the valves: a. b. Steering Pump Unloading Valves Automatic Rams Isolation valves

STEERING PUMP MOTORS 2. Check the following conditions are verified before overhauling the motor: a. b. c. d. The insulation resistance is not less than 0.45 Mohm. The vibration level within acceptable limits. The voltage is balanced in all phases at the motor terminals. The motor is not excessively overloaded. This may be checked by comparing the line amperes with the full load ampere rating stamped on the nameplate.

If the above conditions result satisfactory, proceed to overhauling for purging the bearings and their housings of depleted grease. Clean and closely examine the bearings for incipient flaws and/or feel of roughness. In packing the bearings with grease, do not fill more than 2/3 the bearing housing. Clean grease filling pipe and refill with fresh grease. MAIN SUMPS N.1 AND N.2 OIL RENEWAL 3. Drain the oil from both N. 1 and N. 2 sump, giving priority to the one whose submerged steering pump is to be overhauled. Send a representative sample for analysis. Clean tanks before new fluid is added. Refill through a 60 mesh filter after the overhauled pump(s) is (are) back in place.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY PERIODIC OVERHAUL DATE ___________________________ SHEET 1 OF 1

STEERING GEAR CHECXLIST DUTIES AT SEASHIPS CREW Wheelhouse Equipment 1. Check the rudder angle indicator activity. (Failure of this instrument to indicate does not always mean failure of steering capacity.) Check the ships rate of turn indicator activity and the right direction of turn. Check the independent magnetic off-course alarm is switched on. Make sure the Auto Pilot is properly functioning by checking the following displays: (a) (b) (c) (d) The Status Module legend lights are indicating The Alarm/Heading module alarm lamps illuminate and the audible alarm sounds as long as the Test switch is depressed The three video-graphic-indicators of the CRT presentation, namely, Heading, Rate of Turn, and Rudder Angle, are properly indicating The CRT display for the presence of a Fault and Operator Advisory Message In case of CRT display ma1function, steer by the HAND mode (Helm) and watch the mechanical rudder order indicator located on the Wheel, the analogue rudder angle indicator, and the analogue rate of turn indicator

2 3. 4.

N O T E:

5.

Check the course and the rudder angle tracks on ships course recorder. (They should not be completely straight lines. Their patterns should be used to evaluate the fuel saving feature of the Adaptive Gyro mode.) N O T E S: 1. When in open sea and consistent with ships safety, use alternate method when course changes are made, i.e., by HAND, NFU mode. Consistent with ships safety, change over Bridge Steering Control System once every seven (7) running days at sea, on a rotational watch basis, so all personnel become familiar with the changeover method.

2.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY EACH WATCH DATE ______________________ SHEET 1 OF 2

Steering Gear Flat Equipment 6. Check the oil temperature of the system both by thermometer on the Pump Sump Tanks and by feeling the casing and discharge piping of the running pump. The temperature should not exceed 60 C. Check the oil level in the oil Head Tanks: the oil quantity should not be less than 3/4 full capacity. Make sure the carrier bearing oil level covers the mating working surfaces (the teflon working surface in oil bath). CAUTION: Avoid standing in between the repeatback boxes linkages in checking the oil level.

7.

8.

9.

Check the sight-glass for continuous flow of lubricating, cooling salt water to the rudder stock bushing (phenol resin). Check for signs of hydraulic fluid leakage from the ram glands, steering pump seals, and pilot oil pipings. Keep shut off the power cylinder pressure-gauges root-valves. Watch carefully for any indication of oil seepage from the flange joints and weld seams of the flanges of the hydraulic lines, from pumps to power cylinders. Check the color clogging indicator of the pilot oil system filters. If the yellow is shown (diff, press. 1.0 kg/sq. cm.), change over to the alternate unit, and clean/change the filter element. Examine foreign matter trapped by the filter. (Pilot pressure to be 18 to 20 kg/sq. cm.) Listen to main pumps and motors, while operating, for unusual noise. Listen to main pump motor starters for humming noise. Check the ampermeter of the main pump starters (with the pump in idle condition, it should read approx. _____ A). Check for excessive vibration and chafing of hydraulic pipings and condition of piping hangers. Check for any sign of damage, looseness of lock devices and dislodged connecting pins of: (a) the entire control linkage of the Repeatback Units and Rudder Angle Transmitter; (b) and the 35 and 45 deg. rudder angle electrical limit switches. N O T E: Use grease, hydraulic oils and lubricating oils specified on vessels lubrication chart.

10.

11.

12. 13. 14.

15.

16.

VESSEL CLASS JOHN YOUNG VESSEL ______________________ INITIALS _____________________

FREQUENCY EACH WATCH DATE ______________________ SHEET 2 OF 2

STEERING GEAR CHECKLIST 6 MONTHSSHIPS CREW Wheelhouse Equipment 1. Steering Control Console Open the Control Console, arid while moving the Wheel, visually check: a. b. c. The rudder order transmitters Pin springs and set-screws are not dislodged Gear teeth for sound condition. Apply a film of grease if necessary

Steering Flat equipment 2. Steering Pump Starters N.1 and N.2 With the circuit breaker open and the Warning Tag on, check the following for the pump starter selected for inspection: a. Test the motor overload alarm with the starter power supply switch closed. Move the inner white trip lever (small one) sidewise from right to left on the overload thermal device as indicated by the arrow. The overload visual and audible alarm should go on in W/H and ECR. Push the reset lever (big one). Check the overload thermal switch for evidence of damage. NOTES: 1. The overload device is not designed to stop the motor. 2. Make sure a correct wire diagram is posted inside each starter. b. Check contactor pressure and the wiping motion of the contacts by pushing in slowly on the armature until it bottoms. Be sure it seals against the stationary frame. Release and allow to snap back, the armature should not bind. (Excessive gap between armature and stationary frame causes the coil to draw more current due to lower impedance, which overheat it in a short time.) Check the arc shield for burnt through blow-out fins, the surface of the contacts and contacts alignment. The main contactor contacts are silver plated and should be renewed only when the silver coating has been penetrated. Do not attempt to file them. The silver oxide is self- reducing.

c.

VESSEL CLASS JOHN YOUNG VESSEL________________________ INITIALS _____________________

FREQUENCY 6 MONTHS DATE ___________________ SHEET 1 OF 4

d.

Check the contacts spring tension, Contact heating may draw the temper of the spring and reduce the pressure of the contacts in closed position. Keep contactor coils, control devices and the interior of the controller free of dirty and dust. (Do not use compressed air, brush method is safer.) Look for signs of overheating, charred insulation and odor. Check the auxiliary transformers and the starting autotransformer for the emergency power fed starter, for signs of overheating, charred insulation and odor. Check fuses for correct value. Inspect wires for loose connections (do this by tightening the securing devices, not by moving the wires), and for any sign of deterioration of the insulation. Look at each wire terminal for sign of excess heat, particularly that of the overload heater element. Inspect mechanical parts for damaged loose screws, bolts. With the autopilot power supply switch cut out on the steering pump starter to be tested, megger motor, starter, and auxiliary circuit of main and servo pumps. Record readings.

e.

f.

g. h.

i.

3.

RCU (Rudder Control Unit) N. 1 and N. 2 Check the following: a. For any sign of moisture in the Control Boxes. Inspect cover gasket, smell interior for overheated insulation of transformer For any sign of overheating on solid state switches Fuse rating for correct value For tightness the mounting screws of the torque motor and servo-mechanism assembly Humming noise and abnormal temperature rise of the torque motor and related LVDT (Linear Voltage Detecting Transformer).

b. c. d.

e.

4.

Rudder Repeatback Units N. 1 and N. 2 Check each repeatback box linkage for any lost motion. Check both gear shafts end play. Look for loose wires.

VESSEL CLASS JOHN YOUNG VESSEL________________________ INITIALS _____________________

FREQUENCY 6 MONTHS DATE ___________________ SHEET 2 OF 4

Inspect for proper gear mesh, evidence of wear and backlash of pinion and wheel teeth. Make sure pins fastening the gears to the shafts are not dislodged. 5. Rudder Angle Transmitter Remove cover. Inspect gears for signs of wear, and apply a film of grease if necessary. Rudder Stock Ground Wire Check for effective electrical bond between rudder and ships hull. Couplings of Steering Motor-Pump N.1 and N. 2 Cut out the power switch of the pump to be inspected and post the Warning Tag. Check for tightness and wear the coupling halves. Inspect rubber buffer-rings for sound condition. Oil Seal of Pump Control Unit Check for oil leakage from the drain inspection ports provided at the foot of the torque motor. Renew oil seal, if necessary. Slide Plate of Guide Bar Check for any abnormal wear of white resin slide plate. Rapson SlidePort and Starboard Check the clearance between the tiller hardened steel plate and the roller bearing. Readjust within the permissible value of 0.5 mm., if necessary. Hydraulic Oil Reserve in Steering Flat Check that sufficient reserve oil for the main steering pump sumps is being kept in the steering flat. Replenishment hydraulic oil should be immediately available, easily transferrable to the sump and supplied through a 60 mesh filter. Main Sump Hydraulic Oil Drain a representative sample from N.1 and N.2 system sump tank, examine for discoloration and contamination. Carry out the Millipore test. Send a representative sample of the system oil to laboratory for analysis. Servo-pump Oil Filter of System N. 1 and N. 2 Regardless of the color indicated by the indicator of each filter open up the filter for inspection and examination of any foreign material found. Steering Flat Housekeeping The steering flat sometimes turns into a convenient place for temporary storage of

6.

7.

8.

9.

10.

11.

12.

13.

14.

VESSEL CLASS JOHN YOUNG VESSEL________________________ INITIALS _____________________

FREQUENCY 6 MONTHS DATE ___________________ SHEET 3 OF 4

material but then it becomes a storeroom. Extra space can be utilized as that, but it must be done neatly and safely. Everything should be secured and all aisles should be open. The operating instruction board should be kept legible. Also, the deck, ladders, and platforms, should be kept clean and in sound condition. 15. Securing Devices And Seating Racks of Hydraulic Tubing And Main Hydraulic Lines While underway, examine main hydraulic lines and hydraulic tubing for soundness and tightness of their supports/clamps and for any situation where tubing and/or pipes chafe or abrade each other, Concentrate on checking for piping and tubing working in supporting clamp. Rudder Time Response Check the response time dockside by swinging the rudder from 35 deg. Left to 35 deg. Right, timing from 35 deg. Left to 30 deg. Right. Do the same for the other direction. Record the time. N O T E: The requirement is 65 deg. within 28 sec, at full speed and summer draft, using only one steering pump.

16.

N O T E S: 1. Item N. 16 qualifies as a dockside yearly test required by ABS. Perform the test, and record the result in the inspection and test records. Use grease, hydraulic oil, specified/amended in vessel lubrication chart. Six months lists are to be performed in sequence with periodic overhaul, so a six-month check is done during the overhaul.

2. 3.

VESSEL CLASS JOHN YOUNG VESSEL________________________ INITIALS _____________________

FREQUENCY 6 MONTHS DATE ___________________ SHEET 4 OF 4

APPENDIX 1 STEERING GEAR CHECK LIST FRANK A SHRONTZ CLASS 308 500 DWT CRUDE OIL TANKER

STEERING GEAR CHECKLIST DAILY AT SEA Wheelhouse Equipment 1. Test all Bridge Control Console and Wheelhouse Group Panel indicating and alarm lights, ensuring correct functioning in accordance with the prevailing conditions for the running unit. Renew any lamps found faulty. 2. Verify both Gyro Compasses are running and stabilized. 3. Verify that both ADPT Auto-pilot control panels are adjusted for: Open or confined waters as required Speed input selected Rudder limit control 4. Verify rudder 35/45 degree select switch is set for 35 degrees. 5. Verify that rudder angle indicators are aligned. 6. Transfer from Auto to Helm control and steer briefly by hand, limiting rudder angle to no more than 5 or 6 degrees. Check that the rudder angle tracks on the course recorder and that the independent magnetic off-course alarm sounds. Check the Rate Of Turn indicator for correct response. 7. Check the Voyage Data Recorder ensuring that channels are working and that data is being logged properly. Steering Gear Room Equipment 1. Check oil levels in hydraulic oil sump tank and reserve oil supply tank and top up if necessary. The level in both tanks should not be less than full. 2. Check oil temperature of the system both by thermometer on the system sump tank, and by feeling the discharge piping of the running pump. The temperature should not exceed 60C. 3. Check for signs of hydraulic oil leakage from the ram glands, steering pump seals and pilot oil piping. Check that all pressure gauge root valves are closed. 4. Check that the servo system hydraulic filter differential pressure indicator is green. If indicator is yellow or red, change over to the stand-by filter and clean the dirty element. 5. Check the cooling water sight-glass for continuous flow of lubricating/cooling salt water to the rudder stock bushing. This is especially important when the vessel is in ballast condition when the bushing is not submerged.

6. Listen for any unusual noise coming from the main pumps, motors or starters. Check the oil cooler is clean and that there is no abnormal noise coming from the fan motor. Check the amperes on the motor starters and log them as required. 7. Visually inspect the locking devices and connecting pins of the control linkages for the Rudder Angle Transmitter and the Rudder Repeat back units for signs of looseness.

STEERING GEAR CHECK LIST PRIOR TO DEPARTURE (OR EVERY 3 MONTHS) - SHIPS CREW Wheelhouse Equipment To be coordinated with Steering Gear Machinery Tests 1. On the Bridge Control Console system select #1 system (Port), and confirm motor run light is on. Check that the indicator lamps on the console and the luminous legend markings on the steering stand are properly functioning in accordance with the prevailing conditions for the running unit, and that Power Available indicator is lit for the standby unit. 2. On the BCC engage the Mode select switch to Non Follow-Up (NFU). From the wheelhouse steering stand move rudder from mid-ship to Port and then to Starboard using NFU control. Check that the rudder responds to commands and that all Rudder Angle Indicators accurately track the rudder response. 3. From the BCC using steering toggle switch, move rudder from mid-ship to Port and then to Starboard using NFU control. Check that the rudder responds to commands and that all RAI accurately track the rudder response. 4. On the BCC change the mode select switch to HELM. From the wheelhouse steering stand move rudder from mid-ship to Port and then Starboard. Check that the rudder responds to commands and that all RAI accurately track the rudder response. 5. With the 35/45 Key/switch in the 35 position, move the rudder from 35 Port, through midship to 30 Starboard and check that the rudder completes the movement within 28 seconds as per class requirement. Move the rudder back from 35 Starboard to 30 Port, again checking that it completes the movement within 28 seconds. When the rudder stops at 35 an alarm should sound on the Bridge. With the 35/45 Key/Switch turned to the 45 position, alternatively test run steering gear system #1 and system #2 on Helm (follow-up) and NFU (non-follow-up) and check the following: Rudder will go over to 45 Rudder angle is correctly being recorded on the course recorder. Note: A stuck open 45 rudder angle limit switch will block all steering modes from the bridge. 6. On the BCC set the mode select switch to AUTO and check that the autopilot control lamp is ON. Adjust course setting on the dial and confirm that the rudder responds accordingly. Test the Helm Advisory Alarm as per Sperry procedure. 7. Test the Course Recorder as per Sperry procedure, and check recorder tracks course and rudder response. 8. Test the Magnetic Off-Course Alarm as per manufacturers instruction.

9. Thoroughly test all communication equipment and systems with the Engine Control Room and the Steering Gear Room, including any alternative communication methods such as Radios. Ensure gyro repeater in Steering Flat is synchronized with the Bridge. 10. Cause the Rudder Supervisory Safematic auto isolation system to function by having an engineer in the Steering Gear Room manually operate the Low level oil tank level switch (S1). Check that alarm sounds on Bridge to alert to reduce speed due to only half the steering torque being available. Instruct the engineer to manually operate the Low-Low Level oil tank level switch (S3). Check that: Low Level alarm sounds in the Wheelhouse. Steering control is maintained. Steering gear motors do not change over. 11. On the BCC change over to system #2 (Starboard), and confirm #2 motor run light is ON. 12. Complete items 2 through 6 above using #2 system. 13. Cause the Rudder Supervisory Safematic auto isolation system to function by having an engineer manually operate the Low Level oil tank level switch (S2). Check that alarm sounds on Bridge. Instruct the engineer to manually operate the Low-Low Level oil tank switch (S4). Check that: Low Level alarm sounds in the Wheelhouse. Steering control is maintained. Steering gear motors do not change over. 14. Whilst on HELM mode set the rudder to amidships and verify the rudder position locally. Note and record any misalignment. Prior to stopping the steering pumps, position the rudder amidships.

Steering Gear Room Equipment 1. A licensed engineer must be in attendance in the steering room during pre-arrival/departure tests in order to assist the wheelhouse with alarm simulations, and for recording required data. All means of communication with the wheelhouse should be tested before any tests begin. In cold weather turn on the steering flat heaters and have the pumps running for a few hours before departure. 2. Listen for unusual noise from motor bearings, pump couplings and pump oil sumps. 3. Listen to the starter of the running steering pump motor for humming noise. 4. Check and record the following in the Steering Gear Log: The running motor amperes as the rudder moves. The running motor idle current. (Approximately 40 amps) The pilot oil system pressure. Isolate gauge after reading.

The carrier bearing wear down in mm. (If gauge is fitted) Servo system hydraulic oil filter element differential pressure indicator is green. Oil level in hydraulic sump tank is normal. Oil temperature of system.

5. Test the Steering Gear Power Failure Alarm and the Control Power Failure Alarm by opening the isolating breakers at the main and emergency switchboards. Check that an audible and visual alarm is triggered in the Wheelhouse and the Engine Control Room (ECR). 6. Test the Follow-Up (FFU) and Non-Follow-Up (NFU) steering gear modes on each system by setting select switch to LOCAL at the Rudder Control Unit (RCU). Push the NFU pushbutton for starboard rudder and check rudder moves to starboard. Push the NFU pushbutton for port rudder and check that rudder moves to port. Switch RCU unit back to remote control after tests are completed. 7. With steering motor #1 running cut the power to the RCU. Push the end of the starboard servo control solenoid to move the rudder to starboard, and the end of the port servo control solenoid to move the rudder to port. After test is completed restore power to the RCU. Note: This Manual operation bypasses the electrical limit switches. 8. With steering motor #1 running, manually actuate the Upper oil tank level switch (SO) on the oil tank and ensure Low Level alarm sounds in the ECR and in the Wheelhouse. Manually activate the Mid Level oil tank level switch (S1) on the oil tank and ensure that the auto isolation valve is activated which isolates two rams. Check also that Automatic Hydraulic Supervision alarm is activated on the Bridge. Manually activate the Low oil tank level switch (S3) and confirm that the wheelhouse Low Low Level alarm sounds. 9. Change over to #2 steering motor and complete the same tests in items 7 and 8 using level switches (S2) and (S4), checking that the appropriate alarms sound in the ECR and on the Bridge. When finished ensure that both RCU units are set for remote control. 10. Check that auto grease feeder to rudder bearings is operating and that grease supply unit is full.

STEERING GEAR CHECKLIST PRIOR TO ARRIVAL (OR EVERY 3 MONTHS)- SHIPS CREW Wheelhouse Equipment To be coordinated with Steering Gear Machinery tests 1. Perform Daily At Sea checklist. 2. Thoroughly test all communication systems including alternative communication methods such as radios. This should include the Gyro Repeater in the steering gear room. 3. With the 35/45 key switch set to 35 position, alternatively test run #1 and #2 steering systems on HAND (follow up) and NFU (non follow up) by moving the rudder no more than 10 and checking: The rudder angle indicators of the wheelhouse and bridge wings in relation to the actual position of the rudder with regard to the local mechanical rudder indicator The rudder angle is correctly being recorded on the ships course recorder 4. When vessel speed is reduced to allow testing of Main Engine astern movement, the 35/45 key switch should be set first at 35 and then at 45, and both steering systems tested on HAND and NFU to 35 and then 45 in turn. Verify alarm sounds as rudder reaches 35 limit switches with key set at 35. 5. In conjunction with the duty engineer, test the SAFEMATIC system and confirm all alarms and functions are activated as per system requirements. Steering Gear Room Equipment 1. Confirm communications with the Wheelhouse and ECR. 2. Check oil levels in hydraulic oil sump tank and reserve oil supply tank and top up if necessary. The level in both tanks should not be less than full. 3. Check oil temperature of the system both by thermometer on the system sump tank, and by feeling the discharge piping of the running pump. The temperature should not exceed 60C. 4. Check for signs of hydraulic oil leakage from the ram glands, steering pump seals and pilot oil piping. Check that all pressure gauge root valves are closed. 5. Check that the servo system hydraulic filter differential pressure indicator is green. If indicator is yellow or red, change over to the stand-by filter and clean or change the dirty element. 6. Check the cooling water sight-glass for continuous flow of lubricating/cooling salt water to the rudder stock bushing. This is especially important when the vessel is in ballast condition when the bushing is not submerged.
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7. Listen for any unusual noise coming from the main pumps, motors or starters while the rudder is being moved from the Wheelhouse. Check the oil cooler is clean and that there is no abnormal noise coming from the fan motor. Check the amperes on the motor starters and log them as required. 8. Visually inspect the locking devices and connecting pins of the control linkages for the Rudder Angle Transmitter and the Rudder Repeat back units for signs of looseness. 9. In conjunction with the Bridge Watch Officer test the SAFEMATIC system by the operation of the level switches on the system sump tank, and confirm all alarms and functions are operating as per system requirements. 10. Complete steering gear log and record in Engine Log that test has been completed.

STEERING GEAR CHECK LIST ANNUAL SHIPS CREW Note: Before any work commences on the steering system, ensure OPS-55, OPS-56 and a Job Safety Analysis form have been completed. Wheelhouse Equipment Steering Control Console. Open the Control Console and while moving the wheel visibly check: The rudder order transmitters Pin springs and set screws are not dislodged Gear teeth for sound condition. Apply a thin film of grease if necessary. Steering Gear Room Equipment Steering Pump Starters #1 and #2. With the circuit breaker open and Tagged, check the following for the selected starter that is being inspected. Test the motor overload alarm with the starter power supply switch closed. The overload visual and audible alarm should on the bridge and in the ECR. Note that the overload device is not designed to stop the motor. Check contactor pressure by pushing in slowly on the armature until it bottoms. Check that it seals against the stationary frame before releasing it and allowing it to snap back, checking that it does not bind. Excessive gap between armature and stationary frame causes the coil to draw more current which in turn will cause it to overheat. Check the arc shield for burnt through blow out fins. Check also the surface of the contacts and the contact alignment. The main contactor faces are silver plated and should be renewed only when the silver coating has been penetrated. Do not attempt to clean them by filing. Keep contactor coils, control devices and the interior of the controller free of dust and dirt. Look for signs of overheating, charred insulation and odor. Check fuse ratings are of the correct value. Inspect wires for loose connections. Do this by tightening the securing devices, not by moving the wires. Check for any signs of insulation deterioration or excess heat at the terminals. With the autopilot power supply isolated on the starter being tested, megger the motor, the starter and the auxiliary circuit of the main and servo pumps. Record the readings in RAST. RCU (Rudder Control Unit) #1 and #2 Open the Control Unit control boxes and check the internals for the following: For any sign of over heating on solid state switches Fuse rating for correct values
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Tightness of the mounting screws of the torque motor and servo mechanism assembly Humming noise and abnormal temperature rise of the torque motor and related LVDT (Linear Voltage Detecting Transformer) Inspect cover gasket for any signs of damage before replacing

Rudder Repeatback Units #1 and #2 Check each repeatback box linkage for any lost motion due to wear. Check both gear shafts for endplay. Check for loose wires at contacts. Inspect for proper gear mesh, evidence of wear and backlash of pinion and wheel teeth. Rudder Angle Transmitter Remove cover and inspect gears for signs of wear. Apply a light film of grease if necessary. Rudder Stock Ground Wire Check for effective electrical bond between rudder and ships hull. Steering Pump Motor Couplings With motors isolated and tagged, open pump couplings for internal inspection. Check for tightness and wear and replace grease with recommended lubricant. Slide Plate of Guide Bar Check for any abnormal wear of white resin slide plate. Rapson Slide Port and Starboard Check the clearance between the tiller hardened steel plate and the roller bearing. Readjust within permissible value of 0.5mm if necessary. Hydraulic Oil Reserve in Steering Room Check that sufficient reserve oil for the main steering pump sump tank is available in the steering gear room, approximately 1200 litres. Replenishment oil should be immediately available, easily transferable and supplied through a 60-mesh filter. Main Sump Hydraulic Oil Drain a representative sample from the system sump tank and examine it for discoloration and contamination. Send a sample of the oil to a Chevron approved laboratory for analysis, and file results for future reference. Servo Pump System Oil Filter Regardless of the color indicated by the indicator of each filter, open the filter housing for inspection and examination of any foreign material found, and change the filter element. Hydraulic Piping and Tubing Securing Devices While underway examine all main hydraulic lines and hydraulic tubing for soundness and tightness of their supports and clamps, and for any location where tubing and/or pipes may chafe or abrade each other.

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Rudder Time Response Check the response time dockside by swinging the rudder from 35 Port to 30 Starboard, and then back from 35 Starboard to 30 Port and record the time in RAST records. The time should be no more than 28 seconds for a 65 swing. Steering Gear Room Housekeeping It is common for the steering room to be used as a convenient place for storage of material. It is important when this is the case, that all areas used for storage are kept tidy. All items should be secured, and all aisles kept clear. It is also important to keep all decks, ladders and platforms clean, free of oil and in sound condition.

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STEERING GEAR CHECK-LIST PERIODIC OVERHAUL VENDOR Electronic Equipment Rudder Angle Indicators Check the rudder angle indicators at 5 intervals against mechanical rudder angle indicator in the steering gear room. Check terminals for tightness and synchros for bearing roughness or wear, bearing lubrication and condition of slip rings. Rudder Angle Transmitter Check the synchro for good operating condition, the synchro shaft bearing for excess clearance, the shaft driving linkage for lost motion and the terminals for tightness. ADG 3000 Auto Pilot Only a certified or approved Sperry Technician must service the following equipment. Steering Stand Assembly Rudder Control Units Rudder Servo Units Model ASU811-230 Rudder Repeatback Units Note: Electronic vendor for the above items to submit a written report of all findings. Mechanical Equipment Steering Machinery Survey Examination of the steering machinery is to be carried out, including an operational test and checking of relief valve settings. Further more, a hydrostatic check of the steering system to the relief valve settings is to be conducted using the installed power units. The machinery may be required to be opened further for examination as considered necessary by the attending surveyor. Main Steering Gear Pumps Remove one complete in line assembly as designated by the Repair Superintendent or Chief Engineer. Remove unit to workshop and open for inspection and overhaul. All bearings and seals should be replaced along with any worn parts. A full report is to be completed for vessel records. Steering System Safety Valves Hydrostatically test the steering system safety valves to the safety valve setting of 260 bar. This can be done by removing the valves to the workshop and having them pressure tested on the test bench. Alternatively if a manufacturers representative is present, and with the approval of the attending surveyor, it can be done by removing or by-passing the rudder angle limit switches and stroking the steering pumps to the mechanical stops in each direction, noting the pressure at which the safety valves lift.

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Servo Pump System Relief Valves Hydrostatically test the servo system relief valves by removal to the workshop and pressure testing on the test bench. The pressure should set at 50 bar.

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APPENDIX 1 STEERING GEAR CHECK LIST ANGELICOUSSIS CLASS 306,085 DWT CRUDE OIL TANKER

STEERING GEAR CHECKLIST DAILY AT SEA Wheelhouse Equipment 1. Confirm operations in each steering mode both for No.1 and No.2 systems. Confirm also that the each steering mode is always in the STANDBY condition. Confirm all Steering Stand, Gyro and Bridge Console Display Lamps and Alarm Systems operate normally responding to each steering mode operation. 2. Verify both Gyro Compasses are running and stabilized . 3. Verify that the Auto-Steering control knobs for both systems are adjusted for: Open/Confined waters [ADAPT] and Weather/Rudder/Rate [PID] Pilot watch Rudder limit control 4. Verify that rudder angle indicators are aligned. 5. Transfer from Auto to Helm control and steer briefly by hand, limiting rudder angle to no more than 5 or 6 degrees. Check the Rate Of Turn indicators for correct response. 6. Verify the Magnetic off-course setting.

STEERING GEAR DAILY CHECK LIST-AT SEA.


STEERING GEAR ROOM EQUIPMENT. 1. Check oil levels in hydraulic oil sump tank and top up if necessary 2. Check oil temperature of the system both by thermometer on the system sump tank and by feeling the discharge piping of the running pump. Normal temp is @ 60c and should not exceed 80c. 3. Check for signs of hydraulic oil leakage from the ram glands, steering pump seals and pilot oil piping. 4. Check that the servo system hydraulic filter differential pressure indicator is green. If indicator is yellow or red clean or change the dirty element. Normal pressure is @ 18-20kgf/cm2. Note: Filter change should be done with O.O.W. concurrence.

5. Listen for any unusual noise coming from the main pumps, motors or starters. Check the amperes on the motor starters and log them as required. 6. Visually check for any loose bolts, pins, etc., inspect the unloading device, isolating valves and control linkages for the rudder angle transmitter and the rudder repeat back units for signs of looseness. 7. Check if rudder stock grease pump is working and correct level of grease pot as required.

STEERING GEAR CHECK LIST PRIOR TO DEPARTURE - SHIPS CREW Wheelhouse Equipment To be coordinated with Steering Gear Machinery Tests 1. On the Steering Stand select #1 system (stbd) and on Bridge Console select #1 steering gear pump and confirm that the indicator lamps on the console and the luminous legend markings on the steering stand are properly functioning in accordance with the prevailing conditions for the running unit. 2. On the SS set the mode selection to Non Follow-Up (NFU). From the wheelhouse steering stand move rudder from mid-ship to Port and then to Starboard using NFU control. Check that the rudder responds to commands and that all Rudder Angle Indicators accurately track the rudder response. 3. Test steering wheel override. 4. On the SS set the mode selection switch to HAND. From the wheelhouse steering stand move rudder from mid-ship to Port and then Starboard. Check that the rudder responds to commands and that all RAIs accurately track the rudder response. 5. Move the rudder from 35 Port, through mid-ship to 30 Starboard and check that the rudder completes the movement within 28 seconds as per class requirement. Move the rudder back from 35 Starboard to 30 Port, again checking that it completes the movement within 28 seconds. 6. On the SS set the mode select switch to AUTO and check that the autopilot control lamp is ON. 7. Check the Course Recorder for proper course tracking and time setting. 8. Confirm that the Magnetic Off-Course Alarm operates properly.

9. Thoroughly test all communication equipment and systems with the Engine Control Room and the Steering Gear Room, including any alternative communication methods such as Radios. Ensure gyro repeater in Steering Flat is synchronized with the Bridge. 10. Check oil level alarms (see steering gear room procedure). 11. Complete items 2 through 6 above using # 2 system and # 2 steering gear pump.

STEERING GEAR PRE-DEPARTURE CHECK LIST


Steering Gear Room Equipment 1. A licensed engineer must be in attendance in the steering room during pre-arrival/departure tests in order to assist the wheelhouse with alarm simulations, and for recording required data. All means of communication with wheelhouse should be tested before any tests begin. In cold weather keep the pumps running for a few hours before departure. 2. Listen for unusual noise from motor bearings, pump couplings and pump oil sumps. 3. Listen to the starter of the running steering pump motor for humming noise. 4. Check the rudder moves correctly by the order signal from the wheel house and the actual angle agrees with the order angle. 5. Check that the rudder completes the movement from 30 Starboard within 28 sec as per class requirement. 35 Port, through midship to

6. Check and record the following in the Steering Gear Log: The running motor amperes as the rudder moves. The running motor idle current @ 60 amps. The pilot oil system pressure. Servo system hydraulic oil line filter element differential pressure indicator is green. Oil level in hydraulic sump tank is normal. Oil temperature of system, it should not exceed 80c. 7. Check the lubrication condition of each sliding part, check for any rust. 8. Test the Steering Gear Power Failure Alarm by opening the isolating breakers at the main switchboard. Check that an audible and visual alarm is triggered in the Wheelhouse and the Engine Control Room (ECR). 9. Manually activate the level switch with the System Test Valve for Low and Low-Low oil tank level. Check for isolation valve energizing/de-energizing during this operation and confirm all alarms and functions are operating as per system requirements.

10. Check that auto grease feeder to rudder bearings is operating and that grease supply unit is full.

STEERING GEAR CHECKLIST PRIOR TO ARRIVAL- SHIPS CREW Wheelhouse Equipment To be coordinated with Steering Gear Machinery tests 1. Perform Daily At Sea checklist. 2. Thoroughly test all communication systems including alternative communication methods such as radios. This should include the Gyro Repeater in the steering gear room. 3. Alternatively test run #1 and #2 steering systems on HAND (follow up) and NFU (non follow up) by moving the rudder no more than 10 and checking: The rudder angle indicators of the wheelhouse and bridge wings in relation to the actual position of the rudder with regard to the local mechanical rudder indicator 4. When vessel speed is reduced to allow testing of Main Engine astern movement, test both steering systems on HAND and NFU to 35. 5. In conjunction with the duty engineer, test the steering gear alarms system and confirm all alarms and functions are activated as per system requirements. 6. Record test results in the Deck Log Book (OPS-5)

STEERING GEAR PRE-ARRIVAL CHECK LIST


Steering Gear Room Equipment 1. Confirm communications with the Wheelhouse and ECR. 2. Check oil levels in hydraulic oil sump tank and top up if necessary. 3. Check oil temperature of the system both by thermometer on the system sump tank, and by feeling the discharge piping of the running pump. The temperature should not exceed 80C. 4. Check for signs of hydraulic oil leakage from the ram glands, steering pump seals and pilot oil piping.

5. Check that the servo system hydraulic filter differential pressure indicator is green. If indicator is yellow or red clean or change the dirty element. 6. Listen for any unusual noise coming from the main pumps, motors or starters while the rudder is being moved from the Wheelhouse. Check the amperes on the motor starters and log them as required. 7. Visually inspect the unloading devices, isolating valves and control linkages for the Rudder Angle Transmitter and the Rudder Repeat back units for signs of looseness. 8. In conjunction with the Bridge Watch Officer test the operation of the level switches on the system sump tank with SYSTEM TEST VALVE and confirm all alarms and functions are operating as per system requirements. NOTE: During the above operation the isolation valve is automatically energized and one power unit is isolated. Steering is now carried out only with its two related cylinders, giving 50% torque. 9. Complete steering gear log and record in Engine Log that test has been completed.

INSTRUCTION BOOK FOR STEERING GEAR Drawing Book # H-301 APPENDIX 1

STEERING GEAR CHECK LIST DYNAMIC VISION DYNAMIC ENERGY 82,200 m LPG TANKER
MAKER: KAWASAKI HEAVY INDUSTRIES TYPE: ELECTRO HYDRAULIC MODEL: FE21-126-T050

Reference: US 33 CFR 164.25 WPR 02 01 Para 3.6 WPR 03 04 Para 3.4 18 June 2009

STEERING GEAR CHECKLIST DAILY AT SEA


Wheelhouse Equipment (Every Watch) 1. Test all Bridge Control Console and Wheelhouse Group Panel indicating and alarm lights, ensuring correct functioning in accordance with the prevailing conditions for the running unit. Renew any lamps found faulty. 2. Transfer from AUTO to HAND mode control and steer briefly by hand, limiting rudder angle to no more than 5 degrees. Check that the rudder angle tracks on the course recorder. Check the Rate Of Turn indicator for correct response and confirm the independent magnetic off-course alarm sounds. (See items 5, 6, & 7 following) 3. Switch steering control mode from HAND to NFU and check response. Return to AUTO mode. 4. Check Auto-Pilot settings (Adaptive, Open/Confined, Rudder limit, speed, heading, etc.) 5. Check Course Recorder time, quadrant, etc. 6. Check the Rate Of Turn Indicator (ROT) 7. Check the Magnetic Off Course and Auto-Pilot Off Course Alarms. 8. Test the AUTO OVER-RIDE by turning the helm more than five degrees and observe track indicator light flickers and buzzer sounds. Reset button on stand facial panel above the NFU controller returns the system to AUTO. 9. Ensure correct functioning of the Compass Monitor and verify both Gyro Compasses are running and stabilized. Check also all repeater alignment. 10. Verify that rudder angle indicators are aligned. Notes: When in open sea and consistent with ships safety, use alternate methods when course changes are made, i.e. by auto, Hand, AND NFU modes. Consistent with ships safety, change over Bridge Steering Control System once every seven running days at sea on a rotational basis.

STEERING CHECKLIST

STEERING GEAR CHECKLIST DAILY AT SEA


Steering Gear Room Equipment (Refer to pages 33 of Steering Gear Instruction manual) 1. Check oil levels in both hydraulic oil tanks and the storage oil supply tank and top up if necessary. The levels should not be less than full. 2. Check the motor running current at the motor starters. (25 to 60 Ampere.) 3. Check oil temperature of the system both by thermometer on the system sump tanks, and by feeling the discharge piping of the running pump. The temperature should be about 20 degrees above ambient and not to exceed 60C without shutdown for inspection. 4. Verify water flow to rudder stock (neck) upper bearing. 5. Check for signs of hydraulic oil leakage from the ram glands, steering pump seals and pilot oil piping. Verify that all pressure gauge root valves are closed. Open only for pressure testing. 6. Listen for any unusual noise coming from the main pumps, motors or starters. 7. Verify auto-greasing equipment, linkages and grease supply satisfactory for continued use.

8. Check temperature of the torque motor, normal about 30C above ambient. Not to exceed 80C (too hot to hold) without shutdown for investigation. 9. Visually inspect the locking devices and connecting pins of the control linkages for the Rudder Angle Transmitter and the Rudder Repeat back units for signs of looseness. 10. Check servo oil pressure (1.8 MPa or 18-20 kgf/cm2). 11. Confirm that the operating system hydraulic oil filter clogged indicator is in the GREEN sector.

STEERING CHECKLIST

STEERING GEAR CHECK LIST WITHIN 12 HOURS OF PORT ARRIVAL OR DEPARTURE


Wheelhouse Equipment (To be coordinated with Steering Gear Machinery Tests) 1. (Departure Only): Before testing ensure rudder and propeller are clear. 2. (Departure Only): Conduct tests items #1-10 for Pre-Departure steering gear equipment test. 3. ** Thoroughly test all communication equipment and systems with the Engine Control Room and the Steering Gear Room, including any alternative communication methods such as Radios. Ensure gyro repeater in Steering Flat is synchronized with the Bridge. 4. ** On the Steering Stand system select #1 system (Port), and confirm motor run light is on. Check that the indicator lamps on the console and the luminous legend markings on the steering stand are properly functioning. 5. ** On the Steering Stand, change the Mode select switch to Non Follow-Up (NFU) and move rudder from mid-ship to Port and then to Starboard using NFU control. Check that the rudder responds to commands and that all Rudder Angle Indicators accurately track the rudder response. 6. ** On the Steering Stand, change the mode select switch to HAND and move rudder from midship to Port and then Starboard. Time the rudder response time from 35 Port, through mid-ship to 30Starboard, should be less than 28 seconds. Arrival test can be performed up to 12 hrs prior to arrival and vessel should be in a safe area. 7. ** On the Steering Stand, change the mode select switch to AUTO and while adjusting the course setting, confirm that the rudder responds accordingly. 8. ** Select #2 steering system and repeat test for MODES NFU, HAND and AUTO. Following are only for Prior to Departure Test or at least quarterly 9. Witness the Low Level Alarm for both port and starboard systems as the Engineer in the steering gear room exercises the hydraulic oil level switches. Observe Auto-Isolation valve operation and alarms. 10. Witness the LOW-LOW alarm for both port and starboard systems as the engineer in the steering gear room exercises the hydraulic oil level switches. ** Required by 33 CFR 164.25

STEERING CHECKLIST

STEERING GEAR CHECK LIST PRIOR TO PORT ARRIVAL OR DEPARTURE


Steering Gear Room Equipment (A licensed engineer must be in attendance) 1. **Complete the Daily Check List. 2. Verify all means of communication with the wheelhouse before any tests begin. 3. In cold weather have the pump running for a few hours before departure then listen for unusual noise from motor bearings, pump couplings and pump oil sumps. 4. Listen to the starter of the running steering pump motor for humming noise. 5. Check and record the following in the Steering Gear Log: The running motor amperes as the rudder moves (25-60 Ampere). The pilot oil system pressure (18Kgf/cm2). Isolate gauge after reading. Oil level in both hydraulic sump tanks are minimum full. 6. **Test the Steering Gear Power Failure Alarm and Power Phase Failure Alarm by opening the disconnect switch on the steering gear motor starters or by opening the Main & Emergency Switchboard circuit breakers. Test both port and starboard units. PRIOR DEPARTURE ONLY unless entering US waters. 7. **Test the Control Power failure Alarm by opening the disconnect switch on the Rudder Control Box or the feeder disconnect on the front of the starter box. Test both Port and Starboard units. PRIOR DEPARTURE ONLY unless entering US waters. 8. **Test the Steering Failure Alarm (SFA). Use one of the following methods: a) With both steering gear motors off, move the steering wheel to >5 degrees on the bridge. Alarm will sound after 5 seconds of no response. OR b) With the steering control at the local control position, move the wheel on the bridge to >5 degrees. Alarm will sound after 5 seconds of no response. Do not attempt to perform this test by constraining the movement of the torque motor as serious damage to system may occur. 9. (Departure Test Only) Test the EMERGENCY STEERING CONTROL (for use when autopilot failed) by pushing the pump control knob at the torque motor on the pump control unit. Note: this manual operation bypasses the electrical limit switches so be cautioned not to run ruder into the mechanical stops. 10. (Departure Test Only) Test the automatic isolation system as follows. With steering motor #1 running, block and bleed the level switch chamber on the hydraulic oil tank and witness a) Low Level alarm followed by isolation valve operation. Continue to drain the chamber until the LOW-

STEERING CHECKLIST

LOW level switch operates an alarm in the wheelhouse. After independently testing both systems, restore the level switch chambers to operating condition. ** Required by 33 CFR 164.25

STEERING CHECKLIST

STEERING GEAR CHECK LIST ANNUAL SHIPS CREW


Note: Before any work commences on the steering system, ensure OPS-55 and OPS-56 have been completed. Wheelhouse Equipment Steering Stand. Open the Panel Doors and top facial plate and while moving the wheel visibly check: The rudder order transmitters Pin springs and set screws are not dislodged Gear teeth for sound condition. Apply a thin film of grease if necessary. Steering Gear Room Equipment Steering Pump Starters #1 and #2. (By qualified Electrician or Service Engineer) With the circuit breaker open and Tagged, check the following for the selected starter that is being inspected. Test the motor overload alarm by depressing relay 51X in each starter. The overload visual and audible alarm should activate on the bridge and in the ECR. Check the main contactor (#88) pressure by pushing in slowly on the armature until it bottoms. Check that it seals against the stationary frame before releasing it and allowing it to snap back, checking that it does not bind. Excessive gap between armature and stationary frame causes the coil to draw more current which in turn will cause it to overheat. Check the arc shield for damage. Check also the surface of the contacts and the contact alignment. The main contactor faces are silver plated and should be renewed only when the silver coating has been penetrated. Keep contactor coils, control devices and the interior of the controller free of dust and dirt. Look for signs of overheating, charred insulation and odor. Check fuse ratings are of the correct value. Inspect wires for loose connections. Do this by tightening the securing devices, not by moving the wires. Check for any signs of insulation deterioration or excess heat at the terminals. With the autopilot power supply isolated on the starter being tested, megger the motor, the starter and the auxiliary circuit of the main pump. Record the readings in RAST. RCU (Rudder Control Unit) #1 and #2 (By Crew) Open the Control Unit control boxes and check the internals for the following: For any sign of over heating Fuse rating for correct values Inspect cover gasket and door closure fittings

STEERING CHECKLIST

Rudder Repeatback Units #1, #2 and the SFA Unit (By Crew) Check each repeatback box linkage for any lost motion due to wear. Check both gear shafts for endplay. Check for loose wires at contacts. Inspect for proper gear mesh, evidence of wear and backlash of pinion and wheel teeth. Rudder Angle Transmitter (By Crew) Remove cover and inspect gears for signs of wear. Apply a light film of grease if necessary. Rudder Stock Ground Wire (By Crew) Check for effective electrical bond between rudder stock and the ships hull. Slide Plate of Guide Bar (By crew) Check for any abnormal wear of white resin slide plate. Rapson Slide Port and Starboard (By Crew) Check the clearance between the tiller hardened steel plate and the roller bearing. Readjust within permissible value of 0.5mm if necessary. Hydraulic Oil Reserve in Steering Room (By Crew) Check that sufficient reserve oil for the main steering pump sump tank is available in the steering gear room, approximately 1200 liters. Replenishment oil should be immediately available, easily transferable and supplied through a 60-mesh filter. Main System Hydraulic Oil (By Crew) Drain a representative sample from the system sump tank and examine it for discoloration and contamination. Send a sample of the oil to a Chevron approved laboratory for analysis, and file results for future reference. Servo Pump System Oil Filter (By Crew) Change the filter element. Hydraulic Piping and Tubing Securing Devices (By Crew) While underway examine all main hydraulic lines and hydraulic tubing for soundness and tightness of their supports and clamps, and for any location where tubing and/or pipes may chafe or abrade each other. Steering Gear Room Housekeeping It is common for the steering room to be used as a convenient place for storage. It is important that all areas used for storage are kept tidy. All items should be secured, and all aisles kept clear. It is also important to keep all decks, ladders and platforms clean, free of oil and in sound condition.

STEERING CHECKLIST

STEERING GEAR CHECK-LIST PERIODIC OVERHAUL VENDOR


Electronic & Control Equipment Rudder Angle Indicators Check the rudder angle indicators at 5 intervals against mechanical rudder angle indicator in the steering gear room. Check terminals for tightness and synchros for bearing roughness or wear, bearing lubrication and condition of slip rings. Rudder Angle Transmitter (Tokimek) Check the synchro for good operating condition, the synchro shaft bearing for excess clearance, the shaft driving linkage for lost motion and the terminals for tightness. Auto Pilot Only a certified or approved Tokimek Service Technician must service the following equipment. Steering Stand Assembly Rudder Control Units Rudder Position Repeatback Units Note: Electronic vendor for the above items to submit a written report of all findings.

Mechanical Equipment Steering Machinery Survey Examination of the steering machinery is to be carried out, including an operational test and checking of relief valve settings. Further more, a hydrostatic check of the steering system to the relief valve settings is to be conducted using the installed power units. The machinery may be required to be opened further for examination as considered necessary by the attending surveyor. Main Steering Gear Pumps Remove one complete pump assembly as designated by the Repair Superintendent or Chief Engineer. Remove unit to workshop and open for inspection and overhaul. All bearings and seals should be replaced along with any worn parts. A full report is to be completed for vessel records. Steering System Safety Valves At the service shop, hydrostatically test the steering system safety valves to the safety valve setting of 300kgf/cm2. This can be done by removing the valves to the workshop and having them pressure tested on the test bench. Alternatively if a manufacturers representative is present, and with the approval of the attending surveyor, it can be done by removing or by-passing the rudder angle limit switches and stroking the steering pumps to the mechanical stops in each direction, noting the pressure at which the safety valves lift.

STEERING CHECKLIST

STEERING GEAR SHI Drawing Book 0474001 APPENDIX 1

STEERING GEAR CHECK LIST NEPTUNE VOYAGER STELLAR VOYAGER VEGA VOYAGER AFRAMAX CLASS TANKER
MAKER: SAMSUNG-HATALAPA TYPE: ELECTRO HYDRAULIC MODEL: R4ST-550 Control by Litton Marine ADG 4000

Reference: US 33 CFR 164.25 WPR 02 01 Para 3.6 WPR 03 04 Para 3.4 22 December 2004

STEERING GEAR CHECKLIST DAILY AT SEA


Wheelhouse Equipment (Every Watch) 1. Test all Bridge Control Console and Wheelhouse Group Panel indicating and alarm lights, ensuring correct functioning in accordance with the prevailing conditions for the running unit. Renew any lamps found faulty. 2. Transfer from AUTO to HELM mode control and steer briefly by hand, limiting rudder angle to no more than 5 degrees. Check that the rudder angle tracks on the course recorder. Check the Rate Of Turn indicator for correct response and confirm the independent magnetic off-course alarm sounds. (See items 5, 6, & 7 following) 3. Switch steering control mode from HELM to NFU and check response. Return to AUTO mode. Check the NFU on the Console to observe it over-rides the HELM and AUTO controls. 4. Check Auto-Pilot manual input settings Check Auto pilot alarm list, Scroll up and Down

5. Check Course Recorder time, quadrant, etc. 6. Check the Rate Of Turn Indicator (ROT) 7. Check the Magnetic Off Course and Auto-Pilot Off Course Alarms. 8. Test the HELM ADVISORY ALARM by turning the helm more than five degrees and observe indicator light flickers and buzzer sounds. 9. Ensure that both Gyro Compasses are running and stabilized. Check also all repeater alignment. 10. Verify that rudder angle indicators are aligned. Notes: When in open sea and consistent with ships safety, use alternate methods when course changes are made, i.e. by auto, Helm, AND NFU modes. Consistent with ships safety, change over Bridge Steering Control System once every seven running days at sea on a rotational basis.

STEERING CHECKLIST

STEERING GEAR CHECKLIST DAILY AT SEA


Steering Gear Room Equipment 1. Check oil levels in the hydraulic oil expansion tank and the storage oil supply tank and top up if necessary. The levels should not be less than full. 2. Check the motor running current at the motor starters. (30 to 103 Ampere.) 3. Check oil temperature of the system by feeling the discharge piping of the running pump. The temperature should be about 20C degrees above ambient and not to exceed 60C (too hot to hold) without shutdown for inspection. 4. Check the operation of the hydraulic oil cooling fan. 5. Check for signs of hydraulic oil leakage from the ram glands, steering pump seals and pilot oil piping. Verify that all pressure gauge root valves are closed. (Open only for pressure testing). 6. Listen for any unusual noise coming from the main pumps, motors or starters. 7. Verify carrier bearing auto-greasing equipment and grease supply adequate for continued use.

8. Visually inspect the locking devices and connecting pins of the control linkages for the Rudder Angle Transmitter and the Rudder Repeat back units for signs of looseness or binding. 9. Check servo oil pressure : M1 (2.0 to 3.0MPa or 20 to 30 kgf/cm2). 10. Boost pressure : M2 (1.0 to 1.3 Mpa) 11. Confirm that the operating system hydraulic oil filter clogged indicator is in the GREEN sector. 12. Check entire space for clean decks, properly secured stores and adequacy of ventilation.

STEERING CHECKLIST

STEERING GEAR CHECK LIST WITHIN 12 HOURS OF PORT ARRIVAL OR DEPARTURE


Wheelhouse Equipment (To be coordinated with Steering Gear Machinery Tests) 1. (Departure Only): Before testing ensure rudder and propeller are clear. 2. (Departure Only): Conduct tests items #1-10 for Pre-Departure steering gear equipment test. 3. ** Thoroughly test all communication equipment and systems with the Engine Control Room and the Steering Gear Room, including any alternative communication methods such as Radios. Ensure gyro repeater in Steering Flat is synchronized with the Bridge. 4. ** On the Bridge Console system select #1 system (Starboard), and confirm motor run light is on. Check that the indicator lamps on the console and the luminous legend markings on the steering stand are properly functioning. 5. ** At the Bridge Console, change the Mode select switch to Non Follow-Up (NFU) and move rudder from mid-ship to Port and then to Starboard using NFU control. Check that the rudder responds to commands and that all Rudder Angle Indicators accurately track the rudder response. 6. ** At the Steering Station at the Bridge Console, change the mode select switch to HELM and move rudder from mid-ship to Port and then Starboard. Time the rudder response time from 35 Port, through mid-ship to 30 Starboard, should be about 28 seconds. 7. ** On the Steering Station at the Bridge Console, change the mode select switch to AUTO and while adjusting the course setting, confirm that the rudder responds accordingly. 8. ** At the Steering Station at the Bridge Console, select #2 (Port system) steering system and repeat test for modes NFU, HELM and AUTO. Following are only for Prior to Departure Test (or at least quarterly) 9. Witness the Low Level Alarm (on the AMS monitor) as the Engineer in the steering gear room tests the function of the hydraulic oil tanks level switch S0. 10. Observe that the Auto-Isolation valve operation WARNING indicator light illuminates on the console (STEERING HYDRAULIC LEAK SLOW VESSEL AND SWITCH TO NFU) as the engineer actuates switch S1 (Qty=2) level in the hydraulic oil. 11. Observe that the LOW-LOW WARNING indicator light for illuminates STEERING HYDRAULIC LEAK SWITCH SYSTEMS as the engineers actuates switch S2 (Qty = 2). ** Required by 33 CFR 164.25

STEERING CHECKLIST

STEERING GEAR CHECK LIST PRIOR TO PORT ARRIVAL OR DEPARTURE


Steering Gear Room Equipment (A licensed engineer must be in attendance) 1. 2. 3. **Complete the Daily Check List. Verify all means of communication with the wheelhouse before any tests begin. In cold weather have the pump running for a few hours before departure then listen for unusual noise from motor bearings, pump couplings and pump oil sumps. Listen to the starter of the running steering pump motor for humming noise. Check and record the following in the Steering Gear Log: The running motor amperes as the rudder moves: 60KW (40-103 Ampere). The pilot oil system pressure: M 1(20 to 30 Kgf/cm2). Isolate gauge after reading. Boost pressure : M2 (1.0 to 1.3 MPa) Oil level in the hydraulic sump tank is minimum full. **Test the Steering Gear Power Failure Alarm by opening the disconnect switch on the steering gear motor starters or by opening the Main & Emergency Switchboard circuit breakers. Test both port and starboard units. (Display is on AMS monitor.) **Test the Control Power failure Alarm by selecting LOCAL on the Rudder Control Box or pull auto-pilot power supply fuse FCxx in the motor starter. Test both Port and Starboard units. (Display is on AMS monitor.) **Test the Steering Failure Alarm (SFA) by manually constraining the directional control solenoid valves while wheelhouse gives rudder order signal. Lack of rudder response to an order signal should cause alarm after 5 second delay. Display is at bridge steering control station. (Departure Test Only) Test the Local NFU Control at each Rudder Control Box and EMERGENCY STEERING CONTROL (for use when auto-pilot failed) by manually pushing the by-pass button on the solenoid control valve. Note: This manual operation bypasses the electrical limit switches so be cautioned not to run ruder into the mechanical stops. (Departure Test Only) Test the automatic isolation system as follows. With steering motor #1 running, manually actuate the level switches on the hydraulic oil tank and witness: a) Switch S0 Low Level alarm (Display on AMS monitor). b) Switch S1 (Qty=2) causes auto isolation valve to operate with indication in the wheelhouse to SLOW VESSEL and GO TO NFU. c) Switch S2 (Qty=2) for a LOW-LOW level condition operates a warning indication in the wheelhouse to alert the Watch Officer to SHIFT SYSTEMS.

4. 5.

6.

7.

8.

9.

10

** Required by 33 CFR 164.25

STEERING CHECKLIST

STEERING GEAR CHECK LIST ANNUAL SHIPS CREW


Note: Before any work commences on the steering system, ensure OPS-55 and OPS-56 have been completed. Wheelhouse Equipment Steering Control Station in the Bridge Console (By crew) Open the Panel Doors and top facial plate and while moving the wheel visibly check: The rudder order transmitters Pin springs and set screws are not dislodged Gear teeth for sound condition. Apply a thin film of grease if necessary. Steering Gear Room Equipment Steering Pump Starters #1 and #2. With the circuit breaker open and Tagged, check the following for the selected starter that is being inspected. Test the motor overload alarm by depressing relay 51X in each starter. The overload visual and audible alarm should activate on AMS monitor system.. Check the main contactor (#88) pressure by pushing in slowly on the armature until it bottoms. Check that it seals against the stationary frame before releasing it and allowing it to snap back, checking that it does not bind. Excessive gap between armature and stationary frame causes the coil to draw more current which in turn will cause it to overheat. Check the arc shield for damage. Check also the surface of the contacts and the contact alignment. The main contactor faces are silver plated and should be renewed only when the silver coating has been penetrated. Keep contactor coils, control devices and the interior of the controller free of dust and dirt. Look for signs of overheating, charred insulation and odor. Check fuse ratings are of the correct value. Inspect wires for loose connections. Do this by tightening the securing devices, not by moving the wires. Check for any signs of insulation deterioration or excess heat at the terminals. With the autopilot power supply isolated on the starter being tested, megger the motor, the starter and the auxiliary circuit of the main pump. Record the readings in RAST. RCU (Rudder Control Unit) #1 and #2 (By Crew) Open the Control Unit control boxes and check the internals for the following: For any sign of over heating Fuse rating for correct values Inspect cover gasket and door closure fittings

STEERING CHECKLIST

Rudder Repeatback Units #1, #2 and the SFA Unit (By Crew) Check each repeatback box linkage for any lost motion due to wear. Check both gear shafts for endplay. Check for loose wires at contacts. Inspect for proper gear mesh, evidence of wear and backlash of pinion and wheel teeth. Rudder Angle Transmitter (By Crew) Remove cover and inspect gears for signs of wear. Apply a light film of grease if necessary. Rudder Stock Ground Wire (By Crew) Check for effective electrical bond between rudder stock and the ships hull. Slide Plate of Guide Bar (By crew) Check for any abnormal wear of white resin slide plate. Rapson Slide Port and Starboard (By Crew) Check the clearance between the tiller hardened steel plate and the roller bearing. Readjust within permissible value of 0.5mm if necessary. Hydraulic Oil Reserve in Steering Room (By Crew) Check that sufficient reserve oil for the main steering pump sump tank is available in the steering gear room, approximately 1200 liters. Replenishment oil should be immediately available, easily transferable and supplied through a 60-mesh filter. Main System Hydraulic Oil (By Crew) Drain a representative sample from the system sump tank and examine it for discoloration and contamination. Send a sample of the oil to a Chevron approved laboratory for analysis, and file results for future reference. Servo Pump System Oil Filter (By Crew) Change the filter element. Hydraulic Piping and Tubing Securing Devices (By Crew) While underway examine all main hydraulic lines and hydraulic tubing for soundness and tightness of their supports and clamps, and for any location where tubing and/or pipes may chafe or abrade each other. Steering Gear Room Housekeeping It is common for the steering room to be used as a convenient place for storage. It is important that all areas used for storage are kept tidy. All items should be secured, and all aisles kept clear. It is also important to keep all decks, ladders and platforms clean, free of oil and in sound condition.

STEERING CHECKLIST

STEERING GEAR CHECK-LIST PERIODIC OVERHAUL VENDOR


Electronic & Control Equipment Rudder Angle Indicators Check the rudder angle indicators at 5 intervals against mechanical rudder angle indicator in the steering gear room. Check terminals for tightness and synchros for bearing roughness or wear, bearing lubrication and condition of slip rings. Rudder Angle Transmitter) Check the synchro for good operating condition, the synchro shaft bearing for excess clearance, the shaft driving linkage for lost motion and the terminals for tightness. Auto Pilot Only a certified or approved Service Technician must service the following equipment. Steering Stand Assembly Rudder Control Units Rudder Position Repeat back Units Note: Electronic vendor for the above items to submit a written report of all findings.

Mechanical Equipment Steering Machinery Survey Examination of the steering machinery is to be carried out, including an operational test and checking of relief valve settings. Further more, a hydrostatic check of the steering system to the relief valve settings is to be conducted using the installed power units. The machinery may be required to be opened further for examination as considered necessary by the attending surveyor. Main Steering Gear Pumps Remove one complete pump assembly as designated by the Repair Superintendent or Chief Engineer. Remove unit to workshop and open for inspection and overhaul. All bearings and seals should be replaced along with any worn parts. A full report is to be completed for vessel records. Steering System Safety Valves At the service shop, hydrostatically test the steering system safety valves to the safety valve setting of 268kgf/cm2. This can be done by removing the valves to the workshop and having them pressure tested on the test bench. Alternatively if a manufacturers representative is present, and with the approval of the attending surveyor, it can be done by removing or by-passing the rudder angle limit switches and stroking the steering pumps to the mechanical stops in each direction, noting the pressure at which the safety valves lift.

STEERING CHECKLIST

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