S-10 LBP Planned Maintenance.xlsx

Procedure List

12061 0012 INSPECT AND CLEAN HEAT EXCHANGER PLATES 01. Inspect and clean the heat exchanger plates. The gaskets should be replaced as required.

02. Inspect the tightening pressure plates.

254 0031 CLEAN AND INSPECT SUCTION STRAINER Note: If the strainer in the compressor manifold collects enough dirt to become clogged, the compressor will not reduce the suction pressure enough to maintain the desired temperatures.

01. Pump down the system by closing the main liquid line stop valve (dryer by-pass or inlet valve).

02. Run the compressor with the motor controller in the auto position or with the LP Bypass button held in. Run the compressor until the suction pressure is at 2-3 psig. Stop the unit and pump down again. If the suction pressure rises, re-start the unit and pump down again. Repeat this operation until the suction pressure remains at 2 psig.

03. Close the compressor suction and discharge valves.

04. Remove the suction and discharge manifold cover on the seal end of the compressor and withdraw the suction strainer.

05. Clean the strainer with approved solvent and blow dry with compressed air.

06. Replace the strainer. With cover loose, slightly open the compressor suction valve and allow a small quantity of refrigerant to blow the air out of the strainer housing.

07. Tighten cover and test operate.

2593 0049 LUBRICATE WATERTIGHT DOOR ASSEMBLY 01. Apply a thin film of light, petroleum base grease on the sealing surfaces around the periphery of the door and on the bearing surfaces of the rollers, and dog pins.

02. Using a grease gun, apply a manufacturer's recommended grease or equivalent to the door roller pins, and grease fittings.

03. Check oil level in oil supply and expansion tank using dipstick. Fill as required using manufacturers recommended oil, or equivalent.

259 0054 CLEAN CONDENSATE DRAIN 01. Clean the drain line and drain pan.

02. Check flow by pouring water down drain. Be sure trap is filled to maintain air seal.

12125 0141 INSPECT V-BELT(S) FOR WEAR AND PROPER TENSION 01. Check belts for cracks and signs of deterioration.

02. If applicable, replace all belts in a set if one is worn. Single belts of similar size should not be used as a substitute for a matched belt set - premature belt wear can result because of belt length variation. All belts in a matched set are within .032 inches of their specified center distances.

03.If required, adjust the belt tension as needed for applicable equipment. Typically, a firm push with the thumb at a point midway between the two pulleys should depress the belt 1/2 to 3/4 inch.

04. Inspect belt alignment. Correct as necessary.

Note: Rapid belt wear may indicate misalignment.

05. Ensure belt guard is properly fitted and secured if applicable.

9422 0155 INSPECT SACRIFICIAL ANODES REFERENCE(S): None

PROCEDURE:

01. Remove anodes.

02. Clean anodes with a wire brush. If worn excessively (more than 50% deterioration), replace.

03. When replacing anodes, ensure good metallic contact is established.

9450 0164 LUBRICATE WIRE ROPE REFERENCE:

L-T6893-COT-010 Kirkpatrick Wire Rope Lubrication Systems Technical Manual Standard System Models SU35B, SU120, SU400.

NOTE:

As an alternative to hand cleaning and slushing, a wire rope pressure applicator may be used per the reference manual instructions or other technical manual for the particular model onboard. Ordering and technical information on a system can be obtained online at http://www.thekirkpatrickgroup.com."

01. Using a brush or swab, apply a thin coat of grease to the rope drums and wire rope. Refer to lube chart for lubricants.

02. Apply a coat of grease to accessible wire rope not enclosed in winch housing, working lubricant well into valleys and spaces.

03. Remove excess lubricant.

2641 0183 INSPECT WIRE ROPE PRECAUTIONS:

01. Ensure all shipboard safety precautions are taken in accordance with ships procedures and policies to avoid personnel injury and damage to machinery

02. Ensure unit is Tagged Out in accordance with ships procedures and policies.

NOTE: Only qualified personnel shall be authorized to open wire rope for inspection. Any evidence of corrosion or damage shall be verified by the Work Center Supervisor to determine if wire rope should remain in service or be replaced.

CAUTION: Extreme care shall be exercised when inserting marlinspikes into the wire rope to avoid damaging the strands and core, or disturbing the lay of the wire strands.

01. Inspect the wire rope for rust, corrosion, kinks, excessive wear, broken wires and weakened splices.

a. Inspect wire rope core within 6 feet of end fitting. Carefully insert marlinspikes into the wire rope and open the strands using a prying action to inspect the inner wires and core for rust, corrosion and deterioration.

02. Measure the diameter of the wire rope in a circumscribing circle at six or more places.

03. Count the number of broken wires in each lay length and each lay strand.

04. Replace the wire rope when one or more of the following conditions exist (where sufficient wire rope remains for specific rigging application, the wire rope may be cut and the end fitting reinstalled):

a. Evidence of pitting due to internal or external corrosion.

b. Nominal wire rope diameter is reduced below allowable limits.

1) 1/64" for diameter up to and including 5/16"

2) 1/32" for diameter 3/8" to and including 1/2"

3) 3/64" for diameter 9/16" to and including 3/4"

4) 1/16" for diameter 7/8" to and including 1-1/8"

5) 3/32" for diameter 1-1/4" to and including 2"

c. Six broken wires in one rope lay length or three broken wires in one strand lay length.

d. One broken wire within one rope lay length of any end fitting.

e. Wear of one third the original diameter of outside individual wires.

f. Evidence of heat damage from any cause.

g. Severe kinking, crushing or distortion of the rope structure.

2642 0184 INSPECT WIRE ROPE END FITTING 01. Inspect for cracks, deformity, and tightness of fit as applicable to type(s) installed.

02. Inspect poured sockets for deterioration of zinc and for movement of wire and zinc out of socket.

03. If applicable, Ensure wires in fiege fittings are visible through inspection hole.

04. If applicable, Inspect swage fittings for deterioration, cracks or evidence of wear.

05. Dip the poured sockets and the first foot of wire rope in lubricating oil.

2643 0185 LUBRICATE WIRE ROPE REFERENCE:

L-T6893-COT-010 Kirkpatrick Wire Rope Lubrication Systems Technical Manual Standard System Models SU35B, SU120, SU400."

NOTE:

As an alternative to hand cleaning and slushing, a wire rope pressure applicator may be used per the reference manual instructions or other technical manual for the particular model onboard. Ordering and technical information on a system can be obtained online at http://www.thekirkpatrickgroup.com.

Modified on 11/12/14.

01. Inspect areas of Main Hoist wire ropes exposed to environment for bare spots, rust, corrosion, wear, and hardened grease.

02. Clean exposed areas with rags.

03. Apply lubricant, working the lubricant into the valleys and between the strands using sufficient lubricant to coat the outer wires. Remove excessive grease from the wire rope.

04. Thoroughly lubricate the wire rope at the base of the end fitting.

05. Repeat steps 01-04 for Topping Hoist and Auxiliary Hoist Wire Ropes, as applicable.

67 0236 TEST MOTOR INSULATION RESISTANCE REFERENCE: By direction of MSC N711 Engineering

PRECAUTION 1: ENSURE ALL LOCKOUT/TAGOUT PROCEDURES ARE IN ACCORDANCE WITH CURRENT SHIPBOARD INSTRUCTIONS.

PRECAUTION 2: TO PREVENT DAMAGE TO SENSITIVE CIRCUITS, THE MOTOR LEADS ARE TO BE PHYSICALLY DISCONNECTED INSIDE THE MOTOR CONTROLLER PRIOR TO TAKING MOTOR RESISTANCE READINGS WITH A MEGOHMMETER.

PRECAUTION 3: IF THE MOTOR IS FITTED WITH INSULATION MONITOR, DISCONNECT THE CONTROL POWER TO THE MONITOR TO ISOLATE IT FROM THE MOTOR PRIOR TO PERFORMING THIS MAINTENANCE ACTION. RECONNECT AFTER TESTING.

PRECAUTION 4: DO NOT APPLY INSULATION TEST VOLTAGE TO ELECTRONIC DEVICES OR EQUIPMENT WITH SOLID STATE COMPONENTS.

CAUTION: HIGH VOLTAGE, HIGH CAPACITANCE COMPONENTS. IF UTILIZING A MEGOHMETER FOR RESISTANCE TEST ENSURE THAT THE TEST VOLTAGE IS PROPORTIONAL TO THE RATED VOLTAGE OF EQUIPMENT BEING TESTED

NOTE: It is recommended to accomplish this maintenance at the same time the motor controller is serviced.

ROS-45 Maintenance Prerequisites: A testing of motor insulation resistance should be performed for ROS-45 equipment immediately prior to the equipment being placed in lay-up condition and again once operational after re-activation. If during the lay-up period, the equipment is operated, long enough for at load/temperature and is beyond 1 year since its last testing, a test should be conducted. During ROS-45 a piece of equipment should not be taken from lay-up condition just to perform a insulation resistance test.

DESCRIPTION:

01. Measure and record temperature of windings. Megger readings should be taken at approximately the same temperature conditions to determine possible deterioration of the insulation.

02. Disconnect motor leads from control circuit.

03. Connect one terminal of the megohmmeter to a motor lead and the other to ground. Operate the megohmmeter until the reading stabilizes and record reading.

04. Repeat this procedure with each set of windings and record the results.

05. Re-connect motor leads to control circuit if removed.

06. Replace any safety covers previously removed to gain access to motor leads.

68 0237 INSPECT AND CLEAN MOTOR REFERENCE: By direction of MSC N711 Engineering

TOLERANCE:

None.

SPECIAL TOOLS:

None.

PRECAUTIONS:

01. Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery

DESCRIPTION OF WORK TO BE PERFORMED:

01. With motor running, inspect for any excessive vibration, overheating or faulty operation.

(Note: This step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.)

02. Secure the motor, disconnect power supply and properly tag

03. As applicable, inspect and clean fan.

A. If fan is visible through grating or louvers, inspect fan and vacuum dirt and debris as required.

For enclosed motor equipped with cooling fan perform the following:

B. If required, remove fan cover and clean cover and fan blades as required with vacuum or wiping rags.

04. For open frame motors, or where access to motor windings is available, inspect to ensure windings are free of dirt, dust or grease.

05. As applicable, wipe off dirt, dust, oil, water, or other liquids from external surfaces of the motor.

06. As applicable, remove dirt, dust, or debris from ventilation air inlets.

70 0239 INSPECT AND CLEAN CONTROLLER REFERENCE: By direction of MSC N711 Engineering

Note: Where possible, the procedure should be done in conjunction with MCodes to test motor insulation resistance.

01. Remove all dirt, dust, oil and grease.

02. Check that all moving parts are free and without undue wear at pivots, and that magnets are bedding properly.

03. Check for loose or worn contacts, weak springs, displaced or burned arc shields, defective coils and tightness of electrical connections.

Note: This step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.

04. Check for excessive corrosion both internally and externally.

05. Check that cover or door closes and seals properly.

06. Measure control circuit resistance with a vom.

Note: This step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.

07. Contacts should be inspected for excessive burning or pitting. Wipe contacts with a cloth moistened with cleaning fluid, and then polish with a dry clean cloth.

Note: This step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.

08.Visually check contact alignment by closing and opening the contactor to ensure proper surface mating. Adjust as needed.

09. Inspect box for signs of water intrusion and correct if required.

Note: This step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.

71 0240 TEST OPERATE CONTROLLER REFERENCE: By direction of MSC N711 Engineering

01. Test the controller in all possible configurations, for example, different speeds, different directions, manual/auto, and local/remote.

02. Verify that voltage and amperage readings are balanced between all phases.

102 0245 INSPECT PUMP OPERATION REFERENCE: By direction of MSC N711 Engineering

01. With pump running perform a thorough inspection of the pump. The following should be checked for damage, leakage and proper operation:

A. Gauges and gauge lines B. Piping and piping flanges C. Valves D. Pump joints E. Pump seals/packing F. Vibration (touch/feel) G. Overheating H. Normal suction and discharge pressures

02. Inspect the foundation fasteners and structure for signs of deterioration. Check tightness of and torque of foundation fasteners as necessary.

03. Notify Supervisor of any discrepancies and take corrective actions as necessary.

103 0246 INSPECT COUPLING AND LUBRICATE (IF NECESSARY) REFERENCE: By direction of MSC N711 Engineering

NOTE: If lubrication is not required for the coupling, complete the inspection and the task can be marked as completed.

NOTE: Inspect coupling device, as applicable. Lubrication step is configuration dependent and may not apply. If couplings that do not require lubrication have been installed, ensure that grease fittings have been removed and plugged.

CAUTION: Operating pumps air bound, dry, or with misaligned couplings can cause damage to pump mechanical seal.

01. Inspect coupling device as applicable for deterioration, tightness, tension and alignment. Make corrections as required.

02. Lubricate coupling per manufacturer instructions as applicable.

2595 0253 LUBRICATE HYDRAULIC WATERTIGHT DOORS REFERENCE: By direction of MSC N711 Engineering

01. Inspect and lubricate all mechanical linkages and sliding surfaces.

2596 0254 INSPECT AND CLEAN FILTERS AND BREATHERS REFERENCE: By direction of MSC N711 Engineering

01. Clean or replace breather.

02. Clean or replace all strainer/filters as applicable.

27 0257 SERVICE IDLE EQUIPMENT REFERENCE: By direction of MSC N711 Engineering

NOTE: The intent of this task is to conduct a non-operational inspection on equipment in ROS (Reduced Operating Status). This PM is applied to the driven equipment but is also applicable to the driver and other associated components of the driven equipment. This task is applied to various types of equipment and not all steps are applicable for each equipment.

01. If applicable, inspect all fluid levels.

02. If the equipment has a rotating component, rotate the component by hand (if possible) at least 3 ¼ turns (avoid whole turns) and verify smooth rotation without binding. If rotation by hand is not possible, electrically bump unit on/off. Conduct this step only if it is practical.

03. If applicable, inspect all heat lamps or internal heating circuits.

04. Visually inspect for corrosion and defects.

05. Check for upcoming or expired calibration or replacement dates.

06. Report the findings and general condition, note any deficiencies, and take corrective action as required.

100 0258 INSPECT FOUNDATION FASTENERS REFERENCES: NONE

PRECAUTIONS:

01. Follow standard shipboard precautions to prevent injury to personnel or damage to shipboard equipment.

PROCEDURE:

NOTE 1: For equipment on skids this applies to both prime mover and driven equipment foundation fasteners.

01. Inspect the foundation bolts for signs of deterioration and looseness.

02. Replace, overhaul or tighten fasteners as necessary.

255 0267 TEST COMPRESSOR HIGH PRESSURE SWITCH 01. With the compressor running, and the throttle back on the condenser water, allow the head pressure to gradually rise. Ensure that the compressor shuts off at the proper pressure.

02. Gradually open the cooling water to the condenser. Depending on the equipment's specific configuration, the compressor restart should occur via one of the following three methods.

A. The compressor will restart automatically at the proper pressure.

B. Manually reset the high pressure switch.

C. Manually restart via the start button.

NOTE:

Replace switch or contactor if visible signs of damage are evident and record actions taken in SAMM

256 0268 TEST COMPRESSOR LOW PRESSURE CUT OUT 01. Slowly close the compressor suction service valve. Ensure that the compressor shuts off at the proper cut out pressure.

02. Reopen the suction valve and ensure that the compressor restarts at the proper pressure.

12173 0272 CLEAN AND INSPECT GROUP CONTROLLER 01. An inspection of each controller within the group controller must be made and the following maintenance actions should be performed as applicable:

A. Dirt and grease on the contact surfaces increases the contact resistance and should be removed. The dust is easily removed with a vacuum cleaner, and the greasy film may be removed with a clean dry cloth.

B. Magnet faces should be kept clean and free from grease or oil. Rust should be removed carefully with fine emery cloth, making sure that metal particles are carefully removed and not deposited on contacts or insulation. See that the moving parts are free and without undue wear at the pivots, and that magnets are setting properly.

C. Controllers should be checked for loose or worn contacts, weak springs, displaced or burned arc shields, defective coils, tightness of electrical connections and corrosion. Control circuit and feeder insulation resistance should be measured.

(NOTE: this step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.)

D. Contacts should be inspected for excessive burning or pitting.

E. Heavy copper contacts and cadmium plated contacts should be filed only when large projections, caused by excessive arcing, are evidenced. File carefully with a smooth mill file so that the contacts retain their original shape.

F. Silver plated contacts should not be filed. The black silver oxide that forms on the surface should not be removed. When necessary, dress silver plated contacts with a fine-cut file or grade 0000 sandpaper.

G. After filing, burnishing, or sanding, the contacts should be wiped with a cloth moistened with cleaning fluid, and then polished with a dry clean cloth.

H.Visually check contact alignment by closing and opening the contactor to ensure proper surface mating. Adjust as needed.

(NOTE: this step may be skipped if a thermographic survey, as described in MCode T001, has been performed within the assigned periodicity of this maintenance action.)

188 0282 CLEAN AND INSPECT TRANSFORMER REFERENCES:

(none)

PROCEDURE:

01. Thoroughly clean all surfaces, especially the conducting parts, by means of dry cloth, light brush, and an industrial vacuum cleaner. Recommend not using a high-pressure air line to blow the dust away. Do not use solvents or any kind of liquid (especially on the coils).

02. Clean all ventilation grills / opening.

03. Inspect the electrical connections fasteners for tightness.

04. Inspect conductors for cracked, frayed, or damaged insulation.

111 0290 CLEAN AND INSPECT SUCTION STRAINER 01. Open strainer.

02. Remove basket and clean basket and strainer housing as necessary.

03. Replace basket in strainer housing.

04. Replace cover gasket if necessary.

2614 0362 CLEAN AND INSPECT DISPLAY UNIT 01. Inspect and clean or replace, as required, the air filter for the main display unit.

02. Inspect the interior of the units for dust, dirt, debris and obviously damaged components, take corrective action as required. If necessary, clean the units with a small brush or vacuum cleaner.

2615 0363 DOPPLER SPEED LOG MAINTENANCE REFERENCES: (a) MSC Drawing No. 424-6978418, Doppler Speed Log Block and Elementary Wiring Diagram

(b) TM# 056253 Northrop Grumman Sperry Marine Manual, Operation, Installation and Service Manual, NAVIKNOT 600SD

(c) TM# 005005-0125-01, Northrop Grumman Sperry Marine Document 005005-0125-01, Installation, Maintenance and Service Instruction, Doppler Transducer and Preamplifier D

NOTE 1: This maintenance action will require the vessel to be drydocked and will require subcontractor assistance.

PROCEDURE:

01. Using References (a), (b) and (c) as guidance, clean, inspect, and test the DSL System.

a. Remove all dust corrosion, and foreign material from equipment cabinets and face plates.

b. Inspect for loose, missing, worn, damaged, burned, hardware, wiring, PCB, modules, and subassemblies.

c. Inspect cables, terminations and weatherproofing.

d. Replace missing and damaged hardware with manufacturer's recommended parts (i.e. nuts, bolts, washers, connectors, burned lamps, LEDs, and fuses).

e. Any major assembly degradation such as a PCB or module shall be reported to the OMT REP on a condition report and handled by change order.

02. Using Reference (c) as guidance, clean the DSL transducer in the ship's hull and the immediate hull penetration to remove all rust, scale, corrosion, or other foreign materials 2587 0366 INSPECT AND LUBRICATE WINCH 01. Properly secure unit.

02. Inspect winch and gear for signs of damage or corrosion. Inspect foundation fasteners for tighteness.

a. Grease winch if applicable

b. Ensure gear oil is clean and replenished as required if applicable..

03. If applicable, inspect all connections to the gangway ensuring the connections are tight and secure.04. Ensure all mechanical linkages move freely and are out of contact with any restraints. Take corrective action if necessary.

05. Test operate winch.

2548 0422 INSPECT ROLLER CURTAIN DOOR REFERENCE: (a) NFPA 80, Standard for Fire Doors and Other Openings

PROCEDURE:

01. Inspect door for damage, corrosion, or other defects.

02. Operate door for one full cycle and check for unusual noises or other improper operation.

03. If fitted, inspect fusible links. Replace any that are corroded, painted or damaged. Reference technical manual for applicable temperature rating of fusible link.

04. Report findings to supervisor.

2550 0423 LUBRICATE ROLLER CURTAIN DOOR REFERENCE: (a) NFPA 80, Standard for Fire Doors and Other Openings

01. Lubricate shafts upon which cradle assembly, gears, crane gears rotate with manufacturer recommended lubricant or equivalent.

02. Inspect and lubricate roller chains, sprockets and gears. Replace sprockets or gears with teeth worn to less than 1/2 their original depth.

2552 0424 TEST ROLLER CURTAIN DOOR AUTOMATIC DROP REFERENCE: (a) NFPA 80, Standard for Fire Doors and Other Openings

NOTE: Rolling Fire Doors and Shutters are to have an average closing speed of not less than 6” per second or not more than 24” per second in accordance with Ref. (a).

PROCEDURE:

01. Perform Drop Tests per Ref. (a):

a. First test shall be to check for operation and full closure.

b. Second test shall be done to verify that the automatic-closing device has been reset.

02. Take corrective action if door does not close in prescribed time.

1 0614 INSPECT COMBUSTIBLE/HAZARDOUS GAS INDICATOR PROCEDURE:

Refer to your equipment Technical Manual for specific instructions.

01. Ensure that the unit is complete and readily accessible.

02. Visually inspect condition of all components including hoses and battery and repair or replace as necessary.

03. Recharge batteries if necessary.

04. Restow equipment and place back in operation.

300 0617 INSPECT AND TEST PORTABLE SUBMERSIBLE PUMP REFERENCE: (a) MRC H0SF

(b) MRC U97C

PRECAUTIONS:

01. Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery.

02. Ensure unit has been secured; and that all power sources have been disconnected and properly tagged out using approved lockout/tagout procedures.

SPECIAL TOOLS AND TEST EQUIPMENT:

01. Megohmmeter, 500v, 100 Mohm

02. Multimeter, AC/DC

PROCEDURE:

01. Measure Circuit Resistance to Ground, and Test Electric Submersible Pump Plug Type:

a. Disconnect plug from power supply.

b. Extend pump power cable; inspect sheath for cuts, tears, and abrasions. Ensure cable has no splices or exposed conductors.

c. If applicable, inspect reinforcement sleeve for cut and cracked surfaces; sleeve construction should be of nonconducting material, where installed.

d. Perform visual and tactile inspection of pump power cable stuffing tube for pump casing watertight integrity.

e. Inspect power control box for loose, broken, and missing parts.

f. Inspect attachment plug for loose, broken, and missing parts.

g. Inspect plug insulation for cracks, chips, and overheating.

h. Inspect plug contacts for foreign matter and pitted and corroded surfaces.

i. Test and verify continuity of lead connected to dummy receptacle with multimeter before proceeding.

j. Ensure pump is not in physical contact with electrical ground; place pump on electrical grade rubber matting.

k. Insert pump attachment plug into dummy receptacle.

l. Position pump control switch to on.

NOTE 1: If any resistance measurements made are not within allowed limits, remove pump from service and attach safety tag(s) in accordance with the TUM and/or local tag-out instruction. Notify Work Center Supervisor.

m. Measure resistance between dummy receptacle and each exposed metal part of pump with multimeter; resistance must be less than 1 ohm.

n. Observe meter and simultaneously work cable with a twisting and bending motion to detect broken strands; no change of resistance should occur.

o. Remove pump attachment plug from dummy receptacle.

p. Remove switchbox cover; inspect cover gasket.

q. Inspect switchbox interior for dryness; verify spare fuse is in place.

r. Inside access cover of the ESP control box, megger insulation resistance on the output side of the line fuses to ground, minimum insulation resistance is 1 megohm.

s. Measure insulation resistance between pump casing and each power lead plug contact with megger; minimum insulation resistance is 1 megohm.

t. Position pump control switch to OFF.

u. Measure insulation resistance between pump casing and each power lead plug contact with megger; minimum insulation resistance is 1 megohm.

v. Tag unit(s) with safety check tag indicating date of testing.

y. Inspect cable stuffing tube for evidence of leakage; inspect cable for deterioration, cuts, kinks, or other visible defects.

z. Reinstall switchbox gasket and cover.

02. Inspect Portable Submersible Pump:

NOTE 2: Obtain the following to perform test:

a. Obtain temporary 440 volt electrical service with plug; stage on pier.

b. Obtain clean 55 gallon drum; stage on pier.

c. Obtain fresh water hose; stage on pier.

d. Obtain pump discharge hose (with current hydrostatic test date); stage on pier.

NOTE 3: Line length is 30'.

a. Inspect handling line; cuts, nicks, or fraying is not acceptable. Replace line, if necessary.

b. Remove portable submersible pump, cable, and switch-box; stage on pier.

c. Inspect electrical cable; cuts in outer protective coating that expose wiring or kinking of cable is not acceptable.

d. Remove carry handle and retain.

e. Remove strainer and retain.

f. Inspect discharge fitting threads; galled, chipped, or missing threads are not acceptable.

g. Inspect suction fitting threads; galled, chipped, or missing threads are not acceptable.

h. Inspect strainer threads; galled, chipped, or missing threads are not acceptable.

i. Inspect foot valve; binding or sticking of foot valve is not acceptable.

j. Inspect impeller shaft seal; oil leakage or degradation of seal is not acceptable.

k. Inspect impeller locknut/locking screw; loose or missing locknut/locking screw is not acceptable.

l. Rotate impeller by hand; binding or rubbing is not acceptable.

m. Apply light coat of grease to suction fitting threads.

n. Reinstall strainer.

03. Test Portable Submersible Pump:

CAUTION: Portable submersible pumps are water cooled; do not operate pump out of water.

a. Connect electrical cable to temporary 440 volt power supply.

b. Connect pump discharge hose to discharge fitting.

c. Place portable submersible pump into clean 55 gallon drum.

NOTE 4: Testing operation of portable submersible pump is best accomplished in fresh water to preclude need for additional flushing.

d. Fill 55 gallon drum with fresh water 2/3 full; continue discharging fresh water into drum until test is complete.

NOTE 5: Portable submersible pump will empty 55 gallon drum very quickly; verify sufficient supply of water for testing.

e. Energize portable submersible pump for 3-5 seconds; verify water flow from discharge pump hose.

f. De-energize portable submersible pump.

g. Secure fresh water supply.

h. Disconnect electrical cable from temporary 440 volt power supply.

i. Remove pump discharge hose.

j. Apply light coat of grease to discharge fitting threads.

k. Reinstall carry handle on discharge fitting.

l. Remove portable submersible pump from 55 gallon drum.

m. Drain excess water from portable submersible pump casing.

n. Dry portable submersible pump with clean, dry rags.

o. Restow portable submersible pump to normal onboard storage location.

p. Empty remaining water from 55 gallon drum; place drum in storage.

q. Restow fresh water hose and pump discharge hose.

r. Request temporary 440 volt electrical service be removed.

s. Report completion supervisor.

301 0618 TEST PORTABLE SUBMERSIBLE PUMP DISCHARGE HOSE PRECAUTIONS:

01. Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery.

PROCEDURE:

01. Test Portable Submersible Pump Discharge Hose to 100 PSI:

NOTE 1: More than 1 section of portable submersible pump discharge hose (discharge hose) may be tested at one time. Total length of hose to be tested shall not exceed 300 ft.

a. Remove discharge hose from normal onboard storage location; deliver topside to suitable test area.

b. Inspect test pump gage for current calibration sticker; missing or out of date calibration sticker is not acceptable.

c. Connect test pump to fresh water supply.

d. Connect discharge hose to discharge side of test pump.

e. Secure test pump end of hose line with 3/4" rope at point 10 to 15 inches from coupling.

f. Install reference (creep) mark completely around and directly next to both couplings on discharge hose with marker, if required.

g. Install vari-nozzle tightly on discharge end of hose; fill with fresh water while bleeding air using nozzle.

WARNING: Do not allow personnel to stand in front of free end of discharge hose, stand closer than 15 feet of either side of hose, or straddle hose during test.

h. Increase pressure at rate not to exceed 15 psi per second until 100 psi is obtained on gage; maintain 100 psi for 3 minutes minimum.

i. Inspect discharge hose during 3 minute test period; leaks or indications of separation between reference (creep) mark and coupling are not acceptable.

j. Secure test pump; relieve pressure from discharge hose using vari-nozzle.

l. Remove vari-nozzle; disconnect test pump and disconnect fresh water supply.

k. Drain discharge hose; allow to air dry.

l. Stencil discharge hose with date (mo/yr) of test. If testing new hose, test date (mo/yr) shall be stenciled 6" from either coupling. If testing older hose, black out previous test date using black paint; stencil new date 2" from previously blacked out date.

m. Restow discharge hose to normal onboard storage location.

n. Report completion to Supervisor.

302 0619 RENEW SUBMERSIBLE PUMP OIL REFERENCE: (a) Tech Manual #0347-LP-183-0000, A.C. PORTABLE SUBMERSIBLE PUMP, INSTRUCTION BOOK

PRECAUTIONS:

01. Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery.

02. Ensure unit has been secured; and that all power sources have been disconnected and properly tagged out using approved lockout/tagout procedures.

NOTE 1: Lubricant requirement is NAVY 2135th or equivalent. Refer to Ship’s Lube Chart for current contract equivalent.

PROCEDURE:

01. Replace Oil in Portable Submersible Pump:

NOTE 2: Line length is 30'.

a. Inspect handling line; cuts, nicks, or fraying is not acceptable. Replace line, if necessary.

b. Relocate portable submersible pump, cable, and switch-box to suitable work area.

c. Remove strainer and retain.

d. Remove gunn cut gloves; put on disposable gloves and goggles.

NOTE 3: "Oil Here" may stamped next to lower pipe plug for identification. If not stamped, refer to Ref. (a) for guidance.

e. Remove lower pipe plug from intermediate chamber; drain oil into sample bottle.

f. Remove excess oil with clean, dry rag.

g. Allow oil sample to settle for 30 minutes.

h. Inspect oil sample; water or metallic particles are not acceptable.

CAUTION: Do not fill intermediate chamber in excess of 1/2-pint (8 ounces) of oil.

i. Fill intermediate chamber with 8 ounces of oil.

NOTE 4: Grease shall be used on all threads, joints, gasketed, and adjacent unplasticized areas to prevent corrosion. Where sealing areas have become rough or deteriorated, they should be made up with sealing compound in place of grease.

j. Apply light coat of grease or sealing compound to lower pipe plug threads.

k. Reinstall lower pipe plug; wrench tighten.

l. Apply light coat of grease or sealing compound to suction fitting threads.

m. Reinstall strainer.

n. Restow portable submersible pump to normal onboard storage location.

o. Report completion to Supervisor.

12 0620 TEST BATTERY REFERENCE: (a) Tech Manual #S6290-AQ-MMC-A10, OPERATING INSTRUCTIONS, MAINTENANCE INSTRUCTIONS and PARTS NOMENCLATURE, THE ARCAIR SLICE PECU, PORTABLE EXOTHERMIC CUTTING UNIT

PRECAUTIONS:

01. Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery.

02. Ensure unit has been secured; and that all power sources have been disconnected and properly tagged out using approved lockout/tagout procedures.

PROCEDURE:

01. Test battery, ensuring proper voltage readings as per manufacturers specifications.

02. Recharge or replace as deemed necessary.

03. Return to readiness condition and replace in designated area.

11 0621 CLEAN, INSPECT AND TEST PECU REFERENCE: (a) Tech Manual #S6290-AQ-MMC-A10, OPERATING INSTRUCTIONS, MAINTENANCE INSTRUCTIONS and PARTS NOMENCLATURE, THE ARCAIR SLICE PECU, PORTABLE EXOTHERMIC CUTTING UNIT

PRECAUTIONS:

01. Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery.

02. Ensure unit has been secured; and that all power sources have been disconnected and properly tagged out using approved lockout/tagout procedures.

PROCEDURE:

01. Ensure that the unit is complete and readily accessible.

02. Visually inspect condition of all components and repair or replace as necessary.

03. Inspect emergency cutting outfit.

04. Test unit and correct any deficiencies.

05. Rotate battery from spare and recharge removed battery per Ref. (a).

06. Clean unit and return to readiness condition and place in secure designated storage.

07. Inspect Cylinder(s):

a. Perform cylinder external visual inspection for damage.

b. Any cylinder(s) with obvious or questionable damage or a cylinder showing signs of a leakage shall be removed from service and replaced. Repairs can NOT be done onboard by shipboard personnel.

276 0635 RENEW FILTER/DRYER CARTRIDGE Note: Renew cartridge annually or as indicated by inspection of the moisture indicator.

01. Close the dehydrator bypass and the valve upstream from the dehydrator. Allow the compressor to run, pumping out the dehydrator. Secure the valve downstream of the dehydrator and secure the compressor.

02. Remove the coverplate carefully to allow any pressure inside the dehydrator to dissipate.

03. Remove the flange bolts and coverplate, then remove the cartridge.

04. Insert a new cartridge, paying attention to proper direction if necessary. Renew cover gasket as required.

05. With the cartridge cover in place, and the cover fasteners almost snug, crack the downstream valve to purge the air from the cartridge. Quickly secure the cover plate.

06. Restore the valves to the proper positions.

2598 0636 CLEAN AND INSPECT SELF CONTAINED REFRIG CONDENSER 01. Clean dust or other obstructions from the condenser using a vacuum cleaner or bristle brush.

02. Check and tighten all electrical connections.

123 0654 INSPECT BLOWER HOUSING REFERENCE: By direction of MSC N711 Engineering

01. While the fan is running, check for excessive noise and vibration.

02. Check housing assembly for loose fasteners and cracked welds.

03. If access can be gained to the interior of the fan; secure and clean.

04. As applicable, inspect surrounding vent plenum area, fan/duct flanges, and ducting work for corrosion, coating system failure, and structural deficiencies. All deficiencies shall be documented into a SWFL or VRR for correction 125 0656 RENEW FILTER REFERENCE: By direction of MSC N711 Engineering

PRECAUTIONS:

.01 Ensure all shipboard safety precautions have been followed to prevent personnel injury or damage to machinery when performing this maintenance action.

DESCRIPTION OF WORK TO BE PERFORMED:

NOTE: Filters should be replaced when static pressure reading indicates or by schedule.

.01 For disposable (throw away filters), perform the following:

.02 For cleanable viscous type (wire mesh) filters, perform the following:

C. Remove tags and restore to service.

170 0660 PERFORM DIESEL ENGINE ANALYSIS PROCEDURE:

Note 1: If Diesel Doctor is installed, proceed to step 06. If Diesel Doctor is installed and cannot used, submit a help call to resolve issue and perform the following steps to accomplish test.

Note 2: Engine should operate as consistently close to normal operating load as practical (desirable: at a minimum of 80% load) while performing this check. Load on engine should remain stable during check. For engines with a common rail fuel system, the engine data must be taken at a consistent, set specific load of 75, 85, or 100% for a proper analysis. Since there is automated, variable injector timing, any fixed load outside of these specific parameters will result in inconsistent data collection on each cylinder. Injection timing is only non-variable and fixed at 75, 85, and 100% loads.

Note 3: For FOS conditions, engine should operate as consistently close to normal operating load as practical (desirable: at a minimum of 80% load) while performing this check. Load on engine should remain stable during check.

Note 4: For ROS conditions. If engine operation under normal load conditions is not practical, defer the planned maintenance until vessel can run the engine under suitable load. Vessel should verify the operational integrity of the Doctor Diesel System by taking data on a single cylinder per engine but not upload data into SAMM.

Note 5: For ROS conditions, and unable to operate Main Propulsion Engines due to Direct Drive Plant configuration, the following actions Shall be performed:

-Defer Maintenance in SAMM to next known scheduled underway, make remark "ROS-DIRECT DRIVE."

-Perform Operational Test of Diesel Doctor equipment utilizing Diesel Engine Simulator Equipment included in Diesel Doctor Kit. Perform test in accordance with Technical Manual Identification Number System (TMINS #): L-T7982-COT-010, Title: SAMM RECIPROCATING ANALYSIS OPERATIONS MANUAL, USING DK-2 AND DK-20 DIESEL DOCTOR PORTABLE DATA COLLECTOR, Pages 40-42 (PDF Pages 45-47). Note test results in remarks.

*************IF DIESEL DOCTOR IS NOT IN USE *************

01. Indicator cocks should be briefly opened and closed before attaching the indicator to blow out any built up carbon to prevent damage to the indicating device.

02. Attach indicator to indicator cock and slowly open the cock. Record firing pressure, close cock and remove indicator. Take firing pressure for each cylinder in turn.

03. All data required by standard shipboard practice should also be recorded at this time. The following may be used as a guide in the absence of detailed procedures.

A. For each cylinder:

1. Firing pressure

2. Fuel pump rack setting

3. Fuel pump timing

4. Exhaust temperature

B. For each engine:

1. Lube oil temperature

2. Jacket water temperature

3. Air manifold pressure

4. Air manifold temperature

5. RPM

6. Turbocharger pre and post temperatures

7. Load - HP or KW (if known)

C. For ship (if main engine):

1. Speed

2. Ballast condition (drafts if known)

3. Sea state

4. Months since last hull cleaning

Compare test results with previous test results to determine whether any corrective action is required.

04. Adjustments of rack settings and/or fuel pump timing should only be made after comparison with previous readings, reference to the manufacturer's technical manual and with permission of proper authority.

05. If engine configuration permits, compression pressures should also be taken on an annual basis. Some engines allow the fuel to be cut out to individual cylinders while the engine is running. Where this is possible, compression pressures may be taken just as for firing pressures but with the fuel off. On engines where this is not possible, it may be valuable to take firing pressures at idle speed to get an indication of compression pressures.

************* IF USING DIESEL DOCTOR*************

06. Prepare the Diesel Doctor unit for data collection:

A. Verify battery is charged B. Inspect pressure sensor and interconnecting cable for integrity C. Collect required tools to manipulate indicator cocks and attach/remove pressure sensor to the indicator cocks.

D. Inspect TDC-crank cable for integrity.

E. Inspect TDC junction boxes and plugs for cleanliness and free of oil contaminants.

F. Review memory slot assignments for each engine and each cylinder to be analyzed.

G. Identify each engine cylinder number one (refer to DTAG if required).

H. Attach TDC-crank cable and verify TDC sensor operation using Utilities/Crank Setup.

07. Record all ancillary data required by standard shipboard practice after the engine is at stabilized load. The following may be used as a guide in the absence of detailed procedures.

A. For each cylinder:

1. Fuel pump rack setting

2. Fuel pump timing

3. Exhaust temperature

B. For each engine:

1. Lube oil temperature

2. Jacket water temperature

3. Air manifold pressure

4. Air manifold temperature

5. RPM

6. Load - HP or KW (if known)

C. For ship (for propulsion engine analysis):

1. Speed

2. Ballast conditions and draft

08. Download collected Diesel Doctor data to SAMM including load conditions (percent load or compression only), scavenge pressures and rack readings in the appropriate data fields.

09. Once data download to SAMM is complete, view the data to ensure the data was taken and downloaded correctly and review the data for obvious/critical engine operating faults that require immediate corrective action. Report findings to the appropriate authority. If the data is corrupted due to collection errors, retake the data as soon as practical.

10. If engine configuration permits, compression pressures should also be taken on an annual basis. Some engines allow the fuel to be cut out to individual cylinders while the engine is running. Where this is possible, compression pressures may be taken just as for firing pressures but with the fuel off. On engines where this is not possible, it may be valuable to take firing pressures at idle speed to get an indication of compression pressures.

316 0674 INSPECT HYDRAULIC WATERTIGHT/FIRE STOP DOORS REFERENCE: By direction of MSC N711 Engineering

01. Visually inspect watertght/fire doors for overall condition and to ensure that no obstructions are in way of door operation.

02. Clean and inspect door sealing surfaces.

03. Inspect level of hydraulic oil in system and fill as required.

04. Open and close watertight/fire doors from remote and local control locations observing door operation.

191 0675 SERVICE BATTERIES REFERENCE: By direction of MSC N711 Engineering

01. Inspect battery connections and terminals for corrosion and tightness.

02. Clean battery connections having corrosion build-up.

03. If applicable, record the specific gravity of the electrolyte in each cell.

04. Record battery bank voltage with charger in off position.

05. If necessary, replace the battery. Battery replacement can be accomplished with power on, careful not to ground connections. In some panels the K1 relay can be pulled.

06. If applicable, perform 2 hour drop test.

14 0719 INSPECT AND TEST SMALL ELECTRICAL EQUIPMENT 01. Make a visual inspection of equipment ensuring that equipment is clean, in proper state of repair and, as applicable, properly oiled. Switches should operate normally. Cords should be clean and free of defects, kinks, and patches. Electrical plug should be securely connected to cord, prongs should be free of distortions and plug should be in overall good condition.

02. As applicable use a volt-ohmeter or megohmeter of appropriate voltage to measure equipment resistance for:

A. Continuity between conductors through motor.

B. Continuity between ground wire and equipment casing.

C. Infinity between conductors and ground wire.

D. Infinity between conductors and equipment case.

03. Remove from use any equipment failing test and tag defective.

04. Make note of tests in equipment history.

27293 0724 INSPECT REFRIGERATION SYSTEM FOR LEAKS REFERENCES: (a) NONE

NOTE: Test the refrigerant system for leaks by testing all refrigerant piping joints, fittings, valves and compressor gasketed joints. The most positive method for finding leaks in a system is with an electronic or halide leak detector. Testing with soapsuds or oil at the joints will only detect larger leaks and, therefore, is ineffective in determining the tightness of a system. If the system is losing the refrigerant, and a piping leak cannot be detected, the condenser should be tested for leaks. Before testing for leaks, at times it may be necessary to raise the pressure in the system by reducing the flow of condenser water.

PROCEDURE:

01. Using an electronic leak detector:

a. Adjust the sensitivity of the electronic leak detector according to the instructions of the manufacturer.

b. Move the detector probe tip around the joint or suspect leak area about 1 or 2 inches per second. The probe continuously draws in air. As the probe tip passes near a leak, leaking refrigerant gas is drawn in and detected. A light in the transparent probe gives a short flash for a small leak and a long flash for a large leak.

02. Using a halide leak detector:

a. The halide leak detector consists of a burner, needle valve, suction (exploring) tube and a chimney with a copper reaction plate. Some torches use alcohol and/or other propane as fuel.

b. Adjust the detector flame so that the top of the blue flame cone is level with or slightly above the reaction plate.

c. Place the end of the exploring tube at the point to be tested. The exploring tube draws a sample of air to the burner where the refrigerant decomposes by reaction with the copper plate and changes the color, observe the flame, small leaks give a greenish tint, large ones a vivid blue.

27319 0756 CLEAN AND INSPECT VOLTAGE REGULATOR 01. Inspect the regulator to ensure that it is clean and free of moisture. A vacuum may be used to clean the unit.

02. Inspect connections between the regulator and the system to ensure that they are tight. Tighten the connections as required.

7036 0825 SERVICE CONTROL PANEL NOTE: A Thermographic Survey utilizing Industrial Assistance can be done in lieu/in addition to performing the following procedure.

01. Inspect the control panel interior components for any evidence of overheating.

02. Inspect relays, switches, and potentiometers for freedom of movement.

03. Inspect the relay and switch contacts for pitting, corrosion, and wear.

04. Check all electrical connections for tightness.

05. Inspect conductors for cracked, frayed, or damaged insulation.

27470 0829 TEST MAGAZINE SPRINKLER SYSTEM 01. Locally test and operate all systems as per standard shipboard procedures.

02. Check all alarms associated with the system for operational condition.

03. Check the operational condition for reach rods in:

A. Forward pump room eductor and bilge valves B. Forward diesel fuel oil shutoff valve C. Through the suction valves for each hold D. Aft diesel fuel oil shutoff valve

04. Lubricate the reach rod linkages as required. If any reach rods fail to operate properly, report the failure to the chief engineer immediately and make any appropriate log entry reflecting the test results.

7025 0835 INSPECT AND CALIBRATE DEEP FAT FRYER

TOLERANCE:

Do not let the temperature of grease to exceed flash temperature of 475 deg F.

SPECIAL TOOLS:

Pyrometer

PRECAUTIONS:

.01 Ensure all standard shipboard safety precautions have been followed to prevent injury to personnel or damage to machinery.

.02 Ensure unit has been secured; and that all power sources have been disconnected and properly tagged out using approved lockout/tagout procedures.

.03 Warning: Injury may result if grease temperature is raised above it’s flash temperature (475 deg F). Use extreme caution when calibrating the thermostatic controls.

DESCRIPTION OF WORK TO BE PERFORMED:

.01 Make a general inspection of the equipment and controls. Remove any grease deposits, dirt, or foreign matter. Inspect all connections for tightness or corrosion.

.02 Report the findings and general condition, note any deficiencies, and take corrective action as required..

.03 Test the equipment thermostatic controls in accordance with manufacturer's…