Kongsberg SR 562, Maintenance Manual

Page 1: ...Maintenance Manual Kongsberg Steering Gear type SR and SV 2020 09 24 13 41 CET RELEASED ...

Page 2: ...rwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2020 KONGSBERG All rights reserved P a g e 2 Doc no DMN000278736 Rev Date Reason for issue Author dept and name Authorizing dept name sign A 15 April 2020 First issue SU EM GB EK OM Motion Control JA B_01 22 April 2020 Minor changes SU Motion Control C_01 24 Sept 2020 Minor ch...

Page 3: ...y controlled pumps 13 6 2 Steering gear with conventional pumps 14 7 Maintenance task procedures 15 7 1 Frequency converter error log 15 7 2 Oil recommendations 16 7 3 System oil volume 18 7 4 Inspection of oil level and condition 19 7 5 Oil level 19 7 6 Oil sampling 20 7 7 Internal leakage test with frequency controlled pumps 21 7 8 Manoeuvring time test with frequency controlled pumps 23 7 9 Fee...

Page 4: ...ROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY LEGAL AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE PERSONS UNDERTAKING THE WORK IT IS ALSO THE USER S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED BY THIS DOCUMENT...

Page 5: ... Safety annotations All safety directions must be respected in order to avoid damage to personnel environment and equipment In this document the following annotations are used with belonging significance WARNING Indicates possibilities for hazards or unsafe practices which COULD result in fatal or severe personnel injuries or substantial product or property damage if the required precautions are n...

Page 6: ...ecommended to be performed by Kongsberg Maritime engineers Any other information may be found in the steering gear OPERATING AND MAINTENANCE MANUAL USER MANUAL or by contacting service dmss km kongsberg com After a certain number of years in operation it is however necessary to service the equipment and replace internal and external wear parts in order to achieve a predictable and safe life cycle ...

Page 7: ...uipment condition and service history X Recommendation based on number of years in service minimum every 10 years X Condition based recommendatation The Condition based recommendation is based on several condition values reported through a mobile application provided by KM to the customer to perform inspection of the steering gear equipment themselves The Mobile application contains a Self Assessm...

Page 8: ...sed on previous service and maintenance completed current equipment performance and condition reported through the Kongsberg Mobile application including Self Assessment or Maintenance Inspection report ref chapter 8 Leakage and manoeuvring time test Steering gear PMS log files for the last 12 months if SG PMS amplifier card is available 20 years Recommended service and maintenance according to ab...

Page 9: ...Steering Gear modes Emergency Steering and normal steering from all stations Prev 1 mth TST A A Steering Gear system Actuator Check manoeuvring time according to SOLAS Prev 1 mth CHK A A Steering Gear system Hydraulic System Duplex Filter Check filter blockage indicators change filter element if necessary Prev 1 mth CHK A A Steering Gear system Controls System Controll Panels Make sure that all el...

Page 10: ...aulic Pump No2 Change flexible coupling prev 10 yr REP C A Steering Gear system Controls System Frequency Converter No1 Replace frequency converter Prev 10 yr REP C A Steering Gear system Controls System Frequency Converter No2 Replace frequency converter Prev 10 yr REP C A Steering Gear system Hydraulic System Hydraulic Pump No1 Replace Pump Prev 10 yr REP C A Steering Gear system Hydraulic Syste...

Page 11: ...vels indicate the skill level of the person responsible for the maintenance task the facility indicates the physical location of the vessel during the maintenance procedure The skill and facility codes are Maintenance Level A is general operational maintenance carried out by the ships crew on board with no additional support or facilities Maintenance Level B is maintenance carried out in port usin...

Page 12: ...chambers The housing is divided with an upper and lower part which are connected by several bolts The synthetic bearing pads maintain hundred percent surface contact at all times even as the rudder stock flexes It will also absorb and suppress vibrations and shock pulses The bearing surface is continuously lubricated by the hydraulic oil Note In order to access the lower seals and bearing pads the...

Page 13: ...ted to the steering gear The electrical motor for each pump unit starts when a rudder command signal is given and stops when the rudder has reached the desired position The power for operating control and steering systems are both hydraulically and electrically separated and independent The normal running condition is achieved when one pump is running when both pump units are running the steering ...

Page 14: ...ning and the oil is controlled by a manoeuvring valve The pump unit consists of a tank with foundation manoeuvring valve on steering gear for PU50 andFV2 or FV10 valve return filter and vane pump PU30 uses gear pumps with flexible coupling The electric motor is flanged to the top plate flanged to the side on PU30 The pump runs submerged in oil and an arrow on the pump flange indicates the directio...

Page 15: ...enance support procedure and guidelines required for maintaining the steering gear system in a safe and correctly manner 7 1 Frequency converter error log 1 Check that there are no obstructions to the flow of cooling air over the cooling ribs of the FC and that the FC is not covered by dust 2 Check that the cover is properly secured 3 Press the alarm log push button on the frequency converter s lo...

Page 16: ...raulic oil with other types of oil Even very small amounts of other oil in the hydraulic oil will considerably lower the quality of these oils The performance of the unit is highly depended on the viscosity of the oil The surrounding temperatures of the hydraulic components when operating at extreme temperature conditions tropic or arctic waters shall be taken into account when selecting type of o...

Page 17: ...ype CEPSA CEPSA HV 32 CHEVRON RANDO HDZ32 SHELL TELLUS S2 VX 32 STATOIL HYDRAWAY HVXA 32 TEXACO RANDO HD Z32 YUKONG ZIC SUPERVIS X32 EXXON MOBIL DTE10 EXCEL 32 NYNÄS HYDOL 32 ESSO Exxon UNIVIS N 32 HISPANO QUIMICA S A HYDRO DRIVE HP150 LUB MARINE TOTAL VISGA 32 MOBIL SYNTHETIC MOBIL SHC 524 Change the oil when laboratory tests show High neutralizing number Low remaining amount of EP additives High...

Page 18: ...2 Approx 35 litre SR 622 Approx 45 litre SR 642 Approx 50 litre SR 662 Approx 65 litre SR 722 Approx 125 litre SR 723 Approx 120 litre SR 742 Approx 160 litre SR 743 Approx 160 litre Model type SV Oil volume SV 430 Approx 145 litre SV 650 Approx 135 litre SV 570 Approx 250 litre SV 850 Approx 230 litre Oil volume for steering gears with conventional driven pumps Actuator type Pump unit type Oil vo...

Page 19: ...il level and condition WARNING IT IS EXTREMELY IMPORTANT THAT OIL BOTTLE USED FOR OIL SAMPLING IS CHEMICALLY PURE AND THAT THE PROCEDURE IS PERFORMED WITH A HIGH DEGREE OF CLEANLINESS 7 5 Oil level Examine the oil level in the expansion tank When oil is visible in the upper level gauge glass the tank is properly filled up Unchanged oil level for a long time indicates no leakage If the oil level in...

Page 20: ... sample test The oil sampling points 1 can be located either on the upper housing port and stbd upper rear side of the valve block or on the filter housing as illustrated in the picture 1 Locate the sampling point 2 Remove the protecting cap 2 as illustrated in the picture below The sampling plug contain a non return valve to prevent oil spill prior to connection of sampling hose 3 Connect the sam...

Page 21: ... switch to Local Control Use Emergency Steering push buttons 3 to operate the steering gear with Pump no 1 5 Start test Move the rudder to a position about 33 deg angle to Stbd Start moving the rudder to Port by using the push buttons 3 Start timing when the rudder passes 30 deg angle and stop timing when position reaches 30 deg Port Release the push button Measure the amount of oil collected the ...

Page 22: ... not otherwise explicitly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2020 KONGSBERG All rights reserved P a g e 22 TEST RESULTS To be recorded in the table in chapter 7 9 Feedback form of this document test 3 when requested or if any alarms occure send a copy to Kongsberg Maritime For vessels with two steering gears please perform one ...

Page 23: ...EN position 2 Preparing for test with Pump 1 at Motor Controller Cabinet in Steering gear room Pump no 2 Turn selector switch to Stop Pump no 1 Turn selector switch to Local Control Use Emergency Steering push buttons 3 to operate the steering gear with Pump no 1 3 Start test Move the rudder to a position about 33 deg angle to one side Start moving the rudder to the other side by using push button...

Page 24: ... 1 Seal integrity test only prior to docking or on request Position Leakage Time Pressure Temp Pump no 1 Hard to Port Liter Sec Bar o C Pump no 1 Hard to Stbd Litre Sec Bar o C Pump no 2 Hard to Port Litre Sec Bar o C Pump no 2 Hard to Stbd Litre Sec Bar o C Test 2 Steering Gear manoeuvring time 300 00 300 Direction Time Pressure Pump no 1 Stbd to Port Sec Bar Pump no 1 Port to Stbd Sec Bar Pump n...

Page 25: ...se ball valve on return pipe to expansion tank 2 Loosen return pipe from fitting on top of actuator 3 Make up a suitable pipe or hose to divert escaping return overflow oil into a drum or bucket and attach to fitting on top of actuator 4 By using emergency controls on solenoids run the steering from hard over STBD to hard over PORT Measure amount of oil collected in 1 minute or 30 secs 5 Run actua...

Page 26: ...on one side to 35 deg on the opposite side Note Performance of this test to be managed by the Chief Engineer when vessel is lying still in sheltered waters The test is to be done first with Pump no 1 and then again with pump no 2 1 Switch to Local Control on Control Cabinet located in SG room 2 Use pump unit 1 measure time used from 300 Port 350 STBD 3 Using pump unit 1 measure time used from 300 ...

Page 27: ...nspection Check the Limit Switches 1 Open feedback unit and observe the limit switch activation when running the Steering Gear 2 Check the setscrews on the activation cams are present and tight 3 Activate the switches by hand to confirm spring and switch functionality Check the Solenoids Coil Check solenoid coil connection plug for water or moist that can cause earth fault or short circuit Check o...

Page 28: ...a g e 28 7 13 Test of emergency steering Make sure that the crew is informed before doing emergency steering test operations While doing emergency steering operation always be in radio contact with the bridge 1 Turn selector switch for both Motor Controllers to position 3 LOCAL CONTROL to enable the emergency push buttons located on the Motor Controllers 2 Perform steering by pushing the Emergency...

Page 29: ...ce The stand by pump should start if not already running PU systems Push the test button on the overload relay in motor controller The stand by pump should start if not already running Phase failure alarm Remove one of the fuses supplying the phase failure monitoring relay in the motor controller cabinet the stand by pump should start if not already running Pw Frequency failure Turn of main switch...

Page 30: ...stems only Keep pump 1 3 running and pump 2 4 in stop from bridge disconnect the plug on the magnetic coil for pump 1 3 the pump 1 3 should stop and the pump 2 4 should auto start Note there are a class requirement for 5 sec delay in the alarm system repeat for all pumps Aux alarm Missing feedback from steering gear to the control system Locate the U10 module inside the control system cabinet Remo...

Page 31: ...o investigate With verified potential free component to true earth a visual verification of component protective earth connection can be done For testing on units without power supply Use an ohmmeter to check the resistance between a component s earth potential and the ship s hull true earth neutral ground 7 16 Check for system temperature While examining the hydraulic system it is recommended to ...

Page 32: ... 32 7 17 Replacement of filter Note Verify if normal system temperature is achieved as this is important for the oil viscosity Too cold oil can indicate as clogged filter A clogged filter will be indicated either by an alarm or locally by an indicator 1 on the Steering gear filter as illustrated 1 Turn the selector switch on the current motor controller 2 to position 2 stop 2 Turn the connecting o...

Page 33: ...tly agreed with KONGSBERG in writing Any authorized reproduction in whole or in part must include this legend 2020 KONGSBERG All rights reserved P a g e 33 6 Change the filter insert 6 7 Replace the filter bowl and tighten and refit the nut and tighten 8 Open the connecting oil chocks on the expansion tank 9 De air by drain the top of distributing valve 10 Turn the selector switch on the motor con...

Page 34: ...ion and using the other hose to route the water from the inlet connection to a bucket then opening the supply water valve until the water runs clear See also step 5 5 With heavy contamination fouling may be removed by flushing a solution of water with 5 phosphoric acid or if cleaned frequently a solution of water with 5 oxalic acid from an external source If performed continue with step 6 Otherwis...

Page 35: ...attern pointing down and the gasket holes to the right Next alternate the direction between each plate and gasket set The gasket between the last plate and the front frame with the connections is made up of two gaskets to seal around each hole Illustration show Cooler Plate with Gaskets and Front Frame 13 Install the outer bolts and washers and use screw clamps to tighten the cooler unit in parall...

Page 36: ... in writing Any authorized reproduction in whole or in part must include this legend 2020 KONGSBERG All rights reserved P a g e 36 15 Reconnect the cooler water supply hoses tighten turn after torque starts to noticeable increase reinstall the holding clamp and open the water supply valves 16 Place the motor controller selector switch temporarily in position 1 LOCAL CONTROL to fill the cooler with...

Page 37: ...corded into individual files on the SD memory card on daily basis with following naming convention File name RRYYMMDD LOG RR Rolls Royce YY Year MM Month DD Day These log files can be used as input during remote troubleshooting or as part of the condition based maintenance recommendation When asked log files should be submitted to sg pmscard km kongsberg com email or through the Mobile Form applic...

Page 38: ...in CS cabinet and Figure 3 of this document The SGPMS online LED LED 7 which blinks every second will blink twice per second as the system closes the file on the memory card Once the file is closed the SD card removal OK LED LED 8 will turn off Remove the SD card from the holder on amplifier card by first pushing it inwards Using the USB reader that you have received in the upgrade kit access file...

Page 39: ... pictures How to access the Self Assessment mobile application Download application called Kongsberg Mobile forms application in App store When installed follow this procedure when starting the application When application installed enter login information provided by Kongsberg in a separate mail to access the check lists Please allow the device to synchronize with internet connection Whenever dat...

Page 40: ...trical cabinets KONGSBER recommend to keep the below listed spare parts on board as a minimum of on board spare parts for additional tailored recommendations please contact km support kongsberg com Mechanic Hydraulic On board spare parts On board Need to replace 4x Filter 2x Load sense valve 2x Proximity switch 2x Magnetic coils Controls On board spare parts On board Need to replace 1x Phase failu...

Page 41: ...authorized reproduction in whole or in part must include this legend 2020 KONGSBERG All rights reserved P a g e 41 10 Contact Country Contact information NORWAY KONGSBERG MARITIME CM AS Deck Machinery and Motion Control Aarsundveien 24 N 6270 Brattvaag Support and Spares for Deck Machinery and Motion Control Phone 47 700 13 300 E mail service dmss km kongsberg com 24 7 Global Customer Support Phon...