REPAIR AND CALIBRATION OF BOTH MAIN ENGINE CONTROL SYSTEMS -IN SHIP

Overhauling & testing of ME pneumatic control components.1)Pneumatic Supply Frame a) 30 bar /7 bar filters b) 30 bar/7 bar reducer c) OR module d) Non return valve e) Manometer 2) LCP Pneumatic Circuit a) a) Solenoid valves: (1)Fuel Rack Limiter, (2)Safety Stop,(3)start b) Electra Pneumatic valves: (1)start,(2)stop,(3)P2P1 open/close, (4)P2P4 open/close, (5)Air valve open/close, (6) Gas valve open/close, c) Pressure Transmitter Control Air Pressure. d) Pressure Switch : "LOW CONTROL AIR PRESSURE ALARM e) Pressure Switch: Control air low pressure for stc operation, f) Pneumatic Valve 19/9 , g) 7 bar filter with cock.

Checking / Overhauling, calibration and proving of main engine safeties. Calibration/testing of Safety PMS Rack: Testing of PCB's AE24-24 & AE24-15 power supply card, SVAE card, SPH card, C155 SE card, MTP1 & MTP2 card, AlP card, RSP card, ICM1 ICM2 & ICM3 card, ROM card, ACM card..1)Emergency stop ( Push button MCR-S280/Remote)a) Testing Emergency PB(LCP/MCR) 2)ME Overspeed (112%) a) RPM sensor (ST001) b) SAVE card calibration c) U126 calibration (Threshold module) d) Oaverhauling of overspeed electro-pneumatic valve(C621) 3) ME lub oil pressure very low a) PT 206 calibration of LO press. Transmitter (0-10 bar) b) calibration of SPH card 4) Gear box safeties 5) LO temp. very high a) Calibration of ME lub oil temp. module U552(sfare) & RTD sensor TT218 6) ME Jacket cooling water very low level a) Overhauling/testing of FW tank float switch (LLLS 311) b) checking Timer (K272) 7) ME fresh water very high temperature a) Calibration of FW temperature module U554 & RTD sensor TT314 8) ME very high bearing temperature a) Testing of bearing sensors (PT-100 sensor - TT223 -1 to TT223 -7) b) Calibration Of MTP 1 & MTP 2 card c) Calibration of safety threshold d) 07 nos/engine bearing sensor (RTD) check 9) Clutch air very low pressure 10) Watch dog or major fault (Digital governor).

Calibration of Fresh Water temperature regulator.1) Calibration temp. regulator 2) RTD sensor.

Calibration & testing of temp. sensor & module:.1) U581 -Lub oil temperature at engine inlet & TT217 RTD sensor 2) U584 -Aie temp. at air cooler at outlet & TT210 RTD sensor 3) U587 FW temp. at engine outlet & U589 mA isolator & TT313 RTD sensor 4)U591 FW temp. at engine inlet & TT321 RTD sensor 5) U594 FW temp.at heater outlet (Spare).

EC PARAMETER:.1) Analog input 2) Frequency input 3) Anolog output 4) Logic input 5) Logic output.

Calibration & testing.Calibration & testing of 1. Fuel Rack measure 2. Fuel rack sensor(ZT006) 3. Remote speed set point 4. U395 (4-20 mA) isolator 5.Charging air pressure a) Pressure transmitter(PT119) b) 0398 (4-20 mA) isolator 6. FW temp..

Inspect the overspeed solenoid valve & Repair/replace overspeed solenoid valve if found defective.Inspect the overspeed solenoid valve & Repair/replace overspeed solenoid valve if found defective.

Checking /Overhauling/Testing & proving ME starting inter locks.Checking /Overhauling/Testing & proving ME starting inter locks a) LCP/Remote control location b) ME RPM < 200 rpm c) No safety stop d) safety reset e) safety circuit failure f) No ME turning gear engaged g) No manual to handle stop position h) No Overspeed pressure low i) Pre-lubrication correct..

Checking /Overhauling/Testing & proving ME Clutch interlocks.Checking /Overhauling/Testing & proving ME Clutch interlocks a) ME speed > 400 rpm <540 rpm b) Pitch at zero c) Shaft bline condition are correct d) Shaft break off e)Shaft lock off g) Shaft turning gear disengaged.

START RELEASE:.START RELEASE: a) ME turning gear pneumatic limit SW for start release, b) ME fuel control handle lock limit SW c) Fuel rack at zero proximity sensor (ZS007) d)Priming pump flow SW (FS210 e) Overspeed air pressure SW (PLA603).

Checking of STC valve operation:.Checking of STC valve operation: a) Gas Valve (Open/Close) -25112/113 b)Air Valve (Open/Close) -ZS110/111 c)By pass P2-P4 Valve (Open/Close) -ZS108/109 d)By pass P2-P1 Valve (Open/Close) -ZS106/107 e) STC manual/auto operation f) Load limiting valve (C229).

Checking of various Cards:.Checking of various Cards: 1) RPM sensor (ST 005) 2) SE card calibration 3)Calibration of speed threshold 4) RPM indicator(analog/digital ) calibration (P154) 5) Calibration of U154.

Checking of various Alarms:.Checking of various Alarms: 1)STC failure 2)Safety circuit failure 3)STC alarm 4)Manual handle to stop 5)Turning gear engaged 6)starting allowed 7)Engine shutdown 8)24V DC safeties 9)Remote position 10)Governor major fault 11)Over speed air pressure low 12) Control air pressure low 13) High temp. of LCP 14)Air valve open 15)Gas valve open 16)Engine controller minor fault 17)Starting in progress 18)24V DC control oil 19)Local position 20)Governor limitation 21)Engine controller fault 22) Lack of priming lub oil 23)ME starting fault 24) Air valve close 25) Gas valve close 26) Engine alarm 27) STC manual 28)STC Auto 29)Bypass P2-P1 open 30)Bypass P2-P1 close 31)Bypass P2-P4 open 32)Bypass P2-P4 close 33) Safeties stop overridden 34)Remote start interlock 35)Emergency stop 36)Prelub in progress 37)Clutched engaged 38)Pre-lub failure 39)Clutch allowed.

Calibration and testing.Calibration and testing of : 1) ME speed sensor(0-1250)-01 a)RPM sensor(19127/ST002) b)Frequency divider (U401/divider/3) 2)ME speed sensor -2(0-1250 rpm/0-1958.33 Hz) a)RPM sensor(19127/ST003) b)Frequency divider (L 3)ME TC-A speed sensor -2(0-35000 rpm/0-1166.66 Hz) a)TC A RPM sensor(19126/ST116) b)Frequency divider (U405/divider/1) 4)ME TC-B speed sensor -2(0-35000 rpm/0-1166.66 Hz) a)TC A RPM sensor(19126/ST117) b)Frequency divider (U407/divider/1).

Calibration and testing.Calibration and testing of : 1) Power merging limit a)4-20mA isolator(U428) 2)Actuator control (0-1A) a)U432 power supply module b)Actuator (CO20) 3)TC-B speed a)4-20 mA module(U433) 4)Me speed(0-1250 rpm) a) threshold module (U434) 5)ME fuel rack (0-35 mm) a) ME fuel rack analogy indicator(0-35mm/P434) b)4-20 mA isolator (U435) 6)TC-A speed a)4-20 mA module(U438).

Calibration and testing.Calibration & testing of 1)Start 2)Stop 3)Analog speed set point 4)Fault reset 5)Engine clutched 6)Engine declutched 7)Clutched demand 8)Declutched demand 9)Clutched allowed 10)Engine shutdown 11)Local position 12)Starting allowed 13)Fuel rack SW at stop 14)Priming lub oil ok 15)Start fault inhabitation.

Calibration and testing.Calibration & testing of 1)1TC mode , 2)Limitation ON 3)2TC mode 4)Starting & Fuel rack limitation timer & 5)Stop 18)Starting possible 6)Pitch blocking 22)Pitch reducing 23)Starting failure 7)Pre lub & clutch/declutch fault 8)Clutch order 26)Declutch order.

OPERATION CHECK.OPERATION CHECK OF: 1)Injector pipe leakage A Bank float SW 2)Injector pipe leakage A Bank float SW 3)Fuel filter clogging sensor 4)Lub oil filter clogging sensor 5)Lub oil sump level SW.

Fluid pressure transmitter to PCS.Fluid pressure transmitter to PCS 1)Air pressure at CAC outlet(PT105) 2)Lub oil perticle detection filter(PT220) 3) FW pressure at engine inlet(PT323) 4)SW pressure at engine outlet(PT404) Fuel pressure at engine inlet(PT505) 6)Starting air pressure(PT604) 7)Lub oil pressure engine inlet (PT231).

OPERATION CHECK OF Various sensor of engine room.Various sensor of engine room: 1)Crank case pressure high(PHS224) 2)FW tank low level float(LLA310) 3)Fuel tank high level(LHA508) 4)Fuel tank low level(LLA511) 5)Low over speed air pressure SW(PLA603).

Calibration of ME mechanical pressure gauge.Calibration of ME mechanical pressure gauge 1)Lub oil engine inlet(PI212) 2)Charge air(PI118)3)Diesel oil engine inlet(PI516) 4)Starting air(PI609) 5)FW pump outlet(PI307) 6)SW pump outlet(PI406).

Calibration & repair / replacement of thermostat.a)Check thermostat for correct functioning b)Replace if required.

Calibration of Pressure Transmitter.Pressure Transmitter: 1)Starting air pressure(0-40bar ).

Calibration & testing of main engine Exh. gas sensor & indication:.Calibration & testing of main engine Exh. gas sensor & indication: 1)16 no. engine exhaust gas thermocouple sensor 2)02 nos. compensation RTD 3)02 nos. pyro duct & 02 nos. pyro cable check..

Check in HMI touch screen calibration & parameter linearization..Check in HMI touch screen calibration & parameter linearization..

safety device checks for both main engine as per DTTT(V) check list Cold and hot SDC’s on BME to trials teams and proving the control circuit during FPT.safety device checks for both main engine as per DTTT(V) check list Cold and hot SDC’s on BME to trials teams and proving the control circuit during FPT.

Mandatory Spares.TEMP, CONVERTOR ,0-150 DEG, 24VDC.EX.068.00.1.03

Mandatory Spares.TEMP.CONVERTER,0-150 DEG, WITH 2C/O RELAY,24.EX.067.00.1.03

Mandatory Spares.PRESSURE GAUGE WITH GLYCERINE,I/P - 0-10 BAR.EX.013.00.1.03

Mandatory Spares.SENSOR - 19050.74.480.61.0.00

Mandatory Spares.SWITCH FOR MANUAL STOP.74.482.08.0.00

Mandatory Spares.PROXIMITY DETECTOR.74.482.11.0.00

Mandatory Spares.LIMIT SWITCH BOX- FOR AX90/5 ACTUATOR.74.489.46.0.00

Mandatory Spares.LIMIT SWITCH BOX.74.449.71.0.00

Mandatory Spares.FUEL RACK SENSOR 19127MN.74.404.02.0.00

Mandatory Spares.TEMPERATURE SENSOR.74.603.50.0.00

Mandatory Spares.REGULATOR FOR FW TEMP.,24VDC,I/P-RTD,O/P-4-20MA.EX.091.00.103

Mandatory Spares.GALVANIC INSULATOR.76.904.13.0.00

Mandatory Spares.SIGNAL ISOLATOR.EX.045.00.1.03

Mandatory Spares.FREQUENCY DIVIDER - TURBO SPEED.EX.124.00.1.02

Mandatory Spares.FREQUENCY DIVIDER FOR GOVERNOR SPEED SENSOR.EX.062.00.1.03

Mandatory Spares.ENGINE SPEED INDICATOR 0-1250 RPM, 96X96.EX.047.00.1.03

Mandatory Spares.THRESHOLD MODULE.EX.042.00.1.03

Mandatory Spares.TEMPERATURE SENSOR.74.478.16.0.00

Mandatory Spares.TEMPERATURE SENSOR.74.478.17.0.00

Mandatory Spares.INDICATING LAMP-RED, WITH LENS,HOLDER AND LAMP.EX.070.00.1.03

Mandatory Spares.INDICATING LAMP WHITE, WITH LENS,HOLDER AND LAMP.EX.071.00.1.03

Mandatory Spares.INDICATING LAMP WHITE, WITH LENS,HOLDER AND LAMP.EX.071.00.1.03

Mandatory Spares.FUSECATRIDGE 0.5A-GF 10X38 (SET OF 10).74.910.14.0.00

Mandatory Spares.GLASS FUSE 300MA, SIZE 5X20, FAST BLOW, SET OF 10.E6.002.02.0.99

Mandatory Spares.GLASS FUSE 500MA, SIZE 5X20, FAST BLOW, SET OF 10.E6.003.02.0.99

Mandatory Spares.GLASS FUSE 4A, SIZE 5X20, SLOW BLOW, SET OF 1.E6.024.02.0.99

Mandatory Spares.ENGINE CONTROLLER.EK3010B-9719D0009AL

Mandatory Spares.COMPENSATION PROBE FOR EXH. PYROMETERIC DUCT.79.426.89.0.00

Mandatory Spares.FUSE 1 A Gg 10 * 38.72.910.06.0.00

Mandatory Spares.FUSE CARTRIDGE 2A-GL 10 X 38.75.971.13.0.00

Mandatory Spares.FUSE 4 A Gg 10 * 38.72.910.07.0.00

Mandatory Spares.FUSE 10X38 6A Gg.76.901.95.0.00

Mandatory Spares.FUSECATRIDGE 0.4A(AM)10X38.EX.305.00.1.03

Mandatory Spares.LEVEL SWITCH.74.382.01.0.00

Mandatory Spares.PRESSURE DROP / CLOGGING INDICATOR.74.419.69.0.00

Mandatory Spares.CRANCASE PRESURE SWITCH.74.903.20.0.00

Mandatory Spares.FILTER.EX.008.00.1.03

Mandatory Spares.PRESSURE REGULATOR, I/P-30 BAR, O/P-7 BAR.EX.103.00.1.03

Mandatory Spares.PRESSURE GAUGE WITH GLYCERIN 0-10 BAR.EX.108.00.1.03

Mandatory Spares.TERMINAL, STANDARD UNBREAKABLE,CTS2.5-U,RATED 27A,CONNECTWELL,CONDUCTOR 0.5-2.5sq.mm.E6.023.01.0.09

Mandatory Spares.ISO1 ELECTRO DISTRIBUTOR, (FOR 24V DC,SOLENOID RETURN).EX.002.00.1.03

Mandatory Spares.PNEUMATIC DISTRIBUTOR PNEU/PNEU.EX.003.00.1.03

Mandatory Spares.SOLENOID VALVE CNOMO DIA-1.6,24VDC.EX.083.00.1.03

Mandatory Spares.PRESSURE TRANSMITTER, 0-4 BAR,24V DC,O/P-4-20mA.EX.010.00.1.03

Mandatory Spares.PRESSURE SWITCH-1 TO 10 BAR.EX.022.00.1.03

Mandatory Spares.PRESSURE TRANSMITTER.EX.011.00.1.03

Mandatory Spares.PRESSURE TRANSMITTER.EX.023.00.1.03

Mandatory Spares.PRESSURE TRANSMITTER, 40 BAR,24V DC,O/P-4-20mA.EX.024.00.1.03

Mandatory Spares.FLOW SWITCH MOBREY ND 50 NP16.74.604.70.0.00

Mandatory Spares.CLOGGING INDICATOR.74.475.01.0.00

Mandatory Spares.SVAE OVERSPEED CARD.EX.041.00.1.03

Mandatory Spares.REGR.SAFETIES TEMP. CARD (RSP CARD).EX.050.00.1.03

Mandatory Spares.ON RELEASE SAFETY CARD ( RGM CARD).EX.055.00.1.03

Mandatory Spares.ON RELEASE SAFETY ICM CARD.EX.053.00.1.03

Mandatory Spares.PRESSURE GAUGE WITH GLYCERINE, I/P-0-40 BAR.EX.012.00.1.03

Mandatory Spares.PRESSURE GAUGE WITH GLYCERINE,I/P -0-6 BAR.EX.014.00.1.03

Mandatory Spares.PRESSURE CAUGE WITH GLYCERINE I/P - 0-4 BAR.EX.015.00.1.03

Mandatory Spares.SENSOR - 19050.74.480.61.0.00

Mandatory Spares.OVER SPEED SOLENOID VALVE.74.608.21.0.00

Mandatory Spares.SENSOR FOR BEARING TEMP.75.352.01.0.00

Mandatory Spares.LEVEL SWITCH.74.603.60.0.00

Mandatory Spares.PRESSURE SWITCH.74.608.23.0.00

Mandatory Spares.BREAKER SWITCH.74.482.33.0.00

Mandatory Spares.SENSOR REF 19127MN.74.480.01.0.00

Mandatory Spares.TURBO CHARGER SPEED TRANSMITTER.74.480.07.0.00

Mandatory Spares.TEMP.SENSOR.74.609.25.0.00

Mandatory Spares.TEMP.SENSOR.74.609.24.0.00

MAN ENERGY SOLUTIONS INDIA PRIVATE LIMITED