Subject : This AEB is for the following applications:

Sea Trial Procedures Automotive Industrial G-Drive Marine

Date Created: 10/30/2003 File Name : 0.14.02 MAB No.

Revision Date : 11/08/2005 Sea Trial Tests & 0.14.02-10/30/2003

Expire Date : 11/08/2006 Equipment
Engine Family : All
Engine Model : All

Author : Diana Cobb Page 1 of 10

Purpose

The purpose of this document is to explain how to conduct a sea trial for
propulsion and auxiliary engines. This document also covers the following
procedures:

A. Set-up, Start-up, and Warm-up.

B. Cold start and Idle Stability Test.
C. Steady State Prop Curve (Free Sailing).
D. Steady State Prop Curve (Dead Push or Bollard Pull).
E. Wide Open Throttle (WOT) Acceleration.
F. Max Load Test for Fixed Speed Auxiliary.
G. Sound Level (dBA).
H. Tools and Instrumentation.
I. Sea Trial Data sheets.

Introduction

There are many situations that require both an installation review and a sea trial.
The sea trial process ensures that the engine is operating correctly. It also
serves as a benchmark for comparison in case problems arise in the future. Sea
Trial tests are required for every new engine installation, following a major engine
repair, and for troubleshooting.

Summary of Installation Requirements

• Sea trial tests must be completed according to the procedures specified

within this document for all new engine installations and following
major engine repairs.

Cummins Confidential
• Sea trial measurements must be above the minimum and below the
maximum values listed in the Engine General Data Sheet or the Engine
Performance Data Sheet.

• Electronic (INSITE) measurements must be recorded along the propeller

curve (idle to full throttle) for electronic engines.

• Engines must achieve or exceed rated speed at full throttle under any
steady state operating condition; except engines in variable
displacement boats, which must achieve no less than 100 rpm below
rated at full throttle during a dead push or bollard pull.

• Engines must achieve or exceed rated rpm when accelerating from idle
to full throttle.

Discussion

The Marine Policy regarding sea trials can be found in Section III of the IBU
Worldwide Sales Policy bulletin 1.1.02. Section III of the bulletin includes the
following statement:

"...it is Cummins Marine's policy for distributors to review all marine applications
and to conduct sea trials for conformance to Cummins installation guidelines.
Any mis-application or improper installation of marine engines, or auxiliaries, is
ultimately the responsibility of the selling distributor....also responsible for
application and installation of marine engines sold to dealers or other parties."

Each installation review report form includes a sea trial data sheet. These data
sheets can be used for engines with mechanical and electronic fuel systems. For
Cummins engines with electronic fuel systems, there is additional information
that must be captured using INSITE. The following sections explain required sea
trial procedures.

Sea trial tests must be completed according to the procedures specified

within this document for all new engine installations and following major
engine repairs.

It is important that the vessel is operated during sea trial in a manner similar to
the way it will be loaded and operated during its normal duty. The expected
loading should consider cargo capacity, fuel and water, number of personnel,
hard tops, soft tops, rigging, dingys, personal water craft, nets or other items
which add significant weight or drag for vessels routinely outfitted with these
items.

Conduct a sea trial made up of the individual tests listed below on all engines as
appropriate:

Page 2 of 10
 Measurement
Sea Trial Test Required? Application
Type
Steady State Prop Curve Basic and Yes Constant load
(Free Sailing) * INSITE
Steady State Prop Curve Basic and Yes Highly variable
(Dead Push or Bollard Pull) INSITE load
*
Wide Open Throttle (WOT) Basic and Yes All
Acceleration INSITE
Neutral and in-gear Idle Basic Yes All
Stability
Max Load Test (Fixed Basic and Yes Auxiliary
speed) INSITE
Sound levels Basic No All

* Required prop curve test depends upon application; vessels that are loaded
beyond their own displacement use dead push or bollard pull.

A. Set-up, Start-up, and Warm-Up:

This is a pre-trial procedure that should be accomplished before the formal sea
trial event.

1. Review sea trial test plan with people that will be operating or on the boat
during the sea trial.
2. Install sea trial instrumentation.
3. Fill out Vessel / Application, Propulsion System, and General Conditions
sections on the Sea Trial Pre-Test data sheet. THIS IS REQUIRED
INFORMATION.
4. Prior to engine startup, check engine, marine gears and additional equipment
per Manufacturer's Operating Instructions.
5. Start engines dockside and confirm normal operation while idling. Repair any
leaks or anomalies before proceeding with sea trial tests.
6. Run engines at part load (sailing) to achieve normal coolant operating
temperature. Sustain warm engine conditions for at least fifteen minutes.
Confirm all test instrumentation is functioning correctly.
7. Run engines at full throttle for at least five minutes. Confirm full throttle and
rated speed can be achieved and check for leaks or anomalies before
proceeding with other sea trial procedures.

The intervals of recording measurements vary among the applications as

outlined in the requirements below:

• Recreation Propulsion - Every 200 rpm intervals.

Page 3 of 10
• Commercial Propulsion and Variable Speed Auxiliary- Full throttle rpm,
Cruise rpm (200 below rated), and Peak Torque rpm.

• Fixed Speed Auxiliary - At rated speed under maximum load.

B. Cold Start and Idle Stability Test:

The Idle Stability Test consists of the following conditions:

• Cold Start w/idle neutral and drive - should be the first test scheduled.
• Warm engine w/idle neutral and drive - can be scheduled whenever
convenient.

1. Unloaded and in-gear idle engine speed can be measured as follows:

2. Ensure that engines are at normal operating temperature.
3. Ensure that transmission is in neutral position and throttle is at idle
position.
4. Record engine measurements (below).
5. Shift into forward gear maintaining the throttle at idle position
6. Wait for vessel speed to stabilize.
7. Record engine measurements (below).

For mechanical engines a handheld or shop tachometer should be used to

ensure accuracy.

Recommended Insite Recommended Insite

Measurements for Quantum Measurements for Centry
Battery Voltage Battery Voltage
Cold Idle Override Switch Engine Speed
Coolant Temperature Percent Fuel Control Valve (EFC)
Engine Speed Percent Throttle
Intake Manifold Temperature Percent Torque
Percent Torque Rail Pressure
Rail Pressure Step Timing Control Actuator Status
Timing Pressure
Final Throttle Command
Intake Manifold Pressure
Desired Rail Fueling
Fueling Current Offset

C. Steady State Prop Curve Procedure (Free Sailing):

• Engines must achieve or exceed rated speed at full throttle under any
steady state operating condition; except engines in variable

Page 4 of 10
 displacement boats, which must achieve no less than 100 rpm below
rated at full throttle during a dead push or bollard pull.

Correct propeller sizing is required to ensure expected engine life, acceleration,

and minimize acceleration smoke. Propeller selection should be made
considering the maximum expected loading of the vessel. The full throttle test is
designed to confirm that the propulsor device does not overload the engine.

In certain operating conditions, such as crew boat maneuvering and station

holding, it is possible to lug the engine down while at full throttle. Sustained
operation in this mode is not permissible. Such operation may cause major
engine damage.

1. Warm up engines and allow them to stabilize at normal operating

temperatures.
2. Record all measurements at slow and/or low idle (in-gear)
3. Increase the engine speed to the first test rpm. Allow the engines to achieve a
stabilized rpm for 30-60 seconds. Record all of the required test parameters
shown in the following tables. Repeat at every interval to WOT.
4. Basic measurements for the steady state prop curve are required for both
mechanically and electronically controlled engines. Refer to Table 1.
5. INSITE measurements listed in Table 1 for the steady state prop curve are
additional measurements required for electronically controlled engines. Some
measurements may be applicable only to CENTRY or only to Quantum
controls.
6. INSITE measurements must be recorded on all electronically controlled
engines. There are two ways to record the required INSITE data during a sea
trial. At this time both ways are acceptable.
a. Set up INSITE at the beginning of the sea trial using one file name
and letting it log data until the steady state prop curve is complete.
b. Record a new INSITE log file for each engine interval speed tested.
A column is provided on the sea trial data sheet to record the
INSITE data file names.
7. For steady state sea trial data, set the INSITE sample rate to 5 seconds.
Allow at least 30 seconds stabilized operation at each RPM interval.

• Electronic (INSITE) measurements must be recorded along the propeller

curve (idle to full throttle) for electronic engines.

Page 5 of 10
 Table 1- Parameters for Basic and Insite Measurements
Basic Measurements INSITE Measurements
(If Applicable) (If Applicable)

Engine Speed Engine Speed

Vessel Speed Intake Manifold Pressure (Turbo
Boost)
Exhaust Back Pressure Intake Manifold Temperature
Sea Water Inlet Restriction % Throttle
Sea Water Pump Outlet Pressure % Fuel or % Torque
Fuel Inlet Restriction Engine Oil Pressure
Fuel Drain Restriction Engine Oil Temperature
Intake Manifold Pressure (Turbo Coolant Temperature
Boost)
Exhaust Temperature Ambient Air Pressure
Intake Air Temperature Fuel Rate
Oil Pressure Battery Voltage
Coolant Temperature Fuel Rail Pressure
Fuel Supply Temperature Timing Rail Pressure
Fuel Pump Out/Rail Pressure Desired Fueling
Engine Coolant Pressure In % EFC
Engine Coolant Pressure Out Step Timing Control Status
LTA Coolant Temperature In Crankcase Pressure
LTA Coolant Temperature Out
LTA Coolant Pressure In
LTA Coolant Pressure Out
Air Intake Restriction

C. Steady State Prop Curve Procedure (Dead Push or Bollard Pull):

• Engines must achieve or exceed rated speed at full throttle under any
steady state operating condition; except engines in variable
displacement boats, which must achieve no less than 100 rpm below
rated at full throttle during a dead push or bollard pull.

The dead push or bollard pull procedure is required only for vessels that
can be loaded beyond their own maximum displacement (weight). For
example, tugboats, pushboats, net-dragging fishing boats, and dredgers are
required to conduct this sea trial test procedure. The dead push or bollard
pull test subjects the engines to the maximum load, thereby simulating the
vessel's worst case towing or pushing operation.

CAUTION - This test should not be conducted on any recreational vessels,

or any vessel that has a hull design that cannot handle the resultant loads.

Page 6 of 10
1. Confirm with the vessel owner, captain, and/or shipyard that it is acceptable
to conduct a dead push or bollard pull using their vessel. Have them
determine what facilities and equipment should be used to handle the thrust
resulting from full throttle operation. Take care to avoid dock/pier erosion that
can result from propeller wash, and be considerate of nearby boat traffic.
2. Secure the vessel to a stationary bulkhead either with lines (in the case of a
bollard pull) or a pier head, sand bank, etc. (in the case of a dead push).
CAUTION - Confirm with the captain that the equipment used to secure the
vessel can handle the maximum thrust.
3. Follow the same propeller curve test procedure and record the measurements
as outlined in the free sailing test describe above.
4. Confirm that all engines achieve a value greater than 100 rpm below rated
speed when at full throttle.

Z-drive

It may be difficult to conduct a static push or pull from a shoreline on boats with
Z-drives due to their deep draft requirement. Z-drive propellers can easily suck
up debris from a shallow bottom potentially causing damage to the propeller. An
alternative method for achieving full load conditions may be used for boats with
twin Z-drives. The full load propeller curve test can be conducted in deep open
water with the Z-drives positioned transversely such that the thrust is directed
outboard, and the boat remaining stationary. However, operating the boat in this
condition could induce excessive hull vibration, especially if the fuel tanks are not
completely full of fuel. The captain and boat owner should confirm acceptable
operation prior to running this test.

E. Wide Open Throttle Acceleration (WOT)

• Engines must achieve or exceed rated rpm when accelerating from idle
to full throttle.

Acceleration time and planing time can be measured as follows:

1. Determine desired engine speed(s) at which the time interval will be

measured.
a. For commercial and displacement hulled vessels this is typically
rated engine speed.
b. For recreational vessels 50%, 75%, 90%, 100% of rated engine
speed and WOT should be recorded.
c. For recreational planing and semi planing hull vessels time to plane
should also be recorded, see below.
2. Ensure that engines are at normal operating temperature.
3. Bring vessel to rest.
4. Shift into forward gear at idle.

Page 7 of 10
5. Wait for vessel speed to stabilize.
6. Advance throttles to WOT as quickly as possible, simultaneously starting
stopwatch or logging data with INSITE.
7. Log time to each engine speed as determined in step 1.
8. Repeat steps 3 through 7 for a total of 6 runs (3 each in opposite directions to
account for wind or current effects). It is acceptable to make three runs in
one direction then three acceleration runs in the opposite direction, or to
make a run followed by a run in the opposite direction and repeat three times.
9. Average times to each engine speed and planing time and record value on
sea trial form.

F. Max Load for Fixed Speed Auxiliary

For fixed speed marine auxiliary drives, measurements should be taken at

rated speed under maximum load and documented on the sea trial data
sheet.

Variable speed engines used in auxiliary applications should apply the

appropriate prop curve test.

G. Sound level measurement procedure (dBA):

The vessel application dictates whether the sound level measurement should
be taken in the engine room or at the helm. Larger vessels with manned
engine rooms should have the sound level measurements taken in the engine
room. Typical recreational vessel should have the sound measurements
made at the helm or in the case of flybridge vessels it may be appropriate to
measure sound level in the salon or other interior spaces. In all cases the
location where the sound measurement was made should be documented.

1. Determine desired engine speed(s) at which sound level measurements will

be taken. Typically in gear idle, cruise and WOT engine speeds.
2. Ensure that engines are at normal operating temperature.
3. Ensure other equipment is not operating and area for testing is away from
external sources of noise.
4. Run engine at desired speeds and measure the sound level using dBA scale
a. Sweep the meter through the space
b. Observe the worst case position, highest sound pressure level, and
record value and location (including distance and direction from
engine or fixed reference).

H. Tools and Instrumentation

A combination of mechanical and electronic gauges are used to measure the

basic parameters mentioned in section C in additon to engine installation angle.

Page 8 of 10
A laptop personal computer capable of operating INSITE is also necessary.
Tools and instrumentation can include, but are not limited to the following:

• Angle Indicator (Inclinometer)

• Fluke Digital Multimeter System (inc luding 80TK thermocouple module and
PV350 digital pressure module)
• Tachometer
• Appropriately sized fittings and adaptors
• Exhaust temperature probe
• Stopwatch
It is highly recommended that applicable tools be calibrated on a periodic basis to
ensure the integrity of sea trial measurements.

I. Sea Trial Data Sheets

• Sea trial measurements must be above the minimum and below the
maximum values listed in the Engine General Data Sheet or the Engine
Performance Data Sheet.

All measurements must be compared to the va lues provided on either the Engine
General Data Sheet or the Engine Performance Data Sheet for the specific
engine. If a minimum value is specified, the measured value must be above the
minimum. If a maximum value is specified, the measured value must be below
the maximum. However, some parameters (like oil pressure) may have a normal
operating range specified, and the measured value may be higher than the range
shown. This is acceptable. In these cases some judgement must be used to
verify that the measured value is better than the value shown on the data sheet.

Sea Trial Data Sheets are revised periodically as the need arises. To assure use
of the most current form, it is recommended that users download the file from this
MAB each time a new review report is created.

There are currently four different types of sea trial data sheets which are shown
as follows:

Commercial Sea Trial Sheet.xls Gen Sets- Sea Trial Sheet.xls Recreation Sea Trial Sheet.xls

Packaged Product Sea Trial Sheet.xls

Page 9 of 10
Change Log

Revising Author’s
Date Change Page
Name
11/08/2005 No content change/Uploaded to website DDC

Distribution of this document is intended for Cummins personnel and distributors. The information contained in this
document is only considered valid while published on the Marine Website. Copies and archived documents are not
considered current.

Page 10 of 10