Hylas 54 Specifications | H ome
Commissioning
Dock and Sea Trials
Introduction:
We searched high and low for some guidance as to what process we should use and in general found that surveyors were generalist. Most of them do not operate with a detailed systems checklist that we could review for completeness prior to beginning the survey. As a result, we have put together our own list of details to be surveyed and tasks to be completed prior to closure. Others are welcomed to use this list as they see fit.
We will provide a full report on our experiences with the contracting, commissioning, dock trial, sea trial and acceptance processes after the "ordeal" is completed.
We have received a list of problem areas from previous owners and we intend to check each of those areas in detail. We have retained the services of the following surveyors to assist in providing a detailed analysis of the boat:
 General Surveyor: John Howe, Howe and Associates, Ft. Lauderdale, FL ; Survey overall condition of boat -Rig, hull, internals
 Electrical Surveyor: Ward Marine, Ft. Lauderdale, Fl; Check sizing and "tinned" for all wiring, AC & DC power and electrolysis testing
 Engine Surveyor: RPM Diesel, Yanmar Dealer, Ft. Lauderdale, FL; 954 587-1620; Installation guidelines and operation
 Genset Surveyor: RPM Diesel, Kohler Dealer, Ft. Lauderdale, FL; 954 587-1620; Installation guidelines and operation
 Refrigeration Surveyor: Beard Marine, Ft. Lauderdale, FL ; 954 463-2288; Back flow pressures on water discharge, temperature control, leakage detection and mechanical placement
Commissioning Yard: Summerfield's, Ft. Lauderdale, FL. 954 535-4726
Ft. Lauderdale Maritime Attorney: Mark Ercolin 954 792-5425
Process:
Upon completion of the Yacht, and prior to its acceptance by and transfer of property to the Buyer, tests and trials will be conducted as outlined below.
All trials will be performed in the presence of the Owner and the Builder's representative. A test certificate will be issued reporting all trials and will be duly signed by the Builder, the Owner. The Test and Trials will be broken into two trial phases, consisting of Dock Trials and Sea Trials. The Dock trials will be composed of the following tests:
 Equipment Tests
 Propulsion Plant Tests
Pursuant to successful completion of the Dock Trials, the vessel will be subjected to the Sea Trial phase. The Sea Trial phase will be composed of:
 Components, Machinery, Equipment and Systems Tests
 Sail Tests
 Calibrations
The information provided on this page does not include the detailed listing of standard parts and options. Since this will vary a lot between boats, we will not provide that listing here. We will conduct a line item, by line item inventory that to ensure completeness of all contracted items (Contract Inventory)
 Dock Trials:
Dock Trials will be composed of Equipment Tests and Propulsion Plant Tests while the vessel is still tied to the dock. We will also haul the boat and do a complete inspection of the hull, rudder, skeg, and below water fixtures. We will have the surveyor test for voids and laminate /resin integrity/curing.
Equipment Tests:
Prior to sea trials, all equipment and machinery, will be thoroughly tested for a length of time sufficient to demonstrate satisfactory workmanship and operational suitability for the purpose intended, and that all requirements of the Specifications have been satisfactorily fulfilled.
This equipment shall include but not be limited to the following (For completeness, there may be some redundancy):
 Bilge plant including wiring to the bilge pumps, switches and fuses, high water bilge alarms, etc.
 Fire fighting system and alarms
 Safety equipment including the mandatory Coast Guard safety package - Horns, Flares, Life Jackets, 8 inch Bell, etc.
 Fuel system including the location of tanks, verification of the ability to remove all tanks for servicing, feed lines, manifold system, fuel pumps and the wiring for fuel pumps, Dual Racor fuel filters for the Main Propulsion system and a single Racor fuel filter for the Genset, including vacuum gauges and water detector, purifiers, and tank tenders
 Steering system - Standard wire quadrant steering mechanism
 Electrolysis tests
 Windlasses and windlass control switches, both on deck and remote, fusing and power feed to the windlass battery
 Bow thruster
 Sanitary system including holding tanks, Y valves for manual pump out vs. shore side pump out, double hose clamping, etc.
 Pump out macerator, hold tank gauges
 Galley, domestic equipment & systems as provided
 Calibration of all tanks, both fuel and water
 Inspection for 316 Stainless Steel deck fittings and screws and bolts, including screws for the rub rail
 Priming, pumping and endurance tests for all pumps and piping systems
 Air conditioning and heating equipment
 Hot and Cold fresh Water system including deck wash down and deck shower systems
 Stove and leak detect propane system
 Hydraulic systems, specifically for the autopilot, bow thruster and furling gear if outfitted with hydraulic motors
 Refrigeration and Freezer systems (both AC and DC systems using temp probes and leak detectors)
 Navigation and signaling lights; tri-color, running, steaming, deck, boom, cockpit, and stern spots
 Monitoring/alarms and automation systems; Fire, bilge, engine, Genset, water in fuel alarms, engine overheat and oil pressure, etc.
 Main Engine and generator cooling systems (see below)
 All possible sail handling equipment
 Electrical system, this includes batteries, DC charging, Inverters, AC power from shore and Genset, labeling of wires, etc.
 Identify exceptions to ABYC electrical standards
 Check that equipment installation has been properly carried out and that all the components and accessories have been correctly fitted
 Check that individual components such as switches, lighting equipment, pumps, etc., work properly
 Check that the batteries and emergency batteries function properly
 All tanks and pipelines are to be properly cleaned out and flushed through before any trials are commenced.
 All Floor board and cabinets close, open and lock correctly
 Rigging
Any defects found during dock trials shall be rectified before proceeding on to the Sea Trials.
Engine Tests:
The main propulsion engine and the Genset will be inspected and stress tested to ensure proper operation. The following tests will be done:
Generator System Test:
The generator will undergo operational tests for at least 12 together with shore side load bank testing to the limit of the generator's specified capacity. The Genset will be run with all air conditioners running and battery chargers charging the batteries. Compatibility of Genset output with Inverter, Inverter output charging will be tested as well as stability of Genset AC output.
We received a 10 page checklist from Gulf Coast Marine Electric, Inc. in Ft. Myers Beach, FL, that we will use to check all aspects of the Kohler marine Genset. We will use this checklist as our test plan for Genset acceptance.
Main Propulsion System Test:
When we started asking around for guidance on how to test our engine for acceptance, we received a lot of information that was contradictory. So we went to the source, Yanmar, and got from Mac Boring, their largest US Distributor, guidance on engine performance testing. The table below lists the RPM rates that Yanmar maintains that the engine should attain under varying loads.
Yanmar provide the following performance test information for new installations:
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Idle
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High Idle
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Full Load*
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Prop Match*
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RPM's to Attain
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800
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4000 - 4100
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3600+/-50
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3700 - 3750
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*Note: These items will be check during the Sea Trials
Further Notes wrt RPM's at full load: While in Trinidad, we had the Yanmar warranty people replace our injectors as a result of an warranty advisory issued by Yanmar concerning the size of the injector nozzle holes. Yanmar replaced our injectors with nozzles that had 1 micron smaller hole. This in itself did not seem to make a difference in the performance of the engine, but more interestingly, the Yanmar fold in Trinidad insisted that the Full Load RPM's should be higher than the reported 3600. They claimed that the RPM should be closer to 4000. We spent a considerable amount of time trying to achieve this RPM and have come to the conclusion that 4000+ is obtainable but is a question more of prop pitch given that your engine is properly tuned. As a matter of course, we can achieve 3800 RPM's or more depending upon the cleanliness of our hull, time since last tune -up, prop pitch and cleanliness of our prop and last but not least, the weight of the boat. In our typical cruising style, fully loaded, we are 32 tons, well over the designed weight. It is easy to conceive that we could get another 100-200 RPM's just based upon lessening our wetted surface area. The point of this diatribe is to assert the fact that full load RPM should easily be in the 3800-4000 RPM range, not the suggested 3600 as attested to by many "knowledgeable" experts. If you cannot achieve the 3900+/-100 RPM's, you are probably overpropped. You can tell if your transom is sooty. Properly tuned, soot should be minimal at 2700 RPM and obviously more at 3900 +\- 100 but not extensively so.
Engine room temperature should stabilize at 110 degrees F +/- 5 Degrees for proper engine operation. Higher temperatures will cause excessive wear and decrease engine life expectancy. Higher engine room temperatures indicate poor ventilation. Dave MulChayee from Grunert put that temperature at 104 degrees (954 973-2477).
We received a 2 page Yanmar engine checklist from Mastry Engine Center, Tampa, FL that will be used to check all aspects of engine performance. In addition to the 2 page document , We will also perform the test in accordance with the instructions on page 10-41,  Chapter 10.6 of the Yanmar Service Manual (Hinshi -8009 manual).
Haul:
Inspect Hull, rudder, skeg and all underwater fixtures. Look for voids and spot check for hull integrity and proper curing. Look for damage during shipping.
Sea Trials
After a satisfactory dock trial, the vessel is to proceed on sea trials with the Owner on board during all trials. The vessel will be crewed and under the command of the Builder's Master. Trials shall be conducted under good weather conditions, with sea state not more than wind Beaufort force 3, and in water with a depth of no less than ten times the vessel's trial draft.
During the official sea trials, a thorough examination shall be made of the vessel and all it's components, and machinery, equipment and systems shall be operated under normal service conditions, simultaneously and continuously as far as practicable. Sea Trials will also dynamically test the Sails under the previously defined conditions. Any items requiring calibration will be completed prior to the conclusion of the Sea Trials.
Components, Machinery, Equipment and Systems Tests
Trials to include but not limited to the following:
 All automatic systems to be tested.
 Rig Tuning
 Full Load and Prop Match tests of engine
 Functional/capacity testing (and adjustments as necessary) of all equipment, instruments and systems (including piping)
 Compass calibrations with max. deviation , +/- 3 degrees (to ensure that there are no spurious magnetic anomalies)
 Maneuvering and steering trials
 Crash stops
 Steering and maneuvering trials with bow thruster
 Noise level, acoustic privacy monitoring and vibration survey as performed by owner or surveyor
 Main propulsion engine endurance and speed trials at maximum power - Two runs will be conducted at maximum power over a measured course of 1 mile in a calm sea and with no wind with the Yacht in a half-load condition (i.e. yacht empty save for tank capacity half full), and clean hull. Engine will be run in the same manner as in the static Dock Tests
 Any other trials that may be required by surveyor.
All equipment parameters shall meet manufacturer's specifications prior to acceptance of vessel.
Following the completion of the trials, any item of equipment that is defective, will be repaired or replaced. If major repairs are necessary, the trials are to be rerun until all equipment meets the requirements. If during or before sea trials the vessel is grounded, the Builder shall be required to dry-dock the vessel, for underwater inspection, and the damage, if any, shall be rectified, all costs to be at the Builders account.
Sail Tests:
Functional tests will be carried out on sails and related equipment during sea trials in optimal wind and sea conditions.
 Roller Furling Main Sail (Leisure Furl) and Supporting Gear
 Mast Alignment to within +/- 1 inch athwart ships
 No Rake in mast
 Roller Furling Genoa and Supporting Gear
 Hydraulics
 Boom Vang
 Roller Furling Stays'l and Supporting Gear
 Spinnaker and Spinnaker Gear
 Winches and Winch Motors
 Proper number of Winch Handles
 Leads, Turning Blocks, Halyards, Whipping, and all other deck hardware
 Standing and running rigging
 Norseman fittings
 Shroud Boots
Calibrations:
The following items will be calibrated during the Sea Trial stage (if not before):
 Ritchie Compass
 Autopilot Compasses
 Fuel tanks
 Water tanks
1 Year Warranty Period:
One item that we cannot check prior to acceptance is the fuel consumption rate as a function of RPM's. However, we will measure that as time permits during the initial warranty period to ensure that the engine reasonably matches up with Yanmar published literature.
The targets provided by Yanmar for the 125 HP 4JH3-DTE engine are:
Target Fuel Consumption Rates (GPH) at Various RPM's
Engine
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2000
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2200
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2400
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2600
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2800
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2900
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3000
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3100
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3200
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3300
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3400
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3600
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3800
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4JH3-DTE
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1.35
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1.69
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2.11
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2.54
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2.99
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3.25
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3.54
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3.83
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4.15
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4.49
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4.86
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5.76
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6.87
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