TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, , the Range Statement and the Assessment Guidelines for this Training Package.

1

Critical aspects of evidence required to demonstrate competency in this unit

Assessment must confirm appropriate knowledge and skills to:

a

Fault-find, dismantle, maintain and repair shipboard plant and equipment against specifications on a vessel of unlimited propulsion power

b

Identify malfunctioning and faulty plant and equipment and components and initiate appropriate action for repair or replacement

c

Exercise all safety, environmental and hazard control procedures

d

Identify typical plant and equipment maintenance and repair problems and hazards and take appropriate action

e

Communicate effectively with others during maintenance and repair operations

f

Ensure adherence to relevant regulations, IMO Conventions and Codes

2

Evidence required for demonstration of consistent performance

a

Performance is demonstrated consistently over a period of time and in a suitable range of contexts

b

Consistently applies underpinning knowledge and skills when:

1

assessing operational performance of shipboard plant and equipment

2

identifying shipboard plant and equipment malfunctions and faulty plant and equipment of a vessel of unlimited propulsion power

3

taking action to minimise any damage and safety risk that could be caused by plant and equipment malfunctions

4

fault finding, dismantling, maintaining and repairing shipboard plant and equipment

5

identifying plant and equipment maintenance and repair problems and determining appropriate courses of action

6

applying safety precautions relevant to plant and equipment maintenance and repair operations

7

completing maintenance and repair documentation and records

c

Shows evidence of application of relevant workplace procedures, including:

1

relevant sections of international Conventions and Codes and AMSA Marine Orders

2

OH&S regulations and hazard prevention policies and procedures

3

ISM Code safety management system procedures, quality procedures and work instructions on the fault finding, dismantling, maintenance and repair of shipboard plant and equipment, including plant and equipment specifications and directions on equipment maintenance

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

2

Evidence required for demonstration of consistent performance

(continued)

4

following on-board housekeeping processes

d

Action is taken promptly to report and/or rectify plant and equipment malfunctions, non-conformities, accidents, hazardous occurrences and safety incidents in accordance with statutory requirements, company procedures and the ISM Code

e

Work is managed, controlled and completed systematically with required attention to detail

f

Recognises and adapts appropriately to cultural differences in the workplace, including modes of behaviour and interactions between crew and others

3

Context of assessment

a

Assessment of competency must comply with the assessment requirements of the relevant maritime regulations

b

Assessment of this unit must be undertaken within relevant marine authority approved and audited arrangements by a registered training organisation:

1

As a minimum, assessment of knowledge must be conducted through appropriate written/oral examinations, and

2

Appropriate practical assessment must occur:

i

at the registered training organisation; and/or

ii

on an appropriate working or training vessel

4Specific resources required for assessment

Access is required to opportunities to:

a

participate in a range of practical and theoretical assignments, exercises, case studies, simulated fault situations and other assessments that demonstrate the skills and knowledge to fault-find, dismantle, maintain and repair plant and equipment typically found on a vessel of unlimited propulsion power; and/or

b

fault-find, dismantle, maintain and repair shipboard plant and equipment on a commercial or training vessel of unlimited propulsion power

REQUIRED KNOWLEDGE

This describes the knowledge required for this unit.

1

Knowledge of national and international regulations, IMO Conventions and Codes, including AMSA Marine Orders applicable to the management of shipboard plant and equipment maintenance and repair operations on vessels of unlimited propulsion power

2

Relevant OH&S legislation, policies and procedures

3

Established engineering practice for the fault finding, dismantling, maintenance and repair of marine electrical and equipment

4

Operational characteristics and performance specifications for the different types of shipboard plant and equipment usually found on a vessel of unlimited propulsion power

5

Planned maintenance systems and procedures for the condition monitoring of plant and equipment, including responsibilities and requirements covered by various forms of vessel survey

6

The nature and causes of typical shipboard plant and equipment malfunctions and the available methods for their detection and repair, including established fault finding techniques

7

Procedures for carrying out shipboard plant and equipment fault finding and repair as part of routine maintenance procedures to ensure compliance with the company and survey requirements and established safety rules and regulations

8

Procedures for the completion of temporary and permanent repair and/or replacement procedures for plant and equipment on board vessels at sea, alongside and in dry dock

9

A basic understanding of the plant and equipment typically found on board a vessel of unlimited propulsion power

10

Concepts of unmanned machinery spaces (UMS) and automated monitoring and control of machinery

11

Procedures for reading and interpreting plant and equipment performance readings and instrumentation

12

Basic principles of mechanics as they relate to forces, pressures, stress and strains in shipboard dynamic machinery

13

Basic principles of operation and maintenance of:

a

fluid power control systems

b

air-conditioning and refrigeration systems

c

machinery lubrication systems

14

Purpose and content of material safety data sheets

15

Typical vessel and plant and equipment specifications, equipment drawings, operational manuals, and electrical and control circuit diagrams

16

Types of maintenance and repair records that must be maintained on a vessel to meet the requirements of the company, survey requirements and regulatory authorities

17

Maritime communication techniques needed during maintenance and repair operations

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

18

Maintenance and repair hazards and problems and appropriate preventative and remedial action and solutions during maintenance and repair of shipboard plant and equipment

19

Safety, environmental and hazard control precautions and procedures relevant to shipboard plant and equipment inspection and maintenance operations

20

Safe procedures for handling heavy plant and equipment and component parts during maintenance and repair of shipboard plant and equipment

21

Safe procedures for the use of hand and power tools and maintenance equipment

22

Basic principles of electrotechnology, marine electrical practice and marine automation and control relevant to detection, fault finding and repair of faults in electrical and electronic equipment, including:

a

basic electrical circuit theory

b

basic theory of electromagnetism and electrostatics

c

electrolytic action and cells

d

AC and DC theory and plant and equipment

e

basic cabling, distribution and lighting systems

f

basic control and switch gear

g

instruments, calibration and testing

23

Basic principles of diesel engine operation to a level suitable for an officer of an engineering watch, including:

a

typical starting air and manoeuvring systems of diesel engines, including all components normally found therein

i

starting methods of marine diesel engines and how propulsion manoeuvring is achieved

ii

requirements for diesel engines for propulsion, power generation, and emergency use.

iii

methods of reversing direct reversing engines with their interlocks and other safety arrangements.

.

iv

common faults and appropriate action to be taken with starting/manoeuvring systems.

b

typical diesel engine lubrication systems, including:

i

all components normally found therein

ii

normal operational pressures and temperatures which should be expected.

.

iii

methods of lubricating the principal components of a marine diesel engine, with its associated gearing and/or chain drives, including common lubrication faults, symptoms, causes, and actions to be taken with such faults

c

the operating principles and adjustments of diesel engine fuel injection equipment, including common service faults, symptoms, and causes of diesel fuel injection problems, explaining appropriate actions to be taken

d

means of pressure charging diesel engines, including common service faults, appropriate actions to rectify these faults, and emergency operation and isolation procedures

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

e

different methods of cooling marine diesel engines, including common requirements of cooling

f

common faults and appropriate action to be taken with cooling of diesel engines

g

the causes of crankcase and air-line explosions, and scavenge and uptake fires

24

Basic thermodynamics as it relates to the responsibilities of an officer in charge of an engineering watch, including:

a

basic thermodynamic properties of common working fluids

b

methods of heat transfer and related problems

c

principles of heat transfer by conduction, convection and radiation and their application to marine systems

d

elementary principles of steam plants

e

basic steam plant cycles and the function of each component

f

the combustion process and the calorific value of fuels

g

air/fuel ratio and the significance of excess air on combustion

h

the operating cycle of single stage reciprocating air-conditioners, including methods for calculating the mass of air delivered

i

clearance volume, its effect on volumetric efficiency and methods of calculating volumetric efficiency

j

advantages of multistaging and intercooling

k

meaning of gauge and absolute pressure

l

temperature and temperature scales

m

SYSTEM INTERNATIONAL (SI) units and common thermodynamic terms and principles

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

REQUIRED SKILLS

This describes the basic skills required for this unit.

1

Communicate effectively with other personnel when fault finding, dismantling, maintaining and repairing shipboard plant and equipment

2

Communicate with multilingual crew where applicable using established techniques

3

Interpret and follow procedures for fault finding, dismantling, maintaining and repairing shipboard plant and equipment

4

Interpret and follow all safety management procedures and precautions when fault finding, dismantling, maintaining and repairing shipboard plant and equipment

5

Read and interpret material safety data sheets

6

Read and interpret vessel and machinery specifications, machinery design drawings, machine drawings, operational manuals, specifications and electrical and control circuit diagrams

7

Work collaboratively with other shipboard personnel when fault finding, dismantling, maintaining and repairing shipboard plant and equipment

8

Identify problems that can occur when fault finding, dismantling, maintaining and repairing shipboard plant and equipment and take appropriate action to report and rectify problems identified

9

Carry out calculations required when fault finding, dismantling, maintaining and repairing shipboard plant and equipment

10

Adapt to differing types of plant and equipment from one vessel to another and when equipment is changed

11

Take appropriate precautions to prevent pollution of the marine environment

12

Select and use tools and equipment required when fault finding, dismantling, maintaining and repairing shipboard plant and equipment

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance.

VARIABLE

SCOPE

1. GENERAL CONTEXT

a.

Work must be carried out:

1

in compliance with mandatory rules and regulations and IMO Conventions and Codes, including the relevant sections of the AMSA Marine Orders and to ensure that applicable codes, guidelines and standards recommended by IMO, the classification societies and maritime industry organisations are taken into account

b.

Work is performed:

1

relatively independently within an established maintenance plan and in consultation with a senior engineer, with accountability and responsibility for self and others in achieving the prescribed outcomes

c.

Work involves:

1

the application of marine engineering practice to the repair of plant and control equipment typically found on vessels of unlimited propulsion power across a wide and often unpredictable variety of equipment malfunctions or faults. Following of an established plan or strategy for the maintenance and repair of shipboard plant and control equipment is required and accountability and responsibility for self and others in achieving the outcomes is involved

d.

Work requires:

1

some judgement in engineering functions related to plant and equipment maintenance and repair operations and procedures. This includes working with a senior engineer in fault finding and in the dismantling, maintenance and repair of shipboard plant and equipment

2. WORKSITE ENVIRONMENT

a

Shipboard plant and control equipment may include:

1

that typically found on any Australian or international commercial vessels of unlimited propulsion power

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

VARIABLE

SCOPE

b

Performance monitoring and repair of shipboard plant and control equipment may be carried out:

1

by day or night in both normal and emergency situations

2

under any permissible conditions of weather

3

while underway

4

during berthing and unberthing operations

5

while anchored or moored

6

in dry dock

7

when bunkering

8

during cargo operations

c

Types of plant and equipment may include:

1

steam, diesel, diesel electric and gas turbine propulsion systems and controls

2

electrical systems and controls, including prime movers

3

batteries, transformers, switchboards, distribution systems, lighting systems

4

steering gear, stabilisers, bow thrusters, rudders

5

fluid power systems and controls

6

deck machinery, including cranes and winches

7

pumps and pumping systems

8

emergency supply systems, including emergency generators and battery banks

9

auxiliary systems and controls, including

i

fresh and salt water cooling systems

ii

lubricating oil cooling systems

iii

fuel, oil, gas and coal systems and centrifuges

iv

compressed air and air starting systems

v

lubrication

vi

bilge and ballast system, oily water separator

vii

refrigeration and air-conditioning plant and equipment

viii

on-board air compressors and compressed air and control air systems

ix

waste management and pollution control systems

x

evaporators

xi

inert gas generator

xii

cargo pumps, tank washing machines and associated systems

xiii

purifiers and clarifiers

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

VARIABLE

SCOPE

c

Types of plant and equipment may include:

(continued)

xiv

heaters

xv

sewage plant

xvi

fixed firefighting installations and fire control systems

xvii

auxiliary boilers and waste heat generators

xix

lifesaving appliances

xx

maintenance to hull and vessel side valves

d

Testing and repair equipment may include:

1

electronic instrumentation, meters and gauges

2

computer displays of performance parameters

3

hand tools, such as spanners, wrenches, screwdrivers, hacksaws, soldering irons, pliers, cutters, wire strippers, etc.

4

greasing and lubrication tools

5

electric power tools, such as grinders, lathes, drills, etc.

6

pneumatic power tools, such as grinders, sanders, drills, etc.

8

welding equipment

9

block and tackle

10

portable and manual lifting equipment and hydraulic jacks

11

material safety data sheets

12

protective clothing and equipment such as:

i

eye and ear protection

ii

safety boots

iii

dust and fume masks

e

Maintenance and repair hazards may include:

1

moving heavy loads in an unsafe work environment

2

unsecured plant and equipment, components or repair equipment

3

sharp tools and implements

4

power tools

5

moving and rotating plant and equipment

6

faulty equipment, handling equipment and lifting gear

7

using equipment beyond safe working limits

8

poor housekeeping procedures

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

VARIABLE

SCOPE

e

Maintenance and repair hazards may include:

(continued)

9

non-compliance with safe working procedures

10

electrical wiring and systems

11

exposed live circuits

12

faulty earth connections

13

hot pipes and valves (steam, fuel oil, lubricating oil)

14

cold pipes and valves (refrigeration and liquefied gas cargoes)

15

working at heights

16

exposed live circuits

17

faulty earth connections

f

Emergencies may include:

1

loss of propulsion

2

loss of electrical power

3

loss of steering

4

flooding, fire or explosion in engine room

5

loss of refrigeration

6

loss of water making ability

7

fuel oil, lubrication oil, steam and gas leaks

8

overheating and overspeed of machinery, governors, emergency trips

g

Documentation and records may include

1

safety management system plans, procedures, checklists and instructions

2

planned maintenance system, repair procedures and instructions

3

plant and equipment and vessel manufacturer's specifications, instructions and recommended procedures

4

plant and equipment maintenance log, running sheets and records, including computer databases of running information and maintenance records

5

vessel's survey as it relates to shipboard plant and equipment

6

sections of relevant maritime regulations

7

instructions of relevant maritime authorities

TDMMB1207B FAULT-FIND, DISMANTLE, MAINTAIN AND REPAIR SHIPBOARD PLANT AND EQUIPMENT

VARIABLE

SCOPE

h

Applicable legislation, regulations and codes may include:

1

sections of relevant maritime regulations, IMO Conventions and Codes

2

relevant international, Commonwealth, State and Territory OH&S legislation

3

relevant international, Commonwealth, State and Territory engineering practice standards