TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

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

Investigate machinery malfunctions and faults

b

Dismantle, inspect and repair vessel machinery within the limits of responsibility and skill of an Engineer Class 3

c

Reassemble and check repaired machinery

d

Complete maintenance and repair documentation

e

Exercise all required safety, environmental and hazard control precautions and procedures when carrying out maintenance and repair of shipboard machinery

f

Identify machinery maintenance and repair problems and hazards and take appropriate action

g

Communicate effectively with others during maintenance and repair operations

h

Ensure adherence to relevant national and international 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

investigating machinery malfunctions and faults

2

dismantling, inspecting and repairing vessel machinery

3

reassembling and checking repaired machinery

4

completing maintenance and repair documentation

5

applying safety precautions relevant to mechanical and electrical machinery and equipment maintenance and repair operations

c

Shows evidence of application of relevant workplace procedures, including:

1

relevant maritime regulations

2

OH&S regulations, and pollution control and hazard prevention policies and procedures

3

work instructions on the checking and repair of shipboard machinery, including machinery specifications and directions on equipment capability and limitations

(continued)

TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

2

Evidence required for demonstration of consistent performance

(continued)

4

machinery security procedures

5

following on-board housekeeping processes

6

waste, pollution and recycling management processes

d

Action is taken promptly to report and/or rectify machinery malfunctions and safety incidents in accordance with regulations, 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 among 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

4

Specificresourcesrequired for assessment

Access is required to opportunities to:

a

Participate in a range of practical and theoretical assignments, exercises, case studies and other assessments that demonstrate the skills and knowledge to check and repair machinery and equipment typically found on a commercial vessel of less than 3,000kW propulsion power, including the ability to identify an appropriate range of possible machinery malfunctions and carry out related maintenance and repair solutions; and/or

b

Carry out checks and related repairs of shipboard machinery in a range of operational situations on a commercial or training vessel less than 3,000kW propulsion power

REQUIRED KNOWLEDGE

This describes the knowledge required for this unit.

1

Applicable sections of relevant maritime regulations

2

Relevant OH&S and pollution control legislation and policies

3

Established engineering practice for the checking, maintenance and repair of marine machinery on commercial vessels of less than 3,000kW propulsion power operating within offshore limits, including:

a

fitting

b

machining

c

gas cutting and welding

d

arc welding

e

workshop practice

4

Operational characteristics and performance specifications for the different types of shipboard machinery usually found on vessels of less than 3,000kW propulsion power

5

Procedures for carrying out shipboard machinery testing, troubleshooting and repair as part of routine maintenance procedures falling within the limits of responsibility and skills of an Engineer Class 3

6

The nature and causes of shipboard machinery malfunctions and the available methods for their detection and repair, including marine machinery malfunction fault finding techniques

7

Maintenance and repair hazards and problems and appropriate preventative and remedial action and solutions

8

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

9

Safe procedures for the use of hand and power tools and maintenance equipment during maintenance and repair of shipboard machinery

10

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

11

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

12

Principal features of vessel construction and basic principles of transverse stability for vessels of less than 3,000kW propulsion power

13

A basic understanding of the properties and application of materials and structures typically used in the construction of a vessel of less than 3,000kW propulsion power and its associated operational machinery

14

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

15

Maritime communication techniques needed during maintenance and repair operations

16

Purpose and content of material safety data sheets

17

Procedures for the testing of boiler water, machinery cooling water and lubricating oil

18

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

19

Mathematical techniques required to solve engineering problems falling within the limits of responsibility of an Engineer Class 3

20

Basic properties of common marine engineering materials and principles and methods of cutting, joining and heat treatment

21

Basic properties of liquids and gases commonly used aboard vessels

22

Principles and precautions that must be taken when carrying out 'hot work'

23

Precautions that must be taken to minimise danger of fire or explosion

24

Safety precautions that must be taken before entering tanks or confined spaces

25

Principles and procedures of machinery lubrication, including:

a

theory and types of lubrication

b

relative characteristics, and applications of mineral and synthetic oils

c

contaminants that may affect lubricants, their effect on machinery performance, and action that can be taken to avoid and remedy contamination of lubricants

26

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

a

statics (non-concurrent systems only)

b

friction

c

dynamics

e

balancing

d

radial, circumferential and, longitudinal stress

f

shear stress

g

fluid mechanics

h

torsion, hollow and solid shafts

i

loads due to liquid head

27

Basic principles of transverse stability and principles of naval architecture and vessel construction relevant to detection, identification and repair of faults, including:

a

draught, trim and heel

b

propellers

c

structural strength and vibration of vessels

d

vessel measurement and classification

e

load-line

f

basic principles of transverse stability

g

principles of free surface effects

h

dry docks

i

lifesaving equipment

j

hull repairs and maintenance

28

Basic principles of thermodynamics and heat and heat engines relevant to detection, identification and repair of faults, including:

a

heat transfer

b

gases

c

properties and expansion of steam

d

steam cycles

e

boilers and evaporators

f

steam turbines

g

combustion

h

refrigeration and air-conditioning.

29

The construction features of a ship that impact on its watertight integrity and stability

30

Principles involved in the alignment of machinery and machinery parts

31

Elementary principles and care and management of the various types of auxiliary pumps and pumping and piping systems and other shipboard auxiliaries

32

The basic principles of engine cooling, fuel and lubricating systems and fuel consumption

33

The basic principles of air compressors, their care and maintenance

34

The basic principles of operation and safety of boilers, steam and feed systems, steam engines and turbines

35

The colour coding system used for electric conductors

36

Definitions of electrical terms and solve basic electrical problems using mathematics

37

The basic principles of operation and operating procedures for AC and DC generators

38

Basic principles of preventative and remedial maintenance

39

Basic principles of the operation and maintenance of two and four stroke compression ignition engines, including engine construction and starting and reversing systems

40

Safety precautions and procedures during repair and inspection of electrical circuitry and equipment.

41

Basic principles of electrotechnology, marine electrical practice and marine automation and control relevant to detection, identification and repair of faults falling within the limits of responsibility of an Engineer Class 3, including:

a

the electric circuit

b

electrolytic action and cells

c

basic principles of relevant AC and DC machines

d

cabling, distribution and lighting systems

e

control gear

f

switch gear

g

deck machinery

REQUIRED SKILLS

This describes the basic skills required for this unit.

1

Use communication skills required when dismantling, inspecting, repairing and reassembling machinery on a vessel of less than 3,000kW propulsion power

2

Read, interpret and apply maintenance and service manuals and instructions and equipment specifications and drawings for equipment and machinery, including all required OH&S procedures and precautions

3

Read, interpret and follow standard operating and emergency procedures when dismantling, inspecting, repairing and reassembling machinery on a vessel of less than 3,000kW propulsion power within limits of responsibility of an Engineer Class 3

4

Read and interpret material safety data sheets

5

Read and interpret and indications of machinery performance

6

Complete any required maintenance records

7

Provide leadership to other crew members when dismantling, inspecting, repairing and reassembling machinery on a vessel of less than 3,000kW propulsion power

8

Work safely and collaboratively with others when dismantling, inspecting, repairing and reassembling vessel machinery

9

Plan and organise maintenance and repair activities on a small vessel

10

Monitor the selection and use of relevant tools and equipment as per instructions

11

Recognise faulty equipment and take appropriate action as per operating instructions

12

Recognise routine problems when dismantling, inspecting, repairing and reassembling vessel machinery and take appropriate action

13

Adapt to differences in vessels, equipment and machinery and standard maintenance procedures

14

Monitor that all safety precautions and procedures are followed when dismantling, inspecting, repairing and reassembling machinery on a vessel of less than 3,000kW propulsion power

TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

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 relevant maritime regulations

b.

Work is performed:

1

under broad guidelines, with accountability and responsibility for self and others in achieving the prescribed outcomes within the limits of responsibility and skill of an Engineer Class 3

c.

Work involves:

1

the application of marine engineering practice to the dismantling, inspecting, repair and reassembly of machinery typically found on a vessel of less than 3,000kW propulsion power across a range of machinery malfunctions or faults. Implementation of a broad plan or strategy for shipboard machinery maintenance and repair is required and accountability and responsibility for self and others in achieving the outcomes is involved

d.

Work requires:

1

some judgement in planning and carrying out machinery repair operations and procedures. This includes analysis of the faulty machinery and decision making on the repairs required and the processes to be used

2. WORKSITE ENVIRONMENT

a

Machinery may include:

1

that typically found on any Australian or international commercial vessel of up to 3,000kW propulsion power operating within offshore limits

b

Machinery performance monitoring and repair 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

(continued)

TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

VARIABLE

SCOPE

b

Machinery performance monitoring and repair may be carried out:

(continued)

7

when bunkering

8

during cargo operations

c

Types of machinery may include:

1

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

2

electrical systems and controls, including prime movers (where relevant)

3

batteries, transformers, switchboards, distribution systems, lighting systems

4

steering gear, stabilisers, bow thrusters, rudders

5

fluid power systems and controls

6

deck machinery

7

pumps and pumping systems

8

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

air compressor 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 as per the MARPOL Convention

x

evaporators

xi

inert gas generator

xii

cargo pumps, tank washing machines and associated systems

xiii

purifiers and clarifiers

xiv

heaters

xv

sewage plant

xvi

fixed firefighting installations and fire control systems

xvii

auxiliary boilers and waste heat generators

xviii

lifesaving appliances

xix

hull and vessel side valves

(continued)

TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

VARIABLE

SCOPE

d

Propulsion plant configurations may include:

1

low speed, medium and high speed diesel propulsion

2

stern tube bearing

3

CPP

4

direct drive shaft

5

diesel electric

6

steam

7

gas turbine

8

water jets and control systems

9

reduction gears

10

thrust blocks, detuners and shaft bearings

e

Testing and repair equipment may include:

1

meters and gauges

2

computer displays of performance parameters

3

hand tools, such as spanners, wrenches, screwdrivers, hacksaws, 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.

7

welding equipment

8

block and tackle

9

portable and manual lifting equipment and hydraulic jacks

10

material safety data sheets

11

protective clothing and equipment such as:

i

safety boots, helmet and eye and ear protection

ii

dust and fume masks

f

Maintenance and repair hazards may include:

1

moving heavy loads using unsafe lifting procedures

2

unsecured machinery, components or repair equipment

3

slippery deck

4

welding equipment

5

sharp tools and implements

6

power tools

(continued)

TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

VARIABLE

SCOPE

f

Maintenance and repair hazards may include:

(continued)

7

moving and rotating machinery

8

flammable liquids, vapours and fuel

9

faulty machinery equipment handling equipment or lifting gear

10

using equipment beyond safe working limits

11

poor housekeeping procedures

12

non-compliance with safe working procedures

13

electrical wiring and systems

14

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

15

cold pipes and valves (refrigeration and liquefied gas cargoes)

16

working at heights

g

Emergencies may include:

1

loss of propulsion

2

loss of electrical power

3

loss of engine and/or transmission control

4

loss of steering

5

flooding of engine room

6

fire or explosion in engine room

7

loss of refrigeration

8

loss of water making ability

9

fuel oil, lubrication oil, steam and gas leaks

10

overheating and overspeed of machinery, governors, emergency trips

h

Documentation and records

may include:

1

vessel's and company's planned maintenance system, repair procedures and instructions

2

machinery and vessel manufacturer's specifications, instructions and recommended procedures

3

maintenance log, running sheets and records

4

computer database of running information and maintenance records

5

vessel's survey as it relates to shipboard machinery

6

vessel's safety and emergency contingency plans and procedures

7

machinery and vessel manufacturer's specifications, instructions and recommended procedures

(continued)

TDMMB3807B DISMANTLE, INSPECT, REPAIR AND REASSEMBLE VESSEL MACHINERY

VARIABLE

SCOPE

h

Documentation and records

may include:

(continued)

8

relevant maritime regulations

9

instructions of relevant maritime authorities and classification societies concerning shipboard machinery maintenance and repair

i

Applicable legislation, regulations and codes may include:

1

State and Territory marine regulations related to the operation of small vessels

2

National Standard for Commercial Vessels and USL Code

3

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

4

relevant international, Commonwealth, State and Territory engineering practice standards