1

Follow safe work practices

1.1

Work health and safety (WHS)/occupational health and safety (OHS) procedures relevant to maintaining shipboard machinery and equipment are complied with

1.2

Safety hazards are identified and reported according to safety and vessel procedures

1.3

Prior to use, tools, equipment and testing devices needed to carry out maintenance activities for correct operation and safety are checked according to safety and vessel procedures

1.4

Before commencing maintenance activities, isolation precautions are implemented according to safety and vessel procedures

2

Maintain marine pumps

2.1

Maintenance requirements for pump are determined according to safety, manufacturer and vessel procedures and documentation

2.2

Appropriate procedures, materials, tools and equipment for maintaining pump are selected according to safety, manufacturer and vessel procedures

2.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

2.4

Pump is disassembled, inspected and serviced according to safety, manufacturer and vessel procedures

2.5

Pump is reassembled and tested according to safety, manufacturer and vessel procedures

2.6

Performance of pump is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

3

Maintain valves

3.1

Maintenance requirements for valve are determined according to safety, manufacturer and vessel procedures and documentation

3.2

Appropriate procedures, materials, tools and equipment for maintaining valve are selected according to safety, manufacturer and vessel procedures

3.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

3.4

Valves are removed for maintenance according to safety, manufacturer and vessel procedures and documentation

3.5

Valve is disassembled and valve maintenance is performed according to safety, manufacturer and vessel procedures and documentation

3.6

Valves are reassembled and tested according to safety, manufacturer and vessel procedures and documentation

4

Maintain air compressors

4.1

Maintenance requirements for air compressor are determined according to safety, manufacturer and vessel procedures and documentation

4.2

Appropriate procedures, materials, tools and equipment for maintaining air compressor are selected according to safety, manufacturer and vessel procedures

4.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

4.4

Air compressor is disassembled and inspected according to safety, manufacturer and vessel procedures

4.5

Air compressor is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

4.6

Performance of air compressor is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

5

Maintain heat exchangers

5.1

Maintenance requirements for heat exchanger are determined according to safety, manufacturer and vessel procedures and documentation

5.2

Appropriate procedures, materials, tools and equipment for maintaining heat exchanger are selected according to safety, manufacturer and vessel procedures

5.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

5.4

Heat exchanger is disassembled and inspected according to safety, manufacturer and vessel procedures

5.5

Heat exchanger is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

5.6

Performance of heat exchanger is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

6

Maintain diesel engines

6.1

Maintenance requirements for diesel engine are determined according to safety, manufacturer and vessel procedures and documentation

6.2

Appropriate procedures, materials, tools, measuring instruments and equipment for maintaining diesel engine are selected according to safety, manufacturer and vessel procedures

6.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

6.4

Diesel engine components are disassembled and inspected for wear and deterioration according to safety, manufacturer and vessel procedures

6.5

Routine maintenance on diesel engines is performed according to manufacturer and vessel procedures

6.6

Diesel engine components are refurbished, as required, according to manufacturer and vessel procedures

6.7

Specialised tools and measuring instruments are used to maintain and refurbish diesel engines/components according to safety, manufacturer and vessel procedures

6.8

Diesel engine is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

6.9

Performance of diesel engine is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

7

Maintain turbochargers

7.1

Maintenance requirements for turbocharger are determined according to safety, manufacturer and vessel procedures and documentation

7.2

Appropriate procedures, materials, tools and equipment for maintaining turbocharger are selected according to safety, manufacturer and vessel procedures

7.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

7.4

All components of turbocharger are disassembled and inspected for wear and deterioration according to safety, manufacturer and vessel procedures

7.5

Turbocharger is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

7.6

Performance of turbocharger is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

8

Inspect marine boilers

8.1

Inspection requirements for marine boiler are determined according to safety, manufacturer and vessel procedures and documentation

8.2

Appropriate procedures for inspecting marine boiler are selected according to safety, manufacturer and vessel procedures

8.3

Relevant information is extracted from drawings and technical specifications required to perform inspection activities

8.4

Marine boiler is inspected for repair or general maintenance according to safety, manufacturer and vessel procedures

8.5

Performance of marine boiler is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

9

Inspect marine refrigeration units

9.1

Inspection requirements for marine refrigeration unit are determined according to safety, manufacturer and vessel procedures and documentation

9.2

Appropriate procedures for inspecting marine refrigeration unit are selected according to safety, manufacturer and vessel procedures

9.3

Relevant information is extracted from drawings and technical specifications required to perform inspection activities

9.4

Marine refrigeration unit is inspected for repair or general maintenance according to safety, manufacturer and vessel procedures

9.5

Performance of marine refrigeration unit is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

10

Maintain marine lubricating systems

10.1

Inspection and maintenance requirements for lubricating systems are determined according to safety, manufacturer and vessel procedures and documentation

10.2

Relevant information is extracted from drawings and technical specifications required to perform inspection and maintenance activities

10.3

Purifier maintenance procedures are applied according to safety, manufacturer and vessel procedures

10.4

Components of lubricating system are inspected according to safety, manufacturer and vessel procedures

11

Maintain and repair deck machinery

11.1

Maintenance and/or repair requirements for deck machinery are determined according to safety, manufacturer and vessel procedures and documentation

11.2

Appropriate procedures, materials, tools and equipment for maintaining and/or repairing deck machinery are selected according to safety, manufacturer and vessel procedures

11.3

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

11.4

Deck machinery maintenance and/or repair procedures are implemented according to safety, manufacturer and vessel procedures

11.5

Deck machinery is tested and adjusted according to safety, manufacturer and vessel procedures

11.6

Performance of deck machinery is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

Required Skills:

Carry out cargo operations according to cargo plan or other documents and established safety rule/regulations, equipment operating instructions and shipboard stowage limitations

Establish and maintain effective communications during loading and unloading

Handle dangerous, hazardous and harmful cargo to comply with international regulations, recognised standards and codes of safe practice

Identify and solve problems associated with loading, unloading, stowage and care of cargo

Monitor and anticipate problems and risks associated with loading, unloading, stowage and care of cargo

Monitor use of equipment in loading, unloading, stowage and care of cargo

Read, interpret and apply instructions, regulations, procedures and information associated with loading, unloading, stowage and care of cargo

Required Knowledge:

Ballast management issues and procedures

Cargo handling documentation requirements

Cargo lifting equipment and safe working loads

Container position numbering

Effect of cargo, including heavy lifts, on the seaworthiness and stability of the vessel

Effects of different types of cargo operations on vessel trim and stability

Effects on cargo handling of sea conditions, wind and weather

Effects on stability during loading and discharging operations including heeling moments from gear and loads

Methods of caring for various types of cargo

Methods of handling various types of cargo

Operational characteristics of different types of shipboard and terminal-based cargo handling equipment and facilities

Principles of cargo care

Procedures for carrying out calculations involving weights, capacities, stowage factors

Relevant sections of applicable maritime regulations

Relevant work health and safety (WHS)/occupational health and safety (OHS) and cargo handling legislation, codes of practice, policies and procedures

Safe handling, stowage and securing of cargo including dangerous, hazardous and harmful cargo, and their effect on the safety of life and the vessel

Standard stowage position numbering systems used on container vessels

Typical cargo handling problems and hazards, and appropriate preventative and remedial actions and solutions

Typical types and sizes of shipping containers

Usual methods of container packing, loading and discharging, stowage, dunnaging

Various types of cargo likely to be carried; their peculiar characteristics, liability to damage, decay or deterioration; their measurements, hazards and problems; appropriate preventative and remedial action and solutions

Ways of restricting vessel stress levels within permitted levels within permitted limits during loading/discharging cargo

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, the required skills and knowledge, the range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the Elements, Performance Criteria, Required Skills, Required Knowledge and include:

ensuring currency of relevant WHS/OHS skills and knowledge

ensuring currency of relevant legislative and regulatory knowledge

initiating timely action in response to defects or damage.

Context of and specific resources for assessment

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

Resources for assessment include access to:

industry-approved marine operations site where maintaining and repairing shipboard machinery and equipment can be conducted

tools, equipment and personal protective equipment currently used in industry

relevant regulatory and equipment documentation that impacts on work activities

range of relevant exercises, case studies and/or other simulated practical and knowledge assessments

appropriate range of relevant operational situations in the workplace.

In both real and simulated environments, access is required to:

relevant and appropriate materials and equipment

applicable documentation including workplace procedures, regulations, codes of practice and operation manuals.

Method of assessment

Practical assessment must occur in an:

appropriately simulated workplace environment and/or

appropriate range of situations in the workplace.

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate to this unit:

direct observation of the candidate maintaining and repairing shipboard machinery and equipment

direct observation of the candidate applying relevant WHS/OHS requirements and work practices.

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended.

In all cases where practical assessment is used it should be combined with targeted questioning to assess Required Knowledge.

Assessment processes and techniques must be appropriate to the language and literacy requirements of the work being performed and the capacity of the candidate.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below.

Pumps may include:

Axial

Centrifugal

Gear

Reciprocating

Screw

Serviced may include:

Dismantling rod and gears, seals, bearings and relief valve

Identifying wear and deterioration

Measuring wear in cylinders, neck rings and rods

Protecting finished surfaces

Removing:

gland packing

studs, intact and broken

Replacing and adjusting seals

Valves may include:

Ball

Butterfly

Check

Diaphragm

Gate

Globe:

screw down non return

screw lift

Valve maintenance may include:

Examining seats, valves, spindles and glands

Gland packing:

selection

removal

repacking

Lapping valves and seats

Machining valves and seats

Air compressor is disassembled and inspected may include:

Coolers and cooling passages

Lubricating systems

Piston and rings

Suction and delivery valves and seats

Heat exchanger is disassembled and inspected may include:

Corrosion

Erosion

Fouling

Leakage

Provision for tube expansion

Diesel engine components are disassembled and inspected may include

Bearings

Cooling system

Crankshaft alignment

Liners

Lubrication system

Pistons

Rings

Valves

Routine maintenance on diesel engines may include:

Air intake system:

inspecting and changing air filters

inspecting turbocharger to make sure there is no fouling of compressor blades from crankcase gases

Cooling system:

fluid level checks

coolant sampling for trending analysis

draining, flushing and refilling system when required

Emissions systems:

inspecting crankcase ventilation systems, selective catalytic reduction (SCR) systems and diesel particulate filters (if so equipped)

Exhaust system:

inspecting for leaks, corrosion, wet stacking

Fuel system:

changing fuel filters, fuel injectors

checking water separators

Lubrication:

checking levels

changing oil, oil filters

taking oil samples for trending analysis to optimise oil change intervals and to detect engine wear

Mechanical systems:

inspecting resilient engine mounts and torsional couplings

generally inspecting for leaks, wear or deterioration

Operating systems:

downloading data from digital engine management system to note and review alarm conditions

Valves and heads:

inspecting, adjusting and recording valve train wear for trending analysis

inspecting and recording cylinder head wear for trending analysis

Diesel engine components are refurbished may include:

Air start valves

Cylinder heads

Exhaust valves

Fuel injectors

Relief valves

Components of turbocharger may include:

Air casing

Air filters

Bearings

Diffuser

Gas inlet grid

Impeller

Inducer

Nozzle ring

Rotor

Volute

Inspection requirements for marine boiler may include:

Fire side

Water side

Inspection requirements for marine refrigeration unit may include:

Compressors

Condensers

Evaporators

Expansion valves

Oil separators

Components of lubricating system may include:

Settling tank

System bearings

System filters

Deck machinery may include:

Cranes

Lifeboat davits and gear

Mooring winch

Winch

Windlass