UEPMNT313B
Maintain internal combustion engines

1)Scope:1.1) DescriptorThis unit deals with the skills and knowledge required to conduct maintenance and major overhauls of fixed or pad mounted internal combustion engines.

Application

2)

This unit is intended to augment formally acquired competencies. It is suitable for employment-based programs under an approved contract of training.


Prerequisites

Prerequisite Unit(s)

4)

Competencies

4.1)

Granting of competency in this unit shall be made only after competency in the following unit(s) has/have been confirmed.

Where pre-requisite pathways have been identified. All competencies in the Common Unit Group must be have been completed.

Common Unit Group

Unit Code

Unit Title

MEM18006C

Repair and fit engineering components

MEM09002B

Interpret technical drawing

MEM12023A

Perform Engineering Measurements

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM18003C

Use tools for precision work

MEM18055B

Dismantle, replace and assemble engineering components

Literacy and numeracy skills

4.2)

Participants are best equipped to achieve this unit if they have reading, writing and numeracy skills indicated by the following levels. A description of what each level entails is provided in Section 2.3.1 Language, Literacy and Numeracy.

Reading

3

Writing

3

Numeracy

3


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1

Plan and prepare for the work

1.1

Work requirements are identified from request/work orders or equivalent and clarified/confirmed with appropriate parties or by site inspection

1.2

Occupational Health and Safety standards, statutory requirements, relevant Australian standards, codes of practice, manufacturers’ specifications, environmental requirements and enterprise procedures are identified, applied and monitored throughout the work procedure

1.3

Resources required to satisfy the work plan are identified, obtained and inspected for compliance with the job specifications

1.4

Relevant plans, drawings and texts are selected and interpreted in accordance with the work plan

1.5

Correct size, type and quantity of materials/components are determined, obtained and inspected for compliance with the job specifications

1.6

Work is planned in detail including sequencing and prioritising and considerations made, where appropriate, for the maintenance of plant security and capacity in accordance with system/site requirements

1.7

Coordination requirements, including requests for isolations where appropriate, are resolved with others involved, affected or required by the work

1.8

Potential hazards are identified and prevention and/or control measures are selected in accordance with the work plan and site procedures

1.9

Work area is prepared in accordance with work requirements and site procedures

1.10

Where appropriate, the teams and individuals roles and responsibilities within the team are identified and, where required, assist in the provision of on-the-job training

2

Assess engine condition

2.1

Engine is run and components are assessed visually and/or aurally to determine condition of engine under load in accordance with the work plan

2.2

Engine condition is tested whilst under load using appropriate test equipment and procedures according to manufacturer specifications and the work plan

3

Remove auxiliary systems

3.1

Required isolations are confirmed where appropriate in accordance with enterprise/site procedures

3.2

Auxiliary systems are removed, marked and labelled to facilitate replacement in accordance with the work plan

3.3

Load device is uncoupled and removed in accordance with the work plan

4

Overhaul/maintain engine

4.1

Engine is systematically dismantled and component parts are clearly marked for identification in accordance with the work plan

4.2

Engine components are examined and dimensional inspection is performed to determine conformance to manufacturer specifications

4.3

Faulty components are replaced in accordance with manufacturer specifications

4.4

Engine components are reassembled and necessary adjustments made in accordance with manufacturer specifications and enterprise requirements

5

Replace auxiliary systems

5.1

Load device is coupled in accordance with manufacturer specifications and enterprise requirements

5.2

Auxiliary equipment is maintained as required in accordance with manufacturer specifications and the work plan

5.3

Auxiliary equipment is aligned and installed in accordance with manufacturer specifications and the work plan

5.4

Engine is started and function tested in accordance with manufacturer specifications and enterprise requirements

5.5

Engine operating characteristics are monitored, recorded and adjustments made as required to obtain optimum performance in accordance with manufacturer specifications and enterprise requirements

5.6

Where appropriate auxiliary equipment and/or components are overhauled in accordance with manufacturer specifications and enterprise requirements

6

Complete the work

6.1

Work is completed and appropriate personnel notified in accordance with site/enterprise requirements

6.2

Work area is cleared of waste, cleaned, restored and secured in accordance with site/enterprise procedures

6.3

Plant, tools and equipment are maintained and stored in accordance with site/enterprise procedures

6.4

Work completion details are finalised in accordance with site/enterprise procedures

Required Skills

8) This describes the essential skills and knowledge and their level, required for this unit.

Evidence shall show that knowledge has been acquired of maintaining internal combustion engines.

All knowledge and skills detailed in this unit should be contextualised to current industry practices and technologies.

The extent of the Essential Knowledge and Associated Skills required follows:

KS01-PM313B Internal combustion engines

T1 Evidence shall show that knowledge has been acquired for safe working practices of:

Relevant Environmental, Occupational Health and Safety legislation and regulations

Relevant plant and equipment, its location

Technical drawings and manufacturers manuals

Introduction to and typical arrangements of power production plant

Hand and portable power tools

Precision measuring equipment

Rigging and lifting

Specialised tools and jigs

Levelling and aligning

Data recording techniques

Diagnostic and testing techniques

Gaskets and seals

Diesel fuel injection systems

Governor systems

Non-destructive testing

Torqueing techniques

Pumps (gear and centrifugal)

Speed control mechanisms

Balancing and vibration analysis

Maintenance procedures

Dismantling and reassembling techniques

T2 Specific skills needed to achieve the Performance Criteria:

Apply Relevant Environmental, Occupational Health and Safety legislation and regulations

Apply levelling and alignment techniques

Interpret Technical drawings and manufacturers manuals

Select resources Inspect and identify correct materials, tools and components

Apply dismantling techniques to work requirements

Apply re-assembly techniques to work requirements

Apply repair techniques

Apply maintenance techniques

Observe isolation procedures

Use hand and portable power tools

Use precise measuring equipment

Use rigging and lifting equipment

Use specialised tools and jigs

Diagnose and test

Manufacture gaskets and seals

Inspect, scrape and blue-check bearings

Identify hazardous materials

Apply torqueing techniques

Apply data recording techniques

Communicate effectively.

Evidence Required

9) This provides essential advice for assessment of the competency standard unit and must be read in conjunction with the Performance Criteria and the range statement of the competency standard unit and the Training Package Assessment Guidelines.

The Evidence Guide forms an integral part of this unit and shall be used in conjunction with all components parts of this unit and, performed in accordance with the Assessment Guidelines of this Training Package.

Overview of Assessment

9.1)

Longitude competency development approaches to assessment, such as Profiling, require data to be reliably gathered in a form that can be consistently interpreted over time. This approach is best utilised in Apprenticeship programs and reduces assessment intervention. It is the Industry preferred model for apprenticeships. However, where summative (or final) assessment is used it is to include the application of the competency in the normal work environment or in a realistically simulated work environment. It is recognised that, in some circumstances, assessment in part or full can occur outside the workplace; however, it must be in accord with Industry and regulatory policy.

Methods chosen for a particular assessment will be influenced by various factors. These include the extent of the assessment, the most effective locations for the assessment activities to take place, access to physical resources, additional safety measures that may be required and the critical nature of the competencies being assessed.

The critical safety nature of working with electricity, electrical equipment, gas or any other hazardous substance/material carries risk in deeming a person competent. Hence, sources of evidence need to be ‘rich’ in nature so as to minimise error in judgment.

Activities associated with normal every day work have a bearing on the decision as to how much and how detailed the data gathered will contribute to its ‘richness’. Some skills are more critical to safety and operational requirements while the same skills may be more or less frequently practised. These points are raised for the assessors to consider when choosing an assessment method and developing assessment instruments. Sample assessment instruments are included in the Assessment Guidelines of this Training Package.

Critical aspects of evidence required to demonstrate competency in this unit

9.2)

Before the critical aspects of evidence are considered all pre-requisites shall be met.

Evidence for competence in this unit shall be considered holistically. Each element and associated Performance Criteria shall be demonstrated on at least two occasions in accordance with the “Assessment Guidelines – UEP12”. Evidence shall also comprise:

A representative body of work performance demonstrated within the timeframes typically expected of the discipline, work function and industrial environment. In particular this shall incorporate evidence that shows a candidate is able to:

Implement Occupational Health and Safety workplace procedures and practices including the use of risk control measures as specified in the Performance Criteria and Range Statement

Apply sustainable energy principles and practices as specified in the Performance Criteria and Range Statement

Demonstrate an understanding of the essential knowledge and associated skills as described in 6) Essential Knowledge and Associated Skills of this unit

Demonstrate an appropriate level of employability skills

Conduct work observing the relevant Anti Discrimination legislation, regulations, polices and workplace procedures

Demonstrated performance across a representative range of contexts from the prescribed items below:

The knowledge and application of relevant sections of: Occupational Health and Safety legislation; Statutory legislation; Enterprise/site safety procedures; Enterprise/site emergency procedures

Competence is demonstrated in the context of provision to employees of clear directions and information and work instructions

Evidence of knowledge of significant hazards in the workplace is required

Evidence of understanding of symbols used for Occupational Health and Safety signs is required

Competence may need to be assessed in conjunction with units relating to communication competencies, particularly those relating to information provision.

Dealing with an unplanned event by drawing on essential knowledge and skills to provide appropriate solutions incorporated in the holistic assessment with the above listed items

Context of and specific resources for assessment

9.3)

This unit should be assessed as it relates to normal work practice using procedures, information and resources typical of a workplace. This should include:

OHS policy and work procedures and instructions.

Suitable work environment, facilities, equipment and materials to undertake actual work as prescribed by this unit.

Competency Standards should be assessed in the workplace or simulated workplace and under the normal range of workplace conditions.

Assessment of this unit will be supported with documentary evidence, by means of endorsement stating type and application of work.

In addition to the resources listed above in Context of assessment’, evidence should show competency working, in limited spaces, with different types of plant and equipment as well as different structural/construction types and method and in a variety of environments.

Method of assessment

9.4)

This unit shall be assessed by methods given in Section 1.3.00 Assessment Guidelines.

Note:

Competent performance with inherent safe working practices is expected in the Industry to which this unit applies. This requires that the specified essential knowledge and associated skills are assessed in a structured environment which is primarily intended for learning/assessment and incorporates all necessary equipment and facilities for learners to develop and demonstrate the essential knowledge and skills described in this unit.

Concurrent assessment and relationship with other units

9.5)

There are no recommended concurrent assessments with this unit, however in some cases efficiencies may be gained in terms of learning and assessment effort being concurrently managed with allied competency standard units where listed.

Nil


Range Statement

10) This relates to the competency standard unit as a whole providing the range of contexts and conditions to which the Performance Criteria apply. It allows for different work environments and situations that will affect performance.

Internal combustion engines may refer to medium speed diesels, high speed diesels, petrol engines, gas engines or dual fuel (gas/diesel) powered engines.

Engine auxiliary systems may include cooling systems, lubrication systems, fuel systems and induction and exhaust systems.

Engine components may include bearings (shell and white metal) pistons, cylinders, valves, cams, lifters, springs, timing gear, crankshaft, pumps, gaskets and seals, coolers, filters and governors.

Measuring equipment may include micrometers, verniers (internal/external) dial indicators, bore gauges, depth and height gauges and optical fibre scope.

Test equipment may include pressure and vacuum gauges, gas analysers, timing light, injector tester and dyno test equipment.

Running checks may include cylinder peak pressure, exhaust gas temperature, lube oil flow checks and fuel injection timing.

Re-assembly techniques may include crankshaft deflections, advanced levelling and alignment.

Work completion details may include plant and maintenance records, job cards, check sheets, on device labelling updates and reporting and/or documenting equipment defects.

Work site environment may be affected by nearby plant or processes, e.g. chemical, heat, dust, noise, gas and oil.

Isolations can refer to electrical/mechanical or other appropriate processes.

Generic terms are used throughout this Training Package for vocational standard shall be regarded as part of the Range Statement in which competency is demonstrated. The definition of these and other terms are given in Section 2.1.00 Preliminary Information and Glossaries.


Sectors

Not applicable.


Employability Skills

5)

The required outcomes described in this unit of competency contain applicable facets of Employability Skills. The Employability Skills Summary of the qualification in which this unit of competency is packaged will assist in identifying Employability Skill requirements.


Licensing Information

License to practice

3)

The skills and knowledge described in this unit do not require a licence to practise in the workplace. However, practice in this unit is subject to regulations directly related to occupational health and safety.