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Evidence Guide: MARL027 - Demonstrate intermediate knowledge of marine diesel engines and systems

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

MARL027 - Demonstrate intermediate knowledge of marine diesel engines and systems

What evidence can you provide to prove your understanding of each of the following citeria?

Evaluate diesel fuel systems

  1. Why atomisation and penetration of fuel and air turbulence are essential to optimum combustion is explained
  2. Typical injection pressures and viscosities for different grades of fuel are documented and compared
  3. Design modifications of pumps, camshafts and injectors for fuel types are outlined
  4. Difference between constant and variable injection fuel pump timing, showing materials, principal parts, method of operation and adjustments of common pump types is compared and explained
  5. Injection requirements for slow speed and high speed diesel engines are compared, including pilot injection and pre-combustion chambers
  6. Common service faults, symptoms and causes of diesel fuel injection problems are identified, specifying appropriate adjustments, including methods of fuel pump timing
  7. Work health and safety/occupational health and safety (WHS/OHS) requirements for handling and testing fuel injection systems are explained
  8. Normal operating pressures and temperatures for fuel valve cooling arrangements, and uni-fuel and dual-fuel systems, including both high/medium viscosity fuel types are explained
Why atomisation and penetration of fuel and air turbulence are essential to optimum combustion is explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Typical injection pressures and viscosities for different grades of fuel are documented and compared

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Design modifications of pumps, camshafts and injectors for fuel types are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Difference between constant and variable injection fuel pump timing, showing materials, principal parts, method of operation and adjustments of common pump types is compared and explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Injection requirements for slow speed and high speed diesel engines are compared, including pilot injection and pre-combustion chambers

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Common service faults, symptoms and causes of diesel fuel injection problems are identified, specifying appropriate adjustments, including methods of fuel pump timing

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Work health and safety/occupational health and safety (WHS/OHS) requirements for handling and testing fuel injection systems are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Normal operating pressures and temperatures for fuel valve cooling arrangements, and uni-fuel and dual-fuel systems, including both high/medium viscosity fuel types are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Evaluate different methods of diesel engine cooling

  1. Importance of maintaining diesel engine thermal efficiency and evaluate thermal loads on engine components is outlined
  2. Cooling media selection is justified, and advantages and disadvantages of different diesel cooling methods are outlined
  3. Appropriate action to be taken with common faults in cooling systems is explained and different cooling water treatments are compared
  4. How cooling systems are commissioned, stored during idle periods and restored after contamination is confirmed
  5. Methods of load-dependent cooling of diesel alternators on heavy fuels are evaluated
  6. Normal operation temperatures, pressures, and methods of cooling medium and slow speed diesel engine pistons, exhaust valves, cylinders, turbochargers and cylinder heads are identified
Importance of maintaining diesel engine thermal efficiency and evaluate thermal loads on engine components is outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Cooling media selection is justified, and advantages and disadvantages of different diesel cooling methods are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Appropriate action to be taken with common faults in cooling systems is explained and different cooling water treatments are compared

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

How cooling systems are commissioned, stored during idle periods and restored after contamination is confirmed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Methods of load-dependent cooling of diesel alternators on heavy fuels are evaluated

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Normal operation temperatures, pressures, and methods of cooling medium and slow speed diesel engine pistons, exhaust valves, cylinders, turbochargers and cylinder heads are identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Evaluate diesel engine lubrication requirements

  1. Principles of engine lubrication are outlined
  2. Lubricant types, physical and chemical properties and applications are assessed
  3. Sources of diesel lubricant contamination and deterioration are identified
  4. Ways of testing for diesel lubricant contamination and deterioration, interpreting test results and identifying appropriate action to be taken are outlined
  5. Distribution of lubricating oil to guides, top-end, bottom-end and main bearings of diesel engines, showing direction of flow, typical clearances and stating normal operating temperatures and pressure is explained
  6. Principles of bearing lubrication are outlined
  7. Materials used in bearing construction are identified
  8. Bearing faults are evaluated and remedies to prevent them from occurring are determined
Principles of engine lubrication are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Lubricant types, physical and chemical properties and applications are assessed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Sources of diesel lubricant contamination and deterioration are identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Ways of testing for diesel lubricant contamination and deterioration, interpreting test results and identifying appropriate action to be taken are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Distribution of lubricating oil to guides, top-end, bottom-end and main bearings of diesel engines, showing direction of flow, typical clearances and stating normal operating temperatures and pressure is explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Principles of bearing lubrication are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Materials used in bearing construction are identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Bearing faults are evaluated and remedies to prevent them from occurring are determined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Compare different propulsion, manoeuvring and starting methods

  1. Starting procedures of diesel engines for power generation, propulsion, and emergency use are clarified
  2. Starting and manoeuvring requirements/sequences for direct-coupled reversible and geared propulsion diesels, including CPP applications are explained
  3. Common faults are analysed and appropriate action to be taken with typical diesel starting and manoeuvring systems is identified
  4. Manoeuvring and reversing systems of propulsion diesel engines are outlined
  5. Different methods of achieving reversing capability with direct-coupled propulsion diesels are compared
  6. Layout of a diesel-electric drive is compared and contrasted with the layout of a turbo electric drive
Starting procedures of diesel engines for power generation, propulsion, and emergency use are clarified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Starting and manoeuvring requirements/sequences for direct-coupled reversible and geared propulsion diesels, including CPP applications are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Common faults are analysed and appropriate action to be taken with typical diesel starting and manoeuvring systems is identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Manoeuvring and reversing systems of propulsion diesel engines are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Different methods of achieving reversing capability with direct-coupled propulsion diesels are compared

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Layout of a diesel-electric drive is compared and contrasted with the layout of a turbo electric drive

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Analyse materials used in constructing diesel engines

  1. Common materials used in diesel engine construction are assessed, selection is justified, and typical compositions and physical properties of components are specified
  2. Dynamic stresses and loads are interpreted, service limitations are identified and different methods of component fabrication are evaluated
  3. Two-stroke and four-stroke operating cycle forces, couples and moments, relating to design principles of crankshafts, bedplates, foundations and crossheads are outlined
  4. Out-of-balance gas and inertia forces, couples and moments are related to flywheels, balance weights and first/second order balancing
  5. Factors contributing to torsional vibration are explained and methods of minimising or eliminating harmful effects of critical speeds are clarified
  6. Pistons, liners, piston rings, bearings and crankshafts are calibrated to identify wear patterns, limits and means of correction
  7. Alignment and adjustment criteria of crankshafts, chain-drives, integral thrust bearings and crossheads are specified
  8. Specified working clearances and limits of all bearings, sliding surfaces and interference fits of typical diesel engines are compiled using engine builder manuals
Common materials used in diesel engine construction are assessed, selection is justified, and typical compositions and physical properties of components are specified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Dynamic stresses and loads are interpreted, service limitations are identified and different methods of component fabrication are evaluated

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Two-stroke and four-stroke operating cycle forces, couples and moments, relating to design principles of crankshafts, bedplates, foundations and crossheads are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Out-of-balance gas and inertia forces, couples and moments are related to flywheels, balance weights and first/second order balancing

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Factors contributing to torsional vibration are explained and methods of minimising or eliminating harmful effects of critical speeds are clarified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Pistons, liners, piston rings, bearings and crankshafts are calibrated to identify wear patterns, limits and means of correction

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Alignment and adjustment criteria of crankshafts, chain-drives, integral thrust bearings and crossheads are specified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Specified working clearances and limits of all bearings, sliding surfaces and interference fits of typical diesel engines are compiled using engine builder manuals

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Explain uptake and scavenge fires and air line, gearbox and crankcase explosions

  1. Design and operational factors that contribute to fires in waste heat units are explained and methods of extinguishing and/or containing soot and hydrogen fires are specified
  2. Routine cleaning procedures, inspection criteria, symptoms of fire and risks of isolation in service associated with waste heat units are identified
  3. Operational factors that contribute to scavenge fires are identified, symptoms are outlined, methods of extinguishing are evaluated and routine inspection criteria of scavenge spaces are stated
  4. Principles of explosive mixtures are clarified and how a starting airline explosion can occur is explained
  5. How risk of scavenge fires may be minimised in service by protective devices and routine evaluation of starting air systems is clarified
  6. Causes of gearbox and crankcase explosions in propulsion and auxiliary drives are outlined
  7. How risks of gearbox and crankcase explosions may be minimised in service are explained and correct procedures to be taken in the event of warning of a hazardous atmosphere in both oil and dual-fuel engines are clarified
  8. Operating principles of an oil-mist detector, crankcase breather and explosion relief doors are explained
  9. Function of a piston rod scraper box is outlined, and causes of wear and appropriate adjustments are identified
Design and operational factors that contribute to fires in waste heat units are explained and methods of extinguishing and/or containing soot and hydrogen fires are specified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Routine cleaning procedures, inspection criteria, symptoms of fire and risks of isolation in service associated with waste heat units are identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Operational factors that contribute to scavenge fires are identified, symptoms are outlined, methods of extinguishing are evaluated and routine inspection criteria of scavenge spaces are stated

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Principles of explosive mixtures are clarified and how a starting airline explosion can occur is explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

How risk of scavenge fires may be minimised in service by protective devices and routine evaluation of starting air systems is clarified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Causes of gearbox and crankcase explosions in propulsion and auxiliary drives are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

How risks of gearbox and crankcase explosions may be minimised in service are explained and correct procedures to be taken in the event of warning of a hazardous atmosphere in both oil and dual-fuel engines are clarified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Operating principles of an oil-mist detector, crankcase breather and explosion relief doors are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Function of a piston rod scraper box is outlined, and causes of wear and appropriate adjustments are identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Explain correct working practices associated with diesel engine operation, maintenance and repair

  1. Safe working practices associated with isolating main and propulsion diesels under all emergency and routine situations are explained, including use of protective devices, interlocks and evaluation of their status
  2. Safe working practices associated with working in crankcases and other enclosed spaces are explained
  3. Safe working practices associated with safe handling of hydraulic tools and dangers of lifting/isolating heavy components both unaided and with lifting gear are explained
  4. Hazards of working with flammable liquids under pressure, chemicals, acids and hydrocarbons as well as selection criteria for appropriate protective clothing are explained
  5. Safe working strategies for diesel engine maintenance are planned using engine manufacturer instruction manuals and product data safety sheets
Safe working practices associated with isolating main and propulsion diesels under all emergency and routine situations are explained, including use of protective devices, interlocks and evaluation of their status

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Safe working practices associated with working in crankcases and other enclosed spaces are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Safe working practices associated with safe handling of hydraulic tools and dangers of lifting/isolating heavy components both unaided and with lifting gear are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Hazards of working with flammable liquids under pressure, chemicals, acids and hydrocarbons as well as selection criteria for appropriate protective clothing are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Safe working strategies for diesel engine maintenance are planned using engine manufacturer instruction manuals and product data safety sheets

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Analyse faults using combustion diagnostic equipment

  1. Two-stroke and four-stroke theoretical cycle diagrams are compared with results recorded using diagnostic tools
  2. Combustion faults from typical diagrams are evaluated and corrective adjustments are specified
  3. Service combustion values are compared with trials or test bed figures
  4. Common faults associated with pressure charging and fuel injection systems are outlined
  5. Methods of pressure charging diesel engines are compared, and materials of construction, design features, operational maintenance and emergency procedures are correctly identified
  6. Causes of efficiency loss and surge are explained
  7. Scavenging systems and gas/air flow paths through a turbocharger, under normal and emergency operation modes are explained using relevant diagrams
Two-stroke and four-stroke theoretical cycle diagrams are compared with results recorded using diagnostic tools

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Combustion faults from typical diagrams are evaluated and corrective adjustments are specified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Service combustion values are compared with trials or test bed figures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Common faults associated with pressure charging and fuel injection systems are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Methods of pressure charging diesel engines are compared, and materials of construction, design features, operational maintenance and emergency procedures are correctly identified

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Causes of efficiency loss and surge are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Scavenging systems and gas/air flow paths through a turbocharger, under normal and emergency operation modes are explained using relevant diagrams

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Analyse construction and operation of marine gas turbines

  1. Flow of air and gas through a simple cycle marine gas turbine is analysed
  2. Materials and construction of compressor, combustion system and turbine in single and two shaft designs are outlined
  3. Controls required for control and protection of marine gas turbines are detailed
  4. Function of accessories necessary for safe operation of marine gas turbines are explained
Flow of air and gas through a simple cycle marine gas turbine is analysed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Materials and construction of compressor, combustion system and turbine in single and two shaft designs are outlined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Controls required for control and protection of marine gas turbines are detailed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Function of accessories necessary for safe operation of marine gas turbines are explained

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Evaluate diesel fuel systems

1.1

Why atomisation and penetration of fuel and air turbulence are essential to optimum combustion is explained

1.2

Typical injection pressures and viscosities for different grades of fuel are documented and compared

1.3

Design modifications of pumps, camshafts and injectors for fuel types are outlined

1.4

Difference between constant and variable injection fuel pump timing, showing materials, principal parts, method of operation and adjustments of common pump types is compared and explained

1.5

Injection requirements for slow speed and high speed diesel engines are compared, including pilot injection and pre-combustion chambers

1.6

Common service faults, symptoms and causes of diesel fuel injection problems are identified, specifying appropriate adjustments, including methods of fuel pump timing

1.7

Work health and safety/occupational health and safety (WHS/OHS) requirements for handling and testing fuel injection systems are explained

1.8

Normal operating pressures and temperatures for fuel valve cooling arrangements, and uni-fuel and dual-fuel systems, including both high/medium viscosity fuel types are explained

2

Evaluate different methods of diesel engine cooling

2.1

Importance of maintaining diesel engine thermal efficiency and evaluate thermal loads on engine components is outlined

2.2

Cooling media selection is justified, and advantages and disadvantages of different diesel cooling methods are outlined

2.3

Appropriate action to be taken with common faults in cooling systems is explained and different cooling water treatments are compared

2.4

How cooling systems are commissioned, stored during idle periods and restored after contamination is confirmed

2.5

Methods of load-dependent cooling of diesel alternators on heavy fuels are evaluated

2.6

Normal operation temperatures, pressures, and methods of cooling medium and slow speed diesel engine pistons, exhaust valves, cylinders, turbochargers and cylinder heads are identified

3

Evaluate diesel engine lubrication requirements

3.1

Principles of engine lubrication are outlined

3.2

Lubricant types, physical and chemical properties and applications are assessed

3.3

Sources of diesel lubricant contamination and deterioration are identified

3.4

Ways of testing for diesel lubricant contamination and deterioration, interpreting test results and identifying appropriate action to be taken are outlined

3.5

Distribution of lubricating oil to guides, top-end, bottom-end and main bearings of diesel engines, showing direction of flow, typical clearances and stating normal operating temperatures and pressure is explained

3.6

Principles of bearing lubrication are outlined

3.7

Materials used in bearing construction are identified

3.8

Bearing faults are evaluated and remedies to prevent them from occurring are determined

4

Compare different propulsion, manoeuvring and starting methods

4.1

Starting procedures of diesel engines for power generation, propulsion, and emergency use are clarified

4.2

Starting and manoeuvring requirements/sequences for direct-coupled reversible and geared propulsion diesels, including CPP applications are explained

4.3

Common faults are analysed and appropriate action to be taken with typical diesel starting and manoeuvring systems is identified

4.4

Manoeuvring and reversing systems of propulsion diesel engines are outlined

4.5

Different methods of achieving reversing capability with direct-coupled propulsion diesels are compared

4.6

Layout of a diesel-electric drive is compared and contrasted with the layout of a turbo electric drive

5

Analyse materials used in constructing diesel engines

5.1

Common materials used in diesel engine construction are assessed, selection is justified, and typical compositions and physical properties of components are specified

5.2

Dynamic stresses and loads are interpreted, service limitations are identified and different methods of component fabrication are evaluated

5.3

Two-stroke and four-stroke operating cycle forces, couples and moments, relating to design principles of crankshafts, bedplates, foundations and crossheads are outlined

5.4

Out-of-balance gas and inertia forces, couples and moments are related to flywheels, balance weights and first/second order balancing

5.5

Factors contributing to torsional vibration are explained and methods of minimising or eliminating harmful effects of critical speeds are clarified

5.6

Pistons, liners, piston rings, bearings and crankshafts are calibrated to identify wear patterns, limits and means of correction

5.7

Alignment and adjustment criteria of crankshafts, chain-drives, integral thrust bearings and crossheads are specified

5.8

Specified working clearances and limits of all bearings, sliding surfaces and interference fits of typical diesel engines are compiled using engine builder manuals

6

Explain uptake and scavenge fires and air line, gearbox and crankcase explosions

6.1

Design and operational factors that contribute to fires in waste heat units are explained and methods of extinguishing and/or containing soot and hydrogen fires are specified

6.2

Routine cleaning procedures, inspection criteria, symptoms of fire and risks of isolation in service associated with waste heat units are identified

6.3

Operational factors that contribute to scavenge fires are identified, symptoms are outlined, methods of extinguishing are evaluated and routine inspection criteria of scavenge spaces are stated

6.4

Principles of explosive mixtures are clarified and how a starting airline explosion can occur is explained

6.5

How risk of scavenge fires may be minimised in service by protective devices and routine evaluation of starting air systems is clarified

6.6

Causes of gearbox and crankcase explosions in propulsion and auxiliary drives are outlined

6.7

How risks of gearbox and crankcase explosions may be minimised in service are explained and correct procedures to be taken in the event of warning of a hazardous atmosphere in both oil and dual-fuel engines are clarified

6.8

Operating principles of an oil-mist detector, crankcase breather and explosion relief doors are explained

6.9

Function of a piston rod scraper box is outlined, and causes of wear and appropriate adjustments are identified

7

Explain correct working practices associated with diesel engine operation, maintenance and repair

7.1

Safe working practices associated with isolating main and propulsion diesels under all emergency and routine situations are explained, including use of protective devices, interlocks and evaluation of their status

7.2

Safe working practices associated with working in crankcases and other enclosed spaces are explained

7.3

Safe working practices associated with safe handling of hydraulic tools and dangers of lifting/isolating heavy components both unaided and with lifting gear are explained

7.4

Hazards of working with flammable liquids under pressure, chemicals, acids and hydrocarbons as well as selection criteria for appropriate protective clothing are explained

7.5

Safe working strategies for diesel engine maintenance are planned using engine manufacturer instruction manuals and product data safety sheets

8

Analyse faults using combustion diagnostic equipment

8.1

Two-stroke and four-stroke theoretical cycle diagrams are compared with results recorded using diagnostic tools

8.2

Combustion faults from typical diagrams are evaluated and corrective adjustments are specified

8.3

Service combustion values are compared with trials or test bed figures

8.4

Common faults associated with pressure charging and fuel injection systems are outlined

8.5

Methods of pressure charging diesel engines are compared, and materials of construction, design features, operational maintenance and emergency procedures are correctly identified

8.6

Causes of efficiency loss and surge are explained

8.7

Scavenging systems and gas/air flow paths through a turbocharger, under normal and emergency operation modes are explained using relevant diagrams

9

Analyse construction and operation of marine gas turbines

9.1

Flow of air and gas through a simple cycle marine gas turbine is analysed

9.2

Materials and construction of compressor, combustion system and turbine in single and two shaft designs are outlined

9.3

Controls required for control and protection of marine gas turbines are detailed

9.4

Function of accessories necessary for safe operation of marine gas turbines are explained

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Evaluate diesel fuel systems

1.1

Why atomisation and penetration of fuel and air turbulence are essential to optimum combustion is explained

1.2

Typical injection pressures and viscosities for different grades of fuel are documented and compared

1.3

Design modifications of pumps, camshafts and injectors for fuel types are outlined

1.4

Difference between constant and variable injection fuel pump timing, showing materials, principal parts, method of operation and adjustments of common pump types is compared and explained

1.5

Injection requirements for slow speed and high speed diesel engines are compared, including pilot injection and pre-combustion chambers

1.6

Common service faults, symptoms and causes of diesel fuel injection problems are identified, specifying appropriate adjustments, including methods of fuel pump timing

1.7

Work health and safety/occupational health and safety (WHS/OHS) requirements for handling and testing fuel injection systems are explained

1.8

Normal operating pressures and temperatures for fuel valve cooling arrangements, and uni-fuel and dual-fuel systems, including both high/medium viscosity fuel types are explained

2

Evaluate different methods of diesel engine cooling

2.1

Importance of maintaining diesel engine thermal efficiency and evaluate thermal loads on engine components is outlined

2.2

Cooling media selection is justified, and advantages and disadvantages of different diesel cooling methods are outlined

2.3

Appropriate action to be taken with common faults in cooling systems is explained and different cooling water treatments are compared

2.4

How cooling systems are commissioned, stored during idle periods and restored after contamination is confirmed

2.5

Methods of load-dependent cooling of diesel alternators on heavy fuels are evaluated

2.6

Normal operation temperatures, pressures, and methods of cooling medium and slow speed diesel engine pistons, exhaust valves, cylinders, turbochargers and cylinder heads are identified

3

Evaluate diesel engine lubrication requirements

3.1

Principles of engine lubrication are outlined

3.2

Lubricant types, physical and chemical properties and applications are assessed

3.3

Sources of diesel lubricant contamination and deterioration are identified

3.4

Ways of testing for diesel lubricant contamination and deterioration, interpreting test results and identifying appropriate action to be taken are outlined

3.5

Distribution of lubricating oil to guides, top-end, bottom-end and main bearings of diesel engines, showing direction of flow, typical clearances and stating normal operating temperatures and pressure is explained

3.6

Principles of bearing lubrication are outlined

3.7

Materials used in bearing construction are identified

3.8

Bearing faults are evaluated and remedies to prevent them from occurring are determined

4

Compare different propulsion, manoeuvring and starting methods

4.1

Starting procedures of diesel engines for power generation, propulsion, and emergency use are clarified

4.2

Starting and manoeuvring requirements/sequences for direct-coupled reversible and geared propulsion diesels, including CPP applications are explained

4.3

Common faults are analysed and appropriate action to be taken with typical diesel starting and manoeuvring systems is identified

4.4

Manoeuvring and reversing systems of propulsion diesel engines are outlined

4.5

Different methods of achieving reversing capability with direct-coupled propulsion diesels are compared

4.6

Layout of a diesel-electric drive is compared and contrasted with the layout of a turbo electric drive

5

Analyse materials used in constructing diesel engines

5.1

Common materials used in diesel engine construction are assessed, selection is justified, and typical compositions and physical properties of components are specified

5.2

Dynamic stresses and loads are interpreted, service limitations are identified and different methods of component fabrication are evaluated

5.3

Two-stroke and four-stroke operating cycle forces, couples and moments, relating to design principles of crankshafts, bedplates, foundations and crossheads are outlined

5.4

Out-of-balance gas and inertia forces, couples and moments are related to flywheels, balance weights and first/second order balancing

5.5

Factors contributing to torsional vibration are explained and methods of minimising or eliminating harmful effects of critical speeds are clarified

5.6

Pistons, liners, piston rings, bearings and crankshafts are calibrated to identify wear patterns, limits and means of correction

5.7

Alignment and adjustment criteria of crankshafts, chain-drives, integral thrust bearings and crossheads are specified

5.8

Specified working clearances and limits of all bearings, sliding surfaces and interference fits of typical diesel engines are compiled using engine builder manuals

6

Explain uptake and scavenge fires and air line, gearbox and crankcase explosions

6.1

Design and operational factors that contribute to fires in waste heat units are explained and methods of extinguishing and/or containing soot and hydrogen fires are specified

6.2

Routine cleaning procedures, inspection criteria, symptoms of fire and risks of isolation in service associated with waste heat units are identified

6.3

Operational factors that contribute to scavenge fires are identified, symptoms are outlined, methods of extinguishing are evaluated and routine inspection criteria of scavenge spaces are stated

6.4

Principles of explosive mixtures are clarified and how a starting airline explosion can occur is explained

6.5

How risk of scavenge fires may be minimised in service by protective devices and routine evaluation of starting air systems is clarified

6.6

Causes of gearbox and crankcase explosions in propulsion and auxiliary drives are outlined

6.7

How risks of gearbox and crankcase explosions may be minimised in service are explained and correct procedures to be taken in the event of warning of a hazardous atmosphere in both oil and dual-fuel engines are clarified

6.8

Operating principles of an oil-mist detector, crankcase breather and explosion relief doors are explained

6.9

Function of a piston rod scraper box is outlined, and causes of wear and appropriate adjustments are identified

7

Explain correct working practices associated with diesel engine operation, maintenance and repair

7.1

Safe working practices associated with isolating main and propulsion diesels under all emergency and routine situations are explained, including use of protective devices, interlocks and evaluation of their status

7.2

Safe working practices associated with working in crankcases and other enclosed spaces are explained

7.3

Safe working practices associated with safe handling of hydraulic tools and dangers of lifting/isolating heavy components both unaided and with lifting gear are explained

7.4

Hazards of working with flammable liquids under pressure, chemicals, acids and hydrocarbons as well as selection criteria for appropriate protective clothing are explained

7.5

Safe working strategies for diesel engine maintenance are planned using engine manufacturer instruction manuals and product data safety sheets

8

Analyse faults using combustion diagnostic equipment

8.1

Two-stroke and four-stroke theoretical cycle diagrams are compared with results recorded using diagnostic tools

8.2

Combustion faults from typical diagrams are evaluated and corrective adjustments are specified

8.3

Service combustion values are compared with trials or test bed figures

8.4

Common faults associated with pressure charging and fuel injection systems are outlined

8.5

Methods of pressure charging diesel engines are compared, and materials of construction, design features, operational maintenance and emergency procedures are correctly identified

8.6

Causes of efficiency loss and surge are explained

8.7

Scavenging systems and gas/air flow paths through a turbocharger, under normal and emergency operation modes are explained using relevant diagrams

9

Analyse construction and operation of marine gas turbines

9.1

Flow of air and gas through a simple cycle marine gas turbine is analysed

9.2

Materials and construction of compressor, combustion system and turbine in single and two shaft designs are outlined

9.3

Controls required for control and protection of marine gas turbines are detailed

9.4

Function of accessories necessary for safe operation of marine gas turbines are explained

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions on at least one occasion and include:

accessing diagnostic information related to marine diesel engines and systems

applying relevant work health and safety/occupational health and safety (WHS/OHS) requirements and work practices

assessing own work outcomes and maintaining knowledge of current codes, standards, regulations and industry practices

explaining operation of marine diesel engines and systems

identifying and applying relevant solutions for addressing problems associated with marine diesel engines and systems

identifying and interpreting diagnostic information, and performing mathematical calculations related to operating, maintaining and repairing marine diesel engines and systems

identifying methods, procedures and materials needed for operating, maintaining and repairing marine diesel engines and systems

imparting knowledge and ideas through verbal, written and visual means

reading and interpreting manuals, technical specifications, safety data sheets/material safety data sheets and manufacturer guides related to operating, maintaining and repairing marine diesel engines and systems.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions and include knowledge of:

chemical and physical properties of fuels and lubricants

components of diesel engines

crankcase and air-line explosions, scavenge and uptake fires

diesel engine lubrication systems

diesel engine propulsion and power generation

manoeuvring systems of diesel engines

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

principles of diesel engine operation

properties and characteristics of fires

safe working practices associated with diesel engines during operation, repair and maintenance

starting methods of diesel engines

WHS/OHS legislation, policies and procedures.

Range Statement

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Methods of component fabrication include one or more of the following:

ceramics

composite

forged

laser-hardening

plasma-spraying

welded

Accessories include one or more of the following:

accessory gear

lube oil:

cooler

pump

filter

starting devices