This unit involves the skills and knowledge required to maintain and repair shipboard machinery and equipment on a vessel. This includes maintaining marine pumps, valves, air compressors, heat exchangers, diesel engines, turbochargers, marine lubricating systems and deck machinery as well as conducting inspections of marine boilers and marine refrigeration units.

This unit applies to people working in the maritime industry in the capacity of:

Electro-Technical Officer (STCW Electro-Technical Officer Unlimited)

Engineer Class 3 Near Coastal

Engineer Watchkeeper (STCW Engineer Watchkeeper Unlimited).

Licensing/Regulatory Information

Legislative and regulatory requirements are applicable to this unit.

This unit is one of the requirements to obtain Australian Maritime Safety Authority (AMSA) certification as an Engineer Class 3 Near Coastal as defined in the National Standard for Commercial Vessels (NSCV) Part D.

This unit is one of the requirements to obtain AMSA certification as an Electro-Technical Officer (STCW Electro-Technical Officer Unlimited) or Engineer Watchkeeper (STCW Engineer Watchkeeper Unlimited) and to meet regulatory requirements this unit must be delivered consistent with Marine Orders and with the relevant sections of the International Convention on Standards of Training, Certification and Watchkeeping for Seafarers (STCW).

Those regulatory requirements include STCW International Maritime Organization (IMO) model course competencies and areas of knowledge, understanding and proficiency, together with the estimated total hours required for lectures and practical exercises. Teaching staff should note that timings are suggestions only and should be adapted to suit individual groups of trainees depending on their experience, ability, equipment and staff available for training.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

1

Follow safe work practices

1.1

Work health and safety (WHS)/occupational health and safety (WHS/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

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

1.4

Isolation precautions are implemented prior to commencing maintenance activities 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 valves are determined according to safety, manufacturer and vessel procedures and documentation

3.2

Appropriate procedures, materials, tools and equipment for maintaining valves 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

Valves are 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

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

explaining principles of shipboard machinery and equipment and imparting knowledge and ideas verbally and in writing

initiating timely action in response to defects or damage

performing calculations and interpreting graphical information used in maintaining shipboard machinery and equipment

reading and interpreting written information related to the operation, performance and maintenance of shipboard machinery and equipment, including machinery specifications and operational manuals

scheduling maintenance of shipboard machinery and equipment

using testing equipment and explaining test and performance results relevant to shipboard machinery and equipment.

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

basic principles of diesel engine operation, including:

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

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

crankshafts

cylinder liners and heads

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

exhaust valves

materials used to construct diesel engine major parts

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

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

typical diesel engine lubrication systems, including:

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

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

alternating current (AC) and direct current (DC) theory and plant and equipment

basic cabling, distribution and lighting systems

basic control and switchgear

basic electrical circuit theory

basic theory of electromagnetism and electrostatics

electrolytic action and cells

instruments, calibration and testing

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

basic principles of operating and maintaining:

fluid power control systems

machinery lubrication systems

marine boilers and materials used to construct boiler major parts

refrigeration systems:

furnace

steam and water drum

superheaters

water tubes

basic thermodynamics, including:

advantages of multi-staging and inter-cooling

air/fuel ratio and significance of excess air on combustion

basic steam plant cycles and function of each component

basic thermodynamic properties of common working fluids

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

combustion process and calorific value of fuels

elementary principles of steam plants

meaning of gauge and absolute pressure

methods of heat transfer and related problems

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

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

International System of Units (SI) and common thermodynamic terms and principles

temperature and temperature scales

deck machinery, including:

cranes

lifeboat davits and gear

mooring winch

winch

windlass

diesel engine routine maintenance, including:

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:

coolant sampling for trending analysis

draining, flushing and refilling system when required

fluid level checks

emissions systems:

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

exhaust system:

inspecting for leaks, corrosion and wet stacking

fuel system:

changing fuel filters and fuel injectors

checking water separators

lubrication:

changing oil and oil filters

checking levels

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

mechanical systems:

generally inspecting for leaks, wear or deterioration

inspecting resilient engine mounts and torsional couplings

operating systems:

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

valves and heads:

inspecting and recording cylinder head wear for trending analysis

inspecting, adjusting and recording valve train wear for trending analysis

inspection and disassembling, including:

air compressors:

coolers and cooling passages

lubricating systems

piston and rings

suction and delivery valves and seats

diesel engine components:

bearings

cooling system

crankshaft alignment

liners

lubrication system

pistons

rings

valves

heat exchangers:

corrosion

erosion

fouling

leakage

provision for tube expansion

inspection requirements for:

marine refrigeration:

compressors

condensers

evaporators

expansion valves

oil separators

marine boiler:

fire side

water side

lubricating system components, including:

settling tank

system bearings

system filters

maintenance and repair hazards and problems, and appropriate preventative and remedial action and solutions during maintaining and repairing shipboard plant and equipment

maritime communication techniques needed during maintenance and repair operations

materials used to construct the following gas turbine major parts:

compressors

gas generators

rotors

turbine casing

materials used to construct the following steam turbine major parts:

blades

nozzles

reduction gears

rotors

turbine casings

national and international regulations, International Maritime Organization (IMO) conventions and codes, including Australian Maritime Safety Authority (AMSA) Marine Orders applicable to managing shipboard plant and equipment maintenance and repair operations

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

operating principles and performance specifications for different types of shipboard plant and equipment usually found on a vessel of unlimited propulsion power

operating principles of unmanned machinery spaces (UMS) and automated monitoring and control of machinery

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

plant and equipment typically found onboard a vessel of unlimited propulsion power

procedures for:

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

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

reading and interpreting plant and equipment performance readings and instrumentation

pumps, including:

axial

centrifugal

gear

reciprocating

screw

purpose and content of safety data sheets (SDS)/material safety data sheets (MSDS)

refurbished diesel engine components, including:

air start valves

cylinder heads

exhaust valves

fuel injectors

relief valves

safety procedures for:

handling heavy plant, equipment and component parts during maintenance and repair of shipboard plant and equipment

using hand and power tools and maintenance equipment

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

servicing, including:

dismantling rod and gears, seals, bearings and relief valve

gland packing

identifying wear and deterioration

measuring wear in cylinders, neck rings and rods

protecting finished surfaces

replacing and adjusting seals

removing studs: intact and broken

turbocharger components, including:

air casing

air filters

bearings

diffuser

gas inlet grid

impeller

inducer

nozzle ring

rotor

volute

types of vessel maintenance and repair records to be maintained to meet requirements of company, survey and regulatory authorities

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

valves, including:

ball

butterfly

check

diaphragm

gate

globe:

screw down non return

screw lift

valve maintenance, including:

examining seats, valves, spindles and glands

gland packing

lapping valves and seats

machining valves and seats

removal

repacking

selection

work health and safety (WHS)/occupational health and safety (WHS/OHS) legislation, policies and procedures.

Assessors must hold credentials specified within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must satisfy the Principles of Assessment and Rules of Evidence and all regulatory requirements included within the Standards for Registered Training Organisations current at the time of assessment.

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

Practical assessment must occur in a workplace or realistic simulated workplace, under the normal range of workplace conditions.

Simulations and scenarios may be used where situations cannot be provided in the workplace or may occur only rarely, in particular for situations relating to emergency procedures and adverse weather conditions where assessment would be unsafe, impractical or may lead to environmental damage.

Resources for assessment must include access to:

applicable documentation, such as legislation, regulations, codes of practice, workplace procedures and operational manuals

tools, equipment, machinery, materials and relevant personal protective equipment (PPE) currently used in industry.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

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

Not applicable.

B – Equipment Checking and Maintenance