Repairing marine mechanical components
Overview
This standard identifies the competences you need to restore marine mechanical components to usable condition by repair, in accordance with approved procedures. You will be required to restore a range of mechanical components and equipment to operational condition, by repairing assemblies/sub-assemblies and components, by reworking the surface, recutting threads or replacing worn parts. You will also be required to select the appropriate equipment to use, based on the nature of the repair, the operations that will need to be carried out and the accuracy to be achieved.
In repairing the components, you will be expected to use a range of hand tools, machine tools, portable power tools and shaping and fitting techniques that are appropriate to the type of material and repair being performed. These activities will include such processes as sawing (hand, machine), drilling, reaming, grinding (hand or pedestal), filing, scraping or lapping, threading (internal or external), basic machining (turning, milling) and thermal processes.
Your responsibilities will require you to comply with organisational policy and procedures for the repairing activities undertaken and to report any problems with these activities, or with the tools, equipment or materials used, that you cannot personally resolve or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, either alone or in conjunction with others, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will be sufficient to provide a sound basis for your work and will provide an informed approach to applying marine component repair procedures. You will have an understanding of the various repair techniques that are used, in sufficient depth to enable you to carry out the required repairs, safely and correctly. You will also understand the organisational policy on repairing components and its application.
You will understand the safety precautions required when carrying out the repair activities, especially those for isolating the equipment. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace, both ashore and afloat.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant specifications for the component to be repaired
- prepare the component for repair
- carry out the repairs within agreed timescale using approved materials and components and methods and procedures
- ensure that the repaired component meets the specified operating conditions
- produce accurate and complete records of all repair work carried out
Knowledge and Understanding
You need to know and understand:
- the health and safety requirements of the area in which the repair activity is to take place and the responsibility these requirements place on you
- the isolation procedure or permit-to-work procedure that applies to the equipment being repaired
- the specific health and safety precautions to be applied during the repair procedure and their effects on others
- the importance of wearing protective clothing and other appropriate safety equipment (PPE) during repair activities
- the hazards associated with the repair/restoration operations being carried out (sawing (hand, machine), drilling, reaming, grinding (hand or machine), filing, scraping or lapping, threading (internal or external), turning, milling and thermal processes) and how they can be minimised
- where to obtain and how to interpret job instructions, drawings, specifications, manufacturers' manuals, maintenance schedules and other relevant documents
- the methods, techniques and procedures to be followed for repairing the marine mechanical equipment
- the types of repairs that can be made to components in order to prolong their useful life (such as bushing/plugging worn holes, recutting threads, joining mating surfaces by thermal process)
- how to use a range of hand tools (such as files, scrapers)
- how to cut internal and external threads (using hand dies and taps)
- how to select saw blades (for different materials and different operations)
- the types and application of portable power tools that can be used for the fitting operations
- how to identify that portable power tools and extension cables are tested and in a safe usable condition
- the operating requirements of the machine tools and accessories being used (guards, workholding devices, speeds and feeds, specific statutory regulations such as Abrasive Wheels Regulations)
- how to handle and store tools and equipment safely and correctly
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the application of cutting fluids
- the company recording procedures to be used following the repair activity and how to apply them
- the problems associated with repair and how to resolve them
- the extent of your own authority and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the repair activity:
- undertake the repair activities, in conjunction with others involved, to cause minimal disruption to normal working
- adhere to risk assessment, COSHH and other relevant safety standards
- under supervision, ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids)
- under supervision, provide safe access and working arrangements for the maintenance area
- in conjunction with others, carry out the repair activities, using appropriate techniques and procedures
- record the repair, using appropriate methods or documentation
- dispose of waste items in a safe and environmentally acceptable manner
- leave the work area in a safe condition and to the prescribed category of cleanliness
Use appropriate techniques to carry out four of the following types of repair:
- reforming the component surface by adding metal
- replacing internal threads (thread inserts)
- sleeving worn components
- reworking a fit (shimming)
- making stepped dowels or studs
- replacement/reworking of worn keys/keyways
- cutting new keyways
- replacing damaged or missing gear teeth
- making a temporary fix
- stopping cracks running and filling them
- bushing worn holes
- plugging holes
- reworking surface finish (using techniques such as filing, scraping, lapping, grinding)
- reconditioning units by replacement of worn components
- other specific repair procedure
Use a range of methods and techniques to repair components, to include four of the following:
- sawing (hand or machine)
- filing
- turning
- drilling
- scraping or lapping
- milling
- reaming
- threading (external)
- thermal processes
- grinding (hand or machine)
- threading (internal)
- other specific method
Repair components made from different types of material, to include two from the following:
- low carbon steel
- aluminium
- plastic/synthetic
- high carbon steel
- brass/bronze
- composite
- cast iron
- stainless steel
- other specific material
Carry out repairs to mechanical equipment in accordance with one of the following standards:
- organisational guidelines and codes of practice
- specific equipment requirements/manufacturer's data
- BS, EN and/or ISO standards
- customer (contractual) standards and requirements
- recognised compliance agency/body's standards
Complete the relevant paperwork, to include one of the following, and pass it to the appropriate people:
- repair record
- job cards
- time sheets
- system log
- other specific recording method
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment