Overhauling and repairing marine electrical power generation and distribution equipment and systems
Overview
This standard identifies the competences you need to carry out overhauling activities on marine electrical power generation and distribution equipment and systems, in accordance with approved procedures. The equipment to be overhauled will include alternating current and direct current generators/alternators, breakers/ contactors, bus bars, regulators, inverters, transformers, rectifier units and changeover devices. This will include low voltage (below 115V), mid voltage (above 115 V and below 440 V) and high voltage (above 440 V) equipment.
This will involve dismantling, removing and replacing faulty equipment at component or unit level on a variety of electrical power generation and distribution assemblies/sub-assemblies. You will be expected to apply a range of dismantling and reassembly methods and techniques, such as removing and replacing mechanical fasteners, removing and replacing damaged, faulty, worn or out-of-date components, soldering/de-soldering, crimping, harnessing and securing cables and components.
Your responsibilities will require you to comply with organisational policy and procedures for the overhaul of the marine power generation and distribution equipment and to report any problems with the overhauling activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used in the overhaul are removed from the work area on completion of the activities and that all necessary job/task documentation is completed accurately and legibly. You will be expected to work with a minimum of supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying overhauling procedures to marine power generation and distribution equipment. You will understand the dismantling/reassembly methods and procedures used and their application. You will know about the marine power generation and distribution equipment being worked on, its component properties, functions and associated defects, in adequate depth to provide a sound basis for carrying out the overhauling activities, correcting faults and ensuring that the overhauled equipment functions to the required specification.
You will understand the safety precautions required when carrying out the overhauling activities, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout and will understand your responsibility for taking the necessary safeguards to protect yourself and
others in the workplace.
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 maintenance schedules to carry out the required work
- carry out the maintenance activities within the limits of your personal authority
- carry out the maintenance activities in the specified sequence and in an agreed time scale
- report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule
- complete relevant documentation in line with organisational procedures and pass them on to the appropriate person
- dispose of waste materials in accordance with safe working practices and approved procedures
Knowledge and Understanding
You need to know and understand:
- the specific safety practices and procedures that you need to observe when overhauling marine electrical power generation and distribution systems (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)
- the health and safety requirements of the work area where you are carrying out the activities and the responsibility these requirements place on you
- the hazards associated with the overhauling of marine power generation and distribution systems/equipment and with the tools and equipment used and how they can be minimised
- how to recognise and deal with emergencies and the procedures to be followed (such as methods of safely evacuating and closing down of compartments in the case of fire or other major incident, first aid, fire fighting and resuscitation of personnel)
- the isolation and lock-off procedure or permit-to-work procedure that applies to the overhauling activities (to include electrical isolation, locking off switchgear, removal of fuses, placing maintenance warning notices, proving that isolation has been achieved and secured)
the protective equipment that you need to use for both personal protection (PPE) and protection of the overhauled item/system
the precautions to be taken to prevent electrostatic discharge (ESD) damage to circuits and sensitive components (such as use of earthed wrist straps, anti-static mats, special packaging and handling areas)
what constitutes a hazardous voltage and how to recognise victims of electric shock
how to reduce the risks of a phase to earth shock (such as insulated tools, rubber matting and isolating transformers)
how to obtain and interpret drawings, circuit and physical layouts, charts, specifications, manufacturers' manuals, history/maintenance reports, graphical electrical symbols, IET wiring regulations and other documents needed in the overhauling process
- how to carry out currency/issue checks of the specifications you are working with
- the items to be overhauled and their function within the associated system
- the importance of using the specified fasteners and terminations for the particular overhauling process and why you must not substitute others
- the different types of cabling used in marine power generation and distribution systems, and their application (such as multicore cables, single core cables, steel wire armoured (SWA), mineral insulated (MI), screened cables)
- the application and use of a range of electrical components (such as plugs, switches, sockets, indicators)
- the different types of wiring enclosures that are used (to include conduit, trunking and traywork systems)
- the care, handling and application of ohmmeters, multimeters and other electrical measuring instruments
- company policy on the repair/replacement of components and the procedure for obtaining replacement parts, materials and other consumables necessary for the overhauling process
- how to check that the replacement components meet the required specification/operating conditions (such as values, tolerance, current carrying capacity, voltage rating, power rating, ambient temperatures)
- the techniques used to remove, dismantle, dimensionally measure, inspect re-assemble, align, adjust and secure the components in the equipment/unit, without damage
- methods of attaching identification marks/labels to removed components or cables, to assist with re-assembly
- methods of removing and replacing cables/wires in wiring enclosures, without causing damage to existing cables
- the factors to take into account when deciding id a component/module can be repaired or not
- the different types and methods of repair that can be used
- methods of lifting, handling and supporting the components/equipment during the overhauling activities
- why unit electrical bonding, earth prevention and continuity are critical and why earth bonds must be both mechanically and electrically secure
- the use of IET and other regulations when selecting wires and cables and when carrying out tests on systems
- how to recognise equipment defects (such as degradation of finish, wear, misalignment, ineffective fasteners/terminations, damage or contamination and lack of fitness for purpose)
- how to make adjustments to components/assemblies to ensure that they function correctly
- the importance of making 'off-load' checks before proving the equipment with the electrical supply on
- the generation of documentation and/or reports following the overhauling activity
- the importance of ensuring that the overhauled equipment is completed to the prescribed category of cleanliness
- the tools, equipment and measuring devices used in the overhauling activities and their calibration/care, testing and control procedures
- the problems that can occur with the overhauling operations and how these can be overcome
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
1. Carry out all of the following during the overhaul of the marine navigational equipment:
- plan the overhauling activities to cause minimal disruption to normal working
- use the correct issue of vessel/system drawings and overhauling documentation
- adhere to risk assessment, COSHH and other relevant safety standards
- obtain clearance to work on the equipment and observe the appropriate power isolation and safety procedures
- provide safe access and working arrangements for the overhauling area
- carry out the overhauling activities, using approved techniques and procedures
- re-connect and return the system for setting to work on completion of the overhaul
- leave the work area in the prescribed category of cleanliness
2. Carry out overhauling activities on six of the following types of marine power generation and distribution equipment:
- single phase power supply contactors/breakers
- three-phase power supply contactors/breakers
- direct current power supply breakers
- generators and motor generators
- alternators
- voltage regulators
- protection devices
- inverters
- frequency change equipment
- switchgear/isolators
- transformers
- rectifier units
- change-over mechanisms
- battery charging facilities
3. Carry out all of the following overhauling activities, as applicable to the equipment being overhauled:
- isolating and locking-off equipment
- dismantling equipment to unit level
- removing electrical units/components
- disconnecting and reconnecting wires and cables
- removing and replacing damaged wires and cables
- visually checking components for serviceability
- dimensional inspection of components
- measurement of electrical values of components
- replacing damaged/defective units/components
- repair damaged/defective units/components
- adjustment of variables to return to tolerance
- replacing 'lifed' or updated items/components
- replacing damaged wiring enclosures
- attaching suitable cable identification markers
- harnessing and securing wires/cables
- securing, screening and locking
- earth bonding
- setting and adjusting replaced components
- making 'off-load' checks before powering up
- functionally testing the completed system
4. Replace and/or repair a range of electrical components, to include six of the following groups of components:
- cables
- connectors
- contactors
- relay components
- overload protection devices
- locking and retaining devices (such as cable ties, clips, proprietary fasteners)
- electronic modules
- electrical modules
- circuit boards
- indicator lamps
- batteries
- other specific components
5. Make three of the following types of mechanical securing connections to the equipment:
- threaded fasteners
- locking devices
- screws
- quick release fasteners
- torque loaded bolts
6. Make four of the following types of electrical connection to the equipment:
- module blocks
- terminal blocks
- tray-mounted sockets
- free plugs
- crimping
- soldering
- fibre-optic connections
7. Carry out five of the following checks on the overhauled equipment/system:
- earth bonding
- insulation checks
- continuity checks
- resistance checks
- frequency checks
- phase balance
- functional checks of safety devises
- over voltage and under voltage checks
- speed/rotational checks
- standing waveform reflection checks
- alignment readings
- clearance checks
- flow rate checks
- liquid level checks
8. Ensure that the overhauled electrical power generation and distribution equipment meets all of the following:
- all components and sub-assemblies are fit for purpose
- all connections are safe and sound
- equipment static checks, after overhaul, meet specifications
- all potential defects are identified, recorded and reported for future action
9. Overhaul marine power generation and distribution equipment, in compliance with one of the following standards:
- BS or ISO standards and procedures
- customer (contractual) standards and requirements
- company standards and procedures
- specific equipment requirements/manufacturer's data
- Institute of Electrical Technicians (IET) regulations
- recognised compliance agency/body's standards
- other accepted international standards
10. Complete the relevant documentation in line with organisational procedures, to include one from the following and pass it to the appropriate people:
- job cards
- system log
- maintenance/overhaul logs or reports
- work authorisation documents
- vessel wiring documentation
- other specific reporting method
Scope Knowledge
Values
Behaviours
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