Preparing and testing marine pipework systems

URN: SEMME3045
Business Sectors (Suites): Marine Engineering Suite 3
Developed by: Enginuity
Approved on: 2019

Overview

This standard identifies the competencies you need to test ferrous, non-ferrous and non-metallic marine pipework systems, in accordance with approved procedures. You will be required to select appropriate tools and test equipment to be used, based on the pipework system being tested and the test procedures being carried out. Pipework systems to be tested could include high pressure/low pressure air, hydraulics, lubricating oil, fresh water, distilled water, waste water, chilled water, main service, fuel, steam, refrigeration gases, salvage. In preparing and testing the pipework system, you will be expected to use a range of hand tools, test equipment and techniques, as required by the test procedures. These activities will include such items as purging equipment and materials, using appropriate test equipment (such as hydraulic, compressed air, gas and water) and the use of pressure gauges and leak repair equipment and materials.

Your responsibilities will require you to comply with organisational policy and procedures for the preparation and testing of the marine pipework and to report any problems with the testing equipment, testing activities or installations tested, that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision taking personal responsibility for your own 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 marine pipework preparation and testing activities. You will understand the pipework system being tested and its application and will know about the preparations required, the equipment to be used and tests to be carried out, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the completed system performs to the required specification. 

You will understand the safety precautions required when testing the pipework installation and with using the associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.


Performance criteria

You must be able to:

  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. follow the appropriate procedures for use of tools and equipment to carry out the required tests
  3. set up and carry out the tests using the correct procedures and within agreed timescales
  4. record the results of the tests in the appropriate format
  5. review the results and carry out further tests if necessary
  6. deal promptly and effectively with problems within your control and report those that cannot be solved

  7. complete relevant documentation in line with organisational procedures


Knowledge and Understanding

You need to know and understand:

  1. the specific safety precautions to be taken when carrying out test procedures on pipework systems, used both on land and on board vessels (including general workshop and site safety, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)
  2. the importance of vessels boundaries to testing and the tag-out system
  3. the reasons for a 'permit to pressure-test' certificate prior to testing on board a vessel
  4. the personal protective equipment (PPE) to be worn whilst carrying out the testing activities
  5. the hazards associated with the testing activities and how they can be minimised 
  6. how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
  7. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
  8. how to carry out currency/issue checks of the specifications you are working with
  9. the colour code standard used for identifying pipes and why it is important to adhere to these standards
  10. the importance of using the correct type of pipe material
  11. the basic principles of operation of the pipework system to be tested and the function of the various components within the system
  12. the various pressure test methods used on ferrous, small-bore non-ferrous and non-metallic pipelines
  13. the importance of components being fitted in the correct relation to the direction of flow

  14. the reasons for purging and venting pipework systems and the consequences of not purging the system

  15. how to identify the fluids that can be used for flushing pipework systems
  16. the consequences of not flushing or of using the incorrect flushing agent
  17. methods of testing the system and the need to gradually increase pressure in the pipework system
  18. the methods used to isolate parts of the pipework system for testing and how this can be achieved
  19. how the amount of test fluid for the pipework system is determined and what problems would be caused if the incorrect amount were used 
  20. the factors that govern the choice of test equipment used in pressure testing of pipework systems and the importance of equipment being calibrated
  21. how the test pressures are determined
  22. the reasons for maintaining test pressures for specific times
  23. how the results of the pressure test are analysed and why this is important
  24. how pipework systems are depressurised and what environmental precautions must be taken, especially in confined spaces on board vessels
  25. the procedures for recording and reporting test results to the relevant people
  26. 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 testing activities:

    1. use the correct test procedures and specifications
    2. check that all tools and test equipment are within calibration date
    3. obtain clearance/authority/permit to pressure-test the installation
    4. ensure that isolation and tag-out procedures are followed
    5. ensure that safe working distance procedures are set up
    6. erect relevant warning notices or safety signs
    7. ensure that appropriate safety measures are taken to protect test personnel (such as guards, distance, incremental pressure tests)
    8. return all tools and equipment to the correct location on completion of the assembly activities
    9. leave the work area in a safe and tidy condition on completion of the activities
  2. Carry out tests on both of the following types of pipework installations:

    1. ferrous
    2. non-ferrous
  3. Carry out tests on three of the following pipework systems:

    1. fresh water
    2. salt/raw water
    3. chilled water
    4. waste water
    5. deck drains
    6. fuel
    7. air conditioning
    8. lubricating oil
    9. steam drains
    10. hydraulic
    11. fire main
    12. refrigeration gas
    13. distilled
    14. main services
    15. high pressure/low pressure air
    16. other salvage drainage systems
  4. Prepare the installation for testing by carrying out all of the following:

    1. checking security of all joints
    2. purging or flushing the system (as appropriate)
    3. fitting appropriate blanking plugs/plates to exposed ends of pipe or equipment 
    4. connecting an appropriate test source
    5. fitting leak detection equipment and/or pressure gauges
  5. Use one of the following methods of testing:

    1. hydraulic test equipment
    2. compressed air test equipment
    3. gas test equipment
    4. water test equipment
    5. non destructive testing (such as dye penetration)
  6. Deal with all the following types of complexity:

    1. systems with no fault
    2. systems with faults
    3. systems with intermittent faults
  7. During tests, use two of the following fault finding techniques:

    1. half-split technique
    2. input/output technique
    3. six point technique
    4. unit substitution
  8. Carry out all of the following during the testing activities:

    1. filling the system with appropriate test medium
    2. venting air from the system (where appropriate)
    3. applying test pressures in incremental stages
    4. checking for leaks at each stage
    5. depressurising the system
    6. draining down the system (where appropriate)
  9. Record the test results in an appropriate format, to include one from the following:

    1. system/installation test documentation
    2. vessel/craft/structure log
    3. job sheet
    4. handover report
    5. corrective action report
    6. other specific reporting method
  10. Carry out the testing activities in line with one of the following standards:

    1. BS or ISO standards and procedures
    2. customer (contractual) standards and requirements
    3. company standards and procedures
    4. specific system requirements
    5. recognised compliance agency/body's standards
    6. other accepted international standards

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

Skills


Glossary


Links To Other NOS


External Links


Version Number

3

Indicative Review Date

2021

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMME3045

Relevant Occupations

Marine Engineering Trades

SOC Code

5235

Keywords

engineering; marine; prepare; test; pipework; systems; water; air; fuel; steam; waste