Installing marine auxiliary power units for electrical power generation
Overview
This standard identifies the competences you need to install marine auxiliary power units for electrical power generation, such as self-contained steam turbine, backpressure steam turbine and gas turbine generators, ICE two-stroke and four-stroke turbo blown, mechanically blown, naturally aspirated generators in accordance with approved procedures. You will be required to use appropriate installation drawings, specifications and documentation to install the various items of equipment. You will be required to select the appropriate equipment and installation techniques, based on the operations to be made and the components to be installed.
The marine power unit components to be installed will include turbo blowers, gearboxes, air intakes, combustion system, engine control units, fuel injectors, fuel pipes, fire detection systems, exhaust units, sea water cooling pumps, feed water extraction pumps, turbine rotors, lubricating oil coolers and other associated equipment. The installation activities will include making all necessary checks and adjustments to ensure that components are correctly positioned, aligned, locked and fastened and that correct sealants are used.
Your responsibilities will require you to comply with organisational policy and procedures for the installation of the marine auxiliary power units and to report any problems with the installation activities, equipment or components used that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the installation are correctly accounted for on completion of the activities and to complete all necessary job/task documentation accurately and legibly. 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 installation techniques and procedures for marine auxiliary power units. You will understand the marine auxiliary power unit being installed and its application and will know about the installation techniques, tools and methods, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the completed installation is to the required specification.
You will understand the safety precautions required when carrying out the installation operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to 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 all relevant drawings and specifications for the installation being carried out
- use the correct tools and equipment for the installation operations and check that they are in a safe and usable condition
- install, position and secure the equipment and components in accordance with the specification
- ensure that all necessary connections to the equipment are complete
- deal promptly and effectively with problems within your control and report those that cannot be solved
- check that the installation is complete and that all components are free from damage
- complete relevant documentation in line with organisational procedures
Knowledge and Understanding
You need to know and understand:
- the specific safety practices and procedures that you need to observe when working with marine auxiliary power units (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)
- the procedures to be carried out before starting work on the installation (such as obtaining permits to work, obtaining and complying with risk assessments and other health and safety requirements)
- the health and safety requirements of the work area where you are carrying out the activities and the responsibility they place on you
- 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 hazards associated with installing marine auxiliary power units and with the tools and equipment used and how these can be minimised
the protective equipment that you need to use for both personal protection (PPE) and protection of the power unit
the interpretation of drawings, standards, quality control procedures and specifications used for the installation (including BS and ISO mechanical schematics, symbols and terminology)
- how to carry out currency/issue checks of the specifications you are working with
- the basic operating principles of the marine auxiliary power unit being installed
- the components to be installed and their function within the particular marine auxiliary power unit
- the various mechanical fasteners that will be used and their method of installation (including threaded fasteners, special securing and locking devices)
- the importance of using the specified fasteners and locking devices for the particular installation and why you must not substitute others
- why securing devices need to be locked and labelled and the different methods that are used
- the torque loading requirements on the fasteners and what to do if these loadings are exceeded or not achieved
- the quality control procedures to be followed during the installation operations
- procedures for ensuring that you have the correct tools, equipment, components and fasteners for the activities
- the techniques used to position, align, adjust and secure the components without damage
- methods of lifting, handling and supporting the components/equipment during the installation activities
- the use of seals, sealant and adhesives and the precautions to be taken
- why electrical bonding is critical and why it must be both mechanically and electrically secure
- the procedure for the safe disposal of waste materials
- how to conduct any necessary checks to ensure the system integrity, functionality, accuracy and quality of the installation
- how to recognise installation defects (such as leaks, poor seals, misalignment, ineffective fasteners and foreign object damage or contamination)
- the importance of ensuring that the completed installation is free from foreign object debris and that any exposed components or pipe ends are correctly covered/protected
- the tools and equipment used in the installation activities and their calibration/care and control procedures
- why tool/equipment control is critical
- the problems that can occur with the installation operations and how these can be overcome
- the recording documentation to be completed for the activities undertaken and where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
- the extent of your own responsibility 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 installation of the marine auxiliary power units:
- use the correct issue of the vessel or craft installation drawings and technical documentation
- use copies of relevant COSHH sheets, risk assessment and marine or hovercraft standards
- check the calibration dates of tools and equipment to be used
- obtain clearance to work on the equipment and observe the power isolation procedures
- ensure that correct part numbers are used (including port or starboard items)
- return all tools and equipment to the correct location on completion of the installation
- leave the work area in a safe condition and to the prescribed category of cleanliness
Install one of the following types of marine auxiliary power unit:
- gas turbine generator
- steam turbine generator
- ICE 2-stroke turbo blown/ mechanically blown/naturally aspirated generator
- ICE 4-stroke turbo blown/ mechanically blown/naturally aspirated generator
Assemble and install auxiliary power unit components, to include six of the following:
- air Intake
- air charger (blower)
- combustion system
- journal bearing
- gas turbine rotor
- engine monitoring unit
- fire extinguishing system
- air ejector
- lubricating oil pump
- steam turbine rotor
- gland vapour condenser
- extraction pump
- sea water pump
- fuel system
- isolating valve
- fuel pump
- exhaust system
- air start system
- governor gear
- turbine nozzle box
- lubricating oil cooler
- float regulator
- shaft
- gearbox
- gland sealing
- instrumentation
- condenser
Use twelve of the following installation methods and techniques:
- marking/setting out of locating and securing positions
- preparing holes (such as drilling, cleaning out threads)
- positioning equipment/components
- levelling of equipment
- aligning of equipment
- assembly/connection of components or sub-assemblies
- setting timings
- setting and adjusting equipment
- torque setting of mechanical fasteners
- lifting and handling
- lubricating
- connecting wires and cables
- securing using mechanical fixings
- securing using adhesives
- sealing
- applying screw fastening locking devices
- making pipe connections
- earth bonding
- ensuring the system cleanliness (such as covering exposed pie ends or components)
Use six of the following types of fasteners and securing devices:
- swing bolts
- screws
- dowels
- quick-release fasteners
- studs with nuts
- wing nuts
- bolts
- flexible bellows
- locking devices (such as split, parallel, clevis or taper pin)
- keys/keyways (such as slotted, semi-circular, woodruff, taper)
Produce installations which comply with one of the following standards:
- BS or ISO standards and procedures
- customer (contractual) standards and requirements
- company standards and procedures
- specific system requirements
- recognised compliance agency/body's standards
- other accepted international standards
Complete the relevant documentation in line with organisational procedures, to include one from the following and pass it to the appropriate people:
- installation record
- acceptance documentation
- work authorisation documents
- job cards
- time sheets
- system log
- other specific recording 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