Installing marine steering gear, control systems and equipment
Overview
This standard identifies the competences you need to install marine vessel/craft steering gear and its associated control systems and equipment, 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 expected to select the appropriate tools and equipment to use, based on the operations to be performed and components to be installed.
The mechanical items to be fitted will include equipment such as cables and pulleys, rack and pinion, connecting rods, hydraulic relay units, hydraulic pistons, hydraulic cylinders, pumps, seals, rudder posts, rudders, locking plates, stops, emergency steering devices and other associated equipment. The installation activities will include making all necessary checks and adjustments to ensure that components are correctly positioned and aligned, have appropriate tension or working clearances, are tightened to the correct torque, and that they function as per the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the installation of the steering control gear and to report any problems with the installation activities, components or equipment 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 vessel/craft steering controls and systems. You will understand the steering system being worked on and the function of the mechanical controls being installed and will know about the relevant components, fastening and securing devices, 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 vessel/craft steering gear (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 installation activities and the responsibility these requirements 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 steering gear and with the tools and equipment used and how they can be minimised
the protective equipment that you need to use for both personal protection (PPE) and protection of the equipment
the interpretation of drawings, standards, quality control procedures and specifications used for the installation (including BS and ISO schematics, symbols and terminology)
- how to carry out currency/issue checks of the specifications you are working with
- the components to be installed and their function within the particular steering control system
- the various mechanical fasteners that will be used and their method of installation (such as keys, keyways, threaded fasteners, special securing devices)
- the importance of using the specified fasteners for the particular installation and why you must not substitute others
- why securing devices need to be locked 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 to the vessel without damage
- methods of lifting, handling and supporting the components/equipment during the installation activities
- the use of seals, sealants and adhesives and the precautions to be taken
- 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, poor seals, misalignment, ineffective fasteners, 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 steering gear and control systems:
- use the correct issue of the marine vessel or craft installation drawings and technical documentation
- use copies of relevant COSHH sheets, risk assessment and marine or hovercraft units
- check the calibration dates of tools and equipment to be used
- obtain clearance to work on the vessel and observe the power isolation procedures
- 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 components for one of the following steering gear systems:
- hydraulic
- electro-hydraulic
- mechanical
Install six of the following marine steering gear and control systems and equipment:
- mechanical helm
- telemotor transmitter
- fluid power system/pump
- rudder posts
- local steering mechanism
- mechanical steering gear
- telemotor receiver
- steering hand pump
- rudders
- hydraulic relay unit
- emergency mechanical steering
- emergency hydraulic steering gear
- pintle
Install ten of the following types of steering gear system components:
- cables and pulleys
- levers and linkages
- connecting rods
- shock and by-pass valve
- vent system
- receiver
- hydraulic relay unit
- shackle
- turnbuckle
- rack and pinion
- gland packing
- pipework
- piston
- cylinder
- seals/lubricants
- greasing system
- gland
- gauge glass
- stops
- pump
- tank
- bearing
- instrumentation
- other specific components
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 operating conditions (travel, clearance)
- torque setting of mechanical fasteners
- earth bonding
- lifting and handling
- making pipe connections
- lubricating
- connecting wires and cables
- securing by using mechanical fixings
- securing by using adhesives
- sealing
- venting and flushing
- applying screw fastener locking devices
- tensioning cables
- ensuring the system cleanliness (such as covering exposed pipe 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)
locking plates
- 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 records
- acceptance documentation
- work acceptance documentation
- job card
- time sheet
- 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