Setting to work and testing marine mechanical control equipment and systems
Overview
This standard identifies the competences you need to set to work and test marine mechanical control equipment used for hydraulic, pneumatic, sewage treatment, fuel, fire-main, fresh water, oil, power transmission and engine/propulsion systems, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and test documentation to set up and test the various types of equipment. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed. The mechanical controls to be set to work and tested will include items such as rod gearing, universal joints, gearing support bearings, gearing bevel boxes, pipe hangers, cables, pulleys and turnbuckles, levers and linkages, control rods, pivots and bell cranks, microswitches and stops, servo actuators and tie rods. You will be required to carry out formal setting to work and testing under no load, partial load and full load conditions, meeting a range of operational criteria to establish that the units on test are functioning at optimal level and to specification.
Your responsibilities will require you to comply with organisational policy and procedures for the setting-up and testing activities undertaken, and to report any problems with these activities, or with the tools and equipment used, 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 sound understanding of your work, and will provide an informed approach to applying appropriate setting-up and testing procedures to marine mechanical control equipment and systems. You will understand the equipment being worked on, any test equipment to be used and the various testing procedures, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the equipment functions to the required specification. In addition, you will be expected to review the outcome of the tests, to compare the results with appropriate standards, to determine the action required and to record and report the results in the appropriate format.
You will understand the safety precautions required when carrying out the setting to work and testing of marine mechanical control equipment, especially those relating to the risk of seizure or mechanical failure and for taking the necessary safeguards to protect yourself and others against injury. 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 in harbour and at sea.
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 all relevant setting up and operating specifications for the products or assets being configured 3. follow the defined procedures and set up the equipment correctly ensuring that all operating parameters are achieved 4. set to work and test marine mechanical control equipment and systems using appropriate methods and techniques 5. deal promptly and effectively with problems within your control and report those that cannot be solved 6. check that the configuration is complete and that the equipment operates to specification 7. complete relevant documentation in line with organsiational procedures |
Knowledge and Understanding
You need to know and understand:
- the specific safety practices and procedures that you need to observe when carrying out the setting-up and testing activities on marine mechanical control equipment and systems (including any specific legislation, regulations and codes of practice for the activities, equipment or materials)
- the health and safety requirements of the work area in which you are carrying out the setting-to-work and testing activities and the responsibility they place on you
- the safety procedures that must be carried out before work is started on setting up and testing the marine mechanical controls (such as standby supplies, warning notices, notification of trials to be conducted)
- the specific safety precautions to be taken when carrying out formal inspection, safety checks and testing of marine mechanical control equipment
- the methods used to safely control equipment in the case of seizure or mechanical failure of the controls under test
- 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 importance of wearing protective clothing and other appropriate safety equipment (PPE) during the setting-to-work and testing procedure
protection techniques for mechanical systems, to prevent risk of seizure
- how to obtain and interpret system drawings, circuit and physical layouts, charts, specifications, manufacturers' manuals, history/maintenance reports, graphical symbols and other documents needed for the setting-to-work and testing process
- how to carry out currency/issue checks of the specifications you are working with
- the correct operating procedures of the equipment and system being set up and tested
- the basic principle of operation of the marine mechanical controls being set to work and tested and the function of the various components within the system
- the adjustments/corrections/tuning required to bring the equipment/system to operational standard through full range parameters
- types of test equipment to be used and their selection for particular types of tests
- the various testing methods and procedures, as recommended in approved operating manuals and how to apply them to different operating conditions
- displaying/recording test results and the documentation to be used
- how to recognise defects (such as under or over performance)
- how to interpret the test readings obtained and the significance of the readings gained
- the various fault finding techniques that can be used if the system fails the test
- the importance of ensuring that test equipment is used only for its intended purpose and within its specified range and limits
- potential problems or errors that could occur and which may affect the test results and how they can be avoided
- the environmental control and company operating procedures relating to the testing activities
- authorisation procedures for changes to test procedures
- the documentation required and the procedures to be followed on completion of the testing
- 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 setting to work and testing of the marine mechanical control equipment:
- plan the set-to-work and test activities to cause minimal disruption to normal working
- use the correct issue of the company and/or manufacturers' setting and testing procedures and quality documentation
- adhere to risk assessment, COSHH and other relevant safety standards
- ensure the availability of equipment and check that it is in a safe and usable condition (especially equipment associated with fire fighting and personnel protection)
- provide safe access and egress for the area containing the equipment to be set to work and tested
- shut down and make safe the system on completion of setting to work and testing
- complete the records and returns to ensure that the setting to work and testing is correctly documented
- leave the work area in a safe condition and to the prescribed category of cleanliness
Carry out setting to work and testing of mechanical controls connected to six of the following systems:
- hydraulic systems
- pneumatic systems
- sewage treatment
- ballast
- salt water
- drain
- fire-main/main service
- fuel systems
- lubricating oil
- ventilation
- steam
- hot/cold fresh water
- pre-wet
- generator engine
- propulsion engine
- power transmission
Use the appropriate procedure to set up and test ten of the following mechanical control components:
- cables and pulleys
- levers and linkages
- gearing bevel box
- gearing support bearing
- control rods
- struts and stays
- shackle
- turnbuckle
- tie rods and locks
- universal joint
- rod gearing
- pipe hangers
- pivots and bell cranks
- servo actuators
- microswitches and stops
- seals/lubricants
- inlet valve
- outlet valve
- cross connection valve
- start valve
- stop valve
- air flaps and dampers
- fire-fighting and pre-wet sprays
- steam drench valve
- CO2 drench system
Use appropriate test equipment to carry out all of the following tests, as applicable to the equipment concerned:
- torque loading
- travel
- operating clearance checks
- no load checks
- partial load
- full load
Carry out one of the following trials on the mechanical controls:
- harbour acceptance trials
- sea acceptance trials
- partial repair trials
Deal with two of the following complexities during the test activities:
- equipment without fault
- equipment with fault
- equipment with intermittent fault
- system fault
Use two of the following fault finding techniques:
- half-split technique
- input/output
- equipment self-diagnosis
- injection and sampling
- unit substitution
- emergent problem sequence
Carry out all of the following checks to ensure the accuracy and quality of the tests carried out:
- the test equipment is correctly calibrated and in date for use
- test equipment used is appropriate for the tests being carried out
- test procedures used are as recommended in the appropriate testing and setting-to-work procedure
- test equipment is operated within its specification range
Provide a record/report of the test outcomes, using one of the following:
- preventative maintenance log/report
- company specific reporting procedure
- acceptance documentation
- system log
- inspection schedule
- specific test report/test records
- job card/time sheet
Set to work marine mechanical control equipment and systems, in compliance with one of the following quality and accuracy standards:
- BS or ISO standards and procedures
- customer (contractual) standards and requirements
- company standards and procedures
- specific equipment requirements/manufacturer's data
- recognised compliance agency/body's standards
- 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