Restoring marine mechanical components to usable condition by repair
Overview
This standard identifies the competences you need to restore marine mechanical components to usable condition by repair, in accordance with approved procedures. You will be required to restore a range of marine mechanical components and equipment to operational condition, by repairing assemblies/sub-assemblies and components, by reforming, reworking the surface, replacing threads or the replacement of worn parts. You will also be required to select the appropriate equipment to use, based on the nature of the repair required, the operations that will need to be carried out and the accuracy required.
In producing the components, you will be expected to use a range of hand tools, machine tools, portable power tools and shaping and fitting techniques, appropriate to the type of material and repair being performed. These activities will include such processes as sawing (hand or machine), drilling, reaming, grinding (hand or machine), filing, scrapping or lapping, threading internal, threading external, turning, milling and thermal processes. Materials to be used may include ferrous, non-ferrous, non-metallic and composites, which may be in sheet form, bar sections (such as square/rectangular, round, angle) and part-machined components.
Your responsibilities will require you to comply with organisational policy and procedures for the repairing activities undertaken and to report any problems with these activities or with the tools, equipment or materials 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 good understanding of your work and will provide an informed approach to applying repair procedures to marine mechanical components. You will understand the function and operating conditions of the components being repaired, in sufficient depth to determine a suitable repair sequence and to ensure that the repairs carried out are safe and practical in operation. You will also understand the organisational policy on repairing components and its application.
You will understand the safety precautions required when carrying out the repair activities, especially those for isolating 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, 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 the relevant specifications for the component to be repaired
- prepare the component for repair
- carry out the repairs within agreed timescale using approved materials and components and methods and procedures
- ensure that the repaired component meets the specified operating conditions
- produce accurate and complete records of all repair work carried out
Knowledge and Understanding
You need to know and understand:
- the health and safety requirements of the area in which the repairing activity is to take place and the responsibility they place on you
- the isolation procedures or permit-to-work procedure that applies
- the specific health and safety precautions to be applied during the repairing procedure and their effects on others
- 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 repair process
- being carried out (sawing: hand or machine; drilling; reaming; grinding: hand or machine; filing; scraping or lapping; threading internal; threading external; turning; milling; and thermal processes) and how they can be minimised
- where to obtain and how to interpret, drawings, specifications, manufacturers' manuals, maintenance schedules and other documents identifying parameters of the equipment being repaired
- how to carry out currency/issue checks of the specifications you are working with
- the methods and techniques to be followed for repairing marine mechanical equipment, in compliance with company procedures
- the types of repair that can be made to components in order to prolong their useful life (such as bushing worn holes, fitting thread inserts, building up surfaces by thermal process or metal spraying, making stepped keys, cutting new keyways, making stepped/oversize dowels or studs)
- the factors to be taken into account when deciding if a repair is practical and possible (such as replacement component availability, cost of replacing, safety of repair, age and condition of equipment)
- the need to liaise with other departments in order to have specialised operations carried out on the components (such as thermal processes, metal spraying)
- how to use filing, scraping and lapping to achieve the required surface finish (such as various types of files/scrapers, ensuring that file/scraper handles are in good condition, selection and use of lapping mediums)
- how to cut internal and external threads (such as by using hand dies and taps, machine cutting)
- how to produce a sliding or mating fit and the techniques to be adopted
- how to select saw blades for different materials and different operations
- the types and application of portable power tools that can be used for the repair operations
- how to check that portable power tools and extension cables are in a safe, tested and usable condition
- how to use hand power tools and specialist equipment (such as electrical, pneumatic, lifting equipment) correctly
- the operating requirements of the machine tools and accessories being used (such as guards, workholding devices, taper turning attachments, steadies, dividing heads, specific statutory regulations, abrasive wheels regulations)
- the various shapes and types of tooling that can be used (such as solid, high-speed tooling, brazed-tip tooling, interchangeable-tipped tooling)
- how to handle and store tools and equipment, safely and correctly
- factors which affect the selection of cutting feeds and speeds and the depth of cut that can be taken (such as workpiece rigidity, machine condition, type of tooling being used, material type, finish and tolerance required)
- the application of cutting fluids with regard to a range of different materials and processes
- the clamping of a workpiece in a chuck/workholding device (including safely secured for the process, not causing distortion in the finished components)
- how to recognise machining faults and how to identify when tools need re-sharpening/dressing
- the operating requirements of the thermal processes and accessories being used (including any statutory regulations and quality standards to be observed, guards, workholding devices, fume extraction, gas storage)
- the methods that can be used to position the workpiece in relation to the cutting tools
- the effects of backlash in the machine slides and how this can be overcome
- the company recording procedures to be used following a repair and how to apply them
- the procedure for the safe disposal of waste materials
- the sorts of problem associated with repairs and how to resolve them
- 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 repair activity:
- plan the repair activities to cause minimal disruption to normal working
- adhere to risk assessment, COSHH and other relevant safety standards
- ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids)
- provide safe access and working arrangements for the maintenance area
- record the repair using appropriate methods or documentation
- dispose of waste items in a safe and environmentally acceptable manner, and leave the work area in a safe condition
Use appropriate techniques to carry out six of the following types of repair:
- reforming the component surface by adding metal
- replacement of internal thread (thread inserts)
- recondition a unit by replacement of worn components
- reworking fit (shimming)
- sleeving worn components
- replacement/reworking of worn keys/keyways
- replacing flexible mounts
- making stepped dowels or studs
- replacing damaged or missing gear teeth
- cutting new keyways
- plugging holes
- making a temporary fix
- stopping cracks running and filling them
- bushing worn holes
- reworking the surface finish (using techniques such as filing, scraping, lapping, grinding)
- other specific repair procedure
Use a range of methods and techniques to repair components, to include six of the following:
- sawing (hand, machine)
- filing
- turning
- drilling
- scraping or lapping
- milling
- reaming
- threading external
- thermal processes
- grinding (hand or machine)
- threading internal
- cleaning processes such as chemical and shot blasting
Repair components made from different types of material, to include two from the following:
- low carbon steel
- aluminium
- plastic/synthetic
- high carbon steel
- brass/bronze
- composite
- cast iron
- stainless steel
Carry out repairs to marine mechanical equipment which complies with one of the following standards:
- BS or ISO standards and procedures
- company standards and procedures
- specific system requirements
- customer (contractual) standards and requirements
- 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