Maintaining marine propulsion systems
Overview
This standard identifies the competences you need to carry out planned maintenance on marine propulsion systems, in accordance with approved procedures, without complete removal of the unit(s) for overhaul. You will be required to maintain a range of marine propulsion systems, such as alternating current (AC) and direct current (DC) motors, steam turbines, gas turbines, two-stroke and four-stroke diesel/petrol engines. This will involve dismantling, removing and replacing faulty equipment, at unit or component level, on a variety of different types of marine propulsion equipment and assemblies.
The marine propulsion units to be maintained will include turbo blowers, air intakes, combustion system, engine control units/nozzle boxes, fuel systems, fire detection systems, exhaust units and other associated mechanical and electronic control equipment/systems. The maintenance activities will include making all necessary checks and adjustments to ensure that components are correctly replaced, positioned and aligned, locked and fastened correctly and that the correct sealants are used.
You will be expected to apply a range of dismantling and assembling methods and techniques, such as proof marking to aid reassembly, dismantling components requiring pressure or expansion/contraction techniques, setting, aligning and adjusting components, torque loading components and making `off-load' checks before starting up the maintained equipment.
Your responsibilities will require you to comply with organisational policy and procedures for the maintenance 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 must ensure that all tools, equipment, and materials used in the maintenance activities are removed from the work area on completion of the activities and that all necessary job/task documentation is completed 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 mechanical maintenance procedures to marine propulsion systems. You will understand the dismantling and reassembly methods and procedures used and their application. You will know how the equipment functions, the purpose of the individual components and associated defects, in adequate depth, to provide a sound basis for carrying out the maintenance activities, correcting faults and ensuring that the repaired equipment functions to the required specification. In addition, you will have sufficient in-depth knowledge of these components to ensure they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the re-assembly.
You will understand the safety precautions required when carrying out the maintenance activities associated with marine propulsion systems, especially those for isolating the 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 maintenance schedules to carry out the required work
- carry out the maintenance activities within the limits of your personal authority
- carry out the maintenance activities in the specified sequence and in an agreed time scale
- report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule
- complete relevant documentation in line with organisational procedures, and pass them on to the appropriate person
- dispose of waste materials in accordance with safe working practices and approved procedures
Knowledge and Understanding
You need to know and understand:
- the health and safety requirements of the area in which the maintenance activity is to take place and the responsibility they place on you
- the isolation and lock-off procedures or permit-to-work procedure that applies
- the specific health and safety precautions to be applied during the maintenance 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)
- hazards associated with carrying out maintenance activities on marine propulsion systems (such as handling oils, greases, stored pressure/force, misuse of tools, using damaged or badly maintained tools and equipment, not following laid-down maintenance procedures)
- the importance of wearing protective clothing and other appropriate safety equipment (PPE) during maintenance process
- how to obtain and interpret mechanical and electrical drawings, specifications, manufacturers' manuals and other documents needed in the maintenance process
- how to carry out currency/issue checks/configuration state of the specifications you are working with
- the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance
- company policy on repair/replacement of components during the maintenance process
- the sequence to be adopted for the dismantling/reassembling of various types of assemblies
- the methods and techniques used to dismantle/assemble marine propulsion systems (such as release of pressures/force, proof marking, extraction, pressing, alignment)
- methods of checking that components are fit for purpose and how to identify defects and wear characteristics
- how to make adjustments to components/assemblies to ensure that they function correctly (bedding in of white metal bearings, laser alignment of propeller shafts, balancing of rotating components such as armatures and turbines, setting working clearance, setting travel, setting backlash in gears, preloading bearings)
- the basic principles of how the equipment functions, its operation sequence, the working purpose of individual units/components and how they interact
- the basic principles of electronic engine management control and sensor systems
- the identification and application, fitting and removal of different types of bearings (such as roller, ball, thrust, shell)
- methods and techniques of fitting keys and splines
- the identification and application, fitting and removal of different types of gears
- how to set up timing marks correctly and how to position and set tension of belts and chains correctly
- the identification and application of different types of locking devices
- methods of checking that components are fit for purpose and the need to replace `lifed' items (such as seals, belts and gaskets)
- the uses of measuring equipment (such as micrometers, verniers, expansion indicators, electrical test equipment and other measuring devices)
- the importance of making `off-load' checks before running the equipment under power
- how to check that tools and equipment are free from damage or defect, are in a safe and usable condition and are configured correctly for the intended purpose
- the generation of maintenance documentation and/or reports following the maintenance activity
- the equipment operating and control procedures to be applied during the maintenance activity
- how to use lifting and handling equipment in the maintenance activity
- the problems associated with the marine maintenance activity and how they can be overcome
- the organisational procedure to be adopted for the safe disposal of waste and all other types of materials
- the extent of your own authority and whom you should report to if you have a problem that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the maintenance of the marine propulsion system:
- plan the maintenance activities to cause minimum disruption to normal working
- use the correct issue of company and/or manufacturer's drawings and maintenance documentation
- adhere to risk assessment, COSHH and other relevant safety standards
- ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids, steam)
- provide safe access and working arrangements for the maintenance area
- use lifting and handling equipment in accordance with health and safety guidelines and procedures
- carry out the maintenance activities using appropriate techniques and procedures
- reconnect and return the system to service on completion of the activities
- dispose of waste items in a safe and environmentally acceptable manner and leave the work area in a safe condition
Carry out maintenance activities on two of the following types of propulsion system equipment:
- direct current electric motor
- steam turbine
- alternating current electric motor
- two-stroke turbine/mechanical/naturally aspirated diesel/petrol engine
- gas turbine
- four-stroke turbine/mechanical/naturally aspirated diesel/petrol engine
Carry out maintenance activities on four of the following propulsion system components:
- air intake
- bearings
- turbine
- shafts
- air/turbo/super charger
- engine control unit
- exhaust system
- fire extinguishing system
- combustion system
- fuel system
- air start system
- electrical start system
Carry out twelve of the following activities, as applicable to the equipment being maintained:
- dismantling equipment to unit/sub-assembly level
- bedding in of white metal bearings
- dismantling units to component level
- lapping in valves
- proof marking/labelling of components
- preloading bearings
- checking components for serviceability
- setting backlash in gears
- replacing all lifed items (such as seals, bearings, gaskets)
- laser alignment of propeller shafts
- replacing all damaged or defective components
- electrical bonding of components
- setting timings and adjusting replaced components
- making `off-load' checks before starting up
- tightening fastenings to the required torque
- assess contaminant levels using oil sampling
- replenishing oils and greases
- applying gaskets and sealant/adhesives
- balancing of rotating components such as armatures and turbines
- re-assembling components to sub-assembly level
- re-assembling sub-assemblies to unit level
- securing components using mechanical fasteners and threaded devices
- applying bolt locking methods (such as split pins, wire locking, lock nuts, stiff nuts, swage nuts)
- functionally testing the completed system
Replace a range of propulsion system components, to include twelve of the following:
- shafts
- shell bearings
- slides
- couplings
- bearing housings
- rollers
- Gears
- keys
- static and dynamic seals
- clutches
- springs
- housings
- brakes
- diaphragms
- actuating mechanisms
- valves and seats
- cams and followers
- structural components
- pistons
- chains and sprockets
- wire thread inserts
- splines
- pulleys and belts
- locking and retaining devices (such as circlips, pins)
- roller or ball bearings
- levers and links
- pipes and unions
- shims and packings
- other specific components
Carry out maintenance activities on engine management systems and components if applicable to the propulsion system to include:
- diagnostic software
plus two from the following
2. electronic control module (ECU)/engine control module (ECM)
3. sensors (such as pressure, temperature, flow and speed)
4. engine cathodic protection
5. unit injectors
Maintain marine propulsion equipment which complies with one of the following quality and accuracy
- 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
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