Overhauling marine power transmission systems
Overview
This standard identifies the competences you need to carry out a complete overhaul of marine power transmission systems, in accordance with approved procedures. The equipment to be overhauled will have been removed from the vessel or craft and the overhauling activities may take place in a shipyard or manufacturer's workshops. The marine power transmission equipment covered by this standard includes items such as bow thrusters, stern thrusters, gearboxes, controllable pitch propeller systems, propulser nozzles, azimuth pods and pump jets. The overhauling activities will involve stripping the equipment down to component level, cleaning and inspecting the components for wear, replacing all defective and `lifed' components and rebuilding the equipment in line with the overhauling specification.
The marine power transmission units to be overhauled could include clutches, shafting, plummer blocks, P' bracket andA' bracket bearings, fixed and controllable pitch propellers, controllable pitch propeller systems, hovercraft fan units and other associated mechanical equipment. The overhauling activities will include making all necessary checks and adjustments to ensure that components are correctly replaced, positioned, aligned, adjusted, torque loaded, locked and fastened and that the correct sealants are used.
Your responsibilities will require you to comply with organisational policy and procedures for the marine power transmission equipment overhauling 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 overhauling 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 overhauling procedures to marine power transmission equipment. 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 overhauling 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 that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out reassembly.
You will understand the safety precautions required when carrying out the overhauling activities associated with marine power transmission equipment, especially those for lifting and handling 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 overhauling activity is to take place and the responsibility they place on you
- the specific health and safety precautions to be applied during the overhauling procedure and their effects on others
- hazards associated with carrying out overhauling activities on marine power transmission equipment (such as using lifting and handling equipment, handling oils, greases, release of 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 the overhaul
how to obtain and interpret drawings, specifications, manufacturers' manuals and other documents needed in the overhauling process
- how to carry out currency/issue checks of the specifications you are working with
- the procedure for obtaining replacement parts, materials and other consumables necessary for the overhaul
- company policy on the repair/replacement of components during the overhauling process
- the sequence to be adopted for the dismantling/reassembling of various types of assemblies
- the methods and techniques used to dismantle/reassemble marine power transmission equipment (such as release of pressures/force, proof-marking, extraction, pressing, alignment)
- methods of checking that components are fit for purpose, how to identify defects and wear characteristics and the need to replace `lifed' items (such as seals and gaskets)
- how to make adjustments to components/assemblies to ensure that they function correctly (such as bedding in of white metal bearings, laser alignment of propeller shafts, balancing of rotating components, setting working clearance, setting travel, setting backlash in gears, preloading bearings)
- the basic principles of how the equipment functions, its operating sequence, the working purpose of individual units/components and how they interact
- the identification, 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, application, fitting and removal of different types of gears
- how to set up timing marks and position and set tension of belts and chains, correctly
- the identification and application of different types of locking devices
- the uses of measuring equipment (such as micrometers, verniers, expansion indicators and other measuring devices)
- 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 technical documentation and/or reports following completion of the overhauling activity
- the equipment operating and control procedures to be applied during the overhauling activity
- how to use lifting and handling equipment in the overhauling activity
- the problems associated with the overhauling of marine power transmission equipment and how they can be overcome
- the organisational procedure to be adopted for the safe disposal of waste of all types of materials
- the extent of your own authority and to whom you should report if you have a problem that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the overhaul of the marine power transmission equipment:
- use the correct issue of company and/or manufacturers' drawings and overhauling 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 overhauling area
- use lifting and handling equipment, in accordance with health and safety guidelines and procedures
- carry out the overhauling activities using appropriate techniques and procedures
- comply with the organisational requirements with regard to the renewal or replacement of existing components
- ensure that the overhauled components meet the required specification
- ensure that there are no foreign objects left in the completed equipment
Carry out overhauling activities on one of the following types of marine power transmission equipment:
- bow thrusters
- hovercraft fan unit
- propulser and nozzle
- stern thrusters
- controllable pitch propeller system
- pump jet
- main gearbox
- propeller shaft
- hovercraft propulsion unit
- azimuth pod
Carry out overhauling activities on four of the following components of marine power transmission equipment:
- thruster
- lubrication system
- thrust block
- nozzle
- gearing
- plummer block
- propeller/propeller blade
- fan
- stern tube bearing
- torque tube
- shaft brakes
A' orP' bearing bracket- drive shaft
- torsion meter
Carry out eighteen of the following activities on the transmission equipment being overhauled:
- 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
- pre-loading bearings
- checking components for serviceability
- setting backlash in gears
- replacing all `lifed' items (such as seals, bearings, gaskets)
- electrical bonding of components
- replacing all damaged or defective components
- making `off-load' checks before starting up
- setting propeller shaft docking marks
- replenishing oils and greases
- laser alignment of propeller shafts
- tightening fastenings to the required torque
- applying gaskets and sealant/adhesives
- re-assembling components to sub-assembly level
- re-assembling sub-assemblies to unit level
- balancing of rotating components (such as shafts and armatures)
- 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 marine power transmission system components, to include sixteen of the following:
- shafts
- pipes and unions
- slides
- couplings
- bearing housings
- rollers
- gears
- keys
- housings
- clutches
- springs
- actuating mechanisms
- brakes
- diaphragms
- structural components
- valves and seats
- chains and sprockets
- wire thread inserts
- pistons
- levers and linkages
- static and dynamic seals
- splines
- shims and packing
- roller or ball bearings
- shell bearings
- locking and retaining devices (such as circlips, pins)
- other specific components
Overhaul marine power transmission equipment, in compliance 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 of the following and pass it to the appropriate people:- job cards
- permit to work/formal risk assessment
- maintenance log or report
- chart of dimensional inspection
- other specific reporting 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