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Overhauling marine systems, plant and equipment

URN: SEMME3286
Business Sectors (Suites): Marine Engineering Suite 3
Developed by: Enginuity
Approved on: 2019

Overview

This standard identifies the competences you need to carry out overhauling activities on a range of marine systems, plant and equipment, 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 systems, plant and equipment covered by this standard include areas such as propulsion, power transmission, fuel, hydraulic, pneumatic, auxiliary power, mechanical control, steering gear, lifting equipment, weapons equipment, ancillary plant, steam, liquid ballast, fire, refrigeration, air conditioning, pantry and galley . 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 overhauling activities will include making all necessary checks, adjustments or tests to ensure that components are correctly replaced, positioned, aligned, adjusted, torque loaded, locked and fastened and that the correct joints, seals, gaskets and sealants are used.

Your responsibilities will require you to comply with organisational policy and procedures for the marine systems, plant and equipment to be overhauled, the 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 systems, plant and 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 and completing the overhauling activity.

You will understand the safety precautions required when carrying out the overhauling activities and 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:

  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. follow the relevant maintenance schedules to carry out the required work
  3. carry out the maintenance activities within the limits of your personal authority
  4. carry out the maintenance activities in the specified sequence and in an agreed time scale
  5. report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule
  6. complete relevant maintenance records accurately and pass them on to the appropriate person
  7. dispose of waste materials in accordance with safe working practices and approved procedures
  8. complete relevant documentation in line with
    organisational procedu    res

Knowledge and Understanding

You need to know and understand:

  1. the health and safety requirements of the area in which the overhauling activity is to take place and the responsibility they place on you
  2. the specific health and safety precautions needed to be applied during the overhauling procedure and their effects on others
  3. hazards associated with carrying out overhauling activities on marine  systems, plant and equipment (such as using lifting and handling equipment, handling oils and greases, releasing stored pressure/fluids, misuse of tools, using damaged or badly maintained tools and equipment, not following laid-down overhauling procedures)

  4. the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the overhaul

  5. how to obtain and interpret drawings, charts, circuit and physical layouts, specifications, manufacturers' manuals, history/maintenance reports, symbols used in documents needed in the overhauling process

  6. how to carry out currency/issue checks of the specifications you are working with
  7. the procedure for obtaining replacement parts, materials and other consumables necessary for the overhaul
  8. company policy on the repair/replacement of components during the overhauling process
  9. 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
  10. the equipment operating and control procedures to be applied during the overhauling activity
  11. the sequence to be adopted for the dismantling/reassembling of various types of equipment, assemblies and components
  12. the methods and techniques used to dismantle/reassemble marine systems, plant and equipment components (such as release of pressures/force, proof-marking, extraction, pressing, alignment)
  13. 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 filters, seals and gaskets)
  14. the process used to identify any contaminants in the equipment/system
  15. the damage that can be caused if any contaminants or foreign objects are not removed
  16. how to make adjustments to components/assemblies to ensure that they function correctly (such as setting working clearance, bedding in new components, setting travel, alignment)
  17. the importance of ensuring that fasteners are tightened to the required torque
  18. the basic principles of how the equipment functions, its operating sequence, the working purpose of individual units/components and how they interact
  19. the identification and application of different types of locking and securing devices
  20. how to identify the different types and uses of different system components (such as shafts, bearings, gears, keys, belts, pumps) 
  21. the uses of measuring equipment (such as micrometers, verniers, expansion indicators and other measuring devices)
  22. how to use lifting and handling equipment in the overhaul activity
  23. the problems associated with the overhauling of marine systems plant and equipment and how they can be overcome
  24. the generation of technical documentation and/or reports following completion of the overhauling activity
  25. the organisational procedure to be adopted for the safe disposal of waste of all types of materials
  26. 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

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  1. Carry out all of the following during the overhaul of the marine systems, plant and equipment:

    1. use the correct issue of company and/or manufacturers' drawings and overhaul documentation
    2. adhere to risk assessment, COSHH and other relevant safety standards
    3. ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids, steam)
    4. provide safe access and working arrangements for the overhauling area
    5. use lifting and handling equipment, in accordance with health and safety guidelines and procedures
    6. carry out the overhauling activities using appropriate techniques and procedures
    7. comply with organisational requirements with regard to renewal or replacement of existing components
    8. ensure that the overhauled components meet the required specification
    9. ensure that there are no foreign objects left in the completed equipment
    10. re-instate the work area on completion of the overhaul

  2. Carry out overhauling activities on four of the following types of marine  systems/plant/equipment:

    1. propulsion systems
    2. power transmission systems
    3. fuel system and equipment
    4. hydraulic systems and equipment
    5. pneumatic systems and equipment
    6. mechanical control systems and equipment
    7. steering gear, control systems and equipment
    8. auxiliary power units
    9. lifting equipment
    10. weapons systems and equipment
    11. ancillary plant and equipment (such as laundry, garbage, osmosis, hospital)
    12. steam plant and equipment
    13. liquid ballast arrangements
    14. fire main systems and equipment
    15. refrigeration and air conditioning systems and equipment 
    16. pantry and galley equipment

  3. Carry out eighteen of the following activities on the marine systems, plant and equipment being overhauled:

    1. de-pressurising the system/equipment
    2. draining system/equipment/component fluids
    3. dismantling equipment to unit/sub-assembly level 
    4. dismantling equipment to component level
    5. flushing out and cleaning the system/equipment/components
    6. proof-marking/labelling of components                      
    7. checking components for wear and/or serviceability 
    8. replacing all `lifed' items (such as seals, filters, gaskets)
    9. recording information on lifed components                    
    10. applying gaskets and sealants/adhesives
    11. replacing all damaged or defective components           
    12. setting, aligning and adjusting replaced components
    13. bedding in any new components
    14. balancing components
    15. chocking/supporting equipment/components     
    16. disconnecting and removing hoses and pipes
    17. blanking pipes/hoses/components to prevent contamination or to provide isolation
    18. replenishing oils and greases
    19. filling and re-pressurising the system
    20. adding preservation fluids        
    21. electrical bonding of components                                              
    22. re-assembling sub-assemblies to unit level
    23. re-assembling components to sub-assembly level
    24. electrical bonding of equipment
    25. securing components using mechanical fasteners and threaded devices
    26. applying bolt locking methods (such as split pins, wire locking, lock nuts, stiff nuts, swage nuts)
    27. tightening fastenings to the required torque
    28. making `off-load' checks before starting up
    29. carry out any required tests or checks before powering up
    30. functionally testing the completed system

  4. Remove and replace a range of marine systems, plant and equipment components, to include twenty of the following:

    1. shafts
    2. pumps                      
    3. cams and followers 
    4. static/dynamic seals
    5. couplings          
    6. spools        
    7. chains and sprockets  
    8. housings
    9. gears                
    10. bearings   
    11. pulleys, belts or cables        
    12. actuating mechanisms
    13. clutches               
    14. pipes/hoses and unions
    15. levers and linkages        
    16. structural components
    17. brakes               
    18. housings
    19. bushes  
    20. wire thread inserts
    21. valves and seats   
    22. keys                    
    23. slides            
    24. sensors
    25. pistons                 
    26. springs             
    27. rollers     
    28. regulators
    29. splines              
    30. diaphragms            
    31. receivers                 
    32. switches and trips
    33. cylinders
    34. rams
    35. bladders
    36. backing rings
    37. gaskets             
    38. lubricators/filters
    39. reservoirs         
    40. accumulators
    41. locking and retaining devices (such as circlips, pins) 
    42. seats
    43. gauges/instrumentation
    44. site glasses
    45. connecting rods
    46. rack/pinion
    47. lubricators
    48. shackles
    49. cranks
    50. rods
    51. struts
    52. mounts 
    53. doors/shutters
    54. glands
    55. bellows
    56. venturis
    57. manifolds
    58. strainers
    59. guards/safety devices
    60. flanges
    61. impellers
    62. chambers
    63. burners
    64. other specific components

  5. Overhaul marine systems, plant and equipment, in compliance with one of the following standards:

    1. BS or ISO standards and procedures
    2. customer (contractual) standards and requirements
    3. company standards and procedures
    4. specific system requirements
    5. recognised compliance agency/body's standards
    6. other accepted international standards

  6. Complete the relevant documentation in line with
    organisational procedu    res, to include one of the following and pass it to the appropriate people:

    1. job cards
    2. permit to work/formal risk assessment
    3. maintenance/overhaul log or report
    4. chart of dimensional inspection
    5. other specific reporting method

Scope Knowledge

Values

Behaviours

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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

Skills

Glossary

Links To Other NOS

External Links

Version Number

2

Indicative Review Date

2021

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMME3286

Relevant Occupations

Marine Engineering Trades

SOC Code

5235

Keywords

Engineering; marine; overhaul; systems; equipment; plant; remove; replace; checks; tests; adjust