Release 1. This is the first release of this unit of competency in the MAR Maritime Training Package.

This unit involves the skills and knowledge required to maintain and repair shipboard machinery and equipment on a vessel. This includes maintaining marine pumps, valves, air compressors, heat exchangers, diesel engines, turbochargers, marine lubricating systems and deck machinery as well as conducting inspections of marine boilers and marine refrigeration units.

This unit applies to people working in the maritime industry in the capacity of:

• Electro-Technical Officer (STCW Electro-Technical Officer Unlimited)
• Engineer Class 3 Near Coastal
• Engineer Watchkeeper (STCW Engineer Watchkeeper Unlimited).

Licensing/Regulatory Information 

Legislative and regulatory requirements are applicable to this unit.

• This unit is one of the requirements to obtain Australian Maritime Safety Authority (AMSA) certification as an Engineer Class 3 Near Coastal as defined in the National Standard for Commercial Vessels (NSCV) Part D.

• This unit is one of the requirements to obtain AMSA certification as an Electro-Technical Officer (STCW Electro-Technical Officer Unlimited) or Engineer Watchkeeper (STCW Engineer Watchkeeper Unlimited) and to meet regulatory requirements this unit must be delivered consistent with Marine Orders and with the relevant sections of the International Convention on Standards of Training, Certification and Watchkeeping for Seafarers (STCW).

• Those regulatory requirements include STCW International Maritime Organization (IMO) model course competencies and areas of knowledge, understanding and proficiency, together with the estimated total hours required for lectures and practical exercises. Teaching staff should note that timings are suggestions only and should be adapted to suit individual groups of trainees depending on their experience, ability, equipment and staff available for training.

Not applicable.

B – Equipment Checking and Maintenance

Not applicable.

ELEMENTS 

PERFORMANCE CRITERIA 

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1  

Follow safe work practices 

1.1 

Work health and safety (WHS)/occupational health and safety (WHS/OHS) procedures relevant to maintaining shipboard machinery and equipment are complied with

1.2 

Safety hazards are identified and reported according to safety and vessel procedures

1.3 

Tools, equipment and testing devices needed to carry out maintenance activities are checked for correct operation and safety prior to use according to safety and vessel procedures

1.4 

Isolation precautions are implemented prior to commencing maintenance activities according to safety and vessel procedures

2 

Maintain marine pumps 

2.1 

Maintenance requirements for pump are determined according to safety, manufacturer and vessel procedures and documentation

2.2 

Appropriate procedures, materials, tools and equipment for maintaining pump are selected according to safety, manufacturer and vessel procedures

2.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

2.4 

Pump is disassembled, inspected and serviced according to safety, manufacturer and vessel procedures

2.5 

Pump is reassembled and tested according to safety, manufacturer and vessel procedures

2.6 

Performance of pump is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

3 

Maintain valves 

3.1 

Maintenance requirements for valves are determined according to safety, manufacturer and vessel procedures and documentation

3.2 

Appropriate procedures, materials, tools and equipment for maintaining valves are selected according to safety, manufacturer and vessel procedures

3.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

3.4 

Valves are removed for maintenance according to safety, manufacturer and vessel procedures and documentation

3.5 

Valves are disassembled and valve maintenance is performed according to safety, manufacturer and vessel procedures and documentation

3.6 

Valves are reassembled and tested according to safety, manufacturer and vessel procedures and documentation

4 

Maintain air compressors 

4.1 

Maintenance requirements for air compressor are determined according to safety, manufacturer and vessel procedures and documentation

4.2 

Appropriate procedures, materials, tools and equipment for maintaining air compressor are selected according to safety, manufacturer and vessel procedures

4.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

4.4 

Air compressor is disassembled and inspected according to safety, manufacturer and vessel procedures

4.5 

Air compressor is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

4.6 

Performance of air compressor is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

5 

Maintain heat exchangers 

5.1 

Maintenance requirements for heat exchanger are determined according to safety, manufacturer and vessel procedures and documentation

5.2 

Appropriate procedures, materials, tools and equipment for maintaining heat exchanger are selected according to safety, manufacturer and vessel procedures

5.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

5.4 

Heat exchanger is disassembled and inspected according to safety, manufacturer and vessel procedures

5.5 

Heat exchanger is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

5.6 

Performance of heat exchanger is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

6 

Maintain diesel engines 

6.1 

Maintenance requirements for diesel engine are determined according to safety, manufacturer and vessel procedures and documentation

6.2 

Appropriate procedures, materials, tools, measuring instruments and equipment for maintaining diesel engine are selected according to safety, manufacturer and vessel procedures

6.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

6.4 

Diesel engine components are disassembled and inspected for wear and deterioration according to safety, manufacturer and vessel procedures

6.5 

Routine maintenance on diesel engines is performed according to manufacturer and vessel procedures

6.6 

Diesel engine components are refurbished, as required, according to manufacturer and vessel procedures

6.7 

Specialised tools and measuring instruments are used to maintain and refurbish diesel engines/components according to safety, manufacturer and vessel procedures

6.8 

Diesel engine is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

6.9 

Performance of diesel engine is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

7 

Maintain turbochargers 

7.1 

Maintenance requirements for turbocharger are determined according to safety, manufacturer and vessel procedures and documentation

7.2 

Appropriate procedures, materials, tools and equipment for maintaining turbocharger are selected according to safety, manufacturer and vessel procedures

7.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

7.4 

All components of turbocharger are disassembled and inspected for wear and deterioration according to safety, manufacturer and vessel procedures

7.5 

Turbocharger is reassembled, tested and adjusted according to safety, manufacturer and vessel procedures

7.6 

Performance of turbocharger is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

8 

Inspect marine boilers 

8.1 

Inspection requirements for marine boiler are determined according to safety, manufacturer and vessel procedures and documentation

8.2 

Appropriate procedures for inspecting marine boiler are selected according to safety, manufacturer and vessel procedures

8.3 

Relevant information is extracted from drawings and technical specifications required to perform inspection activities

8.4 

Marine boiler is inspected for repair or general maintenance according to safety, manufacturer and vessel procedures

8.5 

Performance of marine boiler is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

9 

Inspect marine refrigeration units 

9.1 

Inspection requirements for marine refrigeration unit are determined according to safety, manufacturer and vessel procedures and documentation

9.2 

Appropriate procedures for inspecting marine refrigeration unit are selected according to safety, manufacturer and vessel procedures

9.3 

Relevant information is extracted from drawings and technical specifications required to perform inspection activities

9.4 

Marine refrigeration unit is inspected for repair or general maintenance according to safety, manufacturer and vessel procedures

9.5 

Performance of marine refrigeration unit is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

10 

Maintain marine lubricating systems 

10.1 

Inspection and maintenance requirements for lubricating systems are determined according to safety, manufacturer and vessel procedures and documentation

10.2 

Relevant information is extracted from drawings and technical specifications required to perform inspection and maintenance activities

10.3 

Purifier maintenance procedures are applied according to safety, manufacturer and vessel procedures

10.4 

Components of lubricating system are inspected according to safety, manufacturer and vessel procedures

11 

Maintain and repair deck machinery 

11.1 

Maintenance and/or repair requirements for deck machinery are determined according to safety, manufacturer and vessel procedures and documentation

11.2 

Appropriate procedures, materials, tools and equipment for maintaining and/or repairing deck machinery are selected according to safety, manufacturer and vessel procedures

11.3 

Relevant information is extracted from drawings and technical specifications required to perform maintenance activities

11.4 

Deck machinery maintenance and/or repair procedures are implemented according to safety, manufacturer and vessel procedures

11.5 

Deck machinery is tested and adjusted according to safety, manufacturer and vessel procedures

11.6 

Performance of deck machinery is confirmed against recommended performance specifications according to safety, manufacturer and vessel procedures

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Range is restricted to essential operating conditions and any other variables essential to the work environment.

This unit is equivalent to MARB014 Maintain and repair shipboard machinery and equipment.

Release 1. This is the first release of this unit of competency in the MAR Maritime Training Package.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria on at least one occasion and include:

• explaining principles of shipboard machinery and equipment and imparting knowledge and ideas verbally and in writing
• initiating timely action in response to defects or damage
• performing calculations and interpreting graphical information used in maintaining shipboard machinery and equipment
• reading and interpreting written information related to the operation, performance and maintenance of shipboard machinery and equipment, including machinery specifications and operational manuals
• scheduling maintenance of shipboard machinery and equipment
• using testing equipment and explaining test and performance results relevant to shipboard machinery and equipment.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

• basic principles of diesel engine operation, including:

• causes of crankcase and air-line explosions, and scavenge and uptake fires
• common faults and appropriate action to be taken with cooling of diesel engines
• crankshafts
• cylinder liners and heads
• different methods of cooling marine diesel engines, including common requirements of cooling
• exhaust valves
• materials used to construct diesel engine major parts
• means of pressure charging diesel engines, including common service faults, appropriate actions to rectify these faults, and emergency operation and isolation procedures
• operating principles and adjustments of diesel engine fuel injection equipment, including common service faults, symptoms and causes of diesel fuel injection problems, and appropriate actions to be taken
• typical diesel engine lubrication systems, including:
• typical starting air and manoeuvring systems of diesel engines, including all components normally found therein

• basic principles of electrotechnology, marine electrical practice and marine automation and control relevant to detection, fault finding and repair of faults in electrical and electronic equipment, including:

• alternating current (AC) and direct current (DC) theory and plant and equipment
• basic cabling, distribution and lighting systems
• basic control and switchgear
• basic electrical circuit theory
• basic theory of electromagnetism and electrostatics
• electrolytic action and cells
• instruments, calibration and testing

• basic principles of mechanics as they relate to forces, pressures, stress and strains in shipboard dynamic machinery
• basic principles of operating and maintaining:

• fluid power control systems
• machinery lubrication systems
• marine boilers and materials used to construct boiler major parts
• refrigeration systems:

• furnace
• steam and water drum
• superheaters
• water tubes

• basic thermodynamics, including:

• advantages of multi-staging and inter-cooling
• air/fuel ratio and significance of excess air on combustion
• basic steam plant cycles and function of each component
• basic thermodynamic properties of common working fluids
• clearance volume, its effect on volumetric efficiency and methods of calculating volumetric efficiency
• combustion process and calorific value of fuels
• elementary principles of steam plants
• meaning of gauge and absolute pressure
• methods of heat transfer and related problems
• operating cycle of single stage reciprocating air conditioners, including methods for the mass of air delivered
• principles of heat transfer by conduction, convection and radiation and their application to marine systems
• International System of Units (SI) and common thermodynamic terms and principles
• temperature and temperature scales

• deck machinery, including:

• cranes
• lifeboat davits and gear
• mooring winch
• winch
• windlass

• diesel engine routine maintenance, including:

• air intake system:

• inspecting and changing air filters
• inspecting turbocharger to make sure there is no fouling of compressor blades from crankcase gases

• cooling system:

• coolant sampling for trending analysis
• draining, flushing and refilling system when required
• fluid level checks

• emissions systems:

• inspecting crankcase ventilation systems, selective catalytic reduction (SCR) systems and diesel particulate filters (if so equipped)

• exhaust system:

• inspecting for leaks, corrosion and wet stacking

• fuel system:

• changing fuel filters and fuel injectors
• checking water separators

• lubrication:

• changing oil and oil filters
• checking levels
• taking oil samples for trending analysis to optimise oil change intervals and to detect engine wear

• mechanical systems:

• generally inspecting for leaks, wear or deterioration
• inspecting resilient engine mounts and torsional couplings

• operating systems:

• downloading data from digital engine management system to note and review alarm conditions

• valves and heads:

• inspecting and recording cylinder head wear for trending analysis
• inspecting, adjusting and recording valve train wear for trending analysis

• inspection and disassembling, including:

• air compressors:

• coolers and cooling passages
• lubricating systems
• piston and rings
• suction and delivery valves and seats

• diesel engine components:

• bearings
• cooling system
• crankshaft alignment
• liners
• lubrication system
• pistons
• rings
• valves

• heat exchangers:

• corrosion
• erosion
• fouling
• leakage
• provision for tube expansion

• inspection requirements for:

• marine refrigeration:

• compressors
• condensers
• evaporators
• expansion valves
• oil separators

• marine boiler:

• fire side
• water side

• lubricating system components, including:

• settling tank
• system bearings
• system filters

• maintenance and repair hazards and problems, and appropriate preventative and remedial action and solutions during maintaining and repairing shipboard plant and equipment
• maritime communication techniques needed during maintenance and repair operations
• materials used to construct the following gas turbine major parts:

• compressors
• gas generators
• rotors
• turbine casing

• materials used to construct the following steam turbine major parts:

• blades
• nozzles
• reduction gears
• rotors
• turbine casings

• national and international regulations, International Maritime Organization (IMO) conventions and codes, including Australian Maritime Safety Authority (AMSA) Marine Orders applicable to managing shipboard plant and equipment maintenance and repair operations
• nature and causes of typical shipboard plant and equipment malfunctions and available methods for their detection and repair, including established fault-finding techniques
• operating principles and performance specifications for different types of shipboard plant and equipment usually found on a vessel of unlimited propulsion power
• operating principles of unmanned machinery spaces (UMS) and automated monitoring and control of machinery
• planned maintenance systems and procedures for condition monitoring of plant and equipment, including responsibilities and requirements covered by various forms of vessel survey
• plant and equipment typically found onboard a vessel of unlimited propulsion power
• procedures for:

• carrying out shipboard plant and equipment fault finding and repair as part of routine maintenance procedures to ensure compliance with company and survey requirements, and established safety rules and regulations
• completing temporary and permanent repair and/or replacement procedures for plant and equipment on board vessels at sea, alongside and in dry dock
• reading and interpreting plant and equipment performance readings and instrumentation

• pumps, including:

• axial
• centrifugal
• gear
• reciprocating
• screw

• purpose and content of safety data sheets (SDS)/material safety data sheets (MSDS)
• refurbished diesel engine components, including:

• air start valves
• cylinder heads
• exhaust valves
• fuel injectors
• relief valves

• safety procedures for:

• handling heavy plant, equipment and component parts during maintenance and repair of shipboard plant and equipment
• using hand and power tools and maintenance equipment

• safety, environmental and hazard control precautions and procedures relevant to shipboard plant and equipment inspection and maintenance operations
• servicing, including:

• dismantling rod and gears, seals, bearings and relief valve
• gland packing
• identifying wear and deterioration
• measuring wear in cylinders, neck rings and rods
• protecting finished surfaces
• replacing and adjusting seals
• removing studs: intact and broken

• turbocharger components, including:

• air casing
• air filters
• bearings
• diffuser
• gas inlet grid
• impeller
• inducer
• nozzle ring
• rotor
• volute

• types of vessel maintenance and repair records to be maintained to meet requirements of company, survey and regulatory authorities
• typical vessel and plant and equipment specifications, equipment drawings, operational manuals, and electrical and control circuit diagrams
• valves, including:

• ball
• butterfly
• check
• diaphragm
• gate
• globe:
• screw down non return
• screw lift

• valve maintenance, including:

• examining seats, valves, spindles and glands
• gland packing
• lapping valves and seats
• machining valves and seats
• removal
• repacking
• selection

• work health and safety (WHS)/occupational health and safety (WHS/OHS) legislation, policies and procedures.

Assessors must hold credentials specified within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must satisfy the Principles of Assessment and Rules of Evidence and all regulatory requirements included within the Standards for Registered Training Organisations current at the time of assessment.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Practical assessment must occur in a workplace or realistic simulated workplace, under the normal range of workplace conditions.

Simulations and scenarios may be used where situations cannot be provided in the workplace or may occur only rarely, in particular for situations relating to emergency procedures and adverse weather conditions where assessment would be unsafe, impractical or may lead to environmental damage.

Resources for assessment must include access to:

• applicable documentation, such as legislation, regulations, codes of practice, workplace procedures and operational manuals
• tools, equipment, machinery, materials and relevant personal protective equipment (PPE) currently used in industry.