8. USE OF VARIOUS TYPES OF SEALANTS AND PACKINGS
Required performance:
– Explains what is meant by sealant, gasket and packing
– Explains the differences between gasket and packing
– Explains how packings are used showing actual packings such as various types of O-rings, gland packings, mechanical seals, oil seals and labyrinth packings
– Explains how gaskets are used showing actual gaskets such as various types of non-metallic gaskets, non-ferrous metallic gaskets, metallic gaskets and semi-metallic gaskets
– explains how sealants are used showing actual sealants such as various types of sealants, liquid packings and seal tapes
– Uses various sealants and packings to acquire skills of using them with sample materials provided
9. MAINTENANCE AND REPAIR SUCH AS DISMANTLING, ADJUSTMENT AND
REASSEMBLING OF MACHINERY AND EQUIPMENT
Required performance:
9.1 Fastening
– Identifies types of threaded fastener
– States that bolts/nuts should be equally tightened in correct sequence when fastening plates/blocks with more than two bolts/nuts
– Explains why studs are used
– Fits studs and bolts and uses correct tightening procedures
– Removes studs (intact and broken) and split nuts
– Demonstrates how to protect finished surfaces
9.2 Centrifugal Pumps
Required performance:
– Dismantles:
– casing
– impeller
– wear rings
– shaft
– bearings
– gland/seal
– air pump
– float chamber
– Examines and measures all parts for wear and deterioration
– Re-fits, checking, clearances
– Replaces and adjusts seals
9.3 Reciprocating Pumps
Required performance:
– Dismantles:
– cylinders
– piston/buckets
– rings
– valves
– joins
– glands
– relief valves
– Measures wear in cylinders, neck rings and rods; checks ring gaps
– Machines and/or grinds in valves and seats
– Removes gland packing
– Selects and fits new gland packing
9.4 Screw and Gear Pumps
Required performance:
– Dismantles:
– rotors and gears
– seals
– bearings
– relief valve
– Examines for wear and deterioration
– Reassemble, checking end clearances and backlash
– Replaces and adjusts seals
9.5 Valves
Required performance:
The followings are applied to typical stop valves and safety/relief valves:
– Examines seats, valves, spindles, glands
– Machine valves and seats
– Beds in valves on seats, using grinding paste
– Removes old gland packing
– Selects correct gland packing
– Repacks glands
– Tests
9.6 Air Compressors
Required performance:
– Dismantles, examines and replaces or repairs as found necessary:
– suction and delivery valves and seats
– piston and rings
– glands/seals
– relief valves and bursting discs
– coolers and cooling passages
– lubricating oil system
– drains
9.7 Heat Exchangers
Required performance:
– Dismantles and examines:
– for leakage
– for corrosion
– for erosion
– for fouling
– Checks provision for tube expansion:
– descales
– replaces tubes
– plugs tubes
– secures tube tightness in tube plates
– checks means of reducing corrosion
– fills and tests
9.8 Diesel Engine
Required performance:
– Dismantles and inspects all parts for wear and deterioration, including:
– pistons
– rings
– liners
– bearings
– valves
– cooling passages
– crankshaft alignment
– lubrication system
– Refurbishes Diesel Engine Components
– cylinder heads
– exhaust valves
– air-start valves
– fuel injector
– relief valve
– fuel injection pump
– Reassembles
– Checks timing and ascertains freedom of movement
– Checks condition of lubrication oil
– Purges air from fuel system
– Test runs
9.9 Turbocharger
Required performance:
– Dismantles:
– air filter
– air casing
– inducer(if fitted)
– impeller
– volute
– diffuser
– gas inlet grid
– nozzle ring
– rotor
– bearings
– Examines all parts for wear and deterioration, paying particular attention to:
– erosion in the air side
– erosion in the turbine nozzles and in the blades
– corrosion of the gas casing
– hard deposits
– condition of bearings
– condition of labyrinths
– lubrication system
– Reassembles and checks clearances
9.10 Boiler
Required performance:
– Explains the need for cleaning the fire side of a boiler and how to do it
– Describes how to inspect the fire side of a boiler and repair/maintenance
– Explains the need of cleaning up the water side of a boiler and how to do it
– Describes how to inspect the water side of a boiler and the repair/maintenance
– Describes how to restore the boiler after cleaning up the fire/water side
– Describes how to repair the firebrick wall of a furnace
9.11 Shafting System
Required performance:
– Thrust block
– Stern tube
– Shaft bearings
– Shaft sealing equipment
9.12 Refrigerator
Required performance:
– Compressors
– Evaporator
– Condenser
– Expansion valve
– Oil separator
9.13 Oils Fuels and Lubricating System
Required performance:
– Filters
– Purifiers
– Bearings
– Settling-tanks
– Tank contents gauges
9.14 Deck Machinery
Required performance:
– Lifeboat davits and gear
– Mooring winch
– Windlass
– Winch