Replace components in mechanical plant and equipment

Business Sectors (Suites): Process Engineering Maintenance
Developed by: Cogent
Approved on: 27 Mar 2018


This standard is about your competence in replacing components in mechanical plant and equipment. You will be required to ensure the replaced components meet the required specifications, protect them from damage, replace using the appropriate tools and techniques and making any final adjustments. You will be following your organisation's safe working practices and working within the work permit procedures.

This standard deals with the following:
1 Replace components in mechanical plant and equipment

During this work you must take account of the relevant worksite operational requirements, procedures and safe working practices AS THEY APPLY TO YOU.

Performance criteria

You must be able to:

P1 work safely at all times, complying with health and safety and other relevant regulations and guidelines
P2 obtain all the required components and ensure that they are in a suitable condition for replacement and fit for purpose
P3 ensure that any replacement components used meet the required specification
P4 take adequate precautions to prevent damage to components, tools and equipment during replacement
P5 replace the components in the correct sequence using appropriate tools and techniques
P6 make any necessary settings or adjustments to the components to ensure they will function correctly
P7 deal promptly and effectively with problems within your control and report those that cannot be solved
P8 maintain documentation in accordance with organisational requirements

Knowledge and Understanding

You need to know and understand:

K1 you must have a working knowledge and understanding of what your responsibilities are in respect of Health, Safety and Environment. This should include the limits of your personal responsibility, your legal responsibility for your own health and safety and the health and safety of others
K2 you must have a working knowledge of the relevant regulations and the safe working practices and procedures required within your work area
K3 you must have a working knowledge and understanding of the engineering drawings and related specifications to which you will be expected to work, including technical drawings (component, assembly, general arrangements, isometrics, 1st and 3rd angle projections), method statements, product worksheets and tolerances
K4 you must have a working knowledge and understanding of the component replacement methods and techniques including the types of reconnection that have to be made, and which tools, equipment and methods can be used to replace specific components in specific plant and equipment
K5 you must have a working knowledge and understanding of handling equipment, methods and techniques. This could be expected to include manual handling pressure and thermal methods and techniques
K6 you must have a working knowledge and understanding of what your responsibilities are for tool and equipment care and control procedures thereby ensuring the security of tools and equipment that you use. This could be expected

to include ingress protection ratings, explosion protection rating, corrosion, portable appliance testing, heating and ventilation and permit systems
K7 you must have a working knowledge and understanding of your responsibilities with regard to the reporting lines and procedures in your working environment


Scope Performance

1 The level and extent of responsibility will involve you being responsible for ensuring the equipment and work site is safe for others or yourself to work in by following defined procedures. You will be accountable for the integrity of the work site and ensuring the work is recorded in a formal manner. Authorisation for proceeding with the work will be given by authorized signatories within the PTW system

2 The equipment to be worked on are those that are resistant to most forms of damage or disruption during their working lives. Fragile components are those that are easily disrupted or damaged. Damage or disruption could be due to physical, chemical other forces (e.g. Electro-magnetic). Typical equipment could be:
2.1 Heat Exchangers
2.2 Pumps
2.3 Engines
2.4 Components of Process Systems

3 The type of components to be replaced could be:
3.1 Components of mechanical/hydraulic/pneumatic systems
3.2 Mechanical metering devices
3.3 Gaskets
3.4 Components of engines
3.5 Safety limit protection devices
3.6 Actuators/valves
3.7 Components of pumps
3.8 Bearings

4 The assembly methods and techniques could involve:
4.1 Hydraulic
4.2 Thermal
4.3 LOLER and manual handling

5 The assembly operations may be simple or complex. Simple replacement of components refers to situations where the component is quickly and easily removed from its position. Typical examples could include lifting out of plug-in components and undoing threaded fasteners to release the component. Complex replacements refers to situations where the components can only be replaced by disrupting the surrounding areas e.g. by cutting or de-soldering and/or where replacement of one component necessitates replacements of other interacting components.

6 The quality standards and accuracy to be achieved are as set down in the work specifications.

Scope Knowledge

The Knowledge and Understanding levels expressed indicate the minimum level of knowledge and understanding sufficient to perform your role in a manner that would normally be associated with the minimum acceptable performance of a competent person undertaking your role.

The expression ”working knowledge and understanding” indicates you are able to:
1 Identify and apply relevant information, procedures and practices to your usual role in your expected working environments needing only occasional recourse to reference materials
2 Describe, in your own words, the principles underlying your working methods. This does not mean the ability to quote “Chapter and verse”. Rather you must know what supporting information is available, how and where to find it and from whom to seek further guidance and information confirm any additional required detail
3 Interpret and apply the information obtained to your role, your working practice and in your expected working environment





Links To Other NOS

External Links

Version Number


Indicative Review Date

27 Mar 2022





Originating Organisation


Original URN

MPS Mech 6

Relevant Occupations

Engineering and Manufacturing Technologies, Engineering Professionals, Manufacturing Technologies

SOC Code



replace, components, mechanical, process, plant, equipment