Testing fluid power equipment and systems
Overview
This standard identifies the competences you need to test fluid power equipment, on mobile or static plant, in accordance with approved procedures. You will be required to carry out tests on a range of fluid power equipment, which includes pneumatic, hydraulic and vacuum systems. You will be expected to test a range of components, such as pumps, motors, valves and actuators, to establish that they are functioning at optimal level and to specification. You will also be required to use a range of test equipment, methods, procedures and diagnostic/analytical techniques, as applicable to the particular system under test.
Your responsibilities will require you to comply with organisational policy and procedures for the testing activities undertaken, and to report any problems with these activities or with the equipment used that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with minimal 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 test procedures to fluid power equipment. You will understand the system under test, the various test procedures, and their application, and will know about the appropriate test equipment, in adequate depth to provide a sound basis for carrying out the activities safely and correctly and ensuring that the equipment remains compliant with all standards and regulations. In addition, you will be expected to review the outcome of the tests, to compare the results with appropriate standards, to determine the action required, and to record and report the results in the appropriate format.
You will understand the safety precautions required when carrying out the test activities, especially those for isolating the equipment and taking the necessary safeguards to protect yourself and others in the workplace. You will be required to demonstrate safe working practices throughout.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety legislation and other relevant regulations, directives and guidelines
- follow the appropriate procedures for use of tools and equipment to carry out the required tests
- set up and carry out the tests using the correct procedures and within agreed timescales
- complete and store all relevant documentation of the test outcome in accordance with organisational requirements
- review the results and carry out further tests if necessary
- dispose of waste materials in accordance with safe working practices and approved procedures and leave the work area in a safe condition
Knowledge and Understanding
You need to know and understand:
- the health and safety requirements of the work area where you are carrying out the activities, and the responsibility these requirements place on you
- the equipment isolation procedure or permit-to-work procedure that applies to the testing activities, and the safety procedures that must be carried out before work is started on the equipment
- the specific safety practices and procedures that you need to observe when testing fluid power systems, including any specific legislation, regulations/codes of practice for the activities, equipment or materials
- the importance of following the correct de-contamination procedure
- hazards associated with testing fluid power equipment (such as handling hydraulic fluids, stored pressures, moving cylinders or equipment), and how to minimise these and reduce any risks
- the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the testing activities
- how to obtain and interpret drawings, circuit and physical layouts, charts, specifications, manufacturers' manuals, history/maintenance reports, graphical symbols for fluid power circuits, and other documents needed for the testing activities
- the test specifications of the systems you are working on, their interpretation and currency/issue checks
- the basic principles of how the circuit/equipment functions, operation and application of the individual units/components and their interrelations with other components and assemblies
- types of test equipment to be used, and their selection for particular tests
- the importance of checking the equipment is within current calibration dates, and the procedure for getting the test instruments correctly calibrated
- how the test equipment is connected into the circuit, and the methods of doing this
- the techniques, methods and procedures to be used during the tests
- displaying/recording test results, and the documentation used
- how to create and apply logic or sequential charts/tables
- authorisation systems for changes to test procedures
- how to interpret the test readings obtained, and the significance of the readings gained
- the importance of ensuring that test equipment is used only for its intended purpose and within its specified range and limits
- potential problems or errors that may occur and that could affect the test results
- the environmental control and organisational operating procedures relating to the testing activities
the documentation required and the procedures to be followed on completion of the tests
the extent of your own authority and to whom you should report if you have problems that you cannot resolve
Scope/range
Carry out all of the following during the testing activities:
- plan the testing activities to cause minimal disruption to normal working
- obtain and use the correct issue of organisational and/or manufacturers drawings and testing documentation
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- adhere to organisational-specific contamination and control procedures at all times
- ensure the safe isolation of equipment
- provide and maintain safe access and working arrangements for the maintenance area
- check all tools and test equipment are in date for calibration
- carry out the testing activities using appropriate techniques and procedures
- reconnect and return system to service on completion of activities
- dispose of waste materials in accordance with safe working practices and approved procedures and leave the work area in a safe condition
Carry out tests on two of the following fluid power systems:
- pneumatic
- hydraulic
- vacuum
Test two types of fluid power generation/consumption equipment from the following:
- gear pumps/motor
- compressor
- vane pumps/motor
- piston pumps/motor
Test four types of fluid power valve equipment from:
- flow
- pilot
- pressure
- memory
- proportional valve
- directional
- non-return
- solenoid
Test two of the following types of fluid power actuator equipment:
- cylinders
- motors (air/hydraulic)
- semi-rotary actuators
Test three of the following types of fluid power conditioning equipment:
- coolers
- lubricators
- storage
- filters
- heaters
- dryers
Test fluid power systems equipment using tools or test equipment, to include three of the following:
- pressure devices
- flushing blocks
- bleeding equipment
- sampling devices
- testing rigs
- flushing pipes
- blanking equipment
Carry out three of the following types of test:
- pressure test
- flow
- fluid contamination test
- leak test
- electrical signal
- sequence
- time
- pilot test
Carry out all of the following checks to ensure the accuracy and quality of the tests carried out:
- the test equipment is correctly calibrated
- the test equipment used is appropriate for the tests being carried out
- test procedures used are as recommended in the appropriate specifications
- test equipment is operated within its specification range
Complete and store all relevant documentation of the test outcome in accordance with organisational requirements, using one of the following:
- preventative maintenance log/report
- inspection/test schedule
- organisational-specific reporting procedure
- specific test report
- electronic reports