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Maintaining fluid power equipment within an engineered system

URN: SEMEM326
Business Sectors (Suites): Engineering Maintenance Suite 3
Developed by: Enginuity
Approved on: 2021

Overview

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This standard identifies the competences you need to carry out corrective maintenance activities on fluid power equipment within an engineered system, in accordance with approved procedures. You will be required to maintain a range of equipment, such as pumps, valves, actuators, sensors, compressors and other fluid power equipment, which are working in an integrated system on mobile or static plant involving two of the following interactive technologies: mechanical, electrical, or process controller.

You will be expected to isolate and disconnect items and components of the interactive technologies in order to gain access to and remove the fluid power units and components that require replacing or repair. This will involve dismantling and reassembling a variety of different types of assemblies and sub-assemblies which, in some instances, will need to be dismantled to component level.

Your responsibilities will require you to comply with organisational policy and procedures for the maintenance activities undertaken, and to report any problems with the maintenance activities, tools or equipment used that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used in the maintenance activities are removed from the work area on completion of the work, and that all necessary job/task documentation is completed accurately and legibly. 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 fluid power maintenance procedures. You will also know about the integrated technology assemblies and sub-assemblies, their properties, functions and associated defects, in adequate depth to provide a sound basis for carrying out the dismantling and reassembly process safely and effectively. You will understand the maintenance methods and procedures used, and their application within an engineered system, in sufficient depth to enable you to carry out the maintenance activities, correct faults, and ensure that the maintained equipment functions to specification and remains compliant with all standards and regulations. You will also know about the interaction of the other associated integrated technologies and have sufficient knowledge to carry out the dismantling and reassembly safely and effectively.

You will understand the safety precautions required when carrying out the maintenance activities, especially those for isolating the equipment and for 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:

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  1. work safely at all times, complying with health and safety legislation 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 timescale
  5. report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule
  6. complete and store all relevant maintenance documentation in accordance with organisational requirements
  7. 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:

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  1. the health and safety requirements of the area in which the maintenance activity is to take place, and the responsibility these requirements place on you
  2. the isolation and lock-off procedure or permit-to-work procedure that applies to the system being worked on
  3. the specific health and safety precautions to be taken during the maintenance activities, and their effects on others
  4. the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities, and where to obtain it
  5. hazards associated with carrying out maintenance activities on an integrated system (such as handling fluids, stored pressure/force, electrical supplies, process controller interface, using damaged or badly maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks
  6. regulations and codes of practice that apply to working with fluid power equipment
  7. how to obtain and interpret drawings, charts, circuit and physical layouts, specifications, manufacturers' manuals, history/maintenance reports, symbols used in fluid power, and other documents needed for the maintenance activities
  8. the basic principles of operation of the equipment to be maintained
  9. the importance of following the correct de-contamination procedures
  10. principles and theories associated with fluid power equipment (such as cascading and truth tables, logic/ladder diagrams)
  11. how to construct and apply ladder logic, sequential charts/tables or functional diagrams
  12. dry and lubricated systems and their application
  13. selection, types and characteristics of fluids for the system
  14. the effects of pressure and flow on the performance of the system
  15. the identification of different compressors (such as screw piston, rotary vane)
  16. the identification of different hydraulic motors (such as piston, gear, vane)
  17. the effects, and likely symptoms, of contamination in the system
  18. the different types of pipework, fittings and manifolds, and their application
  19. the identification, application, function and operation of different types of valves (such as poppet, spool, piston, disc and slide)
  20. the identification, application function and operation of different types of sensors and actuators (such as rotary, linear, mechanical, electrical)
  21. the identification, application function and operation of different types of actuators/cylinders (such as single acting, double acting and telescopic)
  22. the identification and application of different types of pumps (positive, gear vane and piston)
  23. the application and fitting of static and dynamic seals
  24. organisational policy on repair/replacement of components, and the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance activities
  25. the sequence to be adopted for the dismantling and reassembling of the equipment, to both sub-assembly and individual component level
  26. the techniques used to dismantle/re-assemble integrated equipment (release of pressures/force, proofmarking to aid assembly, plugging exposed pipe/component openings, dealing with soldered joints, screwed, clamped and crimped connections)
  27. methods of attaching identification marks/labels to removed components or cables, to assist with re-assembly
  28. methods of checking that components are fit for purpose, and the need to replace `lifed' items (such as seals, gaskets, filters, pistons, spools and bearings)
  29. how to make adjustments to components/assemblies, to ensure they function correctly
  30. how to check tools and equipment are free from damage or defects, are in a safe and usable condition, and are configured correctly for the intended purpose
  31. the importance of making `off-load' checks before applying full pressure
  32. the generation of maintenance documentation and/or reports on completion of the maintenance activity
  33. the manufacturer's equipment operating and control procedures to be applied during the maintenance activity
  34. how to use lifting and handling equipment in the maintenance activity
  35. the problems that can occur during the maintenance activity, and how they can be overcome

  36. the organisational procedure to be adopted for the safe disposal of waste of all types of materials

  37. the extent of your own authority and to whom you should report if you have a problem that you cannot resolve

Scope/range

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  1. Carry out all of the following during the maintenance activity:

    1. plan and communicate the maintenance activities to cause minimal disruption to normal working
    2. obtain and use the correct issue of organisational and/or manufacturers' drawings and maintenance documentation
    3. 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
    4. ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids)
    5. provide and maintain safe access and working arrangements for the maintenance area
    6. carry out the maintenance activities using appropriate techniques and procedures
    7. reconnect and return the system to service on completion of the maintenance activities
    8. record the results of the maintenance activity and report any defects found
    9. dispose of waste materials in accordance with safe working practices and approved procedures and leave the work area in a safe condition

  2. Use appropriate dismantling and re-assembly techniques to deal with two of the following:

               mechanical components:

    1. draining and replenishing fluids                             
    2. removing major mechanical units (gear boxes, pumps, workholding/transfer equipment)
    3. removing and refitting locking and retaining devices             
    4. removing minor mechanical units/sub-assemblies(such as guards, structures)                   
    5. proofmarking components to aid re-assembly          
    6. setting, aligning and adjusting replaced units

electrical components:
7. isolating power supply                                   
8. removing / replacing minor electrical components (such as relays, sensing devices, limit switches)
9. disconnecting and reconnecting wires/cables                 
10. removing and replacing major electrical components (such as motors, switch/control gear)             
11. removing and replacing wiring enclosures (such as conduit, trunking, traywork and cable ways)

programmable controller components:
12. de-activating and resetting program controller 
13. disconnecting/re-connecting wires/cables
14. reloading programs and making minor amendments   
15. removing and replacing programming devices (such as laptop, programmer, PDA)
16. removing and replacing input/output interfacing

  1. Carry out maintenance activities on two of the following types of fluid power equipment:

    1. pneumatic                           
    2. hydraulic                  
    3. vacuum

  2. Carry out all of the following maintenance activities, as applicable to the equipment being maintained:

    1. chocking/supporting actuators/rams/component  
    2. releasing stored pressure
    3. draining, removing and replacing oil/fluids (as applicable)        
    4. replacing damaged/defective components
    5. disconnecting/removing hoses, pipes and tubing     
    6. replacing all `lifed' items (seals, filters, gaskets, hoses)
    7. proofmarking/labelling of removed components               
    8. checking components for serviceability                  
    9. tightening fastenings to the required torque
    10. removing and replacing units/components (such as pumps, cylinders, valves, actuators)
    11. setting, aligning and adjusting replaced components
    12. making `off-load' checks before re-pressurising system
    13. priming and bleeding the system (where applicable)
    14. functional/performance testing of the maintained system

  3. Carry out maintenance activities to component level on one of the following fluid power components:

    1. pumps              
    2. valves          
    3. motors              
    4. actuators

  4. Replace/refit a range of fluid power components, to include seven of the following:

    1. pumps            
    2. bearings  
    3. compressors
    4. sensors
    5. pistons           
    6. reservoirs     
    7. receivers            
    8. lubricators/filters
    9. spools                
    10. accumulators  
    11. gaskets and seals    
    12. regulators
    13. valves       
    14. pressure intensifiers  
    15. pipework and hoses   actuators/cylinders 
    16. switches
    17. other specific components

  5. Ensure that maintenance activities comply with one of the following:

    1. organisational guidelines and codes of practice
    2. equipment manufacturer's operation range      
    3. BS, ISO and/or BSEN standards

  6. Complete and store all relevant maintenance documentation in accordance with organisational requirements, using one of the following:

    1. job cards
    2. maintenance log or report
    3. permit to work/formal risk assessment and/or sign on/off procedures
    4. organisational-specific documentation
    5. electronic reports

Scope Performance

Scope Knowledge

Values

Behaviours

Skills

Glossary

Links To Other NOS

External Links

Version Number

3

Indicative Review Date

2024

Validity

Current

Status

Original

Originating Organisation

Enginuity

Original URN

SEMEM3-26

Relevant Occupations

Maintenance Engineer

SOC Code

5223

Keywords

Engineering; manufacturing; maintenance; engineered system; integrated system; fluid power; pneumatic; hydraulic; vacuum systems; pumps; valves