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Carrying out maintenance activities on fluid power equipment within an engineered system

URN: SEMEM447
Business Sectors (Suites): Engineering and Manufacture Suite 4
Developed by: Enginuity
Approved on: 2017

Overview

This standard identifies the competences you need to lead maintenance activities by carrying 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 or more of the following interactive technologies: mechanical, electrical, or process controller. You will also be required to identify and implement a systematic approach to improving the equipment maintenance activities undertaken and ensure that the maintenance team have to appropriate skills, knowledge and understanding to maintain the equipment efficiently, effectively and safely.

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 an in depth 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:

  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. produce and update relevant maintenance schedules and plans
  3. lead 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 relevant maintenance documentation accurately
  7. dispose of waste materials in accordance with safe working practices and approved procedures
  8. identify and lead on making improvements to maintenance processes and procedures
  9. update management information and systems to support the activities of the maintenance department

Knowledge and Understanding

You need to know and understand:

  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. how to prioritise your own and the team's workload to ensure that targets are met
  3. how to communicate effectively, listen, question, support and coach others to work towards the departmental targets
  4. the importance of ensuring that teams have the required skills, knowledge and understanding in order to maintain equipment to the required standards
  5. how to complete a skills audit of team members
  6. how maintenance teams can access the appropriate training and development programmes once a need training need has been identified
  7. the isolation and lock-off procedure or permit-to-work procedure that applies to the system being worked on
  8. the specific health and safety precautions to be taken during the maintenance activities, and their effects on others
  9. the importance of wearing protective clothing and other appropriate safety equipment during the maintenance activities and where to obtain it
  10. 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
  11. regulations and codes of practice that apply to working with fluid power equipment
  12. 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
  13. the basic principles of operation of the equipment to be maintained
  14. the various fault finding techniques that can be used, and how they are applied (such as half-split, input/output, emergent problem sequence, six point technique, functional testing, unit substitution, injection and sampling techniques, and equipment self-diagnostics)
  15. how to evaluate the various types of information available for fault diagnosis (such as operator reports, monitoring equipment, sensory inputs, machinery history records, and condition of the end product)
  16. how to evaluate sensory information from sight, sound, smell, touch
  17. the procedures to be followed to investigate faults, and how to deal with intermittent conditions
  18. how to use the various aids and reports available for fault diagnosis
  19. the types of equipment that can be used to aid fault diagnosis (such as mechanical measuring instruments, electrical measuring instruments, test rigs, and pressure and flow devices), and how to check the equipment is calibrated or configured correctly for the intended use, and that it is free from damage and defects
  20. the application of specific fault finding methods and techniques that are best suited to the problem
  21. how to analyse and evaluate possible characteristics and causes of specific faults/problems
  22. how to make use of previous reports/records of similar fault conditions
  23. how to evaluate the likely risk of running the equipment with the displayed fault, and the effects the fault could have on the overall process
  24. the importance of following the correct de-contamination procedures
  25. principles and theories associated with fluid power equipment (such as cascading and truth tables, logic/ladder diagrams)
  26. how to construct and apply ladder logic, sequential charts/tables or functional diagrams
  27. dry and lubricated systems and their application
  28. selection, types and characteristics of fluids for the system
  29. the effects of pressure and flow on the performance of the system
  30. the identification of different compressors (such as screw, piston, rotary, vane)
  31. the identification and application of different hydraulic pumps and motors (such as piston, gear, vane)
  32. the effects, and likely symptoms, of contamination in the system
  33. the different types of pipework, fittings and manifolds, and their application
  34. the identification, application, function and operation of different types of valves (such as poppet, spool, piston, disc and slide)
  35. the identification, application function and operation of different types of sensors and actuators (such as rotary, linear, mechanical, electrical)
  36. the identification, application function and operation of different types of actuators/cylinders (such as single acting, double acting, linear and telescopic)
  37. the application and fitting of static and dynamic seals
  38. company policy on repair/replacement of components, and the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance activities
  39. the sequence to be adopted for the dismantling and reassembling of the equipment, to both sub-assembly and individual component level
  40. 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)
  41. methods of attaching identification marks/labels to removed components or cables, to assist with re-assembly
  42. 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)
  43. how to make adjustments to components/assemblies, to ensure they function correctly
  44. 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
  45. the importance of making `off-load' checks before applying full pressure
  46. the generation of maintenance documentation and/or reports on completion of the maintenance activity
  47. the manufacturer's equipment operating and control procedures to be applied during the maintenance activity
  48. how to use lifting and handling equipment in the maintenance activity
  49. the problems that can occur during the maintenance activity, and how they can be overcome
  50. the organisational procedure to be adopted for the safe disposal of waste of all types of materials
  51. the organisational procedure to be adopted for the safe disposal of waste of all types of material
  52. how to conduct a systematic plan, do, check, act (PDCA) approach to problem-solving and business improvement
  53. how to evaluate improvement ideas in order to select those that are to be pursued
  54. how improvements to the process are achieved by engaging the knowledge and experience of the people working on the process
  55. how to create or update Standard Operating Procedures (SOP's) maintenance schedules and plans.
  56. the techniques required to communicate information using visual control systems (such as, card systems, colour coding, floor footprints, graphs and charts, team boards, tool/equipment shadow boards)
  57. the extent of your own authority and to whom you should report if you have a problem that you cannot resolve

Scope/range

Scope Performance

​

  1. Lead a maintenance team by carrying out all the following:

    1. communicate the maintenance activities to the team
    2. involve the team in planning how the maintenance activities will be undertaken
    3. allocate specific maintenance activities to each team member
    4. involve the team in identifying improvements that could be made to the maintenance process and/or procedures
    5. encourage the team and/or individuals to take the lead where appropriate

  2. Review and update maintenance procedures and plans to include three the following:

    1. preventive maintenance (routine inspections, and adjustments)
    2. corrective maintenance (activities identified from preventative maintenance activities)
    3. predictive maintenance (analysis of the equipment's condition)
    4. reactive maintenance (unexpected equipment/component failure)
    5. maintenance prevention (equipment/component design and development)

plus supporting documentation associated with two **of the following
6. equipment performance
7. equipment downtime/failure
8. overall equipment effectiveness (OEE)
9. maintenance costs
10. health and safety
11. staff development and training
12. maintenance procedures/instructions
13. operator manuals/working instructions
14. regulatory compliance

  1. Collect fault diagnosis evidence from three of the following sources:

    1. the person or operator who reported the fault         
    2. sensory input (such as sight, sound, smell, touch)          
    3. test instrument/rig measurements (such as pressure, flow, sequence)          
    4. plant/machinery records
    5. monitoring equipment or gauges                           
    6. condition of the end product
    7. recording devices

  2. Use a range of fault diagnostic techniques, to include two of the following:

    1. half-split technique
    2. input/output               
    3. emergent sequence
    4. injection and sampling       
    5. unit substitution
    6. six point technique              
    7. functional/performance testing
    8. equipment self-diagnostics

  3. Use a variety of diagnostic aids and equipment, to include two of the following:

    1. manufacturer's manual                       
    2. physical layout diagrams
    3. algorithms                                                
    4. flow charts
    5. probability charts/reports                                 
    6. fault analysis charts (such as fault trees)
    7. equipment self-diagnostics                               
    8. troubleshooting guides
    9. sequence charts                                                
    10. function diagrams

  4. Use all of the following diagnostic procedures:

    1. inspection (for leaks, loose fittings, breakages, wear/deterioration, damage to pipes/hoses, alignment)
    2. operation (such as manual operation, timing, sequencing)
    3. measurement (such as pressure, flow, timing, sequence, movement)

  5. Use two of the following types of test equipment to aid fault diagnosis:

    1. measuring devices/meters
    2. flow indicators
    3. pressure indicators
    4. thermal indicators
    5. test rigs
    6. self-diagnostic equipment
    7. contamination monitoring and analysing devices

  6. Find faults that have resulted in two of the following breakdown categories:

    1. intermittent problem
    2. partial failure/out-of-specification output
    3. complete breakdowns

  7. 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 company 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. dispose of waste items in safe and environmentally acceptable manner, and leave the work area in a safe condition

  8. 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 (gearboxes, 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, 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 (such as 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

* *

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

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

* *

  1. 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  
    16. switches
    17. actuators/cylinders 
    18. other specific components

* *

  1. Identify and implement improvements in the services provided by the maintenance team to include two **of the following:

    1. equipment downtime during maintenance
    2. equipment performance monitoring systems
    3. overall equipment effectiveness (OEE)
    4. maintenance procedures
    5. operator instructions
    6. visual management systems/documentation
    7. resource planning
    8. costs
    9. staff development and training
    10. health and safety
    11. procurement
    12. other specific improvement

  2. Ensure that maintenance activities comply with three of the following:

    1. organisational guidelines and procedures
    2. equipment manufacturer's operating specification/range
    3. British, European or International standards or directives
    4. recognised compliance agency/body standards or directives
    5. health, safety and environmental requirements
    6. customer standards and requirements

  3. Complete the relevant paperwork from one of the following, and pass it to the appropriate people:

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

Scope Knowledge

Values

Behaviours

​Additional Information

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

  • strong work ethic
  • positive attitude
  • team player
  • dependability
  • responsibility
  • honesty
  • integrity
  • motivation
  • commitment

Skills

Glossary

Links To Other NOS

External Links

Version Number

2

Indicative Review Date

2020

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMEM4-47

Relevant Occupations

Corporate Managers and Senior Officials, Engineering, Engineering and Manufacturing Technologies, Functional Managers

SOC Code

5223

Keywords

Engineering; leading; design; process; maintenance; quality; customer; function; features; objectives; manufacturing; installation; commissioning; testing; carrying out; problems; specifications; quality; research; evaluate; fluid; power; system