Assembling fluid power components to mechanical equipment
Overview
This standard identifies the competences you need to assemble and fit fluid power components (such as pneumatic, hydraulic, or vacuum) to mechanical equipment, in accordance with approved procedures. You will be required to check the specified components are available and fit for purpose, to obtain all relevant and current documentation, to obtain the tools and equipment required for the assembly operations and to check that they are in a safe and usable condition. In carrying out the fitting and assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to assemble the required components.
The assembly activities will also include making all necessary checks and adjustments, to ensure the fluid power components are correctly positioned and aligned, that moving parts have the correct working clearances, all fasteners are tightened to the correct torque and that the assembled parts are checked for completeness.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of 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 be sufficient to provide a good understanding of your work, and will provide an informed approach to applying fluid power assembly techniques and procedures. You will understand the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 follow the relevant instructions, assembly drawings and any other specifications
P3 ensure that the specified components are available, prepared and that they are in a usable condition
P4 use the appropriate methods and techniques to assemble and fit the components in their correct positions
P5 secure the components using the specified connectors and securing devices
P6 check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
P7 complete and store all relevant documentation in accordance with organisational requirements
P8 deal with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K3 how to extract and use information from engineering drawings and related specifications in relation to work undertaken
K4 the general principles of fluid power, and the purpose and function of the components and materials used
K5 preparations to be undertaken on the components prior to fitting them onto the assembly
K6 the fitting and assembly methods and procedures to be used, and the importance of adhering to these procedures
K7 how the components are to be aligned, adjusted and positioned prior to securing, and the tools and equipment that are used
K8 the importance of using the specified components for the assembly, and why you must not use substitutes
K9 the quality control procedures to be followed during the assembly operations
K10 how to detect assembly defects/faults and what to do to rectify them
K11 the methods and equipment used to transport, lift and handle components and assemblies
K12 how to check that the tools and equipment to be used are in a safe and serviceable condition
K13 the importance of ensuring that all tools are used correctly and within their permitted operating range
K14 the issues that can occur with the assembly operations, and what to do if they occur
K15 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
1. Carry out all of the following during the assembly activities:
1.1 obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation)
1.2 adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
1.3 check that tools and measuring instruments to be used are fit for service
1.4 ensure that components and pipes used are free from damage, foreign objects, dirt or other contamination
1.5 use appropriate and approved fitting and assembly techniques at all times
1.6 leave the work area in a safe and appropriate condition on completion of the activities
2. Assemble and fit components for one of the following types of fluid power systems:
2.1 pneumatic
2.2 vacuum
2.3 hydraulic
2.4 electro-fluid power systems
3. Prepare and fit four of the following fluid power components and materials to mechanical equipment:
3.1 power generation components (such as motors, pumps, compressors, intensifiers)
3.2 fluid conditioning components (such as filters, lubricators, separation units, heaters/driers, cooler units)
3.3 storage devices (such as reservoirs, accumulators)
3.4 monitoring components (such as sensors, meters, gauges and indicators)
3.5 pipe work (such as rigid pipe, flexible pipe, hoses)
3.6 connection devices (such as manifolds, couplings, cables and wires)
3.7 control components (such as valves, actuators/cylinders, regulators)
4. Carry out the quality checks using appropriate equipment, to include four of the following:
4.1 dimensions
4.2 correct direction and flow
4.3 electrical continuity
4.4 positional accuracy
4.5 leak or pressure tests
4.6 completeness
4.7 alignment
4.8 component security
4.9 function
4.10 pipe work (free from ripple and creases)
5. Produce fluid power assemblies which comply with one of the following quality and accuracy standards:
5.1 BS, ISO or BSEN standards and procedures
5.2 customer standards and requirements
5.3 organisational standards and requirements
5.4 specific system requirements