Dismantling mechanical equipment in preparation for overhaul
Overview
This standard identifies the competences you need to dismantle mechanical equipment in preparation for complete overhaul, in accordance with approved procedures. This will involve dismantling equipment down to component or unit level, as applicable to the equipment being overhauled.
Your responsibilities will require you to comply with organisational policy and procedures for the dismantling of the mechanical equipment, and to report any problems with the dismantling activities 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 activities are removed from the work area on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly. You will be expected to work with a minimum of supervision, taking personal responsibility for your 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 appropriate dismantling techniques to mechanical equipment. You will understand the dismantling methods and procedures used, and their application. You will know about the mechanical equipment being dismantled, in adequate depth to provide a sound basis for carrying out the dismantling activities to the required specification.
You will understand the safety precautions required when carrying out the dismantling activities, especially those for ensuring that stored energy is released safely. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- establish and, where appropriate, mark component for re-assembly
- ensure that any stored energy or substances are released safely and correctly
- make all isolations and disconnections to the equipment, in line with approved procedures
- carry out the dismantling to the agreed level, using correct tools and techniques
- store components for re-use in approved locations
- dispose of unwanted components and substances in accordance with approved procedures
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- the hazards associated with dismantling mechanical equipment, and the tools and equipment used, and how to minimise them and reduce any risks
- the importance of wearing protective clothing (PPE) and other appropriate safety equipment during the mechanical dismantling activities
- the health and safety requirements of the area in which the mechanical dismantling activity is to take place, and the responsibility these requirements place on you
- the isolation procedure or permit-to-work procedure that applies to the dismantling activities
- how to use and extract information from drawings, manufacturers' manuals, history/maintenance reports, and other documents needed in the dismantling process
- the basic principles of operation of the mechanical equipment being dismantled, and the function of the components within the equipment
- the extent to which the equipment is to be dismantled for overhaul
- the techniques used to dismantle the mechanical equipment
- methods of dismantling mechanical assemblies and sub-assemblies without causing damage to surrounding structures
- the various mechanical fasteners that are used, and their methods of removal
- methods of supporting and lifting the components/equipment being removed
- the need to ensure that lifting and handling equipment is within its current test dates
- the tools and equipment used in the dismantling activities, and how to check that they are in a safe and usable condition
- good practice/approved procedures to be followed during the dismantling of the mechanical equipment
- the need to clean and safely store all components ready for reassembly
- the storage requirements of removed units and assemblies which are not part of the overhaul process
- the procedure for the safe disposal of waste materials
- the recording documentation to be completed for the dismantling activities undertaken and, where appropriate, the importance of identifying specific components in relation to the documentation
- the problems that can occur during the dismantling activity, and how they can be overcome
- 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
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- Carry out all of the following during the dismantling of the mechanical equipment:
- plan the dismantling activities relevant to the mechanical equipment being overhauled
- obtain and use the appropriate dismantling documentation
- 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
- provide and maintain safe access and working arrangements for the work area
- follow good practice/approved dismantling procedures at all times
- carry out the dismantling activities using the appropriate tools and equipment at all times
- leave the work area and tools in a safe and appropriate condition on completion of the activities
- Dismantle two of the following types of equipment:
- equipment with rotating parts
- equipment with sliding or moving parts
- equipment with oscillating or reciprocating parts
- electro-mechanical equipment
- fluid power/mechanical equipment
- support structures
- Carry out ten of the following dismantling activities:
- removing outer casings/covers
- dismantling equipment to unit/sub-assembly level
- cleaning parts prior to dismantling
- dismantling units to component level
- carrying out pre-dismantling checks and tests
- removing components having interference fits (such as by expansion, contraction, pressure)
- releasing stored energy safely prior to dismantling
- draining/removing any remaining fluids
- proof-marking/labelling of components to aid reassembly
- disconnecting and removing wires and cables
- attaching suitable cable identification markers
- supporting the equipment to be removed
- disconnecting and removing pipework
- removing mechanical fastening devices
- disconnecting and removing levers and linkages
- storing all components and peripheral units safely, ready for inspection and reassembly
- disconnecting and removing all peripheral devices
- Dismantle and remove ten of the following components and assemblies:
- shafts
- seals and gaskets
- housings
- couplings
- keys
- cables and wires
- gears
- springs
- electrical/electronic units
- clutches
- diaphragms
- fluid power components
- valves and seats
- cams and followers
- actuating mechanisms
- pistons
- chains and sprockets
- structural components
- brakes
- pulleys and belts
- covers and casings
- splined components
- levers and links
- locking and retaining devices (such as circlips, pins)
- bearings
- slides
- pipes and hoses
- rollers
- other specific components
- Dismantle mechanical equipment in compliance with one of the following:
- company standards and procedures
- customer (contractual) standards and requirements
- specific equipment requirements/manufacturer's data
- recognised compliance agency/body's standards