This standard covers a range of basic fluid power assembly competences that will prepare you for entry into the engineering or manufacturing sectors, creating a progression between education and employment, or that will provide a basis for the development of additional skills and occupational competences in the working environment.

You will be expected to prepare for the fluid power assembly activities by obtaining all the necessary job instructions, components, tools, equipment and any documentation that may be required. You will be required to use the appropriate equipment, based on the assembly operations to be carried out and the type of fluid power equipment being assembled, which will include hydraulic, pneumatic or vacuum systems.

In carrying out the fluid power assembly operations, you will be required to work to instructions, in order to produce the required assembly. The assembly activities will also include making all necessary checks and adjustments, to ensure that fluid power components are correctly orientated and positioned, and that all pipework connections are correctly made and are secure. On completion of the fluid power assembly activities, you will be expected to return all tools and equipment to the correct location, and to leave the work area in a safe and tidy condition.

Your responsibilities will require you to comply with health and safety requirements and organisational policy and procedures for the fluid power assembly activities undertaken. You will need to report any difficulties or problems that may arise with the assembly activities, and to carry out any agreed actions. You will work under a high level of supervision, whilst taking responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide an understanding of your work, and will enable you to apply appropriate fluid power assembly techniques safely. You will understand the assembly process, and its application, and will know about the fluid power equipment being assembled, the components, tools and consumables used, to the required 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, and when using assembly tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Specific Standard Requirements

At least one of the fluid power assemblies produced must include a combination of components and assembly techniques and procedures, for example: by mounting control valves, cylinders/actuators, switches/sensing devices and correctly connecting these, using the appropriate pipework and/or hoses, so that they make a simple operational system and perform some defined function.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
2. obtain and prepare the appropriate fluid power components, assembly tools and equipment
3. use the appropriate methods and techniques to assemble the components in their correct positions
4. secure the components, using the specified connectors and securing devices
5. produce fluid power assemblies
6. check the completed assembly to ensure that all operations have been completed, and that the finished assembly meets the required specification
7. report any difficulties or problems that may arise with the fluid power assembly activities, and carry out any agreed actions
8. leave the work area in a safe and tidy condition on completion of the fluid power assembly activities

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1. the health and safety requirements, and safe working practices and procedures required for the fluid power assembly activities undertaken
2. the importance of wearing appropriate protective clothing and equipment (PPE), and keeping the work area safe and tidy
3. hazards associated with carrying out assembly activities on fluid power equipment (such as handling fluids, stored energy/force, misuse of tools), and how these can be minimised
4. the procedure for obtaining the required drawings, job instructions and other related specifications
5. how to obtain and interpret drawings, charts, circuit and physical layouts, specifications, manufacturers' manuals, symbols used in fluid power to appropriate BS or ISO standards, and other documents needed in the assembly activities
6. how to prepare the components in readiness for the assembly activities (such as visually checking for defects, cleaning the components, removing burrs and sharp edges)
7. the general principles of fluid power, and the purpose and function of the components used
8. how to identify the fluid power components to be used (such as valves, actuators, sensors, manifolds, pumps)
9. the techniques used to assemble/install fluid power equipment (such as positioning components; making pipe bends using fittings and by hand bending methods; connecting components using rigid and flexible pipework; using gaskets/seals and jointing/sealing compounds)
10. the importance of using the specified fluid power components for the assembly, and why you must not use substitutes
11. the need to ensure that pipework is supported at appropriate intervals, and the need to eliminate stress on the pipework connections
12. the need to ensure cleanliness of the fluid power system, and the ways of purging pipework before connection to components and pressure sources
13. recognition of contaminants and the problems they can create, and the effects and likely symptoms of contamination in the system
14. how to check that tools and test equipment are free from damage or defect, and are in a safe and usable condition
15. the problems associated with the fluid power assembly and testing activity, and how they can be overcome
16. when to act on your own initiative and when to seek help and advice from others
17. the importance of leaving the work area in a safe and clean condition on completion of the fluid power assembly activities (such as returning tools and equipment to the designated location, cleaning the work area, and removing and disposing of waste)

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1. Carry out all of the following during the assembly of the fluid power equipment:

   1. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment (PPE) and other relevant safety regulations
   2. follow job instructions, fluid power assembly drawings and procedures
   3. check that all tools and equipment to be used are in a safe and usable condition
   4. ensure that all components and pipes used are kept free from foreign objects, dirt or other contamination
   5. apply safe and appropriate fluid power fitting and assembly techniques at all times
   6. return all tools and equipment to the correct location on completion of the assembly activities

2. Assemble components for one of the following types of fluid power systems:

   1. pneumatic     
   2. hydraulic   
   3. vacuum

3. Produce fluid power assemblies which contain five of the following types of component:

   1. pipework (such as rigid pipe, flexible pipe, hoses)
   2. valves (such as poppet, spool, piston, disc)
   3. cylinders (such as single or double acting)
   4. actuators (such as rotary or linear, mechanical or electrical)
   5. power generation components (such as motors, pumps, compressors, intensifiers)
   6. fluid conditioning components (such as filters, lubricators, separation units, heaters/driers, cooler units)
   7. storage devices (such as reservoirs, accumulators)
   8. monitoring components (such as sensors, meters, gauges and indicators)
   9. connection devices (such as manifolds, couplings, cables and wires)

4. Apply fluid power assembly methods and techniques, to include all of the following:

   1. checking components for serviceability
   2. positioning equipment/components
   3. securing by using mechanical fixings
   4. making pipework connections to components
   5. dressing and securing pipes and hoses

5. Produce fluid power assemblies which meet all of the following:

   1. the system is complete, as per specification
   2. components are correctly positioned and aligned
   3. direction and flow indicators on components are correct
   4. all components are securely held in place
   5. all connections to components are correct and are tightened to the required torque
   6. pipework is free from ripple and creases and is correctly clipped/supported

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​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

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3

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31 Mar 2020

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Current

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Original

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Semta

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SEMPEO1-11

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Engineering, Engineering and Manufacturing Technologies

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5221

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performing engineering operations; fluid power equipment; fluid power assembly; manufacturing; hydraulic systems; pneumatic systems; vacuum systems; pipework; tools; equipment

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