Carry out scheduled maintenance on traction and rolling stock fluid power equipment
Overview
This standard identifies the competencies you need to carry out scheduled maintenance activities on traction and rolling stock electrical equipment. You will be required to carry out maintenance on electrical equipment such as single and three-phase power supplies, traction motors, switchgear and distribution panels, control systems and equipment, luminaries and other specific electrical equipment to minimise downtime and ensure that the equipment performs at optimal levels and functions to specification. The term traction and rolling stock used in this standard applies to passenger, freight and on-track machinery (OTM). Where it is relevant, these standards also apply to traction and rolling stock that has been fitted with the European Train Control System (ETCS).
You must ensure that all tools, equipment and materials used in the maintenance activities are removed from the work area on completion of the activities and that all necessary job/activities documentation is completed accurately and legibly. You will be expected to work to instructions, alone or in conjunction with others.
You will have an understanding of the process of implementing scheduled maintenance activities, the importance of carrying them out at specific times and recording their outcomes and actions taken. In addition, you will be expected to report where the outcomes identify the need for further investigation or maintenance work.
You will understand the safety precautions required when carrying out the maintenance activities, especially those for isolating the equipment and informing others of the work you are carrying out. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
P1 maintain safe working practices and comply with all relevant health and safety regulations, directives, and guidelines
P2 follow the relevant fluid power maintenance schedules to carry out the required work
P3 carry out the fluid power maintenance activities within the limits of your personal authority
P4 carry out the fluid power maintenance activities in the specified sequence and in an agreed time scale
P5 report any instances where the maintenance activities cannot be met or where there are identified defects outside the planned schedule
P6 complete relevant maintenance records and pass them on to the appropriate person, in accordance with your organisation's procedures
P7 dispose of waste materials in accordance with safe working practices and approved procedures
Knowledge and Understanding
You need to know and understand:
K1 the relevant health and safety regulations, directives, guidelines, and safe working practices and procedures defined by your organisation, as appropriate to the activity and your working area
K2 the isolation procedure or permit-to-work procedure that applies to the equipment being maintained (such as electrical isolation, locking off switchgear, placing of maintenance warning notices, proving the isolation has been achieved and secured)
K3 the steps to be followed to vent or de-pressurise the areas to be worked on
K4 the specific health and safety precautions to be applied during the scheduled maintenance activities, and their effects on others
K5 the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities
K6 the hazards associated with carrying out scheduled maintenance on fluid power equipment (such as handling oils/greases, stored pressure/force, misuse of tools), and how they can be minimised
K7 how to obtain and extract information from job instructions, drawings, specifications, manufacturers' manuals and other documents needed in the maintenance process
K8 the various checks to be carried out during the scheduled maintenance procedure
K9 the importance of following correct preventive contamination procedures
K10 the effects of contamination in the system
K11 the maintenance requirements for 'lifed', consumable and on condition components
K12 how to use maintenance software tools provided for the equipment
K13 the procedure for obtaining the consumables to be used during the scheduled maintenance activity
K14 methods of checking that components are fit for purpose, and the need to replace `lifed' items
K15 how to check that any replacement components meet the required specification/operating conditions
K16 how to make appropriate sensory checks (such as sight, sound, smell and touch)
K17 the appropriate testing instructions to be adopted during the maintenance activity hoW to make adjustments to components/assemblies to ensure they function to specification
K18 the basic principles of how the equipment functions, its operating sequence, the working purpose of individual units/components, and how they interact with other systems such as ETCS, AWS or TPWS
K19 how to complete scheduled maintenance records/logs/reports, in accordance with company policy and procedures
K20 the importance of recording an adjustments and modifications to the system and the implications if this is not carried out
K21 the equipment operating and control procedures, and how to apply them in order to carry out scheduled maintenance
K22 the problems that can occur whilst carrying out the scheduled maintenance activities, and how they can be avoided
K23 the organisational procedure(s) to be adopted for the safe disposal of waste of all types of materials
K24 the extent of your own authority and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
In carrying out scheduled fluid power maintenance activities, individuals will:
- undertake the maintenance activities to cause minimal disruption to normal working
- use the correct issue of maintenance documentation (such as drawings, manuals, maintenance records)
- adhere to procedures or systems in place for risk assessment, control of substances, personal protective equipment and other relevant safety regulations
- adhere to company specific contamination and control procedures at all times
- confirm with the authorised person that the equipment is ready for carrying out the scheduled maintenance
- ensure the safe isolation and de-pressurising, where applicable, of equipment (such as mechanical, electricity, air or fluids)
- ensure that safe access and working arrangements have been provided for the maintenance area
- carry out the scheduled maintenance activities, using appropriate techniques and procedures
- dispose of waste items in a line with your organisation's procedures
- leave the work area in a safe and tidy condition
Scheduled maintenance activities may be carried out on following types of fluid power equipment:
- pneumatic equipment
- hydraulic equipment
- vacuum equipment
Maintenance activities may be carried out on following:
- pumps
- compressors
- pipework and hoses/tubing
- storage devices (such as reservoirs, receivers, accumulators)
- control devices (such as valves, sensors, switches)
- power devices (such as cylinders, actuators, motors)
- supply devices (such as gauges, filters, dryers, regulators)
- other specific system components
Types of scheduled maintenance activities carried out, include:
- removing excessive dirt and grime
- making sensory checks (such as sight, sound, smell, touch)
- draining down water traps
- checking equipment for leaks
- replacing 'lifed' consumables (such as gaskets/seals, filters, hoses)
- monitoring the condition/deterioration of components (such as actuators, mechanical control devices, pipework, hoses)
- checking that any safety equipment or controls are operating as designed (such as switches and sensors)
- checking the operation of instrumentation (such as gauges and indicators)
- carrying out and/or checking equipment self-analysis data
- making adjustments to components and connections
- checking/tightening fastenings to the required torque
- correct fitting of locking devices
- replenishing items (such as oils, greases or other fluids)
- reviewing and checking the equipment operation and performance
- recording the results of the scheduled maintenance activity
- reporting or taking action with regard to any defects that require immediate attention (such as replacing non-'lifed' components)
- other specific maintenance activity
Fluid power equipment maintenance may need to comply with the following:
- organisational guidelines and codes of practice
- equipment manufacturer's operation range
- BS, ISO and/or BSEN standards
- company standard operating procedures (SOP's)
- documents such as technical procedures, vehicle maintenance instructions, vehicle overhaul instructions, workshop overhaul standards specifications
Types of maintenance records that need to be completed and passed to the appropriate people could include:
- job cards
- specific company documentation
- permit to work/formal risk assessment
- maintenance log or report
- electronic records