Assist in the installation of traction and rolling stock equipment
Overview
This standard identifies the competencies you need to assist in the installation of traction and rolling stock equipment. You will be required to assist in the installation of a range of equipment, all of which encompass an integrated system involving two of the following interactive technologies: mechanical, electrical, electronic, fluid power or process controller. Typical systems will include equipment such as wheel sets, bogies, traction motors, engines, transmission, compressors, electrical/electronic control or communication systems, environmental systems and devices such as doors with fluid power and electrical mechanisms attached. 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).
This standard includes the connection of sub-assemblies where these have been broken down for transportation purposes. You will use the appropriate tools and equipment throughout the installation activities, apply a range of installation methods and techniques to position, level and align the equipment and make connections to sensors and actuators which could be electrical, fluid power, water/coolant or fuel supply, as appropriate to the equipment installed. You may also assist in working with computers or electronic controllers, making connections, installing hardware and loading and updating software. The installation activities will include making checks and adjustments, in line with your permitted authority and assisting others to ensure that the installed equipment functions to the required specification.
Safety is a key theme; you must practice and demonstrate safe working methods, understanding and implementing necessary precautions to protect yourself and others.
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 all relevant instruction documentation for the installation being carried out
P3 use the correct tools and equipment for the installation operations, and check that they are in a safe and usable condition
P4 assist in the installation, positioning and securing of the equipment, using appropriate methods and techniques
P5 assist in checking the installation, and make any adjustments in accordance with the specification
P6 address problems within your control and report unresolved issues
P7 dispose of waste materials in accordance with safe working practices and approved procedures
P8 assist in the completion of installation documentation
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 and lock-off procedure or permit-to-work procedure that applies to the installation activities (such as electrical isolation, locking off switchgear, placing of maintenance warning notices, proving the isolation has been achieved and secured)
K3 the specific health and safety precautions to be applied during the installation procedure, and their effects on others
K4 the hazards associated with installing traction and rolling stock equipment, and with the tools and equipment used, and how they can be minimised
K5 the steps to take to secure the vehicle from movement and protect it from other vehicle movements
K6 the classification of different voltage levels and the authority requirements for working on them
K7 the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the installation
K8 what constitutes a hazardous voltage/current and how to recognise victims of electric shock
K9 how to reduce the risks of an electric shock (such as insulated tools, rubber matting and isolating transformers)
K10 how to obtain and interpret information from job instructions and other documentation used in the installation activities (such as installation drawings, specifications, manufacturers' manuals, regulations, symbols and terminology)
K11 the basic principles of how the system functions, and its operating sequence
K12 methods of preparing the traction and rolling stock for positioning the equipment, and the tools and equipment used for this
K13 the various mechanical fasteners and locking devices that will be used, and their correct method of installation
K14 methods of lifting, handling and supporting the equipment during the installation activities
K15 methods of levelling and aligning the equipment, and the types of tools, instruments and techniques used
K16 methods of connecting to mechanical power transmission devices (such as shafts, couplings belt and chain drives)
K17 the different types of cabling used in the installation activities, and their methods of termination
K18 the different types of wiring enclosures that are used (to include conduit, trunking and traywork systems)
K19 the installation and termination of a range of electrical components (such as plugs, switches, sockets, lighting and fittings)
K20 why electrical bonding is critical, and why it must be both mechanically and electrically secure
K21 the care, handling and application of multimeters and other electrical measuring instruments
K22 methods of assembling and installing pipework, hoses and fittings
K23 how to recognise a range of fluid power components
K24 recognition of contaminants and the problems they can create, and the effects and symptoms of contamination in the system
K25 the recognition of sensors, instrumentation and associated peripherals (such as pressure, flow, temperature)
K26 the recognition of electronic systems and associated peripheral devices (such as input/output (I/O) devices)
K27 how to conduct any necessary checks to ensure the equipment integrity, functionality, accuracy and quality of the installation (including the fitting of guards to all moving parts, and covers on electrical connections)
K28 how to recognise installation defects (such as leaks, poor seals, misalignment, ineffective fasteners, foreign object damage)
K29 the problems that can occur with the installation operations, and how these can be overcome
K30 the fault-finding techniques to be used if the equipment fails to operate as required
K31 the recording documentation to be completed for the activities undertaken the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
During the installation of the traction and rolling stock equipment, individuals will:
- adhere to procedures or systems in place for risk assessment, control of substances, personal protective equipment and other relevant safety regulations
- confirm that authorisation to carry out the installation activities has been given
- check that safe access and working arrangements for the installation area have been provided
- confirm that services have been isolated, following safe working practices, ready for the installation (such as mechanical, electricity, air or fluids)
- check that all required installation consumables are available
- leave the work area in a safe condition and free from foreign object debris
Assisting in the installation of a traction and rolling stock system could include the following:
- installing mechanical equipment/components:
- installing mechanical equipment (such as bogies, transmission, engines, pumps)
- levelling equipment
- aligning and securing sub-assemblies and units
- connecting units (such as shafts, couplings, drives)
- setting and adjusting drive mechanisms (such as shafts, couplings, drives)
- setting and adjusting operating mechanisms (such as levers, linkages, cams and followers)
- setting and adjusting control mechanisms (such as clutches, brakes, end stops)
- installing electrical and electronic equipment/components:
- installing electrical/electronic equipment (such as traction motors, switch gear, distribution panels, inverters, luminaires, line replaceable units (LRU's))
- attaching suitable cable identification (such as colour coding or numbering systems)
- installing wiring enclosures/cable protection systems (such as conduit, trunking and tray work)
- installing, routeing and securing wires and cables (such as PVC, armoured cables, data cables)
- terminating cables to electrical components
- installing fluid power components:
- installing fluid power equipment (such as compressors, pumps, accumulators, storage reservoirs and receivers)
- installing fluid power components (such as cylinders, valves, sensors, actuators, filters and regulators)
- installing rigid and flexible pipework and hoses
- connecting components to pipework, using appropriate fittings
- dressing and securing piping and hoses
- installing process controller components:
- installing process controllers or sequential controllers (such as PCs, data communication links)
- installing and connecting wires and cables to components
- installing input/output interfacing
- installing peripherals (such as sensors, relays, switches)
- checking and confirming that signal measurement and transmission are satisfactory
- installing instrumentation and control components:
- installing instrumentation and control equipment (such as pressure, flow, level, temperature, speed, weight, vibration)
- installing and connecting peripherals (such as sensors, actuators, relays, switches)
- installing and connecting process pipework (as appropriate)
- connecting electrical/pneumatic supply to instruments/sensors
- connecting signal transmission supply to instruments/sensors
- checking and confirming that signal measurement and transmission are satisfactory
Types of installation methods and techniques applied, include:
- torque loading of fasteners
- applying fastener locking devices
- marking out positions of all equipment
- drilling and/or preparing mounting holes
- aligning and levelling equipment
- securing by using mechanical fixings (threaded fasteners)
- securing by using adhesives
- shimming and packing
- fitting anti-vibration mountings
- moving and positioning equipment, using appropriate lifting and handling equipment
Groups of instruments used during the installation activities could include:
- alignment devices (such as plumb lines, levels, inclinometers, laser equipment) linear measuring devices (such as tapes, dial test indicators, micrometers, verniers, feeler gauges)
- electrical measuring equipment (such as multimeter, continuity tester, insulation resistance)
- fluid/power testing equipment (such as pressure or flow testing devices, speed or temperature measurement)
Checks and adjustments carried out, as appropriate to the equipment being installed, include:
- making visual checks of the installation, for completeness and freedom from damage
- topping up fluid/oil reservoirs (as appropriate)
- ensuring that all bolts are torqued, and that locking devices are fitted to fasteners
- ensuring that all pipe connections are made in line with your organisation's procedures, secure and leak free
- ensuring that all moving parts are clear of obstructions and are guarded, where required
- making sensory checks of the system (sight, sound, smell, touch)
- confirming that the correct data/software has been loaded
- ensuring that all electrical connections are made in accordance with your organisation's procedures, earth bonding is secure and connections covered
- testing that the system operates to the installation specification
Types of conditions to be dealt with during the installation process could include:
- installations with no faults
- partial equipment malfunction
- complete malfunction of equipment
Types of fault location methods and techniques used on the installation could include:
- diagnostic aids (such as company records/history, manufacturers' manuals, fault analysis charts, troubleshooting guides)
- fault finding techniques (such as six point, half-split, unit substitution)
- functional testing the installation/running equipment self-diagnostics
Installations 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 paperwork/records that need to be completed and passed to the appropriate people could include:
- installation records
- job cards
- specific company documentation
- permit to work/formal risk assessment
- maintenance log or report
- electronic records