Maintain fluid power equipment within a traction and rolling stock system
Overview
This standard identifies the competencies you need to carry out corrective maintenance activities on fluid power equipment within a traction and rolling stock system, in accordance with approved procedures. You will be required to maintain a range of equipment, such as pumps, valves, actuators, sensors, compressors and other fluid power equipment, which are working in an integrated system involving two of the following interactive technologies: mechanical, electrical, or process controller. The term traction and rolling stock used in this standard applies to passenger, freight and on-track machines (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 will be expected to isolate and disconnect items and components of the interactive technologies in order to gain access to and remove the fluid power units and components that require replacing or repair. This will involve dismantling and reassembling a variety of different types of assemblies and sub-assemblies which, in some instances, may need to be dismantled to the component level.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying fluid power maintenance procedures within a traction and rolling stock system. You will also know about the integrated technology assemblies and sub-assemblies, their properties, functions and associated defects, in adequate depth to provide a sound basis for carrying out the dismantling and reassembly process safely and effectively. You will understand the maintenance methods and procedures used, and their application within a traction and rolling stock system, in sufficient depth to enable you to carry out the maintenance activities, correct faults, and ensure that the maintained equipment functions to specification and remains compliant with all standards and regulations. You will also know about the interaction of the other associated integrated technologies and have sufficient knowledge to carry out the maintenance and testing safely and effectively.
You will be required to demonstrate safe working practices throughout.
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 maintenance schedules to carry out the required work
P3 carry out the maintenance activities within the limits of your personal authority
P4 carry out the maintenance activities in the specified sequence and in an agreed timescale
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
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 and lock-off procedure or permit-to-work procedure that applies to the system being worked on (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 taken during the maintenance activities, and their effects on others
K4 the classification of different voltage levels and the authority requirements for working on them
K5 what constitutes a hazardous voltage/current and how to recognise victims of electric shock
K6 how to reduce the risks of an electric shock (such as insulated tools, rubber matting and isolating transformers)
K7 the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities, and where to obtain it
K8 the hazards associated with carrying out maintenance activities on an integrated system (such as handling fluids, stored pressure/force, electrical supplies, electrical/electronic interfaces, using damaged or ill-maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks
K9 regulations and codes of practice that apply to working with fluid power equipment
K10 how to obtain and interpret drawings, charts, circuit and physical layouts, specifications, manufacturers' manuals, history/maintenance reports, symbols used in fluid power, and other documents needed for the maintenance activities
K11 the principles of operation of the equipment to be maintained and how it interacts with other systems such as ETCS, AWS or TPWS and Wheel Slip/Slide Protection circuits
K12 principles and theories associated with fluid power equipment (such as cascading and truth tables, logic/ladder diagrams, sequential charts/tables or functional diagrams)
K13 dry and lubricated systems and their application
K14 selection, types and characteristics of fluids for the system
K15 the effects of pressure and flow on the performance of the system
K16 the identification of different compressors (such as screw, piston, rotary vane)
K17 the identification of different hydraulic motors (such as piston, gear, vane)
K18 the importance of following the correct preventative contamination procedures
K19 the effects, and potential symptoms, of contamination in the system
K20 the different types of pipework, fittings and manifolds, and their application
K21 the identification, application, function and operation of different types of valves (such as poppet, spool, piston, disc and slide)
K22 the identification, application function and operation of different types of sensors and actuators (such as rotary, linear, mechanical, electrical)
K23 the identification, application function and operation of different types of actuators/cylinders (such as single acting, double acting and telescopic)
K24 the identification and application of different types of pumps (positive, gear vane and piston)
K25 the steps to be followed to vent or de-pressurise the areas to be worked on
K26 the application and fitting of static and dynamic seals
K27 company policy on repair/replacement of components, and the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance activities
K28 the sequence to be adopted for the dismantling and reassembling of the equipment, to both sub-assembly and individual component level
K29 the techniques used to dismantle/re-assemble integrated equipment (release of pressures/force, proofmarking to aid assembly, plugging exposed pipe/component openings, dealing with soldered joints, screwed, clamped and crimped connections)
K30 methods of attaching identification marks/labels to removed components or cables, to assist with re-assembly
K31 methods of checking that components are fit for purpose, and the need to replace `lifed' items (such as seals, gaskets, filters, pistons, spools and bearings)
K32 the maintenance requirements for lifed, consumable and on condition components
K33 the torque loading and locking devices requirements for the maintained fluid power components and appropriate torque marking of fixings
K34 how to make adjustments to components/assemblies
K35 how to check tools and equipment are free from damage or defects, are in a safe and usable condition, and are configured for the intended purpose
K36 the importance of making integrity checks before applying full pressure
K37 the generation of maintenance documentation and/or reports on completion of the maintenance activity
K38 the manufacturer's equipment operating and control procedures to be applied during the maintenance activity
K39 how to use lifting and handling equipment in the maintenance activity
K40 the problems that can occur during the maintenance activity, and how they can be overcome
K41 the organisational procedure to be adopted for the safe disposal of waste of all types of materials
K42 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
During the maintenance activity, individuals will:
- plan and communicate the maintenance activities to cause minimal disruption to normal working
- obtain and use the correct issue of company and/or manufacturers' drawings and maintenance documentation as well as the correct version of any maintenance software tools required
- adhere to procedures or systems in place for risk assessment, control of substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- ensure the safe isolation of equipment (such as mechanical, electricity, air or fluids)
- provide and maintain safe access and working arrangements for the maintenance area
- warn others in the maintenance area if they are at risk of injury from the system being tested
- carry out the maintenance activities using appropriate techniques and procedures
- reconnect and return the system to service on completion of the maintenance activities
- dispose of waste items to comply with environmental protection guidelines and ensure the work area remains safe
Appropriate dismantling and re-assembly techniques may be used to deal with the following:
- mechanical components:
- draining and replenishing fluids
- removing major mechanical units (such as gear boxes, pumps, engines)
- removing and refitting locking and retaining devices
- removing minor mechanical units/sub-assemblies (such as guards, structures)
- proofmarking components to aid re-assembly
- setting, aligning and adjusting replaced units
- electrical components:
- isolating power supply
- removing / replacing minor electrical components (such as relays, sensing devices, limit switches)
- disconnecting and reconnecting wires/cables
- removing and replacing major electrical components (such as motors, switch/control gear)
- removing and replacing wiring supports (such as conduit, trunking, traywork, cable ways, looms)
- process controller components:
- de-activating and resetting program controller
- disconnecting/re-connecting wires/cables
- reloading software/programs and making data amendments
- removing and replacing peripherals
- removing and replacing input/output interfacing
Types of fluid power equipment could include:
- pneumatic
- hydraulic
- vacuum
Maintenance activities, as applicable to the equipment being maintained, will include:
- chocking/supporting actuators/rams/component
- releasing stored pressure
- draining, removing and replacing oil/fluids (as appropriate)
- disconnecting/removing hoses, pipes and tubing
- proofmarking/labelling of removed components
- removing and replacing units/components (such as compressors, cylinders, valves, actuators)
- replacing all `lifed' items (seals, filters, gaskets, hoses)
- checking components for serviceability
- replacing damaged/defective components
- setting , aligning and adjusting replaced components
- tightening fastenings to the required torque
- correct fitting of locking devices
- making 'integrity' checks before re-pressurising system
- priming and bleeding the system (where appropriate)
- functional/performance testing of the maintained system
- other specific maintenance activity
Types of fluid power components, on which maintenance activities are carried out to component level, could include:
- pumps
- compressors
- valves
- motors
- actuators
Types of fluid power components replaced/refitted could include the following:
- pumps
- bearings
- compressors
- sensors
- pistons
- reservoirs
- receivers
- lubricators/filters/dryers
- spools
- accumulators
- gaskets and seals
- regulators
- valves
- pipework and hoses
- actuators/cylinders
- switches
- other specific fluid power components
Maintenance activities may need to comply with the following:
- organisational guidelines and codes of practice
- equipment manufacturer's operation range
- BS, ISO and/or BS EN 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:
- job cards
- maintenance log or report
- permit to work/formal risk assessment and/or sign on/off procedures
- company-specific documentation
- electronic records