Carry out preventative planned maintenance on traction and rolling stock systems
Overview
This standard identifies the competencies you need to carry out preventative planned maintenance activities on traction and rolling stock systems, in accordance with approved procedures. You will be required to carry out the maintenance activities on traction and rolling stock systems involving at least two of the following interactive technologies: mechanical, electrical, fluid power, process controller or communications-electronic systems. You will need to organise and carry out maintenance activities to minimise downtime and ensure that the maintained system performs at optimal levels and functions to the required specifications. 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).
Your responsibilities will require you to comply with organisational policy and procedures for the maintenance activities undertaken and to report any problems with the maintenance activities, tools or equipment used 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 maintenance activities are removed from the work area on completion of the work and that all necessary maintenance documentation is completed accurately and legibly.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying planned maintenance procedures within a traction and rolling stock system. You will know about the integrated technologies within the system, how the system functions, and potential problems or defects that may occur. You will understand the process of developing planned maintenance, and its application, and will know about the maintenance criteria, in adequate depth to provide a sound basis for carrying out the activities safely and effectively, and for ensuring that the system is maintained to the required specification and remains compliant with all standards and regulations. In addition, you will be expected to report where the outcome of the maintenance activity identifies the need for further investigation or maintenance work.
You will understand the safety precautions required when carrying out maintenance activities, especially those for isolating the equipment and taking the necessary safeguards to protect yourself and others in the workplace. 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 system maintenance schedules to carry out the required work
P3 carry out the system maintenance activities within the limits of your personal authority
P4 carry out the system 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 system 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 maintained (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 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 it may be obtained
K8 the hazards associated with carrying out maintenance activities on an integrated system (handling fluids, stored pressure/force, electrical supplies, process controller interface, using damaged or ill-maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks
K9 the procedures and precautions to be adopted to eliminate electrostatic discharge (ESD) hazards when working with and handling electronic devices
K10 how to obtain and interpret drawings, charts, specifications, manufacturers' manuals, history/maintenance reports and other documents needed for the maintenance activities
K11 the various planned maintenance schedules that are used (such as condition based maintenance, scheduled maintenance, and total preventative maintenance (TPM))
K12 the principles of how the system functions, its operation sequence, the working purpose of individual units/components, and how they interact with each other such as ETCS, AWS, or TPWS
K13 the equipment operating and control procedures, and how to apply them in order to carry out the planned maintenance activities
K14 the testing methods and procedures to be used to check that the system conforms to acceptable limits
K15 how to make sensory checks by sight, sound, smell, touch
K16 the procedure for obtaining consumables and 'lifed' items that will require replacing during the maintenance activity
K17 the maintenance requirements for 'lifed', consumable and on condition components
K18 company policy on repair/replacement of components during the maintenance activities
K19 methods of checking that components are fit for purpose, and the need to replace `lifed' items such as batteries, filters, seals, gaskets, belts, chains and bearings
K20 the importance of recording the serial numbers of removed and newly fitted components affecting the rolling stock asset tree
K21 how to make adjustments to components and assemblies
K22 the different types of bearings that are used and their care, handling and maintenance requirements
K23 the torque loading and locking devices requirements for the maintained components
K24 the generation of maintenance documentation and/or reports on completion of the maintenance activity
K25 the problems that can occur during the planned maintenance activity, and how they can be overcome
K26 the organisational procedure to be adopted for the safe disposal of waste of all types of materials
K27 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 activities, 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
Types of interactive technologies, on which maintenance is carried out to sub-assembly/component level, can include:
- mechanical
- fluid power
- electrical
- process control
- communication-electronics
Types of maintenance schedules could include:
- condition based maintenance
- total preventative maintenance (TPM)
- scheduled maintenance
- preventative planned maintenance
Planned maintenance activities can include:
- visual examination and testing of the system against the maintenance schedule
- removing excessive dirt and grime
- checking operation of all gauges and sensors
- monitoring component condition/deterioration
- checking condition of fans, belts, bearings, seals
- making sensory checks (such as sight, sound, smell, touch)
- making routine adjustments
- carrying out leak checks on all connections
- replacing `lifed' consumables (such as batteries, filters, fluids)
- checking the torque loading of fasteners and the condition of locking devices
- checking or updating stored data
- updating software
- testing and reviewing system operation
- carrying out system self-analysis checks
- recording the results of the maintenance activity and reporting any defects found
- other specific maintenance activity
- monitoring for signs of water ingress and the effects of verdigris, where applicable
Maintained equipment/system checks can help verify that:
- all maintenance activities have been completed to the required schedule
- equipment operates within acceptable limits for successful continuous operation to meet output specification
- equipment remains compliant with appropriate regulations and safety requirements
- any potential defects are identified and reported for future action
Maintenance activities may need to be completed in accordance 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:
- job cards
- permit to work/formal risk assessment and/or sign on/off procedures
- maintenance log or report
- company-specific documentation
- electronic records