| 1 | 1a. Repair/overhaul instrumentation and control equipment | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Carry out all of the following during the repair/overhauling activity: • obtain and use the correct equipment repair/overhauling documentation (such as manuals, drawings, maintenance records) • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment (PPE) and other relevant safety regulations • provide and maintain safe access and working arrangements for the repair/overhauling area • where applicable, ensure that appropriate decontamination procedures are used for instruments that have been used with hazardous (such as toxic, corrosive, inflammable, explosive, radioactive) substances • where appropriate, apply electrostatic discharge (ESD) protection procedures • carry out the repair/overhauling activities, using appropriate techniques and procedures • ensure that the equipment is maintained free from damage and foreign objects • return all tools and equipment to ... |
| 1.3 | ... the correct location on completion of the activities • leave the work area in a clean and safe condition on completion of the activities |
| 1.4 | Carry out the repair/overhauling activities on four of the following types of instrumentation and control equipment: • pressure (such as absolute, gauge, vacuum) • flow (such as orifice plate, venturi tube, electromagnetic, ultrasonic, differential pressure cell, positive displacement) • level (such as floats, displacer, differential pressure cells, load cells, ultrasonic, conductivity) • temperature (such as bi-metallic, thermocouples, resistance, infra-red, thermal imaging) • weight (such as mechanical systems, load cells/strain gauges, transducers) • fiscal metering (such as gas, electricity, water, fuel) • detection and alarm (such as smoke, heat, gas, chemical, water, metal) • speed measurement (such as mechanical, electrical, stroboscopic) • emergency shutdown • speed control (such as mechanical governors, electrical governors, DC speed ... |
| 1.5 | ... controller, AC motor control systems, stepper motors, invertors) • vibration monitoring (such as vibration switches, proximity probes, seismic velocity transducer, linear variable differential transformers, portable data collectors) • nucleonic and radiation (such as Geiger-Muller tube, neutron counter, photomultiplier tube, proportional counter) • analysers (such as gas detection, spectroscopy, oxygen analyser, water analysis, moisture measurement, density) • recorders and indicators • telemetry systems (such as master station, outstation, stand alone systems) • valves and valve mechanisms (such as control valves, valve actuators and positioners) • other specific instrumentation |
| 1.6 | Follow the relevant repair/overhauling schedules to carry out the required work |
| 1.7 | Repair/overhaul instrumentation and control equipment in compliance with one or more of the following: • company standards and procedures • BS, ISO and/or BSEN standards • customer standards and requirements • instrument manufacturer’s requirements |
| 1.8 | Establish and, where appropriate, mark/label components to aid re-assembly |
| 1.9 | Carry out the repair/overhaul to the agreed level, using the correct tools and techniques |
| 2 | 1b. Repair/overhaul instrumentation and control equipment (continued) | 2.1 | Carry out all of the following activities, as applicable to the instrumentation/control equipment being repaired or overhauled: • cleaning parts prior to dismantling • carrying out pre-disassembly checks and tests • disconnecting and/or de-soldering electrical connections • removing cable securing devices • removing bolt securing devices and mechanical fasteners • dismantling equipment to unit/sub-assembly level • dismantling units to component level • marking/labelling of components to aid reassembly • checking components for serviceability • replacing all ‘lifed’ items (such as seals, gaskets, batteries) • replacing all damaged or defective components • reassembling equipment • making mechanical connections (such as pipes) • making electrical connections (such as crimping, soldering, heat shrinking) • setting and adjusting/calibrating replaced ... |
| 2.2 | ... components • securing components by using mechanical fasteners and threaded devices • applying locking and retaining devices (such as circlips, pins, wire locking, cable securing devices) |
| 2.3 | Ensure that all removed components are correctly identified and stored in the correct location |
| 2.4 | Replace a range of instrumentation components, to include eight of the following: • printed circuit boards/electronic cards • electronic modules • relays • electronic components (such as resistors, capacitors diodes) • transmitters • transducers • load cells • thermocouples • wires/cables • plugs/sockets/terminations • switches (such as limit, proximity) • gaskets/seals • bellows • diaphragms or discs • bourdon tubes • actuators or actuator components (such as pistons, springs, glands linkages) • valves or valve components (such as glands, spindles, seats) • pipework/pipework components • other specific components |
| 2.5 | Carry out checks on the serviced/overhauled instruments, to include four of the following: • visual inspection of the instrument for completeness and freedom from damage or foreign objects • checking security of all mechanical connections • checking integrity of all electrical connectors • standard serviceability test • operational/function checks |
| 2.6 | Report any instances where the repair/overhauling activities cannot be fully met, or where there are identified defects outside the planned repair/overhauling schedule |
| 2.7 | Complete the relevant documentation, in accordance with organisational requirements |
| 2.8 | Dispose of unwanted components, waste materials and substances, in accordance with safe working practices approved procedures |
| 2.9 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to repair/overhaul instrumentation and control equipment | 3.1 | Describe the safe working practices and procedures and the specific safety precautions to be taken when repairing/overhauling instrumentation and control equipment (to include wearing protective clothing and equipment; decontamination procedures for the instruments being repaired/overhauled; lifting and handling techniques; safe working practices, procedures and guidelines which satisfy current regulations such as HASAWA, COSHH and other work related legislation and guidelines) |
| 3.2 | Describe the hazards associated with repairing/overhauling instrumentation and control equipment, and with the tools and equipment used, and how to minimise them and reduce any risks |
| 3.3 | Describe the protective equipment that they need to use for both personal protection and protection of the instrumentation and control equipment being repaired |
| 3.4 | Explain how to extract and use information from equipment manuals, history/maintenance reports, charts, circuit and physical layouts, specifications, symbols used in instrumentation and control circuits, and other documents needed in the repair/overhaul process |
| 3.5 | Describe the terminology used with instrumentation and control equipment, and the use of system diagrams and associated symbols |
| 3.6 | Describe the basic principles of operation of the instrumentation and control equipment being repaired/overhauled, and the performance characteristics and function of the components within the equipment |
| 3.7 | Describe the techniques used to remove components from the instrumentation and control equipment without damage to the components or surrounding structure (such as de-soldering components, applying electrostatic discharge (ESD) protection procedures) |
| 3.8 | Describe the various types of electrical connector that are used, their methods of unlocking, orientation indicators and locating and locking-in of the connections |
| 3.9 | Describe the various mechanical fasteners that are used, and their methods of removal and replacement (such as threaded fasteners, special securing devices) |
| 3.10 | Describe the importance of using the specified components for the particular instrument, and why they must not substitute others |
| 3.11 | Describe the need to label and store components correctly, and to check that replaced components have the correct part/identification markings |
| 4 | 2b. Know how to repair/overhaul instrumentation and control equipment (continued) | 4.1 | Describe the procedure for obtaining replacement parts, materials and other consumables necessary for the repair/overhaul |
| 4.2 | Describe the techniques used to position, align, adjust and secure the replaced components to the equipment without damage to the components or surrounding structure |
| 4.3 | Describe the quality control procedures to be followed during the repair/overhauling operations |
| 4.4 | Describe the procedures for ensuring that they have the correct tools, equipment, components and fasteners for the activities |
| 4.5 | Explain how to conduct checks of the instruments to ensure the integrity, accuracy and quality of the repair/overhaul |
| 4.6 | Describe the problems that can occur with the repair/overhauling operations, and how these can be overcome |
| 4.7 | Explain how to recognise defects (such as poor seals, misalignment, incorrectly seated plugs and sockets, ineffective fasteners, foreign object damage or contamination) |
| 4.8 | Describe the recording documentation to be completed for the activities undertaken |
| 4.9 | Describe the procedure for the safe disposal of waste materials and scrap components |
| 4.10 | Describe the extent of their own responsibility, and to whom they should report if they have problems that they cannot resolve |
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