necc

PORTFOLIO REPORTCandidates name: Jamie Middleton

Description of job: Carrying out Maintenance, fault finding and repair on a pneumatic fluid power system on Pneumate 200Date: 10-06-15

Job Risk AssessmentHazard table tick as necessary

Preventative measuresAFalling

BTripping/ Slipping

Pressure drained to ensure safety of those around system to allow work carried outCTrapping

Personal protection required as a last resort from any given risk in the working areaDFlying Particles

Relieve the pressure before powering the system.EFire/ Flammable Atmosphere

Ensure all of the actuators have been relieved of pressure before inspecting/ working on the machine in case the excessive pressure makes the actuator move unexpectedly.FOxygen Enrichment

Check the condition of the hoses for excessive wear, rips and broken seals.GCollapse

HOverturning

IElectric Shock

JMoving Machinery/ Parts

KMoving Vehicles

LDrowning

MNoise

NAsphyxiation

OBurns

PBurning/ Explosion Risk

QVibration

ROxygen Depletion

SProtruding Objects/ Parts

TSubstances/ Fumes/ Dusts

UOther

Pneumate200 Practical Assessment

Activity:TDRPneuA103 Control of a double acting cylinder with double valve

Objectives: Understand the constructive and operational differences between the single and the double air pilot valves.Understand the operation of the double valve as a memory element

Description: - A double acting cylinder will move operated by the air pilot power 5/2 way double valve.- Two push-button operated 3/2 way valves will give the corresponding signals to energise the double valve in both directions so that the cylinder can move.- The cylinder will extend when pressing the first push-button M1 and will return to the starting position when pressing the second push-button M2.- Without pressing any push-button, the cylinder will maintain its last position.

Materials used:1 double acting cylinder with auto switches1 3/2 way NC valve operated by push-button1 air pilot 5/2 way double valve

Solution A

Instructions and documentation for job (attach any documentation and photographs to continuation sheet)Photo

Circuit diagram

Instructions/documentation provided by instructor

Test equipment

tools

Preparation of materials and working areasPower off?I ensured the power was isolated.

Drained?I made sure the pressure was drained.

Persons at risk briefed?I briefed anyone I was working with to meet all health and safety requirements.

Quality of spares tools etcI checked all parts and spares so that they were fit for use and in good working condition.

Progression of the job (what was done, methods used, who worked with, etc.)When I started the system up I noticed there was no pneumatic power running. I checked the compressor and it was running. I then checked the actuators and the valves, which were all piped up correctly. Through this trial and error, I deducted this was down to the hoses. After going through all the hoses, I found the fault. I retrieved another hose from stores and re-piped the valve, which I found rectified the issue.

My next course of action was to check the electrical, to which I discovered a bad connection to a number of wires. I changed these faulty wires and the electrics worked as normal.

Then, I tested the system to make sure it was back into working order. I gave it a visual

check to make sure everything was connected correctly and also to ensure there were no

health risks.

After I carried out all the tests I had to return the area back to its original state by cleaning the area and returning all the tools to where they belonged.

If you noticed a tool was broken then you should make a note of the broken tool and replace it as soon as possible in case this occurs again and you need that job specific tool.

Conclusion: After I corrected all the known problems, I powered up the system to make sure

it was fully functioning

All documentation such as before stated image and circuit diagram was provided before

the jobs inception. A full safety brief was given.

Quality checks (monitoring and checking at all stages of the production)Isolate the machine before working on it.

Make sure the working area is clean and tidy.

Start with sense checks, i.e. Visual, auditory, touch etc.

Problems encountered during job and how solvedNo pneumatic power.

No electrical power.

Badly connected hoses.

Completion (Return of materials and tools, tidying of area, removal of surplus materials and waste)Exercise good housekeeping and set a good example by cleaning up the work area once

youve finished you work.

Inform your superiors that you have finished the job.

Completed a maintenance log.

Trainee Signature:Date:

Iaaued: 18/08/09TDR 100Revision No: 1T/Tdr/Quality/FormsPage 2 of 5