tdr 100 portfolio report modified
DESCRIPTION
Pneumatic system risk assessment portfolioTRANSCRIPT
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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