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Maintaining Pneumatic Process Controllers

Maintaining Pneumatic Process Controllers

The selected actuator MUST be a Spring Return of a similar specification and complexity to that of the example.

The Examiner will provide the candidate with a full set of spares to allow a complete overhaul of the actuator.

The Examiner should make available a range of tube connectors for the candidate to select for the function test of the actuator following overhaul.

The Examiner should make available a number of service supplies from with the candidates shall be required to select a suitable test medium to function check the operation of the actuator following overhaul.

The Examiner should make available to the Candidate a copy  of a selection of vendor installation and commissioning  manuals from which the candidate will need to select the appropriate one for the test.

Technical Assessment – The candidate is required to inspect and overhaul a Spring Return Actuator. The candidate must fit a new set of seals to the actuator and complete the activity with a function check of the refurbished actuator.

Objective - To ensure a candidate has the skills, knowledge and ability to overhaul a typical pneumatic 1actuator in line with safe working practice. They must demonstrate an understanding of the dangers associated with working on equipment under tension as well as how to determine the condition of materials to ensure correct operation of equipment in line with specifications. The candidate will also be required to demonstrate skills and knowledge to facilitate a function check on the actuator to operational specification.
The candidate will have to demonstrate they can work safely whilst working on the actuator using appropriate methods and techniques

Technical Assessment Requirements

Range of screwdrivers of various size and types (flat, crosshead and Phillips)
Range of spanners (open ended, combined and ring)
Range of Allen keys (Metric & Imperial)
Strap Wrench
Hide Hammers
Operational Double Acting Pneumatic Actuator (see MPS07 Drawing)
Spare set of seals and springs for selected actuator
Lubrication Grease (if specified by manufacturer)
Tension Release Equipment (Actuator Vendor Specific)
Air Service Supply
Air Pressure Regulator and Gauge
Selection of suitable hose and pressure fittings
Selection of Pneumatic Actuator Vendor Manuals (Installation and Commissioning)
Personal Protective Equipment
Examiner instructions
Model Answer Sheet
Candidate instructions
Candidate Question Paper
Examiner Results Report

The candidate must overhaul the actuator following vendor procedures and drawings to meet the specifications. The designed test area must have good lighting and be away from any production area. The operational condition of the actuator will be fundamental in the Examiners judgement on the candidate’s ability to PASS the test.

The candidate is expected to complete the test, being observed using correct tools and equipment to complete the overhaul and using safe working practices to achieve a ‘PASS’. Where the candidate does not achieve the set criteria this is recorded as ‘REFERRED’ and a brief note recorded on the criteria not met in the test activity.

The candidate must record a PASS in all practical test sections and score a minimum of 80% in the multiple choice section.