1

Identify scope of fluid power related systems installation

1.1

Review machine and equipment drawings, manufacturer manuals and other technical data for fluid power systems specifications

1.2

Determine performance and production requirements expected from fluid power equipment

1.3

Determine if any commissioning or modification of fluid power systems are required to ensure production requirements are met

1.4

Determine relevant regulatory requirements

1.5

Inspect site and equipment to confirm or determine suitability, availability of other services and control requirements

1.6

Produce or review fluid power management schedule, including any required installation, commissioning, modification or maintenance requirements

2

Brief team on fluid power work requirements

2.1

Distribute and discuss drawings, schedules, and major materials and equipment with team

2.2

Arrange for request for further information (RFIs) with designers, where required

2.3

Brief team on key compliance and risk factors, including regulatory, occupational health and safety (OHS) and environmental requirements

2.4

Agree with team on critical control points and reporting requirements

3

Commence installation, commissioning, modification or maintenance tasks

3.1

Supervise machine and equipment shutdowns required for task

3.2

Confirm availability of equipment components and materials for scheduled fluid power tasks

3.3

Check and determine that supply of services to work are adequate for task commencement

3.4

Ensure all tradespersons have correct drawings

4

Monitor progress and deal with contingencies

4.1

Establish procedures to ensure assembly and connections are against drawing specifications

4.2

Ensure electrical, fluid power and control systems and circuits are consistent with specifications and regulations

4.3

Identify problems and contingencies and establish and rectify root cause

5

Finalise fluid power installation, commissioning, modification or maintenance tasks

5.1

Conduct final check to ensure completed work is consistent with drawings, manufacturer manuals and any regulatory requirements

5.2

Conduct test run of equipment and system

5.3

Identify and correct any malfunctions or errors in required output

6

Conduct handover and finalise documentation

6.1

Brief client and operators on machine or equipment operation after installation

6.2

Prepare and submit any required reports on installation, commissioning or modification

Required skills

Required skills include:

performing responsibilities in priority order in accordance with implementation schedules

investigating and validating performance analysis, modelling and simulation software

interpreting fluid power design and detailed drawings

identifying sustainability and environmental issues and implications for the fluid power system

selecting and using software and validation techniques, including 2-D and 3-D modelling

identifying situations and issues that require additional technical or professional assistance

evaluating solutions for feasibility against the installation, commissioning, modification or maintenance criteria, including relevant engineering and financial calculations and analysis

establishing budget and control measures for team, and incorporating within installation, commissioning or modification project control plan

delegating roles, responsibilities and levels of authority, as appropriate, to team members

communicating, negotiating and reviewing with stakeholders and team members throughout duration of installation, commissioning or modification project

Required knowledge

Required knowledge includes:

current options and trends in fluid power modelling and simulation software, including underpinning programme techniques and software validation techniques

research and investigations methods

principles of fluid power systems

dimensions, capacity and position of system components

electrical and mechanical behaviours of fluid power systems and system responsiveness

hydraulics and hydraulics components

applications and characteristics of servo valves

electronic controllers for proportional and servo valves

sensor/transducer/amplifiers:

pneumatics and designing with pneumatic components

multiple actuator control circuits

compressed air system design

OHS and regulatory requirements, codes of practice, standards, risk minimisation and registration requirements

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently:

interpret plans, specifications and other documentation to determine features and performance characteristics and requirements of fluid power systems

advise other technicians, tradespersons and production personnel on fluid power installation, modification, commissioning, operation and maintenance

determine adequacy of standard operating procedures for fluid power systems and adjust, if required

check fluid power systems for safe operation, including automation safety

determine situations that require other technical and professional assistance

research sustainability implications and current industrial design techniques

determine OHS, regulatory and risk management requirements.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is, the candidate is not in productive work, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Sustainability

Sustainability may include:

resources and energy

social and economic

life cycle design of product raw material, solids and hazardous waste, and production by-products

contamination of land, air and stormwater pollutants, and discharge to sewerage

climate change

Appropriate software

Appropriate software may include software for:

computer-aided design (CAD)

circuit design and analysis

animation

simulation

modelling

performance analysis

Validation techniques

Validation techniques include:

comparison of traditional solutions for simple design problems with software solutions to the same design problems

review of previously implemented designs which were completed using the software

use of failure modes and effects analysis (FMEA)

Fluid power related technologies

Fluid power related technologies refers to:

hydraulic and pneumatic systems used for industrial and mobile equipment applications

Fluid power system maintenance

Fluid power systems maintenance refers to maintenance fluid power systems for fitness for purpose and includes:

safety and integrity of the system

adequacy and correct operations of controls

automation safety

adequacy of standard operating procedures for users

safe integration with mechanical and electrical equipment

OHS requirements

OHS requirements may include:

OHS Acts and regulations

relevant standards

industry codes of practice

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements

Standards

Standards may include:

AS 4024.1-2006 Series Safety of machinery

AS/NZS ISO 31000:2009 Risk management – Principles and guidelines

NOHSC:1010 National standard for plant

NOHSC:1014 National standard for the control of major hazard facilities

AS 61508.1-2011 Functional safety of electrical/electronic/programmable electronic safety-related systems – General requirements

Sequence and mode control methods for multi-actuator circuit

Sequence may include:

sequential operations with or without conditional jumps

optimisation techniques

functions such as:

timing, counting, stop start, cycle selection and boundary conditions

Control methods may include:

pneumatic and electrical relay cascade control.

pneumatic and electrical relay step-sequenced control

PLC control

microcontrollers for special purpose machines

Stand alone and network control

Options for stand alone and network control of fluid power systems may include:

compressor control and application control

fluid powered machine control, includingproportional-integral-derivative (PID) parameter control from remote host controller

communications bus systems, serial systems

distributed control systems (DCS)

system control and data acquisition (SCADA)

computer-interated manufacture (CIM) options