Level 2 Certificate in Engineering (2800) - OneFile · progression in the Engineering sector contribute to the knowledge and understanding towards the related Level 2 NVQ in Performing

Level 2 Certificate in Engineering (2800) Qualification handbook 500/1726/3 Manufacturing Technology Maintenance Technology Fabrication and Welding Technology Materials Processing Technology Electrical Technology Electronics Technology Gas Operations Electricity Operations

www.cityandguilds.com October 2008 Version 5.1

About City & Guilds City & Guilds is the UK’s leading provider of vocational qualifications, offering over 500 awards across a wide range of industries, and progressing from entry level to the highest levels of professional achievement. With over 8500 centres in 100 countries, City & Guilds is recognised by employers worldwide for providing qualifications that offer proof of the skills they need to get the job done. City & Guilds Group The City & Guilds Group includes ILM (the Institute of Leadership & Management) providing management qualifications, learning materials and membership services and NPTC which offers land-based qualifications and membership services. City & Guilds also manages the Engineering Council Examinations on behalf of the Engineering Council. Equal opportunities City & Guilds fully supports the principle of equal opportunities and we are committed to satisfying this principle in all our activities and published material. A copy of our equal opportunities policy statement Access to assessment and qualifications is available on the City & Guilds website. Copyright The content of this document is, unless otherwise indicated, © The City and Guilds of London Institute 2005 and may not be copied, reproduced or distributed without prior written consent. However, approved City & Guilds centres and learners studying for City & Guilds qualifications may photocopy this document free of charge and/or include a locked PDF version of it on centre intranets on the following conditions:

• centre staff may copy the material only for the purpose of teaching learners working towards a City & Guilds qualification, or for internal administration purposes

• learners may copy the material only for their own use when working towards a City & Guilds qualification

• the Standard Copying Conditions on the City & Guilds website. Please note: National Occupational Standards are not © The City and Guilds of London Institute. Please check the conditions upon which they may be copied with the relevant Sector Skills Council. Publications City & Guilds publications are available on the City & Guilds website or from our Publications Sales department at the address below or by telephoning +44 (0)20 7294 2850 or faxing +44 (0)20 7294 3387. Every effort has been made to ensure that the information contained in this publication is true and correct at the time of going to press. However, City & Guilds’ products and services are subject to continuous development and improvement and the right is reserved to change products and services from time to time. City & Guilds cannot accept liability for loss or damage arising from the use of information in this publication. City & Guilds 1 Giltspur Street London EC1A 9DD T +44 (0)20 7294 2800 www.cityandguilds.com F +44 (0)20 7294 2400 [email protected]

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Level 2 Certificate in Engineering (2800) Qualification handbook

www.cityandguilds.com October 2008 Version 5.1

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Contents

1 About this document 9 2 About the qualification 10 3 Candidate entry and progression 16 4 Course design and delivery 23 5 Assessment 26 Unit 701 Working in Engineering 29 Unit 702 Engineering Technology 42 Unit 703 Manufacturing Technology 51 Unit 704 Machining by Milling 56 Unit 705 Machining by Turning 62 Unit 706 Machining by Grinding 69 Unit 707 Using Bench Fitting Techniques 77 Unit 708 Using Computer Aided Manufacturing Processes 85 Unit 709 Maintenance Technology 91 Unit 710 Assembling and Maintaining Hydraulic Systems 102 Unit 711 Assembling and Maintaining Pneumatic Systems 112 Unit 712 Maintaining Mechanical Devices and Equipment 121 Unit 713 Maintaining and testing Electrical Circuits 132 Unit 714 Installing and Maintaining Electrical Wiring Support Systems 141 Unit 715 Maintaining Instrumentation and Control Systems 149 Unit 716 Fabrication and Welding Technology 161 Unit 717 Welding by Manual metal arc process 172 Unit 718 Welding by MIG process 180 Unit 719 Welding by TIG process 189 Unit 720 Welding by Oxy-acetylene process 199 Unit 721 Fabricating Sheet metalwork 206 Unit 722 Fabricating thick plate, bar and sections 214 Unit 723 Fabricating pipework assemblies 223 Unit 724 Fabricating steelwork assemblies 232 Unit 725 Materials Processing Technology 240 Unit 726 Using wood for engineering activities 247 Unit 727 Hand forging engineering materials 257 Unit 728 Heat treating engineering materials 265 Unit 729 Finishing surfaces by applying coatings/treatments 273 Unit 730 Preparing sand moulds and core for casting 280 Unit 731 Producing Composite Assemblies 289

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Unit 732 Producing Composite Moldings 299 Unit 733 Electrical Technology 310 Unit 734 Maintaining Electrical Equipment and Systems 317 Unit 735 Wiring and testing Electrical Circuits 325 Unit 736 Installing and Maintaining Electrical Wiring Support Systems 332 Unit 737 Working with Instrumentation and control systems 343 Unit 738 Installing PLC based control systems 349 Unit 739 Producing Electrical/ Electronic Drawings using CAD 357 Unit 740 Customer Service Principles 365 Unit 741 Gas Operations Technology 369 Unit 742 Gas Technology Installations & Relationships 380 Unit 743 Understanding the Power Business Operations 389 Unit 744 Understanding Power Technology Operations 398 Appendix 1 Connections to NVQs and other qualifications 403 Appendix 2 Funding 403


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1 About this document This document contains the information that centres need to offer the following certificate: Level 2 Certificate in Engineering City & Guilds qualification number 2800 QCA accreditation number 500/1726/3 This document includes details and guidance on:

• centre resource requirements • candidate entry requirements • information about links with, and progression to, other qualifications • qualification standards and specifications • assessment requirements

• evidence recording forms.

2 About the qualification 2.1 Aim of the qualification

This vocationally related qualification has been designed by City & Guilds in order to: meet the needs of candidates who work or want to work in the Engineering sector support Government initiatives towards the National Qualifications Framework (NQF). For further information on the NQF, visit the QCA websites www.qca.org.uk and www.openquals.org.uk allow candidates to learn, develop and practice the skills required for employment and/or career progression in the Engineering sector contribute to the knowledge and understanding towards the related Level 2 NVQ in Performing Engineering Operations, whilst containing additional skills and knowledge which go beyond the scope of the NOS. replace the City & Guilds Level 2 Progression Award in Appling Engineering Principles. This qualification functions as a stand alone qualification, accredited as part of the NQF at Level 2 as a technical certificate as part of the Apprenticeship framework

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2 About the qualification 2.2 The structure of the qualification

The following certificate will be awarded to successful candidates on completion of the required combinations of units. Candidates completing one or more units, rather than the full qualification, will receive a Certificate of Unit Credit (CUC). To gain the full 2800 Level 2 Certificate in Engineering, candidates will be required to successfully complete five units under their chosen pathway. The following pathways are available: Manufacturing Technology Maintenance Technology Fabrication and Welding Technology Materials Processing Technology Electrical Technology Electronics Technology To gain the full award candidates must take both mandatory units 701 - Working in Engineering 702 – Engineering Technology They must also take an additional three units, one of which must be a technology unit 703 – Manufacturing Technology or 709 – Maintenance Technology or 716 – Fabrication and Welding Technology or 725 – Materials Processing Technology or 733 – Electrical / Electronics Technology Of the final two units one must relate to their chosen technology pathway, the other is a ‘free choice’ option that may or may not be from their chosen pathway. The pathways are as follows: 701 Working in Engineering (Compulsory) 702 Engineering Technology (Compulsory) 703 Manufacturing Technology 704 Machining by Milling 705 Machining by Turning 706 Machining by Grinding 707 Using Bench Fitting Techniques

708 Using Computer Aided Manufacturing Processes 709 Maintenance Technology 710 Assembling and Maintaining Hydraulic Systems 711 Assembling and Maintaining Pneumatic Systems 712 Maintaining Mechanical Devices and Equipment 713 Maintaining and testing Electrical Circuits 714 Installing and Maintaining Electrical Wiring Support Systems 715 Maintaining Instrumentation and Control Systems 716 Fabrication and Welding Technology 717 Welding by Manual metal arc process 718 Welding by MIG process 719 Welding by TIG process 720 Welding by Oxy-acetylene process 721 Fabricating Sheet metalwork 722 Fabricating thick plate, bar and sections 723 Fabricating pipework assemblies 724 Fabricating steelwork assemblies 725 Materials Processing Technology 726 Using wood for engineering activities 727 Hand forging engineering materials 728 Heat treating engineering materials 729 Finishing surfaces by applying coatings/treatments 730 Preparing sand moulds and core for casting 731 Producing Composite Assemblies 732 Producing Composite Moldings 733 Electrical Technology 734 Maintaining Electrical Equipment and Systems 735 Wiring and testing Electrical Circuits 714 Installing and Maintaining Electrical Wiring Support Systems 739 Producing Electrical or Electronic Drawings using CAD 733 Electronics Technology 736 Building and Testing Electronics Circuits 737 Working with Instrumentation and Control Systems 715 Maintaining Instrumentation and Control Systems 738 Installing PLC based Control Systems 739 Producing Electrical or Electronic Drawings using CAD

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In addition there are two further pathways; Gas Operations Electricity Operations Each pathway contains 5 compulsory units.

Gas Operations 701 Working in Engineering 702 Engineering Technology 740 Customer Services Principles 741 Operations Technology 742 Gas Technology Installations & Relationships Electricity Operations 701 Working in Engineering 702 Engineering Technology 740 Customer Services Principles 743 Understanding the Power Business Operations 744 Understanding Power Technology Operations

2 About the qualification There are City & Guilds documents which contain general information on City & Guilds qualifications:

• Providing City & Guilds qualifications – a guide to centre and qualification (scheme) approval: This document contains detailed information about the processes which must be followed and requirements which must be met for a centre to achieve ‘approved centre’ status, or to offer a particular qualification.

• Ensuring quality – This document contains updates on City & Guilds assessment and policy issues.

• Centre toolkit – This document contains additional information on Providing City & Guilds qualifications, in a CD-ROM, which links to the internet for access to the latest documents, reference materials and templates

• Directory of qualifications – This document contains details of general regulations, registration and certification procedures and fees. This information also appears on the Walled Garden, the online qualification administration service for City & Guilds approved centres. If there are any differences between the Directory of qualifications and this handbook, the Directory of qualifications contains the more up-to-date information.

For the latest updates on our publications and details of how to obtain them and other City & Guilds resources, please refer to the City & Guilds website.

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City & Guilds websites Website Address Purpose and content

City & Guilds main website

www.cityandguilds.com This is the main website for finding out about City & Guilds qualifications. It contains qualification documentation and updates.

SmartScreen www.smartscreen.co.uk SmartScreen is the City & Guilds online learning support website. It gives registered subscribers access to qualification-specific support materials.

Walled Garden www.walled-garden.com The Walled Garden is a qualification administration portal for approved centres, enabling them to register candidates and claim certification online.

3 Candidate entry and progression

Candidate entry requirements There are no formal entry requirements for candidates undertaking this qualification. However, centres must ensure that candidates have the potential and opportunity to be successful in gaining their qualification. Please note that for funding purposes, candidates should not be entered for a qualification of the same type, content and level as that of a qualification they already hold.

Age restrictions and legal considerations There are no age limits attached to candidates undertaking the qualification unless this is a legal requirement of the process or the environment.

Progression The qualification provides knowledge and practical skills related to the NVQ in Performing Engineering Operations On completion of this qualification candidates may progress into employment or to the following City & Guilds qualifications: Level 3 2800 Certificate in Engineering

Apprenticeship frameworks The Level 2 Certificate in Engineering has been approved by SEMTA as a technical certificate for the Apprenticeship in Engineering in England. Full details of the requirements of the apprenticeship framework for the Engineering Sector are available from: Name of SSC SEMTA Address 14 Upton Road, Watford, WD17 0JT Telephone 01923 238441 Fax 01923 256086 URL http://www.semta.org.uk/

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3 Candidate entry and progression 3.1 Obtaining centre and qualification approval

Only approved organisations can offer City & Guilds qualifications. Organisations approved by City & Guilds are referred to as centres. Centres must meet a set of quality criteria including:

• provision of adequate resources, both physical and human • clear management information systems • effective assessment and quality assurance procedures including candidate support and

reliable recording systems. An organisation that has not previously offered City & Guilds qualifications must apply for approval to become a centre. This is known as the centre approval process (CAP). Centres also need approval to offer a specific qualification. This is known as the qualification approval process (QAP), (previously known as scheme approval). In order to offer this qualification, organisations which are not already City & Guilds centres must apply for centre and qualification approval at the same time. Existing City & Guilds centres will only need to apply for qualification approval for this [these] particular qualification[s]. Full details of the procedures and forms for applying for centre and qualification approval are given in Providing City & Guilds qualifications - a guide to centre and qualification (scheme) approval, which is also available on the City & Guilds centre toolkit, or downloadable from the City & Guilds website. Regional offices will support new centres and appoint a Quality Systems Consultant to guide the centre through the approval process. They will also provide details of the fees applicable for approvals. Assessments must not be undertaken until qualification approval has been obtained. City & Guilds reserves the right to withdraw qualification or centre approval for reasons of debt, malpractice or non-compliance with City & Guilds’ policies, regulations, requirements, procedures and guidelines, or for any reason that may be detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. Further details of the reasons for suspension and withdrawal of approval, procedures and timescales, are contained in Providing City & Guilds qualifications.

Fast track approval Centres approved to offer the qualification 6983 Progression award in Applying Engineering Principles will be given automatic approval to run the new [Level 2 Certificate in Engineering (2800).

3 Candidate entry and progression 3.2 Approval for global online assessment (GOLA)

The two compulsory units 701, 702 are assessed by global online assessment (GOLA). In addition to obtaining centre and qualification approval, centres are also required to set up a GOLA profile in order to offer online examinations to candidates. Setting up a GOLA profile is a simple process that need only be completed once by the centre. Details of how to set up the profile and GOLA technical requirements are available on the City & Guilds website (www.cityandguilds.com /e-assessment). The GOLA section of the website also has details of the GOLA helpline for technical queries and downloads for centres and candidates about GOLA examinations. Centres should also refer to Providing City & Guilds qualifications - a guide to centre and qualification (scheme) approval for further information on GOLA.

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3 Candidate entry and progression 3.3 Resource requirements

Physical resources Centres must have access to sufficient equipment in the centre or workplace to ensure candidates have the opportunity to cover all of the practical activities. It is acceptable for centres to use specially designated areas within a centre for some of the units, for example to assess the installation of specialised electrical systems, alignment and setting up of electric motors and driven devices (pumps, compressors, generators).

Centre staff Centre staff must satisfy the requirements for occupational expertise for this [these] qualification[s]. These requirements are as follows:

• Staff should be technically competent in the areas for which they are delivering training and/ or should also have experience of providing training.

Assessor and verifier requirements While the Assessor/Verifier (A/V) units are valued as qualifications for centre staff, they are not currently a requirement for the qualification[s]. Continuing professional development (CPD) Centres are expected to support their staff in ensuring that their knowledge of the occupational area and of best practice in delivery, mentoring, assessment and verification remains current, and takes account of any national or legislative developments.

3 Candidate entry and progression 3.4 Registration and certification

Full details of City & Guilds’ administrative procedures for this qualification are provided in the Directory of qualifications, provided online to City & Guilds registered centres via the Walled Garden. This information includes details on:

• registration procedures • enrolment numbers • fees • entry for examinations • claiming certification. These details are also available in the Directory of qualifications. Centres should be aware of time constraints regarding the registration and certification periods for the qualification, as specified in the City & Guilds Directory of qualifications. Centres should follow all guidance carefully, particularly noting that fees, registration and certification end dates for the qualification are subject to change.

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3 Candidate entry and progression 3.5 Quality assurance

Internal quality assurance Approved centres must have effective quality assurance systems to ensure optimum delivery and assessment of qualifications. Quality assurance includes initial centre approval, qualification approval and the centre’s own internal procedures for monitoring quality. Centres are responsible for internal quality assurance, and City & Guilds is responsible for external quality assurance. National standards and rigorous quality assurance are maintained by the use of:

• City & Guilds online examinations • City & Guilds assignments, marked by the centre according to externally set marking criteria • internal (centre) quality assurance • City & Guilds external verification. To meet the quality assurance criteria for this qualification, the centre must ensure that the following internal roles are undertaken:

• assessor • internal verifier/moderator Full details and guidance on the internal and external quality assurance requirements and procedures, are provided in Providing City & Guilds qualifications and in the Centre toolkit together with full details of the tasks, activities and responsibilities of quality assurance staff. In order to fully support candidates, centres are required to retain copies of candidates’ assessment records for three years after certification.

External quality assurance External verifiers are appointed by City & Guilds to approve centres, and to monitor the assessment and internal quality assurance carried out by centres. External verification is carried out to ensure that assessment is valid and reliable, and that there is good assessment practice in centres. To carry out their quality assurance role, external verifiers/moderators must have appropriate occupational and verifying knowledge and expertise. City & Guilds external verifiers attend training and development designed to keep them up-to-date, to facilitate standardisation between verifiers and to share good practice. External verifiers: The role of the external verifier is to:

• provide advice and support to centre staff • ensure the quality and consistency of assessments within and between centres by the use of

systematic sampling

• regularly visit centres to ensure they continue to meet the centre and qualification approval criteria

• provide feedback to centres and to City & Guilds External quality assurance for the qualification[s] will be provided by the usual City & Guilds external verification process. This includes the use of an electronically scannable report form which is designed to provide an objective risk analysis of individual centre assessment and verification practice. Further details of the role of external verifiers are given in Providing City & Guilds qualifications.

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4 Course design and delivery

Recommended delivery strategies Centre staff should familiarise themselves with the structure, content and assessment requirements of the qualification before designing a course programme. In particular, staff should consider the skills and knowledge related to the national occupational standards. Provided that the requirements for the qualification are met, centres may design course programmes of study in any way that they feel best meets the needs and capabilities of their candidates. Centres may wish to include topics as part of the course programme, which will not be assessed through the qualification[s].

Relationship to other qualifications and the wider curriculum City & Guilds recommends centres address the wider curriculum, where appropriate, when designing and delivering the course. Centres should also consider links to the National Occupational Standards, Key/Core Skills and other related qualifications. The following relationship tables are provided to assist centres with the design and delivery of the qualification: Relationship to the NOS/NVQs can be found in Appendix 1.

Health and safety The requirement to follow safe working practices is an integral part of all City & Guilds qualifications and assessments, and it is the responsibility of centres to ensure that all relevant health and safety requirements are in place before candidates start practical assessments. Should a candidate fail to follow health and safety practice and procedures during an assessment, the assessment must be stopped. The candidate should be informed that they have not reached the standard required to successfully pass the assessment and told the reason why. Candidates may retake the assessment at a later date, at the discretion of the centre. In case of any doubt, guidance should be sought from the external verifier.

Data protection and confidentiality Centres offering this qualification may need to provide City & Guilds with personal data for staff and candidates. Guidance on data protection and the obligations of City & Guilds and centres are explained in Providing City & Guilds qualifications.

Initial assessment and induction Centres will need to make an initial assessment of each candidate prior to the start of their programme to ensure they are entered for an appropriate type and level of qualification. The initial assessment should identify any specific training needs the candidate has, and the support and guidance they may require when working towards their qualification. City & Guilds recommends that centres provide an induction programme to ensure the candidate fully understands the requirements of the qualification[they will work towards, their responsibilities as a candidate, and the responsibilities of the centre. It may be helpful to record the information on a learning contract. Further guidance about initial assessment and induction, as well as a learning contract that centres may use, are available in the Centre toolkit.

Equal opportunities It is a requirement of centre approval that centres have an equal opportunities policy (see Providing City & Guilds qualifications). The regulatory authorities require City & Guilds to monitor centres to ensure that equal opportunity policies are being followed. The City & Guilds equal opportunities policy is set out on the City & Guilds website, in Providing City & Guilds qualifications, in the Directory of qualifications, and is also available from the City & Guilds Customer Relations department. Access to qualifications on the National Qualifications Framework is open to all, irrespective of gender, race, creed, age or special needs. The centre co-ordinator should ensure that no candidate is subject to unfair discrimination on any ground in relation to access to assessment and the fairness of the assessment.

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Access to assessment City & Guilds’ guidance and regulations on access to assessment are designed to facilitate access for assessments and qualifications for candidates who are eligible for adjustments to assessment arrangements. Access arrangements are designed to allow attainment to be demonstrated. For further information, please see Access to assessment and qualifications, available on the City & Guilds website.

Appeals Centres must have their own, auditable, appeals procedure that must be explained to candidates during their induction. Appeals must be fully documented by the quality assurance co-ordinator and made available to the external verifier or City & Guilds. Further information on appeals is given in Providing City & Guilds qualifications. There is also information on appeals for centres and learners on the City & Guilds website or available from the Customer Relations department.

Learning and support resources City & Guilds provides the following resources for this [these] qualification[s]. City & Guilds will provide the following learning and support resources which will be posted on our website.

Resource How to access

SmartScreen www.smartscreen.co.uk

Downloadable assignments www.cityandguilds.com/

5 Assessment 5.1 Summary of assessment requirements

For this qualification, candidates will be required to complete the following assessments: one GOLA (Online) test for each mandatory unit (701,702) one short answer test for the chosen technology unit one assignment and short answer test for each chosen optional unit.

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5 Assessment

Grading and marking Assessments will be graded pass, credit or distinction

Regulations for the conduct of examinations Regulations for the conduct of examinations for online and written examinations are given in Providing City & Guilds qualifications - a guide to centre and qualification (scheme) approval and in the Directory of qualifications. Centres should ensure they are familiar with all requirements prior to offering assessments.

6 Units

Availability of units The units for this qualification follow.

Structure of units The units in this qualification are written in a standard format and comprise the following:

• title • unit reference • rationale • assessment details • learning outcomes in detail expressed as practical skills and/ or underpinning knowledge.

Philosophy and principles behind the qualification The units have been designed to support the attainment of an apprenticeship and as such support the NVQ in Performing Engineering Operations. There will be additional units and pathways added throughout the lifecycle of this qualification.

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Unit 701 Working in Engineering

Rationale This unit will encourage candidates to find out about working in engineering. It will cover the basic skills and knowledge needed to enter the engineering or manufacturing sectors. This will cover the need to recognise and use safe working practices, consideration of the environment and working effectively as a part of a team. It includes the basic materials and tools that engineers use in their everyday work as well as the different career routes and the training required for those routes. The unit also includes the impact of engineering on our world today. Learning outcomes There are four outcomes to this unit 701.1 health and safety 701.2 communication 701.3 drawings and specifications 701.4 working together in the world of engineering. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcome for this unit will be assessed by global online assessment (GOLA). Test Specifications: Core Unit The knowledge requirements will be assessed by a multiple choice GOLA test

Subject: Certificate in Engineering Level 2

Paper No. 2800-701 Paper Title The World of Engineering Duration 60 minutes No. of items 40 Section/Heading (outcome)

Group/topic/objective No. of items

Total %

01.01-01.02 Basic safety legislation/ Employer’s responsibilities

2

01.03-01.05 procedures/ safe practices/ first aid

1

01.06-01.07 PPE/ safety signs/

2

01.08 responsibility

2

01.09-01.11 accident prevention/hazards/ dangerous occurrence

1

01 Health & Safety

01.12-01.14 fire/ safe working/ safety checks

2

10

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02.01 employment rights

1

02.02 communication

2

02.03-02.04 department roles/ instructions

3

02.05-02.07 resources/ drawings/ interpreting drawings or diagrams

3

02 Communication

02.08-02.10 design brief/ seek advice/ behaviours

1

10

25

03.01 Technical drawings

2

03.02-03.03 projections/ information

4

03.04 Standard conventions

2

03 Drawings & Specifications

03.05 quality assurance

3

14

35

31

03.06 Tables, graphs and specifications

1

04.01 Expected behaviour

1

04.02 Conduct

1

04.03-04.04 request advice/ deal with conflict

1

04.05 Avoid conflict

1

04 Working together in the World of Engineering

04.06 Team member responsibilities

2

6

15

Totals 40 40 100

Unit 701 Working in Engineering 701.1 health and safety

Practical activities The candidate will be able to: 1. recognise warning signs that are used in an engineering/manufacturing workshop 2. identify a range of safety equipment within the work area 3. select appropriate personal protective equipment (PPE) and safety equipment for a

designated task 4. recognise hazards in an engineering/manufacturing workshop 5. identify possible sources of fire within the workplace 6. identify types of fire extinguisher and match them with various types of fires. Underpinning knowledge The candidate will be able to: 1. state the general current safety regulations applicable to engineering operations

a. Health and Safety at Work Act b. Control of Substances Hazardous to Health Regulations c. Provision and Use of Work Equipment Regulations d. Reporting of Injuries, Diseases and Dangerous Occurrences Regulations e. Safety Representatives and Safety Committees Regulations

2. state employers’ responsibilities to maintain safety in terms of providing

a. a safe place of work b. safe plant and equipment c. a safe system of work d. a safe working environment e. safe methods of handling, storing and transporting goods and materials f. reporting of accidents g. information, instruction, training and supervision of employees h. a safety policy

3. explain the implementation within individual organisations of

a. safety policies b. codes of practice c. safe working practices and procedures

4. describe essential operator and bystander safety requirements

a. Personal Protective Equipment (PPE) b. Respiratory Protective Equipment (RPE) c. secure areas

5. recognise safety signs designated

a. warning b. prohibition c. mandatory d. advisory

6. state the roles, responsibilities and powers of

a safety officers

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b safety representatives c health and safety executive inspectors

7. state the human and environmental conditions leading to accidents in the workplace and

the means of controlling them a. causes of accidents

i human: carelessness; improper behavior and dress; lack of training ii supervision and experience; fatigue; drug-taking and drinking iii environmental: unguarded or faulty machinery or tools; inadequate iv ventilation; untidy, dirty, overcrowded, badly-lit workplaces

b. accident prevention measures i eliminate the hazard ii replace the hazard with something less dangerous iii guard the hazard iv personal protection v safety education and publicity

8. describe how to carry out a risk assessment and prepare a report identifying potential

health hazards a. slippery or uneven surfaces b. pillages c. scrap or waste material d. inflammable materials e. faulty or missing machine guards f. faulty electrical connections or damaged cables g. dust and fumes h. contaminants and irritants i. materials handling and transportation

9. list the general rules for the observance of safe practices

a. be alert b. maintain personal hygiene c. protect yourself and other people d. know emergency procedures e. report all hazards

10. state the need for the provision of First Aid treatment

a. location of facilities b. location of qualified first aiders

11. define what is meant by a dangerous occurrence 12. describe methods of fire prevention and methods of controlling fires

a. conditions required for combustion and extinction i causes of fire ii fire prevention

b. fire procedures i fire drills ii fire fighting equipment for different types of fires

A. extinguishers B. automatic equipment

13. describe the methods and procedures necessary to make an area safe before starting

work by a. using barriers and/or tapes b. placing warning signs in appropriate positions

c. informing any persons who may be affected d. isolating power or pressure sources e. obtaining official clearance (Permit to Work)

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14. state the basic reasons for carrying out safety checks a. upholding or improving safety standards b. ensuring work area is free from hazards c. any required safety procedures are implemented d. any necessary personal protective equipment is in a usable condition e. tools and equipment are in a safe and usable condition.

Unit 701 Working in Engineering 701.2 communication

Practical activities The candidate will be able to: 1. identify employment rights 2. use sources of information to complete an engineering project/task 3. use technical communication methods to complete an engineering project/task. Underpinning knowledge The candidate will be able to: 1. state procedures regarding employment rights and responsibilities

a. describe procedures for requesting/recording time off work for: i illness; medical/dental reasons ii holidays iii family reasons

2. state the communication systems used in the workplace

a. verbal b. written c. drawings d. electronic e. signs

3. state the roles and responsibilities of various departments and personnel within an

engineering organisation a. departments

i finance/purchasing ii manufacturing/production iii quality assurance/control iv inspection v despatch vi maintenance vii human resources

b. personnel i managers ii engineers iii supervisors iv trainers v inspectors vi safety officers vii personnel staff

c Trade unions 4. State how to categorise

a instructions b requests c advice

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5. State various sources of engineering information a BS EN standards b instruction manuals c technical handbooks d tables, charts, graphs, data sheets e textbooks, reference materials f computer programmes, internet, intranet

6. State methods of communicating technical information

a sketches, drawings, diagrams b test and inspection reports c planning documents and schedules

7. state the relevance and interpretation of engineering information in 2.6 8. state the importance of a design brief 9. state where to seek advice or guidance

a mentor b trainer c supervisor

10. describe the correct behaviour when seeking advice a politeness b timeliness c attentiveness.

Unit 701 Working in Engineering 701.3 drawings and specifications

Practical activities The candidate will be able to: 1. identify and interpret common forms of engineering drawing 2. identify and interpret specifications 3. use manufacture’s tables, graphs and current engineering standards 4. prepare an operations sheet from a drawing/specification. Underpinning knowledge The candidate will be able to: 1. state the purpose of technical drawings and specifications

a. characteristics of a product i shape ii size iii material iv features

b. provide additional product information i materials ii manufacturing or installation data iii special processes/equipment requirements

2. describe technical drawings using current standards

a. projections i orthographic ii isometric iii oblique

b. assembly c. schematic d. exploded views e. sketches

3. state the essential information found on drawings

a. projection b. scale c. dimensions d. issue number e. author f. tolerances g. symbols h. tool/equipment references i. warning notes j. state the need for a product specification k. detailed design drawings l. materials m. batch requirements n. parts list o. performance details

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4. describe the purpose of an engineering standard a communicates technical information/data b produced in universal language for all stakeholders c provides the basis for quality assurance

5. describe the use of manufacturers’ tables, graphs and specifications a material type and section b tooling requirements c fastening devices d operating conditions e coding systems f safety requirements

6. describes standard conventions used on drawings

a. lines b. shading c. symbols d. views e. describes the need for an operations sheet f. detailed drawings g. manufacturing process(s) h. product make up (number of components) i. sequence of operations j. quality control requirements k. storage and dispatch requirements.

Unit 701 Working in Engineering 701.4 working together in the world of engineering

Practical activities The candidate will be able to: 1. role play a conflict situation 2. participate in a team working activity 3. research an aspect of the role of engineering in transforming society from an agricultural

to an industrial bases. Underpinning knowledge The candidate will be able to: 1. state the behaviour expected within an organisation with regard to

a. timekeeping and absenteeism b. observation of rules, regulations and procedures c. conduct within the workplace d. relationships with colleagues, supervisors and managers e. respect for company property f. observing safety policies and regulations

2. state the conduct expected when dealing with

a. customers b. visitors c. inspectors.

3. state how to effectively request advice from colleagues, trainers or supervisors by

a. stating the problem clearly and succinctly b. listening to the response attentively c. seeking clarification on points not fully understood

4. state how to deal with conflict situations 5. state how to avoid conflict situations by

a. approaching people politely b. timing the approach when seeking advice or assistance c. avoiding aggression by withdrawing from the situation d. listening carefully e. following reasonable requests from supervisors f. offering help when colleagues are in need of assistance

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6. state how to function as a member of a team a. the roles and responsibilities of

i the team leader ii the team member

b. difficulties or situations that can occur due to i differences of opinion ii unpopular team leader decisions iii working within time constraints iv team member aspirations and/or ambitions v individual skill levels vi team member personalities

c. participating in group discussions and decision making i suggesting solutions to problems ii how to give and receive constructive criticism iii when to be assertive iv when to concede to individual or group pressure

7. state the impact of engineering on the development of the industrial world

a. machines b. transport c. migration of labour.

Unit 702 Engineering Technology

Rationale This unit is concerned with the basic numerical principles and technologies that underpin the skilled engineering processes. The unit deals with subjects that are fundamental to the application and understanding of common engineering process applications. Learning outcomes There are three outcomes to this unit 702.1 material technology 702.2 workshop calculations 702.3 innovation in engineering. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed by global online assessment (GOLA). Test Specifications: Core Unit The knowledge requirements will be assessed by a multiple choice GOLA test

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Subject: Certificate in Engineering Level 2

Paper No. 2800-702 Paper Title Engineering Technology Duration 60 minutes No. of items 40 Section/Heading (outcome)

Group/topic/objective No. ofitems

Total %

01.01 Range Of Materials

5

01.02 Supply Of Materials

2

01.03 Engineering Materials

2

01.04 Properties

3

01.05 Heat Treatments

2

01 Material Technology

01.06 New Materials

1

15

37.5

02.01 Numerical solutions

1

02.02 Tolerance

1

02.03 Tapers

2

02.04 Powers

3

02.05 Square Roots

1

02.06 Mixed Calculations (BODMAS)

1

02.07 Simple Problem Solving

2

02.08 Area

2

02 Workshop calculations

02.09 Volumes

2

20

50

02.10 Density

1

02.11 Plot Graphs

1

02.12 Pythagoras

1

02.13 Angles

1

02.14 Efficiency

1

03.01 Areas Of Innovation

1

03.02 Improvement

1

03.03 Sectors of engineering

1

03.04 Technologies

1

03 Innovation in Engineering

03.05 Global Economy

1

5

12.5

Totals 40 40 100

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Unit 702 Engineering Technology 702.1 material technology

Practical activities The candidate will be able to:

1. identify materials by colour, density and texture

2. perform simple workshop tests to compare material properties

3. identify castings, forgings, mouldings and extrusions

4. harden and temper a steel component.

Underpinning knowledge The candidate will be able to:

1 state the range of materials commonly used in engineering

a. ferrous metals

i low, medium and high carbon steels

ii stainless steel

iii cast iron

b. non-ferrous metals

i aluminium and aluminium alloys

ii copper

iii brass

iv bronze

v lead

c. non-metallic materials

i hard and soft woods

ii composites

iii plastic materials

iv glass

v ceramics

vi laminates

vii rubber

d. reinforcing materials

i glass fibres

ii carbon fibres

iii aramid

2 state the form of supply of materials

a. bar

i flat

ii round

iii square

iv hexagonal

b. plate and sheet

i plain

ii coated

A tin plate

B galvanised

C plasticised

c. pipe and tube

d. castings

e. forgings

f. extrusions

3. state how to identify engineering materials

a. colour

b. surface texture

c. comparison of density

4. State the properties of materials in 1.1a-d

a. tensile strength

b. toughness/brittleness

c. hardness

d. elasticity

e. ductility/malleability

f. insulation

g. conductivity

h. corrosion resistance

5. state how heat treatments can affect the properties of carbon and low alloy steels

a. annealing

b. normalising

c. hardening and tempering

6. identify new materials and describe their uses

a. high temperature materials – space rockets, gas turbines.

b. metallic foams – energy absorption, filtration, shielding

c. biomedical materials – titanium, 316 type stainless steel

d. shape-memory alloys – eyeglass frames, medical tools.

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Unit 702 Engineering Technology 702.2 workshop calculations

Practical activities The candidate will be able to: 1. select appropriate formulae to solve simple engineering problems 2. perform simple workshop calculations using appropriate formulae 3. assess the reliability of calculated solutions by estimation. Underpinning knowledge The candidate will be able to: 1. state numerical solutions to a degree of accuracy that is appropriate to the value being

calculated, express a. decimals in standard form b. a numerical value to a given number of significant figures c. fractions as a decimal quantity

2. describe tolerance in terms of limits of size 3. describe tapers in terms of length to radius/diameter (proportionality) 4. raise a number to a power

a. arithmetically b. electronically (calculator)

5. determine square roots electronically (calculator) 6. state the law of precedence for mixed calculations (BODMAS) 7. explain the use of formulae to solve simple problems

a. complete simple transpositions involving combinations of addition, subtraction, multiplication and division

b. solve problems by substituting known values 8. state the formulae for calculating areas of basic shapes

a. square/rectangle b. triangle c. circle

9. State the formulae for calculating volumes and surface areas of regular shaped solids

a. cube b. rectangular prism c. cylinder (curved surface area only)

10. state the formulae for calculating the relative density of regular shaped solids 11. describe how to plot and interpret simple straight line graphs using given data 12. state ‘Pythagoras’ Theorem’ and apply it to simple workshop problems

13. determine the value of angles in triangle a. right angled b. isosceles c. equilateral

14. state the meaning of efficiency in terms of input and output.

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Unit 701 Working in Engineering

Unit 702 Engineering Technology 702.3 innovation in engineering Practical activities The candidate will be able to: 1. identify key areas of engineering innovation 2. identify the impact of developing technology on different sectors of engineering 3. identify the benefits to society and the environment Underpinning knowledge The candidate will be able to: 1. state the key areas of innovative development

a. information and communication technology (ICT) b. materials technology c. operations management d. control technology e. energy supply f. recycling

2. state the areas of improvement brought about by innovation

a. rapid sourcing and handling of information b. miniaturisation of components and systems c. manufacturing processes and control systems d. integrated production, increased productivity and flexibility e. product design, development, characteristics and life cycle f. working environments g. natural and renewable forms of energy h. global environments and sustainability

3. state the sectors of engineering that have directly benefited from innovation

a. automotive/mechanical b. electrical/electronic c. telecommunications d. aerospace e. services f. medical

4. state the technologies underpinning some innovative developments

a. lasers b. microfluidics c. microprocessors/integrated circuits (silicon chips) d. radioactivity e. satellite systems f. materials

i composites ii smart iii memory alloys

5. describe improvements to the global economy and environment achieved through innovation a. consumer products

i availability ii range

b. type/characteristics c. reliability d. size e. safety and efficiency f. sustainability of resources g. travel h. communications i. control systems j. individuals’ health and welfare.

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Unit 703 Manufacturing Technology

Rationale This unit is concerned with the methods of manufacture. It includes the range of functions found in Manufacturing Organisations and will provide the candidate with the knowledge to plan the production of and manufacture of an engineering component by the most suitable manufacturing process. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 703.1 understand the functions within a manufacturing organization 703.2 select suitable materials and components to manufacture the product 703.3 produce a production plan from a given specification. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

Unit 703 Manufacturing Technology Unit 701Working in Engineering

703.1 understand the functions within a manufacturing organization

Practical activities The candidate will be able to: 1. produce a chart/block diagram to show the relationship between the different

departments within a manufacturing organization 2. identify different types of manufacturing organizations 3. identify differences between the different scales of production 4. identify different types of equipment used for manufacture Underpinning knowledge The candidate will be able to: 1. state the relationship between the various departments: design, planning, stores,

purchasing, quality, maintenance and sales 2. state the function of each department and their order in the production process

a. design b. planning c. stores d. purchasing e. quality f. maintenance g. sales

3. state the different types of manufacturing organizations to include

a. light, medium and heavy engineering b. mechanical c. motor vehicle d. tools and equipment e. aerospace f. electrical/electronic g. plant supplies h. process industries i. maintenance/installation

4. state what is meant by scales of production

a. jobbing b. small batch c. repeated batch d. mass production

5. state the different types of equipment used in manufacture

a. general purpose b. dedicated c. computerized.

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Unit 703 Manufacturing Technology 703.2 select suitable materials and components to

manufacture the product

Practical activities The candidate will be able to: 1. identify the materials and their forms of supply for the product 2. identify the types of mechanical fastenings required 3. identify the electrical/electronic components required 4. identify the criteria for efficient production Underpinning knowledge The candidate will be able to: 1. state the different materials plus their properties and forms of supply used in the

manufacture of the product a. properties

i plasticity ii elasticity iii ductility iv malleability v toughness vi hardness vii tensile strength viii compressive strength ix shear strength x corrosion resistance

b. forms of supply i sheet ii bar iii tube and pipe iv extrusions v casting vi forming vii pressing viii moulding ix granules x powders xi liquids.

2. state the different types of mechanical fastenings

a. permanent i nuts ii bolts iii studs iv screws v pins vi springs vii keys viii bearings

b. non permanent

i welded ii soldered iii brazed iv riveted

3. state the different components used in electrical/electronic production to include:-

a. capacitors b. diodes c. LED’s d. resisters e. batteries f. cables/wire g. buzzers h. meters and transformers

i millimeters ii voltmeters

4. understand the reason for selection criteria for profitable production

a. costs i capital ii overheads iii inflation

b. availability of materials and components c. fitness for purpose d. production methods (to include ease of production).

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Unit 703 Manufacturing Technology 703.3 produce a production plan from a given

specification

Practical activities The candidate will be able to: 1. produce production drawings suitable for the component 2. produce a production plan using flowchart or similar 3. identify the related information required for the production of the component. Underpinning knowledge The candidate will be able to: 1. state the details to manufacture a simple component

a. materials b. processes c. sequence of production d. tools and equipment e. speeds and feeds f. inspection procedures g. Health and safety requirements

2. state the information is required to produce a component to the specification

a. production drawings b. quantities c. specifications d. bought in parts e. materials f. processing method

3. state the related information required for production

a. Direct costs i material ii wages iii production time

b. Indirect costs i heating ii lighting iii machine depreciation iv scrap v rework vi down time vii advertising.

Unit 704 Machining by Milling

Rationale This unit covers a broad range of milling activities which are required in the engineering and manufacturing sectors. It covers skills and knowledge needed to produce milled components in different materials, using appropriate tools and equipment, and inspection techniques to achieve the required tolerances and conforming to specifications, whilst complying with health and safety legislation and regulations. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 704.1 plan and prepare for milling activities 704.2 apply techniques and procedures to produce component parts 704.3 return the work area to a safe and tidy condition. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

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Unit 704 Machining by Milling 704.1 plan and prepare for milling activities

Practical activities The candidate will be able to: 1. identify the types of milling machine 2. select and check milling cutters and work holding devices 3. select the precision measuring tools and gauges 4. interpret drawings and extract the required data 5. produce an operation 6. produce an inspection schedule to check conformity. Underpinning knowledge The candidate will be able to: 1. state the safety regulation and acts applicable to fitting

a. Health and Safety at Work Act b. Personal Protective Equipment (PPE) c. Control of Substances Hazardous to Health (COSHH) d. Provision and Use of Work Equipment (PUWER).

2. state the employee’s responsibilities under (HSaW Act). 3. state the procedures to implement COSHH. 4. state the importance of wearing (PPE) and describe briefly what protection each will

provide the user a. overalls b. safety footwear c. eye protection d. barrier cream.

5. state the need for procedures to prevent personal injury. 6. state the basic principles of risk assessment 7. interpret information from engineering drawings.

a. dimensional b. geometrical c. materials.

8. state the type of tools used on milling machines, how they are mounted and their

application a. side and face cutters b. face mills c. slab/cylindrical cutters d. slot cutters e. slitting saws f. vee cutters g. form cutters h. end mills

i. slot drills j. twist and core drills (parallel and taper shank) k. taps l. machine reamers m. boring bars.

9. describe tool nomenclature for a. milling cutters b. twist drills c. reamers.

10. state the operation, features and applications of

a. vertical mills b. horizontal mills c. universal d. bridgeport type.

11. calculate spindle speeds using

a. standard tables b. formula

i cutting speed = πdN/1000. 12. describe how to obtain classes of fit using charts (H8 range).

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Unit 704 Machining by Milling 704.2 apply techniques and procedures to produce

component parts

Practical activities The candidate will be able to: 1. produce a chart showing the hazards associated with milling and how they can be minimised 2. check milling machines and equipment for safe operation 3. mount work and cutting tools 4. machine component parts using safe working practice 5. use charts to obtain dimensions for specified classes of fit 6. check component for accuracy and quality. Underpinning knowledge The candidate will be able to: 1. state the safety precaution specific to operating milling machines

a. emergency stop procedures b. use of guards c. operating procedures d. moving parts e. removal of swarf.

2. describe the setting of work datum’s

a. faces b. centres.

3. describe the classes of fit

a. clearance b. interference.

4. describe the accuracy and range of precision measuring equipment and gauges

a. micrometers i external ii depth

b. vernier i calliper ii depth iii protractor.

c. dial test indicator (DTI) d. gauges

i plug ii blocks iii thread iv radius/profile v bore/hole

e. surface finish (comparison plates). 5. state how to check measuring equipment is within current calibration dates.

6. state the type and the use of coolants and cutting oils a. oils b. compounds c. synthetic.

7. describe cutting tool materials and their application

a high speed steel (HSS) b carbide tips

8. state factors that affect cutting speeds and feeds

a. cutting tool material/material being cut b. surface finish required c. type of cutting operation d. power output of the machine e. use of coolant.

9. state the method of mounting cutters, their position and benefits

a. arbour b. chucks

i auto lock ii jacobs

c. pull collets. 10. describe workholding devices

a. machine vice i fixed jaw ii swivel and universal

b. direct clamping c. fixtures d. angle plates e. vee blocks f. indexing devices

i rotary table ii dividing head.

11. explain methods of milling

a. up cut b. down cut.

12. state the need to record inspection results

a. quality control b. compliance records.

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Unit 704 Machining by Milling 704.3 return the work area to a safe and tidy condition

Practical activities The candidate will be able to: 1. recycle of waste materials 2. return tools, equipment and unused materials 3. carry out checks on milling cutters, equipment and holding devices 4. leave the work area in a safe and tidy condition. Underpinning knowledge The candidate will be able to: 1. state Health and Safety requirements for the correct disposal of waste and implications of

failure to comply. 2. state the requirements for leaving the work area in a safe and clean condition on

completion of the machining activities. a return cutting tools, equipment and holding devices to its designated storage

location b return surplus materials to stores c remove waste material and debris.

3. outline problems that can occur during reinstating the work area and the appropriate

remedial actions. 4. state the procedure for recycling different types waste

a. materials i metallic materials ii plastics iii cloths and paper

b. procedures i segregate ii label iii dispose.

5. state who needs to be informed when the machining activity is complete.

Unit 705 Machining by Turning

Rationale This unit covers a broad range of turning activities which are required in the engineering and manufacturing sectors. It covers skills and knowledge needed to produce turned components in different materials, using appropriate tools and equipment, and inspection techniques to achieve the required tolerances and conforming to specifications, whilst complying with health and safety legislation and regulations. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 705.1 plan and prepare for turning activities 705.2 apply techniques and procedures to produce component parts 705.3 return the work area to a safe and tidy condition. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

63

Unit 705 Machining by Turning 705.1 plan and prepare for turning activities

Practical activities The candidate will be able to : 1. identify types of lathe 2. select and check lathe tools and work holding devices 3. select precision measuring equipment and gauges 4. interpret drawings and extract the required data 5. produce an operation sheet 6. produce an inspection schedule to check conformity Underpinning knowledge The candidate will be able to: 1. state the safety regulation and acts applicable to fitting

a. Health and Safety at Work Act b. Personal Protective Equipment (PPE) c. Control of Substances Hazardous to Health (COSHH) d. Provision and Use of Work Equipment (PUWER)

2. state the employee’s responsibilities under (HSaW Act) 3. state the procedures to implement COSHH 4. state the importance of wearing (PPE) and describe briefly what protection each will provide the user

a. overalls b. safety footwear c. eye protection d. barrier cream

5 state the need for procedures to prevent personal injury 6 state the basic principles of risk assessment 7 interpret information from engineering drawings

a. dimensional b. geometrical c. materials

8. state the type of tools used on lathes and their application

a. roughing b. knife c. facing d. parting e. forming f. chamfer g. recessing h. screw cutting (single point) i centre drills j. twist and core drills (parallel and taper shank)

k. taps and dies l. machine reamers m. thread chasers

9. describe tool nomenclature for

a. lathe tools b. twist drills c. reamers

10. state the operation, features and applications of lathes

a. centre b. capstan c. turret

11 calculate spindle speeds using

a. standard tables b. formula

i cutting speed = πdN/1000 12. state how to obtain classes of fit using charts (H8 range)

65

Unit 705 Machining by Turning 705.2 apply techniques and procedures to produce

component parts

Practical activities The candidate will be able to: 1. produce a chart showing hazards associated with turning and how they can be minimised 2. check lathes and equipment for safe operation 3. mount work and cutting tools 4. machine component parts using safe working practice 5. use charts to obtain dimensions for specified classes of fit 6. check component for accuracy and quality. Underpinning knowledge The candidate will be able to: 1. state safety precaution specific to operating lathes

a. emergency stop procedures b. use of guards c. operating procedures d. moving parts e. removal of swarf

2. describe the setting of work datum’s

a. faces b. centres

3. state classes of fit

a. clearance b. interference

4. describe the accuracy and range, of precision measuring equipment and gauges


b. vernier i calliper ii depth iii protractor



e. surface finish (comparison plates) 5. state how to check that measuring equipment is within current calibration dates 6. state types and use of coolants and cutting oils

a. oils b. compounds c. synthetic

67

7. describe cutting tool materials and their application a. high speed steel (HSS) b. carbide tips


a. cutting tool material/material being cut b. surface finish required c. type of cutting operation d. power output of the machine e. use of coolant

9. state the method of mounting tools, their position and benefits

a. tool post i four way ii quick change iii tailstock iv turret

10. describe workholding devices

a. chuck i three jaw self centring with soft jaws ii collet iii four jaw independent

b. face plate c. steadies

i fixed ii travelling

11. describe briefly methods of taper turning

a. compound slide b. off set tailstock c. taper turning attachment

12. describe methods of cutting threads

a. single point i plung ii half included angle

b. chasers c. taps d. die box

13. describe methods used to machine chafers and profiles

a. form tool b. coping attachment

14. state the need to record and report inspection results


Unit 705 Machining by Turning 705.3 return the work area to a safe and tidy condition

Practical activities The candidate will be able to: 1. recycle of waste materials 2. return tools, equipment and unused materials 3. carry out checks on cutting tools, equipment and holding devices 4. leave the work area in a safe and tidy condition. Underpinning knowledge The candidate will be able to: 1. state Health and Safety requirements for the correct disposal of waste and implications of

failure to comply 2. state the requirements for leaving the work area in a safe and clean condition on

completion of the machining activities a. return cutting tools, equipment and holding devices to its designated storage

location b. return surplus materials to stores c. remove waste material and debris


remedial actions 4. state the procedure for recycling different types waste


b. procedures i segregate ii label iii dispose


69

Unit 706 Machining by Grinding

Rationale This unit covers a broad range of grinding activities which are required in the engineering and manufacturing sectors. It covers skills and knowledge needed to produce grounded components in different materials, using appropriate tools and equipment, and inspection techniques to achieve the required tolerances and conforming to specifications, whilst complying with health and safety legislation and regulations. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 706.1 plan and prepare for grinding activities 706.2 apply techniques and procedures to produce component parts 706.3 return the work area to a safe and tidy condition. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current versions.

Unit 706 Machining by Grinding 706.1 plan and prepare for grinding activities

Practical activities The candidate will be able to: 1. identify the types of grinding machine 2. select precision measuring equipment and gauges 3. select and check abrasive wheels 4. interpret drawings and extract the required data 5. produce an operation sheet 6. produce an inspection schedule to check conformity. Underpinning knowledge The candidate will be able to 1. state the safety regulation and acts applicable to fitting

a. Health and Safety at Work Act (HSaW) b. Personal Protective Equipment (PPE) c. Control of Substances Hazardous to Health (COSHH) d. Provision and Use of Work Equipment (PUWER).

2. state the employees responsibilities under (HSaW Act). 3. state the procedures to implement COSHH. 4. state the importance of wearing (PPE) and describe briefly what protection each will


5. state the need for procedures to prevent personal injury. 6. state the basic principles of risk assessment. 7. interpret information from engineering drawings

a dimensional b geometrical c materials.

8. state the type of wheels used on grinding machines, how they are mounted and their

application a. solid

i plain (type1) ii ring (type 2) iii tapered (type 4) iv recessed (type 5) v dish (type 12) vi saucer (type13)

b. cup i straight (type 6)

71

ii flared (type 11) c. internal d. segmented.

9. state the operation, features and applications of grinding machines

a. surface b. cylindrical c. vertical spindle.

10. calculate spindle speeds using

a. standard tables b. Formula

i N(rev/min) = surface speed (m/min) x 1000 π x wheel diameter (D)

11 List the exposure angles for guards

i surface ii cylindrical iii off-hand.

12. explain abrasive wheel marking to current standards

a. manufacturer’s code b. abrasive code

i aluminium oxide ii Silicon

c. grain size (range 10 to 600) d. grade of bond (letters A to Z) e. structure (1 to 14) f. bond

i vitrified ii silicate iii resinoid iv rubber.

13. state how to obtain classes of fit using charts (H8 range).

Unit 706 Machining by Grinding 706.2 apply techniques and procedures to produce

component parts

Practical activities The candidate will be able to: 1. produce a chart showing the hazards associated with grinding and how they can be

minimised 2. check grinding machines and associated equipment for safe operation 3. carry out a ring test 4. balance test an abrasive wheel 5. true, dress and balance abrasive wheels 6. mount work, and abrasive wheels 7. machine component parts using safe working practice 8. use charts to obtain dimensions for specified classes of fit 9. check component for accuracy and quality. Underpinning knowledge The candidate will be able to: 1. state the safety precaution specific to operating grinding machines

a. emergency stop procedures b. use of guards c. operating procedures d. moving parts e. removal of swarf.

2. describe the setting of work datums

a. faces b. centres.

3. state classes of fit

a. clearance b. interference.

4. describe the accuracy and range of precision measuring equipment and gauges




i plug ii blocks iii radius/profile iv bore/hole

e. surface finish i comparison plates

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ii machine.

5. state the type and the use of coolants and cutting oils a. chemical b. straight mineral.


a. cutting tool material/material being cut b. surface finish required c. type of cutting operation d. power output of the machine e. use of coolant.

7. describe workholding devices

a. chucks i magnetic ii four jaw independent

b. vice i fixed jaw ii swivel and universal

c. direct clamping d. fixture e. angle plates f. vee blocks.

8. explain methods of grinding

a. surface b. cylindrical.

9. describe the accuracy and range, of precision measuring equipment and gauges





e. surface finish i i) comparison plates ii ii) machine.

10. describe briefly arc and area of contact

a. type of operation b. relative wheel/work sizes c. amount of infeed.

11. state the factors affecting the selection of the correct grinding wheel

a. workpiece material b. workpiece properties c. material remove rate d. arc and area contact

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e. machine type and condition. 12. describe briefly wheel faults and how to true and dress abrasive wheels

a. chips b. loaded c. glazed.

13. describe how to carry out a ring test. 14. describe briefly how to true and dress abrasive wheels. 15. describe how to examine a vitrified wheel for soundness. 16. describe briefly how to balance abrasive wheels. 17 state the affects of using an unbalance wheel

a. vibration b. chatter marks c. damage machine spindle.

18. state how to record inspection results and how to report/rectify

a. assembly defects b. quality control c. compliance records.

Unit 706 Machining by Grinding 706.3 return the work area to a safe and tidy condition

Practical activities The candidate will be able to: 1. recycle of waste materials 2. return tools, equipment and unused materials 3. carry out checks on wheels equipment and holding devices 4. leave work area in a safe and tidy condition. Underpinning knowledge The candidate will be able to 1. state Health and Safety requirements for the correct disposal of waste and implications of

failure to comply. 2. state the requirements for leaving the work area in a safe and clean condition on

completion of the machining activities a. return abrasive wheels, equipment and holding devices to its designated storage

location b. return surplus materials to stores c. remove waste material and debris.


remedial actions. 4. state the procedure for recycling different types waste




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Unit 707 Using Bench Fitting Techniques

Rationale This unit covers a broad range of fitting activities which are required in the engineering and manufacturing sectors. It covers skills and knowledge needed to produce components for assembly using appropriate tools, different materials and inspection techniques to achieve the required tolerances and conforming to specifications, whilst complying with health and safety legislation and regulations. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 707.1 plan and prepare for fitting activities 707.2 apply techniques and procedures to produce component parts 707.3 return the work area to a safe and tidy condition. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

Unit 707 Using Bench Fitting Techniques 707.1 plan and prepare for fitting activities

Practical activities The candidate will 1. select and inspect hand and powered hand tools 2. select measuring equipment and gauges 3. interpret drawings and extract the required data 4. produce a plan of action 5. produce an inspection schedule to check conformity. Underpinning knowledge The candidate will be able to 1. state the safety regulation and acts applicable to fitting

a. Health and Safety at Work Act b. Personal Protective Equipment (PPE) c. Control of Substances Hazardous to Health (COSHH) d. Provision and Use of Work Equipment (PUWER)

2. state the employee’s responsibilities under (HSaW Act) 3. state the procedures to implement COSHH 4. state the importance of wearing (PPE) and describe briefly what protection each will

provide the user a. overalls b. safety footwear c. eye protection d. barrier cream

5. state the need for procedures to prevent personal injury 6. state the basic principles of risk assessment 7. interpret information from engineering drawings

a. dimensional b. geometrical c. materials

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8. state the type, size and applications of tools and equipment a. marking out

i scribers ii scribing block iii punches (centre and dot) iv surface plate/table v angle plate and blocks

b. hand tools i files ii screwdrivers iii hammers and mallets iv pin punches v spanners

A open ended B ring C sockets D torque wrench

c. measuring and gauging equipment i engineers square ii callipers

A inside B outside

iii protractor iv micrometers

A external B depth

v verniers A calliper B height gauge C protractor D depth

vi gauges A feeler B blocks/slip C radius D thread

vii dial test indicator viii surface finish

A comparison plates B tactile machines

d. cutting and shaping i saws

A hand B mechanical

ii drills iii powered hand drills iv tin snips v files vi taps and dies vii hand reamers viii guillotines ix nibblers x abrasive discs

9. state the forms of power supply a. mains electricity

i 240volts ii 110 volts

b. pneumatic c. battery

10. state types of powered hand tools

a. drills b. screwdrivers c. angle grinders d. saws

11. state type of equipment used for forming

a. folders i bench ii box pan iii fly press iv pinch rollers v taps and dies vi hand reamers vii guillotines Viii nibblers ix abrasive discs

12. state the forms of power supply

a. mains electricity i 240volts ii 110 volts

b. pneumatic c. battery

13. state types of powered hand tools

a drills b screwdrivers c angle grinders d saws

14. state type of equipment used for forming

a. folders i bench ii box pan

b. fly press c. pinch rollers.

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Unit 707 Using Bench Fitting Techniques 707.2 apply techniques and procedures to produce

component parts

Practical activities The candidate will 1. check portable machines and equipment for safe operation 2. produce and assemble component parts using safe working practice 3. check component for accuracy and quality. Underpinning knowledge The candidate will be able to 1. state the safety precaution specific to operating portable and powered machines

a. emergency stop procedures b. use of guards and interlocking devices c. operating procedures d. moving parts e. removal of swarf

2. describe the setting of work datums

a. faces b. lines c. centres

3. state the need to mark out

a. datum and centre lines b. circles and radial lines c. squares and rectangles d. linear hole positions e. witness mark

4. state the need to use limits and fits charts 5. state drill materials and application

a. high speed steel (HSS) b. carbide tips c. coatings

6. state the types and the use of coolants and cutting oils a. oils b. compounds

7. describe different types and application of

a. taps i straight flute

A taper B second C bottoming

ii spiral flute b. dies

i circular split

ii rectangular iii pipe

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8. state need to select drill speeds a. using standard tables b. using cutting speed formula (cutting speed = πdN/1000)

9. state the need to use charts for selecting of tapping sizes 10. understand allowances for

a. bending b. curves c. circumferences

11. state the correct procedure for setting, checking and operating

a. off hand grinding machine i gap between rest and wheel ii wheel imperfections iii changing the wheel

b. angle grinder i position of guards ii wheel selection iii changing the wheel

12. state precautions necessary to prevent hazards during assembly by

a. providing stands and jacks b. securing components to prevent movement

13. state the terms used to describe types of hole

a. countersunk b. counterbored c. spotface

14. state the need for template

a. applications b. materials types

15. state the need to record and report inspection results


Unit 707 Using Bench Fitting Techniques 707.3 return the work area to a safe and tidy condition

Practical activities The candidate will be able to: 1. recycle waste materials 2. carry out checks on all tools, equipment and holding devices 3. return tools, equipment and unused materials 4. leave the work area in a safe and tidy condition. Underpinning knowledge The candidate will be able to 1. state Health and Safety requirements, for the disposal of waste and the implications of

failure to comply 2. state the requirements for leaving the work area in a safe and clean condition on

completion of the fitting activities a return hand tools, equipment and holding devices to its designated storage

location b return surplus materials to stores c remove waste material and debris

3. outline problems that can occur during reinstatement of the work area and appropriate

remedial actions 4. state the need for recycling different types of waste



5. state who needs to be informed when the fitting activity is complete.

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Unit 708 Using Computer Aided Manufacturing Processes

Rationale This unit is concerned with the production of components using computer aided manufacturing techniques. It includes the production of a component and suitable files to produce such components. It will also cover the relevant Health and Safety procedures required. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 708.1 use a computer to produce a suitable file to enable the production of a component 708.2 manufacture the component using the appropriate machine tool 708.3 re-instate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.


708.1 use a computer to produce a suitable file to enable the production of a component

Practical activities The candidate will be able to: 1. open up a suitable package to produce a drawing. 2. produce an appropriate drawing for manufacture to current standards (bs8888) 3. save the drawing using appropriate drawing exchange format. 4. import file into a cam package. 5. produce a suitable file to enable machining. Underpinning knowledge The candidate will be able to: 1. state relevant safety procedures relating to the use of VDU equipment

a. lighting b. seating c. good housekeeping, including any potential danger.

2. state how to power up and check peripheral operating equipment

a. VDU b. keyboard c. mouse d. digitizer and tablets e. printers and plotters f. scanners

3 state correct procedure for start up and shut down

a. good housekeeping arrangements b. cleaning down work area c. care of portable storage media d. leaving the workstation in a safe condition

4. state the appropriate action in the event of an error message being displayed including

a. to act on own initiative b. seek assistance

5. list the different types of projection

a. orthographic (1st and 3rd angle) b. isometric c. oblique d. state the procedure for creating a new drawing e. setting up f. scales and sheet size g. types of lines

6. state the importance of saving as a drawing exchange file

a. .dxf b. .iges

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7. state the type of file required to enable machining.


708.2 manufacture the component using the appropriate machine tool

Practical activities The candidate will be able to: 1. prepare for CNC machining 2. set up and use a part program 3. machine the component to specification 4. inspect the component. Underpinning knowledge The candidate will be able to: 1. state the range and operations of cnc machines

a. lathes i 2 axis ii turning centres

b. milling machines i vertical ii horizontal

c. machining centres 2. state and set appropriate work holding devices

a. machine vice b. grid plate c. rotary tables d. pallets e. chucks

i 3 jaw self-centring ii 4 jaw iii collet

f. steadies i 2 point ii 3point

3. state the different types of safety devices

a. Override switches b. Guarding

i fixed ii interlocking

4. state how to select speeds and feeds

a. tables b. cutting speed formula

i RPM = 1000S ii π D iii Feed = RPM x number of teeth x feed per tooth

5. state the method of setting tools/cutters relative to datum’s for both Lathes and

Milling machines

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a using bar and slip b using cutting tool c probe

6. state the difference between the types of language format used a. Absolute b. Incremental

7. state a range of cutting tools for cnc machining

a. high speed steel b. carbide c. ceramic

8. identify tool geometry

a. top rake b. front rake c. clearance

9. state the range and accuracy of inspection equipment used for checking components

a. during manufacture b. on completion.


708.3 re-instate the work area

Practical activities The candidate will be able to: 1. identify and comply with relevant health and safety legislation 2. restore the work area used 3. dispose of waste/hazardous substance 4. identify remedial actions required to solve problems. Underpinning knowledge The candidate will be able to: 1. state health and safety requirements for waste disposal and implications of failure to

comply 2. state the need for good housekeeping when reinstating the work area

a. isolation of machinery b. cleaning of machine and equipment used for manufacture c. storage and inspection of tooling and equipment used in manufacture d. disposal of waste

3. state the correct procedure for dealing with waste materials

a. segregation b. label c. dispose

4. state potential problems that could occur and how they can be effectively resolved

a. spillages b. losses c. damages.

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Unit 709 Maintenance Technology

Rationale This unit identifies the basic principles and commonly used processes that are required to most maintenance activities. It covers basic maintenance requirements, components, tools and equipment that are commonly used and the ways in which that may be used or applied. Candidates are not expected to have an in-depth understanding of all maintenance, but they should become familiar with the events, terminology and practices that are needed as part of normal maintenance work. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 709.1 use safe and effective working practices 709.2 select suitable working methods, tools and equipment 709.3 use dismantling/assembly techniques for components/systems. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

Unit 709 Maintenance Technology Unit 701 Working in Engineering

709.1 use safe and effective working practices

Practical activities The candidate will be able to: 1. plan a maintenance activity for simple component 2. select tools / equipment to undertake a dismantling or assembly operation 3. prepare a report following a maintenance activity. Underpinning knowledge The candidate will be able to: 1. state the health and safety requirements and safe working practices and procedures for

maintenance activities a. wearing appropriate protective clothing and equipment b. maintaining a clean and tidy work area c. use of barriers and/or tapes d. post warning signs e. informing personnel of maintenance activities f. system isolation procedures for power and pressure sources g. permit-to work procedures

2. state hazards associated with carrying out maintenance activities

a. handling of oils and grease b. misuses of tools c. use of damaged or badly maintained tools d. not following laid-down maintenance procedures

i mechanical ii electrical

3. describe sources of information required for a maintenance activity

a. engineering drawings, current standards (BS EN 8888) b. wiring/circuit diagrams c. manufacturer’s maintenance manuals d. charts e. technical specifications

4. state the general types of maintenance activities

a. routine servicing schedules b. planned / preventive maintenance c. repair / replacement following breakdowns d. monitoring and performance tests

5. state factors to be considered when planning a maintenance activity

a. tools and equipment requirements b. materials and replacement parts c. importance of minimising down time to avoid

i production loss d. site conditions e. component location

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f. provision of services i electricity ii water iii drainage

6. state procedures for cleaning work areas following a spillage or leakage a. approved waste disposal methods b. absorbent substances c. use of detergents and solvents

7. list tools and equipment identification

a. use of catalogue numbers b. bar codes

8. state the storage requirements for tools, equipment and materials for

a. safety b. security

9. state maintenance diagnostic techniques and aids used

a. fault reports b. visual checks c. measurement d. movement and alignment checks e. testing

10. state fault location techniques that can be used, and how they may be applied

a. half split b. input-to-output c. function testing d. unit substitution e. equipment self-diagnostics

11. state how to evaluate using sensory information

a. sight b. sound c. smell d. touch

12. state methods and techniques used to dismantle/re-assemble equipment

a. release of pressure/force b. proof marking c. extraction d. pressing e. alignment

13. list the information required when completing a report following a maintenance activity

a. description of work undertaken b. location(s) c. date and times (commencement, completion, handover) d. parts and consumable used e. test data f. permit to work reference.

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Unit 709 Maintenance Technology 709.2 select suitable working methods, tools and

equipment

Practical activities The candidate will be able to: 1. set up access equipment for safe working 2. demonstrate safe lifting techniques 3. move a heavy component across a flat surface 4. use measuring/alignment equipment Underpinning knowledge The candidate will be able to: 1. describe the setting up and safe use of access equipment

a. ladders b. scaffolding c. platforms d. mobile hoists

2. state the safe use of lifting equipment used in a maintenance activity

a. chains b. rope and wire slings c. hooks d. shackles e. eye bolts

3. describe methods of sling attachment to prevent damage to sling / machinery

a. protective padding b. wooden blocks

4. states factors to be considered when using lifting equipment

a. estimation of approximate weight i use of manufacturers data

b. centre of gravity of component c. angle of splay between two leg sling chains not to exceed 120° d. never exceed the safe working load (SWL) e. inspection records for lifting equipment are current

5. list types of lifting equipment and states their application

a. screw and hydraulic jacks b. overhead gantry cranes c. mobile cranes d. jib cranes and derricks e. fork lift trucks f. tripods, shackles and pulley blocks

6. describe methods of moving heavy equipment across flat surfaces by means of

a. rollers and skates b. crowbars c. pull-lifts

d. lubricated plates

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7. describe types and methods for using tools and equipment a. torque/impact wrenches b. pipe wrenches c. pipe cutting and threading d. spanners and socket sets e. drifts and wedges f. extractors g. feeler gauges h. screw drivers i. pliers j. wire cutter/strippers

8. describe the use of measuring equipment

a. rules/tapes b. micrometers c. verniers d. ammeters e. voltmeters f. multi meters

9. check that tools and equipment are

a. free from damage or defect b. in a safe and usable condition c. within calibration d. configured correctly for the intended purpose

10. state methods of setting up and aligning components

a. use of straight edges b. feeler gauges c. plumb line d. spirit levels e. piano wire f. optical instruments g. lasers

11. state the need to replace ‘life determined’ items such as

a. seals b. gaskets

12. state that use of lubrication reduces

a. friction between moving parts b. wear c. generation of heat d. force required to overcome friction

13. list methods of applying lubricants

a. total loss b. re-circulatory c. splash d. grease guns and nipples

14. list types of oil used

a. mineral b. animal and vegetable c. synthetic

15. states the reasons for oil deterioration a. excessive heat b. oxidation c. contamination d. breakdown of structure e. poor storage conditions.

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Unit 709 Maintenance Technology 709.3 use dismantling/assembly techniques for

components/systems

Practical activities The candidate will be able to: 1. dismantle a engineering device or system 2. re-assemble a engineering device or system. Underpinning knowledge The candidate will 1. state the procedure for isolation and locking off a device/system 2. list sequence of operations used to dismantle/re-assemble a device/system 3. state the reason for proof marking when dismantling

a. to aid re-assembly 4. describe methods and techniques used when dismantling/re-assembling equipment

a. release of pressure/force b. extraction

i bearing extractors ii hub pullers iii diodes/transistors iv fuses v printed circuit boards

c. mandrel presses d. drifts e. alignment

5. state how components are separated by the removal of

a. nuts and bolts b. studs and screws c. clips d. keys e. range of electrical connectors f. soldered connections

6. states how to locate, secure, remove and refit

a. studs, bolts and screws b. pins and dowels c. keys d. bearings and shafts e. gears f. couplings g. springs h. seals and gaskets i. circlips j. rivets k. diodes

l. transistors m. fuses

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7. state how to remove and refit a. seals b. gaskets c. packings d. grommets

8. state how to correctly tension

a. belts b. chains

9. state the techniques used for cleaning dismantle components 10. state components to discard and replace when dismantling and re-assembling

a. high tensile bolts and washers b. nylon insert nuts c. locking devices d. split pins e. seals and gaskets

11. state that the fitting of mating parts may require

a. filing b. scraping c. locating d. cleaning

12. state the need for and use of

a. shims b. packings

13. state types and use of locking devices used for mechanical/electrical applications 14. state how to tighten fastenings correctly

a. correct torque applied b. correct tightening sequence

15. state the importance of completing a maintenance documentation following the

maintenance activity.

Unit 710 Assembling and Maintaining Hydraulic Systems

Rationale This unit identifies the basic principles and commonly used components that are for assembly and maintenance of hydraulic systems. It covers the assembly, testing and maintenance of hydraulic fluid systems. It further deals with assembly techniques, in order to assemble the various components which will include rigid and flexible pipe work, hoses, valves, actuators, cylinders regulators and sensors. Assembly activities include making checks and adjustments to ensure components are correctly positioned and aligned, are dimensionally accurate and secure, pipe work free from ripples, creases and damage, joints are checked for security, with threaded devices tightened correctly. Maintenance activities will involve gathering information from fault reports, using fault finding techniques, measuring, inspection and operation of equipment. Dismantle, remove and replace/repair faulty units/components, reassembly and test system. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 710.1 plan and prepare for assembly and maintenance activities 710.2 apply testing/fault finding techniques 710.3 dismantle, remove and replace/repair, re-assemble and test systems conform to

specification. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

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710.1 plan and prepare for assembly and maintenance activities

Practical activities The candidate will be able to: 1. plan a assembly/maintenance activity for simple hydraulic circuit 2. extracts information from drawings, charts, tables, manufacturers specifications 3. selects tools / equipment to undertake dismantling/assembling operations 4. compile a material/component list. Underpinning knowledge The candidate will be able to: 1. state the health and safety requirements / safe working practices and procedures for

assembly/maintenance activities involved with hydraulic systems a. wearing appropriate protective clothing and equipment b. maintaining a clean and tidy work area c. use of barriers and/or tapes d. post warning signs e. informing personnel of maintenance activities f. system isolation procedures for power and pressure sources g. permit-to work procedures


a. handling of oils and grease i toxicity ii harmful effects to skin and body

b. misuses of tools c. use of damaged or badly maintained tools d. stored energy/force e. not following laid-down maintenance procedures

3. state the procedure for

a. preparing the work area prior to carrying out a assembly/maintenance activity b. leaving the work area in a safe and clean condition c. provision for spillages d. access to tools

4. describe and interpret information relating to hydraulic systems

a. drawings b. charts c. circuit and physical layouts d. specifications e. manufacturers manuals f. maintenance reports

5. state how to compile material/component list from

a drawings b specifications

c associated data

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6. describe symbols used in hydraulic systems, current standards (BS 2917 and ISO 1219) a. valves – pressure, flow control, directional control b. actuators c. accumulators d. pumps e. filters f. reservoirs g. hoses and connectors h. gauges

7. state tools, equipment required for the assembling/maintaining and testing hydraulic

systems a. spanners b. torque wrenches c. screwdrivers d. allen keys

8. describe fastening devices used in assembly/maintaining hydraulic equipment

a. nuts bolts b. studs c. screws d. locking devices


a. description of work undertaken b. location(s) c. date and times (commencement, completion, handover) d. parts and consumable used e. test data f. permit to work reference

10. state when it is necessary to

a. act on your own initiative b. seek help/advice/assistance from others.


710.2 apply testing/fault finding techniques

Practical activities The candidate will be able to: 1. conduct a visual inspection of an assembled hydraulic system 2. connect appropriate test equipment to a hydraulic system 3. carry out a fluid power test 4. identify and rectify leaks or faults 5. prepare a test report. Underpinning knowledge The candidate will be able to: 1. state the safety checks required prior to testing/fault finding

a. ensure all pipes/components are secure b. moving parts are chocked or parked



3. state maintenance diagnostic techniques/aids that can be used



a. half split b. input-to-output c. function testing d. unit substitution e. equipment self diagnostics

5. list diagnostic aids available

a. manuals b. flow charts c. troubleshooting guides d. maintenance records

6. state how to connect and use suitable calibrated test/diagnostic equipment to circuit to

test and/or investigate problem 7. state the importance of correct calibration of test equipment 8. state the requirements for handling/application of mechanical measuring/test equipment

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a. measuring instruments b. press and flow indicators c. self diagnostic equipment

9. state the reason/ purpose of a. static tests

i to guarantee pressure tightness of a system under set conditions ii to locate leaks and faults in a system

b. dynamic test i to ensure correct operation of system components ii to ensure system performs to specification

10. describe how to carrying out tests

a. connecting hydraulic pumps and power packs to circuit b. filling hydraulic system with fluid c. bleeding air from system d. applying test pressures in incremental stages e. check for leaks f. take test readings g. adjust components to give required operating conditions h. re-run of tests to confirm that system performs to specification

11. list pre-test checks to be made

a. no open ends b. valves in test position/status c. moving parts in test position/status d. pipe/components fitted to specification e. clamps/brackets position and fitted correctly f. bleed vents accessible g. equipment/components which may damaged/faulty should be removed

12. list equipment required to carry out a pressure test

a. pump/pressure source b. calibrated pressure gauge c. connections d. leak detection fluids e. smoke candles

13. state how to

a display/record test results b complete relevant documentation

14. state the importance of ensuring test equipment is used only for its intended purpose and

within the specified range and limits 15. state how to make judgments or when to seek advice when deciding to

a replace a faulty unit b repair a simple fault c apply further fault tracing techniques

16. state how to complete relevant test/maintenance records/documentation by recording

a. description of work undertaken b. location(s) c. date and times (commencement, completion, handover) d. parts and consumable used e. test data f. movement of parts g. noise and vibration levels h. temperature i. adjustment required

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j. permit to work reference.


710.3 dismantle, remove and replace/repair, re-assemble and test systems conform to specification

Practical activities The candidate will be able to: 1. dismantle, remove, inspects faulty components in a hydraulic system 2. re-assemble a hydraulic circuit. Underpinning knowledge The candidate will be able to: 1. state the procedure/techniques used for dismantling a hydraulic system

a. release pressure b. proof marking c. extraction

2 state methods of checking that components are fit for purpose 3. state the importance of removing excessive dirt, dust, oil and grease prior to visually

checking for a. damage, distortion b. leaks

i pipes and hose connections ii cylinders and valves

c. corrosion 4. state the techniques used to remove and replace hydraulic system components

a valves i pressure ii flow iii directional control

b. actuators i single and double acting cylinders ii rotary

c. accumulators d. filters, strainers and lubricators e. pumps f. gauges g. pipes, hoses and connectors (rigid and flexible)

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5. state the techniques used to assemble/install hydraulic equipment a. identify and mark out position for components b. making bends for rigid pipework

i use of fittings ii hand bending methods

c. connecting components using i screwed fittings ii flanged fittings iii push in fittings

d. use of gaskets e. use of jointing and sealing compounds f. use of seals

i static ii dynamic

g. use equipment to i cut pipe to length ii form leak free joints

h. secure components and pipes using i clamps ii brackets

j. install flexible hose between rigid and moving components 6. state the need to ensure that pipework is supported at appropriate intervals to prevent

stress on pipework connections 7. state the need for purging pipework before connection to components and pressure

sources 8. state how contaminants can create problems, and can recognize the likely symptoms of

contamination within a hydraulic system 9. state the requirement of checking the condition and operation of tools/equipment 10. describes good house keeping practice

a. returning tools/equipment to storage b. returning unused components to storage c. retrieval of useable scrap and the transfer of waste scrap to safe storage

11. state how to report verbally and in writing all defects related to

a. tools b. equipment c. components.

Unit 711 Assembling and Maintaining Pneumatic Systems

Rationale It covers the assembly, testing and maintenance of pneumatic fluid systems. It further deals with assembly techniques, in order to assemble the various components which will include rigid and flexible pipe work, hoses, valves, actuators and ancillary components. Assembly activities include making checks and adjustments to ensure components are correctly positioned and aligned, are dimensionally accurate and secure, pipe work free from ripples, creases and damage, joints are checked for security, with threaded devices tightened correctly. Maintenance activities will involve gathering information from fault reports, using fault finding techniques, measuring, inspection and operation of equipment. Dismantle, remove and replace/repair fault units/components, reassembly and test system Learning outcomes There are three outcomes to this unit. The candidate will be able to: 711.1 plan and prepare for assembly and maintenance activities 711.2 apply testing/fault finding techniques 711.3 dismantle, remove and replace/repair, re-assemble and test systems conform to

specification. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

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711.1 plan and prepare for assembly and maintenance activities

Practical activities The candidate will be able to: 1. plan a assembly/maintenance activity for simple pneumatic circuit 2. extract information from drawings, charts, tables, manufacturer’s specifications 3. select tools / equipment to undertake a dismantle/assembly operation 4. compile a material/component list. Underpinning knowledge The candidate will be able to: 1. state the health and safety requirements and safe working practices and procedures for

assembly/maintenance activities involved with pneumatic systems a. wearing appropriate protective clothing and equipment b. maintaining a clean and tidy work area c. use of barriers and/or tapes d. post warning signs e. informing personnel of maintenance activities f. system isolation procedures for power and pressure sources g. permit-to work procedures


a. handling of compressed air i harmful effects to skin and body

b. stored energy/force c. misuses of tools d. use of damaged or badly maintained tools e. not following laid-down maintenance procedures


a. preparing the work area prior to carrying out a assembly/maintenance activity b. leaving the work area in a safe and clean condition c. provision for spillages d. access to tools

4. describe and interprets information relating to pneumatic systems

a. drawings b. charts c. circuit and physical layouts d. specifications e. manufacturers manuals f. maintenance reports

5. state how to compile material/component list from

a. drawings b. specifications c. associated data

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6. describe symbols used in pneumatic systems, current standards (BS 2917 and ISO 1219) a. valves

i pressure control – regulating and relief ii flow control – restrictors and by-pass form iii directional control – rotary and spool iv quick exhaust

b. actuators i linear – single and double acting ii cylinders iii rotary

c. accumulators d. pressure intensifiers e. filters f. silencers g. pipework connecting methods – rigid, flexible and push-in h. gauges

7. state tools, equipment required for the assembling/maintaining and testing pneumatic

systems a. spanners b. torque wrenches c. screwdrivers d. allen keys


a. description of work undertaken b. location(s) c. date and times (commencement, completion, handover) d. parts and consumable used e. test data f. permit to work reference




711.2 apply testing/fault finding techniques

Practical activities The candidate will be able to: 1. conduct a visual inspection of an assembled pneumatic system 2. connect appropriate test equipment to a pneumatic system 3. carry out a test on a pneumatic system 4. identify and rectify leaks or faults 5. prepare a test report. Underpinning knowledge The candidate will be able to: 1. state the safety checks required prior to testing/fault finding

a. ensure all pipes/components are secure b. moving parts are chocked or parked


a sight b sound c smell d. touch

3. state maintenance diagnostic techniques/aids that can be used



a. half split b. input-to-output c. function testing d. unit substitution e. equipment self diagnostics



6. state how to connect and use suitable calibrated test/diagnostic equipment to circuit to test and/or investigate problems 7. state the importance of correct calibration of test equipment 8. state the requirements for handling/application of mechanical measuring/test equipment

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a measuring instruments b pressure and flow indicators c self diagnostic equipment

9. state reason/purpose of a. static tests

i to guarantee pressure tightness of a system under set conditions ii to locate leaks and faults in a system

b. dynamic test i to ensure correct operation of system components ii to ensure system performs to specification

10. list equipment required to carry out a pressure tests

a. pump/pressure source b. calibrated pressure gauge c. connections d. leak detection fluids

11. state factors involved with carrying out a pressure test

a. applying pressure incremental stages b. checking for leaks c. taking test readings d. adjustment of components to give required operating conditions

12. state the importance of ensuring test equipment is used only for its intended purpose and

within the specified range and limits 13. state how to conduct visual checks to ensure that

a all connections have been completed b all components are secure c moving parts are ‘parked’

14. state how to make judgments or when to seek advice when deciding to

a. replace a faulty unit b. repair a simple fault c. apply further fault tracing techniques

15. state how to complete relevant test/maintenance records/documentation by recording

a. description of work undertaken b. location(s) c. date and times (commencement, completion, handover) d. parts and consumables used e. test data f. movement of parts g. noise and vibration levels h. temperature i. adjustment required j. permit to work reference.

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711.3 dismantle, remove and replace/repair, re-assemble and test systems conform to specification

Practical activities The candidate will be able to: 1. dismantle, remove, and inspect faulty components in a pneumatic system 2. re-assemble a pneumatic system. Underpinning knowledge The candidate will be able to: 1. state procedures/techniques used for dismantling pneumatic equipment/system

a. release pressure b. proof marking c. extraction d. label and store safely parts that have been removed

2. state methods of checking that components are fit for purpose 3. state the importance of removing excessive dirt, dust, oil and grease prior to visually

checking for a. damage, distortion b. leaks

i pipes and hose connections ii cylinders and valves

c. corrosion 4. mark out position for components

a. make bends for rigid pipework by i use of fittings ii hand bending methods

b. connect components using fittings i screwed ii flanged iii push in

c. use of gaskets d. use of jointing and sealing compounds

i use of seals ii static iii dynamic

e. use equipment to i cut pipe to length ii form leak free joints

f. securing components and pipe using i clamps ii brackets

g. install flexible hose between rigid and moving components

6. state the need to ensure that pipework is supported at appropriate intervals to prevent stress on pipework connections

7. state the need purging pipework before connection to components and pressure sources 8. states that contaminants can create problems, and can recognize the likely symptoms of

contamination within a pneumatic system 9. state the requirement of checking the condition and operation of tools/equipment 10. describe good house keeping practice

a. returning tools/equipment to storage b. returning unused components to storage c. retrieval of useable scrap and the transfer of waste scrap to safe d. storage

11. state how to report verbally and in writing all defects related to

a. tools b. equipment c. Components.

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Unit 712 Maintaining Mechanical Devices and Equipment

Rationale This unit identifies the basic principles and commonly used processes that are required to maintain mechanical devices and equipment. It covers basic maintenance requirements, routine inspection, lubrication and service of mechanical devices and equipment. It further deals with dismantling and re-assembly of equipment and the replacement of ‘life determined’ items. Devices and equipment to be covered include bearings and shafts, linkages, drives, couplings, valves, brakes, pumps and gearboxes. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 712.1 plan and prepare for maintenance activities 712.2 apply fault finding techniques 712.3 dismantle, inspect, replace if required and re-assemble mechanical devices and equipment. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed by a practical assignment together with underpinning knowledge evidence from a centre set question paper using questions from a City and Guilds devised question bank.


712.1 plan and prepare for maintenance activities

Practical activities The candidate will be able to: 1. plan a maintenance activity for simple component 2. extract information from drawings, charts, tables, manufacturers specifications 3. select tools / equipment to undertake a dismantling or assembly operation. Underpinning knowledge The candidate will be able to: 1. state the health and safety requirements and safe working practices and procedures for

maintenance activities a. wearing appropriate protective clothing and equipment b. maintaining a clean and tidy work area c. use of barriers and/or tapes d. post warning signs e. informing personnel of maintenance activities f. system isolation procedures for power and pressure sources g. permit-to work procedures.


a. handling of oils and grease b. misuses of tools c. use of damaged or badly maintained tools d. not following laid-down maintenance procedures


a. preparing the work area prior to carrying out a maintenance activity b. leaving the work area in a safe and clean condition

4. describe and interprets information relating to maintenance, lubrication, dismantling and

re-assembly of mechanical devices / equipment a. drawings

i orthographic ii isometric iii exploded views

b. maintenance manuals c. manufacturers instructions d. technical specifications e. charts f. tables g. job instructions

5. state how to deal with problems encountered during maintaining mechanical

devices/equipment a. fastenings damaged during dismantling b. components not easily parted c. correct tools not available

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d. unavailability of spares

6. state the range of tools, equipment required to undertake a dismantling/re-assembly operation a. spanners

i open ended ii socket sets iii ring

b. hammers and mallets c. screwdrivers d. pliers and grips e. chisels, punches, drifts and wedges f. nut splitters g. stud extractors h. measuring instruments

i rules, tapes ii micrometers iii vernier height gauge and calipers iv feeler gauges v dial test indicators

7. state that tools/equipment should be

a. free from damage or defect b. in a safe and usable condition c. within calibration d. configured correctly for the intended purpose

8. state how to recognize wear and/or damage to component parts

a. bearings and shafts b. linkages c. drive belts and chains d. couplings e. clutches f. brakes g. gearboxes h. seals and gaskets

9. state factors to be considered when using lifting equipment

a. estimation of approximate weight i use of manufacturers data

b. centre of gravity of component c. angle of splay between two leg sling chains not to exceed 120° d. never exceed the safe working load (SWL) e. inspection records for lifting equipment are current

10. list types of lifting equipment and state an application

a. screw and hydraulic jacks b. overhead gantry cranes c. mobile cranes d. jib cranes and derricks e. fork lift trucks f. tripods, shackles and pulley blocks

11. describe methods of moving heavy equipment across flat surfaces

a rollers and skates b crowbars c pull-lifts d lubricated plates

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12 states when it is necessary to a. act on your own initiative b. seek help/advice/assistance from others

13. lists the information required when completing a report following a maintenance activity

a. description of work undertaken b. location(s) c. date and times (commencement, completion, handover) d. parts and consumable used e. test data f. permit to work reference.

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712.2 apply fault finding techniques

Practical activities The candidate will be able to: 1. identify visually common faults in a mechanism 2. use fault finding equipment. Underpinning knowledge The candidate will be able to: 1. state how to evaluate using sensory information


2. state maintenance diagnostic techniques and aids that can be used



a. half split b. input-to-output c. function testing d. unit substitution e. equipment self-diagnostics



5. state the procedures for removing

a. guards b. inspection covers c casings d. fluids

6. state the techniques available to remove excessive a. dust

i blow ii vacuum

b. dirt i brushing ii vacuum

c. grease i degreasing ii solvents iii steam

7. state faults that can be identified by visual, tactile, audible and smell checks

a. metal fractures b. surface cracking c. loose or damaged fastenings d. broken chains/belt drives e. excessive clearance f. leakage from seals and gaskets g. excessive temperature of bearings, breaks and drives h. unfamiliar noise

8. state common faults that occur with mechanical devices and equipment

a. vibration b. wear and abrasion c. overheating d. out of balance e. fractures f. corrosion

9. state common visual checks for

a. signs of leakage b. damage c. missing parts d. wear and deterioration

10. state movement checks for

a. excessive movement or clearance b. loose fittings and connections

11. state force and pressure tests for

a. springs b. belt and chain tension

12. state overheating checks for

a. bearings b. friction surfaces

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712.3 dismantle, inspect, replace if required and re-assemble mechanical devices and equipment

Practical activities The candidate will be able to: 1. dismantle a mechanical device or system 2. re-assemble a mechanical device or system 3. prepare a report following a maintenance activity. Underpinning knowledge The candidate will be able to: 1. list a sequence of operations for dismantle/re-assemble components 2. state the reason for proof marking during dismantling

a. to aid re-assembly 3. state correct storage procedures for removed parts 4. state methods and techniques used to dismantle/re-assemble equipment

a. release of pressure/force b. extraction

i bearing extractors ii hub pullers

c. mandrel presses d. drifts e. alignment

5. state how components are separated by the removal of

a. nuts and bolts b. studs and screws c. clips d. keys

6. state how to remove and refit

a. studs, bolts and screws b. pins and dowels c. keys d. bearings and shafts e. gears f. couplings g. springs h. seals and gaskets i. circlips j. rivets k. seals l. gaskets m. packings

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7. state how to correctly tension a. belts b. chains

8. state how to check dimensional accuracy and clearance of component parts using

a. internal / external micrometers b. vernier calipers c. vernier height gauges d. dial test indicator e. protractor f. feeler gauges

9. state components to discard and replace when dismantling and re-assembling

a. high tensile bolts and washers b. nylon insert nuts c. locking devices d. split pins e. seals and gaskets

10. state the need to lay out components parts in logical sequence in preparation for re-

assembly 11. state fitting of mating parts may require

a. filing b. scraping

12. state the need for the use of

a. shims b. packings

13. state the type and use of locking devices 14. state how to tighten fastenings correctly

a. correct torque applied b. correct tightening sequence

15. state lubrication requirements for a device/system

a. types of oil and grease b. methods of application

16. state the importance of completing a maintenance documentation following the

maintenance activity.

Unit 713 Maintaining and testing Electrical Circuits

Rationale This unit covers the basis competencies required to safely and effectively carry out maintenance and testing of electrical circuits/components. Candidates will be required to plan and prepare resources and equipment, obtain system information, carry out testing and interpret results, repair/replace components, implement safe systems of work to comply with health and safety regulations and effectively reinstate the system and workplace when maintenance activities have been completed. Candidates will be required to maintain a range of electrical equipment/circuits operating on single phase, three phase, and direct current power sources along with their associated control circuits. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 713.1 plan and prepare resources for electrical maintenance activities 713.2 diagnose and repair faults in electrical systems and equipment 713.3 commission the system and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 713 Maintaining and testing Electrical Circuits 713.1 plan and prepare resources for electrical

maintenance activities

Practical activities The candidate will be able to: 1. apply health and safety requirements and safe working practices 2. obtain and correctly interpret fault information/maintenance task 3. obtain all the appropriate systems information 4. develop a work plan 5. select tools, equipment, replacement components, consumable and carry out checks to

ensure they are safe and fit for use 6. apply health and safety requirements and safe working practices Underpinning knowledge The candidate will be able to: 1. state the safety regulations and acts applicable to maintaining and wiring electrical circuits

a. Health and Safety At Work Act b. IEE Wiring Regulations c. Electricity at Work Act d. Portable Appliance Testing (PAT)

2. state the health and safety requirements and safe working practices for undertaking

electrical maintenance activities a. use of protective clothing and equipment b. clean and tidy work area c. use of barriers and/or tapes d. displaying of warning signs e. electrical isolation and locking off switch gear f. permit-to-work procedures and control documentation g. isolation of all potential energy sources h. inform personnel of maintenance activities

3. state sources of support and/or guidance should you encounter any activity that is outside

your lines of responsibility 4. state their responsibilities under the Health and Safety at Work Act 5. state the importance of wearing personal protective equipment and explain what

protection each will provide to the user a. overalls b. safety footwear c. gloves d. barrier cream e. eye protection

6. state how to recognise and deal with victims of electrical shock

a. methods of safely removing the victim from the power source b. isolating the power source c. methods of first aid resuscitation

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7. state the basic principles of risk assessment a. definitions

i risk ii hazard iii harm

b. stages c. reporting

8. state the hazards associated with carrying out electrical maintenance activities and how

they can be minimised a. dangers of electrical shock b. stored energy/force c. capacitor discharge d. misuse of tools e. using damaged or badly maintained tools and equipment f. not following laid-down maintenance procedures

9. state the essential operator and bystander safety requirements

a. permit to work procedure b. warning signs c. barriers

10. state the need to produce a work plan and list the information it should contain

a. names of people involved b. authorisation names/signature c. times/dates d. order of activities e. description of activities f. isolation methods g. materials and equipment required

11. list the types and sources of system information available

a. job instructions/cards b. manufacturer manuals c. circuit/block/flow schematic diagrams d. equipment and system specifications e. maintenance history/records f. equipment self diagnostic information

12. state the procedures for ensuring the care and safe keeping of system information

a. maintain page/document order b. keep clean and free from damage c. storage is suitable and accessible d. return to designated storage

13. state the procedures for obtaining materials, replacement parts and other consumables

for maintenance activities a. complete requisition

i request name/date/times ii job reference and description iii component/replacement part specifications iv material quantities

b. authorisation names/signatures

14. state the range of tools/equipment required and their typical uses a. hand tools

i screwdrivers ii pliers/side cutters iii cable strippers iv crimping tools v spanners/sockets

b. power tools i portable drill (110v) ii battery drill iii jig saw

c. soldering iron, solder and fluxes d. hacksaw, hole cutters and files e. stocks, dies and conduit forming equipment

15. state the checks that should be made to tools and equipment to ensure they are

a. free from damage or defects b. in a safe and usable condition c. appropriate to the job d. within current calibration date e. capable of covering the range of values to be measured

16. state the types of test equipment that can be used when maintaining electrical systems

a. multimeter b. tracing device c. insulation tester d. continuity tester

17. state the basic principles of how the system/equipment to be maintained operates and the

working purpose of individual units/components 18. state the basic operating principles of lighting, power and control circuits 19. state the need for safe lifting and handling of equipment.

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Unit 713 Maintaining and testing Electrical Circuits 713.2 diagnose and repair faults in electrical systems

and equipment

Practical activities The candidate will be able to: 1. set-up test equipment 2. interpret and record instrument readings/test results 3. isolate components to ensure they are safe for disconnection 4. replace/repair faulty components using appropriate tools and techniques 5. carry out “off load” checks. Underpinning knowledge The candidate will be able to: 1. state the procedures for safe handing, care and use of electrical measuring instruments

a. equipment is displaying a current calibration label b. maintained in accordance with manufacturers instructions c. instrument case/covers are utilised d. test leads are suitable and in good condition e. battery powered equipment is sufficiently charged for use

2. state the checks that should be made to ensure

a. system/equipment is isolated b. all sources of potential energy in the system are made safe c. circuits are proven “dead” after isolation

3. state the range of fault diagnosis techniques

a. fault reports b. visual checks c. half split d. input-to-output checks e. measurement, movement and alignment checks f. functional testing g. comparing actual instrument readings to circuit specifications h. component or unit substitution i. equipment/system self diagnostic

4. state the meaning of the terminology used in fault diagnosis

a. symptom b. fault c. cause

5. state the type of test equipment and their mode of operation for testing

a. continuity of main and supplementary equal potential bonding conductors b. continuity of ring main conductors and protective conductors c. insulation resistance between live conductors and earth conductor d. polarity e. earth loop impedance f. functional testing of circuits and residual current devices

6. state the basic units of measurement a. mega b. kilo c. standard units

i volt ii ampere, iii ohm

d. milli e. micro

7. state the Ohms Law calculations for voltage, current and resistance that will enable test

measurements to be evaluated against actual circuit specifications a. V = I x R

8. state the need to know how to take instrument readings and translate them into circuit

values measurements 9. state the need to know how to identify test points from information provided on circuit

diagrams and specifications 10. explain briefly the typical faults and their probable causes that can occur with electrical

equipment and circuits a. open circuit b. short circuit c. resistance fault d. mechanical component fault

11. state how to conduct visual checks for

a. damaged conductors b. insulation stripped back too far c. loose/broken connections d. over heated surface cables or components e. burnt or over heated casings f. correct value circuit fuses/protection devices

12. state the methods available for attaching identification makers/labels to aid the process

of component and/or cable replacement a. push-on numbers/letters b. labels/tape

13. state the methods and techniques used for assembly and terminating system components

a. plug and socket b. soldered joints c. crimped connection d. screw connections e. clamped connections f. junction box g. terminal blocks

14. state the methods for protecting and removing cables/wires from enclosures without

causing damage to existing cables 15. describe how to use BS7671, IEE wiring and other current regulations when selecting

cables and current carrying capacities

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16. state methods of checking that replacement components are fit for purpose and meet specification a. visual inspection b. determine operating characteristics from label/makings c. confirm model/part numbers d. check with manufacturer’s data

17. state how to select equivalent components when direct replacements are not available

a. compare operating characteristics b. source equivalent from parts manuals c. seek advice from component suppliers d. obtain information/data from manufactures

18. state the need to make “off load” checks before re-applying power to the

equipment/system a. testing and final inspection in a safe and controlled environment b. prevents damage to equipment/components if the fault has not been rectified c. reduces the potential risk of injury to personnel.

Unit 713 Maintaining and testing Electrical Circuits 713.3 commission the system and reinstate the work

area

Practical activities The candidate will be able to: 1. Complete isolation procedure and reinstate the supply 2. Carry out final checks to ensure system/equipment meets operational requirements 3. Return the work area into a safe and health environment 4. Update maintenance records accurately and legibly 5. Notify the appropriate personnel when the system is operational Underpinning knowledge The candidate will be able to: 1. state the need to complete isolation control documentation and procedures before

reinstating the supply a. demonstrate you have complied with health and safety procedures b. protect others who may still be working on the system c. formally record your intensions to reinstate the supply

2. state the methods of confirming that the fault/maintenance task has been completed

successfully a. observation of the system/component in operation b. conformation with operator(s) c. information from equipment screens or self test facilities d. readings from test/monitoring equipment

3. state the requirements for leaving the work area in a safe and clean condition

a. return hand tools and equipment to designated storage locations b. remove waste materials and debris c. return surplus components and materials to stores

4. state the information required for recording or updating maintenance documentation

a. description of work undertaken b. fault information c. location(s) d. date and times (commencement, completion, handover) e. parts and consumable used f. test data g. permit to work reference

5. state who to informed when the maintenance activity is complete

a. supervisor b. colleagues involved in the same activity c. operators d. associated departments e. customers

6. state the need to re-ordering used items to maintain stock levels

141

Unit 714 Installing and Maintaining Electrical Wiring Support Systems

Rationale This unit covers the competencies required to carry out the maintenance of electrical wiring support systems that will involve the preparation, assembly and fixing of components that make up conduit, trunking or tray work systems. To carry out the maintenance safely and effectively you will be expected to plan your schedule of work, use a variety of methods to cut, bend and form conduit, construct or modify trunking or tray work systems, make appropriate connections using approved fittings, position and secure components using approved mechanical fastening devices, select and correctly use appropriate tools and consistently implement safe working practices. Your responsibilities will require you to consistently comply with health and safety requirements and organisational policy and procedures. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 714.1 plan and prepare resources for maintenance electrical wiring support systems 714.2 diagnose and repair faults in electrical support systems 714.3 commission the system and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.


714.1 plan and prepare resources for maintenance electrical wiring support systems

Practical activities The candidate will be able to: 1. apply health and safety requirements and safe working practices 2. obtain information for the forming, assembly and replacement activities 3. develop a work plan 4. inspect existing installation and list system/component specifications 5. select tools, equipment, replacement components, consumable and carry out checks to

ensure they are safe and fit for use. Underpinning knowledge The candidate will be able to: 1. state the safety regulations and acts applicable to maintaining and wiring electrical

support systems a. Health and Safety At Work Act b. IEE Wiring Regulations c. Electricity at Work Act


electrical maintenance activities a. use of protective clothing and equipment b. clean and tidy work area c. use of barriers and/or tapes d. displaying of warning signs e. electrical isolation and locking off switch gear f. permit-to-work procedures and control documentation g. isolation of all potential energy sources informing personnel of maintenance

activities 3. state sources of support and/or guidance should you encounter any activity that is outside





143




8. state the hazards associated with carrying out electrical maintenance activities and how

they can be minimised a. dangers of electrical shock b. stored energy/force c. misuse of tools d. using damaged or badly maintained tools and equipment e. not following laid-down maintenance procedures






a. job instructions/cards b. equipment and system specifications c. maintenance history/records d. product catalogues/manuals


a. maintain page/document order b. keep clean and free from damage c. storage is suitable and accessible d. return to designated storage.




b. authorisation names/signatures 14. state the basic components of a conduit, trunking and tray work electrical support system

a. bends b. tees c. straight through connections or couplings d. inspection fittings

e. sets f. screw and cement fittings g. light, power and control outlet boxes

15. state the procedures for obtaining materials, replacement parts and other consumables 16. state the tools/equipment and their typical uses for carrying cutting, bending, forming,

joining, fixing on electrical support systems a. saws b. files c. vices d. hammer e. screwdriver f. stocks and dies g. conduit bending machine h. bending spring i. hole punches and cutters j. hot air guns k. levelling device l. plumb bob m. power tools

i portable drill (110v) ii battery drill iii jig saw

n. access equipment 17. state the checks that should be made to tools and equipment to ensure they are

a. free from damage or defects b. in a safe and usable condition c. appropriate to the job

18. state the need for safe lifting and handling of equipment.

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714.2 diagnose and repair faults in electrical support systems

Practical activities The candidate will be able to: 1. carry out inspection of support systems inline with agreed work plan 2. identify faulty or defective components 3. isolate system/components 4. replace/repair conduit, trunking or tray work components using appropriate techniques 5. determine new or repaired components conform to specification and dimension accuracy Underpinning knowledge The candidate will be able to: 1. state the checks that should be made to ensure


2. state the typical faults that can occur with electrical wiring support systems

a. loose bracketry b. insufficient or missing fixings c. welded joints broken d. excessive weight from cables e. damage from moving vehicles f. wear from moving parts g. links/supports broken on flexible harnesses h. earth bonding devices removed or loose

3. state the types of fitting used to assemble conduit, trunking and tray work systems

a. screw fittings b. cement fittings c. straight connectors d. bends and angles fittings e. unction boxes f. tee and elbow inspections fittings g. light, power and control outlet boxes

4. state the types of fixing devices, supports and joins that are used in electrical support

systems a. masonry fixings b. saddles c. pins, nuts and washers d. threaded rod e. fabricated bracketry f. welded joins g. ceiling/roof suspension fittings h. adhesives

5. state how to determine bedding, screwing and joining allowances when repairing electrical support systems

147

6. state the need to site components clear of other services such as gas, water, electricity, communications and data a. prevent accidental damage to other services b. reduce interference or electrical noise

7. state how to mark out, bend and fabricate conduit, trunking and tray, taking into account

allowances for a. bends b. screwing c. offsets d. bridge sets e. double saddle sets to tolerance within +/- 5mm f. tee junctions g. use of adhesives h. fabricating i. joining operations

8. state the method of securely holding work pieces without causing damage 9. state how to bend plastic conduit using a hot air gun and springs 10. state how to mark out and check alignment of components using

a. levels b. plumb bob c. visual means

11. state the need to maintain the earth bonding continuity throughout the support system. 12. State the methods for protecting and removing cables/wires from enclosures without

causing damage to existing cables. 13. state precautions to be taken when using cutting and bending tools and equipment

a. moving parts b. sharp edges c. skin protection from grease, cutting compounds and fluids

14. state the factors that should be considered when selecting/replacing or repairing conduits,

trunking or tray work a. ambient temperature within the conduit b. cable grouping factors c. environment d. future expansion of the system

15. state the type of device and their operating characteristics for detecting hidden services 16. state the specific safety precautions when carrying out maintenance activities involving

the use of solvents and adhesives.


714.3 commission the system and reinstate the work area

Practical activities The candidate will be able to: 1. complete isolation procedure and reinstate the supply 2. carry out final checks to ensure support system meets specification 3. return the work area into a safe and health environment 4. update maintenance records accurately and legibly 5. notify the appropriate personnel when the system is operational. Underpinning knowledge The candidate will 1. state the need to complete isolation control documentation and procedures before




3. state the information required for recording or updating maintenance documentation

a. description of work undertaken b. fault information c. location(s) d. date and times (commencement, completion, handover) e. parts and consumable used f. permit to work reference


a. supervisor b. colleagues involved in the same activity c. operators d. associated departments e. customers

5. state the need to re-ordering used items to maintain stock levels.

149

Unit 715 Maintaining Instrumentation and Control Systems

Rationale This unit covers the competencies required to carry out the maintenance and calibration of instrumentation and control systems and their associated sensing elements. You will be require to gain a basic understanding of the operating characteristic of system input/output devices that are used to monitor temperature, pressure, levels, flow, weight, mass, speed, vibration, fire and gas detection, alarm systems etc. To carry out the maintenance safely and effectively you will be expected to plan your schedule of work, use a variety of recognised fault finding techniques and diagnostic aids, gather information from fault reports and system documentation, measure, inspect and calibrate components and consistently implement safe working practices. Your responsibilities will require you to comply with health and safety requirements and organisational policy and procedures for the safe and effective maintenance of instrumentation and control equipment. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 715.1 plan and prepare resources for maintaining and testing instrumentation systems 715.2 diagnose and repair faults with instruments and sensing devices 715.3 commission the system, calibrate instruments and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper. .


715.1 plan and prepare resources for maintaining and testing instrumentation systems

Practical activities The candidate will be able to: 1. apply health and safety requirements and safe working practices 2. obtain and correctly interpret fault information/maintenance task 3. obtain all the appropriate systems information 4. establish operating characteristics of system 5. develop a work plan 6. select tools, equipment, replacement components, consumable and carry out checks to

ensure they are safe and fit for use. Underpinning knowledge The candidate will be able to: 1. state the safety regulations and acts and safe applicable to maintaining instrumentation

systems a. Health and Safety At Work Act b. IEE Wiring Regulations c. Electricity at Work Act d. Portable Appliance Testing (PAT)


electrical maintenance activities a. use of protective clothing and equipment b. clean and tidy work area c. use of barriers and/or tapes d. displaying of warning signs e. electrical isolation and locking off switch gear f. permit-to-work procedures and control documentation g. isolation of all potential energy sources h. informing personnel of maintenance activities





a. methods of safely removing the victim from the power source

151

b. isolating the power source c. methods of first aid resuscitation




8. state the hazards associated with maintenance of instrumentation systems and how they

can be minimised a. dangers of electrical shock b. stored energy/force c. misuse of tools d. using damaged or badly maintained tools and equipment e. not following laid-down maintenance procedures






a. Job instructions/cards b. Manufacturer manuals c. Circuit/block/flow schematic diagrams d. Equipment and system specifications e. Maintenance history/records f. Equipment self diagnostic information


a. maintain page/document order b. keep clean and free from damage c. storage is suitable and accessible return to designated storage




b. authorisation names/signatures

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14. state the range of tools/equipment required and their typical uses a. hand tools

i screwdrivers ii pliers/side cutters iii cable strippers iv crimping tools v spanners/sockets


c. soldering iron, solder and fluxes 15. state the types of equipment that can be used when maintaining instrumentation systems

a. multimeter b. insulation tester c. Continuity tester d. Oscilloscope



17. state the operating characteristics and typical applications for the following sensing

devices; a. pressure

i bourdon tube ii diaphragm iii manometer iv barometer

b. temperature i resistance, ii expansion iii thermocouple

c. level i sight glass ii float iii pressure pads

d. flow i venturi tube ii rotometer iii turbine iv inferential

18. state the basic principles of how the system/equipment to be maintained operates and the

working purpose of individual units/components

Unit 715 Maintaining Instrumentation and Control Systems Unit 701 Working in Engineering

715.2 diagnose and repair faults with instruments and sensing devices

Practical activities The candidate will be able to: 1. carry out visual checks to instruments and other system components 2. set-up test equipment 3. interpret and record instrument readings/test results 4. use diagnostic techniques to establish system, unit or component fault 5. isolate components to ensure they are safe for disconnection 6. replace/repair faulty components using appropriate tools and techniques 7. carry out “off load” checks. Underpinning knowledge The candidate will be able to: 1. state the procedures for safe handing, care and use of test/monitoring equipment

a. equipment is displaying a current calibration label b. maintained in accordance with manufacturers instructions c. ensure instrument case/covers are utilised d. test leads are suitable and in good condition e. battery powered equipment is sufficiently charged for use

2. state the reasons for ensuring that control systems are isolated, switched into manual

mode or the appropriate safety interlocks are inserted before any instruments or sensing devices are disconnected from the system and the consequences of this not being undertaken

3. state the checks that should be made to ensure


4. state the methods for ensuring instruments/devices are safe to be worked on

a. full system isolation b. circuit isolation c. individual instrument/component isolation

5. state the reason voltage levels of power supplies should be verified and ratings of

fuses/circuit protection devises be confirmed a. over voltage could damage equipment/component b. circuits/equipment may be incorrectly protected against over current

6. state the range of fault diagnosis techniques

a. fault reports b. visual checks c. half split d. checking Input-to-outputs e. measuring, movement and alignment checks

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f. functional testing g. comparing actual instrument readings to circuit specifications h. component or unit substitution i. equipment/system self diagnostic.

7. state the meaning of the terminology used in fault diagnosis a. symptom b. fault c. cause

8. state the types of equipments used for testing and obtain readings/measurements from

electronic instruments and sensing devices a. multimeter b. continuity tester c. oscilloscope d. signal injection equipment

9. state the basic techniques used to ensure instruments and sensing devices are operating

effectively and to specification a. setting instrument zero readings b. obtaining instrument readings and make comparison to circuit parameters c. making adjustments to instruments/circuit components d. calibration

10. state the basic units of measurement

a. mega b. kilo c. standard units

i volt ii ampere iii ohm

d. milli e. micro





diagrams and specifications 14. explain briefly the typical faults and their probable causes that can occur with

instrumentation systems a. open circuit b. short circuit c. resistance fault d. mechanical component fault e. instruments/devices not calibrated f. interference or noise

15. state how to conduct visual checks for

a. damaged conductors b. insulation stripped back too far c loose/broken connections

d. over heated surface cables or components e. burnt or over heated casings f. correct value circuit fuses/protection devices

157

16. state the methods available for attaching identification makers/labels to aid the process of component and/or cable replacement a. push-on numbers/letters b. labels/tape

17. state the methods and techniques used for assembly and terminating system components


18. state the methods for protecting and removing cables/wires from enclosures without

causing damage to existing cables 19. state how to select replacement instruments and sensing devices by their

a. operating requirements b. working range c. manufactures specification d. name plate/markings

20. state how to select equivalent components when direct replacements are not available

a. compare operating characteristics b. source equivalent from parts manuals c. seek advice from component suppliers d. obtain direct information/data from component manufactures

21. state the techniques used for installing and wiring instruments, sensing devices and

system components to avoid faulty readings caused by a. head correction b. poor flow pass sensors c. blockages d. incorrect wiring e. poor insulation f incorrect materials g. electronic interference h mechanical damage i. pressure surges j. thermal shock




715.3 commission the system and reinstate the work area

Practical activities The candidate will be able to: 1. complete isolation procedure and reinstate the supply 2. calibrate/adjust instrumentation and sensing devices 3. carry out final checks to ensure system/equipment meets operational requirements 4. return the work area into a safe and health environment 5. update calibration and maintenance records accurately and legibly. Underpinning knowledge The candidate will be able to: 1. state the need to complete isolation control documentation and procedures before


2. state the methods of confirming that the fault/maintenance task has been completed

successfully a. observation of the system/component in operation b. conformation with operator(s) c. information from equipment screens or self test facilities d. readings from test/monitoring equipment

3. state why all system instrumentation and devices should be correctly calibrated and what

would be the effect of this not being carried out 4. state how to interpret calibration data from

a. specification charts or tables b. manufacturers manuals or data sheets c. operational requirement parameters d. component specification labels

5. state how to use calibrations equipment to ensure that electronic instruments and sensors

are providing optimum performance a. dead weight tester b. tandem gauge tester c. weight tank d. multimeter e. oscilloscope f. manometer g. barometer h. constant voltage/current power sources

i signal sources ii comparators

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6. state how to identify suitable connection points calibration equipment.

7. state how to make adjustments to recalibrate or improve the accuracy of instrument or device output parameters



9. state the procedures for recording and labelling calibrated equipment 10. state the information required for recording or updating maintenance documentation

a. description of work undertaken b. fault information c. location(s) d. date and times (commencement, completion, handover) e parts and consumable used f. test data g. permit to work reference


a. supervisor b. colleagues involved in the same activity c. operators d associated departments e. customers

12. state the need to re-ordering used items to maintain stock levels.

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Unit 716 Fabrication and Welding Technology

Rationale This unit is concerned with the technology that underpins fabrication and welding processes. The unit covers the basic principles of welding, fabrication materials, weld symbols and terminology, distortion, weld defects, heat affects of welding, forming allowances ad non-destructive and workshop testing. Learning outcomes There are four outcomes to this unit. The candidate will be able to: 716.1 recognise the basic principles of welding 716.2 select and apply welding terminology and symbols 716.3 recognise effects of welding 716.4 identify common metals used in fabrication and determine forming allowances. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an underpinning knowledge test paper.

Unit 716 Fabrication and Welding Technology 716.1 recognise the basic principles of welding

Practical activities The candidate will be able to: 1. identify the effects of electricity in welding 2. demonstrate influence of electrode coverings 3. demonstrate influence of shielding gases/gas mixtures 4. show the effects of welding flame conditions. Underpinning knowledge The candidate will be able to: 1. describe electricity in welding terms

a. arc voltage b. welding current c. types of current

i alternating current (ac) ii direct current (dc)

d. ‘arc blow’ i influence of joint geometry ii influence of type of current iii methods of avoidance

2. explain the main purposes of electrode coverings

a. types of covering i rutile ii basic iii iron powder

b. effects of fluxes and electrode coverings on welding processes i facilitates arc striking ii stabilises and directs the arc iii assists control of the size and frequency of filler metal globules/droplets iv filler metal from atmospheric contamination during transfer vi provides appropriate weld contour vii prevents rapid cooling of weld metal (thermal blanket effect) viii provides a flux for the molten pool to remove oxides and impurities ix supplies additional metal to weld pool

3. explain the main purposes of shielding gases

a. tungsten-inert gas (TIG) welding i argon ii helium iii Ar/H2 for stainless steels iv Ar/N2 for copper v De-oxidised N2 for copper

b. metal inert gas/metal active gas (MIG/MAG) welding non carbon steels. c. influence of shielding gases

i protection from gases in the atmosphere A. composition of air

ii mode of metal transfer iii penetration

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iv weld bead profile v speed of welding vi wetting/undercutting tendency

4. explain the effects of combustion a. geometry of oxy-acetylene gas welding flame

i inner cone ii outer envelope iii different flame types and their applications

A. neutral B. oxidising C. reducing (carburising)

iv hottest region of flame.

Unit 716 Fabrication and Welding Technology 716.2 select and apply welding terminology and symbols

Practical activities The candidate will be able to: 1. use correct terminology to join features 2. identify types of welded joints to current standards 3. select joint preparations for welding applications. Underpinning knowledge The candidate will be able to: 1. describe the features of a welded joint

a. face b. toes c. root d. HAZ (heat affected zone) e. convex fillet profile f. concave fillet profile g. mitred fillet profile h. leg i. throat j. root face k. root gap l. bevel angle m. included angle n. weld width o. fusion zone (depth of fusion) p. excess weld metal q. penetration r. fusion line (boundary)

2. outline the use of current standards and symbols for the communication of the designation

of welded joints on drawings a. types of joint

i butt ii tee iii lap iv corner

b. types of welded preparation i square butt (open) ii square butt (closed) iii flanged butt iv single-vee butt v double-vee butt vi fillet vii spot viii seam ix projection x edge

c. application of types of weld preparation to types of joint in a. i arrow line

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ii reference line iii identification line iv symbol

d. dimensioning of welds i leg length ii throat thickness iii fillet welds iv root gaps.

Unit 716 Fabrication and Welding Technology 716.3 recognise effects of welding

Practical activities The candidate will be able to: 1. demonstrate the heat input of a welded joint 2. identify the heat-affected zone in a welded joint 3. use methods of temperature measurement 4. demonstrate heat transfer/loss 5. identify the effects of distortion 6. use methods of distortion control 7. recognise weld defects and possible causes correctly 8. use non-destructive testing (NDT) methods 9. use workshop testing methods. Underpinning knowledge The candidate will be able to: 1. outline the heat distribution during welding

a. effects on the structure of the weld metal b. effects on the structure of the parent metal

2. outline the effects of heat

a. temperature b. methods of heat production used in welding and related activities

i welding processes A. arc B. resistance C. gas welding

c. methods of temperature measurement used in welding and related activities i pyrometer ii temperature indicating crayons

d. means of heat transfer/loss i conduction ii convection iii radiation 3. describe the reasons for distortion

a uneven expansion and contraction b degree of restraint

4. identify the types of distortion

a. longitudinal b. transverse c. angular

5. explain the methods of distortion control

a. presetting b. pre-bending c. weld sequencing d. skip welding e. back-stepping

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f. tack welding g. joint design h. chills i. restraint

i clamping ii jigs iii back-to-back assembly

6. describe types of weld defects to current standards

a. cracks b. lack of fusion

i side wall ii root iii interpass

c. porosity d. isolated pore e. piping f. craters g. slag inclusions h. tungsten inclusions i. lack of penetration j. undercut k. excessive weld metal l. underfil m. concavity n. overlap o. burn-through

7. explains possible causes of weld defects 8. describe the visual examination of welded joints

a. applications b. equipment c. advantages d. disadvantages

9. describe dye penetrant testing

a. test procedure b. application c. advantages d. disadvantages

10. describe magnetic particle testing

a. magnetic flow i types of magnet

A. horseshoe B. yoke

b. current flow c. types of magnetisation

i prods d. test procedure e. applications f. advantages g. disadvantages

11. describe radiography a. sources of radiation

i x-ray ii gamma ray

b. applications c. advantages d. disadvantages e. radiation hazards

i effects of radiation on the human body ii radiation monitoring iii personal monitoring iv radiation enclosures v precautions for site radiography

f. radiographic techniques i plate

g. film processing i manual ii automatic

h. interpretation of results i radiographic appearance of weld ii radiographic appearance of parent metal

12. describe ultrasonic testing

a. procedure b. applications c. advantages d. disadvantages e. techniques

i thickness testing ii transmission method iii reflection method

13. describe the workshop testing of welded joints

a. bend tests i root ii face iii side

b. fracture (nick break) c. macro examination d. cupping test (ductility).

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Unit 716 Fabrication and Welding Technology 716.4 identify common metals used in fabrication and

determine forming allowances

Practical activities The candidate will be able to: 1. identify common metals used in fabrication 2. group metals as ferrous and non-ferrous 3. select metals for a given application 4. determine the bending allowances for fabricated forms from information supplied 5. determine the rolling allowances for fabricated forms from information supplied. Underpinning knowledge The candidate will be able to: 1. describe the range of common metals used in fabrication engineering

a. low-carbon steel b austenitic stainless steels c. clad and coated materials

i galvanised steel ii tin plated steel iii plastic coated steel iv clad steels v anodised aluminium

d. aluminium/aluminium alloys e. copper/copper alloys

2. describe the range of commercial forms of supply

a. sheet b. plate c. angle

i equal leg ii unequal leg

d. hollow i square ii rectangular iii round (tubular)

e. pipe 3. outline the criteria for the selection of materials for a given application

a. strength b. weight (mass) c. appearance d. corrosion resistance e. malleability

4. Explain heat treatment of carbon steels a. annealing b. normalising c. hardening d. tempering

5. explain the purpose of bending allowances

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6. apply bending allowances using the neutral line a. thin sheet materials b. thick plate materials c. pipe d. circular forms e. ‘U’ bends f. right-angle bends

7. explain the purpose of rolling allowances 8. apply rolling allowance formulas

a. circular cylinders b. taking into account material thickness c. determination of the length of presetting required to avoid ‘flats’ when rolling.

Unit 717 Welding by Manual metal arc process

Rationale This unit is to enable manual metal arc (MMA) welding skills to be developed to BS 4872 part 1 in steel or stainless steel within its scope. The unit has a ‘hands-on’ approach that is underpinned by the specific knowledge required to complement the practical activities. The applied knowledge topics include: health and safety hazards and methods of avoiding them, preparation, electrical requirements, consumables, welding techniques, welding positions, distortion control and rectification, BS 4872 part 1 requirements and non-destructive and workshop testing. Learning outcomes There are four outcomes to this unit. The candidate will be able to: 717.1 recognise the hazards associated with manual metal arc welding 717.2 prepare equipment and materials for welding 717.3 produce welded joints 717.4 check weld quality. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 717 Welding by Manual metal arc process 717.1 recognise the hazards associated with manual

metal arc welding

Practical activities The candidate will be able to: 1. recognise welding hazards 2. understand the use of personal protective equipment (PPE) in manual metal arc (MMA)

welding 3. follow safe working procedures. Underpinning knowledge The candidate will be able to: Underpinning knowledge 1. state the need for personal protective equipment (PPE) in relation to welding process

a. headshield b. filter lens c. cover lens d. light reactive filters e. gauntlets f. protective footwear g. eye protection h. flame retardant overalls i. leather apron j. scull cap k. leather jacket l. factors render PPE provided as protection against the above ineffective or unsafe

2. explain the hazards from welding fume

a. types of fume i visible (particulate) ii invisible (gaseous)

A. carbon monoxide (CO) B. oxides of nitrogen C. nitrous oxide (NO) D. nitrogen dioxide (NO2) E. use of extraction

iii background iv local v natural ventilation (e.g. on-site) vi air-fed headshields vii respirator

3. state the hazards from electricity

a. shock i shock hazards ii use of electrical insulation

A condition B correct size C correct connection D tightness of connection

iii welding lead

iv welding return v welding earth

b. fire c. burns

4. state the hazards from arc radiation

a. visible light b. infra-red c. ultra-violet

i PPE (see 1.f. above) ii Screening

A. types B. purpose

iii warnings A. verbal B. notices

5. state the hazards from hot metal/slag/sparks

a. means of avoiding hazards i identification of hazard ii use of tools (tongs, etc) iii use of PPE.

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Unit 717 Welding by Manual metal arc process 717.2 prepare equipment and materials for welding

Practical activities The candidate will be able to: 1. prepare equipment for a welding operation 2. prepare materials for a welding operation 3. operate equipment safely. Underpinning knowledge The candidate will be able to: 1. describe types of welding equipment

a. alternating current (a.c.) i transformer

b. direct current (d.c.) i transformer/rectifier ii inverter iii engine driven generators

2. describe welding leads

a. welding b. return c. earth

3. recognise electrode holders

a. types i fully insulated ii partially insulated

4. describe return clamps 5. describe with the function and safe use of equipment used for preparing and finishing

materials welded joints a. grinders

i angle ii mini iii safe use

b. linishers c. files d. flame cutting e. chipping hammer f. wire brushes g. hammer and chisel.

Unit 717 Welding by Manual metal arc process 717.3 produce welded joints

Practical activities The candidate will be able to: 1. use welding consumables 2. operate equipment safely 3. produce welded joints in carbon steel or stainless steel, minimum 5 mm thick 4. produce welded lap joints in the horizontal/vertical – EN ISO 6947 PB position 5. produce welded tee joints in the vertical upwards – EN ISO 6947 PF position 6. produce welded single-vee butt joints in the flat – EN ISO 6947 PA position 7. produce welded corner joints in the flat – EN ISO 6947 PA position 8. produce joints that are a minimum of 150 mm long using single or multiple-run welds as

appropriate 9. the weld surface and adjacent parent metal is substantially free from arcing, spatter and

chipping marks. Underpinning knowledge The candidate will 1. describe types of consumable

a. electrodes i cellulosic ii rutile iii basic

b. applications of the above 2. describe electrode storage requirements 3. describe types of welding current and polarity

a. alternating (a.c.) b. direct (d.c.)

i electrode positive ii electrode negative

4. explain the difference between electrode sizes to material thickness and types of joint 5. explain the difference between welding current ranges to electrode sizes 6. differentiate between open circuit voltage and arc voltage 7. describe post welding activities

a. cleaning i slag removal ii spatter removal iii wiring brushing iv removal of excess weld metal where required

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8. explain welding techniques a. arc striking b. crater filling at the end of a weld c. stop/restart d. stringer beading e. weaving f. single – run g. multiple-run

9. describe welding positions

a. flat – EN ISO 6947 PA position b. horizontal/vertical – EN ISO 6947 PB position c. horizontal – EN ISO 6947 PC position d. vertical upwards – EN ISO 6947 PF position e. vertical downwards – EN ISO 6947 PG position

10. refer to BS 4872 part 1: 1982 – specification for approval testing of welders when welding

procedure approval is not required, fusion welding of steel, for the propose of a test type b joint set-up c test piece dimensions d assessment of weld quality e destructive testing

11. explain appropriate assembly and distortion control methods

a. clamping b. alignment jigs c. run on/off plates d. tack welds

12. state methods of distortion rectification

a. mechanical b. thermal.

Unit 717 Welding by Manual metal arc process Unit 701 Working in Engineering

717.4 check weld quality

Practical activities The candidate will be able to: 1. perform visual checks on weld quality 2. perform non-destructive tests on all welds using dye penetrant or magnetic particle

techniques, as appropriate 3. perform destructive tests on fillet welds using macroscopic examination and nick-break

testing 4. perform workshop destructive tests on butt welds using root bend (<10 mm) or side bend

(≥10 mm) testing, as appropriate 5. operate equipment safely 6. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. describe weld flaws

a. lack of continuity b. even or irregular weld profile c. incorrect weld size or profile d. undercutting e. overlap f. inclusions g. porosity h. surface cracks i. internal cracks j. lack of fusion

i root ii side wall iii inter-run

k. lack of penetration 2. explain assessment criteria

a. qualitive i defect levels ii appearance

b. quantitive i extent ii size iii dimensional accuracy

3. explain visual assessment techniques

a. use of magnification b. use of weld gauges

i fillet ii universal

c. use of illumination to aid assessment

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4. describe non-destructive testing techniques a. dye penetrant

i applications ii procedure iii limitations

b. magnetic particle i techniques

A current flow B magnetic flow

ii procedures iii applications iv limitations

5. describe workshop destructive testing methods

a. macroscopic examination i purpose ii preparation of specimen iii examination of specimen

b. nick-break test i purpose ii preparation of specimen iii breaking of specimen iv examination of specimen

c. bend tests i types

A. face B. root C. side

ii purpose iii preparation of specimen iv bending of specimen

A. former sizes B. former arrangements C. bend radius D. angle of bend E. examination of specimen

6. state the need for good housekeeping

a. leave the work area free of unused consumables b. cleaning the work area c. putting tools and equipment into safe storage

d. identifying and recording finished work.

Unit 718 Welding by MIG process

Rationale This unit is to enable metal inert gas (MIG) welding skills to be developed to BS 4872 part 1 in steel or stainless steel within its scope. The unit has a ‘hands-on’ approach that is underpinned by the specific knowledge required to complement the practical activities. The applied knowledge topics include: health and safety hazards and methods of avoiding them, preparation, electrical requirements, consumables, welding techniques, welding positions, distortion control and rectification, BS 4872 part 1 requirements and non-destructive and workshop testing. Learning outcomes There are four outcomes to this unit. The candidate will be able to: 718.1 recognise the hazards associated with metal inert gas (MIG) welding 718.2 prepare equipment and materials for welding 718.3 produce welded joints 718.4 check weld quality. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper

181

Unit 718 Welding by MIG process 718.1 recognise the hazards associated with metal inert

gas (MIG) welding

Practical activities The candidate will be able to: 1. recognise welding hazards 2. understand the use of personal protective equipment (PPE) in metal inert gas (MIG)

welding 3. follow safe working procedures. Underpinning knowledge The candidate will be able to: 1. state the need for personal protective equipment (PPE) in relation to welding process

a. headshield b. filter lens c. cover lens d. light reactive filters e. gauntlets f. protective footwear g. eye protection h. flame retardant overalls i. leather apron j. scull cap k. leather jacket l. factors render PPE provided as protection against the above ineffective or unsafe

2. explain the hazards from welding fumes


A. carbon monoxide (CO) B. ozone (O3) C. oxides of nitrogen

iii use of extraction A. background B. local

iv natural ventilation (e.g. on-site) v air-fed headshields vi respirator

3. state the hazards from electricity

a. shock i shock hazards ii use of electrical insulation

A. condition B correct size C. correct connection D. tightness of connection

iii welding lead

iv welding return v welding earth

b. fire c. burns

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4. state the hazards from arc radiation a. visible light b. infra-red c. ultra-violet

i PPE (see 1.f. above) ii Screening

A. types B. purpose

iii warnings A. verbal B. notices

5. state the hazards from hot metal and sparks


Unit 718 Welding by MIG process 718.2 prepare equipment and materials for welding

Practical activities The candidate will be able to: 1. prepare equipment for a welding operation 2. prepare materials for a welding operation 3. operate equipment safely. Underpinning knowledge The candidate will be able to: 1. describe types of welding equipment

a. direct current (d.c.) i transformer/rectifier ii inverter iii engine driven generators


a. welding i water cooled ii air cooled iii construction of lead iv supplies to gun/torch

b. return c. earth

3. describe welding guns/torches

a. types i goose neck ii pistol iii push iv pull v push-pull vi reel-on-gun vii water cooled viii air cooled

4. describe return clamps 5. describe the function and safe use of equipment used for preparing and finishing materials

welded joints a. grinders


b. linishers c. files d. flame cutting e. chipping hammer f. wire brushes g. hammer and chisel.

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Unit 718 Welding by MIG process Unit 701 Working in Engineering

718.3 produce welded joints

Practical activities The candidate will be able to: 1. use welding consumables 2. operate equipment safely 3. produce welded joints in carbon steel or stainless steel 4. produce welded joints in materials thickness greater than AND less than 5 mm thick 5. produce welded lap joints in the horizontal/vertical – EN ISO 6947 PB position 6. produce welded tee joints in the vertical upwards – EN ISO 6947 PF position 7. produce welded single-vee butt joints in the flat – EN ISO 6947 PA position 8. produce welded corner joints in the flat – EN ISO 6947 PA position 9. produce joints that are a minimum of 150 mm long using single or multiple-run welds as

appropriate 10. refer to BS 4872 part 1 and produce welded joints which meet all of the following

requirements. Underpinning knowledge The candidate will be able to: 1. describe the types of consumable

a. electrode wires i solid

A. copper coated B. uncoated C. reel sizes

ii cored wire A. flux cored B. iron cored C. self-shielded

2. explain electrode storage requirements 3. explain type of welding current and polarity

a. direct (d.c.) electrode positive 4. explain the relationship between electrode sizes to material thickness and types of joint 5. explain the relationship of arc voltage and wire feed speed ranges to electrode sizes 6. explain the difference between open circuit voltage and arc voltage 7. state the shielding gases used

a. inert i argon ii helium iii mixtures of the above

b. active i carbon dioxide (CO2)

ii argon/oxygen (O2) iii argon/CO2 iv argon/O2/CO2 v argon/helium/O2/CO2

c. applications of the above 8. describe post welding activities

a. cleaning i slag removal (for cored wire) ii spatter removal iii wiring brushing iv removal of excess weld metal where required

9. explain welding techniques

a. arc striking b. crater filling at the end of a weld c. stop/restart d. stringer beading e. weaving f. single – run g. multiple-run



11. refer to BS 4872 part 1: 1982 – specification for approval testing of welders when welding

procedure approval is not required, fusion welding of steel, for the propose of a. test type b. joint set-up c. test piece dimensions d. assessment of weld quality e. destructive testing





187

Unit 718 Welding by MIG process 718.4 check weld quality



testing 4. perform workshop destructive tests on butt welds using root bend (<10 mm) or side bend

(≥10 mm) testing, as appropriate 5. operate equipment safely 6. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. describe weld flaws

a. lack of continuity b. even or irregular weld profile c. incorrect weld size or profile d undercutting e. overlap f. inclusions g. porosity h. surface cracks i. internal cracks j. lack of fusion












A. current flow B. magnetic flow

ii procedures C. current flow D. magnetic flow

iii applications iv limitations







A. former sizes B. former arrangements C. bend radius D. angle of bend E. examination of specimen


a. leave the work area free of unused consumables b. cleaning the work area c. putting tools and equipment into safe storage d. identifying and recording finished work.

189

Unit 719 Welding by TIG process

Rationale This unit is to enable tungsten inert gas (TIG) welding skills to be developed to BS 4872 part 1 in steel or stainless steel or BS 4872 part 2 aluminium and its alloys within their scope. The unit has a ‘hands-on’ approach that is underpinned by the specific knowledge required to complement the practical activities. The applied knowledge topics include: health and safety hazards and methods of avoiding them, preparation, electrical requirements, consumables, welding techniques, welding positions, distortion control and rectification, BS 4872 part 1 or part 2 requirements and non-destructive and workshop testing. Learning outcomes There are four outcomes to this unit. The candidate will be able to: 719.1 recognise the hazards associated with tungsten inert gas (TIG) welding 719.2 prepare equipment and materials for welding 719.3 produce welded joints 719.4 check weld quality. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper

Unit 719 Welding by TIG process 719.1 recognise the hazards associated with tungsten

inert gas (TIG) welding

Practical activities The candidate will be able to: 1. recognise welding hazards 2. understand the use of personal protective equipment (PPE) in tungsten inert gas (TIG)

welding 3. follow safe working procedures. Underpinning knowledge The candidate will be able to: 1. state the need for personal protective equipment (PPE) in relation to welding process

a. headshield b. filter lens c. cover lens d. light reactive filters e. gloves f. protective footwear g. eye protection h. flame retardant overalls i. factors render PPE provided as protection against the above ineffective or unsafe

2. explain the hazards from welding fumes


A ozone (O3) B oxides of nitrogen

b. use of extraction i background ii local iii natural ventilation (e.g. on-site) iv air-fed headshields v respirator 3. state the fire hazards associated with the process

a. sources of combustion b. identification of suitable extinguishers c. electric shock

i shock hazards ii use of electrical insulation

A condition B correct size C correct connection D tightness of connection

iii welding lead iv welding return v welding earth

191

d. fire e. burns

4. state the hazards from arc radiation a. visible light b. infra-red c. ultra-violet d. PPE (see 1.f. above)

i Screening A types B purpose

e. warnings i verbal ii notices

5. state the hazards from hot metal and sparks


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Unit 719 Welding by TIG process Unit 701 Working in Engineering

719.2 prepare equipment and materials for welding

Practical activities The candidate will be able to: 1. prepare equipment for a welding operation 2 prepare materials for a welding operation 3. operate equipment safely. Underpinning knowledge The candidate will be able to: 1. describe types of welding equipment

a. direct current (d.c. and a.c.) i transformer/rectifier ii inverter iii engine driven generators iv a.c./d.c. converters


a. welding i water cooled ii air cooled iii construction of lead iv supplies to torch

b. return c. earth

3. describe welding torches

a. types i water cooled ii air cooled iii pencil

4. describe return clamps 5. describe with the function and safe use of equipment used for preparing and finishing

materials welded joints a. grinders


b. linishers c. files d. wire brushes.

Unit 719 Welding by TIG process 719.3 produce welded joints

Practical activities The candidate will be able to: 1. use welding consumables 2. operate equipment safely 3. produce welded joints in carbon steel or stainless steel or aluminium 4. produce welded joints in materials thickness less than 5 mm thick 5. produce welded lap joints in the horizontal/vertical – EN ISO 6947 PB position 6. produce welded tee joints in the vertical upwards – EN ISO 6947 PF position 7. produce welded square or single-vee butt joints in the flat – EN ISO 6947 PA position 8. produce welded corner joints in the flat – EN ISO 6947 PA position 9. produce joints that are a minimum of 150 mm long using single or multiple-run welds as

appropriate Underpinning knowledge The candidate will be able to: 1. describe types of consumable

a. tungsten electrodes i types

A. thoriated B. zirconiated C. ceriated

ii applications for the above iii recognising different electrodes

b. filler wires i copper coated steel ii uncoated

2. explain filler wires storage requirements 3. explain types of welding current and polarity

a. direct (d.c.) electrode negative i heat distribution ii reasons for d.c.

b. alternating (a.c.) i heat distribution ii reasons for a.c.

4. explain electrode sizes to material thickness and types of joint and types of current 5. explain welding current ranges to electrode sizes 6. differentiate between open circuit voltage and arc voltage 7. state the shielding gases used

a. inert i argon ii helium iii mixtures of the above

195

b. active i argon/hydrogen (H2)

c. applications of the above

8. describe post welding activities a. cleaning

i wiring brushing ii polishing iii removal of excess weld metal where required

9. describe welding techniques

a. arc striking b. crater filling at the end of a weld c. stop/restart d. stringer beading e. weaving f. single – run g. multiple-run



11. refer to BS 4872 part 1:1982 – specification for approval testing of welders when welding

procedure approval is not required, fusion welding of steel, and BS 4872 part 2: 1976 – Specification for approval testing of welders when welding procedure approval is not required, TIG or MIG welding of aluminium and its alloys for the propose of a. test type b. joint set-up c. test piece dimensions d. assessment of weld quality e. destructive testing





197

Unit 719 Welding by TIG process 719.4 check weld quality



testing 4. perform workshop destructive tests on butt welds using root bend testing 5. operate equipment safely 6. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. describe weld flaws

a. lack of continuity b. even or irregular weld profile c. incorrect weld size or profile d. undercutting e. overlap f. inclusions (including tungsten) g. porosity h. surface cracks i. internal cracks j. lack of fusion












A current flow B magnetic flow

ii procedures A current flow B magnetic flow








A former sizes B former arrangements C. bend radius D. angle of bend E. examination of specimen


a. leave the work area free of unused consumables b cleaning the work area c. putting tools and equipment into safe storage d. identifying and recording finished work.

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Unit 720 Welding by Oxy-acetylene process

Rationale This unit is to enable oxy-acetylene (gas) welding skills to be developed to BS 4872 part 1 in steel within its scope. The unit has a ‘hands-on’ approach that is underpinned by the specific knowledge required to complement the practical activities. The applied knowledge topics include: health and safety hazards and methods of avoiding them, preparation, electrical requirements, consumables, welding techniques, welding positions, distortion control and rectification, BS 4872 part 1 requirements and non-destructive and workshop testing. Learning outcomes There are four outcomes to this unit. The candidate will be able to: 720.1 recognise the hazards associated with of oxy-acetylene (gas) welding 720.2 prepare equipment and materials for welding 720.3 produce welded joints 720.4 check weld quality. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 720 Welding by Oxy-acetylene process 720.1 recognise the hazards associated with of oxy-

acetylene (gas) welding

Practical activities The candidate will be able to: 1. state the need for personal protective equipment (PPE) in relation to welding process

a. goggles b. filter lens c. cover lens d. gloves e. protective footwear f. eye protection g. flame retardant overalls h. leather apron i. scull cap j. leather jacket k. factors render PPE provided as protection against the above ineffective or unsafe

2. state the hazards from welding fumes


A. carbon monoxide (CO) B. carbon dioxide (CO2)

iii use of extraction A. background B. local

iv natural ventilation (e.g. on-site) v respirator

3. state the fire hazards associated with the process

a. sources of combustion b. hazards from compressed gas cylinders

i safe storage conditions ii safe handling/moving iii safe use

c. the hazards from hot metal/sparks i means of avoiding hazards ii identification of hazard iii use of tools (tongs, etc) iv use of PPE

4. state safe start-up and shutdown procedures for oxy-acetylene welding equipment 5. state the procedure for dealing with a backfire 6. state the procedure for dealing with a flashback.

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Unit 720 Welding by Oxy-acetylene process 720.2 prepare equipment and materials for welding

Practical activities The candidate will be able to: 1. select the welding equipment for a given application 2. prepare the welding equipment for a given application. Underpinning knowledge The candidate will be able to: 1. describe the equipment set-up for the oxy-acetylene welding process

a. cylinders b. pressure regulators c. flashback arrestors d. hoses e. hose check-valves f. hose connectors g. blowpipe/torch h. nozzles

2. explain the function of components of oxy-acetylene welding equipment

a. cylinders i oxygen ii acetylene iii colour coding

b. pressure regulators i types

A single-stage B two-state

c. flashback arrestors d. hoses

i colour coding e. hose check-valves f. blowpipe/torch g. nozzles

i sizes ii selection

h. use of left hand and right hand threaded connections i identification

3. state the correct welding variables

a. gas pressures b. nozzle size c. welding technique

i leftward 4. state types of flame condition

a. neutral i typical flame temperature

b. oxidising c. carburising/reducing

5. state the parts of the flame a. inner core b. outer envelope c. hottest point

6. state the benefits and limitations of process.

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Unit 720 Welding by Oxy-acetylene process 720.3 produce welded joints

Practical activities The candidate will be able to: 1. use welding consumables 2. operate equipment safely 3. produce welded joints in low carbon steel in the range of 1 to 3.2 mm thick 4. produce welded lap joints in the horizontal/vertical – EN ISO 6947 PB position 5. produce welded corner joints in the vertical upwards – EN ISO 6947 PF position 6. produce welded square butt joints in the flat – EN ISO 6947 PA position 7. produce welded corner joints in the flat – EN ISO 6947 PA position 8. produce joints that are a minimum of 150 mm long using single or multiple-run welds as

appropriate Underpinning knowledge The candidate will be able to: 1. describe the types of consumable

a. BS 1453:1972 specification for filler materials for gas welding i sizes

A. 1.6 mm B. 2.4 mm C. 3.2 mm

ii function of copper coating b. storage

2. state the gases used

a. oxygen i cylinder colour ii hose colour iii hazards associated with its use and how to avoid them

b. acetylene i cylinder colour ii hose colour iii hazards associated with its use and how to avoid them

3. explain the relationship between nozzle sizes and joint thicknesses 4. explain the relationship between filler rod sizes and joint thicknesses 5. explain the relationship between gas pressures and joint thicknesses.

Unit 720 Welding by Oxy-acetylene process 720.4 check weld quality



testing 4. perform workshop destructive tests on butt welds using root bend testing 5. operate equipment safely 6. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. describe weld flaws

a. lack of continuity b. even or irregular weld profile c. incorrect weld size or profile d. undercutting e. overlap f. inclusions g. porosity h. surface cracks i. internal cracks j. lack of fusion









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A. current flow B. magnetic flow

ii procedures A. current flow B. magnetic flow






Unit 721 Fabricating Sheet metalwork

Rationale This unit is concerned with the underlying process technology associated with the fabrication of sheet metal products. It covers the health and safety hazards associated with cutting, forming, assembly and joining of sheet metal. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 721.1 prepare equipment and tools for sheet metal cutting 721.2 use equipment and tools for sheet metal forming 721.3 produce fabrications using sheet metalwork assembly techniques Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 721 Fabricating Sheet metalwork 721.1 prepare equipment and tools for sheet metal

cutting

Practical activities The candidate will be able to: 1. prepare equipment and tools for a cutting operation 2. prepare materials for a cutting operation. Underpinning knowledge The candidate will be able to: 1. state the methods of marking out

a. use of datums i line ii edge iii centre point

b. avoiding damage to surface coatings c. minimal wastage

2. state the procedures for use of sheet metalwork cutting equipment

a. drills i bench ii pillar iii portable

b. rotary shears i portable shears ii nibblers

A shear type B punch type

c. guillotines i treadle ii mechanical iii back stops iv front stops

d. fly press e. power punch f. portable angle grinders/sanders

3. state the procedures for use of sheet metalwork fabrication cutting tools

a. hand shears i straight ii left hand iii right hand iv universal

b. bench shears i hand-lever

c. tinman’s hand-level punch.

Unit 721 Fabricating Sheet metalwork 721.2 use equipment and tools for sheet metal forming

Practical activities The candidate will be able to: 1. use equipment and tools for a forming operation 2. use materials for a forming operation 3. operate equipment safely. Underpinning knowledge The candidate will be able to: 1 state the procedures for use of sheet metalwork fabrication forming tools

a. hammers b. planishing hammers c. mallets d. wooden blocks e. range of bench stakes

2. state the procedures for use of sheet metalwork fabrication forming equipment

a. jennys i tooling

b. rolling machines i pyramid type ii pinch type iii slip rolls iv hand-operated

c. folding machines i box and pan ii universal swing-beam

d. fly press i tooling

A dies B forming tools

3. describe stiffening techniques

a. swaging b. beading c. wired edges (including false) d. folds e. flanging f. reinforment g. diamond break

4. describe techniques used to produce forms

a. square b. rectangular c. cylindrical d. cones e. boxed

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5. hand forming techniques a. hollowing b. raising c. planishing d. flanging e. ‘split and weld’ methods.

Unit 721 Fabricating Sheet metalwork 721.3 produce fabrications using sheet metalwork

assembly techniques

Practical activities The candidate will be able to: 1. use a range of sheet metalwork assembly techniques to produce fabrications 2. use sheet metalwork joining techniques to produce fabrications safely 3. produce fabrications with all dimensions are within +/- 3.0 mm 4. produce fabrications meet the required shape/geometry 5. produce fabrications that are free from excessive tooling marks, deformation, cracking,

sharp edges, slivers or burrs 6. produce fabrications that are correctly assembled and have secure and firm joints. Underpinning knowledge The candidate will be able to: 1. describe methods of fabrication assembly

a. holding methods b. clamping c. distortion control methods

2. describe the use of non self-secured joints

a. lap b. corner c. butt d. tee e. joggled lap f. flanged butt g. lock seem h. bottom seam

i internal lap ii external lap

3. recognise the use of self-secured joints

a. grooved seam b. panned down c. slip joint d. allowances

4. recognise the use of mechanical joining methods

a. solid riveting b. hollow riveting c. threaded fastenings

5. recognise soft soldering techniques

a. preparing the joint b. cleaning the joint c. types of soft solder d. types of fluxes e. types of soldered iron f. heat sources

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i electrical ii flame

g. cleaning the soldered joint

6. recognise brazing techniques a. preparing the joint b. cleaning the joint c. types of brazing alloys d. types of fluxes e. heat sources

i flame ii gas mixtures

f. cleaning the brazed joint 7. describe welding methods of joining sheet metalwork fabrications

a. resistance welding processes i spot ii seam iii the electrodes available for spot welding iv electrode functions

A . gripping B. exertion of force C. passage of high current

v electrode material vi electrode tip geometry

A . domed end B . truncated cone

b. metal inert gas (MIG) i equipment

A direct current (d.c.) B wire feed unit C arc ignition

ii gun/torches iii electrodes wires iv electrode sizes

A. 0.6 mm B. 0.8 mm

v shielding gases used for the welding of carbon steels A. carbon dioxide (CO2) B. argon / CO2 C. argon/oxygen/ CO2

c. tungsten inert gas (TIG) i equipment for the welding of steels

A. direct current (d.c.) electrode negative B . methods of arc ignition

ii welding torches iii tungsten electrodes for the welding of steels

A. thoriated B. ceriated C . how to distinguish types of tungsten electrodes

iv electrode sizes A. 1.6 mm B. 2.4 mm

v filler wire sizes A. 1.6 mm B. 2.4 mm

vi common shielding gas used for the welding of carbon steels A. argon

vii techniques A. crater filling at the ned of a weld

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B. stop/restart C. stringer beading D . Weaving

viii types of joint A. butt B. lap C tee D. corner

8. state the need for good housekeeping in the workplace


Unit 722 Fabricating thick plate, bar and sections

Rationale This unit is concerned with the underlying process technology associated with the fabrication of thick plate bar and rolled sections. It covers health and safety hazards associated with cutting (including oxy-fuel gas), forming, assembly and joining of thick plate bar and rolled sections fabrication. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 722.1 prepare equipment and tools for cutting of thick plate, bar and rolled sections. 722.2 use equipment and tools for thick plate, bar and rolled sections 722.3 produce fabrications using thick plate and rolled bar sections joining techniques Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 722 Fabricating thick plate, bar and sections 722.1 prepare equipment and tools for cutting of thick

plate, bar and rolled sections

Practical activities The candidate will be able to: 1. prepare equipment for a cutting operation 2. prepare materials for a cutting operation. Underpinning knowledge The candidate will be able to: 1. state the hazards associated with the lifting of loads

a. common forms of injury b. correct manual lifting techniques c. use lifting aids

I straps Ii bars Iii harnesses

d. use of lifting equipment i wall and overhead mounted travelling cranes ii fork lift trucks iii pallets and pallet truck iv block and tackle v pull/lift lever hoist vi engine hoist vii chains viii ropes Ix slings X shackles Xi lifting eyes xii friction clamps xiii welded lugs xiv lifting capacity (safe working load [SWL])

2. state the methods of marking out

a. use of datums i line ii edge iii centre point

b. minimal wastage 3. describe the procedures of use of thick plate, bar and sections cutting equipment

a. drills i bench ii pillar iii radial arm iv portable

b. nibblers c. guillotines

i mechanical

ii back stops iii front stops iv guides

d. power punch e. oxy-fuel gas cutting equipment

i recognise the hazards from compressed gas cylinders A. safe storage conditions B. safe handling/moving C. safe use

ii recognise safe start-up and shut down procedures for oxy-fuel gas cutting equipment

iii recognise the procedure for dealing with a backfire iv recognise the procedure for dealing with a flashback v recognise the hazards from hot metal/sparks vi types of gasses vii cylinders types and identification viii flashback arrestors ix hose types and identification x connector types and identification xi flashback arrestors xii hose check valves (protectors) xiii cutting torch xiv cutting nozzles

A. types B. gouging

xv guides A. bevel B. circle C. radius bar

xvi portable track cutting machines f. grinders

i portable angle grinders/sanders ii bench iii pedestal

g. abrasive wheel cutting-off machine.

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Unit 722 Fabricating thick plate, bar and sections 722.2 use equipment and tools for thick plate, bar and

rolled sections

Practical activities The candidate will be able to: 1. use equipment for forming thick plate, bar and rolled sections 2. use equipment for assembling thick plate, bar and rolled sections 3. operate equipment safely. Underpinning knowledge The candidate will be able to: 1. describe methods of hot and cold bending

a. principles i application of heat

b. hand methods i use of clamps ii use of vices iii use of levers

c. bench mounted machines i types ii applications

d. bench bending around a former e. fly press

i principles ii tooling

f. brake press i principles ii tooling

g. springback i principle ii allowances

h. ‘split and weld’ methods 2. describe methods of fabrication assembly

a. work holding i clamps ii pins iii plate dogs iv wedges v tack welding

b. work alignment i strong backs ii clamping dogs iii wedges iv draw-bolts and cleats v bridge pieces vi toggle clamps vii alignment jigs

c. distortion control

I tack welding ii presetting iii weld sequencing.

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Error! Bookmark not defined.

Practical activities The candidate will be able to: 1. use a range of thick plate techniques to produce engineering fabrications 2. produce fabrications with all dimensions are within +/- 3.0 mm 3. produce fabrications meet the required shape/geometry 4. produce fabrications that are free from excessive tooling marks, deformation, cracking,

sharp edges, slivers or burrs 5. produce fabrications that are correctly assembled and have secure and firm joints. 6. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. describe non-thermal methods of joining thick plate, bar and sections fabrications

a. solid rivets i types of joint

A. single lap B. double lap C. single strap D. double strap

ii types of rivet head A. flat B. countersunk C. round (or snap) D. pan E. mushroom F. applications

iii riveting defects iv causes of joint failure

A. tearing of metal B. crushing of metal C splitting of metal D. shearing of rivet

v allowances vi sources of pressure

A. hammers B. pneumatic C. hydraulic

b. bolts and nuts i types of bolts

A. black bolts B. turned bolts C. high-strength friction-grip D. cap head

ii types of nuts A. hexagonal B. split C. self-locking D. wing

iii use of washers

A. flat B. taper C. spring

iv defects in bolted connections v use of podging spanners and drifts vi allowances

c. screwed fastenings i types of screwed fastening

A. cap/cheese head B. round head C countersunk D. self-tapping E. use of hank bushes

ii use of taps and dies 2. describe the welding methods of joining thick plate, bar and rolled sections fabrications

a. manual metal arc (MMA) i equipment

A. alternating current (a.c.) B. direct current (d.c.)

ii welding leads A. welding B. return C. earth

iii electrode holders iv return clamps v chipping hammer vi wire brushes vii electrode sizes

A. 2.5 mm B. 3.2 mm C. 4.0 mm

viii techniques A. arc striking B. crater filling at the end of a weld C. stop/restart D. stringer beading E. weaving

ix types of joint A. butt B. lap C. tee D. corner


A. direct current (d.c.) B. wire fed unit C. arc ignition

ii guns/torches iii electrodes wires iv electrode sizes

A. 0.8 mm B. 1.0 mm

v shielding gases used for the welding of carbon steels A. carbon dioxide (CO2) B. argon/CO2

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C. argon/oxygen/CO2

3. keeping house keeping in the workplace a. Leave the work area free of unused consumables b. cleaning the work area c. putting tools and equipment into safe storage d. identifying and recording finished work.

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Unit 723 Fabricating pipework assemblies

Rationale This unit is concerned with the underlying process technology associated with the fabrication of pipework assemblies. It covers the health and safety hazards, associated with cutting (including oxy-fuel gas), bending, assembly, joining and testing methods. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 723.1 prepare equipment and tools for cutting pipework 723.2 use equipment and tools for fabricating pipework 723.3 produce and test fabricated pipework assemblies using joining techniques. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 723 Fabricating pipework assemblies 723.1 prepare equipment and tools for cutting pipework

Practical activities The candidate will be able to: 1. prepare equipment and tools for cutting pipework 2. use equipment and tools for fabricating pipework 3. produce and test fabricated pipework assemblies using joining techniques. Underpinning knowledge The candidate will be able to: 1. state the hazards associated the lifting of loads

a. common forms of injury b. correct manual lifting techniques c. use of lifting aids

i straps ii bars iii harnesses

d. use of lifting equipment i wall and overhead mounted travelling cranes ii fork lift trucks iii pallets and pallet truck iv block and tackle v pull/lift lever hoist vi engine hoist vii chains viii ropes ix slings x shackles xi lifting eyes xii friction clamps xiii welded lugs xiv lifting capacity (safe working load [swl] xv use of temporary supports

2. state the hazards associated with the use of ladders and with working at heights 3. state forms of supply

a. pipe i copper

a. solid drawn b. austenitic

ii carbon steel a. hot finished seamless b. cold finished seamless c. electric resistance welded

iii galvanised steel iv stainless steel v plastic vi sizes

a. outside diameter.

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b. inside diameter c. wall thickness d . nominal bore e relationship between a.-d. above

b. fittings i welded

a. butt welded b. fillet welded

c. slip-on flanges d. socket weld

ii screwed iii friction

a. compression. iv soldered

a. pre-applied solder b. plain soldered

v plastic socket 4. state methods of graphically representing pipework

a. block plans and plant layout i plant equipment and positions ii piping assembly drawings

b. schematic detail i isometric sub assemblies ii specifications

c. current symbols for i pipelines ii pipe equipment and components iii joints iv welds

5. state the methods of marking out

a. use of datums i line ii edge iii centre line iv template wires v setting out on floor or bench

b. minimal wastage.

Unit 723 Fabricating pipework assemblies 723.2 use equipment and tools for fabricating pipework

Practical activities The candidate will be able to: 1. use equipment safely for forming pipework fabrications 2. use equipment safely for assembling pipework fabrications. Underpinning knowledge The candidate will be able to: 1. state methods of hot bending

a. principles b. application of heat c. wire templates d. control of pipe deformation

i sand picking e. use of pin blocks

i pins ii dogs

2. state methods of cold bending

a. hand methods i types ii applications

b. machines methods i types ii applications

c. wire templates d. control of pipe deformation e. springback

i principle ii allowances

3. describe pipework fabrication techniques

a. branches i equal ii unequal iii set-on iv lateral v straight to elbow

b. trunions i equal ii unequal iii set-on iv straight to elbow

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4. describe pipework fittings a. elbows b. tees c. reducers

i eccentric ii concentric

d. flanges i weld-neck ii slip-on iii screwed iv blanks

e. unions f. couplings g. weldolets h. elbowlets i. lateralets j. end caps

5. describe methods of pipework assembly

a. work holding i full-scale setting out ii pipe vice iii pipe clamps iv pin blocks v vee blocks vi wedges vii tack welding

b. work alignment i wedges ii podger spanners iii square iv spirit level

c. distortion control i tack welding ii presetting iii weld sequencing

6. describe the procedures for use of pipework cutting equipment

a. drills v bench vi pillar vii radial arm viii portable

b. oxy-fuel gas cutting equipment i the hazards from compressed gas cylinders

A . safe storage conditions B. safe handling/moving C . safe use

ii safe start-up and shut down procedures for oxy fuel gas cutting equipment iii the procedure for dealing with backfire iv the procedure for dealing with a flashback v the hazards from hot metal sparks ix types of gasses x cylinders types and identification xi regulator types and identification xii hose types and identification

xiii connector types and identification xiv flashback arrestors xv hose check valves (protectors) xvi cutting torch xvii cutting nozzles

c. types xviii orbital pipe cutting machines

d. grinders i portable angle grinders/sanders ii internal grinding

e. abrasive wheel f. hand-held rotary pipe cutters g. machine rotary pipe cutters h. bandsaw.

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Unit 723 Fabricating pipework assemblies 723.3 produce and test fabricated pipework assemblies

using joining techniques

Practical activities The candidate will be able to: 1. produce pipework fabrications to the desired shape and dimension 2. test pipework assemblies safely for signs of leakage 3. reinstate the work area. Underpinning knowledge The candidate will be able to 1. describe non-thermal methods of joining pipework assemblies

a. flanges i types

A. weld-neck B. slip-on C . screwed

ii nuts and bolts A. black bolts B. turned bolts C. high-strength friction-grip D. cap-head E. hexagonal F. locking G. wing H. split

iii use of washers iv use of gaskets v use of seals vi use of spanners

A. adjustable B. ring C. combination D. podging E. socket

vii defects in bolted connections viii use of jointing compounds

A. grease B. copper

ix methods of freeing or disconnecting seized bolted joints A. shock loading (impact) B. dispelling scales and corrosion C. sawing / chiselling D. solvents E. application of heat

b. screwed connections i thread types ii methods of pipe thread cutting iii threading allowances

iv jointing compounds v sealilng tapes Vi methods of tightening

c. compression joints i types ii principle iii allowances iv methods of preparation v methods of tightening vi

d. push-fit fitting connection i advantages and disadvantages

e. cemented/glued fitting connections i methods of joint preparation ii types of adhesive iii joining methods iv safety precautions

A. ventilation B. away from sources of ignition C. avoiding skin contact

v checking of joints 2. recognise thermal methods of joining pipework assemblies

a. soldered i types

A pre-applied solder b. plain soldered

ii types of solder iii types of flux iv techniques

c. welding i manual metal arc (mma)

A. equipment B. welding leads C. electrode holders D. return clamps E. chipping hammer F. wire brushes G. electrode sizes H. techniques I. types of joint

ii metal inert gas A. equipment B. guns/torches C. electrodes wires D. electrode sizes E. shielding gases used for the welding of carbon steels

iii tungsten inert gas (tig) A. equipment for the welding of steels B. welding torches C. tungsten electrodes for the welding of steels D. electrode sizes E. filler wire sizes F. common shielding gas used for the welding of carbon steels.

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3. describe leak testing methods used to prove joint effectiveness a. hydrostatic

i principle ii test media iii test pressure iv test method v methods of detecting leakage vi safety factors

b. pneumatic i principle ii test media iii test pressure iv test method v methods of detecting leakage vi safety factors

c. vacuum i principle ii test media iii test pressure iv test method v methods of detecting leakage vi safety factors

4. state the need for good housekeeping in the workplace

a. leave the work area free of unused consumables b. clean the work area c. return tools and equipment to safe storage d. identify and record finished work

Unit 724 Fabricating steelwork assemblies

Rationale This unit is concerned with the underlying process technology associated with the fabrication of steelwork assemblies. It covers the associated health and safety hazards, cutting (including oxy-fuel gas), assembly and joining methods. The joining methods include non-thermal techniques: mechanical – bolting and thermal: MMA and MIG welding. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 724.1 prepare equipment and tools for cutting steelwork 724.2 use equipment for fabricating steelwork 724.3 produce fabricated steelwork assemblies joining techniques. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 724 Fabricating steelwork assemblies 724.1 prepare equipment and tools for cutting steelwork

Practical activities The candidate will be able to: 1. prepare equipment for cutting operation 2. prepare materials for a cutting operation. Underpinning knowledge The candidate will be able to: 1. state the hazards associated with the lifting of loads

a. common forms of injury b. correct manual lifting techniques c. use of lifting aids

i straps ii bars iii harnesses

d. use of lifting equipment i wall and overhead mounted travelling cranes ii fork lift trucks iii pallets and pallet truck iv block and tackle v pull/lift lever hoist vi engine hoist vii chains viii ropes ix slings x shackles xi lifting eyes xii friction clamps xiii welded lugs xiv lifting capacity (safe working load [SWL]) xv use of temporary supports

2. state the hazards associated with the use of ladders and working at heights 3. state the forms of supply

a. sheet and plate i anti-slip platform and tread materials

b. rolled steel angle i equal ii unequal iii rolled steel joist (RSJ) iv universal beam v universal column vi tee bar vii castellated beam viii structural hollow sections

A. square B. rectangular C. round

ix rolled steel channel c. coatings

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4. describe methods of marking out a. use of datums

i line ii edge iii centre point iv use of back marks

b. minimal wastage 5. describe the procedures for use of steelwork cutting equipment

a. drills i bench ii pillar iii radial arm iv portable

b. nibblers c. guillotines

i mechanical ii back stops iii front stops iv guides

d. power punch e. oxy-fuel gas cutting equipment

i recognize the hazards from compressed gas cylinders A. safe storage conditions B. safe handling/moving C. safe use

ii recognize safe start-up and shutdown procedures for oxy-fuel gas cutting equipment

iii recognise the procedures for dealing with a backfire iv recognise the procedure for dealing with a flashback v recognise the hazards from hot metal/sparks vi types of gazes vii cylinders types and identification viii regulator types and identification ix hose types and identification x connector types and identification xi flashback arrestors xii hose check valves (protectors) xiii cutting torch xiv cutting nozzles

A. types B. gouging

xv guides A. bevel B. circle C. radius bar

xvi portable track cutting machines f. grinders

i portable angle grinders/sanders ii bench iii pedestal

g. abrasive wheel cutting-off machine h. bandsaw.

Unit 724 Fabricating steelwork assemblies 724.2 use equipment for fabricating steelwork

Practical activities The candidate will be able to: 1. Use equipment for steelwork fabrication 2. operate equipment safely 3. produce fabrications with all dimensions are within +/- 3.0 mm 4. produce fabrications meet the required shape/geometry 5. produce fabrications that are free from excessive tooling marks, deformation, cracking,

sharp edges, slivers or burrs 6. produce fabrications that are correctly assembled and have secure and firm joints. Underpinning knowledge The candidate will be able to: 1. describe steelwork assemblies

a. for access i platforms ii decking iii walkways iv stairways v hooped ladders vi handrailing

b. for support i saddles ii brackets iii cleats iv frameworks v bracings vi Ties

c. for security i gates ii guards iii barriers iv fencing v cages vi compounds

d. connections i splices ii splice plates iii gusset plates iv end cleats v flange cleats vi web cleats vii contact surfaces viii packers ix shims x fish plates xi knees xii apexes

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2. describe methods of steelwork assembly a. work holding

i clamps ii pins iii plate dogs iv wedges v tack welding

b. work alignment i strong backs ii clamping dogs iii wedges iv draw-bolts and cleats v bridge pieces vi toggle clamps vii alignment jigs viii crowbar ix podger spanners

c. distortion control i tack welding Ii presetting iii weld sequencing.

Unit 724 Fabricating steelwork assemblies 724.3 produce fabricated steelwork assemblies joining

techniques

Practical activities The candidate will be able to: 1. use joining techniques to produce steelwork assemblies safely 2. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. describe non-thermal methods of joining steelwork assemblies

a. nuts and bolts i types of bolts

A. black bolts B. high tensile C. high-strength friction-grip D. load indicating E. fitted

ii types of nuts A. cap-head B. hexagonal nuts C. locking nuts D. wing nuts E. split nuts

iii use of washers A. flat B. hardened steel C. taper D. spring E. load indicating F. nylon

iv use of spanners and drifts A. adjustable B. ring C. combination D. podging E. socket F. ratchet G. torque H. impact

v allowances A. back marks

vi defects in bolted connections vii use of jointing compounds

A. grease B. copper

viii methods of freeing or disconnecting seized bottled joints A. shock loading impact B. dispelling scale and corrosion

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C. sawing / chiselling D. solvents E. application of heat

2. recognise thermal methods of joining steelwork assemblies welding a. manual metal arc (MMA)

i equipment A. alternating current (a.c.) B. direct current (d.c.)

ii welding leads A. welding B. return C. earth

iii electrode holders iv return clamps v chipping hammer vi wire brushes vii electrode sizes

A. 2.5 mm B. 3.2 mm C. 4.0 mm

viii techniques A. arc striking B. crater filling at the end of a weld C. stop/restart D. stringer beading E. weaving

ix types of joint A. butt B. lap C. tee D. corner


A. direct current ii Gun/torches iii electrodes wires iv electrodes sizes

A. 0.8 mm B. 1.0 mm

v shielding gases used for the welding of carbon steels A. carbon dioxide (CO2) B. argon/CO2 C. argon/oxygen/CO2

3. state the need for good housekeeping in the work place


Unit 725 Materials Processing Technology

Rationale This unit is concerned with the underlying principles that apply to the processing and joining of material(s) used in the production of components without focusing on specific processes. The unit deals with the general behavior and properties of materials, processing/forming techniques and the quality control of processing operations. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 725.1 identify and relate materials to specific processing operations 725.2 interpret and apply design principles to specific processing operations 725.3 identify finishing techniques for material(s) processing operations. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 725 Materials Processing Technology 725.1 identify and relate materials to specific processing

operations

Practical activities The candidate will be able to: 1. identify the comparative properties of materials used in processing operations 2. distinguish between forming and casting processes 3. relate material properties and behavior to process applications 4. identify the factors that affect material behaviour during processing. Underpinning knowledge The candidate will be able to: 1. state the range of common materials used in processing operations

a. metallic i carbon steel ii cast iron iii aluminium & alloys iv copper & alloys.

b. polymers i thermoplastics materials ii thermosetting plastics materials.

c. pomposites i glass reinforced plastics (GRP) ii fibre reinforced plastics (FRP).

d. natural i wood ii rubber iii silicon (ceramics).

2. state the properties that influence the mechanical and physical behaviour of materials

a. structure b. temperature c. elasticity d. plasticity e. fluidity.

3 describe casting processes

a. sand b. die

4. describe forming processes a. hot

i forging ii rolling iii extruding iv drawing v moulding

b. cold i rolling ii bending iii swaging iv punching v shearing vi laying up.

5. state the forms of supply for commercial materials processing applications

a. billets b. bar c. sheet d. plate e. irregular sections f. pipe/tube g. granules

6. outline the criteria for the selection of materials for a given process/application

a. strength/rigidity b. ductility c. malleability d. melting point e. viscosity f. appearance g. cost h. weldability i. bonding capability j. machinability

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Unit 725 Materials Processing Technology 725.2 interpret and apply design principles to specific

processing operations

Practical activities The candidate will be able to: 1. identify the factors that give preference to material(s) processing operations 2. identify the factors governing the effective/efficient processing of materials 3. identify the common features that relate processed materials. Underpinning knowledge The candidate will be able to: 1. state the application of material processing techniques

a. casting i shaped components (complex/intricate) ii repetitive production

b. forming i shaped components (high strength) ii sheet and plate assemblies iii long symmetrical sections

A. wire B. tube C. rail.

2. state the operations used in material processing

a. melting and pouring liquids b. heating and forming solids c. heating and drawing solids d. heating and extruding solids e. cold bending and forming f. laminating and bonding g. cutting and punching.

3. state the factors that influence the selection of processing technique

a. suitability of material b. shape geometry (profile) c. section continuity and reinforcement d. bonding/joining ability.

4. state the factors that determine the selection of processing technique for the production

of components a single or multi-stage manufacture

b. complexity of shape c. dimensional control and accuracy d. finish e. prototyping

5. state the behavioral problems associated with material(s) processing operations

a. distortion b. residual stress

c. fractures d. defects e. structural variation.

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Unit 725 Materials Processing Technology 725.3 identify finishing techniques for material(s)

processing operations

Practical activities The candidate will be able to: 1. identify the range of finishing processes for materials processing operations 2. select equipment and materials appropriate to finishing applications 3. identify the factors governing the quality of processed material. Underpinning knowledge The candidate will be able to: 1. state the range of finishing processes used in materials processing operations

a. grinding b. machining c. filling d. cutting

i mechanical ii thermal

e. chipping f. fettling g. trimming h. blasting

i bead ii grit

i. plating j. painting k. polishing.

2. describe the range of applications for finishing process operations

a. surface finishing of components b. surface painting/plating of components c. removal of casting defects and imperfections d. abrasive cleaning of castings e. cutting off riser fins f. cutting of extruded waste g. truing up surfaces h. shaping components i. trimming up rough edges.

3. state the range of equipment required for finishing operations

a. sealed cabinets b. compressed air supply blasting equipment c. saws

i circular ii reciprocating(hand/mechanical) iii chop iv band

d. drilling machines and drill bits e. machining centres f. thermal cutting equipment

g. chemical baths h. paint brushes i. range of general hand tools j. files and scrapers

4. state the need for control of dimensional accuracy

a. length b. surface contour c. surface finish and texture d. angles

i profiles ii roundness and concentricity iii parallelism iv accuracy of form

5. state the need to maintain an efficient supply of materials during processing operations. 6. state the factors that can affect an efficient operation

a. process interruptions b. process faulty equipment c. unsuitable or defective material d. breakdowns e. untrained personnel f. lack of supervision.

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Unit 726 Using wood for engineering activities

Rationale This unit is concerned with the preparation, planning and tasks required to produce components using wood base materials. It covers the skills and knowledge required to plan and prepare for producing patterns, models or other components for a range of engineering applications. The production methods used should be confined to the application of standard wood cutting and forming machinery, manual and hand held powered tools to manufacture patterns, models and other engineering components using safe working practices. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 726.1 plan and prepare for efficient woodworking operations 726.2 produce an engineering product using woodworking operations effectively and safely 726.3 check that the finished product conforms to the specification. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251 Assessment The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 726 Using wood for engineering activities 726.1 plan and prepare for efficient woodworking

operations

Practical activities The candidate will be able to: 1. identify and compare timbers and sheet materials available for product 2. select hand tools 3. select woodworking machine tools 4. select portable power tools. Underpinning knowledge The candidate will be able to: 1. state the range and form of supply of woodworking materials

a. soft and hard woods b. reconstituted material

i block board ii fibre board iii MDF

c. plywood, laminated and veneered sheets. 2. state the properties, condition and handling of timbers and sheet materials

a seasoning and grading b resistance to warping and shrinkage c identification of common defects d careful movement and treatment e dry and correct storage.

3 describe the factors influencing the choice of material used for products

a. material properties b. surface finish and texture c. bonding ability d. mass e. cost

4. describe the factors influencing the design and selection of the method of construction

a. strength b. rigidity c. weight d. joining capability

5. describe the types of construction a. one-piece b. flat-back c. split pattern d. pattern plate e. sub assembly

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6 state the range of hand tools available for woodworking a. saws b. planes c. carving tools d. paring tools e. finishing tools f. drill braces 7 state the range of machine tools for woodworking

a. band saws b. disc and bobbin sander c. drilling machines d. planer/thicknesses e. circular saw f. router g. lathe h. morticer/tenoner i. spindle moulder

8. describe a range of portable power tools for woodworking

a. drills b. sanders

9. describe a range of materials for temporary and permanent fastenings

a. adhesives b. screwthread devices c. nails d. dogs and clamps

10. describe a range of materials for surface finish and preservation

a. abrasive papers b. other abrasives c. wax and proprietary fillers d. chemical

i primers ii varnishes iii cellulose iv paints v solvents/thinners

e. disposal of waste.

Unit 726 Using wood for engineering activities 726.2 produce an engineering product using

woodworking operations effectively and safely

Practical activities The candidate will be able to: 1. select appropriate techniques for product construction 2. select and prepare materials for specific woodworking operations 3. produce a layout or assembly plan 4. produce an engineering product in wood based material using a range of hand. Underpinning knowledge The candidate will be able to: 1. state essential operator and bystander safety requirements

a. personal Protective Equipment (PPE) i hairnets ii eye protection

b. respiratory Protective Equipment (RPE) i dust extractors

c. secure areas. 2. state basic safety regulations applicable to woodworking processes

a COSHH b Provision and Use of Work Equipment Regulations (PUWER) 1998

3. state the need to use information available for woodworking operations

a. safety instructions b. job instructions c. engineering/technical drawings d. quality control documents e. digital data

4. state the purpose of technical drawings and specifications as a means of determining

a. shape and characteristics of a product b. materials requirements c. tools and equipment d. sequence of operations to manufacture or install the product

5. state methods for dimensioning

a. from a datum b. accumulated areas in assembly

6. state the purpose of woodworking allowances

a. taper b. machining c. contraction d. joint lines e. coreprints f. timber joints

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7. state marking out and measuring techniques

8. state methods of marking out a. lines b. centre marks

9. state the main information gained from layouts

a. optimum constructional method b. joint position c. methods of fixing d. cutting list

10. state the form and uses of specific items of marking out equipment, tools and instruments

a. callipers b. marking out machine c. square

i box ii centre iii mitre

d. dividers e. trammels f. templates g. rules and graduated scale instruments

11. state the marking out procedure for

a. straight lines b. circles and arcs c. lines parallel or perpendicular to the surface plate d. parallel lines on angled sections e. parallel lines along shafts

12. state the methods of manual marking out to ensure

a. accuracy b. no damage to material surfaces

13. state the use of x, y and z axes and co-ordinates 14. state the need to work to the specified tolerances 15. state the basic concept of workholding

a. locate the workpiece b. restrain the forces exerted by the tool

16. state how to safely handle all equipment, machines and materials 17. state the classification of material removal operations in terms of the relative movement

between tool and workpiece when drilling and machining 18. state the correct operating procedures for sawing

a. rip sawing b. sawing joints c. sawing internal and external profiles

19. state the correct operating procedures for planning

a. to size b. end grain c. grooves or profiles

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20. state the correct operating procedures for chiseling a. cutting out waste material on internal and external joints b. paring c. gouging d. carving

21. state the correct operating procedures for drilling

a. braces and power tools i through holes ii flat bottomed holes iii counterbored iv countersunk holes

22. state the correct operating procedures for power saws

a. cutting sheet materials b. roughing down to size c. cutting at angle

23. state the correct operating procedures for planning machines

a. finishing material to thickness b. squaring up material c. producing angular edges and rebates

24. state the range of cutting tools available for the different machines 25. state correct sequences for assembling component parts

a. all parts are correctly positioned, aligned and fit correctly before they are secured into their final position

b. check all dimensional and geometric tolerances are within specification 26. state methods to form permanent joints

a. adhesives i PVA ii contact adhesives iii epoxy resins

b. mechanical fasteners i pins ii nails iii dowels iv special purpose fasteners

27. state the range of self-securing wood joints

a. slots/grooves b. mortice & tenon c. half lap d. dovetail e. combed f. taper wedge

28. state methods to form removable joints

a. screws b. bolts

29. state methods to form temporary joints

a. screws b. couplings

c. keys d. double-sided tape

30. state reasons for using wood fillers and the required precautions.

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Unit 726 Using wood for engineering activities 726.3 check that the finished product conforms to the

specification

Practical activities The candidate will be able to: 1. use measuring and checking devices to assess product quality 2. record the results of the measuring activity 3. reinstate the work area to a safe working environment. Underpinning knowledge The candidate will be able to: 1. state systems of metric and imperial units of measurements 2. state that a measuring process is comparative 3. list the dimensional properties to be measured

a. length b. flatness c. parallelism d. angles e. profiles f. relative position g. roundness and concentricity h. accuracy to form

4. describe quality/calibration for measuring tools/equipment 5. state the range, applications and operation of measuring devices

a length i rules ii vernier callipers iii tapes

b. angular measurement i squares ii indicating tools

A. angle templates B. protractors C. vernier protractors

c. checking position, level and size i surface plates and tables ii vee-blocks iii straight edges

6. state the factors affecting accuracy of measurement

a. accuracy of measuring device b. errors and their causes

i different types of measuring tools/equipment for measuring a specific dimension

ii the human eye — parallax

iii use of equipment without positive datums iv misapplication of force when measuring v correct positioning of measuring tools/equipment vi cleanliness and maintenance of measuring tools/equipment vii positioning of light work pieces to avoid deflection

7. describe methods for recording data in Q/A documentation from inspection process

a. manual b. electronic

8 state the need to reinstate the work area on completion of the activity

a. correct disposal of waste materials b. cleaning and isolation of machine tools c. correct storage of hand tools and hand powered tools d. correct storage of reusable material

9. describe the procedure for the disposal of hazardous waste material in accordance with

current regulations 10. describe the procedure for reporting damaged or faulty tools and equipment.

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Unit 727 Hand forging engineering materials

Rationale This unit covers the general requirements for hand forging engineering materials, including all hand tools and the techniques used, heating and cooling methods and their affects on metals. The forging operation includes the sequence and techniques required to produce a forged component to a required specification using the most appropriate tools and equipment in a safe manner. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 727.1 plan and prepare for efficient hand forging 727.2 carry out hand forging operations 727.3 check that the finished product conforms to the specification and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 727 Hand forging engineering materials 727.1 plan and prepare for efficient hand forging

Practical activities The candidate will be able to: 1. plan and prepare for efficient hand forging 2. check that the finished product conforms to the specification and reinstate the work area 3. carry out hand forging operations. Underpinning knowledge The candidate will be able to: 1. state the methods and reasons for heat treatment of steels

a. hardening b. tempering c. annealing

2. state the need to use engineering drawings/specifications to determine the factors to be

considered when producing a component by forging a. the forging operation(s) required

i bending ii twisting iii drawing down iv upsetting v swaging punching vi parting off vii welding

b. the heating medium i furnace ii blacksmith’s hearth iii gas torch

c. the equipment and hand tools required d. the type and amount of material required and any pre-forging preparation

3. describe the equipment and hand tools used for forging and their purpose

a. the birk, hardie hole, radius edge and the hard face of an anvil b. swage block c. floor mandrel d. different types of hand hammer e. tongs with different shapes of jaw to ensure good secure work holding f. flatters and set hammers g. top and bottom swages h. top and bottom fullers i. hot and cold sets j. punches and drifts

4. describe the methods of forging to produce a required shape

a. drawing down b. bending c. upsetting d. swaging e. twisting

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f. punching g. drifting

5. state how to determine the bending allowance. 6. state the effect forging has on the structure and properties of metal

a. that all metal is composed of crystals or grains that distort under force b. the effect of cold working (below re-crystallising temperature) has on the properties

and grain structure of metal c. the effect of hot working (above re-crystallising temperature) has on the properties

and grain structure of metal d. the advantages of forging components at just above the metal re-crystallising

temperature e. the effects of prolonged heating at too high a temperature on grain structure f. methods of refining coarse or enlarged grain structure g. procedures to avoid burnt or oxidised metal when heating in hearth fire

7. state the methods of quenching

a. the different media used and their cooling rates i water ii oil iii air

iv sand b. the affects of quenching media on the grain structure and properties of different

steels (slow and rapid cooling).

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Unit 727 Hand forging engineering materials 727.2 carry out hand forging operations

Practical activities The candidate will be able to: 1. pproduce a hand forged component(s), which includes

a. bending b. drawing down c. upsetting d. swaging e. punching f. drifting g. twisting

2. hharden and temper a forged component 3. aanneal a forged component. Underpinning knowledge The candidate will be able to: 1. state the need to recognise and take precautions against potential health and safety

hazards associated with forging metal a. the need for PPE

i heat resistant clothing ii anti-splinter spectacles

b. the need for RPE i extraction

c. that the dust and fumes from the heating medium are a source of danger and should be removed by extractor fans

d. that the anvil and swage block should be mounted on a stable base and maintained in good condition

e. that the floor area surrounding the heat source should be of fireproof materials f. to avoid carrying hot metal around; anvils and quenching tanks should

be as close to the heat source as possible g. the danger of hot oxide particles flying in all directions when forging very hot metal

2. state the need to check ,set up and adjust heat source 3. describe different methods of producing heat

a. Blacksmith’s hearth i the purpose of the fire tools used to maintain the fire

A. poker, B. shovel C. rake

ii how to prepare and light a fire using coke breeze or anthracite coal iii how to maintain the fire in an efficient condition iv the importance of keeping the fire as small as possible and at a size and heat

required for the job in hand v the need for the heat in the fire to be in the middle, immediately below the

metal being heated b. furnaces

i how to operate and control the heat output of gas or oil fired furnaces suitable for forging

ii and understands the importance of the correct ratio of air and c. gas torches

i how to operate a coal/natural gas torch ii that limited heat is produced by a natural gas air flame iii how to assemble and operate oxy-fuel gas equipment iv the gas pressures and flame adjustments for different types of nozzles

4. state the need to heat the component to the required temperature for the forging

operation 5. state the common forging temperatures and colours

a. dull red or blood red heat — for making simple bends in low carbon steel b. bright red heat — used for bending over anvil, light punching and hot chiseling c. bright yellow heat — used for forging operations on wrought iron, low carbon steel

and punching thick sections d. full white heat — used for forge welding wrought iron

6. describe how to produce component features by hand forging

a. bending b. drawing down c. upsetting d. swaging e. punching f. drifting g. twisting

7. state the need to exercise quality control during forging to avoid

i excessive hammer marks ii burnt metal iii cracks on surface iv distortion of metal sections

8. recognise the need correct any mistakes or defects that may occur during forging

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Unit 727 Hand forging engineering materials 727.3 check that the finished product conforms to the

specification

Practical activities The candidate will be able to: 1. cconfirm that the forged component meets the required specification 2. rrecord the results to confirm achievement of the required profile(s) 3. rreinstate the work area to safe working environment. Underpinning knowledge The candidate will be able to: 1. state the need to check the completed work piece complies with specification

a. dimensions and tolerances b. shape and profile c. surface finish

2. state the post forging operation workshop checks

a. visual b. abrasive tests

i spark ii file

3. describe the defects that can be identified by visual examination

a. burnt metal b. cracks c. distortion d. pitting

4. state the equipment used for measuring the accuracy and shape of finished forgings

a. rules and tapes b. squares and bevels c. gauges d. templates.

5 describe methods for recording data in Q/A documentation from inspection process

a manual b electronic.

6. state the need to shut down equipment safely and leave in a secure condition

a. extinguish the Blacksmith’s hearth fire fuel b. turn off and isolate furnaces c. turn off and isolate gas equipment

7. state the need to reinstate the work area on completion of the activity

a. correct disposal of waste materials b. all tools should be quenched prior to storage c. correct storage of tools in safe storage racks d. correct storage of reusable material(s)

8. describe the procedure for the disposal of hazardous waste material in accordance with current regulations

9. describe the procedure for reporting damaged or faulty equipment.

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Unit 728 Heat treating engineering materials

Rationale This unit deals with the heat treatment of a range of common engineering materials that include carbon steels, aluminium, aluminium alloys, copper and copper based alloys. The heat treatments include surface hardening, stress relieving, annealing, normalising, tempering and precipitation hardening using a range of heating and cooling mediums in a safe manner. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 728.1 plan and prepare for efficient heat treatment operations 728.2 carry out heat treatment on an engineering metal effectively and safely 728.3 check that the finished product conforms to the specification and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 728 Heat treating engineering materials 728.1 plan and prepare for efficient heat treatment

operations

Practical activities The candidate will be able to: 1. confirm material characteristics and determine heat treatment requirements 2. identify and set up the equipment for heat treatment. Underpinning knowledge The candidate will be able to: 1. state the properties of metals can be modified using heat treatments

a. carbon steels i hardening ii tempering iii carburising/case hardening iv nitrating v normalising vi annealing vii stress relief

b non ferrous i hardening ii annealing iii stress relief

2. state the hardening temperature range of plain carbon steels depends principally on the

carbon content of the material 3. state that it is the rate of cooling which determines the properties of steel after heat

treatments 4. state that hardening of steels is produced by rapidly cooling from above its UCT and the

degree of hardness depends upon a. the size of the work piece b. the type of quenching medium c. the degree of agitation d. the final temperature of the quenching medium

5. state that large components will result in a hardness range through the section

irrespective of the quenching medium 6. List the heating mediums used for heating treating metals

a. furnace b. gas torch c. blacksmith’s hearth d. induction coils e. chemical baths

7. state the mediums for batch tempering

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a. circulating atmosphere furnaces b. chemical baths

8. state that temperature can be measured using a. pyrometers

i disappearing filament ii thermocouples

b. temperature indicating paints and crayons c. tempering colour bands

9. state that the type of quenching medium determines the speed of cooling and hence the

degree of hardness a. brine b. water c. oils

i mineral ii animal iii vegetable iv polymer solutions

d. air 10. state that case hardening/carburising is used where the service conditions demand a hard

surface combined with a tough, shock resistant core a. cams b. gears c. bearing surfaces

11. describe the properties of aluminium and aluminium alloys and how their properties can

be modified a. solution treatment/age hardening b. tempering c. refrigeration d. work hardening

12. describe the properties of copper and copper based alloys and how properties can be

modified using heat treatment a. annealing b. stress relieving c. precipitation hardening d. work hardening

13. state the need to prepare components prior to carrying out heat treatment

a. clean/degrease b. remove scale/coatings c. polish surface prior to heating d. use masking as required e. pre-heating by immersion in salt baths.

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Unit 728 Heat treating engineering materials 728.2 carry out heat treatment on an engineering metal

effectively and safely

Practical activities The candidate will be able to: 1. harden and temper a component 2. make and heat treat a spring 3. case harden a component 4. soften a piece of cold worked non-ferrous metal by heating and quenching Underpinning knowledge The candidate will be able to: 1. state the need to apply safe working practices appropriate to heat treatment processes

a. wear appropriate PPE b. fire prevention c. fume extraction d. handling hot materials

2. describe the safe handling practices for hot materials and heat sources

a. furnaces b. gas-air torches c. oxy-fuel gas equipment d. work pieces

3. state the PPE and RPE appropriate to heat treatment processes 4. describe the technique of case hardening/carburising 5. state that post heat treatment may be required to refine the case or the core of the steel 6. state that tempering reduces stresses and brittleness produced by the hardening process 7. state that tempering involves reheating and quenching the hardened steel 8. state that the reheating temperature used determines the degree of temper produced 9. state that when tempering small numbers of components such as chisels or centre

punches the temperature can be estimated by observing the colour band — tempering colours

10. state that normalising and annealing are similar in the temperatures involved but annealing

involves controlled cooling 11. state that annealing and normalising produce structural and physical changes within the

material a. recrystallisation b. grain growth c. distortion d. scaling (oxidation)

12. state that stress relieving is a process which involves heating the steel to temperatures

below the LCT and does not affect the structure of the material

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13. state that stress relieving produces minimal modification to material properties 14. state that residual stresses produced by forming and welding are redistributed or relaxed

during stress relieving 15. state that work hardened copper can be softened by heating and quenching 16. state that extensive cold working may involve repeated heat treatment 17. describe the variation in heat treatment for

a. brasses i hot working ii cold working iii free cutting iv high tensile

b. bronzes i tin ii phosphor 18. state the process of solution treatment of aluminium alloys 19. state that aluminium alloys precipitation-harden at room temperature over a period of time 20. state that the hardening process can be accelerated artificially 21. state that working of the aluminium-copper alloy for highly stressed components should

occur soon after solution treatment.

Unit 728 Heat treating engineering materials 728.3 check that the finished product conforms to the

specification and reinstate the work area

Practical activities The candidate will be able to: 1. confirm that he heat-treated material(s) meets the required specification 2. record the results to confirm achievement of the required characteristics 3. reinstate the work area to safe working environment. Underpinning knowledge The candidate will be able to: 1. state the post heat-treatment workshop checks

a. visual b. Non Destructive Testing (NDT)

i dye penetrant ii fluorescent penetrant iii magnetic particle

c. abrasive tests i spark ii fire

2. state that more accurate tests can be used confirm the required characteristics

a. Ultra sonics b. vickers c. brinell d. charpy e. Izod

3. State the deficiencies that can be identified by NDT

a. burnt metal b. cracks c. distortion d. pitting

4. describe methods for recording data in Q/A documentation from inspection process

a. manual b. electronic

5. state the need to reinstate the work area on completion of the activity

a. correct disposal of waste materials b. cleaning and isolation of heating equipment c. correct storage of ancillary tools and equipment d. correct storage of reusable material(s)

6. describe the procedure for the disposal of hazardous waste material in accordance with

current regulations 7. describe the procedure for reporting damaged or faulty equipment.

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Unit 729 Finishing surfaces by applying coatings/treatments

Rationale This unit covers a broad range of surface coating/treatment activities that are used in the engineering and manufacturing sectors. It covers the skills and knowledge needed to produce surface finishes by applying coatings/treatment using appropriate tools, different materials and inspection techniques. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 729.1 plan and prepare for finishing surface operations 729.2 apply techniques and procedures to produce finished coated surfaces 729.3 check finished product and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.


729.1 plan and prepare for finishing surface operations

Practical activities The candidate will be able to: 1. interpret drawings and extract the required data 2. select and check equipment used for preparing components 3. select and check surface treatment equipment 4. follow a production schedule. Underpinning knowledge The candidate will be able to: 1. state the safety regulation and acts applicable to surface coating and treatments

a. Local Exhaust Ventilation (LEV) b. Required Air Quantities (RAQs) c. Chemicals Hazards Information and Packaging (CHIP).

2. state the importance of wearing (PPE) and describe briefly what protection each will

provide the user a. body protection against a range of chemicals b. safety footwear against a range of chemicals c. safety goggles and face shields chemical splashes d. barrier cream where protective clothing is not practical.

3. state the need for procedures to prevent personal injury. 4. state the basic principles of risk assessment. 5. state the need to prepare surfaces to be finished

a. cleaning and degreasing b. stripping old finishes c. Filling d. masking up e. pre-surface treatments f. Sealing g. mechanical surface treatment h. re-activating treatment.

6. state the factors influencing the selection of surface coating processes

a. finish i type ii quality

b. size of components c. service operating conditions

i abrasive ii corrosive iii temperature

d. availability e. cost

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7. state the range of consumable materials and compounds a. chromium b. nickel c. tin d. zinc e. paints

i water based ii alkyd based iii synthetic iv polyurethane vi lacquer, stains & waxes.

8. list methods for locating work during treatment

a. wiring b. baskets c. specialised jigs and fixtures

9. state the need to load components safely.


729.2 apply techniques and procedures to produce finished coated surfaces

Practical activities The candidate will be able to: 1. check equipment for safe operation 2. prepare components for surface treatment 3. position and secure components 4. apply surface coating/treatment 5. interpret and apply surface treatments. Underpinning knowledge The candidate will be able to: 1. state the safety precaution specific to treatment processes

a. emergency stop procedures b. use of guards and interlocking devices c. operating procedures d. tanks e. fumes extraction f. railed gantries g. RPE

2. state the methods used to prepare surfaces prior to applying surface coatings

a. abrasive blasting b abrasive sheets

i emery cloth ii glass paper

c. degreasing d. rescaling e. fluxing f. pickling.

3. state the principles underlying the preparation and use of treatments

a. pre-coating b. coating c. post-coating

4. state the sequence of operations of surface treatment processes

a. clean b. prepare c. process d. finish

5. state the need to pre-heat certain components. 6. describe briefly paint techniques

a. brush b. dip

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c. roller d. spray.

7. describe briefly techniques of applying finishes a. powder coating b. electroplating c. hot dip treatments

i galvanising ii tinning

d. metal spraying e. painting f. chemical treatments g phosphating.

8. state operating temperatures of surface coating/treatment processes 9. describe the handling of components

a. manual b. mechanical

10. describe briefly jigs, fixtures and manipulators in terms of

a. movement control b. productivity c. rigidity.

11. state the need for the safe use of tools

a. hand b. power

12. describe briefly post finish treatments and procedures

a. waxing b. lacquering c. plastic film

13. state potential problems that can occur during treatment processes

a. breakdown b. contamination of consumables c. loss of power d. operator error e. overheating.

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729.3 check finished product and reinstate the work area

Practical activities The candidate will be able to: 1. check the treated surfaces 2. carry out checks on equipment and holding devices 3. return consumable materials to designated location 4. recycle waste materials 5. check finished product and reinstate the work area. Underpinning knowledge The candidate will be able to: 1. state Health and Safety requirements, for the disposal of waste and the implications of

failure to comply a. solids b. powders c. liquids.

2. state the requirements for leaving the work area in a safe and clean condition on

completion of the activities a. return equipment and holding devices to there designated storage location b. return consumable materials to store.


remedial actions. 4. state the need for recycling different types of waste



5. state who to informed when the fitting activity is complete

a. supervisor b. colleagues involved in the same activity c. associated departments d. customers.

Unit 730 Preparing sand moulds and core for casting

Rationale This unit covers a broad range of sand moulding and core making activities which are required in the engineering and manufacturing sectors. It covers skills and knowledge needed to produce sand moulds and cores using appropriate tools, different materials and inspection techniques. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 730.1 plan and prepare for moulds and cores making operations 730.2 apply techniques and procedures to produce moulds and cores 730.3 check finished product and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from the unit will be assessed by means of an assignment and questions which will cover the practical and underpinning knowledge. Standards Any reference to British/European/ISO standards refer to current version.

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Unit 730 Preparing sand moulds and core for casting 730.1 plan and prepare for moulds and cores making

operations

Practical activities The candidate will be able to: 1. interpret information relating to mould and core production 2. select processes for mould and core production 3. select materials for mould making and core making 4. select and check ancillary equipment 5. follow a production schedule. Underpinning knowledge The candidate will be able to: 1. state the safety regulation and acts applicable to sand moulds and coremaking

a. Health Surveillance in the Foundry Industry b. Noise at Work Regulations (NAW).

2. state the importance of wearing (PPE) and describe briefly what protection each will


3. list materials used for pattern making and state their applications

a. expanded polystyrene b. metal c. resin d. wood.

4. list materials used for core boxes and state their applications

a. metal b. resin c. wood

5. state the difference between natural and synthetic sands

a. clay content b. location c. grain

i distribution ii shape iii size

6. state the range of binder materials used in a. mould making

i clays ii resins

A air-set B heat-cured

iii sodium silicates A air-set B CO2 gas cured

b. core making i oils ii resins

A air-set B heat-cured C gas/vapour cured.

7. state the range of additive materials used in

a. Mould making i coal bust/replacements ii Inhibitors

b. Core making i breakdown agents.

8. describe briefly the influence of binder and additive materials on the properties of sands

a. bench life b. compactability c. cured strength d. green compression strength e. permeability.

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Unit 730 Preparing sand moulds and core for casting 730.2 apply techniques and procedures to produce

moulds and cores

Practical activities The candidate will be able to: 1. check tools and equipment for safe operation 2. select and prepare test equipment 3. prepare sands 4. produce moulds and cores 5. assemble mould ready for casting. Underpinning knowledge The candidate will be able to: 1. state safety precautions specific to mould and core making

a. safe operation of equipment b. secure areas c. Personal Protective equipment (PPE)

i grades of eye protection ii hands and arms protection iii feet and legs protection iv choice of ear protection

d. Respiratory Protective equipment (RPE) i disposable respirators ii half or full face masks iii hoods or blouses.

2. state how to safely handle equipment and materials. 3. state the benefits and limitations of sand preparing equipment

a. mills b. mixers.

4. state the benefits and limitations of mould making and core making machines and

equipment a cost b environmental c technical

5 describe briefly methods to aid mould making practices

a. cover cores b. draw backs c. mould reinforcement d. loose pieces e. odd-sides.

6. state methods for checking mould and cores prior to assembly

a. callipers b. hardness c. templates.

7. state the principles of running and feeding systems a. adequate feed metal b. control turbulence c. directional solidification d. minimise inclusions.

8. state methods used to test foundry sands

a. compactability b. green compression strength c. moisture content d. permeability e. sieve analysis.

9. state the range of additives used to improve properties of mould and core sands

a. breakdown of core after casting b. expansion characteristics of silica c. green strength d. mould-metal reactions.

10. state the tools, equipment and materials for mould and core production

a. box clamps/weights b. hand tools

i wedge rammer ii strickle

c. mould boxes i size ii number

d. mould/core i chills ii coatings iii reinforcements iv releasing agents.

11. state the procedure for checking pattern and core box equipment

a. job instructions b. visual inspection for defects c. loose pieces, draw backs available d. runners and feeders available e. corebox/es identified.

12. state methods used to prevent core floatation and cope box movement

a. box i clamps ii weights

b. chaplets c. core prints.

13. describe methods of minimising impurities entering mould cavity

a. ceramic foam filters b. ingates in drag c. runner bar in cope d. runner bar extensions e. stoppers in poring basin f. strainer cores g. whirlgate

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14. describe procedures for mould closing to ensure location and avoid sand crushing a. box pins

i fixed ii loose

b. rebates 15. describe briefly defects associated with

a. inadequate prevention of core cope movement during casting b. incorrect procedures for closing and protecting mould prior to casting c. poor control over placing cores in mould d. poor mould making and core making techniques.

16. state procedures to locate cores in moulds

a. chaplets b. core prints c. glue d. sprigs.

17. state how to locate the mould for casting

a. sand bed b. pouring tracks.

Unit 730 Preparing sand moulds and core for casting 730.3 check finished product and reinstate the work

area

Practical activities The candidate will be able to: 1. check moulds and cores comply with specifications 2. carry out checks on tools and equipment 3. return tools, equipment and consumable materials to designated location 4. check the quality of moulds and cores 5. follow an inspection schedule to check conformity 6. recycle waste materials 7. check finished product and reinstate the work area. Underpinning knowledge The candidate will be able to: 1. state Health and Safety requirements, for the disposal of waste and the implications of

failure to comply a. solids b. powders c. liquids.

2. state the requirements for leaving the work area in a safe and clean condition on

completion of the activities a return tools and equipment to designated storage location b return consumable materials to store.


remedial actions. 4. state the need for recycling different types of waste

a. materials i metallic materials ii cloths and paper


5. state who to informed when the moulding activity is complete

a. supervisor b. colleagues involved in the same activity c. operators d. associated departments e. customers.

6. list visual methods for checking moulds and cores

a. correctly dressed and coated b. cracks c. distorted

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d. broken e. friability f. surface deformation g. vents in correct location

7. describe methods for checking mould cleanliness a. hand b. power

8. describe procedures for conducting tests on foundry sands to ensure reproducibility of

test results a. method instructions b. recording correctly c. representative sample d. units of measurement.

9. state the need to check moulds for soft spots. 10. state the need to check specifications

a shape b dimensional accuracy.

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Unit 731 Producing Composite Assemblies

Rationale It covers basic assembly operations and techniques for trial, one off and batch assembly. It will also cover allowable tolerances, methods of fixing, types of joints, alignment, use of specialist fitments together with a range of bonding techniques and the relevant, health and safety and COSHH requirements. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 731.1 plan and prepare for efficient production of composite assembly 731.2 produce composite assemblies using a range of techniques 731.3 check and finish composite assemblies. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 731 Producing Composite Assemblies 731.1 plan and prepare for efficient production of

composite assembly

Practical activities The candidate will be able to: 1. state the current health and safety regulations related to working with chemicals and

hazardous materials a. HSaW b. COSHH

2. state the health and safety requirements and safe working practices/ procedures for

working with composite materials, resins and adhesives a. wearing appropriate protective clothing (PPE)

i eye protection ii protective clothing, dedicated overalls, gloves iii dust/fume masks

b. maintaining a clean and tidy work area i dedicated storage for waste fibre, trimmings ii correct disposal of waste resin and adhesive

c. health and safety hygiene i skin care ii eye care iii respiratory protective equipment (RPE)

d. risk assessments 3. state hazards associated with working with composite mouldings and adhesives

a. handling of fibre materials b. misuses of tools c. mixing of adhesives d. dust and fumes from composite materials and resins

4. state the reasons for the incorporation

a. local fume exhaust ventilation systems (LEV) b. fume cabinets c. washing facilities d. dust proof lighting e. dedicated dust and fume extraction f. temperature and humidity control g. styrene levels to threshold limits

5. state relevant regulations to the safe disposal of waste composite material and

consumables 6. state the correct and safe use of

a. chains b. rope/wire/made made fibre slings c. eye bolts d. shackles

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7. state the correct safe use for a. power cables b. extension leads c. air supply hoses

8. describe information sources and interprets information relating to composite mouldings and assemblies a. drawings b. operation sheets c. data sheets and specifications d. manufacturers recommendations/instructions e. technical specifications

9. state how to use the sources listed in 8) for

a. material preparation for a given specification b. component part listing c. resin systems, adhesives, solvents, fillers for given application d. cloth preparation for joining techniques e. planning and sequencing operations f. determining consumable quantities

10. state the conventions and terminology use in composite assembly

a. gel points b. cure times c. bond thickness d. bond strength e. peel strength

11. states the range of tools/equipment required for assembly

a. measuring equipment b. clamping equipment c. power hand tools

i drills ii linisher’s iii saws

d. adhesive application i brushes ii applicator gun

e. mechanical fastenings f. heating equipment for curing adhesive joints

12. state the range of materials/consumables used in composite assembly

a. glass, carbon, aramid fibre cloth b. water solvent cleaning c. film adhesives d. adhesives

i epoxy ii acrylic

e. sealants 13. state methods used for mixing correct quantities and ratios of adhesives 14. state mechanical fixings used in composite assemblies

a. thread inserts b. quick release fasteners c. mechanical fasteners d. anchor nuts e. rivets f. pins

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15. describe the storage and management for the use of a. pre-impregnated reinforcing materials b. dry reinforcing materials c. adhesives hardeners and accelerators d. sealants e. film adhesive

16. state the equipment required for heat curing

a. heater mats and blankets b. heater lamps c. heated tools/ press d. oven.

Unit 731 Producing Composite Assemblies 731.2 produce composite assemblies using a range of

techniques.

Practical activities The candidate will be able to; 1. select, weigh and mix adhesive in readiness for joining 2. produce assemblies using selected techniques

a. non-permanent fixing – mechanical fastenings b. permanent fixing – use of adhesives

3. use tools/equipment to trim/align component parts to meet specification requirements. Underpinning knowledge The candidate will be able to: 1. state that prior to assembly

a. moulds are correct and complete to specification b. moulds are inspected for defects c. ancillary components are correct and complete d. consumable materials are available e. correct equipment is selected and is safe for use f. mouldings are suitably protected in the work area

2. state the principle features of adhesives

a. one-pack and two pack adhesives b. forms of supply

i powder ii liquid

c. methods of joining i at room temperature ii at temperatures above 200C iii effect of pressure on the joining process

d. shelf life and pot life 3. state the need to follow manufacturers directions for the use of adhesive/sealants 4. describe the preparation, correct quantities/ratios of adhesives

a. epoxy b. acrylic

5. state the methods for applying adhesives and sealants

a. wetting-out by brush b. applicator gun c. hand tool applicator d. laying film adhesives

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6. state the procedures to be followed to achieve a. loose fit tolerances b. close fit tolerances c. non-permanent fixings d. permanent fixings e. joints

i staggered ii return iii overlaps vi butt v joggle

f. alignment 7. describe techniques used for

a. trimming/fettling b. pinning c. clamping d. aligning e. drilling

8. state the reason for a trial fitting 9. state the benefits of assembly jigs

a. aids assembly b. ensures standardisation c. improve efficiency

10. describe the procedure for preparing surfaces that are to be bonded

a. water/solvent cleaning b. abrading c. priming

11. describe techniques used for restraining joints during the curing process

a. applying weights b. clamping c. mechanical fasteners d. pinning joints e. press

12. list composite components that may be used in assemblies

a. trims b. closed panels c. body panes d. tubes e. structural components f. core materials g. sections

13. list non-composite components used in assemblies

a. brackets b. fixtures c. fittings d. flashing/tapes

14. state the types composite assembly

a. one-off

b. batch c. line

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Unit 731 Producing Composite Assemblies 731.3 check and finish composite assemblies

Practical activities The candidate will be able to: 1. check assemblies for conformity against specification 2. reinstate the work area upon completion of activities disposing of waste materials in

accordance with current regulations. Underpinning knowledge The candidate will be able to: 1. state the equipment/tools required to check for dimensional accuracy and geometrical

features a. rule/tape b. calipers c. gauges d. templates/formers

2. describe methods of conducting checks to ensure accuracy

a. position b. security c. completeness d. function of assembly if appropriate

3. state the need to detect assembly defects

a. ineffective joining techniques b. contamination c. component damage

4. describe how to rectify defects in 4) 5. describe methods used to check that mouldings are correctly aligned 6. state how assemblies may be checked for

a. dimensions - measurement b. profiles- templates/formers c. hole size – plug gauges d. hole positions – templates/measurement e. surface texture f. uniformity of size g. alignment – straight edge/piano wire/sight boards

7. state the checks that must be made for moving parts

a. correct alignment b. appropriate clearance

8. state the hazards associated with waste materials a. resin and curing agents can cause

i damage to eyes ii cause skin diseases iii be toxic

b. resin/adhesive/solvent vapours i can cause irritation to eyes, nose and throat ii irritation is more sever when the temperature is elevated

c. solvents causes irritation/permanent damage to eyes and respiratory system d. dust causes irritation to eyes and respiratory system e. broken fibres cause skin irritation

9. state that the work area upon completion of an activity should be left in a

a. clean condition b. safe condition c. tooling and power leads correctly stored d. equipment/tools cleaned e. waste material disposed of in correct manner



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Unit 732 Producing Composite Moldings

Rationale This unit identifies the basic principles and commonly used processes that are required to produce composites mouldings. It covers basic preparation required for the use of moulds, composite materials and resins in order to carry out wet lay up, pre-preg laminating and resin infusion techniques, together with the use of a full range of tools/equipment, planning for manufacture, sequence of operation, inspection and measurement to meet relevant specifications and safe working practices. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 732.1 plan and prepare for efficient production of composite components 732.2 produce component parts using various techniques 732.3 check and finish composite mouldings in accordance with specification. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 732 Producing Composite Moldings 732.1 plan and prepare for efficient production of

composite components

Practical activities The candidate will be able to: 1. read and interpret drawings, specifications and manufacturers’ data sheets 2. extract information from drawings, specifications and data sheets to produce component

parts 3. plan and produce operation sheets for effective and efficient sequential manufacture 4. select materials, moulds formers, tools and equipment for composite manufacture 5. select resin systems for a given task. Underpinning knowledge The candidate will be able to: 1. state the current health and safety regulations related to working with chemicals and

hazardous materials a. HSaW b. COSHH

2. state the health and safety requirements and safe working practices and procedures for

working with composite materials and resins a. wearing appropriate protective clothing (PPE)

i eye protection ii protective clothing, dedicated overalls, gloves iii dust/fume masks

b. maintaining a clean and tidy work area i dedicated storage for waste fibre, trimmings ii correct disposal of waste resin

c. health and safety hygiene i skin care ii eyesight – eye wash available iii respiratory protective equipment (RPE)

d. risk assessments 3. state hazards associated with working with composites and resins

a. handling of fibre materials b. misuses of tools c. mixing of resins d. dust and fumes from composite materials and resins

4. state the reasons for the incorporations of the following into a composite moulding

workplace a. local fume exhaust ventilation systems (LEV) b. fume cabinets c. washing facilities d. dust proof lighting e. dedicated dust and fume extraction f. temperature and humidity control

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5. state relevant regulations to the safe disposal of waste material 6. state the requirement for cleaning tools and equipment upon completion of work 7. describe information sources and interprets information relating to composite mouldings

and assemblies a. EN 8888

i orthographic ii isometric

b. operation sheets c. data sheets and specifications d. manufacturers recommendations/instructions e. technical specifications

8. state procedures for obtaining the sources listed in 7) 9. state how to use the sources listed in 7) for

a. material preparation for a given specification b. material listing c. resin systems, adhesives, solvents, fillers for given application d. moulds and formers e. templates for cloth preparation f. planning and sequencing operations g. determining resin/fibre ratios

10. states the range of tools/equipment required for hand lay-up techniques

a. moulds b. brushes c. rollers d. spray equipment

11. state the range of materials used in composite moulding

a. glass fibre b. carbon fibre c. aramid (Kevlar cloth) d. polyethylene e. foam/honeycomb infill f. peel ply g. film adhesive

12. state the types of weave pattern used in fibre cloth

a. plain weave b. twill weave c. satin weave d. unidirectional weave e. chop strand mat f. woven roving

13. state and uses the conventions and terminology used for

a. wet lay-up techniques i resin/fibre ratio ii material identification, orientation and tailoring iii mixing ratios iv gel times v exotherm vi consolidation

b. pre-preg laminating techniques

i material identification, orientation and templates ii ply lay-up iii pressure plates, vacuum bagging iv bleed plies v cure cycles vi exotherm

c. resin infusion techniques i material identification and orientation ii distribution media iii resin viscosity iv flow paths v ply lay-up vi vacuum bagging vii resin/fibre ratio viii gel times.

14. state the range of resin systems

a. polyester resin b. vinyl ester c. epoxy resin d. phenolic resin e. acrylic resin

15. state methods used for measuring material quantities 16. state the methods used for mixing of resin, hardeners and activators 17. state the importance of the resin/’fibre ratio (Volume Fraction VR) 18. describe the used of additives

a. fillers b. colour pigments c. thixotropic agents

19. describe methods to ensure total wetting of cloth 20 describe methods used to build up successive layer coatings to achieve specification 21. describe methods used to build in mechanical fastenings

a. solid fibre pad inserts b. big head fastenings c. special purpose fittings

22. state the requirement for green trimming 23. describe the storage and management for the use of

a. pre-impregnated reinforcing materials b. dry reinforcing materials c. resins/adhesives hardeners and accelerators d. peel ply

24. state the reason for strict documentation for the storage of materials named in 23) 25. state the main components required for vacuum bagging

a. porous release film b. absorption/bleeder cloth

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c. non-porous release cloth d. air breather e. vacuum bag film f. vacuum bag tape g. vacuum bag connections (various types)

26. state the equipment required for heat curing a. heater mats and blankets b. heater lamps c. autoclave units d. heat bond controllers e. heated tools/moulds/press f. oven.

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Unit 732 Producing Composite Moldings 732.2 produce component parts using various

techniques

Practical activities The candidate will be able to: 1. prepare and use a range of moulds, formers and templates 2. select, weigh and mix resins in readiness for manufacture 3. calculate resin volume/weight/ratio required to wet-out the reinforcing fibres 4. produce components using selected techniques

a. wet lay-up techniques b. pre-preg laminating techniques c. resin infusion techniques

5. use tools/equipment to trim component parts to meet specification requirements. Underpinning knowledge The candidate will be able to: 1. describe related technology to mould and former design and their construction 2. describe the preparation for moulds/formers

a. checking of surfaces for blemishes b. making good and damaged area c. cleaning mould surfaces d. waxing e. application of release agents

3. describe the use of templates for marking out dry cloth fibre 4. describe the related technology for the mixing of resin systems

a. polyester b. vinyl ester c. epoxy d. phenolic e. acrylic f. cyanate ester

5. state the important factors for the preparation of gel coats, resins, additives and catalysts

a. cleanliness b. quantity c. accurate weighing d. mixing ratios e. pot life f. working time

6. calculate resin volume/weight/ratio required to wet-out the reinforcing fibres 7. describe the related technology for tool/equipment use in lay-up activities

a. brush application b. roller application c. spray application

8. state the procedures to be followed to produce a. feather joins b. overlap joins c. oriented plies d. butt joins e. staggered joins f. inserts g. fixings h. stiffening

9. state the procedures to be followed for incorporating core materials

a. solid timber b. foam c. honeycomb – various types d. end grain balsa e. core mat f. expanding core etc.

10. describe techniques and procedures for pre-impregnated lay-ups 11. state the correct methods used with pre-preg materials for

a. storage b. thawing c. handling d. monitoring temperature e. monitoring ‘storage life’ and ‘out-life’

12. state the correct methods of use, storage and handling of ancillary and consumable

materials a. release films b. breather fabrics c. bagging films d. tapes

13. state the important factors to be considered when using pre-preg materials

a. cure cycles b. temperature and pressure ramps c. dwell times d. post curing

14. state the methods used to monitor cure cycles

a. thermocouples b. probes c. chart recorders d. thermometers and data logs

15. describe the construction of a vacuum bag

a. porous release film b. absorption/bleeder cloth c. non-porous release cloth d. air breather e. vacuum bag film f. vacuum bag tape g. connections required for vacuum pump

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16. list techniques used for resin distribution media a. interlaminar b. peel ply c. braid d. networks e. channeled core f. perforated hose g. flow channels h. bleed plies i. meshes j. spiral wrap

17. describe techniques and procedures for the positioning and application of the resin

distribution media 18. state problems that can occur during lay-up process

a. contamination defects b. incomplete wet out c. resin/fibre rich areas d. distortion e. poor consolidation f. under-cure and exotherm g. vacuum leaks h. flow restrictions

19. state that the work area upon completion of an activity should be left in a

a. clean condition b. safe condition c. tooling and power leads correctly stored d. equipment/tools cleaned e. waste material disposed of in correct manner.

Unit 732 Producing Composite Moldings 732.3 check and finish composite mouldings in

accordance with specification

Practical activities The candidate will be able to: 1. checking moulds for conformity against specification 2. select correct tooling and trim moulds to conform to specifications 3. reinstate the work area upon completion of activities disposing of waste materials in

accordance with current regulations. Underpinning knowledge The candidate will be able to: 1. describe how and when to remove components from moulds, formers and fixtures without

causing damage to the component or mould 2. state the equipment/tools required to check for dimensional accuracy and geometrical

features a. rule/tape b. calipers c. gauges d. templates/formers

3. describe how to mark out mouldings in preparation for trimming off excessive material 4. describe the methods and techniques used to trim mouldings

a. knife b. saws c. routers d. cutting wheels/discs

5. state factors that affect the selection of a trimming/cutting tools

a. type of fibre b. type of resin

6. state the need for edge filling cut and trimmed edges 7. state tools used for sanding mouldings

a. rubbing blocks b. diamond files c. discs d. belt sanders e. pencil grinders

8. describe how finished holes in mouldings may be achieved by use of

a. drills b. hole saws c. countersinks d. counterbores e. threading devices

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9. describe how polishing activities on mouldings may be safely carried out a. wet sanding b. cutting

10. state how mouldings may be checked for

a. dimensions - measurement b. profiles- templates/formers c. hole size – plug gauges d. hole positions – templates/measurement e. surface texture f. uniformity of shape g. alignment – straight edge/piano wire/sight boards

11. state tests that are used to detect defects

a. visual inspection b. tap test c. ultrasonic

12. state types of defects that can occur in composite mouldings

a. variation in thickness b. air bubbles c. over consolidation d. resin rich areas e. surface irregularities f. lamination between layers

13. state the hazards associated with waste materials

a. resin and curing agents can cause i damage to eyes ii cause skin diseases iii be toxic

b. resin vapours i can cause irritation to eyes, nose and throat ii irritation is more sever when the temperature is elevated

c. solvents causes irritation/permanent damage to eyes and respiratory system d. dust causes irritation to eyes and respiratory system e. broken fires cause skin irritation

14. state that the work area upon completion of an activity should be

a. left in a b. clan condition c. safe condition d. tooling and power leads correctly stored e. equipment/tools cleaned f. waste material disposed of in correct manner

15. states when it is necessary to


Unit 733 Electrical Technology

Rationale This unit is concerned with Electrical and Electronic Technology required for working with Electronic and Power circuits. The unit covers three performance outcomes. The candidate will be able to state the basic units used in Electrical/Electronic technology, apply the technology to a range of situations and carry out a range of practical exercises. The candidate will be able to plan and mark out Electrical / Electronic circuits, state relevant S.I units, and state electrical theory including but not limited to Basic electron theory, Ohms Law, resistivity etc. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 733.1 state the basic units used in Electrical technology 733.2. apply technology to a range of Electrical situations 733.3 carry out a range of practical exercises. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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Unit 733 Electrical Technology 733.1 basic units

Practical activities The candidate will be able to: 1. plan and mark out Electrical / Electronic circuits. Underpinning knowledge The candidate will be able to: 1. state the S.I basic units for length, area and volume.

a. metre, square metre, cubic metre b. mm, mm2, mm3 c. km, km2.

2. state S.I sub-units for length, area and volume

S.I. Prefixes

Value Name Letter Value Name Letter 1012 Tera T 100 Unity 109 Giga G 10-6 Micro μ 106 Mega M 10-9 Nano. n. 103 Kilo K 10-12 Pico p.

3. State SI derived units

Quantity Unit name Unit Symbol

Force Newton N

Energy Joule J

Power Watt W

Pressure, stress pascal Pa

Electric Potential volt V

Electric Charge coulomb C

Electric Flux coulomb C

Magnetic Flux weber Wb

Magnetic Flux density Tesla T

Electrical Resistance Ohm Ω

Capacitance farad F

Inductance henry H

Temperature degree Celsius o C

Frequency hertz Hz

Current Ampere A

4. state electrical theory

a. basic electron theory b. ohms law c. resistivity d. resistors in series and parallel e. relationship between voltage, current and resistance in series and parallel

circuits f. power, use of basic d.c. theory and formulae. Calculation of power ratings for

common components and equipment g. energy. Describes energy as power x time. Calculates energy used for

common equipment. 5. state basic magnetic theory

a. the layout of basic magnetic fields b. magnets c. magnetic fields surrounding conductors d. magnetic fields surrounding solenoids.

6 understand the construction of capacitors including

a. polarised capacitors b. paper capacitors c. polyethylene d. air

e. mica

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7. state application of capacitors a. capacitors in series and parallel b. understands that capacitors can be used for varying electrical applications c. appreciates dangers associated working with capacitors.

8. show an understanding of

a. rotating a magnet inside a set of coils b. the sine wave, peak, average and RMS values c. Frequency and periodic time.

9. understand transformers

a. the basic construction and use of single phase transformers b. core types

i) shell

ii) toroid

c. use of laminations and ferrite cores d. double wound and Auto transformers.

10. describe and identify

a. semiconductor materials b. diode types and uses c. bipolar transistors d. use of transistors as switching and amplifier devices e. light dependant resistors, light emitting diodes.

11. states connection methods used in electro technical work

a. soldering, safe practice when soldering components in various situations b. crimping, use of appropriate tools for terminating conductors c. idc methods d. commercially available plugs and sockets ( phono, din, edge, ‘d’, co-axial )

Unit 733 Electrical Technology 733.2 application of technology

Practical activities The candidate will be able to: 1. investigate how electro technology is applied to one of the following

a. lighting b power control c motor control d security e emergency supplies.

2. carry out maintenance

a. removing and storing covers and casings b. identification, marking and storing of disconnected or removed components c. checking that replacement components meet specification tolerances d. determining equivalent components when exact replacements are not available e. identifying correct test points in the circuit and carrying out all testing in with

defined procedures and relevant regulations f. carrying out simple visual checks g. carrying out fault finding h. determining a course of action such as replacement or adjustment when repairing

equipment or circuits i. completing all relevant test result documentation accurately and legibly j. reconnecting the equipment

3 carry out tests and adjustments to ensure that the fault has been cured and the equipment

performs within the specification requirements after maintenance Underpinning knowledge The candidate will be able to: a. read and interpret safety instructions b. plan for the installation of circuits c. select the wiring system suitable for the environment, utilization and building d. check the circuit and wiring diagrams and instructions e. list the electrical components, cables, supporting systems and fixing methods required f. check the tools are, equipment and components are safe and suitable for their intended

use.

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Unit 733 Electrical Technology 733.3 practical activities

Practical activities The candidate will be able to: 1. measures and records the current and voltage distribution in series circuits 2. measures and records the current and voltage distribution in parallel circuits 3. sketches the magnetic fields for bar magnets in opposition and attraction 4. determines the polarity of a solenoid 5. sketches the construction of a typical capacitor 6. draws a sine wave as displayed on a CRO. Indicates relevant values 7. measures the input and output voltage of a double wound transformer 8. constructs a simple Bridge rectifier circuit. Underpinning knowledge The candidate will be able to: 1. state how to obtain the drawings, and other technical information. 2. state the need to plan work activities to ensure safety and cost effectiveness. 3. state how to interpret job instructions and guidance relating to the wiring and testing

activities including the use of a) circuit diagrams b) block and schematic drawings c) Technical manuals d) Guidance notes e) Instructions and wiring schedules f) Current edition IEE wiring regulations 4. state the earthing methods for electrical installations. 5. describe the need for circuit protection and the application of fuses, circuit breakers,

residual current circuit breakers and rcbo’s. 6. state the range of electrical equipment and tools used for the wiring operations to be

undertaken a) screwdrivers, pliers, side cutters, cable strippers b) spanners and hammers c) saws and files d) drills for wood, masonry and metal e) battery and power drills f) soldering irons, solders and fluxes g) cable terminating equipment including crimping tools 7. state the types of test equipment used for electrical circuits and installations a) low reading ohm meter b) insulation resistance tester c) earth loop impedance tester d) prospective short circuit tester

e) RCD tester f) Approved voltage indicator 8. state good housekeeping and equipment control a) leaving the work area free of unused consumables and detritus b) cleaning down work area c) storing tools and equipment into safe storage d) labelling and recording finished work.

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Unit 734 Maintaining Electrical Equipment and Systems

Rationale This unit is concerned with the process and equipment essential to the maintenance of electrical engineering equipment and systems up to 400v The candidate should develop an awareness of The Electricity at Work regulations and The IEE wiring regulations. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 734.1 prepare for maintaining electrical equipment / systems 734.2. carry out the maintenance of electrical equipment/systems 734.3 reinstate the work area and apply safe working practices. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.


734.1 prepare for maintaining electrical equipment / systems

Practical activities The candidate will be able to: 1. Gather, read, interpret manufacturers’ maintenance instructions 2. Determine a suitable sequence of testing operations 3. Devise suitable methods for the security of components removed during maintenance 4. Obtain all the test equipment, consumables and tools required to carry out maintenance

activities on different types of a. electrical equipment b. lighting circuits c. power circuits d. control circuits.

Underpinning knowledge The candidate will be able to: 1. state how to obtain the equipment circuit drawings and other related information and the

procedures for their care and safe keeping including a. manuals and / or circuit drawings b. block diagrams c. test schedules d. manuals e. safe guidance and job instructions f. equipment and system specifications g. specific fault diagnosis and testing instructions including advice on any special tools

that may be needed h. current IEE wiring regulations and Electricity at Work Regulations

2. state the

a. need to plan work activities b. methods of producing work plans c. information they must contain

3. state how to correctly identify, label and store components and cables during

disconnection 4. state the range of tests and fault diagnosis that can be carried out . 5. state the type of instruments used to check

a. continuity of main and supplementary equipotent bonding conductors b. continuity of ring final circuits c. insulation resistance d. dead polarity e. functional testing f. circuit and control gear g. residual current device

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6. describe the typical faults that can occur with the equipment and circuits . a. open circuit b. short circuit c. resistance faults d. mechanical component fault

7. describe the range of tools used for maintenance and how to use them a. screwdrivers, pliers, side cutters, cable strippers b. spanners and hammers c. saws and files d. drills e. battery and power tools f. torches and hand lamps g. soldering irons, solders and fluxes h. cable terminating equipment i. multimeter j. insulation and continuity testers

8. state how to check test equipment is

a. safe to use b. suitable for the intended activities c. within current calibration approval dates and d. can cover the range of values to be measured

9. describe how to identify test points on the circuit from information given on the circuit

diagrams and specifications 10. state how to take measurements 11. state how to select cables for different applications

a. voltage and current carrying capacities b. environmental requirements c. prevention of interference

12. state methods of identifying cable and components 13. state the use of components reference manuals to select equivalent components.


734.2 carry out the maintenance of electrical equipment/systems

Practical activities The candidate will be able to: 1. prepare to carry out maintenance

a. carry out risk assessment b. prepare a method statement c. perform safety checks before commencing work

2. carry out maintenance

a. removing and storing covers and casings b. identification, marking and storing of disconnected or removed components c. checking that replacement components meet specification tolerances d. determining equivalent components when exact replacements are not available e. identifying correct test points in the circuit and carrying out all testing in line with

defined procedures and relevant regulations f. carrying out simple visual checks g. carrying out fault finding h. determining a course of action such as replacement or adjustment when repairing

equipment or circuits i. completing all relevant test result documentation accurately and legibly j. reconnecting the equipment

3. Carry out tests and adjustments to ensure that the fault has been cured and the equipment

performs within the specification requirements after maintenance 4. prepare to carry out maintenance. Underpinning knowledge The candidate will be able to: 1. state the need for a risk assessment 2. state the need for a method statement 3. state the need for a Permit to work system 4. state the importance of verifying power supply and the integrity of fuses/circuit protection

devices before proceeding further 5. describe visual checks of the circuits and components for obvious signs of damage

a. broken connections b. burnt or overheated casings c. overheated contact surfaces of cables or components d. component or cable short circuits

6. state methods of identifying components and cables to ensure correct replacement and

reconnection

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7. describe where and how to connect instruments. 8. state the need to

a. isolate equipment b. prove circuits are dead c. use approved voltage indicators to GS 38

9. describe how to take instrument readings and translate these into circuit value measurements, compare test results obtained against specification requirements.

10. describe how to recognise the signals registered on test equipment such as current,

voltage, resistance or impedance and interpret these measurements to determine the actions required

11. state how to use diagnostic aids

a. circuit/wiring diagrams b. equipment manuals c. functional system charts d. probability charts e. maintenance/history records

12. state the various fault finding techniques of tracing faults to block/unit/component level

that are available such as a. function testing b. substitution testing c. injection and sampling d. half split technique

13. state how to decide whether

a. the unit should be replaced b. the fault be further traced to component level c. it is cost effective d. it is a temporary measure whilst a new unit is ordered

14. state how to use the information gained to determine the most likely causes of the fault 15. state how to use heat shunts/shields to prevent overheating components and cables on

reassembly 16. describe the importance of recording faults, symptoms and their identified causes for

future reference 17. describe the principal electrical termination methods and range of other devices used

a. terminal blocks, b. crimped connections c. joint boxes d. glands e. supports f. clips g. earthing devices h. cable connectors

18. state the types of faults that can occur and how they can be overcome

a. open circuit b. short circuit c. resistance fault

d. mechanical component fault 19. state how to deal with problems such as what to do when

a. fault finding procedures are not effective b. the correct tools are not available c. the equipment is damaged in some way d. components cannot be removed as easily as expected e. replacements required are not available f. equipment cannot be re-commissioned.

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20. state the need to check that a. all disconnections have been made b. all components correctly orientated c. fuses/circuit breakers/ protective devices are installed d. equipment is safe to re energise

21. describe the tests required to check the equipment or system is re commissioned and

operating to specification 22. describe the need to put tools and equipment into safe storage on completion of the

activities, leaving the work area in a safe and tidy condition.


734.3 reinstate the work area and apply safe working practices

Practical activities The candidate will be able to: 1. use personal protective equipment 2. identify and deal appropriately with potential hazards 3. comply with current regulations and organisational safety procedures 4. apply approved test procedures 5. commission or re commission systems 6. record and comparing results against specification 7. reinstate the work area. Underpinning knowledge The candidate will be able to: 1. state what might go wrong with instruments, tools, equipment or installation activities and

what to do if they occur 2. describe the isolation techniques used for the various equipment and systems 3. state the importance of recording faults, symptoms and their identified causes for future

reference 4. state the need for protective equipment

a. overalls b. eye protection c. ear protection d. hard hat e. safety shoes f. barrier creams g. gloves

5. state the need for good housekeeping arrangements leaving work areas free of unused

consumables a. cleaning down work areas b. putting serviced instruments, tools and equipment into safe storage c. keeping the work area free of waste and surplus materials, tools and equipment d. labelling and recording finished work.

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Unit 735 Wiring and testing Electrical Circuits

Rationale This unit is concerned with the process and equipment essential to the wiring and testing of electrical circuits connected to a 400 / 230v installation. The candidates should develop an awareness of the requirements of the current IEE Wiring Regulations and the Electricity at Work Regulations. The unit covers three performance outcomes. The candidate will be able to: Assemble components and prepare for wiring and testing of electrical circuits, carry out wiring of electrical circuits and test circuits and reinstate the work area. The candidate will also be able to identify the range of electrical equipment, tools, components and fixings required for the relevant wiring and testing process. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 735.1 assemble components and prepare for wiring and testing of electrical circuits. 735.2 carry out the wiring of electrical circuits 735.3 test circuits and restore the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 735 Wiring and testing Electrical Circuits 735.1 assemble components and prepare for wiring and

testing of electrical circuits

Practical activities The candidate will be able to: 1. read and interpret safety instructions 2. plan for the installation of circuits 3. select the wiring system suitable for the environment, utilization and building 4. check the circuit and wiring diagrams and instructions 5. list the electrical components, cables, supporting systems and fixing methods required 6. check the tools are, equipment and components are safe and suitable for their intended

use 7. select suitable cables suitable for the application from thermoplastic single core, multicore

and armoured cables, including fire resistant cables 8. determine termination methods, fixing methods and earthing methods 9. select suitable test instruments ensuring safety in use. Underpinning knowledge The candidate will be able to: 1. describe the operational principles of lighting , power and control circuits to be

constructed using the following types of cabling system a. pvc single and multicore b. steel wire armoured c. fire resistant such as firetuf, FP200 gold or MI.

2. state the range of electrical equipment and tools used for the wiring operations to be

undertaken a. screwdrivers, pliers, side cutters, cable strippers b. spanners and hammers c. saws and files d. drills for wood, masonry and metal e. battery and power drills f. soldering irons, solders and fluxes g. cable terminating equipment including crimping tools

3. state the range of electrical components, cable fixings and connectors that are used in the

circuits a. circuit breakers b. fuses c. rcd’s d. rcbo’s e. relays f. solenoids g. panel lamps h. switches i. sockets j. joint boxes k. ceiling roses l. lampholders

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m. batten holders n. consumer units o. transformers p. luminaire control gear

4. state the principal electrical termination methods and range of support for fixing and fixing devices used a. terminal blocks b. crimped connections c. joint boxes d. glands e. supports f. clips g. earthing clamps h. cable connectors i. mechanical protection methods

5. state the factors which affect the selection of cables and components for different

applications a. environment b. utilization c. building d. design current e. voltage

6. state how to check that the positions selected for mounting the components does not

interfere with the existing structure and fittings a. water b. gas c. air d. communication e. electrical services.

Unit 735 Wiring and testing Electrical Circuits 735.2 carry out the wiring of electrical circuits

Practical activities The candidate will be able to: 1. fabricate and install support systems 2. install

a. lighting circuits b. power circuits c. control circuits

3. install electrical components 4. remove and replace faulty cables and / components 5. terminate cables to approved standards 6. test circuits to current IEE wiring regulations. Underpinning knowledge The candidate will be able to: 1. state the methods of wiring lighting circuits including

a. 1 – way b. 2-way, conventional & converted 1 way systems c. intermediate circuit

2. power circuits

a. single socket outlets b. radial circuits c. ring final circuits d. fused connection units

3. control circuits

a. lighting b. heating

4. state how to correctly size, fabricate and install support systems 5. state how to mount, fix, and terminate electrical components and cables 6. state how to deal with common problems

a. open circuits b. short circuits c. damaged components

7. state methods of identifying conductors

a. sleeving b. adhesive tags etc

8. describe methods of securing cables to suit the installation

a. clips b. cleats c. saddles

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d. plastic ties e. lacing

9. state the need for segregation of different bands of circuits 10. state methods of earthing and means of connection with earth and bonding 11. state the need of for circuit protection and the use of fuses, circuit breakers, residual

current devices and rcbo’s 12. state the use for personal protective equipment

a. overalls b. safety shoes c. eye protection d. ear protection e. hard hats f. gloves and barrier creams

13. state how to identify and deal appropriately with potential hazards

a. working at heights b. working in confined spaces c. lifting and handling d. corrosive substances e. dust

14. state the importance of making visual checks for

a. damaged insulation, loose and exposed conductors, strain on terminals b. insufficient slack cable at accessories.

Unit 735 Wiring and testing Electrical Circuits 735.3 reinstate the work area and apply safe working

practices

Practical activities The candidate will be able to: 1. carry out all necessary preparatory work 2. check test equipment

a. for visual faults b. is within calibration dates c. is suitable for the tests to be carried out d. can cover the range and values to be measured

3. set up and use an appropriate range of test and measuring equipment 4. confirm that the completed circuit meets appropriate regulations and operational

requirements 5. prove installation dead by approved methods 6. make a full range of dead tests as required by current IEE wiring regulations 7. energise system and carry out appropriate live tests 8. record the results achieved and compare with published acceptable values. Underpinning knowledge The candidate will be able to: 1. state the employees’ responsibilities relating to

a. Electricity at work regulations b. current IEE wiring regulations

2. state the types of test equipment used for electrical circuits and installations

a. low reading ohm meter b. insulation resistance tester c. rcd tester d. approved voltage indicator

3. state the safety precautions to be taken when using electrical test equipment

a. safety checks b. applying approved test procedures

4. state the importance of checking the test equipment is correctly calibrated and set up 5. state how to

a. identify correct test points in the circuit b. using test probes c. position test instruments into circuits d. ensure correct polarity e. set instrument zero readings f. obtain instrument readings and compare them with published acceptable values g. avoid danger when testing

6. list items to be observed during the initial visual inspection.

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7. state how to use an appropriate range of test equipment to carry out the following tests on an installation in the correct sequence before and after connecting to the supply a. continuity of protective conductors, including main and supplementary

equipotential bonding conductors b. continuity of ring final circuits c. insulation resistance d. polarity e. functional testing including rcd testing

8. state the significance of readings obtained and state how to prove compliance with

current IEE wiring regulations. 9. state the importance of carrying out checks and tests before energising circuits 10. state good housekeeping and equipment control

a. leaving the work area free of unused consumables and detritus b. cleaning down work area c. storing tools and equipment into safe storage d. labelling and recording finished work.


Rationale This unit is concerned with the processes and equipment essential to building and testing electronic circuits. This unit covers three learning outcomes. The topics covered will enable the candidate to collect, read and interpret information, plan and prepare for electronics activities and state how to identify basic electronic components. The candidate will also be able to perform quality, circuit and diagnostic checks and decide on the quality checks circuit and functional/ diagnostic tests to be carried out and at what stages they should be made. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 736.1 prepare for building and testing of electronic circuits 736.2 test electronic equipment 736.3 build new, and identify faults on existing electronic equipment Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

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736.1 prepare for building and testing of electronic circuits


1. collect, read and interpret information

2. plan for building, testing and repairing electronic circuits

3. identify and specify electronic components / materials

4. obtain and check necessary tools and equipment

5 identify potential hazards.


1. state how to obtain and extract circuit information from:

a. circuit diagrams

b. block and schematic diagrams

c. equipment reference manuals

d. data sheets

e. test procedures and instructions

f. layout diagrams and the procedures for their care and safe keeping

2. state how to plan work activities, methods of producing work plans and the information they must contain.

3. state how to identify basic electronic components and their values

a. resistors,

i fixed

ii variable

iii carbon film

iv carbon composition

v wire wound

vi metal oxide

b. capacitors, fixed and variable

i ceramic

ii paper

iii electrolytic

iv mica

c. voltage and capacitance ratings of capacitors

d. inductors, fixed and variable

i air core,

ii ferrite core

iii iron core

e. Inductance ratings

f. Diodes

i low/high power

ii Zener

iii LED

iv photo

g. transistors

i bi-polar

ii FET

iii unijunction

h. switches and relays.

i. types of fuses and ratings

i mains fuses

ii quick blow fuses

iii anti-surge fuses

j. panel indicators and holders

k. heat sinks

4. state types and applications of primary and secondary cells

a. zinc carbon

b. zinc chloride

c. silver oxide

d. lithium

e. nickel cadmium

f. lead acid

5. recognise input/output devices

a. transducers

b. transformers

c. sensors

d. actuators

e. stepper motors

f. display units

6. describe the basic function of components within a circuit and their symbols

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7. state units of measurement and their multiples and sub-multiples for electronic circuits

8. define Ohms law.


736.2 test electronic equipment


1. isolate equipment

2. remove covers and casings where appropriate

3. clean circuits where necessary

4. test electronic equipment following the pre-planned sequence

5. carry out functional and diagnostic tests, using a range of test and measuring equipment

6. commission the product and complete quality control documentation.


1. state the range of tools that could be used

a. screwdrivers

b. pliers

c. side cutters

d. soldering irons

e. spanners

f. extraction and insertion tools

2. state how to carry out preparatory work including

a. safety checks

b. checking current calibration approval dates

c. correctly setting up test and measuring equipment

d. checking that the test equipment is suitable for the tests to be carried out and can cover the range and values to be measured

e. identifying correct test points in the circuit

f. connecting power supplies, signal sources and any peripheral components

3. state how to take measurements from information given on the circuit diagrams and specifications.

4. state the safe practices and procedures required when using electronic test equipment

a. protected supplies in a controlled test room

b. the use of isolating transformers and rcd’s

5. state specific safety procedures for connecting clips/probes into circuits

6. state the various types of test equipment.

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a. millimetres

b. insulation resistance testers

c. continuity testers

d. oscilloscopes

e. signal generators

f. signal injectors

7. state the isolation/disconnection techniques for the various types of instrument sensors.

8. describe the meaning of terminology used in fault diagnosis

a. symptom

b. fault

c. cause

9. state the typical faults, fault diagnosis documentation and standard fault diagnosis techniques used on instrumentation systems to trace faults to instrument, sensing element or component level.

a. checking of inputs and outputs

b. component or unit substitution

c. input to output

d. injection and sampling

e. half split technique

10. state how to use the information gained to determine the most likely cause of the faults

11. state how to make decisions

a. whether the unit should be replaced

b. should the fault be further traced to component level

c. the cost effectiveness

12. state the importance of carrying out visual examinations of circuits and components for signs of damage or other faults

a. pipework or cables

b. housings

c. blocked lines

d. faulty sensors

e. sticking instrument needles

f. broken connections

g. leaking seals

h. security of joints

i. correct positioning of components and wiring

j. correct values and identification

13. state the documentation used for recording the symptoms, faults and action taken using different methods of storage

a. manual

b. electronic

c. security of joints.

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736.3 build new, and identify faults on existing electronic equipment


1. interpret circuit diagrams and information correctly

2. use safe working procedures to build an electronic product that functions

3. identify a faults on non-functioning electronic products

4. leave the work area in a safe and tidy condition.


1. state how to interpret the circuit diagram information correctly

2. state how to identify the components and their values

a. component boards

b. resistors, fixed and variable

c. capacitors

d. discrete semiconductor devices

e. integrated circuits

f. transformers

g. rectifiers

h. connectors

i. wire links

j. cables

3. describe the function of the components named in 2 within the circuit and the correct way of connecting them in the circuit

4. state how to:

a. carry out safety checks

b. check and correctly set up test and measuring equipment

c. connect power supplies, signal sources and any peripheral components

5. state the principal electronic assembly/termination methods and range of devices used

a. plug and socket

b. circuit board connectors

c. circuit board pins

6. state how to position components on circuit boards

a. orientation

b. suitable distance above the board

c. clear view of their values

7. state how to

a. select wires/cables

b. remove correct length of insulation

c. avoid damage to conductors

d. tin conductor ends

e. terminate using a range of connectors

f. route and group wires to form a neat layout

g. code conductors using protective sleeving and coded tabs

h. secure cables using clips and straps

i. install peripheral devices to boards for mounting into an enclosure or connect to

i power supplies

ii speakers

iii external sensors/controls

8. state how to handle circuit boards and components to avoid damage

9. state how to use special tools for inserting components

a. manual insertion

b. automatic systems

10. state the types and application of cored solder

a. autosol ( high speed)

b. rosin free

c. hardcore no clean

d. low residue no clean

e. hydro flux

11. state the various types of soldering irons, temperature and shape of tips

12. state how to solder components in a logical sequence tha promotes efficient

a. component handling

b. solder selection

c. materials cleaning

13. state that soldered joints must be

a. mechanically and electrically sound

b. free from

i splatter

ii crossover

iii solderspikes

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c. do not cause heat damage to components or circuit board track

14. state the use of de-soldering equipment.

15. state methods of removing components from single sided, double sided, and surface mounted circuit boards

16. state the methods that can be used to repair damaged circuit boards/tracks.

17. state how to connect external wiring and components in a tidy manner to avoid

a. electronic interference and or

b. mechanical damage

18. state how to recognise the signals registered by multi-meters and oscilloscopes

a. frequency

b. peak to peak

c. average values

d. root mean square

19. state how to take instrument readings and translate these into circuit values and measurements

20. state how to make adjustments to correct or improve circuit characteristics and recognise when optimum circuit performance has been achieved

21. state how to select suitable fixing devices

22. state how to identify component values, their polarity and pin layout from component markings

23. state the importance of carrying out visual examination of circuits and components to check for

a. impact damage

b. entry of water or foreign objects

c. loose/damaged cables or connections

d. component, circuit board track or connecting wire short circuits

e. overheated components

f. burnt or overheated casings

g. blown fuses

24. state the importance of verifying power supply and integrity of fuses/circuit protection devices before proceeding further

25. state how to prepare the circuit by connecting to an approved power supply.

26. state the need to check

a. all connections have been remade

b. all fuses/protective devices have been installed

c. that boards and equipment are free from wire ends, solder blobs and screws which could cause short circuits

d. circuits are safe before reconnecting to the power supply.

27. state how to complete quality control documentation such as test schedules, job assessment records

28. state the need for good housekeeping and equipment control

a. leaving the work area free of unused consumables

b. cleaning down the work area

c. putting tools and equipment into safe storage

d. labelling and recording finished work.

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Unit 737 Working with Instrumentation and control systems

Rationale This unit is concerned with the processes and equipment essential for instrumentation and control. Candidates will be able to identify types and uses of instrumentation systems, install instrumentation systems and carry out fault finding and calibration in instrumentation systems. The types of instruments involved will include basic instruments and their basic principles of operation used for measuring pressure, flow, temperature and level. The candidate will also be able to state types and application of flow instrument sensors, transducers, signal modifiers and indicators. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 737.1 identify types and uses of instrumentation 737.2 install instrumentation systems 737.3 carry out fault finding and calibration of instrumentation. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.


737.1 identify types and uses of instrumentation

Practical activities The candidate will be able to: 1. examine an existing installation and determine the instrumentation required to monitor

the system Underpinning knowledge The candidate will be able to: 1. describe the basic instruments and their basic principles of operation used for measuring

pressure a. pressure

i bourdon tube ii diaphragm iii manometers iv barometers

b. flow i venturi tube ii rotameter iii turbine iv inferential

c. temperature i resistance ii) expansion iii) thermocouple ii expansion iii thermocouple

d. level i sight glass ii float iii pressure pads

2. state types and application of flow instrument sensors, transducers, signal modifiers and

indicators a. pressure b. temperature c. level.

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737.2 install instrumentation systems

Practical activities The candidate will be able to: 1. extract information from installation instructions and instrument diagrams 2. determine a suitable sequence of installation, isolation, removal and replacement of the

system instrumentation 3. check that the tools, equipment, components and instruments are safe to use and are

suitable for their intended use 4. install instruments and sensing devices for measurement of

a pressure b temperature c level d flow

5 make electrical connections to the instruments. Underpinning knowledge The candidate will be able to: 1. describe identification and selection of instruments/sensors by

a. markings b. calibration information c. component values d. operating parameters e. working range

2. describe the fitting of instruments to avoid faulty readings caused by

a. head correction b. poor flow past sensors c. blockages d. incorrect wiring e. poor insulation f. incorrect materials

3 state the correct methods for the installation and connection of instruments, external

wiring and components to avoid a. electronic interference b. mechanical damage c. pressure surges d. thermal shock e. current surge

4. state reporting and recording procedures.


737.3 carry out fault finding and calibration of instrumentation

Practical activities The candidate will be able to: 1. prepare for fault finding and calibration of instrumentation

a. identify the required calibration and test equipment for i pressure ii level iii flow

b. remove and store covers and casings c. remove excessive dirt, dust and grease

2. fault finding and calibration a. visually checking instruments, detectors, transducers, indicators and components b. identifying and locating test points c. connecting the instrument to an approved test rig/source, power supplies and any

peripheral components d. testing instruments and sensing devices for correct measurement e. using appropriate diagnostic aids and fault finding techniques f. repairing or replacing faulty items

3. carry out re-commissioning procedures a. checking that instruments are reading within expected parameters b. maintaining calibration records and recording test results.

Underpinning knowledge The candidate will be able to: 1. state how to deal with problems

a. concerning instruments which are damaged or fitted incorrectly b. the required tools or test equipment are not available or are damaged

2. state when to seek help from others when dealing with problems 3. state the approved methods of

a. carrying out tests on each type of instrument/sensor b. setting instrument zero readings c. obtaining instrument readings and comparing them with circuit parameters d. making adjustments to system components

4. state the isolation/disconnection techniques for the various types of instrument sensors 5. state the importance of verifying power supply and integrity of fuses/circuit protection

devices before proceeding further 6. state the specific safety procedures to be followed when applying fault finding techniques,

current regulations applicable to the equipment worked on 7. state the meaning of terminology used in fault diagnosis

a. symptom

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b. fault c. cause

8. state the standard fault diagnosis techniques used on instrumentation systems to trace faults to instrument, sensing element or compound level. a checking of inputs and outputs b. component or unit substitution c. signal injection and sampling d. half split

9. state how to use diagnostic aids

a. circuit/system diagrams b. equipment manual c. functional system charts d. probability charts e. maintenance records f. planned preventative maintenance schedules

10. state the importance of carrying out visual examinations of circuits and instruments for

signs of damage, or evidence of where any fault may be and state how it was caused a. damaged pipework or cables b. blocked lines c. faulty sensors d. sticking instrument needles e. broken connections f. leaking seals g. security of joints h. correct positioning of components and wiring i. correct values and identification

11. state the documentation used for recording the symptoms and cause for future reference

and the use of electronic storage of calibration and test results 12. describe how to perform the calculations necessary to assess the accuracy of the

measurements taken 13. state how to recognise and understand the signals measured by an oscilloscope 14. state how to make adjustments to correct or improve the indication of measurement

parameter or output signal 15. state the importance of safety checks, correct set up and calibration of test equipment 16. state how to recognise when optimum set-up or calibration performance is achieved. 17. state how to use test equipment

a. deadweight tester b. tandem gauge testing c. weigh tank d. multimeters e. oscilloscopes f. manometers g. barometers

18. State how to avoid

a. damaging instruments b. causing overheating

c. over pressurisation d. physical or other damage to components

19. describe how to take measurements including identification of test points on the actual

instrument from information given on circuit diagrams and specification 20. state the range of instrument test equipment used for mechanical and electronic

instruments/sensors and the tools used for the isolation. Removal and re-installation process and the techniques for their use.

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Unit 738 Installing PLC based control systems

Rationale To carry out the installation safely and effectively you will be expected to develop a plan of work, establish system operating requirements, interpret component specifications, select and obtain components and materials, develop and test system software, use a variety of techniques and diagnostic aids to commission the system and consistently implement safe working practices. Your responsibilities will require you to comply with health and safety requirements and organisational policy and procedures. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 738.1 plan and prepare resources for installing a plc based control system 738.2 install plc unit, input/output devices and systems software 738.3 commission the system and reinstate the work area. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.

Unit 738 Installing PLC based control systems 738.1 plan and prepare resources for installing a plc

based control system

Practical activities The candidate will be able to: 1. apply health and safety requirements and safe working practices 2. establish operational requirements for the system 3. identify hardware and software specifications of system 4. develop a work plan 5. select tools, equipment, components, consumable and carry out checks to ensure they are

safe and fit for use. Underpinning knowledge The candidate will be able to: 1. state the safety regulation and acts applicable to installing PLC based control systems

a. Health and Safety At Work Act b. IEE Wiring Regulations c. Electricity at Work Act d. Portable Appliance Testing (PAT)


electrical maintenance activities a. use of protective clothing and equipment b. clean and tidy work area c. use of barriers and/or tapes d. displaying of warning signs e. electrical isolation and locking off switch gear f. permit-to-work procedures and control documentation g. isolation of all potential energy sources h. informing personnel of maintenance activities






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8 state the hazards associated with maintenance of instrumentation systems and how they

can be minimised a. dangers of electrical shock b. stored energy/force c. misuse of tools d. using damaged or badly maintained tools and equipment e. automatic movement of equipment f. not following laid-down maintenance procedures

9 state the essential operator and bystander safety requirements


10 state the need to produce a work plan and list the information it should contain


11 list the types and sources of system information available

a. job instructions/cards b. manufacturer manuals c. circuit/block/flow schematic diagrams d. equipment and system specifications e. equipment self diagnostic information f. software printouts

12 state the need for correct labelling and safe storage of back-up programs and system

information a. ensure correct version of software is available b. prevent damage or deterioration

13 state how to transfer system software for back-up, modification or monitoring purposes to

an appropriate storage media a. disk b. tape c. EPROM d. RAM


a. maintain page/document order b. keep clean and free from damage c. storage is suitable and accessible d. return to designated storage

15. state the procedures for obtaining materials, parts and consumables 16. state the range of tools/equipment required and their typical uses

a. hand tools i screwdrivers ii pliers/side cutters iii cable strippers iv crimping tools v spanners/sockets


c. soldering iron, solder and fluxes d. hacksaw, hole cutters and files



18. state the types of equipment/diagnostic aids that can be used when installing PLC based

control systems a. programming equipment/console b. laptop computer c. equipment/system self diagnostic displays d. input/output indicators e. multimeter/voltage tester f. continuity tester

19. state the individual modules/parts that form a PLC system and the function of each

a. central processing unit (CPU) b. memory module c. power supply d. input/output modules e. rack/module bus

20. state the basic types of input/output device used within PLC controlled systems and briefly

explain their application a. input signals

i photocell ii proximity iii Positional iv flow v temperature

b. output signals i solenoids ii relays iii indication lamps

21. state how to select components and sensing devices by their

a. operating requirements b. working range

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c. manufactures specification d. name plate/markings

22. state the basic operating principles of the system design and the working purpose of

individual units/components.

Unit 738 Installing PLC based control systems 738.2 install plc unit, input/output devices and systems

software

Practical activities The candidate will be able to: 1. assemble components using appropriate tools and techniques 2. mount and secure plc control unit 3. fix and align input/output devices 4. install and terminate all wiring and connections 5. develop system software to meet operational requirements 6. carry out “off load” checks 7. apply power to system/components 8. down load software to plc unit. Underpinning knowledge The candidate will be able to: 1. state the procedures for safe handing, care and use of programming/test equipment

a. equipment is displaying a current PAT label b. maintained in accordance with manufacturers instructions c. instrument case/covers are utilised d. interface leads are suitable and in good condition e. battery powered equipment is sufficiently charged for use

2. state the reasons for ensuring that control systems are isolated, switched into manual

mode or the appropriate safety interlocks are inserted before any instruments or sensing devices are disconnected from the system and the consequences of this not being undertaken

3. state the methods for ensuring system/components are safe to be worked on

a. full system isolation b. circuit isolation c. individual component isolation

4. state the reason voltage levels of power supplies should be verified and ratings of

fuses/circuit protection devises be confirmed a. over voltage could damage equipment/component b. circuits/equipment may be incorrectly protected against over current

5. state the typical faults that could occur when commissioning a PLC controlled systems

a. open circuit b. short circuit c. resistance d. mechanical e. sensors out of alignment or range f. corrupt systems software g. faulty input/output module h. CPU errors i. interference or noise

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6. state the basic techniques used to ensure sensing devices are operating effectively and to specification a. sensing distances of proximity devices b. alignment of photocells c. supply voltages are correct d. monitor output signal levels

7. state the basic units of measurement a. mega b. kilo c. standard units

i volt ii Ampere iii ohm

d milli e micro





diagrams and specifications 11. state how to test relays, sensors and actuators for correct operation 12. state the type of interface unit and lead to enable the programming equipment to

communicate with the programmable logic controller 13. state how to search within the systems software for specific instructions/elements 14. state the methods and techniques used for assembly and terminating system components




Unit 738 Installing PLC based control systems 738.3 commission the system and reinstate the work

area

Practical activities The candidate will be able to: 1. monitor system software using input/output indicators and programming equipment 2. carry out full systems check 3. return the work area into a safe and health environment 4. update maintenance records accurately and legibly 5. notify the appropriate personnel when the system is operational. Underpinning knowledge The candidate will be able to: 1. state why it is important to follow procedures and complete the relevant documentation

when applying power to the system/components a. demonstrate you have complied with health and safety procedures b. protect others who may still be working on the system c. formally record your intensions to apply power to the system

2. state the need to check overall system integrity

a. emergency and fail safe circuits operate effectively b. all PLC modes of operation are available and working correctly c. all system components are operating to specification d. no errors are being displayed by the PLC unit


a. remove waste materials and debris b. remove waste materials and debris c. return surplus components and materials to stores

4. state the information required for recording or updating system documentation

a. description of work undertaken b. fault information c. location(s) d. date and times (commencement, completion, handover) e. parts and consumable used f. test data g. permit to work reference


a. supervisor b. colleagues involved in the same activity c. operators

d. associated departments e. customers.

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Unit 739 Producing Electrical/ Electronic Drawings using CAD

Rationale This unit is concerned with the production of detail drawings for electrical or electronic engineering activities, using a stand alone or networked CAD system, equipped to output hard copies to appropriate standards. Learning outcomes There are three outcomes to this unit. The candidate will be able to: 739.1 set-up a CAD system to produce electrical or electronic drawings 739.2 produce electrical or electronic drawings using CAD 739.3 output hard copies of electrical or electronic CAD drawings and power down. Connections with other qualifications This unit replaces the corresponding unit in 6983 Applying Engineering Principle and underpins the corresponding unit in the Performing Engineering Operations 2251. Assessment and grading The outcomes from this unit will be assessed using evidence from an assignment that will also contain a short answer question paper.


739.1 set-up a CAD system to produce electrical or electronic drawings


1. check CAD equipment for safe operation

2. power up a CAD system and start software using correct procedures

3. prepare templates for planned drawings, using menus and commands Underpinning knowledge The candidate will be able to:

1. state the health and safety requirements and safe working practices for using VDU equipment and the work station environment

a. lighting

b. seating

c. posture and ergonomic positioning of equipment

d. trailing leads

e. detection of faulty or dangerous

i electrical leads

ii connections

f. housekeeping arrangements

i clean, tidy, safe, work area

ii clear desk/workstation policies

iii filing systems for

a. discs

b. manuals

c. hard copy drawings

2. state(understand) the users responsibilities under

a. data protection act

b. computer misuse act

c. copyright legislation

3. state basic visual and manual checks on system connections

a. monitor

b. keyboard

c. mouse, or light pen or digitising tablet

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d. printer/plotter

e. network

4. state the correct procedure to start up (and close down) a CAD system and run software

5. describe briefly the need to

a. setup CAD software to print/plot

b. check printers/plotters operate correctly

c. use printer/plotters test facilities

d. interrupt the operation of printers/plotters to avoid waste

6. recognise CAD system error messages and state how to deal with basic faults

a. peripherals that do not respond/function

b. routine faults with equipment

c. connecting leads, by visual inspection

7. state the need to take decisions or remedial action

a. using own initiative

b. seeking assistance

8. describe briefly sources of help

a. software

i. in program

Ii. on line

c. technical manuals

9. state the need for drawing types and documentation

a. diagrams

i. circuit and wiring

ii. block

iii. flow

iv. schematic

b. electrical cabling/routing

c. installation and assembly

i. panel

ii. sub assembly

d. system design/modification

e. parts list

10. state sources of data used for producing electrical or electronic drawings

a. drawing/modification briefs

b. notes/minutes of meetings (customer, design team)

c. specifications

d. electrical regulations

e. manuals

f. sketches

g. existing drawings

h. calculations

i. standards

j. manufacturers literature (electrical/electronic component catalogues)

k. reference information such as

i. cable carrying capacity

ii. operating voltages

iii. component values

iv. pin configurations

v. coding systems

11. state the use of menus and commands to create and correctly save templates for producing and outputting electrical or electronic drawings to current standards

a. title

b. Scale

c. date of drawing

d. issue date

e. material/s

f. tolerance

g. surface finish

h. name of:

i. draughtsperson

ii. checker/approver

iii. company/organisation

i. layers, line type, colour, text styles and fonts

j. output scale.

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739.2 produce electrical or electronic drawings using CAD


1. produce electrical or electronic engineering detail drawings

2. produce an electrical or electronic assembly drawing and parts list

3. produce an electrical or electronic engineering related block or schematic diagram.


1. interpret electrical or electronic drawings that meet current, or a company’s/organisation’s standards

2. state the types of projection

a. orthographic

i. first angle

ii. third angle

b. isometric

3. recognise symbols and abbreviations used on electrical or electronic drawings List symbols/abbreviations

4. describe briefly design features incorporating

a. safety

b. quality

c. functionality of circuits

d. interrelationship with other circuits and assemblies

e. components and materials

f. cost

g. life cycle

h. ergonomics

i. operating environment

5. state the need to create, save and access drawing files that

a. meet current, or a company’s/organisation’s standards

b. use layers and colour coding

c. are output to different scale factors and sheet size

6. state that drawings/models are created using a range of drawing/modelling and editing techniques

7. state methods for the efficient production of electrical or electronic CAD drawings

a. lines

i. angled

ii. straight

iii. curved

b. hidden detail

c. circles, ellipses and contours

d. hatching

e. dimensioning

f. text

g. incorporating standard electrical/electronic

i. symbols

ii. abbreviations

h. cable details

i. size

ii. type

j. connection/termination details

k. fault diagnosis, flow diagrams

8. describe (understand) the use and benefits of viewing aids

a. zoom

b. pan

9. state that CAD drawings may be produced with the aid of

a. libraries of

i. symbols

ii. parts

c. existing drawings

d. parts of drawings

10. describe briefly the benefits of inserting common features and symbols from standard part and symbol libraries.

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739.3 output hard copies of electrical or electronic CAD drawings and power down.


1. output hard copies of electrical or electronic drawings

2. store CAD files and back up copies

3. store hard copies of CAD drawings

4. power down the system.


1. state the benefits and limitations of printers/plotters

a. laser

b. ink jet

c. bubble jet

d. electrostatic

e. pen/pencil

2 describe the need to configure a printer/plotter to produce hard copies that meet current, or a company’s/organisation’s standards

3. state the importance of quality assurance (QA) procedures

a. checking/approval process

b. identifying

i company/organisation

ii draughtsperson

iii checker/approver

c. dates

i issue

ii revision

d. drawing number allocation

i contracts

ii customers

iii detail and assembly drawings

e. including

i title

ii projection symbol

iii scale

iv material/s

v tolerance.

f. storage location

4. state the need for a suitable operating environment

a. create directories/folders

b. use directories/folders

c. maintain directories/folders

5. state the need to save drawing files in groups, for ease of access

a. libraries

i parts

ii symbols

b. directories/folders

i contracts

ii customers

iii details and assemblies.

6. state the need for making backup copies of CAD drawing files

7. state the need for archiving CAD drawing files

8. describe briefly the correct procedure for powering down a CAD system.

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Unit 740 Customer Service Principles Unit summary This unit is about enabling the candidate to develop an appropriate knowledge and understanding of the principles of customer service (relating to both internal and external customers) in order to create effective solutions.

Rationale The aim of this unit is to enable the candidate to develop the necessary knowledge and understanding of the principles of both internal and external customer service within their environment to create effective solutions.

Outcomes There are three outcomes to this unit. The candidate will be able to: 1 describe the principles of customer service 2 identify customer needs and expectations 3 identify an effective solution to meet customer needs within the limits of responsibility

Assessment Assessment will be by means of an assignment covering practical activities and a synoptic multiple choice test covering the underpinning knowledge of all three units.

Unit 740 Customer Service Principles 740.1 Describe the principles of customer service

Practical activities The candidate will be able to: 1. identify an organisation’s customers 2. identify which of the organisation’s customers are internal and/or external and those that

require special needs Underpinning knowledge 1 Describe what is meant by

a customer service b customer expectations c customer experience d customer needs e customer feedback f customer loyalty g customer satisfaction h customer rights i customer relationship.

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Unit 740 Customer Service Principles 740.2 Identify customer needs and expectations

Practical activities 1. Identify a range of customer needs and expectations 2. Identify ways of meeting customer needs and expectations Underpinning knowledge 1. Give examples of customer needs and expectations 2. Describe the qualities required of a provider to achieve customer satisfaction

Unit 740 Customer Service Principles 740.3 Identify an effective solution to meet customer

needs within your own limits of responsibility

Practical activities 1. Identify a range of common customer problems and complaints 2. Identify effective solutions within own limits of responsibility and communicate them to

customers Underpinning knowledge 1. Explain different methods of communicating with customers when solving customers

problems or complaints 2. Explain why it is important to adapt methods of communication to meet individual customer

needs

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Unit 741 Gas Operations Technology

Learning Outcomes There are seven outcomes to this unit. The candidate will be able to: 741.1 Prepare Work Locations for the installation of systems and components for basic gas

processes 741.2 Carry out the installation of systems and components for basic gas processes 741.3 Carry out pre-commissioning checks and tests on systems for basic gas processes 741.4 Commissioning Systems for basic gas processes 741.5 Decommission Systems for basic gas processes 741.6 Establish service and maintenance requirements for systems and components 741.7 Diagnose the cause and rectify faults in systems and components

Unit 741 Gas Operations Technology 741.1 Prepare Work Locations for the Installation of

Systems and Components for Basic Gas Processes

Practical Activities The candidate will be able to: 1. Identify and interpret specifications 2. Prepare a Method Statement for individual work locations 3. Carry out a Risk Assessment for individual work locations

Underpinning knowledge The candidate will be able to: 1. State the sources of information on the preparatory work necessary for the systems or

component installation a. the layout of buildings and provisions for systems components including incoming

services b. the requirements of health and safety legislation governing safety in work locations c. the preparatory work to be carried out by other trades (when in attendance)

2. State how to protect customer’s property or the building fabric prior to work commencing

a. the importance of checking work locations to identify any existing damage to customer’s property, including building fabric, furnishings and fittings, ornaments and accessories

b. the importance of recording and reporting any existing damage to the customer’s property before commencing any work

c. the importance of taking appropriate measures to protect a customer’s property including the use of protective sheeting and the removal and safe storage of items that might be damaged during installation work

d. the importance of liasing with the customer on temporary storage arrangements for property that could be damaged by work activities

e. the importance of liasing with other trades on measures to protect work in progress or materials ready to be fitted

3. Identify whom deficiencies in the system supply should be reported and procedures for

isolating input services a. the persons to whom deficiencies in the system should be reported including the

customer co-contractors or other building users b. the importance of ensuring that appropriate actions are taken to remedy deficiencies in

system supply before connection 4. List the tools, equipment, materials and components required for the system installation order

and describe the supply advice delivery and checking procedures a. procedures for ordering materials and components b. the purpose of supply and delivery documents c. the importance of checking deliveries of materials and components for compliance with

the supply order, and noting and reporting and deficiencies or damage d. the importance of ensuring that material orders and supply dates will meet the job

schedule

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5. State the actions to be taken should materials not be available at site to commence the installation activity a. the importance of checking that tools, equipment, materials and components will be on

site before job commencement b. the importance of reporting promptly to the appropriate persons any anticipated delays in

deliveries of tools, equipment, materials and components c. the importance of liasing with other trades whose work may be affected by delayed in

tools, equipment, material or component delivery 6. Describe secure storage procedures for tools, equipment, materials and component basic

stores procedures to ensure security and to minimise loss or wastage a. the types of secure storage provision that may be required for tools, equipment, materials

and components for installation and maintenance b. the importance of arranging storage provision before deliveries

Unit 741 Gas Operations Technology 741.2 Carry Out the Installation of Systems and

Components for Basic Gas Processes

Practical Activities The candidate will be able to: 1. Research industry practice and work standards for the installation 2. Carry out a visual inspection on a piece of equipment 3. Prepare a system installation to industry standard 4. Perform a system installation to industry standard


1. Describe how to measure and record installation and site details for prefabrication purposes

a. how to interpret drawings of installations to establish positions of appliances, fixings, controls

b. methods of measuring locations into which appliances are to be installed and recording dimensions, angles, and sizes of pipe work for refurbishment purposes.

2. State the industry practices and work standards for fabricating and installing system

components a. methods of installing all materials used for system installations b. the industry standards of workmanship for system installations c. the safety practices appropriate to fabrication and installation work on appliances d. how to interpret system design information on the positioning requirements for

appliances

3. State the care and maintenance requirements of tools and equipment and checks for safe condition

a. the maintenance requirements for hand and power tools used for the installation of system components

b. the checks for safe condition for hand and power tools used for the installation of systems and components

c. the maintenance requirements for access equipment, including steps, ladders, trestles d. the checks for safe condition of access equipment, including steps, ladders trestles

4. State job management structures and methods of reporting and recording job progress or

problems delaying progress a. typical job management structures in gas companies b. reporting procedures within gas companies c. reporting procedures when the gas company is sub-contracted to a main contractor 5. State the positioning and fixing requirements for system components to conform to the

system design and intended functions a. positioning of systems pipework components to conform to legislative requirements and

recommendations

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b. positioning of systems pipework components to conform to industry standards and system design requirements

c. how to fix system pipework components to conform to industry standards and system design requirements, including the fixing of pipework and controls

6. State the procedures required for connecting to input services or connecting pipework

into existing systems a. how to connect systems pipework to supply systems using methods that conform to

industry requirements, including positioning of control valves b. how to connect system pipework to existing systems pipework using methods that

conform to industry requirements c. how to connect systems pipework to components d. the joining methods and materials approved for use on systems pipework connections

Unit 741 Gas Operations Technology 741.3 Carry Out Pre-commissioning Checks and Tests on

Systems

Practical Activities The candidate will be able to: 1. Complete relevant documentation 2. Carry out the pre-commissioning checks and tests Underpinning knowledge The candidate will be able to:

1. State the methods of establishing that input services adequately supply all components with a system a. how to check that input supplies to systems pipework installations meet the requirements

of the system or system specification b. how to check that supply controls for systems pipework installations are correctly set c. how to check that systems pipework connections meet the system component or system

specification

2. State the procedures, equipment and legislative requirements for applying soundness tests to systems a. the industry procedures for applying soundness tests to systems b. the sequence of actions for carrying out soundness tests on systems c. the tests and checks to be carried out before testing of systems d. the equipment required to carry out soundness tests on systems e. the requirements of current legislation on soundness testing of appliances

3. Describe the methods of connecting components to systems

a. how to check that components are correctly connected to system pipeworks b. hoe to check that components are correctly connected to system supply c. how to complete commissioning documentation confirming the safe commissioning of

systems and components d. situations in which it may be necessary to complete records of pre-commissioning tests

and checks e. the details that a record of pre-commissioning tests and checks should contain

4. State how to complete commissioning documentation confirming the safe commissioning of systems and components a. situations in which it may be necessary to complete records of pre-commissioning tests

and checks b. the details that a record of pre-commissioning tests and checks should contain

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Unit 741 Gas Operations Technology 741.4 Commissioning Systems for Basic Gas Processes

Practical Activities The candidate will be able to: 1. Identify and interpret relevant legislation and codes of practice for commissioning systems 2. Carry out the commissioning of a system installation to industry standards

Underpinning knowledge The candidate will be able to: 1. Identify the sources of information of systems and components

a. the sources of information on system performance, including job specifications, manufacturers’ specifications or catalogues, contract specification for commissioning larger installations

b. the minimum requirements for system compliance with industry requirements when a formal specification is not available

2. List the routines and sequences for commissioning systems and components

a. the sequence of actions to be followed when commissioning systems b. differences in procedures for testing systems with dwellings and small commercial or

industrial buildings c. commissioning procedures for systems which may affect supplies to industrial or

commercial processes

3. State system hand over procedures and demonstrating the operation of systems and components to end users

a. the importance of ensuring that hand over procedures provide the customer or other system users with all the necessary information on the operation of the system or component

b. the types of information that a customer or other system user will need to ensure that they can operate the system or component correctly

4. State the actions to take when components being commissioned do not meet design

requirements a. the actions to take when systems or components do not meet the design specification b. the persons to be advised on jobs where the gas fitter is the sole contractor and where the

gas fitter is sub contracted to a main contractor 5. State the procedures for establishing correct system or component performance and

checking against the design specification a. the procedures for checking and making adjustments to system pipework controls to

establish correct system performance

Unit 741 Gas Operations Technology 741.5 Decommission Systems for Basic Gas Processes

Practical Activities The candidate will be able to: 1. Identify and interpret relevant legislation and codes of practice for decommissioning systems Underpinning knowledge The candidate will be able to: 1. Identify de-commissioning for temporary and permanent de-commissioning of systems

a. identify the differences between the tests and procedures for temporary and permanent decommissioning of systems

2. State the importance of confirming the system design, specification, functions, and outcomes

of suspending the operation of the system a. the importance of interpreting information on appliances, including information gained

from site inspection, to confirm the outcomes of decommissioning the systems b. the persons with whom liaison should take place before, during and after the

decommissioning process, including customers other appropriate trades, line manager c. the industry requirements, standards, and tests and procedures used for

decommissioning systems 3. List the potential hazards that could arise from decommissioning activities and the checks to

be carried out before decommissioning takes place a. the potential safety hazards that could arise from decommissioning of systems b. the checks to be carried out in advance of components decommissioning to ensure that

any potential hazards that could arise have been removed 4. State the precautions to ensure that de-commissioned systems do not prove a safety hazard –

safety and warning notices a. the precautionary actions including liaison with customers or other system or building

users, sealing of open pipework, labelling of controls, to ensure that decommissioned systems do not become a hazard

b. the types of warning notices that are appropriate for use on temporarily or permanent decommissioned systems

5. Describe how to safety collate and dispose of system contents that may be hazardous to

health or the environment a. the types of materials that could prove hazardous to health or the environment b. how to ensure that materials are disposed of safely

6. Identify the need to liaise with others whose procedures or routines may be affected by the

suspension of the system operation a. how to identify other persons, including customers, and other trades whose work or

routines may be affected by the de-commissioning procedures b. liaise with other persons to minimise disruption to their work or routines

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Unit 741 Gas Operations Technology 741.6 Establish Service and Maintenance Requirements

for Systems and Components for Basic Gas Processes

Practical Activities The candidate will be able to: 1. Carry out a maintenance check in line with relevant legislation and codes of practice 2. Identify the tools and equipment required to carry out a maintenance check 3. Prepare a maintenance report 4. Research the industry fault reporting procedure

Underpinning knowledge The candidate will be able to: 1. List the range of information that should be available on the routine and non-routine service

and maintenance requirements of systems and components a. the range of information that should be available on systems including specifications and

schedules, manufacturers’ information services and maintenance schedules and regulations

b. the details that may be obtained from the different information sources 2. Describe how to plan service and maintenance procedures to minimise interference with

system operation and customer routines a. the other persons including the customer and co-contractor whose work or routines may

be affected by maintenance activities on systems b. the types of commercial and industrial operations that may be affected by maintenance

activities on system components c. how to plan the maintenance of components to minimise the system downtime d. the importance of ensuring that all tolls, equipment, and ,materials will be available as

required and the costs of delays 3. Identify how and when to liaise with others during service and maintenance activities

a. how to identify other users of system components with whom it would be appropriate to liaise, including customers and other trades

b. the points within the maintenance activities at which it would be appropriate to liaise with others

4. List the materials required for routine maintenance and sources of information on the

materials required for routine maintenance operations a. the consumable materials required for the maintenance systems, including replacements. b. the sources of information on the materials required for routine maintenance of systems

5. List the tools and equipment required for routine maintenance operations

a. the tools and equipment required for maintenance operations, including hand and powered tools

b. the access equipment used for routine maintenance operations and systems including stand steps, ladders and trestles.

6. State how to use performance specifications for systems and components and maintenance procedures necessary to restore or maintain the continued performance of systems and components a. the systems that require routine maintenance b. how to interpret the required performance of systems using performance specifications,

manufacturers technical data, codes of practice and BS recommendations c. the routine service and maintenance procedures necessary to maintain systems

performance

7. Describe how to complete records and reports of the maintenance of systems and components

a. the types of service and maintenance activities for which it will be necessary to complete records of work

b. the information that should be included on a service record

8. State the action to take when the system or component does not work to full performance specification

a. procedures for reporting the continued failure of appliances b. the persons to whom it would be necessary to report continued failure of components c. circumstances in which it might be necessary to implement emergency or temporary

provisions due to delay in correcting faults

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Unit 741 Gas Operations Technology 741.7 Diagnose the Cause and Rectify Faults in Systems

and Components for Basic Gas Processes

Practical Activities The candidate will be able to: 1. Identify safety hazards 2. Research emergency procedures for gas leakage

Underpinning knowledge The candidate will be able to: 1. State the work procedures for the rectification of faults in systems or components which will

ensure minimum disruption to customers and routines a. the persons, including customers, co-workers, other system users, with whom it may be

necessary to liaise when carrying out routine service and maintenance on systems b. the points within the maintenance process when liaison with others will be necessary c. The types of commercial or industrial processes whose continuation may be affected by

service or maintenance operations d. the importance of advising appropriate persons of the completion of service or

maintenance activities and the intention to re-activate systems

2. State the measures to ensure that systems do not present a safety hazard to potential users, or the workforce, when carrying out rectification procedures a. the importance of ensuring that appropriate liaison has taken place before during and

after maintenance activities b. the measures to be taken to prevent the unauthorised use of systems on which service or

maintenance work is being carried out, including safe isolation of the component

3. Describe how to interpret information on system or component performance, including advice from users visual inspections or checks or diagnosis test to locate faults a. the types of information sources on system pipework installation performance b. how to carry out visual inspections of systems pipework installations to check their

performance against specifications c. how to obtain information on systems pipework installation performance from customers

or system users d. how to carry out diagnostic tests to determine the causes of faults in systems pipework

components e. the causes of faults in system pipework installations including inadequate gas supply,

leaks in system components, control malfunction, corrosion of system components

Unit 742 Gas Technology Installations & Relationships

Learning Outcomes There are five outcomes to this unit. The candidate will be able to:

1. Inspect work locations for the installation of systems and components

2. Carry out the installation of system and components

3. Carry out pre-commissioning checks and tests on systems

4. Commission systems

5. Effective working relationships in the gas industry

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Unit 742 Gas Technology Installations & Relationships 742.1 Inspect Work Locations for the Installation of

Systems and Components

Practical Activities The candidate will be able to: 1. Identify and interpret specifications 2. Prepare a Method Statement for individual work locations 3. Carry out a Risk Assessment for individual work locations

Underpinning knowledge The candidate will be able to: 1. State the sources of information on the preparatory work necessary for the system or

component installation a. the sources of legislation governing the positioning of components including pipe

materials, fittings, controls and incoming services b. sources of information on the fixing and installation requirements for components c. sizes and locations of components that have to be accommodated within the system

structure 2. List the input services or supplies required for the systems or components or for extending

systems or adding components to existing systems;- how to confirm that input services are adequate a. methods of identifying the gas and/or water supply of systems b. methods of confirming that the system supply meets the requirements of the system or

components

Unit 742 Gas Technology Installations & Relationships 742.2 Carry Out the Installation of Systems and

Components

Practical Activities The candidate will be able to: 1. Prepare a system installation to industry standard 2. Perform a system installation to industry standard

Underpinning knowledge The candidate will be able to: 1. State the positioning and fixing requirements for the system components to conform to the

system design and intended functions a. positioning of systems pipework and other components to conform to legislative

requirements and recommendations b. the positioning of systems pipework and other components to conform to industry

standards and system design requirements c. how to fix systems pipework and other components to conform to industry standards and

system design requirements

2. State the procedures required for connecting to input services or connecting pipework into existing systems a. how to connect systems pipework and other components to supply systems using

methods that conform to industry requirements, including positioning of control valves b. how to connect system pipework and other components to existing pipework using

methods that conform to industry requirements c. how to connect appliances to flues d. the jointing methods and materials approved for use on system pipework and other

components 3. State the industry practices and work standards for fabricating and installing system

components a. methods of installing all materials used for system pipework and other components b. the industry standards of workmanship for systems pipework and other components c. the safety practices appropriate to fabrication and installation work on pipework and

other components d. how to interpret system design information on the positioning requirements for systems

pipework and other components e. how to interpret information on the fixing requirements of system pipework and other

components

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Unit 742 Gas Technology Installations & Relationships 742.3 Carry Out Pre-commissioning Checks and Tests on

Systems

Practical Activities The candidate will be able to: 1. Complete relevant documentation 2. Carry out the pre-commissioning checks and tests

Underpinning knowledge The candidate will be able to: 1. State the procedures, equipment and legislative requirements for applying soundness tests to

systems a. the industry procedures for applying soundness tests to systems and/or for pipework

installations b. the sequence of actions for carrying out soundness tests on systems and/or pipework

installations c. the tests and checks to be carried out before testing systems and/or pipework

installations d. the equipment required to carry out soundness tests on systems and/or pipework

installations e. requirements of current legislation on soundness testing of systems and/or pipework

installations 2. List the methods of establishing that input services adequately supply all components within

the system a. how to check that input supply to pipework installations meet the requirements of the

system component or system specification b. how to check that supply controls for pipework installations are correct c. how to check that pipework installation connections meet the system component or

system specification 3. List the methods of connecting components to systems

a. how to check that system pipework installations are correctly connected b. how to check that systems pipework installations are correctly connected to system

supply 4. List the actions to take where pre-commissioning checks or tests reveal system or component

defects a. the actions to take when systems pipework installations do not comply with the

specification b. the persons to be advised when corrective actions to systems pipework installations are

ineffective 5. List the range of tests used to confirm the soundness of systems and components and how to

use the range of soundness testing equipment

a. the different types of test used for system pipework installation and procedures and work sequences for each type of test

b. the hygiene and charging procedures for newly installed systems pipework installations c. methods of preventing the unauthorised/inadvertent use of system pipework installations

that are not ready for use, including sealing all open ends on pipework, securing controls on incoming service or supply, placing warning notices on controls, advising customers or other trades

d. the importance of advising customers or line managers when testing is about to take place, when testing has been completed and when the system is ready for use

385

Unit 742 Gas Technology Installations & Relationships 742.4 Commission Systems

Practical Activities The candidate will be able to: 1. Carry out the commissioning of a system installation to industry standards Underpinning knowledge The candidate will be able to: 1. State the sources of information on the performance of systems or components

a. the sources of information on system pipework and appliance installation performance, including job specifications, manufacturers’ specifications or catalogues, contract specifications for commissioning larger installations

b. the minimum requirements for systems pipework compliance with industry requirements when a formal specification is not available

2. State the procedures for establishing correct system component performance and checking

against the design specification a. the procedures for checking and making adjustments to systems pipework and/or

installation controls to establish correct system performance 3. State the routines and sequences for commissioning systems or components

a. the sequence of actions to be followed b. system installations within dwellings and small commercial or industrial buildings c. commissioning procedures for systems pipework and/or installations which may affect

supplies to industrial or commercial processes 4. Describe how to interpret information on system or component performance, including

advice from users, visual inspections or checks or diagnosis tests to locate faults a. the types of information sources on systems pipework and/or installations performance b. how to carry out visual inspections of system pipework and/or installations to check their

performance against specifications c. how to obtain information on systems pipework and/or installations performance for

customers or system users d. how to carry out diagnostic tests to determine the causes of faults in systems pipework

and/or installations e. the causes of faults in systems pipework and/or installations including inadequate gas or

air supply leaks in system components control malfunction corrosion of system components

5. State the measure to ensure that systems do not present a safety hazard to potential users or

the workforce when carrying out rectification procedures a. the importance of ensuring that appropriate liaison has taken place before, during and

after maintenance activities b. the measures to be taken to prevent the unauthorised use of the systems pipework and/or

installations on which service or maintenance work is being carried out, including safe isolation of the appliance

6. State how to isolate unsafe systems and components a. how to interpret information including that gained by visual inspection and information

given by customers or persons in authority to determine systems pipework given by customers or persons in authority, to determine systems pipework and appliance installation layouts including the positions of supplies to appliances

b. methods of ensuring that unsafe systems pipework and appliance installations cannot be used including securing of controls, labeling of controls, isolating from electrical supply, posting warning notices informing users

387

Unit 742 Gas Technology Installations & Relationships 742.5 Effective Working Relationships in the Gas industry

Practical Activities The candidate will be able to: 3. Role-play a conflict situation 4. Participate in a team working activity 5. Research the organisational structure 6. Research the history and working relationships of the gas industry

Underpinning knowledge The candidate will be able to: 1. Identify the range of other people encountered within the work environment with whom it

may be necessary to establish working relationships a. the general range of other people likely to be encountered on a large construction site,

whether gas installation work is sub-contracted b. the other people likely to be encountered on domestic installation or maintenance work

where the gas company employer is the main contractor 2. Identify the different types of management structures in organizations employing M.E.S labour

– the roles and responsibilities of the different individuals within the structure a. typical management structures for a large and small gas company – main roles and

responsibilities including the responsibilities of sub-contractors b. typical management structures for a large construction site – main roles and

responsibilities including the responsibilities of sub-contractors c. Describe the actions that are necessary to begin to develop and maintain good working

relationships or restore working relationships d. the initial actions necessary to begin the development of good working relationships

including being helpful to others, co-operating with other trades, listening to others and using appropriate forms of communication

e. Describe the principles of good working relationships and reasons why relationships may break down

f. the ongoing actions necessary to continue good relationships g. recognising the signs of a potential breakdown in working relationships

3. Describe the actions to take to restore working relationships where a breakdown occurs

a. how to establish the underlying reasons for the other’s discontent b. when and how to seek the help of a third party intermediary

4. List the types of job information that may be requested by others in the workplace – sources

of information – methods of accessing information and possible restrictions on passing information to others. a. the range of job information b. the range of job information that may be requested by other trades c. the range of job information that may be requested by the immediate supervisor/site

management

5. List the forms of communication used for the range of job or company information best suited to its purpose – using the key principles of good communication in work situations, including methods of confirming that the communication has been understood a. the different forms of communication, including oral, written, diagrams and sketches b. the most appropriate form of communication for passing detailed technical information c. the importance of confirming that the information has been understood.

389

Unit 743 Understanding the Power Business Operations Rationale This unit is concerned with the requirements that are essential to enable a range of engineering activities to be carried out safely and effectively within the Electricity Distribution and Transmission Industry. It includes dealing with statutory requirements in accordance with regulations. It covers health and safety responsibilities of both the employer and the employee; it includes the environmental impacts and the efficient use of resources. It provides an underpinning knowledge in electrical principles. It provides a broad base of knowledge and understanding of the commercial and engineering activities within the Distribution and Transmission Industry There are five learning outcomes to this unit. The candidate will be able to

1. Demonstrate an understanding of basic electrical theory 2. Demonstrate an understanding of health, safety and environmental considerations of the

industry 3. Demonstrate an understanding of electricity trading arrangements 4. Demonstrate an understanding of the engineering lifecycles within the electricity industry 5. Demonstrate an understanding of the electricity industry roles and responsibilities

Assessment This unit will be assessed through a practical assignment

Level 2 Certificate in Engineering (2800) 390

Unit 743 Understanding the Power Business Operations 743.1 Demonstrate an understanding of basic electrical

theory

Practical Activities Candidates should be able to conduct practical exercises or simulated experiments to: 1. Construct a simple generator/motor 2. Establish the working order of a simple generator/motor through testing

Underpinning Knowledge The candidate will be able to 1. Explain the following principles of electricity a) Atomic structure b) The electrical charge affecting each part of an atom c) Electron flow (current) d) Units of Measurement Describe i) Current - Amperage (I) ii) Voltage (V) iii) Resistance- Ohms (R) iv) Power – Watt (P) e) Simple electrical circuits f) Electrical effects in a circuit Explain i) Voltage drop across the circuit

ii) Resistances in a circuit iii) Relative current flow iv) Resistances in circuits Describe their characteristics

1. In parallel 2. In series 3. Parallel/series combined circuits

v) Use of Ohms Law to calculate voltage drop, current flow and resistance of different parts of circuits

2. State the following methods of producing electricity

a) Electrolytic action Describe i) Batteries

ii) History of batteries iii) Types of battery iv) Output of different batteries v) Different electrolytes effecting voltage vi) Batteries in parallel and series

b) Electro - magnetic induction Describe

i) History – Faradays experiments


ii) Magnetic effects on a conductor iii) Electro magnetic forces on a conductor iv) Magnets and coils v) Variables effecting outputs

1. Coils size 2. Magnetic strength 3. Speed of magnet 4. Proximity of magnet

c) Photo electric cells 3. Explain the following principles of generation

a) Single phase generation (ac) including

i) Opposite effects of north/south pole of a magnet on a coil ii) Alternating Current/voltage

b) Three phase generation explaining i) 120º phase displacement coils ii) Advantages of 3 phase over single phase

4. Explain the following transformer principles a) Construction i) Coils (windings) ii) Steel Core iii) Insulation b) Input and output i) Voltage and current ii) Variable outputs c) Why transformers get warm 5. State the application of semiconductors

a) Describe the principles of diodes b) Describe how half wave and full wave rectification is achieved 6. Calculate power usage using formulae

a) Describe the use of power use formula (e.g. P = V x I) b) Describe the advantage/disadvantage of high voltage c) Calculate power loss in systems/circuits using the power loss formula (P = I x I x R) d) Explain the unit of electricity (kWh) e) Describe different examples of energy used by different household appliances f) Explain electricity tariff unit costs

7. Describe different load effects on the system

a) resistive loads b) inductive loads c) capacitive loads d) explain power factor e) explain power factor correction

8. Explain the correct use of the following instruments

a) Voltmeters b) Ammeters


c) Wattmeters d) Oscilloscopes e) Relays f) Multimeters


Unit 743 Understanding the Power Business Operations 743.2 Demonstrate an understanding of health, safety and

environmental considerations of the industry

Practical activities The candidate will be able to: 1. Identify a range of safety systems in a given work activity 2. Select appropriate PPE for a given work activity 3. Recognise and react to a range of safety signs 4. Complete a risk assessment for a specific task

Underpinning Knowledge The candidate will be able to 1. Describe briefly statutory regulations

a) Health & Safety at Work Act 1974 b) Management of the Health & Safety at Work Regulations 1999 c) Electricity at Work Regulations 1989 d) Electricity Safety, Quality and Continuity Regulations 2002

2. List health and safety responsibilities for the employer

a) Risk Assessments b) Safe systems of work c) Method statements d) Safety training e) Personal Protective Equipment (PPE) f) Safety Auditing g) Safety Representation h) Welfare facilities i) Reporting systems j) First aid

3. List Health and Safety Responsibilities for the employee

a) Take care of themselves b) Take care of others including the public c) Co-operate with employer on safety matters d) Co-operate with others on safety matters e) Work properly and safely f) To inform employer of serious and immediate danger g) To inform employer of shortcomings in their H & S arrangements

4. State accident and emergency procedures

a) Procedure for employees reporting accidents b) First aid box contents c) First aiders d) Removing a casualty from an electricity supply e) Isolating an electricity supply in an emergency f) Effects of electric shock g) Treatment for electric shock h) Additional emergency first aid procedures


5. Identify the following safety signs a) Prohibition b) Warning c) Mandatory d) Emergency

6. State safety procedures associated with

a) Manual lifting and handling b) Working at heights

i) Ladders ii) Scaffold

c) Working in confined spaces d) Fire hazards

i) Fire drill ii) Types of Fire extinguisher iii) Auto fire-fighting equipment

7. State environmental impacts in the electricity industry

a) Generation i) Types of generation ii) Energy use consumables

Coal Gas Nuclear

iii) Renewables Hydro Wind

b) Energy use impacts i) Coal ash ii) Subsidence iii) Smoke and smog iv) Co2 and other waste gases v) Nuclear waste vi) Reprocessing vii) Nuclear leakage

c) Renewables impacts i) Effects on the environment ii) Planing permission iii) Visual

d) Energy conservation e) Visual impacts

i) Power stations ii) Substations iii) Towers and poles

f) Public issues i) Electricity hazards ii) Magnetic fields effects

g) World, country, Industry objectives/targets h) Benefits of achieving objectives/targets


Unit 743 Understanding the Power Business Operations 743.3 Demonstrate an understanding of electricity trading

arrangements

Practical Activities The candidate will be able to: 1. Identify the various trading arrangement throughout the electricity industry 2. Identify the balance between supply and demand 3. Identify the various players in electricity trading

Underpinning Knowledge The candidate will be able to 1. Explain how electricity is traded

a) History of trading arrangements b) Present trading arrangements

2. Explain how national demand is met a) Matching supply with demand b) Capabilities of meeting demand c) Meeting short term needs

3. Explain what influences demand a) Weather b) Human behaviour c) Holidays d) Time, day and seasons e) Special events

4. Explain different generation outputs a) Power stations b) Renewables

5. Explain commercial and domestic usage a) Tariffs available b) Typical demands

6. Explain the relevant market players a) Generators b) National grid c) Suppliers d) Distributors e) Meter operators


Unit 743 Understanding the Power Business Operations 743.4 Demonstrate an understanding of the engineering

lifecycles within the electricity industry

Practical Activities The candidate will be able to 1. Understand the various planning and design requirements for the electricity networks 2. Identify different suppliers of equipment and the competitive purchase approach 3. Understand the pre-commission requirements for the network 4. Understand the repair and maintenance policy of switchgear and plant

Underpinning Knowledge The candidate will be able to 1. Explain the planning of an electricity system of supply 2. Explain the design of an electricity system of supply 3. Explain the company policy for purchase of network assets 4. Explain the approved company commissioning procedures 5. Explain the concept of a monitor and maintenance policy


Unit 743 Understanding the Power Business Operations 743.5 Demonstrate an understanding of the electricity

industry roles and responsibilities

Practical Activities The candidate will be able to 1. Identify structures within the industry 2. Identify company responsibilities

Underpinning Knowledge The candidate will be able to

1. Describe industry structure and relationships 2. Explain the use of business plans 3. Explain the role of company shareholders 4. Explain the role of stakeholders 5. Explain the competition within the industry 6. Explain the role of regulatory bodies


Unit 744 Understanding Power Technology Operations Rationale This unit is concerned with the requirements of providing a reliable supply of electricity. It outlines the fundamental engineering principles relating to the generation, transmission and distribution of electricity. It provides the underpinning knowledge in relation to generation as regards generation types and fuels. It provides the underpinning knowledge in relation to transmission and distribution structures, protection systems, voltage and power levels. It also covers various plant and equipment, safe operation of switchgear and future technologies affecting the electricity industry There are four learning outcomes to this unit. The candidate will be able to: 1. Demonstrate an understanding of different types of electricity generation and fuels used 2. Demonstrate an understanding of network voltage, power levels and system operations 3. Demonstrate an understanding of the properties of plant and equipment 4. Demonstrate an understanding of future technologies Assessment This unit will be assessed through a practical assignment


Unit 744 Understanding Power Technology Operations 744.1 Demonstrate an understanding of different types of

electricity generation and fuels used

Practical Activities The candidate will de able to

1. Identify the different generating companies within the UK 2. Identify which fuels types are utilised by each generating company

Underpinning Knowledge The candidate will be able to 1. Describe the different aspects involved when generating electricity using

a Coal b Nuclear c Gas d Hydro e Renewables f Pump storage

2. Explain the different processes involved when generating electricity using

a Coal b Gas c Nuclear


Unit 744 Understanding Power Technology Operations 744.2 Demonstrate an understanding of network voltages,

power levels and system operations

Practical Activities The candidate will be able to 1. Understand the structure of the electricity system 2. Identify various system symbols representing plant and equipment 3. Identify different cables on the network

Underpinning Knowledge The candidate will be able to 1. State why power stations are interconnected and the advantages of interconnection 2. Describe how the grid system transmits electricity countrywide 3. Describe the relationship between power stations and the grid system 4. Describe the relationship between the grid system, and the DNO’s 5. Describe the DNO’s distribution system 6. Describe the different types of conductors 7. Describe the construction of cables 8. Describe the construction and contents of electricity substations 9. Explain different system diagrams 10. Explain the ratings of different parts of the network 11. Explain the different insulating mediums required at different voltage levels 12. Describe the different voltage levels used on the network from the power station to the customer 13. Describe interlock safety features 14. Explain why systems are earthed 15. Explain switching programme requirements


Unit 744 Understanding Power Technology Operations 744.3 Demonstrate an understanding of the properties of

plant and equipment

Practical activities The candidate will able to 1. Examine different types of switchgear and plant 2. Simulate the taking of a clean oil sample in a controlled environment

Underpinning Knowledge The candidate will be able to

1. Explain standard switchgear terminology 2. Describe the properties of different Distribution and Transmission switchgear found on the

system 3. Identify metering arrangements 4. Identify domestic metering 5. Describe the configuration of tower lines

a) 400/275kV b) 132/33kV

i) Insulators ii) Conductors iii) Identification plates iv) Anti climbing guards

6. Describe overhead transmission and distribution systems

a) circuits b) routes c) equipment

7. Explain factors regarding transformers : - a) Voltage and ratings b) Core and winding designs c) Insulating mediums d) Cooling mediums e) Tap change mechanisms f) Condition monitoring g) Faults occurring

8. Identify ancillary equipment found in electricity substations : - a) Batteries b) Telecontrol/protection c) Remote control automation d) Compressed air systems e) Oil filled cables pressure tank and monitoring systems f) Gas bottles, control and monitoring systems g) Neutral earth resistors h) Dehumidifiers i) Alarms and electric fencing


Unit 744 Understanding Power Technology Operations 744.4 Demonstrate an understanding of future technologies

Practical Activities 1. Understand the current state of future technologies for energy use in the UK 2. Understand the governments perspective on energy conservation and future usage in the UK 3. Understand future application of new technologies in plant and equipment

Underpinning Knowledge The candidate will be able to 1. Explain future technology in terms of

a Renewables b Nuclear fusion c Generation using Hydrogen d Energy conservation

2. Explain new technologies in terms of a Distribution b Transmission


Appendix 1 Connections to NVQs and other qualifications City & Guilds has identified the connections to linked NVQs and other qualifications. This mapping is provided as guidance and suggests areas of overlap and commonality between the qualifications. It does not imply that candidates completing units in one qualification are automatically covering all of the content of the qualifications listed in the mapping. Centres are responsible for checking the different requirements of all qualifications they are delivering and ensuring that candidates meet requirements of all units/qualifications. For example, a qualification may provide knowledge towards a N/SVQ, but centres are responsible for ensuring that the candidate has met all of the knowledge requirements specified in the N/SVQ standards. This qualification has connections to the Level 2 NVQ 2257 in Performing Engineering Operations Level 2 NVQ 1681 in Fabrication and Welding Level 2 NVQ 1682 in Mechanical Manufacturing Engineering Level 2 NVQ 1683 in Materials Processing and Finishing Level 2 NVQ 1688 in Engineering Maintenance.

Appendix 2 Funding This qualification is accredited and included on the National Qualifications Framework, and is therefore eligible for funding. City & Guilds does not provide details on funding as this may vary between regions. Centres should contact the appropriate funding body to check eligibility for funding and any regional/national arrangements which may apply to the centre or candidates. For funding regulatory purposes, candidates should not be entered for a qualification of the same type, level and content as that of a qualification they already hold. Please see the table below for where to find out more about the funding arrangements for this [these] qualification[s].

Nation Who to contact For higher level qualifications

England The Learning and Skills Council (LSC) is responsible for funding and planning education and training for over 16-year-olds. Each year the LSC publishes guidance on funding methodology and rates. There is separate guidance for further education and work-based learning. Further information on funding is available on the Learning and Skills Council website at www.lsc.gov.uk and, for funding for a specific qualification, on the Learning Aim Database http://providers.lsc.gov.uk/lad.

Contact the Higher Education Funding Council for England at www.hefce.ac.uk.

Scotland Colleges should contact the Scottish Further Education Funding Council, at www.sfc.co.uk. Training providers should contact Scottish Enterprise at www.scottish-enterprise.com or one of the Local Enterprise Companies.

Contact the Scottish Higher Education Funding Council at www.shefc.ac.uk.


Wales Centres should contact Education and Learning Wales (ELWa) at www.elwa.ac.uk or contact one of the four regional branches of ELWa.

For higher level qualifications, centres should contact the Higher Education Funding Council for Wales at www.hefcw.ac.uk.

Northern Ireland

Please contact the Department for Employment and Learning at www.delni.gov.uk.


Published by City & Guilds 1 Giltspur Street London EC1A 9DD T +44 (0)20 7294 2800 F +44 (0)20 7294 2400 www.cityandguilds.com City & Guilds is a registered charity established to promote education and training

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Level 2 Certificate in Engineering (2800) - OneFile · progression in the Engineering sector contribute to the knowledge and understanding towards the related Level 2 NVQ in Performing