PORTFOLIO REPORT

Candidates name: Jamie Middleton

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

Job Risk Assessment Hazard table tick as necessary

Preventative measures A Falling
B Tripping/ Slipping

Pressure drained to ensure safety of those C Trapping

around system to allow work carried out
Personal protection required as a last resort D Flying Particles
from any given risk in the working area
Relieve the pressure before powering the E Fire/ Flammable Atmosphere
system.
Ensure all of the actuators have been relieved F Oxygen Enrichment
of pressure before inspecting/ working on the
machine in case the excessive pressure makes
the actuator move unexpectedly.
Check the condition of the hoses for excessive G Collapse
wear, rips and broken seals.
H Overturning
I Electric Shock
J Moving Machinery/ Parts

K Moving Vehicles
L Drowning
M Noise

N Asphyxiation
O Burns
P Burning/ Explosion Risk
Q Vibration

R Oxygen Depletion
S Protruding Objects/ Parts
T Substances/ Fumes/ Dusts
U Other

Iaaued: 18/08/09

T/Tdr/Quality/Forms
 Pneumate200 Practical Assessment

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

Understand the constructive and operational differences between the single

and the double air pilot valves.
Objectives:
Understand the operation of the double valve as a memory element

- A double acting cylinder will move operated by the air pilot power 5/2 way
double valve.

- Two push-button operated 3/2 way valves will give the corresponding signals
to energise the double valve in both directions so that the cylinder can move.
Description:
- The cylinder will extend when pressing the first push-button M1 and will
return to the starting position when pressing the second push-button M2.

- Without pressing any push-button, the cylinder will maintain its last position.

1 double acting cylinder with auto switches

Materials used: 1 3/2 way NC valve operated by push-button

1 air pilot 5/2 way double valve

Solution A

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Instructions and documentation for job (attach any documentation and
photographs to continuation sheet)
Photo
Circuit diagram
Instructions/documentation provided by instructor
Test equipment
tools

Preparation of materials and working areas

Power off?
I ensured the power was isolated.
Drained?
I made sure the pressure was drained.
Persons at risk briefed?
I briefed anyone I was working with to meet all health and safety requirements.
Quality of spares tools etc
I checked all parts and spares so that they were fit for use and in good working condition.

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

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

Then, I tested the system to make sure it was back into working order. I gave it a visual
check to make sure everything was connected correctly and also to ensure there were no
health risks.

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After I carried out all the tests I had to return the area back to its original state by cleaning
the area and returning all the tools to where they belonged.
If you noticed a tool was broken then you should make a note of the broken tool and replace
it as soon as possible in case this occurs again and you need that job specific tool.

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

All documentation such as before stated image and circuit diagram was provided before
the jobs inception. A full safety brief was given.

Quality checks (monitoring and checking at all stages of the production)

Isolate the machine before working on it.
Make sure the working area is clean and tidy.
Start with sense checks, i.e. Visual, auditory, touch etc.

Problems encountered during job and how solved

No pneumatic power.
No electrical power.
Badly connected hoses.

Completion (Return of materials and tools, tidying of area, removal of surplus

materials and waste)
Exercise good housekeeping and set a good example by cleaning up the work area once
youve finished you work.
Inform your superiors that you have finished the job.
Completed a maintenance log.

Trainee Signature: Date:

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