Overview IMPEM163S. Carry out preventative planned maintenance on instrumentation and control equipment used in food and drink operations

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1 Overview This standard identifies the competences you need to carry out preventative planned maintenance activities on instrumentation and, in accordance with approved procedures. You will be required to carry out the planned maintenance activities on instrumentation and control equipment including pressure, flow, level and temperature instruments; fiscal monitoring equipment; smoke, heat, gas, water, chemical and metal detection and alarm systems; industrial weighing systems; linear and rotational speed measurement and control; vibration monitoring equipment; photo-optic instruments; analysers recorders and indicators; telemetry systems; emergency shutdown systems and other specific instrumentation. This will involve checking and maintaining a range of equipment and components including valves, actuators, sensors, switches, transmitters, transducers, transponders, wires/cables, pipework and hoses, in order to minimise down time, and to ensure that the instrumentation and control equipment perform at optimum level and function to specification. Food and drink is a term used in this standard to cover the following sub sectors of Meat, Drinks, Confectionery, Fresh Produce, Bakery, Seafood and Dairy. You must ensure that all tools, equipment and materials used in the maintenance activities are removed from the work area on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions, and for the quality and accuracy of the work that you carry out. 1

2 Performance criteria You must be able to: 1. work safely at all times, complying with health and safety and other relevant food and drink regulations, directives and guidelines 2. follow the relevant maintenance schedules to carry out the required work 3. carry out the maintenance activities within the limits of your personal authority 4. carry out the maintenance activities in the specified sequence and in an agreed timescale 5. report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule 6. complete the relevant maintenance records accurately and pass them on to the appropriate person 7. dispose of waste materials in accordance with safe working practices and approved procedures 2

3 Knowledge and understanding You need to know and understand: See IMPEM164K Understand how to carry out preventative planned maintenance on instrumentation and 3

4 Scope/range 1. Carry out all of the following during the planned maintenance activities: 1.1 plan and communicate the maintenance activities so as to minimise any disruption to normal working 1.2 obtain and use the correct issue of company and/or manufacturers' drawings and maintenance documentation 1.3 adhere to procedures or systems in place for risk assessment, HACCP, TACCP, VACCP, COSHH, personal protective equipment (PPE) and other relevant safety regulations 1.4 where appropriate, ensure the insertion, or program override, of any relevant system trip defeats (including fire extinguishant, emergency shutdown) 1.5 ensure the safe isolation of instruments (including process, electrical, hydraulic, pneumatic, mechanical) 1.6 provide and maintain safe access and working arrangements for the maintenance area 1.7 carry out the maintenance activities, using appropriate techniques and procedures 1.8 functionally test and adjust equipment to specification 1.9 re-connect and return the system to service on completion of the maintenance activities 1.10 dispose of waste items and any spoilt products in a safe and environmentally acceptable manner, and leave the work area in a safe and clean condition 2. Carry out planned maintenance activities on four of the following types of instrumentation and control equipment: 2.1 pressure (including absolute, gauge, vacuum) 2.2 flow (including orifice plate, venturi tube, electromagnetic, ultrasonic, differential pressure cell, positive displacement) 2.3 level (including floats, displacer, differential pressure cells, load cells, ultrasonic, conductivity) 2.4 temperature (including bi-metallic, thermocouples, resistance, infrared, thermal imaging) 2.5 weight (including mechanical systems, load cells/strain gauges, transducers) 2.6 fiscal metering (including gas, electricity, water, fuel) 2.7 detection and alarm (including smoke, heat, gas, chemical, water, 4

5 metal) 2.8 speed measurement (including mechanical, electrical, stroboscopic) 2.9 emergency shutdown 2.10 speed control (including mechanical governors, electrical governors, DC speed controller, AC motor control systems, stepper motors, invertors) 2.11 vibration monitoring (including vibration switches, proximity probes, seismic velocity transducer, linear variable differential transformers, portable data collectors) 2.12 analysers (including gas detection, spectroscopy, oxygen analyser, water analysis, moisture measurement, density) 2.13 recorders and indicators 2.14 telemetry systems (including master station, outstation, stand alone systems) 2.15 valves and valve mechanisms (including control valves, valve actuators and positioners) 2.16 other specific instrumentation or control equipment 3. Carry out planned maintenance activities, using one of the following types of maintenance schedule: 3.1 condition based maintenance 3.2 scheduled maintenance 3.3 preventative planned maintenance 3.4 total preventative maintenance (TPM) 4. Carry out twelve of the following planned maintenance activities: 4.1 removal of excessive dirt and grime from instruments and sensing elements 4.2 visual examination and testing of the instrumentation against the maintenance schedule 4.3 checking condition of all pipework and connections (including free from damage, correctly secured, leak free) 4.4 checking condition of all cables/wires and connectors (including free from damage, correctly clipped up) 4.5 checking correct operation of all gauges and sensors 4.6 checking correct operation of warning and alarm systems (including smoke detectors, alarms and lights) 4.7 monitoring of component condition/deterioration 4.8 replacing `lifed' or consumable items (including filters, seals, gaskets, 5

6 fluids, back-up batteries) 4.9 making routine adjustments (including setting working clearance, adjusting actuator mechanisms) 4.10 cleaning of maintained equipment 4.11 making sensory checks (including sight, sound, smell, touch) 4.12 required food safety checks 4.13 carrying out system self-analysis checks 4.14 carrying out leak checks on all connections 4.15 testing and reviewing system operation 4.16 confirming that signal measurement and transmission are satisfactory 4.17 recording the results of the maintenance, and reporting any defects found 5. Ensure that the maintained instrumentation and control equipment/system meets all of the following: 5.1 equipment remains compliant with appropriate regulations and safety requirements 5.2 all planned maintenance activities have been completed to the required schedule 5.3 instrumentation and control equipment operates within acceptable limits for successful continuous operation 5.4 any potential defects are identified and reported for future action 6. Complete the relevant paperwork from one of the following, and pass it to the appropriate people: 6.1 maintenance log or report 6.2 company-specific documentation 6.3 job cards 6.4 permit to work/formal risk assessment and/or sign-on/off procedures 6

7 Developed by Improve Version Number 1 Date Approved September 2015 Indicative Review Date Validity Status Originating Organisation Original URN Relevant Occupations Suite Keywords September 2020 Current Original Improve Maintenance Engineer; Food Production Operatives Engineering Maintenance in Food Manufacture Food and Drink; Instrumentation; control equipment; control circuits; engineering; planned maintenance; manufacturing; maintenance/manufacturers documentation; total preventative maintenance; condition based maintenance; scheduled maintenance 7

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