Maintenance Shadowing Work Shop Activities - T&D department
Instrumentation practical task
Pressure calibration by using dead weight tester
Name of the candidate
Badge Number
Level of OJT
Task No
Task Name
Date Issued
Duration
Page 1 of 10
Maintenance Shadowing Work Shop Activities - T&D department
TASK 1
Job Instruction:
1. Adhere to procedures or systems in place for risk assessment, COSHH, PPE and other
safety regulations.
2. Ensure the safe isolation of services during the maintenance activities.
3. Produce an effective work plan.
4. Follow job instructions and test procedures at all times.
5. Ensure that the workplace is kept free from foreign objects, dirt or other contamination.
6. Carry out function test on the pressure gauge by using dead weight tester.
7. Use maintenance diagnostic techniques, tools and aids.
8. Perform checks on maintained equipment.
9. Deal promptly and effectively with the problems.
10. Where appropriate apply procedures and precautions to eliminate electrostatic discharge
hazards.
11. Return all the tools and equipment to the correct location on the completion of the
maintenance activities.
Acceptance Criteria:
1. Produce work plan.
2. Prepare tools and material list.
3. Use the correct P.P.E.
4. Check the work area for safe working conditions.
5. Carry out maintenance activity on pressure gauge by using dead weight tester.
6. Able to use manual, flow chart and troubleshooting guides.
7. Performed visual checks (such as signs of damage, missing part, wear/deterioration)
8. Able to use test instruments for measurements (such as dead weight tester).
9. Able to remove and replace required components.
10. Carry out the maintenance activities (such as pressure gauge function test, calibration and
repair).
11. Leave the work area in safe and tidy condition on completion of maintenance activities.
Page 2 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Task Planning Sheet
Candidate Name
Badge No
Task Description
Drawing Number/Manual
Work Plan
Description Ref. No
Request work permit from your trainer
Risk assessment, identify hazards and get control measure
Follow job instruction, wear correct PPE
Get a tool list & material list
Visual check before start working in the pressure gauge calibration
The pressure gauge should be mounted in the dead weight tester for
calibration
Measurement points should be distributed uniformly over the calibration
range
Calibrated weights are placed on the instrument corresponding to the
measurement points.
Results shall be filed and recorded on calibration form
Do housekeeping and clean the area before you leave
Trainer comments: Accepted Not Accepted
Page 3 of 10
Maintenance Shadowing Work Shop Activities - T&D department
PERMIT TO WORK
Type of Work Permit: You are authorized this PTW, to perform the above task in ____ hrs.
From: __________.
Hot work Permit Cold work Permit Confined-space Entry Permit Release of Hazardous
Liquid / Gas
Receiver Sign: ______________________ Issuer/Trainer name:
_____________________
Required Safety shoes Coverall Safety gloves Safety helmet Goggles Ear protection
PPE
Description of work to be carry out
Trainer comments: Accepted Not Accepted
Page 4 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Risk Assessment form
Candidate Name
Candidate Badge
Activity Description
Location of procedure
People in Risk
Before commencing any work activity, a risk assessment must be carried out.
Consider the hazards: - Yes 🗹 No 🗹
1. Slippery floor surfaces 8. Heat/Fire/Explosion
2. Moving Parts 9. Electricity
3. Falling/Flying objects 10. Noise/Vibration
4. Manual Handling 11. Dust/Fumes
5. Materials Handling 12. Poor Lighting
6. Tools Handling 13. Other people
7. Harmful substances 14. Unshielded Processes
Assess the probability to cause harm and the severity
Probability Severity
1 Very unlikely to happen 1 No Injury
2 Unlikely to happen 2 Minor injury
3 Possible to happen 3 Major injury
4 Likely to happen 4 Single Fatality
5 Very likely to happen 5 Multiple Fatalities
Hazard Probability x Severity = Rating
Number
1 1X2 =2
2 4X2 =8
4 4X2 =8
5 5X1 =5
6 4X3 =12
9 5X3 =15
Take another Risk Assessment sheet if Hazards Exceed
Page 5 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Evaluate the Risk
Risk Factor:
1-6 = low risk;
7-9 = medium risk- control measures required;
10-30 =high risk- only undertaken with consent
Take measures to reduce the risks and contribute to improvement in the workplace
by the following means.
Risk rating control measures to be Action
Activity Low/Medium/High taken required
Yes/No
1 Low
4 Medium
6 High
9 High
Trainee comments:
Trainer comments: Accepted Not Accepted
Page 6 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Material and Tool request form
Candidate Name Badge No
Craft Date Issued
Task name Drawing No
Material List
S/N Description Unit Qty Quality
check
Received Name & Signature:
Issued Name & Signature:
Tool List
S/N Description Unit Qty Quality check
Received Name & Signature:
Issued Name & Signature:
Trainer comments: Accepted Not Accepted
Page 7 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Calibration of pressure gauge by using dead weight tester steps:
Proceed with the calibration according to the following steps:
1. Connect the pressure gauge to the test port on the dead weight tester as shown in
the diagram below
2. Ensure that the test gauge is reading zero, if not correct the zero error and ensure
that the gauge is reading zero before proceeding with the calibration exercise.
3. Select a weight and place it on the vertical piston.
4. Turn the handle of the adjusting piston or screw pump to ensure that the weight and
piston are supported freely by oil.
5. Spin the vertical piston and ensure that it is floating freely.
6. Allow a few moments for the system to stabilize before taking any reading. After
system has stabilized, record the gauge reading and the weight.
7. Repeat steps 2 through 5 for increasing weights until the full range or maximum
pressure is applied to the gauge and then decreasing weights until the gauge reads
zero pressure.
8. Calculate the error at each gauge reading and ensure that it is within the acceptable
accuracy limits.
Page 8 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Pressure Calibration Record:
For pressure gauges with less accuracy specifications, calibration at the points:
0%,25%,50%,75% & 100% will suffice. After calibration. Your data can be recorded in a
table as shown below:
Upscale readings:
% Input
Weight (W) DWT Pressure (W/A) Test Gauge pressure Error
reading
0%
25%
50%
75%
100 %
Downscale readings:
% Input
Weight (W) DWT Pressure (W/A) Test Gauge pressure Error
reading
100%
75%
50%
25%
0%
Page 9 of 10
Maintenance Shadowing Work Shop Activities - T&D department
Calibration Results and recommendations:
Trainer comments: Accepted Not Accepted
Page 10 of 10
