Operations Challenge Vaughan Chopper Maintenance Event Tutorial

Introduction

This tutorial provides a comprehensive guide on the Operations Challenge Vaughan Chopper Maintenance Event, outlining the necessary steps, tasks, and what judges will be evaluating. This event is crucial for participants in the operations challenge, and understanding the tasks can significantly enhance performance.

Step 1: Event Setup

• Familiarize yourself with the layout of the event area.
• Ensure all necessary tools and materials are available at each station.
• Review the event rules and requirements for the specific year, as updates may occur.

Step 2: Lockout/Tagout of Control Panel

• Implement Lockout/Tagout (LOTO) procedures to ensure safety during maintenance.
• Follow these steps:
  • Identify all energy sources connected to the control panel.
  • Use lockout devices to isolate the energy sources.
  • Tag the devices to indicate maintenance work is in progress.

Step 3: Gantry Assembly

• Assemble the gantry system needed for lifting and supporting the pump.
• Pay attention to:
  • Aligning all components correctly.
  • Securing bolts and fasteners to ensure stability.

Step 4: Pump Removal

• Carefully remove the pump from its housing.
• Follow these steps:
  • Disconnect any hoses or electrical connections.
  • Use the gantry to lift the pump safely.
  • Ensure the area is clear of obstacles.

Step 5: Pump Rebuild

• Disassemble the pump for inspection and rebuilding.
• Key points to consider:
  • Note the arrangement of parts for reassembly.
  • Check for wear and tear on components.
  • Clean all parts thoroughly before rebuilding.

Step 6: Charge Bolts and Install New Flanged Nozzle

• Charge bolts are essential for securing the new flanged nozzle.
• Steps to follow:
  • Apply the recommended torque specifications.
  • Ensure the flange is seated correctly to prevent leaks.

Step 7: Electrical Motor Checks

• Perform checks on the electrical motor to ensure proper functioning.
• Key checks include:
  • Inspecting electrical connections for corrosion or damage.
  • Testing the motor for electrical continuity.
  • Verifying that the motor is properly grounded.

Step 8: Removing Pump from Worktable/Cradle

• Safely remove the pump from the worktable or cradle.
• Important considerations:
  • Use the gantry for lifting if necessary.
  • Ensure that all tools and parts are clear of the work area.

Step 9: Disassemble Gantry

• Once the pump is removed, disassemble the gantry.
• Follow these steps:
  • Securely remove bolts and components.
  • Store the gantry parts in a designated area.

Step 10: Restore Power to Control Panel

• After maintenance is complete, restore power to the control panel.
• Important steps:
  • Remove all LOTO devices.
  • Test the control panel to ensure it is functioning correctly.

Step 11: Clean Up

• Perform a thorough cleanup of the work area.
• Key tasks include:
  • Properly disposing of any waste materials.
  • Returning tools to their designated places.
  • Ensuring the area is safe and tidy.

Conclusion

This tutorial highlights the essential steps for successfully navigating the Operations Challenge Vaughan Chopper Maintenance Event. By following these steps and understanding the key tasks, participants can improve their performance and ensure compliance with safety standards. For the latest updates and resources, always check the Operations Challenge Resource Center.