This unit covers the skills required to alter the control parameters of fluid power control systems by system modification; this includes the ability to assess system performance based on sound working knowledge of established principles, methods and procedures. System specifications are interpreted/understood from data sheets, circuit diagrams and flow diagrams. Corrections, modifications/alterations are undertaken to specifications to parts of the control system including software timers, gates, associated equipment, flow, ladder and logic diagrams. Fault finding of system hardware input/outputs includes input/output circuitry, cards, external sensors, limits, mnemonic coding and associated equipment. Service reports are prepared according to standard operating procedure. Programmable controllers include PLC and DCS or similar. Band: B Unit Weight: 6 |
Path 1 | Interpret technical drawing | |
Perform engineering measurements | ||
Perform computations | ||
Use graphical techniques and perform simple statistical computations | ||
Plan a complete activity | ||
Write reports | ||
Use hand tools | ||
Use power tools/hand held operations | ||
Use tools for precision work | ||
Repair and fit engineering components | ||
Perform equipment condition monitoring and recording | ||
Analyse plant and equipment condition monitoring results | ||
Maintain pneumatic system components | ||
Maintain pneumatic systems | ||
Maintain hydraulic system components | ||
Maintain hydraulic systems | ||
Maintain fluid power controls | ||
Modify fluid power system operation | ||
Dismantle, replace and assemble engineering components | ||
ELEMENT | PERFORMANCE CRITERIA |
1. Check/test control software program | 1.1. Program steps are checked against manufacturers' and site specifications using schematics, circuit and ladder diagrams. 1.2. Deviations are determined and recorded. |
2. Correct or modify control system software/program | 2.1. Program deviations are corrected and aligned to specification requirements using standard operating procedures. 2.2. Modifications to program are undertaken to specification requirements using standard operating procedures. 2.3. Modification is recorded to standard operating procedures. 2.4. Modified program is backed up to standard operating procedures. |
3. Check/test control system inputs/outputs | 3.1. Input/output signals are checked and assessed against operational specifications using correct and appropriate techniques, tools and equipment. 3.2. Faulty signals are identified, repaired and recorded/reported to appropriate personnel. |
4. Repair faulty control system input/output | 4.1. Faulty signal source is repaired and/or replaced. 4.2. Repaired/replaced signal source is tested for correct operation in system and commissioned in conformance to operational specifications. |
5. Prepare service report | 5.1. Service report is prepared and completed following standard operating procedure. 5.2. Recommendations for improvement and repeat downtime avoidance analysis are included. |
Required skills |
Look for evidence that confirms skills in: reading, interpreting and following information on written job instructions, specifications, standard operating procedures, charts, lists, drawings, circuit and ladder diagrams and other applicable documents planning and sequencing operations checking and clarifying task-related information identifying, recording and correcting deviations of control software program from specification modifying control system software/program and recording modifications backing up the modified control system program checking the input and output signals for conformance to specification using appropriate tools, equipment and techniques in accordance with standard operating procedures identifying, recording and correcting faulty signals marking the source of the faulty signal for repair or replacement obtaining and using supplier catalogues testing repaired/replaced signal source for correct operation in accordance with specifications and standard operating procedures commissioning the repaired/replaced signal source documenting all required service details |
Required knowledge |
Look for evidence that confirms knowledge of: the operational specifications of the control system the program steps and their function the procedures for recording deviations of the control software program from specification the procedures for correcting deviations of the control system software from specification the modifications to be made to the control system software and reasons for modifying the control system software the procedures for recording control system software modifications the procedures for backing up modifications to control system programs the tools, equipment and techniques to be used to check input and output signals for conformance to specification the procedures for recording/reporting faulty input/output signals the procedures for marking items for repair or replacement the tools, equipment and techniques necessary to repair the signal source the disassembly/assembly procedures to be followed when repairing signal sources the specifications of the signal source the procedures for testing signal sources the procedures for commissioning signal sources into operation the procedures for reporting service undertaken on control systems any trends and probable causes, evident in the data collected and collated reasons for recommended improvements safe work practices and procedures hazards and controls associated with modifying fluid power controls, including housekeeping |
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package. | |
Overview of assessment | A person who demonstrates competency in this unit must be able to modify fluid power control systems. Competency in this unit cannot be claimed until all prerequisites have been satisfied. |
Critical aspects for assessment and evidence required to demonstrate competency in this unit | Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts. |
Context of and specific resources for assessment | This unit may be assessed on the job, off the job or a combination of both. Where assessment occurs off the job, i.e. the candidate is not in productive work, an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate. This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with modifying fluid power control systems or other units requiring the exercise of the skills and knowledge covered by this unit. |
Method of assessment | Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning should not require language, literacy and numeracy skills beyond those required in this unit. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials. |
Guidance information for assessment | |
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included. | |
Control system | PCs, programmable controllers, DCS, relay logic (electric-hydraulic-pneumatic) etc. |
Modifications | Modifications covered by this unit are changes to fluid power control systems that lead to desired changes in system performance |
Unit sector |
Maintenance and diagnostics |
This unit contains employability skills. |
Not Applicable