This unit applies to split architecture single/multi loop control instrumentation that includes PLCs, distributed control systems (DCS) and computer-based systems. This unit also includes the basic adjustment of controller modes, checking of the loop operation, identification and fault finding of simple and multiple controller type controls schemes and the adjustment of controller modes.

Where fault finding is required to electronic component level, Unit MEM18056B (Diagnose and repair analog equipment and components) and/or Unit MEM18065B (Diagnose and repair digital equipment and components) should also be selected.

This unit has dual status and is to be regarded as both a Specialisation band A unit and Specialisation band B unit for progression to C5 (AQF level V).

Band: A

Unit Weight: 8

Path 1

MEM05001B

Perform manual soldering/desoldering - electrical/electronic components

MEM09002B

Interpret technical drawing

MEM12004B

Perform precision electrical/electronic measurement

MEM12023A

Perform engineering measurements

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM18054B

Fault find, test, calibrate instrumentation systems and equipment

MEM18055B

Dismantle, replace and assemble engineering components

MEM18057B

Maintain/service analog/digital electronic equipment

MEM18062B

Install, maintain and calibrate instrumentation sensors, transmitters and final control elements

Path 2

MEM09002B

Interpret technical drawing

MEM12002B

Perform electrical/electronic measurement

MEM12023A

Perform engineering measurements

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM18054B

Fault find, test and calibrate instrumentation systems and equipment

MEM18055B

Dismantle, replace and assemble engineering components

MEM18062B

Install, maintain and calibrate instrumentation sensors, transmitters and final control elements

MEM18064B

Maintain instrumentation system components

ELEMENT

PERFORMANCE CRITERIA

1. Determine control loop operating characteristics

1.1. Engineering specifications, technical information and historical trends are examined for relevant data.

1.2. System specifications, operational data and other relevant data sources are examined, read, interpreted and relevant conclusions are noted.

1.3. Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented by appropriate means.

1.4. Using knowledge of all control loop device characteristics, controller mode principles and adjustment methods, operation of the system is observed.

1.5. Appropriate test equipment and testing procedures are used.

1.6. Fault finding and diagnostic techniques are utilised.

1.7. Relevant data is collected by appropriate means from all sources including maintenance records, fault indicators, charts, error codes operational symptoms, observation monitoring and consultation with appropriate personnel.

2. Monitor and record operation of a control loop

2.1. Pneumatic, electrical and electronic circuit diagrams are interpreted and understood.

2.2. Using knowledge of all control loop device characteristics, controller mode principles and calibration/adjustment methods, loop operation from the controller response to set point and manual output changes using correct test equipment, principles and procedures are check tested and monitored.

2.3. Software configuration data for digital control systems is interpreted.

2.4. Operational responses are monitored and recorded by appropriate means.

2.5. Fault finding and diagnostic techniques are utilised throughout checking and testing procedures including simple and multi-controller type control schemes.

2.6. Diagnostic results and conclusions are analysed against predetermined operational specifications.

3. Localise fault condition

3.1. Circuits are tested to the level necessary to identify and localise faults.

3.2. Drawings/diagrams and operational testing data are utilised in identifying and localising fault conditions.

3.3. Fault condition is localised and verified to major component level using appropriate test equipment, principles and procedures.

4. Replace or repair faulty condition

4.1. Components are dismantled for repair or replacement using appropriate tools, equipment and procedures.

4.2. Replaceable items are selected from manufacturers' catalogues, spare parts lists, or data sheets.

4.3. Serviceable items are repaired using correct principles, tools, equipment and procedures.

4.4. Repaired and replaceable items are reassembled using appropriate tools, equipment, techniques and procedures.

5. Calibrate and adjust control instrumentation

5.1. Panel mounted, split architecture single loop/multiple loop control instruments are calibrated and adjusted using correct calibration principles, equipment and methods for all devices according to manufacturers' instructions.

5.2. Adjust controller modes and actions are adjusted according to specifications.

5.3. Zero span and range checks are undertaken using correct and appropriate configuration.

5.4. Correct and appropriate procedures, techniques, tools and equipment are used to make final adjustments to control instrumentation to specifications.

6. Complete service reports and recommission

6.1. Service reports are completed to standard operating procedures.

6.2. Appropriate follow-up procedures are adopted.

6.3. Control instrumentation is recommissioned to standard operating procedures.

Required skills

Look for evidence that confirms skills in:

obtaining and interpreting relevant engineering specifications, technical information, software data, diagrams and drawings, historical records and documents pertaining to the system components and operational data

consulting system operators and other relevant plant personnel with respect to the control loop characteristics

confirming function/malfunction of the system and/or its components

checking operational characteristics of control devices, signal conversion instruments and final control elements for conformance to specification

identifying faults/defects in control system components

locating/reading in-built fault indicators and error codes

obtaining relevant pneumatic, electrical and electronic circuit diagrams

testing and monitoring the control loop for correct operation

monitoring and recording responses of the control system

using appropriate fault-finding and diagnostic techniques and procedures throughout the monitoring and testing process

comparing collected data with the operational specifications of the control system

marking components for repair or replacement

dismantling/disassembling serviceable items

setting up appropriate test and calibration equipment

setting and adjusting the controller modes

checking the control instrumentation for correct zero, span and range

adjusting the control system as required

completing all necessary reports including appropriate follow-up procedures

commissioning the control system

interpreting trends from operational data

interpreting information from in-built devices

calculating control loop characteristics

Required knowledge

Look for evidence that confirms knowledge of:

mathematical computations including algebra, exponentials and logarithms, equations, graphs, charts, vectors, complex numbers, Boolean algebra

relevant data, including information from in-built devices on the control loop characteristics

specifications of each system component

control programming

SCADA systems, programmable logic controller systems (PLC) distributive control systems (DCS) and computer-based systems

procedures for documenting/reporting information

signal transmission including the principles of operation of the final control element, procedures for calibrating and adjusting the control system

correct function of the circuits and components within the control loop

calibration and adjustment methods for the control loop devices

configuration of the digital control system software

operational responses and procedures for monitoring and recording test and operational data

fault-finding and diagnostic techniques throughout the monitoring and testing process

deviations/variations from specification

procedures for documenting control system tests and analysis

hazards associated with testing circuits

procedures for isolating and testing the control system and its components

procedures for verifying apparent faults in circuits and/or control system components

procedures for marking components for repair or replacement including procedures for dismantling/ disassembling components for repair or replacement

correct maintenance procedures for serviceable item(s)

procedures for assembling repaired and/or replacement items

procedures and equipment necessary for the calibration of control system components

adjustments which affect the calibration to control system components

controller modes and actions

procedures for checking control instruments for zero, span and range

procedures for making final adjustments to ensure all control system components conform to specification

reporting/recording requirements associated with the commissioning of the control system

follow-up actions to be undertaken after maintaining/repairing control system instrumentation

procedures for commissioning the control system

safe work practices and procedures

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 maintain, repair control instrumentation - single and multiple loop 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 on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then 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 maintaining, repairing control instrumentation - single and multiple loop 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 techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. 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.

Historical trends

SCADA, charts, chart recorders and data loggers, equipment condition monitoring etc.

Control loop

An opened and closed loop system includes final control elements, process measuring devices, converters, controllers, process signals and the like

Major components can include

Transducers, power supplies, removable circuit boards, sensor units and other like components

Unit sector

Maintenance and diagnostics

This unit contains employability skills.