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Evidence Guide: MEM18060B - Maintain, repair control instrumentation - single and multiple loop control systems

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

MEM18060B - Maintain, repair control instrumentation - single and multiple loop control systems

What evidence can you provide to prove your understanding of each of the following citeria?

Determine control loop operating characteristics

  1. Engineering specifications, technical information and historical trends are examined for relevant data.
  2. System specifications, operational data and other relevant data sources are examined, read, interpreted and relevant conclusions are noted.
  3. Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented by appropriate means.
  4. Using knowledge of all control loop device characteristics, controller mode principles and adjustment methods, operation of the system is observed.
  5. Appropriate test equipment and testing procedures are used.
  6. Fault finding and diagnostic techniques are utilised.
  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.
Engineering specifications, technical information and historical trends are examined for relevant data.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate test equipment and testing procedures are used.

Completed
Date:

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Fault finding and diagnostic techniques are utilised.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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.

Completed
Date:

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Monitor and record operation of a control loop

  1. Pneumatic, electrical and electronic circuit diagrams are interpreted and understood.
  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.
  3. Software configuration data for digital control systems is interpreted.
  4. Operational responses are monitored and recorded by appropriate means.
  5. Fault finding and diagnostic techniques are utilised throughout checking and testing procedures including simple and multi-controller type control schemes.
  6. Diagnostic results and conclusions are analysed against predetermined operational specifications.
Pneumatic, electrical and electronic circuit diagrams are interpreted and understood.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Software configuration data for digital control systems is interpreted.

Completed
Date:

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Operational responses are monitored and recorded by appropriate means.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostic results and conclusions are analysed against predetermined operational specifications.

Completed
Date:

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Localise fault condition

  1. Circuits are tested to the level necessary to identify and localise faults.
  2. Drawings/diagrams and operational testing data are utilised in identifying and localising fault conditions.
  3. Fault condition is localised and verified to major component level using appropriate test equipment, principles and procedures.
Circuits are tested to the level necessary to identify and localise faults.

Completed
Date:

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

Completed
Date:

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

Completed
Date:

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Replace or repair faulty condition

  1. Components are dismantled for repair or replacement using appropriate tools, equipment and procedures.
  2. Replaceable items are selected from manufacturers' catalogues, spare parts lists, or data sheets.
  3. Serviceable items are repaired using correct principles, tools, equipment and procedures.
  4. Repaired and replaceable items are reassembled using appropriate tools, equipment, techniques and procedures.
Components are dismantled for repair or replacement using appropriate tools, equipment and procedures.

Completed
Date:

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

Completed
Date:

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

Completed
Date:

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

Completed
Date:

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Calibrate and adjust control instrumentation

  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.
  2. Adjust controller modes and actions are adjusted according to specifications.
  3. Zero span and range checks are undertaken using correct and appropriate configuration.
  4. Correct and appropriate procedures, techniques, tools and equipment are used to make final adjustments to control instrumentation to specifications.
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.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust controller modes and actions are adjusted according to specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete service reports and recommission

  1. Service reports are completed to standard operating procedures.
  2. Appropriate follow-up procedures are adopted.
  3. Control instrumentation is recommissioned to standard operating procedures.
Service reports are completed to standard operating procedures.

Completed
Date:

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Appropriate follow-up procedures are adopted.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control instrumentation is recommissioned to standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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

Required Skills and Knowledge

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

Range Statement

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