NTISthis.com

Evidence Guide: MEM18061B - Maintain/calibrate complex 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

 

MEM18061B - Maintain/calibrate complex control systems

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

Determine system specifications and control loop characteristics

  1. Engineering specifications, technical information and historical records and trends are examined and relevant data is documented.
  2. System specifications and operational data including those for multiple loop control systems and devices are obtained, read and interpreted.
  3. Circuit and logic diagrams and configuration data are obtained, read and interpreted.
  4. Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented by appropriate means.
  5. Appropriate work clearances are obtained for monitoring and testing the system.
Engineering specifications, technical information and historical records and trends are examined and relevant data is documented.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

System specifications and operational data including those for multiple loop control systems and devices are obtained, read and interpreted.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Circuit and logic diagrams and configuration data are obtained, read and interpreted.

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:

 

 

 

 

 

 

 

Appropriate work clearances are obtained for monitoring and testing the system.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test, monitor and record system operation

  1. Relevant data is collected by appropriate means from all sources including maintenance records, chart recorders, data loggers, fault indicators, error codes, operational symptoms, tests and observation monitoring.
  2. Fault detection and diagnostic data are analysed against predetermined operational specifications, and conclusions are documented.
  3. System operation is observed using knowledge of all individual/multiple element loop device characteristics, controller mode principles, testing, calibration and adjustment methods.
  4. Appropriate test equipment is set up and used correctly.
  5. Appropriate tests are undertaken using standard operating procedures.
  6. Signal transmission test equipment is set up and used where applicable.
  7. Adjustment/maintenance needs are determined through interpretation and analysis of pneumatic, electrical, electronic, logic diagrams and configuration data for all control system devices.
  8. Appropriate field instrumentation is connected to test system configuration.
  9. Field instrumentation is connected and tested for selected control operation, and performance is monitored against specifications.
  10. Diagnostics checks are carried out to ensure correct operation.
  11. Fault finding and diagnostic tests are undertaken using correct equipment, techniques and procedures to detect faulty control system components or elements.
Relevant data is collected by appropriate means from all sources including maintenance records, chart recorders, data loggers, fault indicators, error codes, operational symptoms, tests and observation monitoring.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Fault detection and diagnostic data are analysed against predetermined operational specifications, and conclusions are documented.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

System operation is observed using knowledge of all individual/multiple element loop device characteristics, controller mode principles, testing, calibration and adjustment methods.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate test equipment is set up and used correctly.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate tests are undertaken using standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Signal transmission test equipment is set up and used where applicable.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjustment/maintenance needs are determined through interpretation and analysis of pneumatic, electrical, electronic, logic diagrams and configuration data for all control system devices.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate field instrumentation is connected to test system configuration.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Field instrumentation is connected and tested for selected control operation, and performance is monitored against specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnostics checks are carried out to ensure correct operation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Fault finding and diagnostic tests are undertaken using correct equipment, techniques and procedures to detect faulty control system components or elements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Localise fault condition

  1. System is tested to the level necessary to detect and localise fault condition.
  2. Fault condition is localised and verified using appropriate test equipment, principles and processes.
  3. Fault condition is analysed, evaluated and corrective action is planned.
System is tested to the level necessary to detect and localise fault condition.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Fault condition is localised and verified using appropriate test equipment, principles and processes.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Fault condition is analysed, evaluated and corrective action is planned.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Replace faulty items or repair faulty condition

  1. Faulty items are dismantled for repair or replacement using appropriate tools, equipment and procedures according to manufacturers' recommendations.
  2. Replaceable items are selected from manufacturers' catalogues, spare parts lists, or data sheets.
  3. Using manufacturers' handbooks, correct maintenance procedures for faulty items are established.
  4. Faulty items and/or condition are repaired using correct maintenance procedures and equipment.
  5. Repaired and replaceable items are reassembled using appropriate principles, tools, equipment, techniques and test procedures.
Faulty items are dismantled for repair or replacement using appropriate tools, equipment and procedures according to manufacturers' recommendations.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Using manufacturers' handbooks, correct maintenance procedures for faulty items are established.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Faulty items and/or condition are repaired using correct maintenance procedures and equipment.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Calibrate, configure, adjust complex control systems

  1. Diagnostic checks are carried out to ensure correct operation of system, taking appropriate corrective action as necessary.
  2. Correct calibration and test equipment is selected/set up to enable calibration to manufacturers' specifications.
  3. Mechanical alignment of control devices is undertaken where applicable.
  4. System is configured using appropriate programming tools and techniques.
  5. Relevant alignment procedures are performed for optimum control and in accordance with specifications.
  6. Correct sequence of alignment is used on multiple control loops and multi-element systems.
  7. Correct recording equipment is set up for adjustment and monitoring during alignment.
  8. Calibration and adjustment function are performed on multi-loop devices, multi-element control loops, controller modes and actions according to operational specifications using correct principles and methods applicable to the type of control loop being serviced.
  9. On-line changes are made to parameters in the system to meet specified requirements.
  10. Field instrumentation is connected for selected control operation and system is operated to a satisfactory level of control.
Diagnostic checks are carried out to ensure correct operation of system, taking appropriate corrective action as necessary.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct calibration and test equipment is selected/set up to enable calibration to manufacturers' specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Mechanical alignment of control devices is undertaken where applicable.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

System is configured using appropriate programming tools and techniques.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Relevant alignment procedures are performed for optimum control and in accordance with specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct sequence of alignment is used on multiple control loops and multi-element systems.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct recording equipment is set up for adjustment and monitoring during alignment.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Calibration and adjustment function are performed on multi-loop devices, multi-element control loops, controller modes and actions according to operational specifications using correct principles and methods applicable to the type of control loop being serviced.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

On-line changes are made to parameters in the system to meet specified requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Field instrumentation is connected for selected control operation and system is operated to a satisfactory level of control.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Return system to service

  1. Final adjustments to align system operation to operational specifications including process and optimum control efficiencies are undertaken.
  2. Correct procedures are applied in return to service including configuring, calibrating, adjusting, tuning and final validation of system performance in accordance with specifications.
  3. System is returned to service.
  4. Service reports are completed to standard operating procedures.
Final adjustments to align system operation to operational specifications including process and optimum control efficiencies are undertaken.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct procedures are applied in return to service including configuring, calibrating, adjusting, tuning and final validation of system performance in accordance with specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

System is returned to service.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Service reports are completed 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/calibrate complex 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/calibrating complex 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, historical records and other reference documents

obtaining specifications of system components and operational data

obtaining relevant circuit and logic diagrams and configuration data

planning and sequencing operations

checking and clarifying task-related information

undertake numerical operations, and engineering calculations/formulae within the scope of this unit

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

documenting information obtained from system operators and other relevant personnel

obtaining necessary work clearances for the monitoring and testing of the system

locating and interpreting in-built fault indicators and error codes

comparing collated data with the operational specifications of the control system

documenting results of the analysis of collated data and any conclusions reached

observing operation of the system confirm function/ malfunction of the system and/or its components

setting up and using test equipment

performing tests

measure signals using suitable test equipment and analysis techniques

connecting field test instruments to the system

testing and monitoring the operation of selected controls using field test instrumentation

performing diagnostic checks on the system

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

testing system using fault finding techniques including continuity testing, fault isolation

verifying faults

documenting corrective action

marking items for repair or replacement

dismantling and assembling items

obtaining manufacturers'/suppliers' catalogues, spare parts lists or data sheets

repairing item(s) using appropriate tools and equipment

performing diagnostic checks of the system

taking corrective action to bring system operation into line with specifications

setting up test and calibration equipment

aligning control devices to specifications

configuring the system

aligning controllers for optimum performance

aligning multiple control loops in the correct sequence

setting up and monitoring recording equipment during the tuning process to identify the effects of adjustment made to the system

calibrating and adjusting control system components

changing system parameters on-line to meet specified requirements

connecting field test instrumentation to selected control system

operating the control system

adjusting the control system

validating system performance

returning control systems to service

completing reports

Required knowledge

Look for evidence that confirms knowledge of:

the specification of each system component

relevant data and/or trends

system components and their function

procedures for:

documenting information

obtaining work clearances

documenting control system tests and analysis

using test equipment

testing system configuration, control system components/elements, testing circuits and control lines

testing and monitoring the operation of selected controls

carrying out diagnostic checks

isolating the control system and its components

marking serviceable items for repair or replacement

dismantling/disassembling items for repair or replacement

servicing item(s)

adjusting the system to conform to operational specifications

calibrating the control system components

aligning control devices

configuring the system

tuning controllers, multiple control loops and multi-element systems

recording signals and data during system tuning operations

changing parameters

operating and monitoring a control system

making final adjustments to ensure all control system components conform to specifications

assembling repaired and/or replacement items

returning to service

reporting/recording requirements associated with return to service of control systems

reasons for:

observing the system in operation

selecting the chosen test equipment

identifying the adjustments/maintenance to be carried out

selecting the chosen diagnostic checks

selecting the chosen test and calibration equipment

any deviations/variations from specification

the errors indicated by in-built devices

deviations/variations from specification

the following for the given system: all individual/multiple element loop device characteristics; controller mode principles, testing methods; calibration methods; adjustment methods

equipment:

to be used and reasons for selecting the chosen equipment

required to verify an apparent fault

used to test system configuration

required to undertake maintenance on item(s)

necessary to calibrate the control system components

necessary to carry out the alignment of the control devices

programming tools and techniques to be used

appropriate measuring techniques, tools and equipment

adjustments/maintenance to be carried out

diagnostic checks to be applied to the system to ensure correct operation of the system

fault finding and performing diagnostic tests to be applied to control devices, signal conversion instruments and final control elements

hazards associated with testing circuits and control lines

causes of verified faults and the action to be taken to return the control system/component to specification

appropriate replacement parts

specifications of serviceable item(s)

diagnostic checks to be carried out

specifications of the equipment to be calibrated

alignment specifications

specifications of the controllers

correct sequence of tuning

recording equipment to be used

adjustments that can be made to control system components

effects of those adjustments on the calibration of the control system components

requirements to be achieved by changing system parameters on-line

the level of control to be achieved

hazards and control measures associated with maintaining/calibrating complex control systems

use and application of personal protective equipment

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.

Control loop

A process of documenting and recording measurements and variables within the process

Test equipment

Engineer level, laser alignments etc., and appropriate equipment for measurement of alignment, flatness, squareness, straightness, temperature, vibration, load deflection, noise level, RPM

Tests

Measuring and analysing to ensure correct operation

Control system

Control systems include pneumatic control, analog and/or digital electronics, distributed PLC, DCS, SCADA, and computer-based control systems. Computer-based control systems may include supervisory mode

Field instrumentation

Test and measuring equipment which could include specialised testing fixtures or equipment