Modification History
Not Applicable
Unit Descriptor
Unit descriptor |
This unit covers determining system specification and control loop characteristics, and testing, monitoring and recording system operation. |
Application of the Unit
Application of the unit |
This unit applies to localising the fault condition; repairing or replacing faulty condition; calibrating, configuring and adjusting complex control systems; and recommissioning the system. It extends to the use of pneumatic analog and digital test and recording equipment for the calibration, configuration and testing of multiple loop control systems including pneumatic, analog electronics, distributed PLC and computer-based control systems which include supervisory mode. Work is to be undertaken autonomously or in a team environment in consultation with appropriate personnel, using predetermined standards of quality, safety and workshop procedures. Tasks are to be undertaken in workshop or on-site environments and involve the interpretation of manuals, specifications and diagrams, including pneumatic, electrical, electronic and logic diagrams, as well as program listings and configuration data for control system devices. Control strategies include: ratio, cascade, selector, duplex, feed forward, adaptive, dynamic compensations, computations, energy management and environmental control/systems. Unit MEM05002B (Perform high reliability soldering and desoldering) must also be selected if soldering of components is required to advanced or military specifications, where the reliability of electrical connections is critical, or where surface mounted devices are being soldered/de-soldered. Band : B Unit Weight : 8 |
Licensing/Regulatory Information
Not Applicable
Pre-Requisites
Prerequisite units |
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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 and 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 |
|
MEM18069B |
Maintain, repair instrumentation process control analysers |
|
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 |
|
MEM18064B |
Maintain instrumentation system components |
|
MEM18069B |
Maintain, repair instrumentation process control analysers |
|
Path 3 |
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 and calibrate instrumentation systems and equipment |
|
MEM18055B |
Dismantle, replace and assemble engineering components |
|
MEM18057B |
Maintain/service analog/digital electronic equipment |
|
MEM18060B |
Maintain, repair control instrumentation - single and multiple loop control systems |
|
MEM18062B |
Install, maintain and calibrate instrumentation sensors, transmitters and final control elements |
|
MEM18067B |
Tune control loops - multi controller or multi element systems |
|
Path 4 |
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 |
|
MEM18060B |
Maintain, repair control instrumentation - single and multiple loop control systems |
|
MEM18062B |
Install, maintain and calibrate instrumentation sensors, transmitters and final control elements |
|
MEM18064B |
Maintain instrumentation system components |
|
MEM18067B |
Tune control loops - multi controller or multi element systems |
Employability Skills Information
Employability skills |
This unit contains employability skills. |
Elements and Performance Criteria Pre-Content
Elements describe the essential outcomes of a unit of competency. |
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide. |
Elements and Performance Criteria
ELEMENT |
PERFORMANCE CRITERIA |
1. Determine system specifications and control loop characteristics |
1.1. Engineering specifications, technical information and historical records and trends are examined and relevant data is documented. 1.2. System specifications and operational data including those for multiple loop control systems and devices are obtained, read and interpreted. 1.3. Circuit and logic diagrams and configuration data are obtained, read and interpreted. 1.4. Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented by appropriate means. 1.5. Appropriate work clearances are obtained for monitoring and testing the system. |
2. Test, monitor and record system operation |
2.1. 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. 2.2. Fault detection and diagnostic data are analysed against predetermined operational specifications, and conclusions are documented. 2.3. System operation is observed using knowledge of all individual/multiple element loop device characteristics, controller mode principles, testing, calibration and adjustment methods. 2.4. Appropriate test equipment is set up and used correctly. 2.5. Appropriate tests are undertaken using standard operating procedures. 2.6. Signal transmission test equipment is set up and used where applicable. 2.7. Adjustment/maintenance needs are determined through interpretation and analysis of pneumatic, electrical, electronic, logic diagrams and configuration data for all control system devices. 2.8. Appropriate field instrumentation is connected to test system configuration. 2.9. Field instrumentation is connected and tested for selected control operation, and performance is monitored against specifications. 2.10. Diagnostics checks are carried out to ensure correct operation. 2.11. Fault finding and diagnostic tests are undertaken using correct equipment, techniques and procedures to detect faulty control system components or elements. |
3. Localise fault condition |
3.1. System is tested to the level necessary to detect and localise fault condition. 3.2. Fault condition is localised and verified using appropriate test equipment, principles and processes. 3.3. Fault condition is analysed, evaluated and corrective action is planned. |
4. Replace faulty items or repair faulty condition |
4.1. Faulty items are dismantled for repair or replacement using appropriate tools, equipment and procedures according to manufacturers' recommendations. 4.2. Replaceable items are selected from manufacturers' catalogues, spare parts lists, or data sheets. 4.3. Using manufacturers' handbooks, correct maintenance procedures for faulty items are established. 4.4. Faulty items and/or condition are repaired using correct maintenance procedures and equipment. 4.5. Repaired and replaceable items are reassembled using appropriate principles, tools, equipment, techniques and test procedures. |
5. Calibrate, configure, adjust complex control systems |
5.1. Diagnostic checks are carried out to ensure correct operation of system, taking appropriate corrective action as necessary. 5.2. Correct calibration and test equipment is selected/set up to enable calibration to manufacturers' specifications. 5.3. Mechanical alignment of control devices is undertaken where applicable. 5.4. System is configured using appropriate programming tools and techniques. 5.5. Relevant alignment procedures are performed for optimum control and in accordance with specifications. 5.6. Correct sequence of alignment is used on multiple control loops and multi-element systems. 5.7. Correct recording equipment is set up for adjustment and monitoring during alignment. 5.8. 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. 5.9. On-line changes are made to parameters in the system to meet specified requirements. 5.10. Field instrumentation is connected for selected control operation and system is operated to a satisfactory level of control. |
6. Return system to service |
6.1. Final adjustments to align system operation to operational specifications including process and optimum control efficiencies are undertaken. 6.2. Correct procedures are applied in return to service including configuring, calibrating, adjusting, tuning and final validation of system performance in accordance with specifications. 6.3. System is returned to service. 6.4. Service reports are completed to standard operating procedures. |
Required Skills and Knowledge
REQUIRED SKILLS AND KNOWLEDGE |
This section describes the skills and knowledge required for this unit. |
Required skills |
Look for evidence that confirms skills in:
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Required knowledge |
Look for evidence that confirms knowledge of:
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Evidence Guide
EVIDENCE GUIDE |
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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. |
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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 |
Range Statement
RANGE STATEMENT |
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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. |
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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 |
Unit Sector(s)
Unit sector |
Co-requisite units
Co-requisite units |
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Competency field
Competency field |
Maintenance and diagnostics |