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Elements and Performance Criteria

1. Determine control loop characteristics
   • Engineering specifications, technical information and historical process, records and trends are examined for relevant data.
   • Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented to standard operating procedures.
   • Programmed maintenance/service reports are read and relevant data noted.
   • Data is analysed and control loop characteristics are ascertained.
2. Record control loop responses
   • Using chart recorders and data loggers, control loop responses are recorded in open and closed loop mode.
   • Unit is tested for tuning using appropriate diagnostic techniques.
   • Diagnostic results are analysed against specifications.
3. Tune control loops
   • Using knowledge of control loop device characteristics, controller mode principles and adjustment methods, tuning operations are performed using correct and appropriate techniques, procedures and equipment.
   • Recording equipment used for monitoring and adjustment of control loop components during controller tuning operations is corrected and tested.
   • Step response - open loop tuning calculations are applied to achieve specified loop characteristics.
   • Closed loop tuning methods using ultimate sensitivity and systematic trials are used to achieve specified loop characteristics.
   • Correct sequence of tuning is used on multi controllers and/or multi element systems to achieve specified characteristics.
   • Control loops are tuned to optimum mode settings utilising correct and appropriate techniques, tools, test equipment and procedures.
4. Complete service reports
   • Service reports are completed to standard operating procedures.
   • Appropriate follow up procedures are adopted.
   • Process control loop is recommissioned to specifications.

Required Skills

Required skills

Look for evidence that confirms skills in calculating control loop characteristics 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 functionmalfunction of the system andor its components checking operational characteristics of control devices signal conversion instruments and final control elements for conformance to specification identifying faultsdefects in control system components locatingreading inbuilt fault indicators and error codes obtaining relevant pneumatic electrical and electronic circuit diagrams determining corrective action and interpreting trends from operational data testingmonitoring the control loop for correct operation monitoring and recording operational responses of the control systemloop using appropriate faultfinding 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 dismantlingdisassembling 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 implementing diagnostic techniques and procedures tuning the control loop completing all necessary reports including appropriate follow up procedures commissioning the control system

Required knowledge

Look for evidence that confirms knowledge of proportional integral differential PID control loops tuningcalibration techniques mathematical computations including algebra exponentials and logarithms equations graphs charts vectors complex numbers Boolean algebra relevant data including information from inbuilt 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 computerbased systems procedures for documentingreporting 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 faultfinding and diagnostic techniques throughout the monitoring and testing process deviationsvariations 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 andor 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 items procedures for assembling repaired andor 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 reportingrecording requirements associated with the commissioning of the control system followup actions to be undertaken after maintainingrepairing control system instrumentation procedures for commissioning the control system safe work practices and procedures

Evidence Required

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 tune control loops multi controller or multi element 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 tuning control loops multi controller or multi element 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 supervisors 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

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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 process	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
Test equipment	Pneumatic, analogue and digital electronic test equipment for the monitoring and adjustment of control loop tuning

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