Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

MARL032 Mapping and Delivery Guide
Demonstrate advanced knowledge of marine control systems and automation

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency MARL032 - Demonstrate advanced knowledge of marine control systems and automation
Description
Employability Skills
Learning Outcomes and Application This unit involves the skills and knowledge required to operate control systems on board a commercial vessel. It includes basic knowledge of control theory and knowledge required to analyse the operation and performance of signal transmissions systems, electronic transmitters, final control element arrangements, electronic temperature sensors and transmitters, governors, PID electronic controllers, machinery space monitoring alarm and control systems.It also includes knowledge of fault finding techniques for control systems, measurement and test equipment used for fault finding electronic apparatus, operational applications of analogue and digital programmable logic controllers, and procedures for programming, operating, and maintaining PLC controlled systems.This unit applies to the work of a Marine Engineer Class 1 on commercial vessels of unlimited propulsion power and forms part of the requirements for the Certificate of Competency Marine Engineer Class 1 issued by the Australian Maritime Safety Authority (AMSA).No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Assessors must satisfy National Vocational Education and Training Regulator (NVR)/Australian Quality Training Framework (AQTF) assessor requirements.

Assessment must satisfy the National Vocational Education and Training Regulator (NVR)/Australian Quality Training Framework (AQTF) standards.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Assessment must occur in workplace operational situations or where these are not available, in simulated workplace operational situations or an industry-approved marine operations site that replicates workplace conditions where advanced knowledge of marine control systems and automation can be demonstrated.

Resources for assessment include access to:

applicable documentation including workplace procedures, regulations, codes of practice and operation manuals

appropriate range of relevant operational situations in the workplace

technical reference library with current publications on automation and process control

tools, equipment, materials and personal protective equipment currently used in industry.

Performance should be demonstrated consistently over time and in a suitable range of contexts.
Prerequisites/co-requisites
Competency Field L – Marine Engineering
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Explain control theory
  • Time lag is distinguished from time constant
  • Effect resistance and capacitance has on process system response is demonstrated
  • Transfer function is established and defined
  • Effect of variations in undamped natural frequency on control systems is illustrated
       
Element: Analyse signal transmissions systems used for monitoring, controlling and shutting down machinery
  • Methods and limitations of different signal transmissions systems are compared
  • Standard pneumatic system and standard analogue 4-20 mA system of signal transmission are compared and contrasted
  • System of a communications bus using digital signal transmission with optical and electronic systems is explained
  • Limitations and advantages of a communications bus system are analysed
       
Element: Analyse electronic transmitters
  • Principles of operation of a typical 4-20 mA transmitter are explained
  • Application of strain gauges and changes in capacitance as sensors for pressure and differential pressure transmitters are outlined
  • Methods of testing transmitter outputs are recorded explained
  • Application of differential pressure transmitters to liquid level sensing is analysed
  • Use of a differential pressure transmitter to measure flow is analysed and compared with non-restrictive electronic systems
       
Element: Evaluate final control element arrangements
  • Pneumatic, electric and hydraulic actuation are compared and contrasted
  • Arrangements for locking pneumatic control valves in their last position on air failure are outlined
  • Control valve trim characteristics are explained
  • Control valve selection for machinery space duties are analysed
       
Element: Evaluate electronic temperature sensors and transmitters
  • Colour coding of tails and compensating cables for thermo couple types are identified
  • Temperature/mV outputs and application of common thermo couple types are illustrated
  • Relationship between resistance and temperature for PT100 resistance temperature device and method of testing three wire arrangements is explained
  • Arrangements of interfacing thermo couples and RTDs with 4-20ma systems and 1-5 volt interface cards are analysed
       
Element: Analyse PID electronic controllers
  • Principle of operation of an electronic analogue 3-term controller and how adjustments are made is explained
  • Open loop response and PID controller testing and calibration is demonstrated
  • Application of modern single loop digital controller is explained
  • Programming requirements for manual and auto tuning when adjusting digital controllers are demonstrated
       
Element: Evaluate performance of machinery space monitoring alarm and control systems
  • Capacitance sensing and float level monitoring systems are compared
  • Single, two and three element boiler water level control systems involving feedwater and cascade systems are analysed
  • Requirements and systems to provide advanced combustion control systems and sequential control for burner management are outlined
  • Concepts and arrangements for central cooling and load dependent cooling control systems are explained
  • Main engine control arrangements for fixed pitch propeller and CPP systems requiring sequential control are analysed
  • Tests and procedures to meet UMS requirements are explained, and alarm and monitoring systems involving data loggers, alarm print outers, and trend analysis are evaluated
       
Element: Explain fault-finding techniques for control systems
  • Governor adjustments are demonstrated and effect of incorrect adjustments is explained
  • Common defects in mechanical and electronic governors are itemised
  • Indication of faults and procedures of fault finding in 4-20mA loops are explained
  • Fault-finding techniques in pneumatic control systems and their respective components are analysed
  • Fault-finding flow diagram is illustrated
  • Off limit performance, fault detection and principles of rectifications for common engine room control systems are evaluated
       
Element: Analyse measurement and test equipment used for fault-finding electronic apparatus
  • Principles of operation of cathode ray oscilloscope are explained
  • Need for pulse shaping in electronics is examined
  • Different methods of testing common alarms systems are compared
  • Methods used in stabilisation, surveillance and monitoring of control power supplies are demonstrated
       
Element: Analyse governors
  • Governor faults are diagnosed and interpreted, identifying and evaluating appropriate adjustments and maintenance to be made
  • Specific governor applications requiring torque limitation, critical speed range avoidance are outlined
  • Typical electronic governors are explained using labelled diagrams to indicate major components and features
  • Governor adjustments to allow operation of propulsion and power generation diesels in both shared load and standalone applications are specified
  • Response of a diesel engine governor on change in engine load using both feedback and feed forward control is explained using labelled diagrams to indicate major components and adjustments
       
Element: Explain operational applications of analogue and digital programmable logic controllers (PLC)
  • Methods of programming PLCs are assessed
  • Memory applications of PLCs are outlined
  • Input devices used with analogue PLCs are identified
  • Fibre optic data transmission systems are explained
  • Methods used for storing binary data and operating registers are explained
       
Element: Document procedures for programming, operating and maintaining PLC controlled systems
  • Procedure for identifying required control system functions are explained
  • Procedure for connecting PLC to system control elements is outlined
  • System operating procedure is outlined
  • Procedure for modifying system and program as necessary to provide adequate and appropriate safety requirements, is outlined
  • Maintenance and fault-finding procedures are outlined
  • Required documentation is prepared and accuracy is verified
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Explain control theory

1.1

Time lag is distinguished from time constant

1.2

Effect resistance and capacitance has on process system response is demonstrated

1.3

Transfer function is established and defined

1.4

Effect of variations in undamped natural frequency on control systems is illustrated

2

Analyse signal transmissions systems used for monitoring, controlling and shutting down machinery

2.1

Methods and limitations of different signal transmissions systems are compared

2.2

Standard pneumatic system and standard analogue 4-20 mA system of signal transmission are compared and contrasted

2.3

System of a communications bus using digital signal transmission with optical and electronic systems is explained

2.4

Limitations and advantages of a communications bus system are analysed

3

Analyse electronic transmitters

3.1

Principles of operation of a typical 4-20 mA transmitter are explained

3.2

Application of strain gauges and changes in capacitance as sensors for pressure and differential pressure transmitters are outlined

3.3

Methods of testing transmitter outputs are recorded explained

3.4

Application of differential pressure transmitters to liquid level sensing is analysed

3.5

Use of a differential pressure transmitter to measure flow is analysed and compared with non-restrictive electronic systems

4

Evaluate final control element arrangements

4.1

Pneumatic, electric and hydraulic actuation are compared and contrasted

4.2

Arrangements for locking pneumatic control valves in their last position on air failure are outlined

4.3

Control valve trim characteristics are explained

4.4

Control valve selection for machinery space duties are analysed

5

Evaluate electronic temperature sensors and transmitters

5.1

Colour coding of tails and compensating cables for thermo couple types are identified

5.2

Temperature/mV outputs and application of common thermo couple types are illustrated

5.3

Relationship between resistance and temperature for PT100 resistance temperature device and method of testing three wire arrangements is explained

5.4

Arrangements of interfacing thermo couples and RTDs with 4-20ma systems and 1-5 volt interface cards are analysed

6

Analyse PID electronic controllers

6.1

Principle of operation of an electronic analogue 3-term controller and how adjustments are made is explained

6.2

Open loop response and PID controller testing and calibration is demonstrated

6.3

Application of modern single loop digital controller is explained

6.4

Programming requirements for manual and auto tuning when adjusting digital controllers are demonstrated

7

Evaluate performance of machinery space monitoring alarm and control systems

7.1

Capacitance sensing and float level monitoring systems are compared

7.2

Single, two and three element boiler water level control systems involving feedwater and cascade systems are analysed

7.3

Requirements and systems to provide advanced combustion control systems and sequential control for burner management are outlined

7.4

Concepts and arrangements for central cooling and load dependent cooling control systems are explained

7.5

Main engine control arrangements for fixed pitch propeller and CPP systems requiring sequential control are analysed

7.6

Tests and procedures to meet UMS requirements are explained, and alarm and monitoring systems involving data loggers, alarm print outers, and trend analysis are evaluated

8

Explain fault-finding techniques for control systems

8.1

Governor adjustments are demonstrated and effect of incorrect adjustments is explained

8.2

Common defects in mechanical and electronic governors are itemised

8.3

Indication of faults and procedures of fault finding in 4-20mA loops are explained

8.4

Fault-finding techniques in pneumatic control systems and their respective components are analysed

8.5

Fault-finding flow diagram is illustrated

8.6

Off limit performance, fault detection and principles of rectifications for common engine room control systems are evaluated

9

Analyse measurement and test equipment used for fault-finding electronic apparatus

9.1

Principles of operation of cathode ray oscilloscope are explained

9.2

Need for pulse shaping in electronics is examined

9.3

Different methods of testing common alarms systems are compared

9.4

Methods used in stabilisation, surveillance and monitoring of control power supplies are demonstrated

10

Analyse governors

10.1

Governor faults are diagnosed and interpreted, identifying and evaluating appropriate adjustments and maintenance to be made

10.2

Specific governor applications requiring torque limitation, critical speed range avoidance are outlined

10.3

Typical electronic governors are explained using labelled diagrams to indicate major components and features

10.4

Governor adjustments to allow operation of propulsion and power generation diesels in both shared load and standalone applications are specified

10.5

Response of a diesel engine governor on change in engine load using both feedback and feed forward control is explained using labelled diagrams to indicate major components and adjustments

11

Explain operational applications of analogue and digital programmable logic controllers (PLC)

11.1

Methods of programming PLCs are assessed

11.2

Memory applications of PLCs are outlined

11.3

Input devices used with analogue PLCs are identified

11.4

Fibre optic data transmission systems are explained

11.5

Methods used for storing binary data and operating registers are explained

12

Document procedures for programming, operating and maintaining PLC controlled systems

12.1

Procedure for identifying required control system functions are explained

12.2

Procedure for connecting PLC to system control elements is outlined

12.3

System operating procedure is outlined

12.4

Procedure for modifying system and program as necessary to provide adequate and appropriate safety requirements, is outlined

12.5

Maintenance and fault-finding procedures are outlined

12.6

Required documentation is prepared and accuracy is verified

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions on at least one occasion and include:

accessing information and sketching diagrams, and interpreting and explaining testing requirements related to control systems on commercial vessels

applying relevant work health and safety/occupational health and safety (WHS/OHS) requirements and work practices

assessing own work outcomes and maintaining knowledge of current codes, standards, regulations and industry practices

explaining advance principles of marine automation and process control, and imparting knowledge and ideas verbally, in writing and visually

identifying and interpreting numerical and graphical information, including schematic diagrams, relevant to control systems on commercial vessels

identifying and suggesting ways of rectifying faults and malfunctions in control systems on commercial vessels

identifying methods, procedures and materials needed to operate and maintain control systems on commercial vessels

reading and interpreting written information related to operating control systems on commercial vessels.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions and include knowledge of:

analogue and digital programmable logic controllers

Australian Standards for drawing symbols/layouts for schematic diagrams

characteristics and functions of temperature, pressure and viscosity of fuel

concept of ‘fail safe’ philosophy

concepts of unmanned machinery spaces (UMS), and automated monitoring and control of machinery

control and monitoring of ship machinery

control:

loops

theory

electronic:

temperature sensors and transmitters

transmitters

fault-finding techniques for control systems

final control element arrangements

governors

instrument process and control terms

machinery space monitoring alarm and control systems

measurement and test equipment used for fault-finding electronic apparatus

mechanical and electrical sensors

PID electronic controllers

pneumatic and electrical instrumentation transmitters

principles of:

basic electronic circuits

basic pneumatic systems and action of pneumatic instruments

process control

safety devices, alarms and monitoring systems

sensing and transmitting elements

signal transmissions systems used for monitoring, controlling and shutting down machinery

tests and procedures required to meet UMS requirements

WHS/OHS legislation, policies and procedures.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Explain control theory

1.1

Time lag is distinguished from time constant

1.2

Effect resistance and capacitance has on process system response is demonstrated

1.3

Transfer function is established and defined

1.4

Effect of variations in undamped natural frequency on control systems is illustrated

2

Analyse signal transmissions systems used for monitoring, controlling and shutting down machinery

2.1

Methods and limitations of different signal transmissions systems are compared

2.2

Standard pneumatic system and standard analogue 4-20 mA system of signal transmission are compared and contrasted

2.3

System of a communications bus using digital signal transmission with optical and electronic systems is explained

2.4

Limitations and advantages of a communications bus system are analysed

3

Analyse electronic transmitters

3.1

Principles of operation of a typical 4-20 mA transmitter are explained

3.2

Application of strain gauges and changes in capacitance as sensors for pressure and differential pressure transmitters are outlined

3.3

Methods of testing transmitter outputs are recorded explained

3.4

Application of differential pressure transmitters to liquid level sensing is analysed

3.5

Use of a differential pressure transmitter to measure flow is analysed and compared with non-restrictive electronic systems

4

Evaluate final control element arrangements

4.1

Pneumatic, electric and hydraulic actuation are compared and contrasted

4.2

Arrangements for locking pneumatic control valves in their last position on air failure are outlined

4.3

Control valve trim characteristics are explained

4.4

Control valve selection for machinery space duties are analysed

5

Evaluate electronic temperature sensors and transmitters

5.1

Colour coding of tails and compensating cables for thermo couple types are identified

5.2

Temperature/mV outputs and application of common thermo couple types are illustrated

5.3

Relationship between resistance and temperature for PT100 resistance temperature device and method of testing three wire arrangements is explained

5.4

Arrangements of interfacing thermo couples and RTDs with 4-20ma systems and 1-5 volt interface cards are analysed

6

Analyse PID electronic controllers

6.1

Principle of operation of an electronic analogue 3-term controller and how adjustments are made is explained

6.2

Open loop response and PID controller testing and calibration is demonstrated

6.3

Application of modern single loop digital controller is explained

6.4

Programming requirements for manual and auto tuning when adjusting digital controllers are demonstrated

7

Evaluate performance of machinery space monitoring alarm and control systems

7.1

Capacitance sensing and float level monitoring systems are compared

7.2

Single, two and three element boiler water level control systems involving feedwater and cascade systems are analysed

7.3

Requirements and systems to provide advanced combustion control systems and sequential control for burner management are outlined

7.4

Concepts and arrangements for central cooling and load dependent cooling control systems are explained

7.5

Main engine control arrangements for fixed pitch propeller and CPP systems requiring sequential control are analysed

7.6

Tests and procedures to meet UMS requirements are explained, and alarm and monitoring systems involving data loggers, alarm print outers, and trend analysis are evaluated

8

Explain fault-finding techniques for control systems

8.1

Governor adjustments are demonstrated and effect of incorrect adjustments is explained

8.2

Common defects in mechanical and electronic governors are itemised

8.3

Indication of faults and procedures of fault finding in 4-20mA loops are explained

8.4

Fault-finding techniques in pneumatic control systems and their respective components are analysed

8.5

Fault-finding flow diagram is illustrated

8.6

Off limit performance, fault detection and principles of rectifications for common engine room control systems are evaluated

9

Analyse measurement and test equipment used for fault-finding electronic apparatus

9.1

Principles of operation of cathode ray oscilloscope are explained

9.2

Need for pulse shaping in electronics is examined

9.3

Different methods of testing common alarms systems are compared

9.4

Methods used in stabilisation, surveillance and monitoring of control power supplies are demonstrated

10

Analyse governors

10.1

Governor faults are diagnosed and interpreted, identifying and evaluating appropriate adjustments and maintenance to be made

10.2

Specific governor applications requiring torque limitation, critical speed range avoidance are outlined

10.3

Typical electronic governors are explained using labelled diagrams to indicate major components and features

10.4

Governor adjustments to allow operation of propulsion and power generation diesels in both shared load and standalone applications are specified

10.5

Response of a diesel engine governor on change in engine load using both feedback and feed forward control is explained using labelled diagrams to indicate major components and adjustments

11

Explain operational applications of analogue and digital programmable logic controllers (PLC)

11.1

Methods of programming PLCs are assessed

11.2

Memory applications of PLCs are outlined

11.3

Input devices used with analogue PLCs are identified

11.4

Fibre optic data transmission systems are explained

11.5

Methods used for storing binary data and operating registers are explained

12

Document procedures for programming, operating and maintaining PLC controlled systems

12.1

Procedure for identifying required control system functions are explained

12.2

Procedure for connecting PLC to system control elements is outlined

12.3

System operating procedure is outlined

12.4

Procedure for modifying system and program as necessary to provide adequate and appropriate safety requirements, is outlined

12.5

Maintenance and fault-finding procedures are outlined

12.6

Required documentation is prepared and accuracy is verified

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Methods of testing transmitter outputs include one or more of the following:

MA test point

MV test point

no test points

Faults must include:

earths

electronic component failure

high resistance joints

open circuits

power supply faults

short circuits

Governor adjustments must include:

mismatching between prime mover types and responses

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Time lag is distinguished from time constant 
Effect resistance and capacitance has on process system response is demonstrated 
Transfer function is established and defined 
Effect of variations in undamped natural frequency on control systems is illustrated 
Methods and limitations of different signal transmissions systems are compared 
Standard pneumatic system and standard analogue 4-20 mA system of signal transmission are compared and contrasted 
System of a communications bus using digital signal transmission with optical and electronic systems is explained 
Limitations and advantages of a communications bus system are analysed 
Principles of operation of a typical 4-20 mA transmitter are explained 
Application of strain gauges and changes in capacitance as sensors for pressure and differential pressure transmitters are outlined 
Methods of testing transmitter outputs are recorded explained 
Application of differential pressure transmitters to liquid level sensing is analysed 
Use of a differential pressure transmitter to measure flow is analysed and compared with non-restrictive electronic systems 
Pneumatic, electric and hydraulic actuation are compared and contrasted 
Arrangements for locking pneumatic control valves in their last position on air failure are outlined 
Control valve trim characteristics are explained 
Control valve selection for machinery space duties are analysed 
Colour coding of tails and compensating cables for thermo couple types are identified 
Temperature/mV outputs and application of common thermo couple types are illustrated 
Relationship between resistance and temperature for PT100 resistance temperature device and method of testing three wire arrangements is explained 
Arrangements of interfacing thermo couples and RTDs with 4-20ma systems and 1-5 volt interface cards are analysed 
Principle of operation of an electronic analogue 3-term controller and how adjustments are made is explained 
Open loop response and PID controller testing and calibration is demonstrated 
Application of modern single loop digital controller is explained 
Programming requirements for manual and auto tuning when adjusting digital controllers are demonstrated 
Capacitance sensing and float level monitoring systems are compared 
Single, two and three element boiler water level control systems involving feedwater and cascade systems are analysed 
Requirements and systems to provide advanced combustion control systems and sequential control for burner management are outlined 
Concepts and arrangements for central cooling and load dependent cooling control systems are explained 
Main engine control arrangements for fixed pitch propeller and CPP systems requiring sequential control are analysed 
Tests and procedures to meet UMS requirements are explained, and alarm and monitoring systems involving data loggers, alarm print outers, and trend analysis are evaluated 
Governor adjustments are demonstrated and effect of incorrect adjustments is explained 
Common defects in mechanical and electronic governors are itemised 
Indication of faults and procedures of fault finding in 4-20mA loops are explained 
Fault-finding techniques in pneumatic control systems and their respective components are analysed 
Fault-finding flow diagram is illustrated 
Off limit performance, fault detection and principles of rectifications for common engine room control systems are evaluated 
Principles of operation of cathode ray oscilloscope are explained 
Need for pulse shaping in electronics is examined 
Different methods of testing common alarms systems are compared 
Methods used in stabilisation, surveillance and monitoring of control power supplies are demonstrated 
Governor faults are diagnosed and interpreted, identifying and evaluating appropriate adjustments and maintenance to be made 
Specific governor applications requiring torque limitation, critical speed range avoidance are outlined 
Typical electronic governors are explained using labelled diagrams to indicate major components and features 
Governor adjustments to allow operation of propulsion and power generation diesels in both shared load and standalone applications are specified 
Response of a diesel engine governor on change in engine load using both feedback and feed forward control is explained using labelled diagrams to indicate major components and adjustments 
Methods of programming PLCs are assessed 
Memory applications of PLCs are outlined 
Input devices used with analogue PLCs are identified 
Fibre optic data transmission systems are explained 
Methods used for storing binary data and operating registers are explained 
Procedure for identifying required control system functions are explained 
Procedure for connecting PLC to system control elements is outlined 
System operating procedure is outlined 
Procedure for modifying system and program as necessary to provide adequate and appropriate safety requirements, is outlined 
Maintenance and fault-finding procedures are outlined 
Required documentation is prepared and accuracy is verified 

Forms

Assessment Cover Sheet

MARL032 - Demonstrate advanced knowledge of marine control systems and automation
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MARL032 - Demonstrate advanced knowledge of marine control systems and automation

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