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.
Elements and Performance Criteria
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 of Performance
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 of Knowledge
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. |
Assessment Conditions
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.
Foundation Skills
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency. |
Range Statement
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 |
Sectors
Not applicable.
Competency Field
L – Marine Engineering