1

Explain control theory

1.1

Time lag is distinguished from time constant

1.2

How resistance and capacitance affect control and process system response is shown

1.3

Transfer function is 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 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 listed

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 stand alone 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

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

Required Skills:

Access information and sketch diagrams, and interpret and explain testing requirements related to control systems on commercial vessels

Assess own work outcomes and maintain knowledge of current codes, standards, regulations and industry practices

Explain advance principles of marine automation and process control and impart knowledge and ideas verbally, in writing and visually

Identify and interpret numerical and graphical information, including schematic diagrams, relevant to control systems on commercial vessels

Identify and suggest ways of rectifying faults and malfunctions in control systems on commercial vessels

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

Read and interpret written information related to operating control systems on commercial vessels

Required Knowledge:

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

Work health and safety (WHS)/occupational health and safety (OHS) legislation, policies and procedures

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

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, the required skills and knowledge, the range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the Elements, Performance Criteria, Required Skills, Required Knowledge and include:

attention to detail when completing documentation

providing accurate and reliable information

providing appropriate level of detail in responses.

Context of and specific resources for assessment

Performance is demonstrated consistently over time and in a suitable range of contexts.

Resources for assessment include access to:

industry-approved marine operations site where advanced knowledge of marine control systems and automation can be demonstrated

technical reference library with current publications on automation and process control

tools, equipment and personal protective equipment currently used in industry

relevant regulatory and equipment documentation that impacts on work activities

range of relevant exercises, case studies and/or other simulated practical and knowledge assessments

appropriate range of relevant operational situations in the workplace.

In both real and simulated environments, access is required to:

relevant and appropriate materials and equipment

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

Method of assessment

Practical assessment must occur in an:

appropriately simulated workplace environment and/or

appropriate range of situations in the workplace.

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate to this unit:

direct observation of the candidate demonstrating advanced knowledge of marine control systems and automation

direct observation of the candidate applying relevant WHS/OHS requirements and work practices.

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended.

In all cases where practical assessment is used it should be combined with targeted questioning to assess Required Knowledge.

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

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.

Methods of testing transmitter outputs may include:

MA test point

MV test point

No test points

Faults may include:

Earths

Electronic component failure

High resistance joints

Open circuits

Power supply faults

Short circuits

Governor adjustments may include:

Mismatching between prime mover types and responses