This unit applies to pneumatic, analog and digital electronic test and recording equipment for the monitoring and adjustment of control loop tuning - the recording of control loop responses in open and closed loop modes.

Included is the application of step response - open loop tuning calculations and closed loop ultimate sensitivity trials to achieve specified loop characteristics in conformance to operational specifications.

Where fault finding is required to electronic component level, Unit MEM18056B (Diagnose and repair analog equipment and components) should also be selected.

Band:

This unit has dual status and is to be regarded as both a Specialisation band A unit and Specialisation band B unit for progression to C5 (AQF level V).

Unit Weight: 6

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

MEM18060B

Maintain, repair control instrumentation - single and multiple loop control systems

MEM18062B

Install, maintain and calibrate instrumentation sensors, transmitters and final control elements

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

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

ELEMENT

PERFORMANCE CRITERIA

1. Determine control loop characteristics

1.1. Engineering specifications, technical information and historical process, records and trends are examined for relevant data.

1.2. Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented to standard operating procedures.

1.3. Programmed maintenance/service reports are read and relevant data noted.

1.4. Data is analysed and control loop characteristics are ascertained.

2. Record control loop responses

2.1. Using chart recorders and data loggers, control loop responses are recorded in open and closed loop mode.

2.2. Unit is tested for tuning using appropriate diagnostic techniques.

2.3. Diagnostic results are analysed against specifications.

3. Tune control loops

3.1. 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.

3.2. Recording equipment used for monitoring and adjustment of control loop components during controller tuning operations is corrected and tested.

3.3. Step response - open loop tuning calculations are applied to achieve specified loop characteristics.

3.4. Closed loop tuning methods using ultimate sensitivity and systematic trials are used to achieve specified loop characteristics.

3.5. Correct sequence of tuning is used on multi controllers and/or multi element systems to achieve specified characteristics.

3.6. Control loops are tuned to optimum mode settings utilising correct and appropriate techniques, tools, test equipment and procedures.

4. Complete service reports

4.1. Service reports are completed to standard operating procedures.

4.2. Appropriate follow up procedures are adopted.

4.3. Process control loop is recommissioned to specifications.

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 function/malfunction of the system and/or its components

checking operational characteristics of control devices, signal conversion instruments and final control elements for conformance to specification

identifying faults/defects in control system components

locating/reading in-built fault indicators and error codes

obtaining relevant pneumatic, electrical and electronic circuit diagrams

determining corrective action and interpreting trends from operational data

testing/monitoring the control loop for correct operation

monitoring and recording operational responses of the control system/loop

using appropriate fault-finding 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

dismantling/disassembling 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 tuning/calibration techniques

mathematical computations including algebra, exponentials and logarithms, equations, graphs, charts, vectors, complex numbers, Boolean algebra

relevant data, including information from in-built 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 computer-based systems

procedures for documenting/reporting 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

fault-finding and diagnostic techniques throughout the monitoring and testing process

deviations/variations 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 and/or 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 item(s)

procedures for assembling repaired and/or 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

reporting/recording requirements associated with the commissioning of the control system

follow-up actions to be undertaken after maintaining/repairing control system instrumentation

procedures for commissioning the control system

safe work practices and procedures

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, 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

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

Unit sector

Maintenance and diagnostics

This unit contains employability skills.