MEM18060B Maintain, repair control
instrumentation - single and multiple loop
control systems
Release: 1
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
MEM18060B Maintain, repair control instrumentation - single and
multiple loop control systems
Modification History
Not Applicable
Unit Descriptor
Unit descriptor This unit covers determining control loop characteristics,
monitoring and recording the operation of a control loop,
localising the fault condition, and replacing or repairing the
faulty condition.
Application of the Unit
Application of the unit This unit applies to split architecture single/multi loop
control instrumentation that includes PLCs, distributed
control systems (DCS) and computer-based systems. This
unit also includes the basic adjustment of controller
modes, checking of the loop operation, identification and
fault finding of simple and multiple controller type
controls schemes and the adjustment of controller modes.
Where fault finding is required to electronic component
level, Unit MEM18056B (Diagnose and repair analog
equipment and components) and/or Unit MEM18065B
(Diagnose and repair digital equipment and components)
should also be selected.
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).
Band: A
Unit Weight: 8
Licensing/Regulatory Information
Not Applicable
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
Pre-Requisites
Prerequisite units
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, calibrate
instrumentation systems and
equipment
MEM18055B Dismantle, replace and assemble
engineering components
MEM18057B Maintain/service analog/digital
electronic equipment
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
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
Prerequisite units
equipment
MEM18055B Dismantle, replace and assemble
engineering components
MEM18062B Install, maintain and calibrate
instrumentation sensors,
transmitters and final control
elements
MEM18064B Maintain instrumentation system
components
Employability Skills Information
Employability skills This unit contains employability skills.
Elements and Performance Criteria Pre-Content
Elements describe the Performance criteria describe the performance needed to
essential outcomes of a demonstrate achievement of the element. Where bold
unit of competency. italicised text is used, further information is detailed in the
required skills and knowledge section and the range
statement. Assessment of performance is to be consistent
with the evidence guide.
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
Elements and Performance Criteria
ELEMENT PERFORMANCE CRITERIA
1. Determine control 1.1.Engineering specifications, technical information
loop operating and historical trends are examined for relevant data.
characteristics 1.2.System specifications, operational data and other
relevant data sources are examined, read, interpreted
and relevant conclusions are noted.
1.3.Consultation with system operators and other
relevant plant personnel is carried out, and relevant
data is extracted and documented by appropriate
means.
1.4.Using knowledge of all control loop device
characteristics, controller mode principles and
adjustment methods, operation of the system is
observed.
1.5.Appropriate test equipment and testing procedures
are used.
1.6.Fault finding and diagnostic techniques are utilised.
1.7.Relevant data is collected by appropriate means from
all sources including maintenance records, fault
indicators, charts, error codes operational symptoms,
observation monitoring and consultation with
appropriate personnel.
2. Monitor and record 2.1.Pneumatic, electrical and electronic circuit diagrams
operation of a control are interpreted and understood.
loop 2.2.Using knowledge of all control loop device
characteristics, controller mode principles and
calibration/adjustment methods, loop operation from
the controller response to set point and manual
output changes using correct test equipment,
principles and procedures are check tested and
monitored.
2.3.Software configuration data for digital control
systems is interpreted.
2.4.Operational responses are monitored and recorded
by appropriate means.
2.5.Fault finding and diagnostic techniques are utilised
throughout checking and testing procedures
including simple and multi-controller type control
schemes.
2.6.Diagnostic results and conclusions are analysed
against predetermined operational specifications.
3. Localise fault 3.1.Circuits are tested to the level necessary to identify
condition and localise faults.
3.2.Drawings/diagrams and operational testing data are
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
ELEMENT PERFORMANCE CRITERIA
utilised in identifying and localising fault conditions.
3.3.Fault condition is localised and verified to major
component level using appropriate test equipment,
principles and procedures.
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
ELEMENT PERFORMANCE CRITERIA
4. Replace or repair 4.1.Components are dismantled for repair or
faulty condition replacement using appropriate tools, equipment and
procedures.
4.2.Replaceable items are selected from manufacturers'
catalogues, spare parts lists, or data sheets.
4.3.Serviceable items are repaired using correct
principles, tools, equipment and procedures.
4.4.Repaired and replaceable items are reassembled
using appropriate tools, equipment, techniques and
procedures.
5. Calibrate and adjust 5.1.Panel mounted, split architecture single
control loop/multiple loop control instruments are calibrated
instrumentation and adjusted using correct calibration principles,
equipment and methods for all devices according to
manufacturers' instructions.
5.2.Adjust controller modes and actions are adjusted
according to specifications.
5.3.Zero span and range checks are undertaken using
correct and appropriate configuration.
5.4.Correct and appropriate procedures, techniques,
tools and equipment are used to make final
adjustments to control instrumentation to
specifications.
6. Complete service 6.1.Service reports are completed to standard operating
reports and procedures.
recommission 6.2.Appropriate follow-up procedures are adopted.
6.3.Control instrumentation is recommissioned to
standard operating procedures.
Required Skills and Knowledge
REQUIRED SKILLS AND KNOWLEDGE
This section describes the skills and knowledge required for this unit.
Required skills
Look for evidence that confirms skills in:
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
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
REQUIRED SKILLS AND KNOWLEDGE
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
testing and monitoring the control loop for correct operation
monitoring and recording responses of the control system
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
completing all necessary reports including appropriate follow-up procedures
commissioning the control system
interpreting trends from operational data
interpreting information from in-built devices
calculating control loop characteristics
Required knowledge
Look for evidence that confirms knowledge of:
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
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
REQUIRED SKILLS AND KNOWLEDGE
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
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
Evidence Guide
EVIDENCE GUIDE
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 maintain, repair control instrumentation -
single and multiple loop control systems. Competency in
this unit cannot be claimed until all prerequisites have
been satisfied.
Critical aspects for assessment and Assessors must be satisfied that the candidate can
evidence required to demonstrate competently and consistently perform all elements of the
competency in this unit 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 This unit may be assessed on the job, off the job or a
assessment 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 maintaining, repairing control instrumentation -
single and multiple loop control 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,
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
EVIDENCE GUIDE
standards, manuals and reference materials.
Guidance information for
assessment
Range Statement
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 trends 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
Major components can include Transducers, power supplies, removable circuit
boards, sensor units and other like components
Unit Sector(s)
Unit sector
Co-requisite units
Co-requisite units
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
MEM18060B Maintain, repair control instrumentation - single and multiple loop control systems Date this document was generated: 5 October
2012
Competency field
Competency field Maintenance and diagnostics
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© Commonwealth of Australia, 2012 Manufacturing Skills Australia
