Unit of competency Outline
Date retreived
22/07/2026 9:57 PM AWST
22/07/2026 9:57 PM AWST
Whilst all efforts are made to provide accurate and timely information from the relevant source/documentation, please be aware that the information supplied may not be the most current version. The accuracy of the detail has not been confirmed by the Department and therefore should not be relied upon without first confirming the contents.
Maintain/calibrate complex control systems
Maintain/calibrate complex control systems
Unit of competency
National Code
MEM18061B
MEM18061B
State Code
W5608
W5608
TGA Status
Replaced
Replaced
DTWD Status
Transition (Replaced)
Transition (Replaced)
State Implementation and Classification
Approved Date
26/10/2006
Field of Education
030701 - Mechanical Engineering
Original Release Date
26/10/2006
Nominal Hours
72
Description
This unit covers determining system specification and control loop characteristics, and testing, monitoring and recording system operation.
Notes
Elements and Performance Criteria
1. Determine system specifications and control loop characteristics
- 1.1. Engineering specifications, technical information and historical records and trends are examined and relevant data is documented.
- 1.2. System specifications and operational data including those for multiple loop control systems and devices are obtained, read and interpreted.
- 1.3. Circuit and logic diagrams and configuration data are obtained, read and interpreted.
- 1.4. Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented by appropriate means.
- 1.5. Appropriate work clearances are obtained for monitoring and testing the system.
2. Test, monitor and record system operation
- 2.1. Relevant data is collected by appropriate means from all sources including maintenance records, chart recorders, data loggers, fault indicators, error codes, operational symptoms, tests and observation monitoring.
- 2.2. Fault detection and diagnostic data are analysed against predetermined operational specifications, and conclusions are documented.
- 2.3. System operation is observed using knowledge of all individual/multiple element loop device characteristics, controller mode principles, testing, calibration and adjustment methods.
- 2.4. Appropriate test equipment is set up and used correctly.
- 2.5. Appropriate tests are undertaken using standard operating procedures.
- 2.6. Signal transmission test equipment is set up and used where applicable.
- 2.7. Adjustment/maintenance needs are determined through interpretation and analysis of pneumatic, electrical, electronic, logic diagrams and configuration data for all control system devices.
- 2.8. Appropriate field instrumentation is connected to test system configuration.
- 2.9. Field instrumentation is connected and tested for selected control operation, and performance is monitored against specifications.
- 2.10. Diagnostics checks are carried out to ensure correct operation.
- 2.11. Fault finding and diagnostic tests are undertaken using correct equipment, techniques and procedures to detect faulty control system components or elements.
3. Localise fault condition
- 3.1. System is tested to the level necessary to detect and localise fault condition.
- 3.2. Fault condition is localised and verified using appropriate test equipment, principles and processes.
- 3.3. Fault condition is analysed, evaluated and corrective action is planned.
4. Replace faulty items or repair faulty condition
- 4.1. Faulty items are dismantled for repair or replacement using appropriate tools, equipment and procedures according to manufacturers' recommendations.
- 4.2. Replaceable items are selected from manufacturers' catalogues, spare parts lists, or data sheets.
- 4.3. Using manufacturers' handbooks, correct maintenance procedures for faulty items are established.
- 4.4. Faulty items and/or condition are repaired using correct maintenance procedures and equipment.
- 4.5. Repaired and replaceable items are reassembled using appropriate principles, tools, equipment, techniques and test procedures.
5. Calibrate, configure, adjust complex control systems
- 5.1. Diagnostic checks are carried out to ensure correct operation of system, taking appropriate corrective action as necessary.
- 5.2. Correct calibration and test equipment is selected/set up to enable calibration to manufacturers' specifications.
- 5.3. Mechanical alignment of control devices is undertaken where applicable.
- 5.4. System is configured using appropriate programming tools and techniques.
- 5.5. Relevant alignment procedures are performed for optimum control and in accordance with specifications.
- 5.6. Correct sequence of alignment is used on multiple control loops and multi-element systems.
- 5.7. Correct recording equipment is set up for adjustment and monitoring during alignment.
- 5.8. Calibration and adjustment function are performed on multi-loop devices, multi-element control loops, controller modes and actions according to operational specifications using correct principles and methods applicable to the type of control loop being serviced.
- 5.9. On-line changes are made to parameters in the system to meet specified requirements.
- 5.10. Field instrumentation is connected for selected control operation and system is operated to a satisfactory level of control.
6. Return system to service
- 6.1. Final adjustments to align system operation to operational specifications including process and optimum control efficiencies are undertaken.
- 6.2. Correct procedures are applied in return to service including configuring, calibrating, adjusting, tuning and final validation of system performance in accordance with specifications.
- 6.3. System is returned to service.
- 6.4. Service reports are completed to standard operating procedures.
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.
Control loop
A process of documenting and recording measurements and variables within the process
Test equipment
Engineer level, laser alignments etc., and appropriate equipment for measurement of alignment, flatness, squareness, straightness, temperature, vibration, load deflection, noise level, RPM
Tests
Measuring and analysing to ensure correct operation
Control system
Control systems include pneumatic control, analog and/or digital electronics, distributed PLC, DCS, SCADA, and computer-based control systems. Computer-based control systems may include supervisory mode
Field instrumentation
Test and measuring equipment which could include specialised testing fixtures or equipment
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.
Control loop
A process of documenting and recording measurements and variables within the process
Test equipment
Engineer level, laser alignments etc., and appropriate equipment for measurement of alignment, flatness, squareness, straightness, temperature, vibration, load deflection, noise level, RPM
Tests
Measuring and analysing to ensure correct operation
Control system
Control systems include pneumatic control, analog and/or digital electronics, distributed PLC, DCS, SCADA, and computer-based control systems. Computer-based control systems may include supervisory mode
Field instrumentation
Test and measuring equipment which could include specialised testing fixtures or equipment
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/calibrate complex control 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 maintaining/calibrating complex 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, standards, manuals and reference materials.
Guidance information for assessment
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/calibrate complex control 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 maintaining/calibrating complex 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, standards, manuals and reference materials.
Guidance information for assessment
Replaced By
| State Code | National Code | Title | Type |
|---|---|---|---|
| OAU56 | MEM18061 | Maintain/calibrate complex control systems | Unit of competency |
| State Code | National Code | Title | Type |
|---|---|---|---|
| W245 | MEM40105 | Certificate IV in Engineering | Qualification |
| W247 | MEM50105 | Diploma of Engineering - Advanced Trade | Qualification |