Contentsiascsectorskillcouncil.in/uploads/documents_info/QP... · Contents What are Occupational Standards (OS)? OS describe what individuals need to do, know and ... Instrument Air

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QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR INSTRUMENTATION

AUTOMATION SURVEILLANCE AND COMMUNICATION INDUSTRY

Contents

What are Occupational Standards (OS)?

OS describe what individuals need to do, know and understand in order to carry out a particular job role or function

OS are performance standards that individuals must achieve when carrying out functions in the workplace, together with specifications of the underpinning knowledge and understanding

C o n t a c t U s : IASC Sector Skill Council 201-202 STBP NSIC Complex (Gate No. 02), Okhla Industrial Area, New Delhi-110020 Phone: +91-11-41072471-73

E-mail: [email protected]

1. Introduction and Contacts……….…..P1

2. Qualifications Pack……….……...........P2

3. Glossary of Key Terms ………….…..…P4

4. OS Units……….……………..…..….….…. P2

5. Nomenclature for QP & OS…..…..…P50

6. Assessment Criteria........................P52

Introduction

Qualifications Pack- Instrumentation Technician

(Process Control)

SECTOR: Instrumentation Automation Surveillance & Communication

SUB-SECTOR: Instrumentation, Automation

OCCUPATION: Maintenance

REFERENCE ID: IAS/Q3002

ALIGNED TO: NCO-2015/ NIL

Instrumentation Technician (Process Control) is employed in Process

industries such as - Oil Refineries, Petrochemicals, Fertilizer Units, Power

Plants Steel, Pharmaceuticals and other Process industries.

Brief Job Description: Instrumentation Technician (Process Control) carries out duties related to operation, preventive maintenance and breakdown maintenance of instrumentation and control systems in process plants.

Personal Attributes: This job requires the individual to be disciplined, assertive, team player, possess analytical skills and problem solving ability, effective communicator and have the ability to work for long hours and under pressure.

mailto:[email protected]

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Qualifications Pack For Instrumentation Technician (Process Control)

Job

Det

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Qualifications Pack Code IAS/Q3002

Job Role Instrumentation Technician (Process Control)

Credits(NSQF)

TBD

Version number

1.0

Sector

Instrumentation, Automation Surveillance and Communication

Drafted on

01/06/2017

Sub-sector

Instrumentation, Automation

Last reviewed on

01/06/2017

Occupation

Operation and Maintenance

Next review date

01/06/2019

Job Role

Instrumentation Technician (Process Control)

Role Description

Instrumentation Technician (Process Control) carries out duties related to operation, preventive maintenance and breakdown maintenance of instrumentation and control systems in process plants.

NSQF level 4 ---------------------------------------------------------------------------------------

Minimum Educational Qualifications 12th pass, Preferably ITI - Instrumentation/Electrical/Electronics Maximum Educational Qualifications NA

Training (Suggested but not mandatory)

Basic and Advance Training course on Instrumentation, PLC and Control Loops and Maintenance (eight weeks duration each)

Minimum Job Entry Age 20 years

Experience

1 - 3 years relevant industry experience, depending on qualification For 12th pass: Three years, as Junior Instrumentation Technician For ITI - Instrumentation/Electrical/Electronics: Two years, as a general Instrumentation Technician For Diploma in Instrumentation/Electronics/Electrical: One year, as a general Instrumentation Technician

Applicable National Occupational

Standards (NOS)

Compulsory: 1. IAS/N0300 Site Readiness and Instrument Usability – Process Control 2. IAS/N0301 Preventive Maintenance – Process Control 3. IAS/N0103 Task reporting – Process Control 4. IAS/N0105 Safety, Health and Environment – Process Control 5. IAS/N2105 Work Effectively With Teams 6. IAS/N0106 Predictive, Corrective and Shutdown Maintenance – Process Control 7. IAS/N0107 Instrument Installation and Loop Testing

Optional:

N/A

Performance Criteria

As described in relevant OS units


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Keywords /Terms Description

Automation Industrial automation deals primarily with the automation of manufacturing, quality control and material handling processes. General purpose controllers for industrial processes include Programmable logic controllers, stand-alone I/O modules (input output modules) and Distributed control system (DCS)

Control Valves

Control valves are valves used to control conditions such as flow, level, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers. Control Valve is also termed as the” Final Control Element”.

Control Valve Actuator

An actuator is a control mechanism that is operated by an energy source. This energy can be pneumatic pressure, electric current or hydraulic pressure, which moves the internal mechanical parts of the actuator which in turn opens close or partially open control valve.

Control Valve Positioner

The opening or closing of control valves is usually done automatically by electrical, hydraulic or pneumatic actuators. Positioners are used to control or modulate the opening or closing of the actuator based on pneumatic or electric signals.

Core skills/generic skills

Core skills or generic skills are a group of skills that are key to learning and working in today’s world. These skills are typically needed in any work environment. In the context of the OS these include communication related skills that are applicable to most job roles.

Description Description gives a short summary of the unit content. This would be helpful to anyone searching on a data base to verify that this is the appropriate OS they are looking for.

Digital Valve Controller

Digital valve controllers use microprocessors and have become the dominant replacement technology for conventional and electro-pneumatic positioners .They offer control valve diagnostics which is assistance to Predictive Maintenance.

Function Function is an activity necessary for achieving the key purpose of the sector, occupation, or area of work, which can be carried out by a person or group of persons.

Flow Coefficient (Cv) and Flow Rate (F)

Cv = Flow coefficient or flow capacity rating of valve. F = Rate of flow (US gallons per minute). In more practical terms, the flow coefficient Cv is the volume (in US gallons) of water at 60°F that will flow per minute through a valve with a pressure drop of 1 psi across the valve. Used for Control Valve sizing.

Flow Coefficient (Kv)

Kv is the flow factor, i.e. rate of flow of cold water in cubic meters per hour at a pressure drop of 1 kg/cm squared. Kv is in metric units and does not require US gallons and PSI units. Kv = F*square root of specific gravity/DeltaP F = rate of flow (cubic meters per hour) SG = relational specific gravity of fluid with reference to water=1 Delta P = pressure drop across valve (1 bar or 100Kpa) Conversion formula: Kv=(0.865)(Cv)

Instrumentation Instrumentation is the variety of measuring instruments to monitor and control a process. It is the art and science of measurement and control of process variables within a production, laboratory, or manufacturing area.

Instrument air Instrument air is special compressed air used for pneumatic control valves and accessories such as Valve positioners.


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Instrument air Standard

Instrument Air Quality Standard (ANSI/ISA-S7.0.01-1996)

Job Role Job role defines a unique set of functions that together form a unique employment opportunity in an organization.

Knowledge and understanding

Knowledge and understanding statements which together specify the technical, generic, professional and organizational specific knowledge that an individual needs in order to perform to the required standards.

National occupational standards

NOS are occupational standards which apply uniquely in the Indian context.

Occupation Occupation is a set of job roles under which role holders perform similar/related set of functions in an industry.

Organizational context

Organizational context includes the way the organization is structured and how it operates, including the operative knowledge managers have of their relevant areas of responsibility.

OS (Occupational Standards)

OS specify the standards of performance an individual must achieve when carrying out a function in the work place together with the knowledge and understanding they need to meet that standard consistently. Occupational standards are applicable both in Indian and global contexts.

Performance Criteria Performance criteria are statements that together specify the standards of performance required when carrying out a task.

Qualification pack code

Qualification pack code is a unique reference code that identifies a qualification pack.

Scope Scope is a set of statements specifying the range of variables that an individual may have to deal with, carrying out the function which has a critical impact on the quality of performance required.

Standards Bodies for Control Valve

American Petroleum Institute (API) American Society of Mechanical Engineers (ASME) European Committee for Standardization (CEN) International Society of Automation (ISA) International Electro technical Commission (IEC) International Standards Organization (ISO) American National Standards Institute (ANSI) NACE International, a professional organization for the corrosion testing and chemical resistance IS 10189-(1982) Industrial Process Control Valve–General requirements and test IS/IEC 60534-2-3(1997) Industrial Process Control valve-Flow Capacity test procedure

IS 6157(191) Valve inspection test (Indian standards listed are only indicative and not exhaustive)

Sector Sector is a conglomeration of different business operation having similar businesses and interests. It may also be defined as a distinct subset of the economy whose components share similar characteristics and interests.

Sub Sector Sub sector is derived from a further breakdown based on the characteristics and interests of its components.

Technical Knowledge Technical knowledge is the specific knowledge needed to accomplish specific designated responsibilities.

Unit Code Unit code is a unique identifier for an ‘OS’ unit which can be denoted with either ‘O’ or ‘N’.

Unit title Unit title gives clear overall statement about what the incumbent should be able to do.


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Valve

A valve is a device used for the control of fluid flow. It consists of a fluid retaining assembly, one or more ports between end openings and a movable closure member which opens, restricts or closes the port(s).

Keywords /Terms Description

CM Corrective Maintenance

DCS Distributed Control System

ESD Emergency Shut Down system

IBR Indian Boiler Regulations

PLC Programmable Logic Controller

PM Preventive Maintenance

PRM Proactive Reliability Maintenance

PST Partial Stroke Test, of control valve

PST Partial Stroke Testing of Control Valve

SHE Safety, Health and Environment VFD Variable Frequency Drive

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IAS/N0300 Site Readiness and Instrument Usability - Process Control

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National Occupational

Standard

Overview

This unit is about maintenance of site for its readiness and usability of instrumentation and control systems in the plant at regular intervals.


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Unit Code

IAS/N0300

Unit title (Task)

Site Readiness and Instrument Usability - Process Control

Description

The OS unit is about maintaining general Site Readiness and Instrument Usability as applicable for process control industry

Scope The scope of this task includes:

Instructions relating to Process Plant

Permits to work, Check Sheets & Formats

Plant working and Instrumentation documents

Field Instrumentation, control loops & Control valves On line Analyzers and Analyzer House

DCS & PLC

Package Units –Boilers, Heaters, Compressors, Chillers etc.

Fire and Gas Detection system

Site Guidelines of Field Installations – Visual, Integrity Checks & Electrical Safety norms

Site Guidelines – House Keeping and Lighting Site Guidelines –Consumables, Execution and Follow up action

Performance Criteria (PC) with respect to the scope

Element


Observe Instructions relating to Process Plant

PC1. Follow Process Plant related instructions and directives, including equipment, location, lay out, procedures, forms etc. covering:

Process package units such as Boilers, compressors, heaters, chillers including equipment location /lay out etc.

Work Permits

Various formats and Check Sheets

Field Instrumentation and Control loops Recognize and locate Control Valves

Recognize and locate On line Analyzers and Analyzer House

Recognize and locate DCS and PLC

Recognize and locate Fire and Gas systems Safety, Health, Environment and emergency procedures


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Follow Processes regarding Work Permits, Check Sheets & Formats

PC2. Follow rules regarding various permits to work and use the right one depending on the job he/she undertakes. This includes:

Normal working in plant – WHITE permit

Drilling, Grinding, Welding, Gas cutting in plant - RED Permit or Fire Permit.

Excavation work for underground cables and pipe work etc.- EXCAVATION Permit

PC3. Understand the purpose of Check sheets used in Instrumentation Maintenance work and make entries in it:

Site Hygiene Check Sheets

Calibration Check Sheets Preventive Maintenance check sheets

Follow plant working and instrumentation documents

PC4. Read and Use the Plant working document relevant to a particular Instrument tag/control loop he/she is working on, as required, relating to:

Main Process Plants

Package units such as Boilers, Heaters, Compressors Chillers etc.

PC5. Read and use the Instrumentation document relevant to a particular Instrument tag he/she is working with, as required:

P and I diagram

Instrument Index

Data Sheets

Hook Up diagram

Loop diagram

Instrument lay out diagram.

Wiring Diagrams

Cause and Effect diagram

Support Servicing of Field Instrumentation and Control valves under guidance

PC6. Attend to maintenance requests and resolve the problems with guidance. Request for supervisor’s advice and assistance during difficult problem resolution. This includes:

Measurement sensors and associated impulse lines/sensor cables

Pneumatic/electronic transmitters

Controllers and control room receivers

Control valves and other final control elements.

PC7. Perform basic overhaul and testing under supervision.

Globe, Cage type, Butterfly, Rotary control valves

Control Valve accessories, Solenoid Valves, Fail safe shut down devices

Pneumatic and Digital Valve positioners

Control Valve Data Sheet, control Valve characteristics i.e. quick opening, equal percentage, Linear

Overhaul, testing and calibration of Control Valves

Perform routine checks for On line Analyzers and Analyzer House

PC8. Carry out routine checks of:

Analyzer sampling system

Sensor and electronics section (liquid analyzers, Gas analyzers, Gas Chromatograph etc.)

Receivers and accessories in Analyzer house.

Calibration Gas cylinders storage and procedures.


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Identify and locate DCS & PLC devices

PC9. Locate the field devices and identifies the interface units – able to work on the system with guidance.

Locate and identify trouble in Package Units –Boilers, Heaters, Compressors, Chillers etc.

PC10. Locate faults relating to operation of package units, location, relates instrument tags to respective Process package unit and undertakes routines and perform basic trouble shooting in these units.

Locate Fire and Gas Detection system and Maintain under guidance

PC11. Refer to overview of fire and gas detection, Locate the main field devices, identify interface units and perform maintenance work on the system with guidance.

Follow Site Guidelines of Field Installations – Visual , Integrity Checks and Electrical Safety norms

PC12.Check for visual damage, tampering:

Check for visible damage to specified Instruments (in an inventory list or otherwise provided by the Supervisor) caused by impact of an external body.

a. Check for prominent damage to Accessories of the specified Instruments caused by impact of an external body.

b. Check for water ingress in indoor working area due to seepage/roof leaks /damaged windows.

c. Check for misuse of installation by other agencies for example, using instrument installation as support or for scaffolding build up.

d. Check for prominent deterioration due to environment for example, corrosion / proximity to hot surfaces / process leaks etc.

PC13. Check for any visible loss of installation integrity. Integrity here means that the instrument and the installation is in a healthy working condition without any unusual appearance, breakage or foreign objects fallen in/on/around the installation which is likely to cause or lead to instrument malfunction.

a. Check for improper closure of junction boxes, panels, cable termination.

b. Check for improper tubing /impulse piping connection c. Check for unauthorized /unexplained cable connection disconnection d. Check for unauthorized /unexplained process impulse lines /

instrument air connection /disconnection.

PC14. Check for potential electrical problems due to deviation from standard electrical practices

a. Check for unused flood light /field plug connections with trailing cable. b. Check for bare, untagged or un-insulated wires c. Check for any modifications or deviation in explosion proof enclosures

and intrinsic safety installation with special focus on bolting integrity d. Check to ensure no deviation in ex proof enclosures and intrinsic safety

installation with special focus on bolting integrity

Follow guidelines regarding House Keeping and Lighting

PC15 Check for floor condition and cluttering of items

Check for wet/slippery work areas, improper storage of items and cluttering of items on work areas. These are potential safety hazards

PC16. Check for lighting and their operation. Check for unsafe temporary wiring of lighting.


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Check in plant and indoor areas

Monitor and maintain Consumables and perform follow-up

PC17. Check consumption and storage of consumables. Check for excessive consumption /visible wastage of cleaning solvents,

lubrication oil and grease

Check for excessive consumption of other

related consumables such as waste cloth and gloves

Check for proper storage of solvent and waste cloth (potential fire hazard).

PC18. Complete follow up action as per assigned areas of responsibility and stipulated instructions. Items found unusual outside this boundary to be reported to supervisor.

Complete entry of relevant site Readiness check sheet and obtain required approval /endorsement.

Replace protective covers which have been removed

Knowledge and Understanding(K)

A. Organizational context (Knowledge of the company / organization and its process relevant to areas of responsibilities)

The technician on the job needs to:

KA1. Understands the purpose of the process plant and its operations.

KA2. Understands the layout of the plant and the location of various facilities.

KA3. Understands site conditions and how these impact the operation of instrumentation and control equipment.

KA4. Understands the organization and reporting structure

KA5. Understands rules and regulations to be followed under normal and emergency conditions

KA6. Understands working hours, shifts, off days and leave entitlements

KA7. Understands the job description and responsibility, if any.

B. Technical Knowledge

The technician on the job needs to know and understand:

KB1. Type of chemicals and other process material used in the organization and how these impact the site conditions

KB2. Hazardous chemicals and their handling procedures.

KB3. Type of instruments and controllers used in the plant.

KB4. Type of instruments, accessories and their locations that falls under the individual’s domain of work.

KB5. How instrumentation is located using plant layout drawings.

KB6. How instrumentation maintenance is performed in the organization.

Skill(s)

A. Core Skills / Generic Skills

Writing skills

The individual on the job needs to know and understand how to: SA1. Use Formats and check list for Site Readiness planning and reports SA2. Write emails and messages about site related issues


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Reading Skills

The individual on the job needs to read and understand: SA3. Company policy related to site Readiness SA4. Formats for site Readiness check sheets, list

Oral Communication (Listening and Speaking skills)

The individual on the job needs to know and understand how to: SA5. Describe condition of instruments and accessories and issues to coworkers and supervisor SA6. Communicate to the management in meetings about site issues which need management attention SA7. Interact with coworkers and gather information related to process and instruments conditions

B. Professional Skills

Decision Making

The individual on the job needs to know and understand how to: SB1. Make decisions about the site, in consultation with the Supervisor

Plan and Organize

The individual on the job needs to know and understand how to: SB2. Prioritize daily tasks to conduct site survey effectively

Customer Centricity

The user/individual on the job needs to know and understand how to: SB3. Understand real needs of the customer and suggest most appropriate

solution SB4. Support customer when they need help

Problem Solving

The individual on the job needs to know and understand how to: SB5. Diagnoses reasons for down time due to instrument failure SB6. Track recurring failures in instruments for reasons and concludes SB7. Identify immediate or temporary solutions to resolve delays and discuss with the Supervisor

Analytical Thinking

The user/individual on the job needs to know and understand how to: SB8. Use the existing information to arrive at actionable decision points SB9. Use the existing information for improving the customer satisfaction SB10. Use the existing information to optimize solution and company business SB11. Analyze problems and identify causes and possible solutions

Critical Thinking

The user/individual on the job needs to know and understand how to: SB12. Apply, analyze, and evaluate the information gathered from observation, experience, reasoning, or communication, as a guide to thought and action SB13. Anticipate problems, risks and opportunities and utilize these for mitigation and business optimization


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NOS Version Control

NOS Code

IAS/N0300

Credits (NSQF)

TBD

Version

1.0

Industry

Instrumentation, Automation Surveillance & Communication

Drafted on

01/06/2017

Industry Sub Sector


Last viewed on

01/06/2017

Occupation

Maintenance

Next Review Date

01/06/2019

B ac k to t o p …

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IAS/N0301 Preventive Maintenance - Process Control

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Standard

Overview

The unit is about conducting regular Preventive Maintenance activities of Instruments, Control Valves and accessories in a Process Plant.

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Unit Code

IAS/N0301

Unit title (task)

Preventive Maintenance – Process Control

Description

The OS unit is about performing Preventive Maintenance for general instrumentation in Process Controls under guidance.

Scope This Unit Task covers the following : Obtaining PM-work permit.

Organizing PM-Preparatory tasks

Executing PM-Schedule Preparing PM-Process List

PM-Planning

Performing PM-Visual Checks & action

Completion of PM schedule. Preparing PRM-List

Listing PM to be taken during Shut down

Following up consolidated PM list

Performance Criteria (PC) with respect to the scope:

Element


Obtain PM-work permit

PC1. Obtain work permit (mandatory) from the Process supervisor before commencing maintenance work.

Organize PM- Preparatory tasks

PC2. Organize for the day’s Preventive Maintenance task which include: Check sheets and related documents

Tools and tackles and calibrating equipment

Personal protective safety equipment

Execute PM Schedule

PC3. Execute Preventive maintenance jobs as per available Preventive Maintenance Schedule.

Prepare PM-Process List

PC4. Prepare Process list from process supervisor.

Plan PM Schedule

PC5. Plan for next day’s preventive maintenance schedule

Perform PM Visual Checks & Actions

PC6. Carry out Visual Checks & takes corrective actions wherever possible or else transfer job to shut down list.

Check abnormal noise & locates source.

Check for abnormal vibration – locates source- corrects /informs supervisor.

Check for gland leak and arrests .If not possible informs supervisor and transfers to shut down list

Check for Instrument air leaks –arrests leak-if not possible informs supervisor and transfers to shut down list

Check for control valve bonnet and body flange leaks-informs Process supervisor& Instrument supervisor

Check for poor electric integrity like exposed terminal and opens enclosure- rectifies. If not permitted informs supervisor& transfer to

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shut down list Check pneumatic and electric connections to solenoid valve

Check for pneumatic connections in Pneumatic transmitters and or I/P converters

Check for integrity of valve positioners’ feedback link/connection and rectifies fault after informing Process supervisor

Check for environment impact, water ingress/corrosion rectifies fault. Or else .transfers to shut down list.

Check for loose bolting and rattling in control valve and accessories including manual operator- rectifies fault

Complete PM schedule

PC7. Complete preventive maintenance schedule list of Field Instrumentation and controls. Close the list.

Prepare PRM List

PC8. Collect and consolidate daily-diagnostic messages from control valves which have a digital valve controller and Smart Transmitters and record the same in either Preventive Maintenance list or Opportunistic shut down list for execution.

List PMs to be performed during Shut down

PC9. Include preventive maintenance jobs during annual shut down or opportunistic shut down list.

Follow up PM consolidated list

PC10. Follow up on consolidated preventive maintenance list and closes list.

Knowledge and Understanding

A. Organizational context (Knowledge of the company organization and its process relevant to area of responsibilities)

Needs to know and understand : KA1. Understands PM(Preventive Maintenance ) norms as defined by the company KA2. Understands Production targets and production loss figures for the month and contribution by control valves KA3. Aware of Maintenance Policy of the company with respect to control valve maintenance strategy


Needs to know and understand: KB1. Trouble Shooting of:

Control valve body including valve movement and glands.

Actuator section and valve positioners and diagnostic messages from Digital Valve controller Control valve accessories Solenoid valve and Limit switches

KB2. Hazardous area zone classification and process media hazards KB3. Use of Control Valve Manual when required KB4. PST, a feature of DCS

Skill(s)

A. Core Skills / Generic

Writing skills

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Skills The individual on the job needs to know and understand how to:

SA1. Use Formats and check list for Site Readiness planning and reports SA2. Write emails and messages about site related issues

Reading Skills

The individual on the job needs to read and understand: SA3. Company policy related to Preventive Maintenance SA4. Monthly down time and resulting production loss SA5. Use of Work Permit system SA6. Formats for Preventive Maintenance check sheets, predictive maintenance list


The individual on the job needs to know and understand how to: SA7. Describe condition of control valves and accessories and issues to coworkers and supervisor SA8. Communicate to the management in meetings about maintenance issues which need management attention SA9. Interact with coworkers and gather information related to process and control valve conditions


Decision Making

The individual on the job needs to know and understand how to: SB1. Make decisions about timing and extent of preventive maintenance, in consultation with the Supervisor

Plan and Organize

The individual on the job needs to know and understand how to: SB2. Prioritize daily tasks to conduct Preventive Maintenance effectively

Customer Centricity

The user/individual on the job needs to know and understand how to: SB3. Understand real needs of the customer and suggest most appropriate solution SB4. support customer when they need help

Problem Solving

The individual on the job needs to know and understand how to: SB5. Diagnoses reasons for down time due to control valve failure SB6. Track recurring failures in control valves and analyses reasons and concludes SB7. Identify immediate or temporary solutions to resolve delays and discuss with the Supervisor

Analytical Thinking

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Critical Thinking

The user/individual on the job needs to know and understand how to: SB12. Apply, analyze, and evaluate the information gathered from observation, experience, reasoning, or communication, as a guide to thought and action

SB13. Anticipate problems, risks and opportunities and utilize these for mitigation and business optimization

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NOS Version Control

NOS Code

IAS/N0301

Credits (NSQF)

TBD

Version

1.0

Industry


Drafted on

01/06/2017

Industry Sub Sector


Last viewed on

01/06/2017

Occupation

Maintenance

Next Review Date

01/06/2019

B ac k to t o p …

19

IAS/N0103 Task Reporting - Process Control

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Standard

Overview

This unit is about reporting and record keeping as per company processes and defined Service Levels.


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Unit Code

IAS/N0103

Unit title (task)

Task Reporting – Process Control

Description

The OS unit is about reporting and record keeping as per company processes and job description for Instrumentation Technicians.

Scope This Unit Task covers the following :

Reporting- faults

Reporting – PM

Reporting – Corrective Maintenance Reporting – unusual occurrence

Reporting – Theft

Reporting – security breach


Element


Report faults

PC1. Brief and Escalate faults/issues to immediate supervisor

Report completed PM tasks

PC2. Complete entry of preventive maintenance check lists/reports

Report Corrective Maintenance tasks

PC3. Complete entry of Corrective Maintenance Check lists /reports

Report unusual occurrence

PC4. File report on noticing any visible changes in control valve installation or its accessories. Report for immediate attention of supervisor

Report theft

PC5. Report any theft in control valve assembly/spares to supervisor

Report security breach

PC6. Report suspicious movement of new persons near control valve installation to security and supervisor

Knowledge and Understanding (K)

(A) Organizational context

(Knowledge of the company organization and its process relevant to area of responsibilities)

The individual on the job needs to:

KA1. Understand basic company policy and maintenance strategy as applied to control valves

KA2. Understand importance of reporting potential failures during site Readiness visits / Preventive Maintenance checks/Observation to supervisor

KA3. Provide accurate time for jobs undertaken especially during opportunistic /annual shut down to supervisor

KA4. Provide status on critical spares consumption so that supervisor can take proactive steps


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(B) Technical Knowledge

The individual on the job needs to know and understand how to:

KB1. Prepare daily log and failure reports

KB2. Furnish basic data to supervisor related to specification of control valve

KB3. Send internal mails related to PM or Corrective maintenance to supervisor

KB4. Record Maintenance history

Skill(s)

A. Core Skills/ Generic Skills

Writing Skills


SA1: Write mails about work

SA2. Write reports and logs in company prescribed formats

SA3. Make notes about the observations in the plant and share with the supervisor and co-workers as appropriate

SA4. Write to management about feedback and unresolved issues

Reading Skills


SA5. Read and comprehend formats and check lists for preventive and corrective maintenance.

SA6. Read and understand company policies

Oral Communication Skills


SA7. Communicate the issues / faults / corrective actions / warnings / suggestions with complete details to the supervisor and co-workers as appropriate


Decision Making


SB1. Make decisions on a suitable course of action or response keeping in view resource utilization while meeting commitments

Plan and Organize

The individual on the job needs to know and understand:

SB2. How to prioritize jobs during multiple breakdown situation

SB3. Plan and organize work to achieve targets and deadlines

Customer Centricity

The user/individual on the job needs to know and understand how to: SB4. Understand real needs of the customer and suggest most appropriate solution


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SB5. support customer when they need help

Problem Solving


SB6. Can diagnose control valve faults and communicate effectively to Process and Instrumentation Supervisor

Analytical Thinking

The user/individual on the job needs to know and understand how to:

SB7. Use the existing information to arrive at actionable decision points

SB8. Use the existing information for improving the customer satisfaction

SB9. Use the existing information to optimize solution and company business

SB10. Analyze problems and identify causes and possible solutions

Critical Thinking

The user/individual on the job needs to know and understand how to:

SB11. Apply, analyze, and evaluate the information gathered from observation, experience, reasoning, or communication, as a guide to thought and action



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NOS Version Control

NOS Code

IAS/N0103

Credits (NSQF)

TBD

Version

1.0

Industry


Drafted on

01/06/2017

Industry Sub Sector


Last viewed on

01/06/2017

Occupation

Maintenance

Next Review Date

01/06/2019

B ac k to t o p …

24

IAS/N0105 Safety, Health and Environment - Process Control

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Standard

Overview

This unit is about maintenance of Safety, Health and Environment (SHE) in a Process Control Plant. The focus is on the awareness and responsibility of Instrumentation Technicians who are working in the Process Control environment.

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Unit Code

IAS/N0105

Unit title (task)

Safety, Health and Environment - Process Control

Description

The OS unit is about adhering to Safety, Health and Environment (SHE) norms in Process Control plants.

Scope The scope of this task includes following / performing: SHE Instructions

SHE for Personal Protection Directives

SHE Audit

Performance Criteria (PC) w.r.t. the scope:

Element

Performance Criteria (PC)

Follow SHE Instructions PC1. Interpret and follow formal Instructions from SHE Dept. PC2. Participate in the prescribed drills including familiarization of personal protective equipment, fire extinguisher and first aid. PC3. Follow instructions on Work permit, Fire permit and Hazardous Area Classification, Fire and explosion hazards

Follow SHE for Personal Protection

PC4. Use right personal protective equipment Use safety shoes and helmet at all times in plant

Use ear muffs in prescribed high decibel areas

Adapt right posture during lifting of heavy objects. Use correct gas mask/breathing air apparatus as per area and

directives

Use safety goggles and gloves as per directives

Support SHE - Audit PC5. Support supervisor during SHE Audit

Check for leaks

Check for unsafe scaffolding and temporary installations

Check for correct storage of cleaning solvents and consumable such as waste cloth

Ensure safe working in crane movement area.

Check housekeeping including oil and water spillages on floor

Check for improper bolting or open enclosures / junction boxes


A. Organizational context

(Knowledge of the company organization and its process relevant to area of responsibilities)

The individual on the job needs to know and understand how to: KA1. Understands SHE Instruction

Understands Safety, Health and Environment directives

Understands emergency procedures during site emergencies

Understands Hazards in process as well as process media associated with these hazards

26


B. Technical Knowledge The individual on the job needs to know and understand how to: KB1. Demonstrates familiarity and understanding of documents related to SHE

Understands SHE emergency procedures for the site.

Understands Hazardous Area Classifications and Zones 0,1,2 Understands procedures of permits to work issued by Process

personnel for maintenance work.

Skill(s)

A. Core Skills/Generic Skills

Writing skills

The individual on the job needs to know and understand how to: SA1. Use Formats and check list for SHE SA2. Write emails and messages about SHE related issues

Reading Skills

The individual on the job needs to read and understand: SA3. Company’s SHE policy. SA4. Use of Formats and check list for SHE audits SA5. Understands SHE Directives and SOPs related to maintenance work SA6. Product literature and manuals relevant for the job SA7. Company information about working practices at the site SA8. Information displayed at the workplace


The user/individual on the job needs to know and understand how to: SA9. Describe site conditions and issues to co-workers and supervisor SA10. Communicate to the management in meetings about site Readiness issues to get their support SA11. Interact with coworkers and gather information related to process and site conditions


Decision Making

The individual on the job needs to know and understand how to: SB1. Make decisions pertaining to SHE in the concerned area of work

Plan and Organize

The individual on the job needs to know and understand: SB2. Ensures his personal protective equipment and arrangement of tools conform to safe working norms before he commences his /her daily tasks SB3. Follows SOP/Vendor manual safety instructions with respect to dismantling, assembly and gland repair work on control valves and other field instruments

Customer Centricity

The user/individual on the job needs to know and understand how to: SB4. Understand real needs of the customer and suggest most appropriate solution SB5. support customer when they need help

Problem Solving

27


The user/individual on the job needs to know and understand how to: SB6. Think through the problem, evaluate the possible solution(s) and suggest an optimum /best possible solution(s) SB7. Identify immediate or temporary solutions to resolve delays

Analytical Thinking

The user/individual on the job needs to know and understand how to: SB8. Use the existing information to arrive at actionable decision points SB9. Use the existing information for improving the customer satisfaction

Critical Thinking

The user/individual on the job needs to know and understand how to: SB10. Apply, analyze, and evaluate the information gathered from observation, experience, reasoning, or communication, as a guide to thought and action SB11. Anticipate problems, risks and opportunities and utilize these for mitigation and business optimization

28


NOS Version Control

NOS Code

IAS/N0105

Credits (NSQF)

TBD

Version

1.0

Industry


Drafted on

01/06/2017

Industry Sub Sector


Last viewed on

01/06/2017

Occupation

Maintenance

Next Review Date

01/06/2019

B ac k to t o p …

29

IAS/N2105 Work Effectively With Teams

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Standard

Overview

This unit is about working effectively with colleagues, in own work group

and in other work groups within and outside the organization


30

Nati

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Sta

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Unit Code

IAS/N2105

Unit Title (Task)

Work Effectively With Teams

Description

This NOS unit is about building relationships and working with people and groups inside and outside the organization, using skills and habits, to achieve the team goals and objectives.

Scope This unit/task covers the following: • Creating team environment

• Communicating - giving and receiving

• Working cooperatively

• Participating in team decision making

• Demonstrating Sense of Responsibility

• Showing respect for opinions, customs and preferences

Performance Criteria(PC) w.r.t. the Scope

Element


Create Team Environment

To be competent, the individual on the job must be able to: PC1. Know and understand the team objectives and goals PC2. Know team members by name. Greet them appropriately and

respond to their greetings. PC3. Know the roles and responsibilities of team members. Ensure

others know about you and your role in the team PC4. Learn about the culture and preferences of team

members – especially if they belong to other organizations or nationalities

PC5. Follow organization’s policies and procedures for working with team members within and outside the organization – especially relating to privacy, confidentiality and security.

PC6. Create an environment of trust and mutual respect Communicate – Give and Receive

To be competent, the individual on the job must be able to: PC7. Use appropriate mode of communication – verbal, written, mail,

phone or text and clearly articulate your message to ensure that the recipient understands the message.

PC8. Listen to team members and try to understand what they are wanting to say. Seek or provide clarifications if you see any gap in understanding

PC9. Communicate professionally and follow organization protocols. Do not overload the team members with unnecessary and unsolicited information

PC10. Share important information with the team timely. PC11. Respond to communications promptly.


31

Work Cooperatively To be competent, the individual on the job must be able to:

PC12. Perform own role and produce output in time for other team members to consume

PC13. Receive inputs from others and work upon it per role requirement PC14. Make adjustments within the permissible rules so that work flows

smoothly. PC15. Help team members to perform their role effectively and provide any

clarifications and support they need PC16. Share tools and common resources fairly, taking cognizance of

others’ needs and schedules PC17. Resolve any contentious issues amicably, involving the team lead or

the supervisor if needed PC18. Let team members know in good time if you cannot carry out your

commitments, explaining the reasons and alternate solutions, if any. Let the team lead know about this.

Participate in Team Decision making

To be competent, the individual on the job must be able to:

PC19. Think positively and make constructive suggestions to meet the goals PC20. Accept and give suggestions with open mind PC21. Take initiatives and volunteer to contribute PC22. Help team members with facts and figures to arrive at workable

decisions PC23. Accept decisions professionally and support these, even if these do

not match your suggestions and personal views

Demonstrate Sense of Responsibility


PC24. Act in the interest of the team and the organization to ensure that things do not ‘fall through the gap’ and team goals are achieved.

PC25. Take initiative to correct the situation if something seems to be going wrong.

PC26. Seek help or escalate if the situation demands

Show Respect for Opinions, Customs and Preferences


PC27. Follow organization’s and statutory guidelines about making references or comments to social customs or preferences

PC28. Refrain from making any comments to hurt sentiments PC29. Accommodate team members’ preferences to the extent feasible. If

these come in the way of fulfilling team goals, discuss with the supervisor/ team leader.

PC30. Seek information and clarifications from others if you do not understand any customs.

Knowledge and Understanding (K)


32

A. Organizational Context (Knowledge of the company / organization and its processes)

The user/individual on the job needs to know and understand:

KA1. The organization’s policies and procedures for working with colleagues, roles and responsibilities in relation to this

KA2. The importance of effective communication and establishing good working relationships with colleagues

KA3. Different methods of communication and the circumstances in which it is appropriate to use these

KA4. The importance of creating an environment of trust and mutual respect

KA5. The implications of own work on the work and schedule of others

B. Technical Knowledge The user/individual on the job needs to know and understand: KB1. Different types of information that colleagues might need and the

importance of providing this information when it is required KB2. The importance of helping colleagues with problems, in order to

meet quality and time standards as a team

Skills (S) [Optional]

A. Core Skills/ Generic Skills

Writing Skills

The user/ individual on the job need to know and understand how to: SA1. Complete written work with attention to detail

Reading Skills

The user/individual on the job needs to know and understand how to: SA2. Read instructions, guidelines/procedures


The user/individual on the job needs to know and understand how to: SA3. Listen effectively and orally communicate information SA4. Ask for clarification and advice from the concerned person

B. Professional Skills Decision Making

The user/individual on the job needs to know and understand how to: SB1. Make decisions on a suitable course of action or response keeping in view resource utilization while meeting commitments

Plan and Organize

The user/individual on the job needs to know and understand: SB2. Plan and organize work to achieve targets and deadlines

Customer Centricity


solution SB4. Support customer when they need help

Problem Solving


33

The user/individual on the job needs to know and understand how to: SB5. Apply problem solving approaches in different situations

Analytical Thinking


Critical Thinking

The user/individual on the job needs to know and understand how to: SB10. Apply balanced judgments to different situations


34

NOS Version Control

NOS Code

IAS/N2105

Credits(NSQF)

TBD

Version number

1.0

Industry Instrumentation Automation Surveillance & Communication

Drafted on

01/06/2017

Industry Sub-sector

Instrumentation, Automation Last reviewed on

01/06/2017

Occupation

Maintenance

Next review date

01/06/2019

B ac k to t o p …

35

IAS/N0106 Predictive, Corrective and Shutdown Maintenance – Process Control

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Standard

Overview

The OS unit is about performing Predictive, Corrective and Shutdown Maintenance for Process Control Instrumentation.

36


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Unit Code

IAS/N0106

Unit title (task)

Predictive, Corrective and Shutdown Maintenance – Process Control

Description

The OS unit is about performing Predictive, Corrective and Shutdown Maintenance for Process Control Instrumentation.

Scope

This Unit Task covers the following :

Prepare Predictive Maintenance (PRM) Plan and Include in schedule

Prepare/Follow CM Plan and Schedule

Identify Corrective Maintenance (CM) needs and Spares Execute CM Schedule

Support Planned & Opportunistic Shutdown Maintenance and Overhaul

Complete Corrective Maintenance Check List / Report and Close CM fault list / Planned Shutdown List

Brief Supervisor on Corrective Maintenance/Shut down tasks


Element


Prepare Predictive Maintenance Plan and Include in schedule

To be competent, the individual understands and is able to perform:

PC1. Analyze the observations of Preventive Maintenance visits for any recurrent issues or behavior which points to a possible problem or failure in near future.

PC2. Identify items (instruments, control elements, cabling and other accessories) which are in conditions that needs repair or replacement.

PC3. Prepare a list and discuss with the Engineer or Supervisor and identify items that need maintenance/replacement.

PC4. Include identified items into Corrective Maintenance list, specifying the schedule.

Prepare / Follow Corrective Maintenance Plan and Schedule


PC5. If a CM plan is given, follow it, else prepare corrective maintenance plan from the identified needs

PC6. Schedule execution of CM List

Identify Corrective Maintenance Needs and Spares


PC7. Analyze the observations, reports and behavior of the field instruments and Identify needs for corrective maintenance in the plant. Create CM List

PC8. Identify spares required for corrective maintenance and prepare list PC9. Share the list with the designated persons for ensuring availability of

spares

37


Execute Corrective Maintenance Schedule


PC10. Carry out maintenance of items in the CM list. This includes: PC11. Obtain work permit from the Process supervisor before commencing

maintenance work. PC12. Collect necessary documents and equipment:

a. Check sheets and related documents, b. Tools, tackles and calibrating equipment c. Spares parts, complete instruments / assemblies and consumables

required for Corrective Maintenance d. Personal protective safety equipment

PC13. For each item in the list, perform adjustment/ calibration/part replacement/ instrument replacement as specified.

Support Shutdown Maintenance and Overhaul


PC14. Include Corrective Maintenance jobs during annual shut down or opportunistic shut down list.

PC15. Perform requested services relating to instruments, controllers, field wiring, calibration, testing and adjustments during shutdown and overhaul.

PC16. Coordinate with other departments (such as Cranes, Workshop and Process operations, Mechanical, Electrical, Central stores) to complete extremely time critical activities and support start up.

Complete Corrective Maintenance Check List / Report and Close CM fault list


PC17. Complete entry of corrective maintenance check lists / reports

PC18. Close all faults reported PC19. Complete corrective maintenance schedule list of Field Instrumentation

and controls. Close the list.

Brief Supervisor on Corrective Maintenance


PC20. Brief Supervisor about CM performed

PC21. Escalate Faults / issues if any




KA1. Understands PM, CM and PRM norms of the company. KA2. Understands the impact of CM on productivity and the importance of

avoiding delays/production loss. KA3. Understands how to prioritize and synchronize the timing for

corrective maintenance work. during Opportunistic shut downs /Annual Shut down

KA4. Understands Production targets and production loss figures for the month and contribution by instruments and control valves

KA5. Understands the critical role of interpersonal skills during shut down activities due to strict time line for completion and startup. Extensive coordination with multiple departments is needed (such as Cranes, Workshop and Process operations, Mechanical, Electrical, Central stores).

38




KB1. Possesses functional knowledge of all types of Instrumentation and Control hardware in the Plant.

KB2. Knows how to use the right instrumentation documentation for maintenance.

KB3. Understands critical control loops associated with various l Emergency Shut Down systems.

KB4. Knows how to use calibrators, associated test equipment and test pumps.

KB5. Understands importance of material of construction of sensing elements and control valves in process media.

KB6. Able to read & understand Vendor manuals, drawings and documents including :

a) P&I Diagram b) Hook up & Loop Diagrams c) Layout diagrams d) Instrument list e) Circuit diagram

KB7. Understands critical control loops associated with various Emergency Shut Down systems (ESD).

KB8. Trouble Shooting of: Control valve body including valve movement and glands.

Actuator section and valve positioners and diagnostic messages from Digital Valve controller

Control valve accessories

Solenoid valve and Limit switches KB9. Hazardous area zone classification and process media hazards KB10. Use of Control Valve Manual when required KB11. Partial Stroke Test of control valve (PST), a feature of DCS

Skill(s)


Writing skills

The individual on the job needs to know and understand how to: SA1. Use Formats and check list for Site Readiness planning and reports SA2. Write emails and messages about site related issues

Reading Skills

The individual on the job needs to read and understand: SA3. Company policy related to Preventive Maintenance SA4. Monthly down time and resulting production loss SA5. Use of Work Permit system SA6. Formats for Preventive Maintenance check sheets, predictive maintenance list


The individual on the job needs to know and understand how to: SA7. Describe condition of Field instruments and Control valves and accessories and issues to co-workers and supervisor

39


SA8. Communicate to the management in meetings about maintenance issues which need management attention SA9. Interact with coworkers and gather information related to process and control valve conditions


Decision Making

The individual on the job needs to know and understand how to: SB1. Make decisions about timing and extent of preventive maintenance, in consultation with the Supervisor

Plan and Organize

The individual on the job needs to know and understand how to: SB2. Prioritize daily tasks to conduct Preventive Maintenance effectively

Customer Centricity


solution SB4. support customer when they need help

Problem Solving

The individual on the job needs to know and understand how to: SB5. Diagnoses reasons for down time due to control valve failure SB6. Track recurring failures in Field Instruments, Control valves and Analyses reasons and concludes SB7. Identify immediate or temporary solutions to resolve delays and discuss with the Supervisor

Analytical Thinking


Critical Thinking

The user/individual on the job needs to know and understand how to: SB12. Apply, analyze, and evaluate the information gathered from observation, experience, reasoning, or communication, as a guide to thought and action



40

NOS Version Control

NOS Code

IAS/N1006

Credits(NSQF)

TBD

Version number

1.0


Drafted on

01/06/2017

Industry Sub-sector


01/06/2017

Occupation

Maintenance

Next review date

01/06/2019

B ac k to t o p …

IAS/N0107 Instrument Installation and Loop Testing

41

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Standard

Overview

This OS unit is about performing Installation of instruments and performing Loop Testing under the guidance of the Process Engineer/ Instrumentation Engineer.


42

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Unit Code

IAS/N0107

Unit title (task)

Instrument Installation and Loop Testing

Description

The OS unit is about Installing instruments and performing Loop Testing under the guidance of the Process Engineer and Instrumentation Engineer. Generally done before the plant startup or after any major upgrade or overhaul.

Scope

This Unit Task covers the following :

Obtaining appropriate Work Permit - Installation or Loop Testing

Installation of instruments

Organizing Loop Testing - Preparatory tasks Performing Loop Test

Performing any rework if in scope and verifying the loop


Element


Obtaining appropriate Work Permit


PC1. Obtain work permit of the right kind from the Process Supervisor before commencing work.

Installation of Instruments


PC2. Understand the requirements and specifications of the instrument. PC3. Understand the location where the instrument is to be installed PC4. Understand the installation procedure for the instrument in the process. PC5. Understand whether the process is to be shut down for installing the

instrument – if so, the installation must be scheduled accordingly and included in the schedules for planned / Opportunistic maintenance - Corrective Maintenance / Breakdown Maintenance / Shutdown.

PC6. Get the installation drawings and instructions, along with the tag number and other details.

PC7. Get the instruments and accessories needed for the installation issued from the stores

PC8. Get the proper tools and calibrating equipment PC9. Erect the required brackets, supports, junction boxes, cable conduits and

other accessories per installation instructions. PC10. Lay, route the signal and power cables in the conduits, trays, trenches

following the layout drawing and best practices. PC11. Calibrate the instrument using the correct test equipment, tools and

procedure. PC12. Install the instrument in the process following the instructions. PC13. Wire the instrument in the prescribed manner at the instrument end.

Use proper glands, markers, tags, labels as specified. PC14. Terminate the wires at the appropriate control panel using wiring

diagram, using proper glands, markers /numbered ferrules, tags, labels as specified.


43

PC15. Test the continuity of the wiring and termination at both ends. PC16. Make sure no control loop is active for the instrument. PC17. Power the instrument and observe the display, if available. PC18. Configure the instrument in the PLC, DCS or other system per process

requirement. PC19. Prepare Installation Report and share with the Supervisor / Engineer. PC20. Perform Loop Test if advised by the Process Engineer/Instrumentation

Engineer

Organizing Loop Testing - Preparatory tasks


PC21. Collect the Loop Test list from the Supervisor/ DCS Engineer/Process Engineer.

PC22. Understand the scope and the plan of the Loop Testing. This includes the grouping of the Loops for most efficient testing.

PC23. Get to know the team you are working with at the other end – PLC/DCS/other system, as the loop testing is highly interactive.

PC24. Understand the scope of correction of deficiencies found. PC25. Collect the installation drawings, documents, specifications, along with

the tag numbers, configurations and other details needed for loop test. PC26. Collect the instruments and accessories needed for the loop test PC27. Collect the proper tools and calibrating equipment for the loop test

Performing Loop Test


PC28. For each loop listed for Loop Test, perform operational check of the field instrument, controller and HMI elements. A Loop Check ensures the integrity of the Loop and includes the following checks.

PC29. Testing the continuity of signal from the instrument to the control panel – whether PLC, DCS, ESD or any other logical system.

PC30. Verifying that the field instrument is properly installed according to specifications.

PC31. Verifying that the field instrument properly communicates with the PLC, DCS or any other system using the appropriate communication Protocol.

PC32. Verifying that the field instrument is calibrated according to specifications.

PC33. Verifying that the field instrument is properly connected to PLC, DCS or any other system

PC34. Verifying that the field instrument develops and transmits a proper analogous signal in response to a physical variable impressed upon it or to a simulation command issued to it.

PC35. Verifying that the corresponding logic in the DCS is ranged accordingly for the field instrument and engineering units.

PC36. Verifying that the HMI displays the signal of the field instrument in the engineering unit accurately.

PC37. Testing the range of calibration, alarms, set points and any signal included in the loop folder.

PC38. Testing DCS signal from/to all instruments and actuators using appropriate signal generator such as HART communicator, temperature generator or 4-20mA generator, depending instrument type.

PC39. Testing ESD operation with specified tools to generate the required pressure, level or other parameter.


44

PC40. Testing valves with all types of conditions and signals - such as open, close, HI and LOW limit switches, reset buttons, hand switches, feedback and other relevant parameter depending on the valve.

PC41. Testing Loops for different type of control action - such as direct, reverse, split range etc.

PC42. Recording all data in the folders and forms specified in the SOP PC43. Verifying that the Alarm points are configured properly into the DCS and

the HMI displays and logs these appropriately as they are reached. PC44. Verifying that the signal from the field instrument is received by the

control algorithm and the appropriate corrective output signal is generated and received by the control element.

PC45. Verifying that the field control device (e.g. Actuator, Control Valve, VFD etc.) is properly installed according to specifications.

PC46. Verifying that the field control device is calibrated according to specifications.

PC47. Verifying that the Field control device responds appropriately to the corrective signal received from the DCS and that this action is appropriate for the desired process variable.

PC48. Verifying that the response action of the valve is correctly transmitted to the DCS and displayed on the HMI.

PC49. Prepare the Loop Test Report as defined in the SOP

Performing Rework and Verifying The Loop


PC50. If included in the scope of Loop Test, perform the following functions. PC51. Get the list of corrections required. PC52. For each correction in the list identify the type of correction needed –

adjustment, refitting, cleaning, overhaul, recalibration, wiring change, replacement or any other action.

PC53. Perform the desired action and verify the performance of the device. PC54. If advised, repeat Loop Test to verify correct functioning of the loop. PC55. Close the Loop Test list and report PC56. Ensure drawings/circuits incorporate changes during rework as per SOP



Needs to know and understand :

KA1. Understands Installation policies and norms as defined by the company KA2. Understands Loop Testing policies and norms as defined by the

company


45


Needs to know and understand:

KB1. Types and specifications for Instruments used in the Process Plant KB2. Installation procedures for Instruments used in the Process Plant KB3. Calibration procedures for Instruments used in the Process Plant KB4. Trouble Shooting of Instruments used in the Process Plant. KB5. Types and specifications for control elements used in the Process Plant KB6. Tools and Equipment used for Installation and Calibration KB7. Installation procedures for control elements used in the Process Plant KB8. Calibration procedures for control elements used in the Process Plant KB9. Trouble shooting of control elements used in the Process Plant. KB10. Loop Testing procedure defined for the Process Plant. KB11. Hazardous area zone classification and process media hazards KB12. Safety norms for installation and testing

Skill(s)


Writing skills


SA1. Use Formats and check list for Installation planning and reports SA2. Formats and check list for Loop Test planning and reports SA3. Write emails and messages about site related issues

Reading Skills

The individual on the job needs to read and understand:

SA4. Specifications, Documents, Drawings, Lists, Formats for Instrument Installation and Testing and Reporting

SA5. Specifications, Documents, Drawings, Lists, Formats for Loop Testing



SA6. Describe clearly the condition, values, settings and other details of instruments and accessories and issues to members of Loop Testing team

SA7. Understand and follow the instructions passed on by the members of Loop Testing team

SA8. Communicate to the management in meetings about technical issues which need management attention

SA9. Interact with coworkers and gather information related to conditions of the instruments and process


Decision Making


SB1. Make decisions about the proper functioning of instruments and sharing the information with coworkers


46

Plan and Organize


SB2. Plan and Prioritize Installation work effectively

SB3. Plan and Prioritize Loop Testing work effectively

Customer Centricity


SB4. Understand real needs of the other teams (who request services) and suggest most appropriate solution

SB5. Support other teams when they need help

Problem Solving


SB6. Diagnoses reasons for down time due to instrument malfunction or failure

SB7. Track recurring failures in instrument and analyses reasons and concludes

SB8. Identify immediate or temporary solutions to resolve delays and discuss with the Supervisor

Analytical Thinking


SB9. Use the existing information to arrive at actionable decision points SB10. Use the existing information to optimize solution and company

business SB11. Analyze problems and identify causes and possible solutions

Critical Thinking


SB12. Apply, analyze, and evaluate the information gathered from observation, experience, reasoning, or communication, as a guide to thought and action



47

NOS Version Control

NOS Code

IAS/N0107

Credits(NSQF)

TBD

Version number

1.0


Drafted on

01/06/2017

Industry Sub-sector


01/06/2017

Occupation

Maintenance

Next review date

01/06/2019

B ac k to t o p …

48


Annexure

Nomenclature for QP and NOS

Qualifications Pack

9 characters

[IAS]/Q0101

[Insert 3 letter codes for SSC]

QP number (2 numbers)

Q denoting Qualifications Pack Occupation (2 numbers)

Occupational Standard

An example of NOS with ‘N’ 9 characters

[IAS] /N0001

[Insert 3 letter codes for SSC]

OS number (2 numbers)

N denoting National Occupational Standard Occupation (2 numbers)

49


The following acronyms/codes have been used in the nomenclature above:

Sub-sector

Range of Occupation numbers

Installation and Commissioning 00-29

Operation and Maintenance 30-49

Calibration 50-55

Design, Fabrication / Manufacturing 56-79

Design, Fabrication, Installation & Commissioning

80-89

General 90-99

Sequence Description Example

Three letters Industry name IAS

Slash / /

Next letter Whether QP or NOS Q

Next two numbers Occupation code 01

Next two numbers OS number 01

B ac k to t o p …


50

CRITERIA FOR ASSESSMENT OF TRAINEES

Job Role Instrumentation Technician (Process Control)

Qualification Pack IAS/Q3002

Sector Skill Council Instrumentation Automation Surveillance & Communication

Guidelines for Assessment

1. Criteria for assessment for each Qualification Pack will be approved by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC

2. The assessment for the theory part will be based on knowledge bank of questions approved by the SSC

3. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below)

4. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criteria

5. To pass the Qualification Pack , every trainee should score minimum 70 % marks for each NOS as prescribed by the SSC

6. In case of successfully passing only certain number of NOS's, the trainee is eligible to take subsequent assessment on the balance NOS's to pass the Qualification Pack

Relative Weight of NOSs in the Assessment

Sl. No. NOS no. NOS Name % Weightage

1 IAS/N0300 Site Readiness and Instrument Usability – Process Control 10

2 IAS/N0301 Preventive Maintenance – Process Control 20

3 IAS/N0103 Task reporting – Process Control 10

4 IAS/N0105 Safety, Health and Environment – Process Control 10

5 IAS/N2105 Work Effectively With Teams 10

6 IAS/N0106 Predictive, Corrective and Shutdown maintenance – Process Control

20

7 IAS/N0107 Instrument Installation and Loop Testing 20

100%

51


Marks Allocation

Assessment Outcomes

Assessment Criteria for Outcomes

Total Marks (200+

200+60 +50+

75+110 +265)

Out of

The ory

Skills Pract ical

1. IAS/N0300 Maintain Site Readiness and Instrument Usability - Process Control

PC1. Follow Process Plant related instructions and directives covering equipment, location, lay out, procedures, forms etc.

200

20

10

10

PC2. Follow instructions and directives of various permits to work and uses the right one depending on the job he undertakes

10

5

5

PC3. Use Check sheets used in Instrumentation Maintenance work and makes entries.

10

5

5

PC 4. Use Plant working document relevant to a particular Instrument tag/control loop he is working on, as required

10

5

5

PC5. Use document pertaining to a particular Instrument tag he/she is working with, as required

10

5

5

PC6. Attend to maintenance requests and resolves the problems. Requests for supervisor’s advice and assistance during difficult problem resolution.

20

5

15

PC7. Perform basic overhaul and testing under supervision of all standard types of control valves and accessories and can do basic overhaul and testing under supervision.

10

5

5

PC8. Carry out routine checks of on line Analyzers and Analyzer house.

10

5

5

PC9. Locate the field devices and identifies the interface units – able to work on the system with guidance.

10

5

5

PC10. Locate faults relating to operation of package units, location, relates instrument tags to respective Process package unit and undertake routines and basic trouble shooting in these units.

10

5

5

PC11. Refer to overview of fire and gas detection, locate the main field devices, identifies interface units and perform maintenance work on the system with guidance.

10

5

5

PC12. Checks for visual damage and tampering 15 5 10

PC13. Check for any visible loss of installation integrity. Integrity here means that the instrument and the

15

5

10

52


installation is in a healthy working condition without any unusual appearance, breakage or foreign objects fallen in/on/around the installation which is likely to cause or lead to instrument malfunction.

PC14. Check for potential electrical problems due to deviation from standard electrical practices

10

5

5

PC15. Check for floor condition and cluttering of items 5 2 3

PC16. Check for lighting and their operation. Check for unsafe temporary wiring of lighting.

5

2

3

PC17. Check consumption and storage of consumables. 10 5 5

PC 18. Complete follow up action as per assigned areas of responsibility and stipulated instructions. Items found unusual outside this boundary to be reported to supervisor.

10

5

5

Total

200

89

111

2. IAS/N0301 Preventive Maintenance – Process Control

PC1. Obtain Permit to Work.

200

10 5 5

PC2. Organize for the day’s Preventive Maintenance task.

40

10

30

PC3. Execute Preventive maintenance jobs as per available Preventive Maintenance Schedule.

20

10

10

PC4. Prepare Process list from process supervisor. 20 10 10

PC5. Plan for next day’s preventive maintenance schedule

PC6. Carry out-Visual Checks and action wherever possible or else transfer job to shut down list.

30

10

20

PC7. Complete preventive maintenance schedule list of control valve body, actuator and accessories. Close the issues in the list.

20

5

15

PC8. Collect and consolidate daily diagnostic messages from control valves which have a digital valve controller and record the same in either Preventive Maintenance list or Opportunistic shut down list for execution

15

7

8

PC9. Include preventive maintenance jobs during annual shut down or opportunistic shut down

25

10

15

PC10. Follow up on consolidated preventive maintenance list and close.

20

5

15

Total 200 72 128

3. IAS/N0103 Task reporting – Process Control

PC1. Brief and Escalate faults/issues to immediate supervisor

60

10

5

5

PC2. Complete entry of preventive maintenance check lists/reports

10

5

5

PC3. Complete entry of Corrective Maintenance Check lists /reports

10

5

5

PC4. File report on noticing any visible changes in control valve installation or its accessories. Report for immediate attention of supervisor

10

5

5

PC5. Report any theft in control valve 10 5 5

53


2 1 1

3 1 2

2

1

1

4. IAS/N0105 Safety, Health

PC1. Interpret and follow formal Instructions from SHE Dept.

10 5 5

10 5 5

50

and PC2. Participate in the prescribed drills including Environment– familiarization of personal protective equipment, fire Process extinguisher and first aid. Control PC3. Follow instructions on Work permit, Fire permit

and Hazardous Area Classification, Fire and explosion 10 5 5

hazards

PC4. Use right personal protective equipment 10 5 5

PC5. Support supervisor during SHE Audit 10 5 5

Total 50 25 25

5. IAS/N2105 PC1. Know and understand the team objectives and goals 3 1 2

Work PC2. Know team members by name. Greet them

2

1

1 Effectively appropriately and respond to their greetings. With Teams PC3. Know the roles and responsibilities of team

members. Ensure others know about you and your role in

2

1

1

the team

assembly/spares to supervisor

PC6. Report suspicious movement of new persons near control valve installation to security and supervisor

10 5 5

Total 60 30 30

PC4. Learn about the culture and preferences of team members – especially if they belong to other organizations or nationalities

PC5. Follow organization’s policies and procedures for 75

working with team members within and outside the organization – especially relating to privacy, confidentiality and security.

PC6. Create an environment of trust and mutual respect

PC7. Use appropriate mode of communication – verbal,

written, mail, phone or text and clearly articulate your message to ensure that the recipient understands the message.

PC8. Listen to team members and try to understand what they are wanting to say. Seek or provide clarifications if you see any gap in understanding

PC9. Communicate professionally and follow organization protocols. Do not overload the team members with unnecessary and unsolicited information

5 1 4

3 1 2

4 1 3

PC10. Share important information with the team timely. 3 1 2

PC11. Respond to communications promptly. 3 1 2

PC12. Perform own role and produce output in time for

other team members to consume 3 1 2

PC13. Receive inputs from others and work upon it per role

requirement 2 1 1

PC14. Make adjustments within the permissible rules so

that work flows smoothly. 2 1 1

PC15. Help team members to perform their role effectively

and provide any clarifications and support they need 2 1 1

PC16. Share tools and common resources fairly, taking 2 1 1

54


cognizance of others’ needs and schedules

PC17. Resolve any contentious issues amicably, involving the team lead or the supervisor if needed

2

1

1

PC18. Let team members know in good time if you cannot carry out your commitments, explaining the reasons and alternate solutions, if any. Let the team lead know about this.

2

1

1

PC19. Think positively and make constructive suggestions to meet the goals

2

1

1

PC20. Accept and give suggestions with open mind 2 1 1

PC21. Take initiatives and volunteer to contribute 2 1 1

PC22. Help team members with facts and figures to arrive at workable decisions

2

1

1

PC23. Accept decisions professionally and support these, even if these do not match your suggestions and personal views

4

1

3

PC24. Act in the interest of the team and the organization to ensure that things do not ‘fall through the gap’ and team goals are achieved.

4

1

3

PC25. Take initiative to correct the situation if something seems to be going wrong.

2

1

1

PC26. Seek help or escalate if the situation demands 2 1 1

PC27. Follow organization’s and statutory guidelines about making references or comments to social customs or preferences

2

1

1

PC28. Refrain from making any comments to hurt sentiments

2

1

1

PC29. Accommodate team members’ preferences to the extent feasible. If these come in the way of fulfilling team goals, discuss with the supervisor/ team leader.

2

1

1

PC30. Seek information and clarifications from others if you do not understand any customs.

2

1

1

Total 75 30 45

6. IAS/N0106 PC1. Analyze the observations of Preventive

110

10

5

5 Predictive, Corrective

Maintenance visits for any recurrent issues or behavior which points to a possible problem or failure in near

and future. Shutdown PC2. Identify items (instruments, control elements,

cabling and other accessories) which are in conditions that needs repair or replacement.

8

5

3

2

5

3

Maintenance – Process Control PC3. Prepare a list and discuss with the Engineer or

Supervisor and identify items that need maintenance/replacement.

PC4. Include identified items into Corrective Maintenance list, specifying the schedule.

3

1

2

PC5. If a CM plan is given, follow it, else prepare corrective maintenance plan from the identified needs

5

2

3

PC6. Schedule execution of CM List 5 2 3

PC7. Analyze the observations, reports and behavior of the field instruments and Identify needs for corrective maintenance in the plant. Create CM List

6

2

4

55


PC8. Identify spares required for corrective maintenance and prepare list

5

2

3

PC9. Share the list with the designated persons for ensuring availability of spares

3

1

2

PC10. Carry out maintenance of items in the CM list. 3 1 2

PC11. Obtain work permit from the Process supervisor before commencing maintenance work.

3

1

2

PC12. Collect necessary documents and equipment 3 1 2

PC13. For each item in the list, perform adjustment/ calibration/part replacement/ instrument replacement as specified.

15

5

10

PC14. Include Corrective Maintenance jobs during annual shut down or opportunistic shut down list.

3

1

2

PC15. Perform requested services relating to instruments, controllers, field wiring, calibration, testing and adjustments during shutdown and overhaul.

8

3

5

PC16. Coordinate with other departments (such as Cranes, Workshop and Process operations, Mechanical, Electrical, Central stores) to complete extremely time critical activities and support start up.

10

2

8

PC17. Complete entry of corrective maintenance check lists / reports

3

1

2

PC18. Close all faults reported 3 1 2

PC19. Complete corrective maintenance schedule list of Field Instrumentation and controls. Close the list.

3

1

2

PC20. Brief Supervisor about CM performed 3 1 2

PC21. Escalate Faults / issues if any 3 1 2

Total 110 39 71

7. IAS/N0107 Instrument Installation and Loop Testing

PC1. Obtain work permit of the right kind from the Process Supervisor before commencing work.

265

3

1

2

PC2. Understand the requirements and specifications of the instrument.

3

1

2

PC3. Understand the location where the instrument is to be installed

3

1

2

PC4. Understand the installation procedure for the instrument in the process.

3

1

2

PC5. Understand whether the process is to be shut down for installing the instrument – if so, the installation must be scheduled accordingly and included in the schedules for planned / Opportunistic maintenance - Corrective Maintenance / Breakdown Maintenance / Shutdown.

5

2

3

PC6. Get the installation drawings and instructions, along with the tag number and other details.

3

1

2

PC7. Get the instruments and accessories needed for the installation issued from the stores

3

1

2

PC8. Get the proper tools and calibrating equipment 3 1 2

56


5

2

3

3

1

2

5

2

3

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

5

2

3

3

1

2

5

2

3

3

1

2

5

2

3

3

1

2

5

2

3

3

1

2

3

1

2

3

1

2

3 1 2

10

3

7

PC9. Erect the required brackets, supports, junction boxes, cable conduits and other accessories per installation instructions.

PC10. Lay, route the signal and power cables in the conduits, trays, trenches following the layout drawing and best practices.

PC11. Calibrate the instrument using the correct tools and procedure.

PC12. Install the instrument in the process following the instructions.

PC13. Wire the instrument in the prescribed manner at the instrument end. Use proper glands, markers, tags, labels as specified.

PC14. Terminate the wires at the appropriate control panel using wiring diagram, using proper glands, markers, tags, labels as specified.

PC15. Test the continuity of the wiring and termination at both ends.

PC16. Make sure no control loop is active for the instrument.

PC17. Power the instrument and observe the display, if available.

PC18. Configure the instrument in the PLC, DCS or other system per process requirement.

PC19. Prepare Installation Report and share with the Supervisor / Engineer.

PC20. Perform Loop Test if advised by the Process Engineer.

PC21. Collect the Loop Test list from the Supervisor/ DCS Engineer/Process Engineer.

PC22. Understand the scope and the plan of the Loop Testing. This includes the grouping of the Loops for most efficient testing.

PC23. Get to know the team you are working with at the other end – PLC/DCS/other system, as the loop testing is highly interactive.

PC24. Understand the scope of correction of deficiencies found.

PC25. Collect the installation drawings, documents, specifications, along with the tag numbers, configurations and other details needed for loop test.

PC26. Collect the instruments and accessories needed for the loop test

PC27. Collect the proper tools and calibrating equipment for the loop test

PC28. For each loop listed for Loop Test, perform operational check of the field instrument, controller and HMI elements. A Loop Check ensures the integrity of the Loop and includes the following checks.

57


3

1

2

3

1

2

3

1

2

5

2

3

3

1

2

5

2

3

5

2

3

5

2

3

5

2

3

8

3

5

10

3

7

10

3

7

10

3

7

3

1

2

5

2

3

5

2

3

5

2

3

8

3

5

PC29. Testing the continuity of signal from the instrument to the control panel – whether PLC, DCS, ESD or any other logical system.

PC30. Verifying that the field instrument is properly installed according to specifications.

PC31. Verifying that the field instrument properly communicates with the PLC, DCS or any other system using the appropriate communication Protocol.

PC32. Verifying that the field instrument is calibrated according to specifications.

PC33. Verifying that the field instrument is properly connected to PLC, DCS or any other system

PC34. Verifying that the field instrument develops and transmits a proper analogous signal in response to a physical variable impressed upon it or to a simulation command issued to it.

PC35. Verifying that the corresponding logic in the DCS is ranged accordingly for the field instrument and engineering units.

PC36. Verifying that the HMI displays the signal of the field instrument in the engineering unit accurately.

PC37. Testing the range of calibration, alarms, set points and any signal included in the loop folder.

PC38. Testing DCS signal from/to all instruments and actuators using appropriate signal generator such as HART communicator, temperature generator or 4- 20mA generator, depending instrument type.

PC39. Testing ESD operation with specified tools to generate the required pressure, level or other parameter.

PC40. Testing valves with all types of conditions and signals - such as open, close, HI and LOW limit switches, reset buttons, hand switches, feedback and other relevant parameter depending on the valve.

PC41. Testing Loops for different type of control action - such as direct, reverse, split range etc.

PC42. Recording all data in the folders and forms specified in the SOP

PC43. Verifying that the Alarm points are configured properly into the DCS and the HMI displays and logs these appropriately as they are reached.

PC44. Verifying that the signal from the field instrument is received by the control algorithm and the appropriate corrective output signal is generated and received by the control element.

PC45. Verifying that the field control device (e.g. Actuator, Control Valve, VDF etc.) is properly installed according to specifications.

PC46. Verifying that the field control device is calibrated according to specifications.

58


PC47. Verifying that the Field control device responds appropriately to the corrective signal received from the DCS and that this action is appropriate for the desired process variable.

8

3

5

PC48. Verifying that the response action of the valve is correctly transmitted to the DCS and displayed on the HMI.

5

2

3

PC49. Prepare the Loop Test Report as defined in the SOP

5

2

3

PC50. If included in the scope of Loop Test, perform the following functions.

3

1

2

PC51. Get the list of corrections required. 3 1 2

PC52. For each correction in the list identify the type of correction needed – adjustment, refitting, cleaning, overhaul, recalibration, wiring change, replacement or any other action.

5

2

3

PC53. Perform the desired action and verify the performance of the device.

10

3

7

PC54. If advised, repeat Loop Test to verify correct functioning of the loop.

8

3

5

PC55. Close the Loop Test list and report 4 1 3

PC56. Ensure drawings/circuits incorporate changes during rework as per SOP

5

2

3

Total 265 94 171

5

B ac k to t o p …