Phase 2 Core Power and Control RoA.3

TTE Training Limited Controlled Document: Phase 2 Record of Achievement – Core Power and Control Page 9 of 40

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RECORD OF ACHIEVEMENT – PHASE II CORE POWER and CONTROL (INSTRUMENTS)

This Record of Achievement is to be completed by the Training Officer once the apprentice has achieved the required standard, having completed all practical and written units relevant to the subject area, and may therefore be deemed competent only in a training environment as outlined in the subject synopsis.

This is a Record of: .....................…………….................. whose training started: …....................

Under sponsorship of: .................................................................................

INSTRUMENTS Pg Module

No. Obj. No.

MODULE TITLE COURSE MARK / COMPLETED

DATE

27 CI12 WORKSHOP SAFETY

28 CI13 INSTRUMENT EQUIPMENT and SYSTEMS

29 CI14 PROCESS ANALYSERS

30 CI15 HAZARDOUS AREA EQUIPMENT

31 CI16 CONTROL & SHUTDOWN VALVES

32-33 CI17 PROCESS CONTROL & CONTROLLERS

33 CI18 MODES OF CONTROL

34 CI19 DISTRIBUTIVE CONTROL SYSTEMS

35-36 CI20 SHUTDOWN SYSTEMS DESIGN & CONSTRUCTION

37 CI21 DIGITAL TECHNOLOGY

37 CI22 MAINTENANCE PROCEDURES

Subject Area Test Average

VALIDATION: The above training has / has not* been completed to the specified success criteria.

Signed:.................................................................................... Print: ........................................................................ (Training Officer)

Signed:.................................................................................... Print: ........................................................................ (Apprentice)




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SECTION 2

ELECTRICAL (Power)

SATISFACTORY KNOWLEDGE AND UNDERSTANDING OF THE FOLLOWING ITEMS HAS

BEEN DEMONSTRATED VIA OBSERVATION OF PRACTISE AND THE COMPLETION OF

PRACTICAL AND WRITTEN ASSIGNMENTS AND TESTS.





MODULE TITLE : WORKSHOP SAFETY (PROCEDURES & PRACTICE)

MODULE No. : CE22

SCOPE : Develop apprentice awareness, knowledge, understanding and experience of workshop safety with regards to tools, equipment, behaviour and practises in accordance with the current training objectives.

OBJECTIVE NO. SUCCESS CRITERIA

CE22

1

2

3

4

5

6

The apprentice is able to demonstrate knowledge and understanding of :

• maintaining safety of self by ensuring : a) overalls are a suitable fit and are securely fastened to chest level b) overalls sleeves are rolled down and cuffs are in good condition c) overalls are clean / relatively free from contamination, e.g. grease d) boots are the correct fit and laces are appropriately tied e) jewellery is either removed or suitably covered before work

commences f) any loose items are removed and, when applicable, any long hair is

suitably protected g) gloves and eye protection are worn and are suitable for the task

• the importance of housekeeping before, during and after the task is completed

• awareness of the workshop environment and the associated hazards including :

a) the presence of dangerous voltages b) protruding edges c) heavy and/or unbalanced loads d) the presence of rotating equipment and associated (live) controls e) potentially hot equipment f) contaminated PPE, equipment and tools g) hazardous substances, e.g. resins, adhesives, lubricants, etc)

• visual inspection of all tools and equipment prior to, and following, their use

• selecting the correct tool for the task

• the correct values and behaviours including : a) paying attention to the task and any instructions being given b) testing potentially live terminals with a suitable test instrument before

touching to prove “dead” c) keeping the work area and tools and equipment clean d) recognising potential hazards and act upon them e) maintaining personal hygiene f) recognising the impact of tiredness and/or stress g) awareness of the impact of their behaviour on others




MODULE TITLE : CABLES AND GLANDS

MODULE No. : CE23

SCOPE : Develop apprentice awareness, knowledge and understanding of cables and glands in accordance with the current training objectives.

OBJECTIVE No. SUCCESS CRITERIA

CE23

1

2

3

The apprentice is able to demonstrate :

• the correct selection, preparation, and fitting of suitable cable glands to the following types of cable :

a) steel wire armoured (SWA) b) braided

• how to resin joint two SWA cables including : a) preparation of the cables

b) ensuring earth continuity

c) selection and use of suitable crimp joints and insulation

d) maintain suitable spacing between conductors

e) how to mix and apply the compound

• how to test cables by selection and use of a suitable instrument and how to interpret the instrument readings




MODULE TITLE : ELECTRICAL REGULATIONS

MODULE No. CE24

SCOPE : Develop apprentices prior learning of the I.E.E. (17th Edition) and Electricity At Work Regulations (1989) to incorporate into Electrical procedures in accordance with the current training objectives.


CE24

1

2

3

4

5

The apprentice be able to explain :

• why the Regulations are necessary and the consequences of not adhering to them

• the differences between the following Regulations : a) I.E.E. Regulations (17th Edition) b) Electricity At Work Regulations 1989

• how to obtain information from the I.E.E. Regulations (17th Edition) for the installation of equipment

• how the Electricity at Work Regulations (1989) apply to installation and maintenance activities

• how to determine cable size by:

a) use of the I.E.E. Regulations (17th Edition)

b) calculation

MODULE TITLE : ELECTRICAL ISOLATION

MODULE No. : CE25

SCOPE : Develop apprentice awareness, knowledge, understanding and practice of electrical isolation in accordance with the current training objectives.


CE25

1

2

3

4

5

6

The apprentice will, using Company procedures, be able to explain and demonstrate

• the Regulatory requirements for Electrical Isolation of equipment

• the purpose of the Permit to Work system with regard to the isolation of electrical equipment

• the safe isolation of single phase and 3-phase (415V) circuits with due regard to the Electricity At Work Regulations (1989)

• how to test and disconnect circuits up to 415V AC.

• how to test and re-connect circuits up to 415V AC

• the safe de-isolation of single phase and 3-phase (415V) circuits with due regard to the Electricity At Work Regulations (1989)

Note : This unit can only be completed when all Phase I Electrical units have been completed




MODULE TITLE : TRACE HEATING

MODULE No. : CE26

SCOPE : Develop apprentice awareness, knowledge, understanding and practice of trace heating in accordance with the current training objectives.


CE26

1

2

3

The apprentice will be able to :

• describe the purpose and principles of trace heating in industry

• identify and explain the available methods of trace heating

• explain the purpose, principle of operation and the method of testing of a Residual Current Device (RCD)

MODULE TITLE : ELECTRICAL EQUIPMENT – DISTRIBUTION AND PROTECTION

MODULE No. : CE27

SCOPE : Develop apprentice awareness, knowledge and understanding of the equipment available for electrical distribution and the protection of circuits in accordance with the current training objectives.


CE27

1

2

3

The apprentice will be able to explain, and demonstrate the principle of operation, purpose and application, of the following items :

• circuit protection, e.g. HRC fuse, MCB, RCD and rewireable fuse.

• earthing, e.g. electrodes, circuit protective conductors ( CPC ), earth cable, earth bonding and equipotential bonding.

• distribution switch gear, e.g. isolators, circuit breaker, distributor board, consumer unit, junction box, transformer and capacitor.




MODULE TITLE : ELECTRICAL DRAWINGS

MODULE No. : CE28

SCOPE : Develop apprentice awareness, knowledge and understanding and practice of using and interpreting electrical drawings in accordance with the current training objectives.


CE28

1

2

The apprentice is able to :

• explain the format, application and information found on the following types of drawings :

a) wiring and schematic b) line c) ladder d) flowchart e) timing diagram f) standard figure diagram

• demonstrate the purpose of each type of drawing when installing or fault finding on electrical equipment

MODULE TITLE : BATTERIES

MODULE No. : CE29

SCOPE : Develop apprentice awareness, knowledge and understanding of the construction and operation of batteries in accordance with the current training objectives.


CE29

1

2

3

4

5

6


• identify secondary and primary cells and explain their differences

• describe the action of a secondary cell during charge and discharge

• determine the condition of a cell using a voltmeter, ammeter and load tester

• demonstrate the charging of a battery with the aid of a voltmeter and ammeter

• define series and parallel connections to obtain more current or voltage

• identify and explain all of the necessary safety precautions when working with batteries




MODULE TITLE : MOTORS

MODULE No. : CE31

SCOPE : Develop apprentice awareness, knowledge and understanding of single-phase and 3-phase ac motor theory and operation in accordance with the current training objectives.


CE31 The apprentice is able to :

1

2

3

4

5 6

7.

8 9

• dis-assemble a 3-phase ac induction motor to it's component parts and explain the function of each

• identify and explain the motor maintenance requirements.

• identify external indications of potential breakdown e.g. heat, smell, noise and vibration.

• explain the effect of connecting the motor windings in Star or Delta, with reference to starting and running current and torque

• explain how some motor windings may be connected to operate at "dual voltage"

• explain the principles of how the rotation direction of a motor may be reversed

• Identify the motor identification plate and explain the relevance of the information found on it

• re-assemble the motor and demonstrate knowledge of rotor clearance and shaft, bearing, and end-cover alignment.

Note : This unit can only be completed when all Phase I Electrical units have been completed




MODULE TITLE : MOTOR CONTROL

MODULE No. : CE32

SCOPE : Develop apprentice awareness, knowledge and understanding of single-phase and 3-phase ac motor control theory and operation in accordance with the current training objectives


CE32

1

2

3

4

5

6

7

8


• state and demonstrate the electrical isolation procedure for a motor and the associated control circuit

• describe and demonstrate the methods used to ensure safe working practice including “testing for dead” at the appropriate terminals

• identify the main component parts of the control circuit and describe their principle of operation including

a) contactor b) overload c) current transformers (where applicable) d) thermistor

• demonstrate how the main component parts may be tested, and explain how replacement parts may be obtained if required

• demonstrate selection of test-equipment and the necessary testing and fault-finding techniques

• using drawings, connect up the following types of motor control (inc. a connection to a Remote Control Unit and one (or more) Emergency Stop pus-buttons), and connect to a motor :

a) direct-on-line (DoL) b) direct-on-line with auxiliary controls e.g. hand-off-auto switch, timer,

pressure switch c) forward reverse d) star-delta e) variable speed f) direct-on-line with thermistor protection g) simulated three motor converyors system

• select fuses with regard to the motor Full Load Current (FLC) information on the manufacturers plate

• explain and demonstrate the de-isolation procedure including identification of the correct circuit, de-isolation, and testing




MODULE TITLE : TRANSFORMERS

MODULE No. : CE33

SCOPE : Develop apprentice awareness, knowledge and understanding of the theory and principle of operation of transformers in accordance with the current training objectives.


CE33

1

2

3

4

5

6

7

The apprentice will be able to

• explain the basic theory and operation

• primary and secondary windings

• demonstrate knowledge and understanding of :: a) step-up and step-down transformers b) current transformers c) auto / variable transformers d) safety transformers

• identify the primary and secondary windings by resistance checking

• calculate the number of coil turns required to achieve a specific output voltage

• identify the operational parts by dis-assembly and re-assembly, and fit a new secondary coil

• test the transformer using the following methods : a) insulation and continuity testing using suitable test equipment b) open-circuit (no-load) testing c) load checking




MODULE TITLE : INDUSTRIAL ELECTRONICS – BASIC THEORY AND OPERATION

MODULE NO. : CE34

SCOPE : Develop the apprentices’ knowledge and understanding of electronic components including transistors, diodes, SCR’s and DIAC’s in accordance with the current training objectives


CE34

1.

2.

3.

4.

5.

6.

The apprentice is able to recognise, describe, and, where practical, demonstrate :

• the operation of a semiconductor diode including : a. forward and reverse bias b. power dissipation c. half-wave rectification inc. recognition of the half-wave sinusoidal voltage, the

term “mean value” and the purpose and use of a smoothing capacitor d. full-wave rectification inc. recognition of the waveform both with and without a

smoothing capacitor e. a diode bridge and two-diode rectification.

• the differences between zenner and rectifying diodes including : a. the constant voltage reverse bias characteristics b. use of the zenner diode as a voltage regulator

• the different types of transistor and terminals including : a. PNP and NPN types b. junction biasing c. the direction and magnitude of current flows

• the theory and operation of a common emitter transistor amplifier including the : a. operating point b. load-line c. biasing resistors d. load resistor e. emitter resistor

• the theory and operation of a Silicon Controlled Rectifier (SCR) including the : a. different methods of triggering SCR’s b. break-down voltage c. holding current d. practical industrial applications

• the theory and operation of a Triode for Alternating Current (TRIAC) or triode thyristor including the :

a. bi-directional nature of the TRIAC and its’ applications b. application of the Diode for Alternating Current (DIAC) as a trigger device




MODULE TITLE : INDUSTRIAL ELECTRONICS – OPERATIONAL AMPLIFIERS

MODULE No : CE35

SCOPE : Develop the apprentices’ theory, practical knowledge and understanding of Operational Amplifiers in accordance with the current training objectives


CE35

1.

2.


• describe and demonstrate applications of Operational Amplifiers including : a. scaling / multiplication b. summing c. integration d. differentiation e. differential amplifier

• recognise and explain the implications of Operational Amplifiers in 3-term Proportional, Integral, Derivative (PID) control.




MODULE TITLE : INDUSTRIAL ELECTRONICS – AC/DC MOTOR SPEED CONTROL

MODULE NO. : CE36

SCOPE : Develop the apprentices’ theory, practical knowledge and understanding of speed control of AC & DC motors in accordance with the current training objectives


CE36

1.

2.

3.

4.

5.

6.

With regards to DC motors, the apprentice is able to :

• describe the methods of field excitation and identify the main components inc. the method of construction including :

a. Series, Shunt and Compound windings b. the permanent magnet

• describe the theory of operation including : a. Flemmings Left Hand and Right Hand rules b. back emf, armature volt drop, and supply voltage

• describe the principles applied to control industrial DC motors including : a. variation of armature voltage b. variation of field current

With regards to AC Motors, the apprentice is able to :

• describe the theory of operation including : a. synchronous, rotor & slip speed b. rotating magnetic field in three phase motor c. change of direction of rotating magnetic field d. torque / Slip curves e. methods used to reduce starting current f. the main components inc. the rotor, stator windings, and bearings g. the production of the rotating magnetic field in a single phase AC induction

motor

• describe the principles applied to control AC motors including : a. the number of pairs of poles b. the infinitely variable gearbox c. the variation of supply frequency

• describe the principles applied to control the speed of industrial AC motors including : a. how to interrogate, monitor and modify parameters and programmes in

industrial inverters




MODULE TITLE : PROGRAMMABLE LOGIC CONTROLLERS (PLC)

MODULE NO. : CE37

SCOPE : Develop the apprentices’ theory, practical knowledge and understanding of ladder diagram-based Programmable Logic Controllers (PLC) in accordance with the current training objectives


CE37

1.

2.

3.


• input and output devices including : a. optical isolation of input and output devices from the plc system b. how power is sourced for input output devices c. installation and removal of input / output devices

• ladder diagrams : a. write a simple plc program using ladder diagrams

• PLC programming including : a. monitoring an operational PLC program by use of laptop computer or other

monitoring device b. make software modifications to the PLC ladder diagram c. understanding the safety precautions required prior to down-loading a PLC

program

MODULE TITLE : ELECTRONICS HANDSKILLS

MODULE No. : CE38

SCOPE : Develop the apprentices’ practical knowledge and experience of soldering and circuit board assembly in accordance with the current training objectives


CE38

1.

2.

3.

4.

The apprentice is able to demonstrate practical knowledge and ability to :

• identify and describe the safety requirements for soldering

• solder, de-solder, and replace discrete components on a printed circuit board

• make simple track repairs to a printed circuit board.

• assemble and test basic electronic circuits and/or components mounted on vero-board, strip-board or similar




MODULE TITLE : HAZARDOUS AREA

MODULE NO. : CE39

SCOPE : Develop the apprentices’ theory and practical knowledge and understanding of ladder diagram-based Programmable Logic Controllers (PLC) in accordance with the current training objectives To complete training & assessment in maintenance of electrical & instrument equipment


CE39 1.

The apprentice will be able to demonstrate knowledge of the following in order that they can comply with the Electricity at Work Regulations (1989), ATEX Directives, Dangerous Substance in Explosive Atmosphere Regulations (2002) (DSEAR) :

a. Area Classification and Zoning b. Gas Groups

c. Temperature Classification

d. sources of ignition

e. Ingress Protection (IP) ratings and Impact Protection

f. equipment classification and selection

g. equipment and systems marking and identification

h. earthing and bonding

i. equipment and systems protection methods

j. wiring systems and glanding

k. Permit to Work

l. electrical isolation and de-isolation m. installation, maintenance, inspection & testing




MODULE TITLE : PORTABLE APPLIANCE TESTING (PAT)

MODULE NO. : CE40

SCOPE : To develop knowledge and understanding of the Regulatory requirements for

testing portable electrical equipment, the methods and equipment used to perform

the tests, and how to record and interpret the test results.


CE40

1

2

3

4

5

6

7

8

9

The apprentice will :

• develop their knowledge and understanding of the Regulatory requirements for the testing and maintenance of portable electrical equipment, notably the I.E.T. Regulations (17th Edition) and Electricity At Work Regulations (1989)

• be able to identify the different categories, types, method of construction, and classification of portable electrical equipment

• be able to demonstrate and explain how to visually inspect an item of portable electrical equipment

• develop their knowledge and understanding of the “in-service” tests carried out on different types of classes of electrical equipment

• demonstrate the methods used to complete practical “in service” inspection and testing on items of electrical equipment

• be able to interpret the test and inspection results and determine the suitability of the electrical equipment for use

• develop knowledge and understanding of how to complete formal Inspection and Test records, explain why they are necessary, and the Regulatory requirements for record-keeping

• determine, based upon the Inspection and Test records, suitable frequencies of maintenance and testing

• be able to explain why maintenance and test frequencies are susceptible to change




MODULE TITLE : LOCK OUT TAG OFF SYSTEM

MODULE No. : CE41

SCOPE : Record student knowledge and understanding of Lock out Tag off


CE41

1

2

The student will be able to:

• Explain and demonstrate knowledge of the LOCK OUT TAG OFF system including the following.

a) Understand the meaning /definition/purpose of LOTO. b) Understand the requirements of LOTO. c) Understand the procedures for LOTO d) Understand types of hazardous energies.

• Sit a formal written test on LOTO. (Pass mark 70 out of 100)




SECTION 3

INSTRUMENTS ‘Control’

SATISFACTORY KNOWLEDGE AND UNDERSTANDING OF THE FOLLOWING ITEMS HAS

BEEN DEMONSTRATED VIA OBSERVATION OF PRACTISE AND THE COMPLETION OF

PRACTICAL AND WRITTEN ASSIGNMENTS AND TESTS.








MODULE TITLE : WORKSHOP / PLANT SAFETY (PROCEDURES & PRACTICE)

MODULE No. : CI12

SCOPE : Develop apprentice awareness, knowledge, understanding and experience of workshop safety with regards to tools, equipment, behaviour and practises in accordance with the current training objectives.

OBJECTIVE NO. SUCCESS CRITERIA

CI12

1

2

3

4

5

6


• maintaining safety of self by ensuring : a) overalls are a suitable fit and are securely fastened to chest level b) overalls sleeves are rolled down and cuffs are in good condition c) overalls are clean / relatively free from contamination, e.g. grease d) boots are the correct fit and laces are appropriately tied e) jewellery is either removed or suitably covered before work

commences f) any loose items are removed and, when applicable, any long hair is

suitably protected g) gloves and eye protection are worn and are suitable for the task

• the importance of housekeeping before, during and after the task is completed

• awareness of the workshop/ plant environment and the associated hazards including :

a) the presence of dangerous air pressures b) protruding edges c) heavy and/or unbalanced loads d) the presence of moving parts that have the potential to harm, e.g.

valve gates e) the presence of electrically controlled equipment f) potentially hot equipment g) contaminated PPE, equipment and tools h) hazardous substances, e.g. resins, adhesives, lubricants, etc)

• visual inspection of all tools and equipment prior to, and following, their use

• selecting the correct tool for the task

• the correct values and behaviours including : a) paying attention to the task and any instructions being given b) keeping the work area and tools and equipment clean c) recognising potential hazards and act upon them d) maintaining personal hygiene e) recognising the impact of tiredness and/or stress f) awareness of the impact of their behaviour on others




MODULE TITLE : INSTRUMENT EQUIPMENT and SYSTEMS

MODULE No. : CI13

SCOPE : Refresh previous practice and further develop the apprentice’s knowledge, understanding and experience of basic instrument maintenance procedures on a variety of instrument systems in accordance with current training objectives.


CI13

1

2

3

4

5

6

7

8

9

10

11

12

13

14


• read instrument loop drawings/and data sheets for the purpose of commissioning, maintenance and fault finding

• identify the components through selection, construction and test of basic control loops for measurement and control of the following process variables :

a) flow. b) level c) pressure d) temperature

and can demonstrate an understanding of principles of operation

• select and use appropriate test equipment for commissioning/ testing loops

• calibrate (in-situ, and on the bench) components of an instrument control loop

• re-range transmitters for a different applications

• carry out scheduled checks on instrument loops containing Smart technology

• use a logical fault finding approach, using such techniques as : a) algorithm approach b) functional block diagram c) half splitting technique

• determine faults using fault finding procedures, and identify suitable remedy

• correctly install/ replace instrument air supply and signals lines, using correct pipework and fittings

• install/ replace instrument signal cables, including correct use of cable tray

• can identify a range of methods used for cable marking, paying attention to use of junction boxes

• is aware of IP rating in association with Junction boxes

• identify different methods of installing instrument equipment, paying special attention to how the process media is accessed and transported from the process line/ vessel.

• Identify potential issues associated to impulse piping, and how these may affect process readings




MODULE TITLE : ANALYSIS AND ANALYTICAL INSTRUMENTATION

MODULE No. : CI14

SCOPE : Develop apprentice awareness, knowledge, understanding of process analysis and experience of analytical instrumentation in accordance with the current training objectives.


CI14

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16


• explain the meaning of pH and the scales used.

• demonstrate an understanding of how pH values are measured using the colourimetric method, i.e., litmus, universal indicator.

• recognise industrial type pH installations.

• explain the different types of electrodes used and the need for care during handling and storage.

• demonstrate knowledge of buffer solutions by using them to check an industrial pattern pH meter.

• explain the basic principles of chromatography, how it is used and the basic maintenance procedure.

• describe the basic principles, operation of, and applications for the following : • oxygen analysers • liquid conductivity analysers • radiation absorption analysers • hygrometry • thermal conductivity analysers (katharometers)

• explain and demonstrate the need for a suitable sampling system, and Identify the common faults that may be associated with it

• define Density and Specific Gravity

• explain the use of the Hydrometer to measure Specific Gravity

• explain how temperature can effect density, and other variables such as pH and concentration

• demonstrate an understanding of the buoyancy method of density measurement

• demonstrate an understanding of the equipment used to measure density using a DP transmitter and double dip pipe

• explain the basic principles with regard to the radioactive method of measuring density

• carry out routine tests on a typical Process Analyser systems




MODULE TITLE : HAZARDOUS AREAS

MODULE No. : CI15

SCOPE : Develop apprentice awareness, knowledge and understanding of the designation of a hazardous area and the different levels of protection available for electrical and instrument equipment designed for use in hazardous areas in accordance with the current training objectives.


C115

1

2

3

4

5

6

7

8

9

10


• demonstrate understanding of the design principles used in the construction of equipment suitable for use in hazardous areas (ExN, Exe, Exd) with particular emphasis on :

a) Intrinsically Safe (Exi...) b) Purged (Exp)

• describe the common maintenance procedures for working on hazardous area protected equipment

• demonstrate an understanding of the following terms : a) flashpoint b) auto-ignition c) flammable mixture d) lower explosive limit (LEL) e) upper explosive limit (UEL) f) Gas Groups g) Temperature Classification , T1-T6 and T amb.

• explain the meaning of the term “Area Classification”, the definitions of the different Areas and why specialised equipment is required within them

• carry out maintenance activities on hazardous area equipment: including: isolating, removing, inspect and reinstate hazardous area protected equipment

• identify and explain the certification code found on all the pieces of equipment with reference to applications, limitations and compatibility with other items of hazardous area pieces of equipment

• explain the purpose and principle of operation of Zener Barriers and Galvanic Isolators

• describe the safety procedure when testing equipment in hazardous areas

• demonstrate how to fault-find on an Intrinsically Safe instrument loop, and safety use appropriate test equipment.

• Identify a range of legislations, that relate to use of electrical equipment in Hazardous areas ie: HSE, DSEAR, EPS, ATEX




MODULE TITLE : CONTROL and SHUTDOWN VALVES

MODULE NUMBER CI16

SCOPE : Develop apprentice awareness, knowledge, understanding and experience of control valves and control valve systems in accordance with the current training objectives


CI16

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16


• recognise a range of control valves and describe their operation, including:

Gland Seal Control valve

Bellows Seal Control valve

Ball Valve

Diaphragm valve

Butterfly valve

• identify (from stripped down valve) causes of valve failure or poor performance, and were appropriate take action to correct. Ie: replacing seals/ grinding plug and seat etc

• explain the requirement for a positioner on control valves

• safely strip down a range of actuators, and able to take into account spring loaded tension

• carry out pressure test on refurbished control valve(s) to check for ‘valve passing’, stroke length, and poor shut off

• remove a control valve from a process line, taking in to account appropriate methods of isolation for supply, signal and process

• correctly introduce ‘process’ bypass network, to enable a valve to be isolated for maintenance, to minimise the risk of process disturbance or shutdown

• identify/ demonstrate methods of process decontamination of a control valve, to enable safe maintenance

• install/ commission control valve(s) into a process line and connect up the air lines in the correct sequence and manner

• complete a stroke check on a control valve, from controller and locally

• explain the difference between a direct and a reverse acting positioner

• complete a test of the control valve action in order to achieve the desired action, taking into consideration air fail actions

• explain the characteristics of valve and plug types, and state what is meant by the CV

• explain/ demonstrate the importance of the correct CV and characteristic selection

• explain the operation of, and give applications for “Split Ranging”

• demonstrate an understanding of Digital Valve Positioners (DVC’s)




MODULE TITLE : PROCESS CONTROL

MODULE No. : CI17

SCOPE : Develop apprentice awareness, knowledge, understanding and experience to complete basic maintenance on a number of controlling instruments and control systems in accordance with current training objectives.


CI17

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

The apprentice is able to

• define standard technology in accordance with British Standards.

• state the objectives of a control system.

• identify the elements of a control system and describe purpose of each element

• explain, with the aid of a drawing if required, the characteristics of : a) an open loop system b) a closed loop system

• define the following: a) desire value b) set point value c) measured or process variable d) output signal

• explain, and give examples of, Distance Velocity Lag.

• explain, and give examples of, Transfer Lag.

• explain the operating conditions when a control system is operating in : a) Manual Control b) Hand Bypass Control c) Automatic Control

• define proportional band and gain

• explain integral action in terms of minutes and repeats per minute

• explain proportional action and state examples where a proportional only controller could be used.

• explain the effects of offset with particular regard to load changes.

• explain how the addition of integral action can eliminate offset

• give examples where P+I control would be most advantageous.

• explain the need for derivative action and give one example of a process which would necessitate P+I+D.




MODULE TITLE : PROCESS CONTROL (cont’d)

MODULE No. : CI17


CI17

16

17

18

19

20

21

The apprentice is able to:

• explain the basic function of an electronic controller.

• configure an electronic controller

• tune an electronic controller

• explain bump-less transfer, and its impact when switching from Auto/Man etc

• connect up an electronic controller as part of a control loop

• access the controller faceplate on a DCS system, and use this to perform ‘valve stroke checking’, and adjusting controller parameters.

MODULE TITLE : MODES OF CONTROL

MODULE No. : CI18

SCOPE : Develop apprentice awareness, knowledge and understanding of the available modes of process control in order to complete basic maintenance on control systems in accordance with current training objectives.


CI18

1

2

3

4

5

The apprentice is able to explain :

• a cascade control system and provide an example where this could be an advantage in place of a simple ‘single’ control loop

• a ratio control system and give an example of a typical application

• how a feed forward system operates and give a typical example

• how an adaptive control system operates and identify a typical example.

• how to loop tune a cascade control system, and demonstrate this practically.




MODULE TITLE : DISTRIBUTIVE CONTROL SYSTEMS (DCS)

MODULE No. : CI19

SCOPE : Develop apprentice awareness, knowledge, understanding and experience to complete basic maintenance on DCS control systems in accordance with current training objectives


CI19

1

2

3

4

5

6

7

8

9

10

11


• explain how a supervisory control system operates and the advantages of this system on a process

• understand the basic architecture of the DCS system, and recognise the component parts of a DCS system

• navigate around the screen and toolbar, state what information can be displayed

• interrogate historical information, and demonstrate the value of this

• use faceplates in order to carry out maintenance

• display multiple faceplates

• test discrete inputs and outputs function

• test analogue inputs and outputs function

• complete routine scheduled maintenance using the DCS screen

• investigate how ‘new’ control loops are developed and added in a DCS system

• recognise different types of I/O cards




MODULE TITLE : SHUTDOWN / TRIP and SAFETY SYSTEMS

MODULE No. : CI20

SCOPE : Develop apprentice awareness, knowledge, understanding and experience to carry out basic maintenance and checks on emergency plant shutdown systems in accordance with current training objectives.


CI20

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• state the reasons for emergency shutdown systems, both morally and legally

• explain the need for voting systems

• can recognise and demonstrate basic understanding of functional logic diagrams related to trip systems

• explain the reasons for the following : a) trip override b) long term overrides.

• explain the reasons for manual reset

• install an instrument/ or maintain an instrument which is part of a shutdown system

• recognise a loop containing a safeguard system

• describe the operation of shutdown system

• explain the alarms associated with the following : a) shutdown trip b) trip isolate c) long term override d) pre-alarm

• can describe the operation of a shutdown system from the schematic diagram for the following :

a) 1-10 input b) 2 out of 3

• complete scheduled checks on a shutdown / Trip system

• describe the general characteristics of a common alarm system

• explain the term fail-safe when used in conjunction with alarm systems

• provide examples of typical colour coding for annunciator windows, and explain the necessity for a system

• explain why different audible devices are used to determine alarm priority

• describe the use of the various types of alarm cards, i.e. fleeting, 1st up, etc

• show awareness of Instrument based Safety Systems (S.I.S), IEC 61511 Functional Safety, and S.I.L (Safety Integrity Levels)




MODULE TITLE: IEC61511 Safety Instrumented Systems in the Process Industry

MODULE No. CI20 (point 17)

SCOPE : By the end of this module learners will have an appreciation of : OBJECTIVE No. SUCCESS CRITERIA

CI20 (point17)

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Legislation

• What it Means • How it Evolved • Responsibilities of Process Company • Responsibilities of Employees

Risk Assessment

• Attitudes – Consequence Vs Frequency • Acceptable Risk • Risk Triagle • ALARP

SIL Rating

• What it means • Life Cycle Analysis • Calculating SIL ratings • Creating a SIL system • Maintaining SIL

Probability of Failure on Demand (PFD)

Factors Affecting PFD • Equipment Quality • Process • Environment • Like for Like Replacement • Complexity of Design • Maintenance • Frequency of Checks

Working Practices

• Accuracy • Recording • Overrides Discipline




MODULE TITLE : DIGITAL TECHNOLOGY

MODULE No. : CI21

SCOPE : Develop apprentice awareness, knowledge, understanding of how Digital technology has developed and is applied within instrumentation systems, in accordance with current training objectives.


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• give a basic explanation of Analog to Digital, and Digital to Analog signal Conversion

• demonstrate a basic understanding of HART communication

• demonstrate a basic understanding of FIELDBUS ‘networked systems’

• briefly explain the benefits of using ‘smart’ and ‘Fieldbus’ communication verses standard 4-20mA systems.

• Introduce/ Hook-up , and use a ‘SMART’ communicator to access ‘set up’ information from a range of transmitters (bench and online)

• Use a ‘SMART’ communicator to perform basic maintenance tasks on a SMART transmitter control loop, including re-ranging and loop testing

• Describe how digital technologies can be used in ‘predictive maintenance’.

• Able to identify Fieldbus and HART device(s), from their markings

MODULE TITLE : MAINTENANCE PROCEDURES

MODULE No. : CI22

SCOPE : Develop apprentice awareness, knowledge, understanding and experience to work , and communicate effectively as would an instrument technician on site, in accordance with current training objectives.


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• perform a range of tasks, on a ‘live’ process plant, typical of those carried out by an instrument technician on site.

• understand the impact that maintenance tasks may have on process operations

• use a computer system for logging faults and the retrieval of historical data

• liase with process personnel when carrying out plant maintenance activities

• Carry out appropriate risk assessment, work safely, following appropriate procedures, in accordance with plant permit to work systems

• carry out maintenance activities creating minimal disturbance to plant operations

• use instrument/ process line diagrams to support maintenance activity




Documents

Phase 2 Core Power and Control RoA.3