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MEM18060 Current

Application

This unit of competency defines the skills and knowledge required to determine control loop characteristics, monitor and record the operation of a control loop, localise the fault condition, and replace or repair the faulty condition.

It applies to split architecture single/multiple loop control instrumentation that includes programmable logic controllers (PLCs), distributed control systems (DCS) and computer-based systems.

Where fault-finding is required to electronic component level unit MEM18056 Diagnose and repair analog equipment and components and unit MEM18065 Diagnose and repair digital equipment and components, should also be selected as appropriate.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

What You'll Learn

1. Determine job requirements

  • 1.1 Follow standard operating procedures (SOPs)
  • 1.2 Comply with work health and safety (WHS) requirements at all times
  • 1.3 Use appropriate personal protective equipment (PPE) in accordance with SOPs
  • 1.4 Identify job requirements from specifications, drawings, job sheets or work instructions

2. Determine control loop operating characteristics

  • 2.1 Examine engineering specifications, technical information and historical trends for relevant data
  • 2.2 Examine, read and interpret system specifications, operational data and other relevant data sources and note relevant conclusions
  • 2.3 Consult with system operators and other relevant plant personnel and extract relevant data and document by appropriate means
  • 2.4 Observe operation of the system by applying all control loop device characteristics, controller mode principles and adjustment methods

3. Monitor and record operation of a control loop

  • 3.1 Interpret pneumatic, electrical and electronic circuit diagrams
  • 3.2 Set point and manual output changes by applying all control loop device characteristics, controller mode principles and calibration/adjustment methods, and loop operation from the controller response using appropriate test equipment, principles and procedures
  • 3.3 Interpret software configuration data for digital control systems
  • 3.4 Monitor and record operational responses
  • 3.5 Utilise fault-finding and diagnostic techniques throughout the checking and testing procedures including simple and multi-controller type control schemes
  • 3.6 Analyse diagnostic results and conclusions against predetermined operational specifications

4. Localise fault condition

  • 4.1 Test circuits to the level necessary to identify and localise faults using fault-finding, diagnostic techniques and appropriate test equipment
  • 4.2 Utilise drawings/diagrams and operational testing data in identifying and localising fault conditions
  • 4.3 Verify and localise fault condition to major component level using appropriate test equipment, procedures and techniques

5. Replace faulty items or repair faulty condition

  • 5.1 Dismantle components for repair or replacement using appropriate tools, equipment and techniques
  • 5.2 Select replaceable items from manufacturers’ catalogues, spare parts lists or data sheets
  • 5.3 Repair faulty condition, where applicable
  • 5.4 Reassemble repaired and replaceable items

6. Calibrate and adjust control instrumentation

  • 6.1 Calibrate and adjust panel mounted, split architecture single loop/multiple loop control instruments using appropriate calibration principles, equipment and methods for all devices according to manufacturers’ instructions
  • 6.2 Adjust controller modes and actions are adjusted according to specifications
  • 6.3 Undertake zero span and range checks using appropriate configuration
  • 6.4 Make final adjustments to control instrumentation to meet specifications

7. Complete service reports and recommission

  • 7.1 Complete service reports in accordance with SOPs
  • 7.2 Adopt appropriate follow-up procedures
  • 7.3 Recommission control instrumentation in accordance with SOPs

Assessment Requirements

Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria on at least two (2) occasions and include:

following work instructions, standard operating procedures (SOPs) and safe work practices

identifying and interpreting circuit diagrams, specifications, software data, diagrams and drawings, historical trends and documents and obtaining relevant data pertaining to the system components and operational data

consulting with system operators and other relevant personnel with respect to the control loop and confirming function/ malfunction of the system and/or its components

checking operational characteristics of the control devices, signal conversion instruments and final control elements for compliance to specifications

locating, reading and interpreting in-built fault indicators and error codes and identifying faults/defects in control system

obtaining relevant pneumatic, electrical and electronic circuit diagrams and testing and monitoring control loop for correct operation and recording the responses of the control system

using fault-finding and diagnostic techniques and procedures throughout the monitoring and testing phase and comparing collected data with the operational specifications of the control system

dismantling, repairing and reassembling faulty components, including selecting replacement parts from manufacturer/supplier catalogues

calculating the control loop characteristics for the appropriate system in accordance with specifications

setting and adjusting the controller modes using appropriate test and calibration equipment

checking the control instrumentation for correct zero, span and range and making final adjustments, as required and recommissioning the control system

completing all service reports in accordance with SOPs.

Knowledge Evidence

Evidence required to demonstrate the required knowledge for this unit must be relevant to and satisfy the requirements of the elements and performance criteria and include knowledge of:

safe work practices and procedures and use of personal protective equipment (PPE)

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

relevant data, including information from in-built devices, on the control loop characteristics

specifications of each system component

control programming

supervisory control and data acquisition (SCADA) systems, programmable logic controller (PLC) systems, distributive control systems (DCS) and computer-based systems

procedures for:

documenting/reporting information and control system tests and analysis

isolating and testing the control system and its components

verifying apparent faults in circuits and/or control system components

marking components for repair or replacement

dismantling/disassembling components for repair or replacement

assembling repaired and/or replacement items

calibration of control system components and necessary equipment

checking control instruments for zero, span and range

making final adjustments to ensure all control system components conform to specification

commissioning the control system

signal transmission, including the principles of operation of the final control element, procedures for calibrating and adjusting the control system

correct function of the circuits and components within the control loop

calibration and adjustment methods for the control loop devices

configuration of the digital control system software

operational responses and procedures for monitoring and recording test and operational data

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

deeviations/variations from specification

correct maintenance procedures for serviceable item(s)

adjustments which affect the calibration to control system components

controller modes and actions

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

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

Assessment Conditions

Assessors must:

have vocational competency in maintaining, repairing control instrumentation – single and multiple loop control systems at least to the level being assessed with relevant industry knowledge and experience

satisfy the assessor requirements in the Standards for Registered Training Organisations 2015 or its replacement and comply with the National Vocational Education and Training Regulator Act 2011, its replacement or equivalent legislation covering VET regulation in a non-referring state/territory as the case requires

Where possible assessment must occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors, assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Foundation Skills

  • text: This section describes those required skills (reading, writing, oral communication and numeracy) that are essential to workplace performance in this unit of competency. Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Prerequisite Units

Parent Qualifications

Related Units

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Last updated from training.gov.au: 25 February 2026