Gas Network Craftsperson

Transcription

1 Gas Network Craftsperson Unit EIAU06 Maintaining Instrumentation and Control Equipment Circuits This assessment specification has been developed as part of the network maintenance craftsperson standard for the electrical and instrumentation apprentice. The specification details the required skills, knowledge and behaviour that a learner should expect to be assessed against during their training programme. This module should be designed to develop an apprentice s skills and knowledge on how to maintain instrumentation and control equipment circuits What does this specification look like? This is a training unit that could be delivered by the employer or a training organisation. The assessment specification is the minimum core standard of these requirements, but this does not preclude employers from enhancing the skills and knowledge of the learner through additional or company specific training. The knowledge and performance criteria should be used as the basis for training input. Both practical and written assessment should be included as part of this training. What do I need to take this module? Whilst there are no pre-requisites required for attendance at this training, the apprentice should be competent in the methods used for safe electrical isolation and operations. Candidates to be assessed as competent in this area must successfully meet the criteria listed below or have other unitary evidence demonstrating an equivalent level of competence. Evidence could be from the workplace or from a realistic simulated environment. This should be supported with a written assessment Energy & Utility Skills Group Page 1

2 Performance Criteria To achieve this unit, you will need to be able to: P1. Work safely at all times, complying with health and safety and other relevant regulations and guidelines P2. Carry out all of the following during the maintenance activities: a) Plan and communicate the maintenance activities so as to minimise any disruption to the process / system operation b) Obtain and use the correct issue of company and / or manufacturers drawings and maintenance documentation c) Adhere to procedures or systems in place for risk assessment, COSHH, PPE and other relevant safety regulations d) Where appropriate, ensure the insertion, or program override, of any relevant system trip defeats (such as fire extinguishant, emergency shutdown) e) Ensure the safe isolation of instruments (such as process, electrical, hydraulic, pneumatic, mechanical) f) Where applicable, ensure that appropriate decontamination procedures are used for instruments that have been used with hazardous (such as toxic, corrosive, inflammable, explosive, radioactive) substances g) Provide and maintain safe access and working arrangements for the maintenance area h) Carry out the maintenance activities, using appropriate techniques and procedures i) Dispose of waste items in safe and environmentally acceptable manner, and leave the work area in a safe condition P3. Carry out maintenance activities on four of the following types of instrumentation and control equipment: a) Pressure (such as absolute, gauge, vacuum) b) Flow (such as orifice plate, venturi tube, electromagnetic, ultrasonic, differential pressure cell, positive displacement) c) Level (such as floats, displacer, differential pressure cells, load cells, ultrasonic, conductivity) d) Temperature (such as bi-metallic, thermocouples, resistance, infra-red, thermal imaging) e) Weight (such as mechanical systems, load cells / strain gauges, transducers) f) Fiscal metering (such as gas, electricity, water, fuel) g) Detection and alarm (such as smoke, heat, gas, chemical, water, metal) h) Speed measurement (such as mechanical, electrical, stroboscopic) i) Emergency shutdown j) Speed control (such as mechanical governors, electrical governors, DC speed controller, AC motor control systems, stepper motors, invertors) k) Vibration monitoring (such as vibration switches, proximity probes, seismic 2017 Energy & Utility Skills Group Page 2

3 velocity transducer, linear variable differential transformers, portable data collectors) l) Nucleonic and radiation (such as Geiger-Muller tube, neutron counter, photomultiplier tube, proportional counter) m) Analysers (such as gas detection, spectroscopy, oxygen analyser, water analysis, moisture measurement, density) n) Recorders and indicators o) Telemetry systems (such as master station, outstation, standalone systems) p) Valves and valve mechanisms (such as control valves, valve actuators and positioners) q) Other specific instrumentation P4. Follow the relevant maintenance schedules to carry out the required work P5. Maintain instrumentation and control equipment in compliance with one of the following: a) Company and / or customer standards and procedures b) BS 7671/IEE Wiring Regulations c) BS, ISO or BSEN standards and procedures d) Equipment manufacturer s operation range P6. Carry out the maintenance activities within the limits of their personal authority P7. Carry out the maintenance activities in the specified sequence and in an agreed timescale P8. Carry out ten of the following maintenance activities, as appropriate to the equipment being maintained: a) Disconnecting electrical / pneumatic supply b) Disconnecting signal transmission c) Disconnecting process pipework d) Removing instruments from the system e) Replacing mechanical components f) Replacing electrical components g) Replacing complete instruments h) Tightening fastenings to the required torque i) Replacing peripherals (such as sensors, actuators, relays, switches) j) Replacing lifed items (such as seals, gaskets, batteries) k) Proof marking / labeling of removed wires or components l) Taking electrostatic discharge (ESD) precautions when handling components and circuit boards m) Setting, aligning and adjusting replaced instruments P9. Use four of the following types of test equipment: a) Analogue or digital meters b) Signal sources / generator c) Current injection devices d) Logic probes e) Signal tracer 2017 Energy & Utility Skills Group Page 3

4 f) Oscilloscope g) Standard test gauges h) Pressure sources i) Digital pressure indicators j) Special purpose test equipment P10. Return instruments and systems to service, to include carrying out all of the following: a) Connecting up process impulse pipework b) Connecting up electrical / pneumatic supply c) Connecting up signal transmission (such as electrical, electronic, pneumatic, mechanical) d) Confirming that signal measurement and transmission are satisfactory e) Final re-commissioning of the system and removal of any trip defeats P11. Report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule P12. Complete the relevant maintenance records accurately, to include one of the following, and pass them on to the appropriate person: a) Job cards b) Maintenance log or report c) Permits to work / formal risk assessment d) Company specific documentation P13. Dispose of waste materials in accordance with safe working practices and approved procedures Knowledge and Understanding To achieve this unit, you will need to be able to: K1. Describe the health and safety requirements of the area in which the maintenance activity is to take place, and the responsibility they place on the learner K2. Describe the isolation and lock-off procedure or permit-to-work procedure that applies to the system and instruments being worked on, and how to check that any stored energy in pipework and instruments has been released K3. Describe the specific health and safety precautions to be applied during the maintenance process, and their effects on others K4. Explain how to recognise and deal with victims of electric shock (to include methods of safely removing the victim from the power source, isolating the power source, and methods of first aid resuscitation) K5. Describe the importance of wearing protective clothing and other appropriate safety equipment during the maintenance activities, and where this can be obtained K6. Describe the procedures and precautions to be adopted to eliminate electrostatic discharge (ESD) K7. Describe the hazards associated with carrying out maintenance activities on instrumentation and control systems (such as stored pressure / force, electrical 2017 Energy & Utility Skills Group Page 4

5 supplies, process controller interface, using damaged or badly maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise them and reduce any risks K8. Explain how to obtain and interpret drawings, charts, specifications, manufacturers manuals, history / maintenance reports, symbols used on instrumentation and control documents, and other documents needed in the maintenance process K9. Describe the basic principles of operation of the instrumentation and control equipment being maintained, how the system functions, its operating sequence, the working purpose of individual units / components and how they interact K10. Describe the reasons for making sure that control systems are isolated or put into manual control, and appropriate trip locks; keys or program overrides are inserted, before removing any sensors or instruments from the system K11. Describe the identification and selection of instrument sensors (including how to identify their markings, calibration information, component values, operating parameters and working range) K12. Describe the correct way of fitting instruments to avoid faulty readings (caused by head correction, poor flow past sensor, blockages, incorrect wiring, poor insulation or incorrect materials) K13. Describe the correct and tidy installation and connection of external wiring and components, to avoid electronic interference or mechanical damage K14. Explain how to carry out visual checks of the instruments (such as checking for leaks, security of joints and physical damage) K15. Describe the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance process K16. Describe the company policy on the repair / replacement of components during the maintenance process K17. Describe the techniques used to dismantle / assemble integrated equipment (such as release of pressures/force, proof marking to aid reassembly, plugging exposed pipe / component openings, dealing with soldered joints, screwed, clamped and crimped connections) K18. Describe the methods of attaching identification marks / labels to removed components or cables, to assist with reassembly K19. Describe the methods of checking that components are fit for purpose, and the need to replace electronic modules, sensors, transmitters, transducers, electronic boards and other failed items K20. Explain how to check that tools and equipment are free from damage or defects, are in a safe and usable condition, and are configured correctly for their intended purpose K21. Describe the generation of appropriate documentation and / or reports following the maintenance activity K22. Describe the equipment operating and control procedures to be applied during the maintenance activity K23. Describe the problems that can occur during the maintenance of the instrumentation and control system, and how they can be overcome 2017 Energy & Utility Skills Group Page 5

6 K24. Describe the organisational procedure to be adopted for the safe disposal of waste of all types of material K25. Describe the extent of their own authority and to whom they should report if they have problems that they cannot resolve 2017 Energy & Utility Skills Group Page 6