Contents · This energy can be pneumatic pressure, electric current, or hydraulic pressure, which...
Transcript of Contents · This energy can be pneumatic pressure, electric current, or hydraulic pressure, which...
IAS/Q3001 Instrumentation Technician (Control Valve)
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Contents
1. Introduction and Contacts……….…..P1
2. Qualifications Pack……….……...........P2
3. Glossary of Key Terms.…………………P4
4. OS Units……….……………..…..….….…..P7
5. Nomenclature for QP & OS…..…..…P46
6. Assessment Criteria........................P48
technology consul t ing
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]
Qualifications Pack- Instrumentation Technician
(Control Valve)
SECTOR: INFORMATION TECHNOLOGY-
INFORMATION TECHNOLOGY ENABLED SERVICES
(IT-ITES)ces Helpdesk Attendant
SECTOR: INSTRUMENTATION AUTOMATION SURVEILLANCE & COMMUNICATION
SUB-SECTOR: Automation, Instrumentation
OCCUPATION: Maintenance
REFERENCE ID: IAS/Q3001
ALIGNED TO: NCO-2015/ NIL
Instrumentation Technician (Control Valve) is employed in process industries such as Oil & Gas, Petrochemicals, Fertilizers, Power Plants and Chemical industries. Control Valve is a vital part of a closed control loop in these processes, consisting of measuring transmitters, controllers and final control elements.
Brief Job Description:
Ensuring proper operation, availability, performance and maintenance of Control Valve and Control Valve accessories in rotational or general shift duties and attending to emergency calls.
Personal Attributes: The individual must be self-disciplined; assertive; team player; action-orientated; possess analytical skills and problem solving ability; good inter personnel skills and ability to work under pressure.
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Introduction
QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR INSTRUMENTATION AUTOMATION SURVEILLANCE AND COMMUNICATION INDUSTRY
Qualifications Pack For Instrumentation Technician (Control Valve)
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Job Role Instrumentation Technician (Control Valve)
Role Description
Ensuring proper operation, availability, performance and maintenance of Control Valve and Control Valve accessories in rotational or general shift duties and attending to emergency calls.
NSQF level 4 -------------------------------------------------------------------------------------------
Minimum Educational Qualifications 12th pass, Preferably ITI - Instrumentation/Electrical/Electronics
Maximum Educational Qualifications NA
Training (Suggested but not mandatory)
a. Training course on Control Valve Maintenance (six weeks duration)
b. Practical hands-on training (four weeks duration)
Minimum Job Entry (Age) 20 Years
Experience
2 - 5 years relevant industry experience, depending on qualification
For 12th pass: Five years, of which two year on general Instrumentation Technician and Control Valve Maintenance duties.
For ITI - Instrumentation/Electrical/Electronics: Three years – of which one year as a general Instrumentation Technician and one year on Control Valve Maintenance duties.
For Diploma in Instrumentation/Electronics/Electrical: Two Years - as a general Instrumentation Technician, of which six months on Control Valve Maintenance duties.
Qualifications Pack Code IAS/Q3001
Job Role Instrumentation Technician (Control Valve)
Credits(NSQF) TBD Version number 1.0
Sector
Instrumentation, Automation Surveillance and Communication
Drafted on 30/07/2016
Sub-sector Instrumentation, Automation Last reviewed on 30/07/2016
Occupation Maintenance
Next review date 30/07/2019
Qualifications Pack For Instrumentation Technician (Control Valve)
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Applicable National Occupational
Standards (NOS)
Compulsory: 1. IAS/N0100 Maintain Control Valve Health 2. IAS/N0101 Preventive & Predictive Maintenance- Control Valve 3. IAS/N0102 Site Management – Process Control 4. IAS/N0103 Task Reporting - Process Control 5. IAS/N0104 Corrective Maintenance – Control Valve 6. IAS/N0105 Safety, Health and Environment – Process Control 7. IAS/N2105 Work Effectively With Teams
Optional: N/A
Performance Criteria As described in relevant OS units
Qualifications Pack For Instrumentation Technician (Control Valve)
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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 Digital Valve Controller (DCS]
Control Valve Control Valve 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 Valve 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.
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)
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.
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 Valve
Def
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Qualifications Pack For Instrumentation Technician (Control Valve)
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and accessories such as Valve positioners.
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.
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.
Standards Body 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)
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’.
Qualifications Pack For Instrumentation Technician (Control Valve)
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Unit title Unit title gives clear overall statement about what the incumbent should be able to do.
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
DCS Digital Valve Controller
IBR Indian Boiler Regulations
PM Preventive Maintenance
PRM Predictive Maintenance
PST Partial Stroke Testing of Control Valve
SHE Safety, Health and Environment
Acr
on
yms
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IAS/N0100 Maintain Control Valve Health
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National Occupational
Standard
Overview
This unit is about maintenance of Control Valve Installations by checking Control Valve health at regular intervals.
IAS/N0100 Maintain Control Valve Health
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Unit Code IAS/N0100
Unit title (task) Maintain Control Valve Health
Description The OS unit is about maintaining Control Valve health in a Process Control where instrumentation and control valve related activities take place.
Scope The scope of this task includes performing:
Integrity checks
Visual Checks
Control Valve Installations –Visual Checks
Housekeeping in Control Valve testing bay
Electrical safety norms
Consumables storage and consumption
Status of control valve name plate
Work Area audit
Entries and closing of Check Lists
Performance Criteria (PC) with respect to the scope
Element Performance Criteria
Perform Integrity checks PC1. Perform Control Valve Health Checks as prescribed by Organizational norms in the following areas:
Control valve installations and their accessories
Control Valve testing bay in the Instrumentation workshop, test equipment and test pumps
Perform Visual Checks PC2. Perform following checks and report to supervisor:
Check for visual damage or tampering on actuator
Check for visible damage or tampering on valve positioner
Check for misuse of control valve installation by other agencies – for example, for climbing or using as support for their work
Check for building roof leakage/seepage which result in water splash and ingress
Perform Control Valve Installations –Visual Checks
PC3. Check housekeeping near control valve installations
Check for oil/water spillage
Check for cluttering around the control valve which hampers free access to the valve
Perform Housekeeping in Control Valve testing bay
PC4. Check housekeeping in Control Valve testing bay in Instrumentation Workshop
Check for Oil / water spillage on testing floor
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IAS/N0100 Maintain Control Valve Health
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Check for clear working space and safe parking of overhead crane
Follow Electrical safety norms
PC5. Check for lighting / associated electricals near control valve installation
Ensure lights near Control valve installations operate
Check for temporary/unsafe electrical wiring – report to Electrical department
Monitor Consumables storage and consumption
PC6. Ensure optimum storage of cleaning solvent, lubrication items and related maintenance consumables at designated space. Ensure that these are used optimally (avoid wastage and spillage)
Check Status of control valve name plate
PC7. Check name plate of the manufacturer on the valve and clean with solvent, as required. Inform supervisor if damaged or missing.
Undertake Work Area audit PC 8. Undertake work area audit with supervisor for Control Valve Installations and Control Valve testing bay areas as per work area audit check sheet
Complete Entries and closing of Check Lists
PC9. Complete entries of Check Lists for Control Valve Health issued by the company
Complete check list entries for Control Valve Health for control valve installations and control valve testing bay
Transfer entries as applicable to Preventive Maintenance list or Opportunistic Shut down List
Follow up Check Lists for Control Valve Health and close
Knowledge and Understanding(K)
A. Organizational context (Knowledge of the company / organization and its process relevant to areas of responsibilities)
KA1. Understands how Control Valve impact the process operations.
Understands how control valve malfunction will affect a particular control loop.
Understands relation of maintenance time to production loss in process operations.
KA2. Understands how site conditions impact control valve operations.
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. How Control Valve maintenance is performed in the organization.
KB3. Hazardous chemicals and their handling procedures.
Skill(S)
IAS/N0100 Maintain Control Valve Health
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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 Control Valve Health SA2. Write emails and messages about Control Valve related issues
Reading Skills
The user/individual on the job needs to know and understand how to: SA3. Read product literature and manuals relevant for the job SA4. Read the company information about working practices at the Control Valve SA5. Read the information displayed at the workplace
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA6. Describe Control Valve conditions and issues to co-workers and supervisor SA7. Communicate to the management in meetings about Control Valve Health issues to get their support SA8. Interact with coworkers and gather information related to process and Control Valve conditions
B. Professional Skills Decision Making
The individual on the job needs to know and understand how to:
SB1. Make decisions pertaining to the concerned area of work
Plan and Organize
The individual on the job needs to know and understand: SB2. How to prioritize daily activities for the upkeep of process operation through ensuring availability of operation of Control Valve.
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 user/individual on the job needs to know and understand how to: SB5. Think through the problem, evaluate the possible solution(s) and suggest an optimum /best possible solution(s) SB6. Identify immediate or temporary solutions to resolve delays
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
IAS/N0100 Maintain Control Valve Health
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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 SB12. Anticipate problems, risks and opportunities and utilize these for mitigation and business optimization
IAS/N0100 Maintain Control Valve Health
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NOS Version Control
NOS Code IAS/N0100
Credits (NSQF)
TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector Instrumentation, Automation Last viewed on 30/07/2016
Occupation Maintenance Next Review Date 30/07/2019
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IAS/N0101 Preventive and Predictive Maintenance – Control Valve
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National Occupational
Standard
Overview
The unit is about conducting regular Preventive Maintenance supported by Predictive Maintenance activities of Control Valve in a process plant.
IAS/N0101 Preventive and Predictive Maintenance – Control Valve
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Unit Code IAS/N0101
Unit title (task) Preventive & Predictive Maintenance – Control Valve
Description The OS unit is about performing Preventive Maintenance supported by Predictive Maintenance for Control Valve
Scope This Unit Task covers the following :
Obtaining Work Permit
PM Schedule Execute
Preparing Process List
Planning PM Schedule
Visual checks and action
Completion of preventive maintenance schedule
Preparing PRM List
Listing PM Jobs to be taken during Shut down
Following up PM List
Performance Criteria (PC) with respect to the scope:
Element Performance Criteria
Obtain Work permit PC1. Obtain work permit (mandatory) from the Process Supervisor before commencing maintenance work
Execute PM Schedule PC2. Carry out Preventive maintenance jobs as per available Preventive Maintenance Schedule
Prepare Process List PC3. Prepare list on basis of process request
Plan PM Schedule PC4. Plan for next day preventive maintenance schedule
Perform Visual Checks and corrective actions
PC5. Carry out-Visual Checks and action wherever possible or else transfer job to shut down list.
Check for abnormal vibration – locate source- correct and/or inform the supervisor
Check abnormal noise and locate source. If it is cavitation or flashing induced noise inform supervisor and Process supervisor
Check for gland leak and arrest. If not possible, inform supervisor and transfer to shut down list
Check for Instrument air leaks – arrest leak, if not possible inform supervisor and transfer to shut down list
Check for control valve bonnet and body flange leaks – inform Process supervisor and Instrument supervisor
Check for poor electric integrity like exposed terminal and open enclosure- rectify, .If not permitted inform supervisor and transfer to
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IAS/N0101 Preventive and Predictive Maintenance – Control Valve
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shut down list
Check pneumatic and electric connections to solenoid valve
Check for integrity of valve positioner feedback link / connection and rectify fault after informing Process supervisor
Check for environment impact, water ingress and corrosion. Rectify fault or if not possible, transfer to shut down list
Check for loose bolting and rattling in control valve and accessories including manual operator- rectify fault
Complete PM Schedule
PC6. Complete preventive maintenance schedule list of control valve body, actuator and accessories. Close the issues in the list.
Prepare PRM-List PC7. Collect and consolidate daily diagnostic messages from Control Valve which have a digital valve controller and record the same in either Preventive Maintenance list or Opportunistic shut down list for execution
List PM Jobs to be taken during Shut down
PC8. Include in the list preventive maintenance jobs to be taken during annual shut down or opportunistic shut down
Follow up PM list PC9. Follow up on consolidated preventive maintenance list and close.
Knowledge and Understanding (K)
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 Valve KA3. Aware of Maintenance Policy of the company with respect to control valve maintenance strategy
B. Technical Knowledge
Needs to know and understand: KB1. Trouble Shooting on:
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. Familiar with hazardous area zone classification and process media hazards KB3. Uses Control Valve Manual when required KB4. Familiar with PST, a feature of DCS
Skill(S)
A. Core Skills / Generic Writing skills
IAS/N0101 Preventive and Predictive Maintenance – Control Valve
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Skills The individual on the job needs to know and understand how to: SA1. Use Formats and check list for Control Valve Health 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
Oral Communication (Listening and Speaking skills)
The individual on the job needs to know and understand how to:
SA7. Describe condition of Control Valve and accessories and issues to co-workers 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
B. Professional Skills 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 Valve and analyses reasons and concludes SB7. Identify immediate or temporary solutions to resolve delays and discuss with the Supervisor
Analytical Thinking
IAS/N0101 Preventive and Predictive Maintenance – Control Valve
17
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
IAS/N0101 Preventive and Predictive Maintenance – Control Valve
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NOS Version Control
NOS Code IAS/N0101
Credits (NSQF) TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector
Instrumentation, Automation
Last viewed on 30/07/2016
Occupation Maintenance Next Review Date 30/07/2019
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IAS/N0102 Site Management – Process Control
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National Occupational
Standard
Overview
The unit is about Site Management which involves coordination with Statutory Authorities, Vendors on Service Contract and coordination with other departments during opportunistic and annual shut downs.
IAS/N0102 Site Management – Process Control
20
Unit Code IAS/N0102
Unit title (task) Site Management – Process Control
Description Coordinate work related to audits by Statutory Authorities, Vendors performing Service contract and coordination work with other departments during opportunistic / annual shut downs.
Scope This Unit Task covers the following :
Statutory Audits
Service Contract vendor interaction
Inspection & Test Reports
Shut downs
Store procedures
Performance Criteria (PC) with respect to the scope:
Element Performance Criteria
Support Statutory Audits The individual on the job needs to:
PC1. Support the plant authorities during inspection - such as IBR inspection formalities and stamping of IBR items including Control Valve and associated accessories which fall in the IBR area
Interact with Service contract vendors
The individual on the job needs to:
PC2. Perform formalities of the site visit of the representative of the Service Contract vendor for Control Valve. Locate and identify the Control Valve and accessories to be covered by the vendor.
Prepare Inspection &Test Reports
The individual on the job needs to:
PC3. Prepare the appropriate Inspection and Test reports
Support Shut Down procedures
The individual on the job needs to:
PC4. Support formalities and coordination relating to Process and Mechanical departments during opportunistic shut down and Annual shut down
Perform Stores Procedures
The individual on the job needs to:
PC5. Perform Stores procedures:
Withdraw from and return material to the stores
Inspect new material received at stores
Knowledge and Understanding (K)
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 Valve KA3. Aware of Maintenance Policy of the company with respect to control valve maintenance strategy
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IAS/N0102 Site Management – Process Control
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B. Technical Knowledge Needs to know and understand:
KB1. Understands the processes and equipment information related to control loops which have Control Valve as their final control element
KB2. Understands site emergency procedures
KB3. Understands location and procedure for fire extinguishers, smoke detectors and personal protective equipment
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 management planning and reports SA2. Write emails and messages about site management related issues
Reading Skills
The individual on the job needs to read and understand: SA3. Company policy related to regulatory compliance SA4. Formats for Preventive Maintenance check sheets, predictive maintenance list
Oral Communication (Listening and Speaking skills)
The individual on the job needs to know and understand how to:
SA5. Describe site and process conditions issues to co-workers and supervisor SA6. Interact with inspectors and other visitors according to company policies
B. Professional Skills Decision Making
The individual on the job needs to know and understand how to:
SB1. Make decisions according to the site situations during statutory audit and plant maintenance, in line with company policies and procedures
Plan and Organize
The individual on the job needs to know and understand how to:
SB2. Plan for regulatory compliance
SB3. Plan for preventive and scheduled maintenance
SB4. Plan for opportunistic maintenance
Customer Centricity
The user/individual on the job needs to know and understand how to: SB5. discuss customer needs with co-workers and identify most appropriate solution
Problem Solving
IAS/N0102 Site Management – Process Control
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The individual on the job needs to know and understand how to:
SB6. Diagnoses reasons for down time due to control valve failure
SB7. Track recurring failures in Control Valve and analyses reasons and concludes
SB8. 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: SB9. Discuss use the available information with co-workers to arrive at actionable decision points SB10. Analyze problems in team and identify causes and possible solutions
Critical Thinking
The user/individual on the job needs to know and understand how to: SB11. Collaborate with co-workers to analyze, and evaluate the information gathered from collective observation, experience, reasoning, or communication, as a guide to teamwork
IAS/N0102 Site Management – Process Control
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NOS Version Control
NOS Code IAS/N0102
Credits (NSQF) TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector Instrumentation, Automation
Last viewed on 30/07/2016
Occupation Maintenance Next Review Date
30/07/2019
Back to top…
IAS/N0103 Task Reporting – Process Control
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National Occupational
Standard
Overview
This unit is about reporting and record keeping as per company processes and defined Service Level.
IAS/N0103 Task Reporting – Process Control
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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
Performance Criteria (PC) with respect to the scope:
Element Performance Criteria
Report faults PC1. Report and Escalate faults/issues to immediate supervisor
Prepare PM Report PC2. Complete entry of preventive maintenance check lists/reports
Prepare Corrective Maintenance report
PC3. Complete entry of Corrective Maintenance Check lists /reports
Report unusual occurrence
PC4. Complete 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 Valve
KA2. Understand importance of reporting potential failures during Control Valve Health 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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IAS/N0103 Task Reporting – Process Control
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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
The individual on the job needs to know and understand how to:
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
The individual on the job needs to know and understand how to:
SA5. Read and comprehend formats and check lists for preventive and corrective maintenance.
SA6. Read and understand company policies
Oral Communication Skills
The individual on the job needs to know and understand how to:
SA7. Communicate the issues / faults / corrective actions / warnings / suggestions with complete details to the supervisor and co-workers as appropriate
B. Professional Skills Decision Making
The 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 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
IAS/N0103 Task Reporting – Process Control
27
The user/individual on the job needs to know and understand how to:
SB4. Discuss customer needs with co-workers and identify most appropriate solution
Problem Solving
The individual on the job needs to know and understand how to:
SB5. 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:
SB6. Use the existing information to arrive at actionable decision points
SB7. Use the existing information for improving the customer satisfaction
SB8. Use the existing information to optimize solution and company business
SB9. Analyze problems and identify causes and possible solutions
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
IAS/N0103 Task Reporting – Process Control
28
NOS Version Control
NOS Code IAS/N0103
Credits (NSQF) TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector
Instrumentation, Automation Last viewed on 30/07/2016
Occupation Maintenance Next Review Date
30/07/2019
Back to top…
IAS/N0104 Corrective Maintenance – Control Valve
29
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National Occupational
Standard
Overview This unit is about Corrective Maintenance of Control Valve Installations in a Process Control Plant within defined Service Level Agreement. Corrective maintenance is any maintenance performed to return equipment to proper working order.
IAS/N0104 Corrective Maintenance – Control Valve
30
Unit Code IAS/N0104
Unit title (task) Corrective Maintenance - Control Valve
Description The OS unit is about performing Corrective Maintenance Activities associated with Control Valve in process plants.
Scope This Unit Task covers the following in respect of Corrective Maintenance :
Identify needs
Identify Spares
Follow Plan
Execute Plan
Brief Supervisor
Complete Check List/ Report
Close fault list
Performance Criteria (PC) w.r.t. the scope
Element Performance Criteria (PC)
Identify Corrective Maintenance needs
PC1. Identify need for corrective maintenance in the plant
Identify Corrective Maintenance Spares
PC2. Identify spares required for corrective maintenance and prepare list
Follow Corrective Maintenance plan
PC3. Adhere to corrective maintenance plan
Execute Corrective Maintenance plan
PC4. Carry out Corrective maintenance for items listed. This includes:
Valve disassembly; seat, stem, gland replacement; bonnet gaskets actuator stem connection along with spring actuator servicing
Reassembly, Hydro test and Leak test
Diaphragm replacement, tests on positioner, booster, current to pneumatic convertor, tubing, , valve stroking, leak checks and final line up on the plant
Note that in Industries where PRV( Pressure Relief Valve) come under Instrumentation department and under the Control Valve section- PRV servicing and testing would apply
Brief Supervisor on Corrective Maintenance
PC5. Brief Supervisor and Escalate Faults / issues if any
Complete Corrective Maintenance Check List / Report
PC6. Complete entry of corrective maintenance check lists / reports
Close Corrective Maintenance fault list
PC7. Close all faults reported
Knowledge and Understanding (K)
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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 Preventive Maintenance norms of the company to perform “Opportunistic preventive maintenance”
KA2. Understands Corrective maintenance norms as per company to avoid delays / production loss
KA3. Establishes contact with Central Planning to prioritize and calibrate timing for corrective maintenance work during Opportunistic shut downs / Annual Shut down
B. Technical Knowledge The individual on the job needs to know and understand how to: KB1. Possesses functional knowledge of all types of Control Valve in the process plant including all accessories (including conventional pneumatic valve positioners, position transmitters, limit switches, Digital valve controllers etc.) This includes Globe type(conventional) ,Globe( Cage type) Butterfly , Rotary plug Control Valve(also called eccentric disc control valve), all Trip valves(i.e. Emergency Shutdown Valves including Solenoid valves ,
Possesses functional knowledge of all control valve actuators including Pneumatic diaphragm type, piston type , .Electric and Hydraulic actuators
Possesses knowledge of all valve characteristics such as Quick opening, Linear, Equal Percentage modified characteristics of Butterfly valves and rotary plug valves[ eccentric disc valves)
KB2. Familiar with Standard operating Procedure for Control Valve as published by the organization KB3. Familiar with procedures of permits to work issued by Process personnel for maintenance work. KB4. Uses all relevant control valve vendor manuals and associated Parts list KB5. Familiar with use of instrumentation test equipment including all Calibrators used for Control valve testing KB6. Familiar with use of test pumps for control valve body test and leak test KB7. Uses Spare Gear book / equivalent procedure for withdrawal and return of items to stores KB8. Understands Test and Inspection reports KB9. Understands P & I diagrams, Loop and Hook up diagrams. KB10. Understands General Arrangement Drawing and Piping Isometric drawing with control valve KB11. Has a working knowledge of Standards for Control Valve. KB12. Familiar with Hazardous Area Classification and relation to the control valve installations KB13. Knows to interpret the control valve name plate specification as well as the control valve data sheet KB14. Understands control valve coefficient Cv and simple sizing formula KB15. Possesses working knowledge of Material of construction of control valve bodies and internal parts and compatibility with process media
Skill(s)
IAS/N0104 Corrective Maintenance – Control Valve
32
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 Corrective Maintenance 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. Control valve related drawings and documents SA4. Company policy related to Preventive Maintenance SA5. Monthly down time and resulting production loss figures SA6. Work Permit system SA7. Formats for Corrective Maintenance check sheets, list
Oral Communication (Listening and Speaking skills)
The individual on the job needs to know and understand how to: SA8. Describe condition of Control Valve and accessories and issues to co-workers and supervisor SA9. Communicate to the management in meetings about maintenance issues which need management attention SA10. Interact with coworkers and gather information related to process and control valve conditions
B. Professional Skills Decision Making
The individual on the job needs to know and understand how to:
SB1. Make decisions about timing and extent of corrective maintenance, in consultation with the Supervisor SB2. Uses diagnosis methods to arrive at corrective maintenance method with back ground of process information SB3. Follows procedure for subassembly/spare replacement
Plan and Organize
The individual on the job needs to know and understand how to:
SB4. Prioritize daily tasks to conduct Preventive Maintenance effectively
Customer Centricity
The user/individual on the job needs to know and understand how to: SB5. Discuss customer needs with co-workers and identify most appropriate solution
Problem Solving
The individual on the job needs to know and understand how to: SB6. Uses root cause approach to analyze recurrent failures SB7. Diagnoses reasons for down time due to control valve failure SB8. Track recurring failures in Control Valve and analyses reasons and concludes SB9. 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: SB10. Discuss use the available information with co-workers to arrive at actionable decision points
IAS/N0104 Corrective Maintenance – Control Valve
33
SB11. Analyze problems in team and identify causes and possible solutions
Critical Thinking
The user/individual on the job needs to know and understand how to: SB12. Collaborate with co-workers to analyze, and evaluate the information gathered from collective observation, experience, reasoning, or communication, as a guide to teamwork
IAS/N0104 Corrective Maintenance – Control Valve
34
NOS Version Control
NOS Code IAS/N0104
Credits (NSQF) TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector Instrumentation, Automation
Last viewed on 30/07/2016
Occupation Maintenance Next Review Date 30/07/2019
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IAS/N0105 Safety, Health and Environment – Process Control
35
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National Occupational
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.
IAS/N0105 Safety, Health and Environment – Process Control
36
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 Plants.
Scope The scope of this task includes following / performing:
SHE- Instructions
SHE- Personal Protection Directives
Support 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 - Personal Protection directives
PC4. Use right personal protective equipment, such as:
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
Knowledge and Understanding
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
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.
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IAS/N0105 Safety, Health and Environment – Process Control
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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
Oral Communication (Listening and Speaking skills)
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 Control Valve Health issues to get their support SA11. Interact with coworkers and gather information related to process and site conditions
B. Professional Skills 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 Valve
Customer Centricity
The user/individual on the job needs to know and understand how to: SB4. Discuss customer needs with co-workers and identify most appropriate solution
Problem Solving
The user/individual on the job needs to know and understand how to: SB5. Think through the problem, evaluate the possible solution(s) and suggest an optimum /best possible solution(s) SB6. Identify immediate or temporary solutions to resolve delays
Analytical Thinking
The user/individual on the job needs to know and understand how to: SB7. Discuss use the available information with co-workers to arrive at
IAS/N0105 Safety, Health and Environment – Process Control
38
actionable decision points SB8. Analyze problems in team and identify causes and possible solutions
Critical Thinking
The user/individual on the job needs to know and understand how to: SB9. Collaborate with co-workers to analyze, and evaluate the information gathered from collective observation, experience, reasoning, or communication, as a guide to teamwork
IAS/N0105 Safety, Health and Environment – Process Control
39
NOS Version Control
NOS Code IAS/N0105
Credits (NSQF) TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector Instrumentation, Automation
Last viewed on 30/07/2016
Occupation Maintenance Next Review Date 30/07/2019
Back to top…
IAS/N2105 Work Effectively With Teams
40
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National Occupational
Standard
Overview
This unit is about working effectively with colleagues, either in own work group or in other work groups within and outside organization
IAS/N2105 Work Effectively With Teams
41
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 Performance Criteria
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.
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IAS/N2105 Work Effectively With Teams
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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
To be competent, the individual on the job must be able to:
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
To be competent, the individual on the job must be able to:
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)
IAS/N2105 Work Effectively With Teams
43
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
Oral Communication (Listening and Speaking skills)
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
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
IAS/N2105 Work Effectively With Teams
44
The user/individual on the job needs to know and understand how to: SB5. Apply problem solving approaches in different situations
Analytical Thinking
The user/individual on the job needs to know and understand how to: SB6. Use the existing information to arrive at actionable decision points SB7. Use the existing information for improving the customer satisfaction
SB8. Use the existing information to optimize solution and company business SB9. Analyze problems and identify causes and possible solutions
Critical Thinking
The user/individual on the job needs to know and understand how to: SB10. Apply balanced judgments to different situations
IAS/N2105 Work Effectively With Teams
45
NOS Version Control
NOS Code IAS/N2105
Credits (NSQF) TBD Version 1.0
Industry Instrumentation, Automation Surveillance & Communication
Drafted on 30/07/2016
Industry Sub Sector
Instrumentation, Automation Last viewed on 30/07/2016
Occupation Maintenance Next Review Date
30/07/2019
Back to top…
Qualifications Pack For Instrumentation Technician (Control Valve)
46
Annexure
Nomenclature for QP and NOS
Qualifications Pack
[IAS]/Q 0101
Occupational Standard An example of NOS with ‘N’
[IAS] /N0001
9 characters
N denoting National Occupational Standard Occupation (2 numbers)
OS number (2 numbers)
9 characters
[Insert 3 letter code for SSC]
Qualifications Pack For Instrumentation Technician (Control Valve)
47
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
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Qualifications Pack For Instrumentation Technician (Control Valve)
48
Marks Allocation
Assessment Outcomes
Assessment Criteria for Outcomes
Total Marks
(100+200+ 100+ 100+
200+50 +75)
Out of
Theory
Skills Practic
al
1. IAS/N0100 Maintain Control Valve Health
PC1. Perform Control Valve Health Checks as prescribed by Organizational norms in the following areas: Control valve installations and their accessories, testing bay in the Instrumentation workshop, test equipment and test pumps
100
20 8 12
PC2. Check for visual damage and tampering on control valve installations. Note and report to supervisor
10 4 6
PC3. Check housekeeping near control valve installations 10 2 8
PC4. Check housekeeping in Control Valve testing bay in Instrumentation Workshop
10 2 8
PC5. Check for lighting / associated electricals near control valve installation
10 4 6
PC6. Ensure optimum storage of cleaning solvent, lubrication items and related maintenance consumables at designated space. Ensure that these are used optimally (avoid wastage and spillage)
10 3 7
PC7. Check name plate of the manufacturer on the valve and clean with solvent, as required. Inform supervisor if damaged or missing.
10 5 5
PC 8. Undertake work area audit with supervisor for Control Valve Installations and Control Valve testing bay areas as per work area
10 4 6
CRITERIA FOR ASSESSMENT OF TRAINEES
Job Role Qualifications Pack- Instrumentation Technician (Control Valve)
Qualification Pack IAS/Q3001
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
Qualifications Pack For Instrumentation Technician (Control Valve)
49
audit check sheet
PC9. Complete entries of Check Lists for Control Valve Health issued by the company
10 5 5
Total 100 37 63
2. IAS/N0101 Preventive & Predictive Maintenance – Control Valve
PC1. Obtain Permit to Work.
200
10 5 5
PC2. Carry out Preventive Maintenance as per Schedule for the day.
40 10 30
PC3. Prepare list on basis of process request 20 10 10
PC4. Plan for next day Preventive Maintenance schedule 20 10 10
PC5. Carry out-Visual Checks and action wherever possible or else transfer job to shut down list.
30 10 20
PC6. Complete preventive maintenance schedule list of control valve body, actuator and accessories. Close the issues in the list.
20 5 15
PC7. Collect and consolidate daily diagnostic messages from Control Valve 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
PC8. Include preventive maintenance jobs during annual shut down or opportunistic shut down
25 10 15
PC9. Follow up on consolidated preventive maintenance list and close.
20 5 15
Total 200 72 128
3. IAS/N-0102 Site Management - Process Control
PC1. Familiar with IBR inspection formalities and stamping of IBR items including Control Valve and associated accessories which fall in the IBR area
100
20 15 5
PC2. Familiar with formalities of the site visit of the representative of the Service Contract vendor for control valve
20 10 10
PC3. Familiar with the appropriate Inspection and Test reports 20 15 5
PC4. Familiar with formalities and coordination with Process and Mechanical departments during opportunistic shut down and Annual shut down
20 10 10
PC5. Familiar with Stores procedures 20 10 10
Total 100 60 40
4. IAS/N0103 Task reporting – Process Control
PC1. Escalate faults/issues to immediate supervisor
100
10 5 5
PC2. Complete entry of preventive maintenance check lists/reports
25 10 15
PC3. Complete entry of Corrective Maintenance Check lists /reports
25 10 15
PC4. Complete report on noticing any visible changes in control valve installation or its accessories. Report for immediate attention of supervisor
20 10 10
PC5. Report any theft in control valve assembly/spares to supervisor
10 5 5
PC6. Report suspicious movement of new persons near control valve installation to security and supervisor
10 5 5
Total 100 45 55
5. IAS/N0104 Corrective Maintenance –
PC1. Identify need for corrective maintenance
200
30 15 15
PC2. Identify spares required for corrective maintenance and list. 30 15 15
PC3. Adhere to maintenance plan 30 10 20
Qualifications Pack For Instrumentation Technician (Control Valve)
50
Control Valve PC4. Carry out Corrective maintenance for items listed. 30 10 20
PC5. Escalate Faults /issues to the Supervisor 20 10 10
PC6. Complete entry of corrective maintenance check lists / reports
30 10 20
PC7. Close maximum number of faults reported 30 10 20
Total 200 80 120
6. IAS/N0105 Safety, Health and Environment – Process Control
PC1. Understand formal Instructions from SHE Dept.
50
10 5 5
PC2. Participate in the prescribed drills including familiarization of personal protective equipment, fire extinguisher and first aid.
10 5 5
PC3. Understand Instructions on Work permit, Fire permit and Hazardous Area Classification, Fire and explosion hazards
10 5 5
PC4. Use right personal protective equipment 10 5 5
PC5. Support supervisor during SHE Audit 10 5 5
Total 50 25 25
7. IAS/N2105 Work Effectively With Teams
PC1. Know and understand the team objectives and goals
75
3 1 2
PC2. Know team members by name. Greet them appropriately and respond to their greetings.
2 1 1
PC3. Know the roles and responsibilities of team members. Ensure others know about you and your role in the team
2 1 1
PC4. Learn about the culture and preferences of team members – especially if they belong to other organizations or nationalities
5 1 4
PC5. Follow organization’s policies and procedures for working with team members within and outside the organization – especially relating to privacy, confidentiality and security.
2 1 1
PC6. Create an environment of trust and mutual respect 3 1 2
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.
2 1 1
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
3 1 2
PC9. Communicate professionally and follow organization protocols. Do not overload the team members with unnecessary and unsolicited information
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 cognizance of others’ needs and schedules
2 1 1
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
Qualifications Pack For Instrumentation Technician (Control Valve)
51
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
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