Contents · This energy can be pneumatic pressure, electric current, or hydraulic pressure, which...

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1 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 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 Contact Us: 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: 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. Introduction QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR INSTRUMENTATION AUTOMATION SURVEILLANCE AND COMMUNICATION INDUSTRY

Transcript of Contents · This energy can be pneumatic pressure, electric current, or hydraulic pressure, which...

Page 1: Contents · 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

IAS/Q3001 Instrumentation Technician (Control Valve)

1

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

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Qualifications Pack For Instrumentation Technician (Control Valve)

2

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

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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

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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

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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’.

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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

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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.

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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)

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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

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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

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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

Back to top…

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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.

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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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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

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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

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

Critical Thinking

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

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NOS Version Control

NOS Code IAS/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

Back to top…

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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.

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IAS/N0102 Site Management – Process Control

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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

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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

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IAS/N0102 Site Management – Process Control

23

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…

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IAS/N0103 Task Reporting – Process Control

24

-------------------------------------------------------------------------------------------------------------------------------------

National Occupational

Standard

Overview

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

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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

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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

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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…

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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.

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IAS/N0104 Corrective Maintenance – Control Valve

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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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IAS/N0104 Corrective Maintenance – Control Valve

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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)

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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 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

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IAS/N0104 Corrective Maintenance – Control Valve

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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

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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

Back to top…

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IAS/N0105 Safety, Health and Environment – Process Control

35

--------------------------------------------------------------------------------------------------------- ----------------------------

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.

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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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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

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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

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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…

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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

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IAS/N2105 Work Effectively With Teams

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Unit Code IAS/N2105

Unit Title (Task) Work Effectively With Teams

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

Scope This unit/task covers the following:

• Creating team environment

• Communicating - giving and receiving

• Working cooperatively

• Participating in team decision making

• Demonstrating Sense of Responsibility

• Showing respect for opinions, customs and preferences

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

Element 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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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)

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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

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IAS/N2105 Work Effectively With Teams

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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

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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

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Page 46: Contents · 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

Qualifications Pack For Instrumentation Technician (Control Valve)

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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]

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Qualifications Pack For Instrumentation Technician (Control Valve)

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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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Page 48: Contents · 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

Qualifications Pack For Instrumentation Technician (Control Valve)

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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

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Qualifications Pack For Instrumentation Technician (Control Valve)

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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

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Qualifications Pack For Instrumentation Technician (Control Valve)

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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

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Qualifications Pack For Instrumentation Technician (Control Valve)

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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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