Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Insulated electrical gloves | Isopropyl alcohol (70%) |
| Safety boots | Lint-free cleaning cloth |
| Overall/dust coat | |
| Multimeter | |
| Soft-bristle brush | |
| Isopropyl alcohol (70%) | |
| Lint-free cleaning cloth | |
| Compressed air canister | |
| Phillips screwdriver | |
| Flat screwdriver | |
| Lockout tagout (LOTO) kit |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Insulated electrical gloves | 1 Pair per Candidate |
| 2 | Safety boots | 1 Pair per Candidate |
| 3 | Overall/dust coat | 1 Pc per Candidate |
| 4 | Multimeter | 1 Pc per Candidate |
| 5 | Soft-bristle brush | 1 Pc per Candidate |
| 6 | Isopropyl alcohol (70%) | 100 ml per Candidate |
| 7 | Lint-free cleaning cloth | 2 Pcs per Candidate |
| 8 | Compressed air canister | 1 Pc per Candidate |
| 9 | Phillips screwdriver | 1 Pc per Candidate |
| 10 | Flat screwdriver | 1 Pc per Candidate |
| 11 | PLC system with modules and wiring | 1 Set per Candidate |
| 12 | Lockout tagout (LOTO) kit | 1 Kit per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: PPE and Safety Preparation | |||
| Wore insulated electrical gloves (Award 1 mark for correct use) | 1 | ||
| Wore safety boots (Award 1 mark for correct use) | 1 | ||
| Wore overall/dust coat (Award 1 mark for correct use) | 1 | ||
| Followed Lockout Tagout (LOTO) procedure correctly (Award 1 mark each for placing LOTO tag, clear name, accurate date, and isolating power) | 3 | ||
| Sub-Total | 6 | ||
| TASK 2: Inspection of PLC Hardware Components | |||
| Visually inspected PLC modules for damage or corrosion (Award 2 marks for thorough inspection) | 2 | ||
| Checked all wiring connections for looseness or wear using multimeter (Award 1 mark for checking all connections, 2 marks for using multimeter properly) | 3 | ||
| Verified correct wiring routing and no signs of overheating (Award 2 marks for complete verification) | 2 | ||
| Sub-Total | 7 | ||
| TASK 3: Cleaning of PLC Components | |||
| Used compressed air to remove dust from PLC modules and wiring (Award 2 marks for proper use without damaging components) | 2 | ||
| Cleaned PLC module surfaces with isopropyl alcohol and lint-free cloth (Award 3 marks for correct cleaning technique and no moisture ingress) | 3 | ||
| Used soft-bristle brush to clean connectors and terminals (Award 2 marks for effective and careful cleaning) | 2 | ||
| Rechecked connections after cleaning for tightness (Award 2 marks for thorough re-inspection) | 2 | ||
| Sub-Total | 9 | ||
| TASK 4: Final Safety and Restoration | |||
| Removed LOTO tag and restored power safely (Award 2 marks for correct and safe power restoration) | 2 | ||
| Ensured PLC powered ON without faults (Award 2 marks for successful power-up) | 2 | ||
| Sub-Total | 4 | ||
| PRODUCT CHECKLIST | |||
| PLC hardware components are clean, free from dust and corrosion, and wiring is secure and undamaged (Award marks based on cleanliness, absence of damage, and secure wiring) | 10 | ||
| PLC system powers ON successfully without error indicators after maintenance (Award marks for proper system operation post-maintenance) | 5 | ||
| Sub-Total | 15 | ||
| GRAND TOTAL | 41 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Flat head screwdriver | PLC input module (24V DC) |
| Phillips head screwdriver | PLC output module (24V DC) |
| Wire stripper | Replacement PLC input/output modules (24V DC) |
| Wire cutter | Single-strand control wires (1.5mm2, PVC insulated) |
| Crimping tool | Cable lugs (fork and pin type, 1.5mm2) |
| Multimeter | LOTO tag |
| Electrical gloves | |
| Safety boots | |
| Overall/dust coat |
| S/N | Item | Quantity |
|---|---|---|
| 1 | PLC input module (24V DC) | 1 Pc per Candidate |
| 2 | PLC output module (24V DC) | 1 Pc per Candidate |
| 3 | Replacement PLC input/output modules (24V DC) | 1 set per Candidate |
| 4 | Multimeter | 1 Pc per Candidate |
| 5 | Flat head screwdriver | 1 Pc per Candidate |
| 6 | Phillips head screwdriver | 1 Pc per Candidate |
| 7 | Wire stripper | 1 Pc per Candidate |
| 8 | Wire cutter | 1 Pc per Candidate |
| 9 | Crimping tool | 1 Pc per Candidate |
| 10 | Single-strand control wires (1.5mm2, PVC insulated) | 5 metres per Candidate |
| 11 | Cable lugs (fork and pin type, 1.5mm2) | 30 Pcs per Candidate |
| 12 | LOTO tag | 1 Pc per Candidate |
| 13 | Electrical gloves | 1 Pair per Candidate |
| 14 | Safety boots | 1 Pair per Candidate |
| 15 | Overall/dust coat | 1 Pc per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Safety and Preparation | |||
| Wore personal protective equipment: safety boots, overall/dust coat, electrical gloves (Award 1 mark each) | 3 | ||
| Followed Lock Out Tag Out (LOTO) procedure: placed LOTO tag correctly, indicated name clearly, wrote accurate date, safely isolated power supply (Award 1 mark each) | 4 | ||
| Sub-Total | 7 | ||
| TASK 2: Diagnosis of Faulty PLC Modules | |||
| Used multimeter to test input module for faults (Award 2 marks) | 2 | ||
| Used multimeter to test output module for faults (Award 2 marks) | 2 | ||
| Identified faulty input or output modules correctly (Award 3 marks) | 3 | ||
| Sub-Total | 7 | ||
| TASK 3: Removal and Replacement of Faulty Modules | |||
| Selected correct tools for removing modules: flat and Phillips screwdrivers (Award 1 mark each) | 2 | ||
| Disconnected wiring safely and labeled wires (Award 2 marks) | 2 | ||
| Removed faulty PLC input/output modules without damage (Award 2 marks) | 2 | ||
| Prepared replacement modules and wiring: stripped wires, crimped lugs (Award 1 mark each for stripping, crimping, preparation) | 3 | ||
| Installed replacement PLC input/output modules correctly (Award 3 marks) | 3 | ||
| Connected wiring to replacement modules correctly according to schematic (Award 3 marks) | 3 | ||
| Sub-Total | 15 | ||
| TASK 4: Testing and Commissioning | |||
| Reconnected power supply safely (Award 2 marks) | 2 | ||
| Powered ON the PLC system (Award 1 mark) | 1 | ||
| Tested input and output modules functionality using software or indicators (Award 1 mark each for input test, output test, system response, no error) | 4 | ||
| Sub-Total | 7 | ||
| TASK 5: Finalization | |||
| Powered OFF system and isolated power supply (Award 1 mark) | 1 | ||
| Removed LOTO tag and stored tools and materials properly (Award 1 mark) | 1 | ||
| Cleaned work area and disposed of faulty modules correctly (Award 1 mark) | 1 | ||
| Sub-Total | 3 | ||
| PRODUCT CHECKLIST | |||
| Replacement PLC input/output modules installed securely and aligned with mounting dimensions 200mm x 150mm x 50mm (Award 4 marks) | 4 | ||
| Wiring connections are neat, correctly crimped, labeled, and match schematic wiring (Award 4 marks) | 4 | ||
| PLC system operates without faults after replacement (Award 5 marks) | 5 | ||
| Sub-Total | 13 | ||
| GRAND TOTAL | 52 | ||