By the end of this chapter, you will be able to:
These skills will help you ensure smooth and efficient production, which is essential for quality and success in the control and instrumentation trade.
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Permanent marker pens | Control system training panel with sensors, controllers, and actuators |
| Adhesive labels | Instruction manual for the control system panel |
| Insulated gloves | |
| Safety goggles | |
| Dustcoat or Lab coat |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Control system training panel with sensors, controllers, and actuators | 1 Pc per Candidate |
| 2 | Permanent marker pens | 2 Pcs per Candidate |
| 3 | Adhesive labels (50mm x 20mm) | 10 Pcs per Candidate |
| 4 | Instruction manual for the control system panel | 1 Pc per Candidate |
| 5 | Insulated gloves | 1 Pair per Candidate |
| 6 | Safety goggles | 1 Pair per Candidate |
| 7 | Dustcoat or Lab coat | 1 Pc per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Preparation and Safety | |||
| Wore the appropriate PPE: Dustcoat/Lab coat, Safety goggles, Insulated gloves (Award 1 mark for each PPE worn, 0 for incomplete, max 3 marks) | 3 | ||
| Read and understood the instruction manual before starting (Award 2 marks for clear evidence of reading and understanding, 0 otherwise) | 2 | ||
| Sub-Total | 5 | ||
| TASK 2: Identification and Labelling | |||
| Correctly identified and labelled all sensors on the panel (Award 1 mark per sensor correctly labelled, total 5 marks) | 5 | ||
| Correctly identified and labelled all controllers on the panel (Award 1 mark per controller correctly labelled, total 5 marks) | 5 | ||
| Correctly identified and labelled all actuators on the panel (Award 1 mark per actuator correctly labelled, total 5 marks) | 5 | ||
| Used neat and legible handwriting on labels (Award 2 marks for neat and legible labelling, 0 otherwise) | 2 | ||
| Affixed labels securely in correct positions (Award 3 marks for secure and correct placement, 0 otherwise) | 3 | ||
| Sub-Total | 20 | ||
| PRODUCT CHECKLIST | |||
| All sensors labelled correctly and clearly visible (Award 5 marks if all sensors are labelled correctly and labels are visible) | 5 | ||
| All controllers labelled correctly and clearly visible (Award 5 marks if all controllers are labelled correctly and labels are visible) | 5 | ||
| All actuators labelled correctly and clearly visible (Award 5 marks if all actuators are labelled correctly and labels are visible) | 5 | ||
| Sub-Total | 15 | ||
| GRAND TOTAL | 40 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Screwdrivers (flat and Phillips head) | Control panel base unit |
| Wire stripper and cutter | Pressure sensor (4-20 mA output) |
| Multimeter | Control valve with actuator |
| Insulation tape | PID controller unit |
| Connecting electrical cables (1.5 mm²) | |
| Personal Protective Equipment (PPE): safety gloves, safety shoes, lab coat |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Control panel base unit | 1 Pc per Candidate |
| 2 | Pressure sensor (4-20 mA output) | 1 Pc per Candidate |
| 3 | Control valve with actuator | 1 Pc per Candidate |
| 4 | PID controller unit | 1 Pc per Candidate |
| 5 | Connecting electrical cables (1.5 mm²) | 3 m per Candidate |
| 6 | Screwdrivers (flat and Phillips head) | 1 set per Candidate |
| 7 | Wire stripper and cutter | 1 Pc per Candidate |
| 8 | Multimeter | 1 Pc per Candidate |
| 9 | Insulation tape | 1 roll per Candidate |
| 10 | Personal Protective Equipment (PPE): safety gloves, safety shoes, lab coat | 1 set per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Assembly and Wiring of Control Loop | |||
| Wore the appropriate PPE: safety gloves, safety shoes, lab coat (Award 1 mark for each PPE worn, 0 if incomplete, max 3 marks) | 3 | ||
| Mounted pressure sensor securely on control panel base unit (Award 2 marks for correct mounting and 2 marks for secure fixing, total 4 marks) | 4 | ||
| Mounted PID controller unit correctly on control panel base unit (Award 1.5 marks for correct position and 1.5 marks for secure fixing, total 3 marks) | 3 | ||
| Mounted control valve actuator appropriately on control panel base unit (Award 2 marks for correct mounting and 2 marks for secure fixing, total 4 marks) | 4 | ||
| Connected pressure sensor output to PID controller input using correct wiring and cable (Award 3 marks for correct wiring connections and 2 marks for cable management, total 5 marks) | 5 | ||
| Connected PID controller output to control valve actuator input correctly (Award 3 marks for correct wiring connections and 2 marks for cable management, total 5 marks) | 5 | ||
| Used wire stripper and cutter properly to prepare cables (Award 3 marks for neat and correct cable preparation) | 3 | ||
| Checked continuity and correct wiring connections with multimeter (Award 4 marks for correct use and accurate checking) | 4 | ||
| Insulated all exposed wiring joints with insulation tape neatly (Award 4 marks for neat and complete insulation) | 4 | ||
| Ensured all components are firmly fixed and wiring is tidy on control panel (Award 5 marks for overall neatness and secure assembly) | 5 | ||
| Sub-Total | 40 | ||
| PRODUCT CHECKLIST | |||
| Completed control panel assembly with dimensions 600mm x 400mm, components mounted securely and wiring correct as per control loop schematic (Award 5 marks for correct overall dimensions within ±10mm tolerance, 3 marks for secure mounting of all components, 2 marks for correct wiring and neat cable management) | 10 | ||
| Sub-Total | 10 | ||
| GRAND TOTAL | 50 | ||
At the start of this chapter we promised you would be able to:
Tick each one you can genuinely do.
So, are you there yet?
You're competent when you can confidently do 50% or more of what this chapter promised.
Sign in to record how you're doing.