isa-98.00.02 skill standards for control systems technicians

Technical Report

ISA-TR98.00.02 Skill Standards for Control System Technicians Approved Date

ISA-TR98.00.02 Skill Standards for Control System Technicians

ISBN:

Copyright © 2006 by ISA —The Instrumentation, Systems, and Automation Society. All rights reserved. Not for resale. Printed in the United States of America. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic mechanical, photocopying, recording, or otherwise), without the prior written permission of the Publisher.

ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709

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Preface

This preface, as well as all footnotes, is included for information purposes and is not part of ISA-TR98.00.02-2006.

This document has been prepared as part of the service of ISA⎯the Instrumentation, Systems, and Automation Society⎯toward a goal of uniformity in the field of instrumentation. To be of real value, this document should not be static but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Park, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail: [email protected].

The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the preparation of instrumentation standards. The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric system) in their business and professional dealings with other countries. Toward this end, this Department will endeavor to introduce SI-acceptable metric units in all new and revised standards, recommended practices, and technical reports to the greatest extent possible. Standard for Use of the International System of Units (SI): The Modern Metric System, published by the American Society for Testing & Materials as IEEE/ASTM SI 10-97, and future revisions, will be the reference guide for definitions, symbols, abbreviations, and conversion factors.

It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests in the development of ISA standards, recommended practices, and technical reports. Participation in the ISA standards-making process by an individual in no way constitutes endorsement by the employer of that individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA develops.

CAUTION — ISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDS INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS REQUIRED FOR USE OF THE DOCUMENT, IT WILL REQUIRE THE OWNER OF THE PATENT TO EITHER GRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERS COMPLYING WITH THE DOCUMENT OR A LICENSE ON REASONABLE TERMS AND CONDITIONS THAT ARE FREE FROM UNFAIR DISCRIMINATION.

EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS DOCUMENT, THE USER IS CAUTIONED THAT IMPLEMENTATION OF THE DOCUMENT MAY REQUIRE USE OF TECHNIQUES, PROCESSES, OR MATERIALS COVERED BY PATENT RIGHTS. ISA TAKES NO POSITION ON THE EXISTENCE OR VALIDITY OF ANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING THE DOCUMENT. ISA IS NOT RESPONSIBLE FOR IDENTIFYING ALL PATENTS THAT MAY REQUIRE A LICENSE BEFORE IMPLEMENTATION OF THE DOCUMENT OR FOR INVESTIGATING THE VALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THE USER SHOULD CAREFULLY INVESTIGATE RELEVANT PATENTS BEFORE USING THE DOCUMENT FOR THE USER’S INTENDED APPLICATION.

HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS DOCUMENT WHO IS AWARE OF ANY PATENTS THAT MAY IMPACT IMPLEMENTATION OF THE DOCUMENT NOTIFY THE ISA STANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITS OWNER.

ADDITIONALLY, THE USE OF THIS DOCUMENT MAY INVOLVE HAZARDOUS MATERIALS, OPERATIONS OR EQUIPMENT. THE DOCUMENT CANNOT ANTICIPATE ALL POSSIBLE APPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUES ASSOCIATED WITH USE IN HAZARDOUS CONDITIONS. THE USER OF THIS DOCUMENT MUST EXERCISE SOUND

Copyright 2006 ISA. All rights reserved.

ISA-TR98.00.02-2006 - 4 -

PROFESSIONAL JUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THE USER’S PARTICULAR CIRCUMSTANCES. THE USER MUST ALSO CONSIDER THE APPLICABILITY OF ANY GOVERNMENTAL REGULATORY LIMITATIONS AND ESTABLISHED SAFETY AND HEALTH PRACTICES BEFORE IMPLEMENTING THIS DOCUMENT.

THE USER OF THIS DOCUMENT SHOULD BE AWARE THAT THIS DOCUMENT MAY BE IMPACTED BY ELECTRONIC SECURITY ISSUES. THE COMMITTEE HAS NOT YET ADDRESSED THE POTENTIAL ISSUES IN THIS VERSION.

The following people served as members of ISA Committee SP98:

R. Webb, Managing Director Consultant L. McCaw, Chairman Consultant R. Kosar Consultant D. Gillum Texas St. Technical College T. McAvinew Jacobs Engineering Group A. Ortolani Island Inst. & Control Inc. M. Raines Instrumentation & Controls Inc. N. Sands E I du Pont T. Stout Consultant M. Widmeyer Stanford Linear Accelerator Center This standard was approved for publication by the ISA Standards and Practices Board on

NAME COMPANY

I. Verhappen, Vice-President MTL Instrument Group T. McAvinew, Vice-President Elect Jacobs Engineering Group F. Amir E I Du Pont Co. D. Bishop Consultant M. Coppler Ametek Inc. B. Dumortier Schneider Electric W. Holland Consultant E. Icayan ACES Inc. A. Iverson Ivy Optiks R. Jones Consultant K. P. Lindner Endress + Hauser Process Solutions V. Maggioli Feltronics Corp. A. McCauley Chagrin Valley Controls Inc. G. McFarland Emerson Process Management R. Reimer Rockwell Automation J. Rennie Consultant N. Sands E I Du Pont Co. H. Sasajima Yamatake Corp. T. Schnaare Rosemount Inc. J. Tatera Tatera & Associates R. Webb Consultant W. Weidman Parsons Energy and Chemicals J. Weiss KEMA Inc. M. Widmeyer Stanford Linear Accelerator Center C. Williams Eastman Kodak Co. M. Zielinski Emerson Process Management


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Table of Contents

Preface..........................................................................................................................................................3

1 Scope ....................................................................................................................................................7

2 Purpose.................................................................................................................................................7

3 Equipment Definition.............................................................................................................................7

4 Principal Responsibilities ......................................................................................................................8

4.1 Calibration Work Function................................................................................................................8

4.2 Loop Checking Work Function.........................................................................................................9

4.3 Troubleshooting Work Function .....................................................................................................10

4.4 Start-up Work Function ..................................................................................................................11

4.5 Maintenance/Repair Work Function...............................................................................................11

5 Assessing Skills ..................................................................................................................................12

5.1 Knowledge proficiency ...................................................................................................................13

5.2 Skill proficiency ..............................................................................................................................13

Annex A - Occupational Skills and Technical Knowledge ..........................................................................15

Annex B - Resources ..................................................................................................................................17

Annex C – Academic and Foundational Skills ............................................................................................19


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1 Scope

This document is intended to supply a general list of work-oriented functions, activities, tasks and duties that an instrument, instrument/electrical, automation or control system technician should be skilled at in order to successfully work in this technical area. It is intended to be a dynamic document that will change as the equipment the technician works with evolves. The document is inclusive of the most common work-oriented functions. Specialty area technicians are expected to have additional skills and higher technical competences that are not included in this general list.

This document provides skill standard information beyond that contained in ANSI/ISA-98.00.01-2002 to enhance control system technician education and training. It includes specific demonstrable performance criteria that indicate when the work-oriented activities have been performed successfully. Performance criteria specify the type, quality and level of output required to perform the work. These performance criteria provide benchmarks against which skills and knowledge can be meaningfully evaluated in order to support the development of training curricula and assessment.

2 Purpose

The purpose of the document is to identify the work-oriented functions, activities, tasks and duties that a technician should be able to perform competently. This document should supply an employer or contractor with the ability to judge the qualifications of an individual technician or state the requirements necessary for technicians to be used in the instrumentation field. These skills also provide a framework for educators and employers to develop the educational and training tools necessary to prepare students and incumbent workers for success in the workplace. The document is not intended as detailed work instructions or directions.

The inclusion of worker-oriented information in the annexes completes the definition of skills and knowledge required to successfully perform the work-oriented tasks. Both work and worker-oriented information are required for the development and delivery of relevant, outcome-based training and instructional methods.

3 Equipment Definition

The term “equipment” is used in this document to refer to process control, safety instrumented systems (SIS), and related equipment used to produce quality products and ensure safe, cost-effective operations. Process control, SIS, and related equipment includes: pneumatic, mechanical, electromechanical, electronic microprocessor and computer-based process control equipment as follows:

a) Controllers and remote telemetry units;

b) Control valves, positioners, operators and pressure regulators;

c) Sensing lines, measuring devices and transmitters;

d) Signal transmission lines and transducers;

e) Relays, switches and alarm panels;

f) Analyzers and analyzer sample systems.

Related and auxiliary equipment typically includes:

a) Equipment mounting;

b) Instrument air supply system;


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c) Process control device power; wiring; interface systems;

d) UPS backup/emergency power systems;

e) Variable frequency drive (VFD) or variable speed drive (VSD) motor controllers;

f) SCADA, DCS, PLC and S-50 fieldbus process control networks.

Occasionally, the technician may also apply his/her skills to the maintenance of:

a) Small motors and rotating equipment protection devices such as vibration monitors and motor control relays;

b) Handheld radios, intercom systems and transmitting or repeater stations;

c) HVAC system controls;

d) Indoor and outdoor lighting systems;

e) Cathodic protection systems.

4 Principal Responsibilities

4.1 Calibration Work Function

Calibration is required to confirm the ability of many devices used to measure or sense a process or auxiliary system variable to maintain operation within specified limits. Calibration, as part of this standard, shall include bench and field procedures. This includes electronic calibration and the use of standards.

4.1.1 Work-oriented Activities, Tasks and Duties:

a) Obtain all documents, including historical documentation, needed for device calibration in order to proceed with calibration.

b) Identify the correct device to be calibrated through documentation and instrument identification systems in order to ensure proper calibration.

c) Select the correct test equipment through documentation and visual inspection as identified by site calibration procedures in accordance with manufacturers or other standards such as ISO 9000.

d) Connect the test equipment to the device as required by manufacturer specifications and site procedures in order to properly and safely calibrate the device.

e) Apply input values to the device as specified on instrument data sheet in order to simulate process parameters.

f) Record "as found" readings on calibration sheets in order to provide a history of the device.

g) Compare "as found" readings with the required values as specified by the instrument data sheet in order to identify if the device needs to be adjusted according to allowable tolerances.

h) Make adjustments to the device, if necessary, through site calibration procedures in order to ensure accuracy.


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i) Complete all documentation as required in order to update all calibration records to include as left data.

4.1.2 Performance Criteria:

a) Work is performed to meet the requirements of company/manufacturer/ Health, Safety and Environment work practices, specific application and area classification.

b) Physical inspection meets company/manufacturer/industry parameters.

c) Configuration performed is verified according to the application.

d) Calibration is verified according to engineering specifications with certified standards when applicable and includes the concepts of traceability and of agreed on custom standards developed for an individual company.

e) Functional test meets company/manufacturer/industry standards.

f) Known inputs result in expected outputs as specified by the manufacturer.

g) Documentation is completed according to company guidelines.

4.2 Loop Checking Work Function

Loop checking, as part of this standard, includes lubrication, stroking, cleaning and tuning equipment.


a) Obtain documents, including historical documentation, pertaining to the process loop in order to understand all devices and the processes and their intended functions.

b) Inspect the loop components through visual observation in order to ensure that the components are correctly installed.

c) Verify that appropriate utilities are available and operational through visual inspection in order to perform the loop check.

d) Isolate the process loop from the control system or SIS by following established site procedures in order to perform the loop check in a safe manner.

e) Simulate a change in the measured variable in order to verify proper loop performance.

f) Make necessary corrections in order to bring loop performance within specifications.

g) Complete all documentation as required in order to update all loop records.



b) Points of deviation are identified where the known input results in an unexpected output, calibration points, data table and calibration plots.

c) Corrective repairs are performed according to job scope.


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d) Configuration is verified according to the application.

e) Functional test meets company/manufacturer/industry standards.



4.3 Troubleshooting Work Function

This work function identifies, diagnoses and corrects equipment malfunctions.


a) Examine all pertinent documentation, including historical documentation, in order to identify the proper operation of the control system and devices and to provide a baseline against which to evaluate the problem.

b) Identify any discrepancies between observed and proper operation of the control system in order to determine whether a problem exists.

c) Determine which device or devices of the control system could be causing the observed discrepancies in order to formulate a plan of corrective action.

d) Isolate each suspected device from the control system by following established site procedures in order to perform troubleshooting in a safe manner.

e) Exercise each device across calibrated range in order to determine proper operation.

f) Perform corrective action, if necessary, according to site procedures in order to resolve the problem.

g) Verify that problem has been corrected and make recommendations to prevent further problems.

h) Complete all documentation as required in order to update all records.



b) The point of deviation is identified where the known inputs result in unexpected outputs.

c) Source of malfunction is isolated.

d) Corrective repairs are performed according to job scope.

e) Physical inspection meets company/manufacturer/industry parameters.

f) Configuration is verified according to the application.

g) Calibration is verified according to engineering specifications with certified standards when applicable.


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h) Functional test meets company/manufacturer/industry standards.

i) Known inputs result in expected outputs as specified by the manufacturer.

j) Documentation is completed according to company guidelines.

4.4 Start-up Work Function

This work function includes the Installation, start-up and commissioning of new project equipment in a new application. These skills also apply to the replacement of unrepairable failed devices found during troubleshooting, maintenance and calibration operations.


a) Examine all pertinent documentation in order to verify completion of all control systems that are required for start-up.

b) Implement applicable safety practices to be followed in order to ensure that all personnel are informed of the possible hazards during start-up.

c) Coordinate activities with all personnel involved in order to ensure that all personnel are aware of their responsibilities during start-up.

d) Implement start-up according to site procedures in order to ensure that the system is operating properly.

e) Assist site personnel to identify and correct problems that arise during start-up in order to commission the system.

f) Complete all documentation as required in order to update all records.


a) Installation meets the requirements of company/manufacturer/Health, Safety and Environment work practices, area classifications and specific application.

b) Equipment is configured according to the application.

c) Equipment is calibrated to engineering specifications using certified standards when applicable.

d) Physical inspection meets company/manufacturer/industry standards.

e) Functional test meets company/manufacturer/industry standards to confirm all components and systems are operating properly including alarms and shutdowns.



4.5 Maintenance/Repair Work Function

This function includes the routine checking of installed devices and equipment to ensure proper operation. This skill does not include calibration but may involve checking with a calibration device for proper operation and minor adjustment within manufacturers’ tolerances.


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a) Obtain documents pertaining to the device in order to understand the operation of the device and investigate its performance history.

b) Assess the condition of the device through documentation, inspection and testing in order to maintain the device's performance and determine the need for any repair to confirm all components and systems are operating properly including alarms and shutdowns.

c) If required, remove device from service following all site and safety procedures in order to perform needed repairs.

d) If required, decontaminate device in accordance with material safety data sheets, site and safety procedures in order to ensure safe conditions.

e) Perform any applicable repairs by following proper procedures in order to return the device to service. Replace devices with compatable equipment that can not be repaired.

f) If required, re-calibrate the device following site procedures in order to ensure proper operation.

g) Complete all documentation as required in order to update all device and maintenance records.



b) Routine maintenance is performed according to job scope.

c) The point of deviation is identified where the known inputs result in unexpected outputs.

d) Corrective repairs are performed according to job scope.

e) Physical inspection meets company/manufacturer/industry parameters.

f) Configuration is verified according to the application.

g) Calibration is verified according to engineering specifications with certified standards when applicable.

h) Functional test meets company/manufacturer/industry standards.

i) Known inputs result in expected outputs as specified by the manufacturer.

j) Asset reliability management processes are used to support preventive, corrective and just-in-time maintenance procedures.

k) Documentation is completed according to company guidelines.

5 Assessing Skills

The assessment process should include knowledge testing and skill proficiency demonstrations.


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5.1 Knowledge proficiency

Written examinations should include:

a) True-false, multiple choice and essay questions that rely on extended responses to further clarify an understanding of the knowledge being assessed.

b) Graphic representations and drawings that reveal an understanding of symbology and connections between processes and instrument devices.

c) Preparation and justification of a reasonable solution to a problem scenario.

5.2 Skill proficiency

Hands-on skill demonstrations of knowledge, actual or simulated task performance and attitudes should include real life scenarios, problems or situations to solve that:

a) Represent a problematic or challenging situation in the context of the career or technical perspective.

b) Apply relevant knowledge or skills.

c) Focus on the application of knowledge and skills learned in one situation as it connects to a new and different one.

d) Reveal an ability to plan, organize and create a remedy or expected outcome.

e) Require study to analyze or evaluate the problem or situation.

f) Illustrate by individual performance the attained levels of knowledge, skills and attitudes even if working in teams.

g) Include observation of events, teams and individuals that focuses on the salient traits of the skill or attitude being observed.

h) Demonstrates written and oral communication skills.

i) Documents the development process from initial steps to completion.


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Annex A - Occupational Skills and Technical Knowledge

All work-oriented functions, activities, tasks and duties require technical knowledge, occupational skills and abilities specific to the work context for effective performance. The knowledge, skills and abilities include technical processes or procedures common across the occupation that are critical to the listed work functions, activities, tasks and duties. These include but are not restricted to the following:

1) Utilize appropriate health and safety equipment and practices (PPE, MSDS, work permits, safety procedures, decontamination equipment, etc.)

2) Comply with all safety and environmental procedures required for process integrity, isolating equipment, decontaminating equipment and personnel safety.

3) Identify potential safety and environmental hazards.

4) Analyze drawings and symbology (P&IDs, process flow diagrams, instrument and loop diagrams, engineering diagrams with control logic, cause and effect diagrams, mechanical and electrical diagrams, process control and communication diagrams)

5) Analyze specification sheets (loop sheets, calibration sheets, data sheets, manufacturer’s specifications, instrument indexes, etc.)

6) Interpret appropriate written documentation (ISA standards, certification standards, site procedures and documentation, operation and equipment manuals, manufacturer's and other technical documents)

7) Utilize hand tools, computers and communication devices.

8) Comprehend the use and functions of electrical, electronic and pneumatic test and calibration instruments.

9) Assess the function and performance of instrument equipment, control loops, electrical circuits and the related process or mechanical systems.

10) Utilize pressure and power sources including high-pressure sources, high-temperature sources, voltage and current sources, etc.


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Annex B - Resources

All work-oriented functions, activities, tasks and duties require resources (tools, documentation, hardware, and other materials) to competently perform the activity, task or duty to the performance level listed. These include but are not restricted to the following:

1) Personal Protective Equipment (PPE)

2) Drawings (P&IDs, process flow diagrams, instrument and loop diagrams, mechanical and electrical diagrams, process control and communication network diagrams)

3) Specification sheets (loop sheets, calibration sheets, data sheets, manufacturer’s specifications, instrument indexes, etc.)

4) Logic diagrams (e.g. engineering diagrams with relay, ladder control and motor control logic)

5) Program firmware

6) Reference materials (technical documents, operating manuals, maintenance manuals, ISA standards, certification standards, equipment manuals, etc.)

7) Procedures (site-specific operating and maintenance procedures, Health / Safety / Environment procedures, etc.)

8) Job Safety Analysis (JSA)

9) Material Safety Data Sheets (MSDS)

10) Safety and decontamination equipment

11) Permits and area classification sheets

12) Hand tools (screwdrivers, pliers, wrenches, hammer, tubing and conduit benders, etc.)

13) Data forms

14) Computerized maintenance programs

15) Communication devices (handheld radio, protocol communicator, hand held terminals (HHTs), hand held communicators (HHCs), pneumatic/mechanical/electrical signal simulators, etc.)

16) Test and measuring equipment (volt-ohm meter, digital volt meter, oscilloscope, protocol analyzer, multi-amp tester, hydrometer, megohm meter, cable tester, amp probe, frequency analyzer, phase comparison tester, non-contact voltage tester, power quality monitor, hot sticks, high-voltage tools and equipment, etc.)

17) Equipment specific standards and calibrators (portable pressure tester, temperature calibration equipment, infrared camera, analyzer specific calibration equipment and standards, etc.)

18) Screens, filters, and cylinders


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Annex C – Academic and Foundational Skills

All work-oriented functions, activities, tasks and duties require academic and employability skills, and other abilities for effective performance. These basic, underlying competencies enable a technician to perform the work. The common academic subject areas must be applied in terms that are relevant to the work functions, activities, tasks and duties as illustrated by the following:

Academic/Employability Skill Work Context

1) Reading Reading technical documents

Evaluating relevant manuals/drawings for available information

2) Writing Writing work reports

Technical writing

Completing required documentation

Completing calibration sheets

3) Mathematics Measurement unit conversions

Converting units from metric/English or English/metric

Applying mathematical units and relationships

4) Science Basic measurements units (temperature scales, pressure, flow and level units)

Temperature, pressure, flow and level properties

Temperature, pressure, flow and level fundamentals

Physics of energy and power (mechanical and pneumatic fundamentals)

Fundamental physical properties of matter

Fundamental chemical properties of matter

Electronic fundamentals

Fundamentals of electricity

DC & AC circuits

5) Listening Communicating with others

6) Speaking Communicating safety practices

Communicating problems identified during field walk-downs, calibration, loop checks, etc

7) Self and career development Following all appropriate procedures

Performing task assignments

Ability to learn new technology

8) Using social skills Communicating with others


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9) Adaptability Applying problem-solving techniques

Applying problem analysis techniques

Applying fundamental risk analysis techniques

Developing alternative solutions to a problem

10) Working in teams Participate with basic duties of other disciplines

Interface with operators

11) Leading others Demonstrating safety practices

Assigning tasks

Implementing detail action plans

Proper sequencing of start-up plan

12) Building consensus Establishing priorities for start-up

13) Making decisions and judgments

Reading and interpreting test equipment

Interpreting data and making comparisons

Interpreting, organizing, filing and establishing order for documentation

Interpreting a start-up plan

14) Organizing and planning Obtaining appropriate test equipment

Following all appropriate safety procedures

Following calibration procedures

Following instrument repair/replace procedures

15) Using information and communications technology

Selecting required data forms

Completing required documentation

16) Gathering and analyzing information

Gathering technical information

Searching technical information

Utilize technical and historical information

Manipulating device inputs and interpreting output readings

Checking for variance/error percentage

17) Analyzing and solving problems

Analyzing historical data

Identifying abnormal operating conditions

Identifying abnormal variations in data or readings from charts or indicators

Identifying malfunctions in equipment and possible causes for these malfunctions


Developing and promulgating sound consensus standards, recommended practices, and technical reports is one of ISA’s primary goals. To achieve this goal the Standards and Practices Department relies on the technical expertise and efforts of volunteer committee members, chairmen and reviewers.

ISA is an American National Standards Institute (ANSI) accredited organization. ISA administers United States Technical Advisory Groups (USTAGs) and provides secretariat support for International Electrotechnical Commission (IEC) and International Organization for Standardization (ISO) committees that develop process measurement and control standards. To obtain additional information on the Society’s standards program, please write:

ISA Attn: Standards Department 67 Alexander Drive P.O. Box 12277 Research Triangle Park, NC 27709

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