LEARNING MODULE 5 Logo of TVET Provider

TVET PROGRAM TITLE: Instrumentation and control servicing Level III

MODULE TITLE: Maintaining and repairing instrumentation and control devices
MODULE CODE: EEL ICS3 M05 1115
NOMINAL DURATION: 40Hrs:
MODULE DESCRIPTION: This module describes the knowledge, skills and attitudes needed
to maintain and repair instrumentation and control devices..
LEARNING OUTCOMES:
At the end of this module the trainer will be able to
LO1: Plan and prepare for maintenance/ repair
LO2: Maintain instrumentation and control devices
LO3: Repair instrumentation and control devices
LO4: Inspect and test maintained/ repaired instrumentation and control devices
LO5: Clean-Up
MODULE CONTENTS:
LO1: Plan and prepare for maintenance/ repair
1.1 Personal protective equipment and OH&s
1.2 Types of maintenance
1.2.1 Preventive maintenance
1.2.2 Corrective maintenance
1.3 Purpose of maintenance and repair
1.4 Types and functions of tools and equipment
1.5 Operation of testing devices and instruments
1.6 Equipment, testing devices and instruments signs, symbols and conventions
LO2: Maintain instrumentation and control device
2.1 standard procedures of ICS (instrumentation & control system) maintenance
2.2 maintain ICS
LO3: Repair instrumentation and control devices
3.1 Diagnosing faults/ problems in system components
3.2 Repairing the instrument/control device
LO4: Inspecting and testing maintained/ repaired instrumentation and control devices
4.1 Checking the operation of instrument and control devices
4.2 Conducting appropriate functional test
4.3 Recording and reporting test result
LO5: Clean-Up
5.1 Checking and monitoring tools and equipment
5.2 Cleaning work area
LO1: Plan and prepare for maintenance/ repair
All maintenance work requires the use of proper 'tools and equipment to properly perform the
task to be done. In addition to their ordinary tools (each craftsman (such as carpenters, pipe
fitters, and machinists) uses some special tools or equipment based on the nature of the Work to
be performed.
1 Electrical equipment and apparatus must be maintained in good working order. Any equipment
with an identified fault* must be removed from service, until the fault is rectified. The laboratory
supervisor must be consulted for advice about who is to carry out the repairs.
2 Any such repairs or alterations must be recorded in the laboratory or instrument log book.
3 Repairs* to any mains power circuitry (240 V or 3-phase) may only be undertaken by a
licensed electrician or authorized repair technician. These repairs must be tested and tagged as
electrically safe, by a competent person, before return to use, and this certification must be
recorded in the log book.
4 Repairs to circuitry or components that are separate to the mains power circuit (eg: digital or
low voltage circuits) may be undertaken by laboratory personnel who are approved by the
laboratory supervisor.
5 Before an investigation of any electrical fault, or any repairs are undertaken; the equipment
must be isolated from the mains supply (240 V or 3-phase). If the equipment cannot be
disconnected, the circuit must be disabled at the distribution board.
6 All low voltage repairs must be recorded in the repair log, and must be tested and signed off by
the repairer before the equipment is put back into service.
* In all cases, “repairs” or “faults” mean “non-user serviceable repairs”. General maintenance
activities such as changing light bulbs and fuses, or rewiring a photodiode, do not fall into the
category of repairs or faults, and may be carried out by qualified personnel. Such activities are
also to be recorded in the log book.
1.1 Personal protective equipment and OH&s
 What is personal protective equipment?
Personal protective equipment, or PPE, is designed to protect employees from serious workplace
injuries or illnesses resulting from contact with chemical, radiological, physical, electrical,
mechanical, or other workplace hazards. Besides face shields, safety glasses, hard hats, and
safety shoes, PPE includes a variety of devices and garments such as goggles, coveralls, gloves,
vests, earplugs, and respirators.

 Safety (OH&S)
OH&S requirements are to be in accordance with State or Territory legislation and regulations
and may include protective clothing and equipment, use of tools and equipment, workplace
environment and safety, handling of materials, use of firefighting equipment, use of first aid
equipment, hazard control and hazardous materials and substances
• Personal protective equipment is to include that prescribed under legislation, regulation and
workplace policies and practices

 Environmental Requirements
• Environmental requirements are to include but not be limited to waste management, storm
water protection and clean-up management

 Quality Assurance
• Quality assurance requirements may include but not limited to relevant International Standards
Organization (ISO) and Australian Standards, internal company quality assurance policy and
standards, risk management strategy, Environment Protection Authority (EPA) requirements, the
site safety plan, workplace operations and procedures

 Statutory/Regulatory Authorities
• Statutory/regulatory authorities may include statutory/regulatory Government authorities and
Local Government statutory authorities

 Equipment
• Tools and equipment are to include but not be limited to first aid kits, firefighting equipment
and personal protective equipment
  Materials
• Materials are to include but not be limited to first aid materials

 Communications
• Communications are to include but not limited to verbal instructions and fault reporting and
may include two way radio, hand signals, mobile phone, phone, facsimile, computer, site specific
instructions, written instructions or instructions related to job/task

 Information
• Information sources may include but not be limited to verbal or written and graphical
instructions, signage, work schedules/plans/specifications, work bulletins, charts and
Hand drawings, memos, material safety data sheets (MSDS) and diagrams or sketches
• Safe work procedures or equivalent
• Regulatory/legislative requirements
• Manufacturers' specifications and instructions
• Organization work specifications and requirements
• Instructions issued by authorized organizational or external personnel
• Relevant Australian Standards

1.2 Types of maintenance

1.2.1 Preventive maintenance
Schedule of planned maintenance actions aimed at the prevention of breakdowns and failures”
Primary goal-Preserve and enhance equipment reliability
The purpose of an EPM program is to reduce hazard to life and property that can result from
failure or malfunction of industrial type electrical systems and equipment. The first part of these
recommendations for an effective electrical preventive maintenance (EPM) program has been
prepared with the intent of providing a better understanding of benefits -- both direct and
intangible that can be derived from a well-administered EPM program. This chapter explains the
function, requirements, and economic considerations that can be used to establish such a
program.

There are four basic steps to be taken in the planning and development of an electrical preventive
maintenance program. In their simplest form, they are:

(1) Compile a listing of all plant equipment and systems.

(2) Determine what equipment and/or systems are most critical and most important.

(3) Develop a system for keeping up with what needs to be done.

(4) Train people for the work that needs to be done, or contract for the special services that are
needed.

 Examples of PM

 Oil changes
 Greasing
 Changing filters
 Belt tightening
 Anything that increases life of equipment, and helps it runs more efficiently
 Checking loose connection
  Benefits of PM

•Increases life of equipment

•Reduces failures and breakdowns

•Reduces costly down time

•Decreases cost of replacement
 Who Does PM?
• Only trained, qualified maintenance personnel should perform PM’s

1.2.2 Predictive Maintenance (PdM)

• Definition – “Techniques that help determine the condition of in-service equipment in order to
predict when maintenance should be performed”
• Primary goal – Minimize disruption of normal system operations, while allowing for budgeted,
scheduled repairs

 Examples of Predictive Maintenance

• Vibration Analysis
• Infrared Thermograph
• Oil Analysis
• Visual Inspections

 Benefits of PdM
• Provides increased operational life
• Results in decrease of downtime
• Allows for scheduled downtime
• Allows for money to be budgeted for repairs
• Lowers need for extensive parts inventory
• Reduction in maintenance costs – 25-30%
• Elimination of breakdowns – 70-75%
• Reduction of downtime- 35-45%
• Increase in production – 20-25%
1.2.3 Corrective maintenance

It the action to repair equipment/machinery in order to bring it back to original operating

condition. Corrective maintenance / reactive maintenance/operate to failure/ breakdown
Maintenance are remedial actions taken after a machine failure or after identification of a
Deficiency during preventive maintenance to return the equipment to its operational state
Corrective maintenance action however requires to be acted on urgently by interrupting the
operations through integration or substitution of previously planned work. It has a negative
impact because it is an indication that something is not working and therefore machine
downtime. This type of maintenance should therefore be utilized on non-critical areas where
consequences of failure are low and does not influence the overall functioning of the equipment
hence posing no risk for the operator. Corrective maintenance can either be planned or
unplanned . The challenge for reliability is dealing with data from the past. Failure is modeled,
analyzed and, to some extent, predicted. Unfortunately, the prediction does not take into account
users or working environment-related restrictions, and often the results are not those useful.
Machine conditions are monitored at the machine level, one machine at a time. It is a "Fail and
Fix approach." Troubleshooting is the primary purpose.
A. Immediate/Unplanned Corrective Maintenance Practices.
This is maintenance carried out immediately with no postponement after an error has been
discovered to avoid undesirable consequences. Usually, it is not in the maintenance plan and
therefore very unpredictable that it cannot be planned in advance on a need basis at a particular
time. It’s prompted by machine breakdown. The immediate maintenance practice can either be
break down maintenance system or opportunistic maintenance system.
Run to failure maintenance: also known as breakdown maintenance is described. As a
practice where systems are maintained only after failure mostly of a critical nature.
Equipment is allowed to run till it fails. The action taken to restore the equipment into use can be
servicing, repairing, replacement or overhaul. For manufacturing firms to adopt this practice they
must ensure that they put certain provisions. This includes having a spare or support equipment
that can be quickly brought into service upon failure of the machine in use, having stock of spare
parts and inventories of stock and work in progress that can be used as needed thereby avoiding
lead times, having operators who are able to detect fault and deal with emergency failures and
finally have maintenance staff who are well trained and readily available to carry out
maintenance as and when need arises.
Opportunistic maintenance: is the methodical technique of collecting data about a system,
investigating it, preplanning its maintenance activities, and making known a proposed set of
maintenance activities and acting on them when a repair opportunity arises.

B. Deferred /Planned Corrective Maintenance Practices.

Planned maintenance is maintenance that is defined, documented, and done before equipment
fails. In this type of maintenance practice a fault that has been detected in a part is delayed
according to given maintenance rules so that production can continue without interruption. The
key objective is to identify fault on time and correct it before breakdown occurs. This requires
that firms put in place systems to monitor the machinery, plan for the corrective action within
sufficient lead time without allowing the machine to fail. This type of maintenance is applied on
non-vital areas where there are no immediate safety risks and potential failure can be identified
on time.
Shutdown corrective maintenance: Shutdown maintenance is maintenance that is carried out
when the entire production system is in total stoppage. It is a planned maintenance strategy that
is carried out at least once in a year by manufacturing firms. It involves an overhaul of the entire
manufacturing system therefore the procedures laid out for such maintenance should be followed
strictly. For semi continuous manufacturing systems shutdowns are much easier due to their
flexibility which allows application of both planned and unplanned maintenance.

1.3 Purpose of maintenance and repair

The main purpose of regular maintenance is to ensure that all equipment required for production
is operating at 100% efficiency at all times. Through short daily inspections, cleaning,
lubricating, and making minor adjustments, minor problems can be detected and corrected before
they become a major problem that can shut down a production line. A good maintenance
program requires company-wide participation and support by everyone ranging from the top
executive to the shop floor personnel.
1.4 Types and functions of tools and equipment
USE OF ELECTRICAL TEST EQUIPMENT

Test equipment is necessary for determining proper set-up, adjustment, operation, and
maintenance of electrical systems and control panels.

The following is a general procedure for use of test equipment:

TYPES

VOLTMETERS

For measuring differences of potential (voltage) between two points in an electrical circuit. The
instrument is connected in parallel with the circuit being measured. Ranges vary from a few
tenths volt to a few thousand volts. Instruments are capable of measuring both A.C. and D.C.
voltage.

OHMETERS

For measuring the electrical D.C. ohm resistance of a circuit, circuit part, or component.
Calibrated from zero ohms to infinite. Measures either series or parallel resistance.

AMMETERS

Measure magnitude of electrical current flow in an electrical circuit. When measuring D.C.

currents, some types must be inserted in series with the circuit. A.C. ammeters are of two types.

One requires that it be connected in series with the circuit; the other needs only to be clamped

around the current carrying conductor. Ranges are from less than .0005 to over 100 Amperes,

depending upon the instrument.

HIGH POTENTIAL TESTERS (HI-POT)

Capable of generating calibrated voltages from zero to several thousand for purpose of testing
the integrity of insulation on wiring (usually buried in the earth).

GROUND ROD TESTER

For testing the effectiveness of, and determining the value of resistance of the grounding

Electrode (rod) circuit in an electrical system. Usually operate by a balanced bridge circuit and

Has a direct readout of resistance.

CHART RECORDERS

Electrically driven and operated roll chart indicator. Gives a graphic readout of parameters
versus time. Units are available for recording voltages, currents, pressures, temperatures, light
levels, etc. Some instruments are single channel; others can measure multiple inputs. Useful for

Monitoring a parameter over a period of time. Instrument sensitivities and accuracies vary
approximate proportional to the quality some instruments combine functions and are capable of
measuring different quantities. One is the common VOM, or the volt-ohm- Ammeter

1.5 Operation of testing devices and instruments

Accordingly Ethiopian standard, Unless otherwise specified, the equipment, materials and
installation of the work shall comply with the following criteria:
- Supply System Nominal Voltage: 400/230V 3 phase, 4 wire + 10% or – 6%
240V 1 phase, 2 wire + or – 10%
- Supply System Frequency: 50Hz
- Supply System Earthling: Multiple Earthed Neutral (MEN)
- External Temperature Service Conditions: Maximum 40 degrees C, Minimum –10C
- Relative Humidity Service Conditions: Maximum 95%
 The purpose of this manual is to provide instructions for unpacking, storage, installation,
Operation and maintenance for the Manual Ground & Test Devices. Prior to each use, the
following tests should be completed to assure the G&T device is in good condition.
1.6 Equipment, testing devices and instruments signs, symbols and conventions
 symbols and conventions
LO2: Maintain instrumentation and control device
Maintenance of instrumentation and process control systems from simple gages to complex
distributed control systems is essential for the continuation of our industry.” Statements such as
this have been repeated thousands of times by company presidents, manufacturing directors, and
production superintendents. Maintenance personnel should be involved with new installations
and upgrading older installations. They should ensure that the system is ergonomically easy to
repair and well documented. Training should be done before a new system arrives so the
maintenance department can help in installing and checking it out. Equipment manufacturers
provide engineering and start-up assistance. So the majority of the new opportunities to work in
the I&C field is through original equipment manufacturers or service contract employees.
Because of the equipment’s complexity, assistance is needed from the original equipment
manufacturer. Configuration of control systems and instruments should be done by those very
familiar with the system requirements and system/ instrument capabilities. Instrumentation tells
us the process parameters in which we are operating. A simple gage tells the temperature or
pressure; the more complex instrumentation tells much more about the process. Proper operation
of all equipment is required to make a quality product and to do it safely.
The technological advances of the past few years and the trends for more technical and
specialized equipment require better trained and educated maintenance personnel. The types of
equipment in control systems cover many disciplines: mechanical, electrical, electronic,
computer science, chemical, and environmental, among others.
Because of the many different knowledge factors, the individual crafts (electrician, mechanic,
pipe fitter, etc.) have to work together, and finger pointing will sometimes occur. Electrical
engineers, mechanical engineers, chemical engineers, and process engineers must understand
each other and determine where their responsibilities start and stop.
2.1 standard procedures of ICS (instrumentation & control system)
maintenance
Process Control maintenance
In order to produce a product with consistently high quality, tight process control is necessary.
Process control is the automatic control of an output variable by sensing the amplitude of the
output parameter from the process and comparing it to the desired or set level and feeding an
error signal back to control an input variable.

Block diagram of the elements that make up the feedback path in a process-control loop.

Elements of instrumentation controlled maintainable parts

 Electrical Components
 Electronics
 Analog Circuits
 Discrete amplifiers

Transistors can be used to make discrete amplifiers.

 Operational amplifiers

The integrated circuit made it possible to interconnect multiple active devices on a single chip to
make an operational amplifier (op-amp), such as the LM741/107 general purpose op-amp.

 Current amplifiers

Devices that amplify currents are referred to as current amplifiers.

  Differential amplifiers

A differential amplifier is a dual input amplifier that amplifies the difference between two
signals, such that the output is the gain multiplied by the magnitude of the difference between the
two signals.

 Buffer amplifiers

An impedance matching op-amp is called a buffer amplifier

 Nonlinear amplifiers

Many sensors have a logarithmic or nonlinear transfer characteristic and such devices require
signal linearization. This can be implemented by using amplifiers with nonlinear characteristics

 Amplifier applications

In process control, amplifiers are used in many applications other than signal amplification,
filtering, and linearization. Some of these applications are as follows:

Capacitance multiplier

Sine wave oscillators

Power supply regulators

Level detection

Sample and hold

Voltage reference

Current mirrors

Voltage-to-frequency converters

Voltage-to-digital converters

Pulse amplitude modulation

  Digital Circuits

The study of electronic circuits where the inputs and outputs are limited to two fixed or discrete
values or logic levels is called digital electronics.

Digital signals

Digital signals are either high or low logic levels.

Binary numbers

We use the decimal system (base 10) for mathematical functions, whereas electronics uses the
binary system (base 2) to perform the same functions.

Analog-to-digital conversion
Logic circuits
 Sensors
There are many sensors other than level, pressure, flow, and temperature that may not be
encountered on a day to day basis—such as position, and force, smoke, and chemical sensors—
but play an equally important part in process control in today’s high-technology industries and/or
for operator protection. These sensors will not be discussed in as much detail as the sensors
already discussed. However, the student should be aware of their existence and operation.

 Linear sensors
The output voltage can be fed to a voltmeter, converted to a current with an amplifier, or
digitized to operate a remote sensing indicator, an actuator, or a signal to a controller.

 Float sensors

A float is often used for level measurements. The level can be converted into angular or linear
motion, but gives a somewhat nonlinear output, as many of us have found with our automotive
gas gauge.

 Strain gauge sensors

Diaphragms use strain gauge or capacitive sensing, the movement being too small to control a
pneumatic flapper, slider, or potentiometer. The strain gauge elements are resistors made from
copper or nickel particles glued onto a non conducting substrate; semiconductor strain gauges are
also available that use the piezo resistive effect. A strain gauge normally consists of two strain
elements mounted at right angles to each other and in close proximity, so that they are both at the
same temperature
  Capacitive sensors
Capacitive sensing devices can use single-ended sensing or differential sensing. With single-
ended sensing, capacitance is measured between the diaphragm and a single capacitor plate in
close proximity to the diaphragm. Differential sensing can be used when there are capacitor
plates on either side of, and in close proximity to, the diaphragm.

 Resistance sensors
Resistive temperature detectors (RTD) measure the change in the electrical resistance of a wire-
wound resistor with temperature, typically, a platinum resistance element is used with a
resistance of about 100 Ω. The resistance change can be measured in a bridge circuit, but
normally the resistor is driven from a constant current source and the voltage developed across
the resistor measured.

 Magnetic sensors
Many flow measurements are sensed as differential pressures with the indicator scale graduated
in cubic feet per minute, gallons per minute, liters per second, and so forth. Rotating devices,
such as the turbine, are used for accurate flow measurements. The devices are simple, do not
require conversion to pressure or other medium, have low drag, can be constructed of inert
materials that are resistant to corrosion, do not require regular recalibration, and are low
maintenance.

 Thermocouple sensors
The sensing junction and the reference junction are connected in series. When the junctions are
at the same temperature the voltage output from the junctions is zero, and the output from the
amplifier is zero. When the junctions are at different temperatures, there is a differential voltage
at the input to the amplifier that is amplified and converted to a temperature reading.

 Smart sensors
Smart sensor is a name given to the integration of the sensor with an ADC, processor, and DAC
for actuator control and the like; such a setup for furnace
Figure. Process system with individual inputs and outputs for each variable

Pneumatic Signal Conditioning

Pneumatic signals as well as electrical signals can be used to control actuators. The bourdon
tube, capsule, or bellows convert pressure into mechanical motion which can be used for
pneumatic control.

2.2 maintain ICS

Maintenance is the action after general diagnosis that, replacement, arrangement, procedure and
proper correction of instrumentation and control devices with identifying each component
functions.
LO3: Repair instrumentation and control devices
For planning and implementing maintenance work, it is required; at least the functional and
wiring diagrams, operating modes, machine procedures and connections to other technologies
(mechanic, electric, electronic) are to be understood. The application of the methods of
systematic troubleshooting has to be known.

Furthermore, the maintenance technician has to be instructed regarding the possible hazards and
the resulting protective measures. Fundamental obligations of the employees can be found in the
accident prevention regulation “Basic principles of prevention

Spare parts have to meet the specifications of the machine manufacturer. This means that all
parts to be installed have to be selected especially in accordance with the maximum operating
pressures and suited for the hydraulic fluid used in the system.

Electrical Hazards on maintenance/ replacement

Working on electric parts of machines and systems can result in special hazards, such as

– Direct and indirect contact with live or conducting parts,

– Shock currents,

– Electric arcs/discharges,

– Voltage diversion, e.g. with improper grounding, and especially hazards due to working
in confined spaces, which also comprise the interior of machines and metallic vehicle
superstructures.
3.1 Diagnosing faults/ problems in system components
HYDRAULIC, PNEUMATIC AND ELECTRICAL SYSTEMS

Related Components:-

Hydraulic equipment:
 Hydraulic fluids and filters, pumps, control valves, regulators, safety
valves, solenoids.

Hydraulic equipment is used to supply energy and to control equipment and processes through
the use of liquids. Hydraulic equipment is used for higher pressure applications. Instrumentation
and control technicians install, maintain, diagnose and repair control devices for hydraulic
systems.

Pneumatic equipment:
 Air dryers, conditioning components (filter assemblies, volume
boosters), compressors, regulators, safety valves, solenoids.

Pneumatic equipment servicing.

Pneumatic equipment is used to supply energy and to control equipment and processes through
the use of compressed air, nitrogen and process gases. Instrumentation and control technicians
install maintain, diagnose and repair pneumatic equipment.

Electrical equipment:
 Alternating current/direct current (AC/DC) power supplies,
uninterruptible power supplies (UPS), circuit boards, transformers,
relays.

Electrical and electronic equipment is used to supply energy and to control equipment and
processes through the use of electricity. Instrumentation and control technicians install, maintain,
diagnose and repair electrical and electronic equipment. They work on electrical and electronic
equipment directly related to process control and often in conjunction with electricians on
electrical power sources.
3.2 Repairing the instrument/control device
There is an increase in the use of variable speed drives (VSDs) for motor control and to replace
process control valves in control applications to reduce energy use. Smart electronic petitioners
are replacing pneumatic petitioners. There is an increased use of self-diagnostic software to
determine, enunciate and facilitate maintenance.

Valves, in conjunction with actuators and petitioners, manipulate the process medium. Valves
must be correctly installed and maintained to ensure system efficiency, optimum production and
safety of operations and equipment. Maintenance of valves includes routine and preventative
maintenance. Diagnosis includes troubleshooting and locating faults such as leaks and wear.

Actuators adjust the position of valves. Instrumentation and control technicians install,
maintain, diagnose and repair actuators to ensure proper operation of valves and other control
devices.

Signal converters convert one form of process signal to another that will be understood
by the process control system. For example, they may convert analog to digital signals. They also
may convert one type of energy to another such as electric to pneumatic. Instrumentation and
control technicians install, configure, calibrate, diagnose, maintain and replace these devices.

PLCs employ control strategies and user-created programs to control multiple loops and
systems. These can be used individually or networked with other control systems to operate
equipment and facilities efficiently and safely

Distributed control systems (DCSs) employ control strategies and user-created

programs to control multiple loops and systems. They usually incorporate their own operator
interface functionality or graphical user station. These can be used individually or networked
with other control systems to operate equipment and facilities efficiently and safely

Supervisory control and data acquisition (SCADA) systems.

SCADA systems are data transmission and acquisition systems for remote control and
monitoring of equipment and facilities. They can be used for control applications such as remote
shut-down and start-up of equipment. They may have the added ability to store, measure, trend
and manipulate data for reporting purposes.
LO4: Inspecting and testing maintained/ repaired instrumentation and
control devices
Tests should give an accurate picture of students’ knowledge and skills in the subject area or
domain being tested. Accurate achievement data are very important for planning curriculum and
instruction and for program evaluation. Test scores that overestimate or underestimate students’
actual knowledge and skills cannot serve these important purposes.

The Purpose Of This Section Is To Indicate The Procedures Necessary In Order To Properly
Service The Motor, Ensuring That It Will Continue To Perform Well Over Time.

The Information Contained In This Section Is Intended For All Qualified Technical Personnel In
Charge Of Machine Maintenance, And Some Parts For The Machine Operator.

Implementing an ambient air monitoring network, with the various types of equipment needed,
is no easy task. Through appropriate testing, inspection and maintenance programs, monitoring
organizations can be assured that equipment is capable of operating at acceptable performance
levels. Every piece of equipment has an expected life span, and its use should be discontinued if
its performance quality ceases to meet appropriate standards.

Due to the many types of equipment that can be used in an ambient air monitoring program, this
section provides general guidance on testing, inspection, and maintenance procedures for broad
categories of equipment only. In most cases, equipment manufacturers include inspection and
maintenance information in the operating manuals. The role of monitoring organizations, in
developing a quality system, is to address the scheduling and documentation of routine testing,
inspection, and maintenance. Detailed maintenance documents should be available for each
monitoring site. Elements incorporated into testing, inspection and maintenance documents
include:

 equipment lists - by organization and station;

 spare equipment/parts lists - by equipment, including suppliers;
 inspection/maintenance frequency - by equipment;
 testing frequency and source of the test concentrations or equipment;
 equipment replacement schedules;
  sources of repair - by equipment;
 service agreements that are in place; and
 monthly check sheets and entry forms for documenting testing, inspections
and maintenance performed

Laboratory Support

While it is not required, monitoring organizations should employ full laboratory facilities. These
facilities should be equipped to test, repair, troubleshoot, and calibrate all analyzers and support
equipment necessary to operate the ambient air monitoring network. In cases where individual
laboratories are not feasible, a monitoring organization may be able to find a central laboratory
where these activities can be performed.

4.1 Checking the operation of instrument and control devices

Routine Operations
Routine operations are the checks that occur at specified periods of time during a monitoring
station visit. These duties must be performed and documented in order to operate a monitoring
network at optimal levels. Examples of typical routine operations are detailed in Table bellow
4.2 Conducting appropriate functional test
It Is Appropriate And Ethical To:
1. Communicate to electricians, parents and the public what any test does and does not do, when
and how it will be administered, and how the results may be appropriately used.
2. Teach to the Essential Learning Requirements at each grade level so that electrician will learn
the skills and knowledge they need to accurately show what they know and can do.
3. Incorporate all subject area objectives into the local curriculum throughout the year including,
but not limited to, the objectives of the tests to be administered.
4. Review skills, strategies, and concepts previously taught.
5. Teach and review test-taking and familiarization skills that include an understanding of test
characteristics independent of the subject matter being tested.
6. Use any test preparation documents and materials prepared by the test-maker, the Office of the
Superintendent of Public Instruction or the Commission on Student Learning.
7. Read and discuss the test administration manual with colleagues.
8. Schedule and provide the appropriate amount of time needed for the assessment.
9. Take appropriate security precautions before, during and after administration of the test.
10. Include all eligible students in the assessment.
11. Actively proctor students during tests, keeping them focused and on task.
12. Seek clarification on issues and questions from the administrative team responsible for
ethical and appropriate practices.
13. Avoid any actions that would permit or encourage individuals or groups of students to
receive scores that misrepresent their actual level of knowledge and skill.
4.3 Recording and reporting test result

LO5: Clean-Up
5.1 Checking and monitoring tools and equipment
Station maintenance is an element of preventive maintenance that does not occur on a routine
basis; rather, these tasks usually occur on an “as needed” basis. Station maintenance items are
checked monthly or whenever an agency knows that the maintenance needs to be performed.
Examples of station maintenance items include:
 floor cleaning;
 shelter inspection;
 air conditioner repair;
 AC filter replacement;
 weed abatement and grass cut;
 roof repair;
 general cleaning;
 inlet and manifold cleaning;
 manifold exhaust blower lube;
 desiccant replacement; and
 ladder, safety rails, safety inspection, if applicable.

5.2 Cleaning work area