Examples

• Level 1 read memos from supervisors or suppliers to learn the status of projects or the availability of supplies.
• Level 2 read technical articles in trade magazines such as engineering digests to keep up to date with developments in the field.
• Level 2 read technical notes from manufacturers and past records left by former employees in order to understand the operation of equipment and its breakdown history.
• Level 2 read health and safety bulletins and company health and safety regulations.
• Level 3 read calibration and troubleshooting guides and their descriptions of how equipment works and how it should be installed.
• Level 3 read quality and incident reports in order to understand problems which have emerged, how to solve them and how to take preventive action.
• Level 3 read Workplace Hazardous Materials Information System (WHMIS) materials and Material Safety Data Sheets (MSDS) and WHMIS course materials to learn the hazards of products such as hydrogen sulphide and caustic sodas.
• Level 3 read procedures manuals regarding the removal of machinery and startup and shutdown of machinery.

Examples

• Level 1 read meters such as ph meters and hour meters (timers) when performing calibration checks.
• Level 1 respond to colour codes on computer screens (green and red) which indicate whether any parameters are out of control and respond to a variety of sirens and alarms.
• Level 1 read numerous control gauges, such as temperature and pressure gauges, expansion gauges, and eccentricity gauges for turbines.
• Level 1 read supplier catalogue listings.
• Level 2 fill in a variety of forms to record the name and number of instruments or parts that need to be replaced. This includes order forms.
• Level 2 read numerous computer printouts with numeric information, work order details and alarm history.
• Level 2 read supplier catalogue listings and complete order forms, using parts numbers and codes.
• Level 2 make calculations for combustion tables.
• Level 3 read a variety of graphs, tables and charts, such as circular charts which record turbine rpm, turbine inlet temperature, core temperature and exit temperature.
• Level 3 plot measurements on scatter diagrams.
• Level 3 interpret schematics, such as PLC computer logic control diagrams.
• Level 3 interpret assembly diagrams, such as those showing how 25 or 30 pieces of a transmitter fit together.
• Level 3 interpret blueprints, such as piping diagrams.
• Level 4 interpret exploded views of motors or large exploded views of plant systems.

Examples

• Level 1 write lists for ordering parts.
• Level 1 may write daily log entries and keep their own notes in notebooks that they carry with them.
• Level 1 write short explanatory letters, interoffice memos and e-mail messages.
• Level 2 write maintenance schedules.
• Level 2 write letters or faxes to suppliers.
• Level 3 write reports in a standard format outlining findings from mechanical inspections and what was done to resolve problems.
• Level 4 may write customized task procedures manuals by taking key points from various materials and adapting them to a specific context.

Examples

• Level 1 measure oxygen analyzer malfunctions.
• Level 1 monitor pressure, air and hydraulics.
• Level 2 compare target values to actual values in order to determine the overall efficiency of the boiler and turbine. This information is used to determine cost analysis.
• Level 2 compare previously recorded pressures to existing pressures to establish the variance for troubleshooting and control purposes.
• Level 2 estimate how long it will take to undertake various repairs. This is important, especially if some systems have to be shut down during repairs.
• Level 3 calculate firebox volumes and air flow per minute to gain more efficient combustion.
• Level 3 measure eccentricities to a thousandth of a inch.
• Level 3 calculate volume displacement, i.e, how much fuel or air to put in to retain combustion at an acceptable level.
• Level 3 use a Distributive Control System (DCS) to track system faults and trends in pressures and levels electronically.
• Level 3 interpret a daily preventive maintenance graph (PM) to discern high or low deviations in temperature which may indicate that there is a problem with instrumentation.

Examples

• Level 1 may give instructions to pipefitters about the type of piping needed for an installation.
• Level 2 interact with welders, machinists, electricians, mechanics and suppliers to discuss problems and assess solutions.
• Level 2 may communicate with millwrights about a bad valve flange that needs to be machined.
• Level 2 may provide direction to temporary staff and demonstrate to them safe working habits, such as taking the load off a spring before undoing a valve.
• Level 3 may discuss engineering problems with engineers, such as a transmitter in the wrong location or the lack of sufficient temperature on a system. They provide sufficient information so that engineering can design modifications. They then advise the engineers about the workability of the proposed modification.
• Level 3 communicate with supervisors to recommend repairs or to persuade them to consider non-routine solutions to technical problems, based on stated parameters.
• Level 3 instruct other workers, such as mechanics, on how to operate new pieces of gear. They also demonstrate its use, either formally or informally.
• Level 3 may communicate vital safety instructions to co-workers, such as boiler operators. This communication is important since safe operations depend on the instructions being understood and followed.
• Level 3 may make formal presentations to explain quality monitoring or new equipment.

Examples

• Level 3 may find that a boiler "trips" all of a sudden, causing panic. They consider the options available to solve the problem - getting a load replacement or switching to another boiler which has been held in reserve.
• Level 3 may find that a transmitter does not read properly - e.g., the gauge is reading 20 when it should be reading 30. They determine whether the problem is an instrumentation problem or an operator problem. This is done by sending signals electronically or pneumatically to the control room.
• Level 4 may hear alarms, the warnings from instruments that something is amiss. They take corrective measures in conjunction with boiler operators to lower or raise oxygen levels, in order to avoid an explosion.
• Level 4 may find that power supply lines go down in an icestorm, creating power outages for some customers. They hasten to put reserve systems into running condition, taking into account that it takes 8 to 10 hours to get a boiler running.

Examples

• Level 1 decide which tasks to perform first - e.g., which boiler to work on first.
• Level 2 decide whether to repair or replace an instrument, based on time and cost factors.
• Level 2 decide how many parts to order to maintain an appropriate stock level.
• Level 2 decide whom to notify first of a serious problem with a boiler or transmitter - the supervisor or the engineering department.
• Level 2 decide whether to follow predictive maintenance procedures, replacing parts before they actually break down. These decisions are made through experience, taking into account the likelihood of failure and the affect that breakdowns would have on operations.
• Level 3 decide whether to take a boiler off-line to do a repair in cases where 3 or 4 control functions are on one card and the card cannot be removed. They take into account whether their action will drop the load beyond a safe point and also decide the most suitable time of day to take the unit down (e.g., after peak period of meal time).
• Level 4 decide at what point to tell an operator to switch an analyzer from automatic to manual control, taking into account the seriousness of the problem (e.g. temperature too high) and the likelihood of an outage resulting if the problem is not resolved.

Examples

• remember the location of all the various transmitters and gauges throughout the plant and where to find the pressure transmitter on as many as six different boilers.
• remember what repairs were last carried out on a piece of machinery.
• remember what the normal reading is for each of six sets of gauges and what the reading was when last checked.
• remember the sequence of steps in using calibration equipment, for instance, the 15 steps for calibrating a sodium monitor, and remember the steps in carrying out repairs on various types of equipment.

Examples

• Level 1 refer to colour coded displays on computer screens to monitor pressures and temperatures.
• Level 2 identify trends and the repair/maintenance history of various pieces of equipment by accessing the work order database.
• Level 2 refer to e-mail messages and attachments to obtain shutdown updates and progress reports of shutdowns.
• Level 2 contact engineers and operators to obtain information on specific problems.
• Level 3 synthesize information about machinery, drawing from manuals, trade journals and manufacturers' schematics.

Examples

• Level 1 they send and receive e-mail.
• Level 1 use other computer applications. For example, they use computer controlled machinery on the boilers, referring to multiple computer screens (e.g., 6 screens) and keyboarding for maintenance purposes.
• Level 1 they may use smart, handheld communicators to read pressures, flows and instrumentation setups and to calibrate the transmitters and valve positioners.
• Level 2 they may type an estimate.
• Level 2 they may use a database to access work orders and record the work done to complete the work order. They refer to the database when checking the history of equipment during troubleshooting.
• Level 2 they key in values on Excel or Lotus when setting up a transmitter.

Physical Aspects

Attitudes

The industrial instrument mechanics interviewed felt that industrial instrument mechanics should be patient, tolerant and easy going. It is important that they remain calm in stressful situations. They should be prepared to work long hours and be able to work alone.

Future Trends Affecting Essential Skills

Brand new computer systems are being introduced, calling for industrial instrument mechanics to upgrade their computer skills. The growing use of analyzers, such as gas chromatographs and oxygen and combustible analyzers, for troubleshooting purposes will lead to new training needs in the area of finding information in manuals and interpreting schematics. The use of the Internet will become more prevalent in the future, with Industrial instrument mechanics going online to order supplies directly rather than dealing with supplier representatives. The Internet will also be used to troubleshoot.

Future Trends Affecting Essential Skills