Specialised Sensing Device Maintenance Procedures Training

Objectives:
• Understand the role and importance of specialised sensing devices in industrial applications.
• Identify different types of specialised sensors and their operating principles.
• Recognise relevant safety standards and regulations.
• Explain the course structure and assessment criteria.

Topics:
• Definition and classification of specialised sensing devices
• Overview of sensor technologies (e.g., optical, ultrasonic, capacitive)
• Applications in South African industry (mining, manufacturing, process control)
• Safety, health, and environmental considerations
• Introduction to unit standard 116059 and learning outcomes

Objectives:
• Describe basic measurement principles and sensor characteristics.
• Differentiate between analogue and digital sensors.
• Understand calibration concepts and traceability.
• Interpret sensor datasheets and specifications.

Topics:
• Measurement theory: accuracy, precision, resolution, sensitivity
• Analogue vs. digital signal types
• Calibration standards and traceability to SANAS
• Reading and understanding manufacturer specifications
• Hands-on: identifying sensor types from samples

Objectives:
• Apply Ohm’s law and power calculations in sensor circuits.
• Explain signal conditioning (amplification, filtering, conversion).
• Identify common wiring configurations (2-wire, 3-wire, 4-wire).
• Use a multimeter to test sensor outputs.

Topics:
• DC/AC circuit analysis basics
• Signal conditioning: amplifiers, filters, and converters
• Wiring configurations and colour codes
• Practical: measuring voltage, current, and resistance from sensors
• Troubleshooting simple wiring faults

Objectives:
• Plan sensor placement considering environmental factors.
• Install sensors following manufacturer guidelines.
• Configure sensor parameters using software or hardware.
• Verify correct installation and initial functionality.

Topics:
• Mounting considerations: alignment, distance, angle
• Environmental protection: IP ratings, enclosures
• Configuration tools: DIP switches, potentiometers, software
• Practical: installing a proximity sensor and a temperature probe
• Commissioning checklist

Objectives:
• Explain the importance of regular calibration.
• Perform zero and span calibration on a pressure sensor.
• Document calibration results according to ISO 17025.
• Identify out-of-calibration conditions and corrective actions.

Topics:
• Calibration methods: zero, span, multi-point
• Use of calibration equipment (dead weight tester, reference standards)
• Documentation and record-keeping
• Practical: calibrating a pressure transmitter
• Uncertainty of measurement basics

Objectives:
• Apply systematic fault-finding approaches (e.g., 5-step method).
• Use diagnostic tools: multimeter, oscilloscope, signal generator.
• Interpret error codes and diagnostic LEDs.
• Identify common sensor failures (drift, noise, dead).

Topics:
• Fault-finding methodology: observe, isolate, test, repair, verify
• Tool usage: oscilloscope for signal analysis
• Common failure modes: contamination, wear, electrical issues
• Practical: diagnosing a faulty ultrasonic sensor
• Root cause analysis techniques

Objectives:
• Develop a preventive maintenance schedule for sensors.
• Perform cleaning, inspection, and component replacement.
• Understand wear patterns and lifespan of sensor components.
• Maintain maintenance logs and compliance records.

Topics:
• Preventive maintenance planning (frequency, tasks)
• Cleaning methods for different sensor types
• Inspection criteria: visual, mechanical, electrical
• Practical: servicing a photoelectric sensor
• Maintenance software and documentation

Objectives:
• Describe advanced sensor types: laser, radar, chemical, biosensors.
• Compare wired vs. wireless sensor networks.
• Understand smart sensors and IoT integration.
• Evaluate suitability of advanced sensors for specific applications.

Topics:
• Laser and radar sensors for distance measurement
• Chemical sensors for gas detection
• Biosensors in medical and food industries
• Wireless protocols: Bluetooth, Wi-Fi, LoRaWAN
• Smart sensors with self-diagnostics

Objectives:
• Interface sensors with data acquisition systems (DAQ).
• Configure analogue-to-digital conversion parameters.
• Apply basic signal processing (filtering, averaging).
• Use software (e.g., LabVIEW) to log and visualise data.

Topics:
• DAQ hardware: modules, terminals, sampling rates
• ADC resolution and sampling theory
• Digital filtering techniques
• Practical: connecting a temperature sensor to a DAQ
• Data logging and trend analysis

Objectives:
• Connect sensors to PLCs and SCADA systems.
• Configure analogue and digital input modules.
• Program basic logic using sensor inputs.
• Test and validate sensor-controller communication.

Topics:
• PLC architecture and I/O modules
• Wiring sensors to PLC inputs
• Ladder logic programming with sensor signals
• Practical: integrating a level sensor with a PLC
• SCADA data visualisation

Objectives:
• Diagnose faults in integrated sensor-controller systems.
• Implement safety protocols (lockout/tagout, SIL).
• Analyse system-level failures using cause-effect diagrams.
• Comply with OHS Act and relevant SANS standards.

Topics:
• System-level fault isolation
• Safety integrity levels (SIL) and safety sensors
• Lockout/tagout procedures
• Practical: troubleshooting a multi-sensor conveyor system
• Incident reporting and corrective actions

Objectives:
• Demonstrate competence in sensor maintenance procedures.
• Complete a practical assessment: install, calibrate, diagnose, and report.
• Prepare a maintenance report and improvement recommendations.
• Review course outcomes and receive feedback.

Topics:
• Practical assessment: sensor installation, calibration, fault finding
• Written test on theory and standards
• Maintenance report writing
• Course review and Q&A
• Issuance of certificates