Elements and Performance Criteria
- Determine system specifications and control loop characteristics
- Engineering specifications, technical information and historical records and trends are examined and relevant data is documented.
- System specifications and operational data including those for multiple loop control systems and devices are obtained, read and interpreted.
- Circuit and logic diagrams and configuration data are obtained, read and interpreted.
- Consultation with system operators and other relevant plant personnel is carried out, and relevant data is extracted and documented by appropriate means.
- Appropriate work clearances are obtained for monitoring and testing the system.
- Test, monitor and record system operation
- Relevant data is collected by appropriate means from all sources including maintenance records, chart recorders, data loggers, fault indicators, error codes, operational symptoms, tests and observation monitoring.
- Fault detection and diagnostic data are analysed against predetermined operational specifications, and conclusions are documented.
- System operation is observed using knowledge of all individual/multiple element loop device characteristics, controller mode principles, testing, calibration and adjustment methods.
- Appropriate test equipment is set up and used correctly.
- Appropriate tests are undertaken using standard operating procedures.
- Signal transmission test equipment is set up and used where applicable.
- Adjustment/maintenance needs are determined through interpretation and analysis of pneumatic, electrical, electronic, logic diagrams and configuration data for all control system devices.
- Appropriate field instrumentation is connected to test system configuration.
- Field instrumentation is connected and tested for selected control operation, and performance is monitored against specifications.
- Diagnostics checks are carried out to ensure correct operation.
- Fault finding and diagnostic tests are undertaken using correct equipment, techniques and procedures to detect faulty control system components or elements.
- Localise fault condition
- Replace faulty items or repair faulty condition
- Faulty items are dismantled for repair or replacement using appropriate tools, equipment and procedures according to manufacturers' recommendations.
- Replaceable items are selected from manufacturers' catalogues, spare parts lists, or data sheets.
- Using manufacturers' handbooks, correct maintenance procedures for faulty items are established.
- Faulty items and/or condition are repaired using correct maintenance procedures and equipment.
- Repaired and replaceable items are reassembled using appropriate principles, tools, equipment, techniques and test procedures.
- Calibrate, configure, adjust complex control systems
- Diagnostic checks are carried out to ensure correct operation of system, taking appropriate corrective action as necessary.
- Correct calibration and test equipment is selected/set up to enable calibration to manufacturers' specifications.
- Mechanical alignment of control devices is undertaken where applicable.
- System is configured using appropriate programming tools and techniques.
- Relevant alignment procedures are performed for optimum control and in accordance with specifications.
- Correct sequence of alignment is used on multiple control loops and multi-element systems.
- Correct recording equipment is set up for adjustment and monitoring during alignment.
- Calibration and adjustment function are performed on multi-loop devices, multi-element control loops, controller modes and actions according to operational specifications using correct principles and methods applicable to the type of control loop being serviced.
- On-line changes are made to parameters in the system to meet specified requirements.
- Field instrumentation is connected for selected control operation and system is operated to a satisfactory level of control.
- Return system to service
- Final adjustments to align system operation to operational specifications including process and optimum control efficiencies are undertaken.
- Correct procedures are applied in return to service including configuring, calibrating, adjusting, tuning and final validation of system performance in accordance with specifications.
- System is returned to service.
- Service reports are completed to standard operating procedures.