Identifying and Dealing with Faults in Distributed Control Systems

The selected DCS must be operational in respect of the receiving and posting of data to control process plant. The DCS and integrated power and communications cards should be of a similar complexity to the one show (ABB). The Examiner must also provide a suitable means of communication to the DCS. This would normally comprise of a software program loaded onto a PC or Laptop. Suitably authorised Usernames and Passwords will be required for access and upload.

The Examiner should make available to the Candidate a selection of DCS Maintenance Procedures Manuals from which the candidate will need to select the appropriate one for dealing with any issues they find during the card change-out.

Technical Assessment – The Candidate is required to identify and change out an Input/output Control Card (I/O Card) within an operational Distributed Control System. This requires the temporary flip to the “Back-up” I/O Card and re-commissioning to “Primary Control” on completion.

Objective - To ensure a candidate has working skills, knowledge and ability to identify and deal with faults within a DCS System. The candidate will have to demonstrate their ability to change out an I/O Card whilst maintaining the integrity of the process operation. The candidate must also demonstrate that they can work safely throughout the work scope.

Technical Assessment Requirements

Range of screwdrivers (flat, crosshead and Phillips)
Range of Allen keys (Metric & Imperial)
Anti-Static Strap Wrench
DCS Maintenance Manual
DCS Equipment Layout Drawings
DCS Username and Password (as required)
Selection of replacement I/O Cards (Analogue, Digital, etc.)
Personal Protective Equipment
Examiner instructions
Personal Protective Equipment
Examiner instructions
Model Answer Sheet
Candidate Instructions
Candidate Question Paper
Examiner Results Report

The candidate must carry out the work on a live and functional DCS.

The candidate is expected to complete the test, being observed using the correct tools, equipment and DCS maintenance instructions as well as following safe working practices to achieve a „PASS‟. Where the candidate does not achieve the set criteria this is recorded as „REFERRED‟ and a brief note recorded on the criteria not met in the test activity.

The candidate must record a PASS in all practical test sections and score a minimum of 80% in the multiple choice section.