Maintain process controller equipment within a traction and rolling stock system
Overview
This standard identifies the competencies you need to carry out corrective maintenance to process controller equipment within a traction and rolling stock system, in accordance with approved procedures. You will be required to maintain a range of process controller equipment that typically includes process controllers, sequential controllers or programmable controllers, which work in an integrated traction and rolling stock system involving two of the following interactive technologies: mechanical, electrical or fluid power. The term traction and rolling stock used in this standard applies to passenger, freight and on-track machines (OTM). Where it is relevant these standards also apply to traction and rolling stock that has been fitted with the European Train Control System (ETCS).
This will involve dismantling, removing and replacing faulty peripheral components, process controller units, and line replaceable components, on process controller systems. You will also need to be able to load and download process controller programs, check them for errors, make alterations to programs (if applicable), input data and create and maintain backup copies of completed programs.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying maintenance procedures on process controller systems within an integrated system. You will understand the maintenance methods and procedures used, and their application, and will know about the various process controller units and peripheral components, their functions and associated defects, in adequate depth to provide a sound basis for carrying out the maintenance activities, correcting faults and ensuring that the equipment operates to the required specification and remains compliant with all standards and regulations. You will also know about the interaction of the other associated integrated technologies and have sufficient knowledge to carry out the maintenance and testing of the process controller system safely and effectively.
You will be required to demonstrate safe working practices throughout.
Performance criteria
You must be able to:
P1 maintain safe working practices and comply with all relevant health and safety regulations, directives, and guidelines
P2 follow the relevant maintenance schedules to carry out the required work
P3 carry out the maintenance activities within the limits of your personal authority
P4 carry out the maintenance activities in the specified sequence and in an agreed timescale
P5 report any instances where the maintenance activities cannot be met or where there are identified defects outside the planned schedule
P6 complete relevant maintenance records and pass them on to the appropriate person
P7 dispose of waste materials in accordance with safe working practices and approved procedures
Knowledge and Understanding
You need to know and understand:
K1 the relevant health and safety regulations, directives, guidelines, and safe working practices and procedures defined by your organisation, as appropriate to the activity and your working area
K2 the isolation and lock-off procedure or permit-to-work procedure that applies to the system being worked on
K3 the isolation procedure which is specific to the process controller system being worked on (such as electrical isolation, locking off switchgear, placing of maintenance warning notices, proving the isolation has been achieved and secured)
K4 the specific health and safety precautions that need to be applied during the maintenance activities, and their effects on others
K5 the classification of different voltage levels and the authority requirements for working on them
K6 what constitutes a hazardous voltage/current and how to recognise victims of electric shock
K7 how to reduce the risks of an electric shock (such as insulated tools, rubber matting and isolating transformers)
K8 the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities, and where this can be obtained
K9 the procedures and precautions to be adopted to eliminate electrostatic discharge (ESD) hazards when working with and handling electronic devices
K10 hazards associated with carrying out maintenance activities on a process controlled integrated system (such as handling fluids, stored pressure/force, electrical supplies, process controller interface, using damaged or ill-maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks
K11 how to obtain and interpret drawings, charts, specifications, manufacturers' manuals, history/maintenance reports, symbols used on process controller documents, and other documents needed for the maintenance activities
K12 the principles of how the system functions, its operation sequence, the working purpose of individual units/components, and how they interact
K13 the devices and systems for storing programmes
K14 procedures to be applied to storage, location and method of backing up programmes
K15 the basic principles of networking devices together to produce a system
K16 the different types of interface cards, port connections, test card and breakout boards/boxes used and their applications
K17 the numbering system and codes used for identification inputs and outputs
K18 how to search a programme within the process controller for specific elements
K19 the methods used to input data parameters and the codes used
K20 the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance process
K21 company policy on repair/replacement of components during the maintenance activities
K22 the techniques used to dismantle/assemble integrated equipment (such as release of pressures/force, proofmarking to aid re-assembly, plugging exposed pipe/component openings, dealing with soldered joints, screwed, clamped and crimped connections)
K23 methods of attaching identification marks/labels to removed components or cables to assist with re-assembly
K24 methods of checking that components are fit for purpose, and the need to replace items such as batteries, boards and other failed items
K25 the importance of recording the serial numbers of removed and newly fitted components affecting the rolling stock asset tree
K26 how to check that tools and equipment are free from damage or defects, are in a safe and usable condition, and are configured for the intended purpose
K27 the importance of making integrity checks before proving the equipment with the electrical supply on
K28 the generation of maintenance documentation and/or reports on completion of the maintenance activity
K29 the equipment operating and control procedures to be applied during the maintenance activity
K30 how to use lifting and handling equipment in the maintenance activity
K31 the problems that can occur during the maintenance of the process controller system, and how they can be overcome
K32 the organisational procedure to be adopted for the safe disposal of waste of all types of materials
K33 the extent of your own authority and to whom you should report if you have a problem you cannot resolve
Scope/range
Scope Performance
During the maintenance activity, individuals will:
- plan and communicate the maintenance activities to cause minimal disruption to normal working
- obtain and use the correct issue of company and/or manufacturers' drawings and maintenance documentation as well as the correct version of any maintenance software tools required
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- ensure the safe isolation of equipment (such as mechanical, electricity, air or fluids)
- provide and maintain safe access and working arrangements for the maintenance area
- warn others in the maintenance area if they are at risk of injury from the system being tested
- carry out the maintenance activities using appropriate techniques and procedures
- reconnect and return the system to service on completion of the maintenance activities
- dispose of waste items to comply with environmental protection guidelines and ensure the work area remains safe
Appropriate dismantling and re-assembly techniques may be used to deal with the following:
- mechanical components:
- draining and replenishing of fluids
- removing and refitting locking and retaining devices
- removing minor mechanical units/sub-assemblies (such as guards, structures)
- removing major mechanical units (such as gear boxes, compressors, reservoirs)
- proofmarking components to aid reassembly
- setting, aligning and adjusting replaced units
- electrical components:
- isolating the power supply using correct lock-off communication procedure
- disconnecting and re-connecting wires/cables
- removing and replacing major electrical components (such as motors, switch/control gear)
- removing and replacing minor electrical components (such as relays, sensing devices, limit switches)
- removing and replacing wiring supports (such as conduit, trunking, traywork, cable ways, looms)
- fluid power components:
- releasing stored pressure
- chocking/supporting cylinders/rams/components
- disconnecting/removing hoses / pipes
- removing and replacing units/components (such as pumps, valves, actuators)
Types of program maintenance activities carried out on the process controller system could include:
- select and use appropriate programming devices (such as terminals, handheld programmers and personal computers)
- use ladder logic, statement lists, or system flowcharts
- carry out on-line monitoring of systems
- upload data parameters
- update/install program software
- read and save programmes
- interrogate controller memory for stored faults
- interpret system fault log/records
- download data parameters
- analyse downloaded data
- produce back-ups of completed programs
- check controller condition, filters and cooling fans
- reset system and warning codes
- restore controller default settings
- other specific maintenance activities
During the maintenance activities, individuals will carry out the following:
- take electrostatic discharge (ESD) precautions when working on or close to sensitive components and circuit boards
- proofmark or label removed wires and components
- inspect and/or test components for serviceability
- change or add circuit boards (as appropriate)
- replace power supplies
- replace peripherals (such as sensors, actuators, relays, switches)
- replace process controller units
- replace back-up batteries (as appropriate)
- torque loading of fasteners and correct fitting of locking devices
- functionally test the system
Maintenance activities may need to comply with the following:
- organisational guidelines and codes of practice
- BS, ISO and/or BSEN standards
- equipment manufacturer's operation range
- company standard operating procedures (SOP's)
- documents such as technical procedures, vehicle maintenance instructions, vehicle overhaul instructions, workshop overhaul standards specifications
Types of paperwork/records that need to be completed and passed to the appropriate people could include:
- job cards
- maintenance log or report
- permits to work/formal risk assessment and/or sign on/off procedures
- company-specific documentation
- electronic records