The division of the work interface leads to one’s own technical shortcomings
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During the last night shift, there was a problem with one of the production packaging lines in the factory. Upon inspection, it turned out that one of the modules in the Siemens PLC control system wasn’t working. I checked the voltage and found it to be present, so I concluded that the module was damaged and needed to be replaced. In our company, responsibilities are divided: we are only responsible for the on-site work, while another team is tasked with handling DCS and PLC systems. I have theoretical knowledge of this, but I’ve never actually done this kind of work before. I know that after replacing the module, it’s necessary to program it and calibrate it as well, but I really don’t know how to do that. If I were to do it, I believe I could solve the problem over time. But there was no other choice; I had to call someone who knew how to do it. I know that in many petrochemical plants, instrument maintenance is handled in its entirety, from the control room to the field, which allows for more comprehensive technical expertise; whereas we are only responsible for the field portion, up to the safety barriers at most. Well, there’s nothing we can do about it – we just have to handle the work on site!
It’s due to the overly detailed division of responsibilities for instruments across different companies. In my previous company, the instruments were divided into an analytical and metering team (responsible for maintaining the company’s analytical instruments as well as calibrating instruments related to pressure and temperature), a systems team (responsible for maintaining the company’s DCS, SIS, CCS, PLC, and other systems), and a field instruments team (responsible for maintaining instruments in the field). Generally, each team was only in charge of maintaining the instruments within their own area. The only positive aspect was that there was regular rotation of staff, with members from the field maintenance team and the systems team exchanging roles, which helped everyone gain a broader understanding of various aspects and improved their technical skills. The unit I joined later required me to be responsible for the maintenance of both control systems and field instruments.
Indeed, each company has a different division of responsibilities regarding instruments; taking the two petrochemical companies I have worked for as examples. The instrumentation tasks in the first company are divided into four categories: measurement instruments, analysis instruments, control systems, and field instruments. The technicians working with these instruments follow a shift system aligned with production processes; they receive regular training and assessments on control systems, but they do not get the opportunity to work with them in practice. The second company’s division of labor involves the control system and on-site instruments; instrument operators work on a shift basis, which requires those working at night to be versatile and knowledgeable in various areas. The person in charge of the control system technology develops standard procedures for dealing with emergencies, such as using bypass systems and checking the unit’s alarms. There’s also the issue of replacing faulty PLC cards. Of course, it’s not about connecting a computer to replace the CPU card; rather, it’s about how to replace ordinary DI/DO cards, how to identify their models, and how to set the dip switches. Most professionals working with control system instruments spend three to five years on the field before taking the opportunity to switch to another role. If you want to continue working on the field and gain more knowledge about the practical applications of control systems, then that’s the right path for you. If you instead want to transition to a role related to systems, you need to delve deeper into your knowledge and build good relationships with your supervisors in order to seize the right opportunities. You have to believe that the bottom determines the head; you’ll get the hang of it as you keep doing it. Best regards
This post was last edited by brevon on 2024-9-10 13:54 with xxx