Guideline for certification of UNITROL/MEGATROL field service engineers Guideline for expert days and re-certification of UNITROL/MEGATROL field service engineers ____________________________________________________________________________
1 INTRODUCTION
WHY IS CERTIFICATION NECESSARY – WHAT ARE EXPERT DAYS UNITROL excitation systems stand for high reliability and excellent performance. Competent and educated field service engineers are an important element to guarantee professional start-up and excellent service of our equipment. The number of engineers involved in commissioning and service in the UNITROL community has grown more and more.
Therefore the PRUs Excitation Systems and Service have decided to introduce a systematic certification program for field service engineers in order to guarantee high quality and to make sure that our equipment is commissioned and serviced in a proper way.
To maintain the know how, the PRU is organizing annual meetings for service engineers. During these so called “Expert Days” a know-how and experience exchange takes place which guarantees an equal quality and know-how understanding in the different countries and organizations. The “Expert Days” are normally held two times a year in ABB Switzerland. The participation of certified engineers is mandatory at least every second year in order to become re-certified. People without or with expired certification are not allowed to do any UNITROL/MEGATROL service or commissioning work and will not be supported by the PRU. Access to product and support databases will be blocked.
All certified engineers are registered in a world wide accessible database called PCS-2 (http://service.it.abb.com/pcs/Login.aspx). This database is at the same time the controlling tool for certification, re-certification, visit of expert days and training.
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
3 CERTIFICATION ....................................................................................................... 3 3.1 WHO CAN APPLY FOR CERTIFICATION .................................................. 3 3.2 CERTIFICATION PROCEDURE .................................................................. 3
APPLICATION................................................................................................ 3 CERTIFICATION PROCESS .......................................................................... 4 LEVELS IN CERTIFICATION PROCESS....................................................... 5 CERTIFICATION ............................................................................................ 6 PCS 2 6
4 EXPERT DAYS ......................................................................................................... 6 4.1 LOCATION................................................................................................... 6 4.2 DURATION .................................................................................................. 6 4.3 PERSONNEL FOR CONDUCTING UNITROL EXPERT DAYS ................... 6 4.4 PROGRAM OF UNITROL EXPERT DAYS .................................................. 7 4.5 CONDITIONS TO PARTICIPATE ON UNITROL EXPERT DAYS ............... 7 4.6 ORGANISATION OF EXPERT DAYS.......................................................... 7
Commissioning and field service engineers employed by an ABB organization reporting into BU4129 (Service Power Electronics) or employed by an authorized channel partner of BU4129 can apply if the following criteria are met:
Strategic necessity to have a certified engineer for this territory/region (confirmed by the PRU).
Measures:
1) Number of retrofit or new projects in the future (5 years)
2) Service potential (service contracts, trouble shooting) in the coming 5 years
3) Number of service or commissioning cases per year shall be minimum 3
4) No competition to other service hubs in this region
5) Justification due to special reasons, like political, geographical or others
Pay back of the training & certification cost for the local organization are secured:
1) Training cost, (estimate: 15kCHF for UN-F/5000, 25kCHF for UN-6)
2) Tools, approx. (estimate:20kCHF)
3) Unproductiveness cost during training, (estimate:50kCHF)
4) Certification and re-certification cost
Bachelor Degree in Electrical Engineering or equivalent
Advanced knowledge of English language (speaking and writing)
Proven UNITROL training
Stage in test lab for the corresponding system
Having attended one commissioning as guest
Having performed one commissioning under supervision of a certified engineer
3.2 CERTIFICATION PROCEDURE
APPLICATION If criteria under 2.1 are fulfilled, the candidate can apply for certification as follows:
Apply for certification in PCS 2 (people certification system) under http://service.it.abb.com/pcs
Fulfill the objectives in PCS 2 (as described in the tool) in order to get certified
Fill out all required documents (linked in PCS 2)
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
CERTIFICATION PROCESS Generally the certification process includes several steps starting with product training provided by training centers of excitation systems. After completion of the training program the trainee gains practical experience in the test fields and on real systems. The trainee must be supervised by a certified field service engineer. The trainee can apply for the final exam to get the level “certified”. In order to attain the expert level he need to participate on the announced exert days conducted twice a year. Mater level will be achieved if the field service engineer is holder of more then 4 UNITROL expert levels. Please find more details in this document.
The several objectives and requirements for the various UNITROL/MEGATROL products are shown in the figure below. Every block in the figure below equals a certificate in PCS 2 consisting of several objectives which have to be fulfilled to attain the certificate. The certificates are linked in a way that the certificates on the low level have to be fulfilled first before starting with a higher level certificate. Field service engineers need to attain at least level expert. Note1) The MEGATROL course G850 requires completion of J681, J688, J692,J693, G830, G839.
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
Basic Basic is defined as the level, where the user has completed the theoretical education and is therefore able to continue with commissioning under supervision.
Certified The Certified Level is applied for external partners mainly. After passing successfully the final exam the field service engineer will be allowed to commission UNITROL excitation systems manufactured by the external partners. Access to the UNITROL DB will be enabled if at least one of the partner’s field service engineers achieve the expert level.
Expert Level 1
The actual field service engineers need to attain level “Expert Level 1”. On this level, a user has, additionally to the theoretical education, also acquired practical knowledge and experience on the systems. Level “Expert Level 1” therefore allows to work as a field service engineer on the certified system. After having fulfilled this certificate, the user obtains a certificate which he can use as an official proof of his skills. Additionally, a user on level “Expert Level 1” gains the right to work on the support line for the
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
For UNITROL6000 based systems the field service engineer may achieve “Expert Level 2”. This level is required for MEGATROL and UNITROL6800/6080 with programming skills using Control Builder. After having fulfilled this certificate, the user obtains a certificate which he can use as an official proof of his skills. Additionally, a user on level “Expert Level 2” gains the right to work on the support line for the specific system.
Master
As a last step, a user can go for level “Master”. Prerequisite is to own all four “Expert” certificates and to additionally show comprehensive knowledge and experience on old and new systems. By reaching level “Master”, a user keeps all rights of an “Expert” but additionally is allowed to work for the senior support line, meaning to give support on all qualified UNITROL Systems.
CERTIFICATION The certification is done in a personal or on-line interview by an experienced person from the PRU (see tested subjects in appendix 2). The interview lasts between two and four hours depending on the product and the knowledge of the candidate. This will be repeated for every new product where expert status wants to be obtained. The detailed certification process is shown in Appendix 2 of this document.
PCS 2 PCS 2 (people certification system) is a web-based tool to display certification processes. It allows to capture the processes and therefore to make them transparent. On the other hand, it’s helpful in planning and allocation of field service engineers as it shows what competences a field service engineer has.
Field service engineers have to sign in to this tool and keep it updated at their own. The tool is accessible through internet by this address: http://service.it.abb.com/pcs
More detailed instructions about the use and concept of PCS 2 can be found in the “Guidelines PCS 2”.
4 EXPERT DAYS
4.1 LOCATION
The “Expert Days” are normally held two times a year in ABB Switzerland. It’s every candidates own responsibility to enroll for expert days. 4.2 DURATION
3 days
4.3 PERSONNEL FOR CONDUCTING UNITROL EXPERT DAYS Leader of expert days (3 days)
Administration of expert days
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
4.4 PROGRAM OF UNITROL EXPERT DAYS Day 1: Exchange of experience
Factory tour
Day 2: Presentation of product news
Kiosks
Refresher training
Day 3: Speeches about special topics (related to UNITROL/MEGATROL product in active phase)
Hands on trainings
4.5 CONDITIONS TO PARTICIPATE ON UNITROL EXPERT DAYS Ready for 1st- or re-certification
4.6 ORGANISATION OF EXPERT DAYS
The PRU organizes the expert days. It offers services for the participants such as:
Announcement of Expert Days by mail to superiors
Publish Expert Days in PCS-2 at the beginning of every year
Organizing location for expert days
Handling of Expert Days enrollment
Organizing the controlling of Expert Days
Providing Hotel reservations, transport schedules and entertainment
10 days Mo-Fr 2 days Mo-Tue 3 days Wd-Fr 5 days Mo-Fr
J681, J688, J692
Final Exam
Certification
Expert Days
Re-certification Control Builder
J693
5 RE-CERTIFICATION
Re-certification will be granted if candidate visits expert days at least every second year and demonstrates sufficient practice in field service during the past year. This is evaluated based on handed in field service reports of at least 3 personally performed commissioning tasks.
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
The PRU shall announce Expert Days by mail to superiors and publish them in PCS-2 at the beginning of every year.
The rough agenda of the expert days can be seen under 4.4.
6 CERTIFICATE
After successful certification or re-certification the PRU will issue a UNITROL or MEGATROL service license valid for two years. On this UNITROL or MEGATROL license (credit card size batch), the candidates name, photograph, certification level and expiry date will be printed. Customers will have the right to see this batch.
7 EMPOWERMENT AFTER CERTIFICATION
A successful certification empowers the service and field service engineer as follows:
Entitled to perform service and commissioning work on UNITROL or MEGATROL systems with full support of PRU
Free support via UNITROL support line
Access to Lotus Notes based know how database of business unit 4129
Entry in world wide PCS-2 database (People Certification System)
8 CONSEQUENCES OF NON-COMPLIANCE AND EXPIRED CERTIFICATIONS
The UNITROL systems must be commissioned and maintained by certified personnel. If non-certified personnel or personnel with expired certifications commissions or serves UNITROL or MEGATROL equipment, the licensee will not get the same support from the Service PRU. Moreover, the PCS-2 profile will be deleted and access to support lines and databases blocked. Any support from the Service PRU will be charged at cost.
9 FEES
Expert Day fee and initial certification fee is set and communicated by the PRU. Currently the participation fee amounts to CHF 1000.-.
1 Safety measures 2a. Commissioning preparations at home 2b. Commissioning program 2c. Commissioning preparation on site 3 Handling of test- and commissioning protocol 4 Inspection of installation 5 HV or isolation test 6 Pre-commissioning
7a Hot commissioning: AVR 7b Hot commissioning: Various 8 Knowledge about UNITROL or MEGATROL hardware 9 Tool handling (CMT, GAD, Control Builder, ECT , PEC configurator, Flash Utility etc.)
10 Understanding of UNITROL/MEGATROL philosophy 11 Administrative work 12 Tool calibration
Any aid is allowed during the certification (e.g. Notebook, documentation, UN-hardware)
AP Division - BU Power Electronics 3BHS 216658 ZAB E01 Issued by department Date Lang. Revision
14-13-12-11-10-8,7-6-5-4-4.5-4 Meter band 3m Padlock Screwdriver short, straight no.2 Screwdriver short, cross Isolation tape Screwdriver straight 4-3-2-1-0-00 Screwdriver Philips 1-2 Life tester (preferably straight
screwdriver no.1) Tweezers EMC grip/calibration tools Scissors Set of Torx keys T8-10-15-20-25-
27-30-40 Hexagonal set of keys Knife Small sharp tongued pliers Side cutter small Side cutter big Roll spanner 20mm Pair of pliers Pipe wrench Crimp pliers (faston) Brush Crimper
Files Cable stripper Telescope mirror Telescope magnet Torch Center puncher Punch 3mm Arm + Extension for nuts Small hammer (50g) Soldering iron Solder (1mm) De-soldering lead Solder sucker Isolation tape Super glue Universal key (for different
A all Review of complete document 30.11.06/RR B all Wording changed, appendix 3 added 26.9.06/ero C all Various additional comments 21.12.06/LMr D 5,6&7 Pictures of tools 4.1.07/RR E all Extension with Expert Days. Small corrections in
Appendix 2 and formatting 15.5.08/RR
F 3 Adding chapter 7 7.7.2008/RR G 2 Delete of “3day meeting” H 1, 4, 9 UNITROL6000 adaptations / PCS-2 adaptations 28.10.08/RR I 2, 3 Certification Process adaption / Levels added 27.01.09/PK J 1 One place of certification only. No final exam anymore
Tool set adapted. Page index. Concept of exp.days 12.5.09/RR
K 3, 4 Combo Training added, Time line modified 8.6.09/AE L 8 Non-compliance and expired certifications 24.8.09/AE M 1, 3, 4, 5, 6 MEGATROL has been added
