Troubleshooting: A Technicians Guide

Format:

Book

Author/Creator:

Mostia, William L., Author.

Series:

International Society of Automation Series

Language:

English

Physical Description:

1 online resource (0 pages)

Edition:

2nd ed.

Place of Publication:

[Place of publication not identified] ISA 2005

Language Note:

English

Summary:

Troubleshooting: A Technician's Guide, 2nd Edition Troubleshooting loops and systems is something all technicians must do, but that few truly master.This newly revised edition draws on the author's long experience as an instrument and electrical engineer and his maintenance expertise to provide a detailed look at the skills and knowledge required.

Contents:

Cover

Title Page

Copyright

Dedication

Table of Contents

Chapter 1: Learning to Troubleshoot

1.1 Experience

1.1.1 Information and Skills

1.1.2 Diversity and Complexity

1.1.3 Learning from Experience

1.2 Apprenticeships

1.3 Mentoring

1.4 Classroom Instruction

1.5 Individual Study

1.6 Logic and Logic Development

Summary

Quiz

Chapter 2: The Basics of Failures

2.1 A Definition of Failure

2.2 How Hardware Fails

2.2.1 Measures of Reliability

2.2.2 The Wear-out Period

2.3 How Software Fails

2.4 Environmental Effects on Failure Rates

2.4.1 Temperature

2.4.2 Corrosion

2.4.3 Humidity

2.4.4 Exceeding Instrument Limits

2.5 Functional Failures

2.6 Systematic Failures

2.7 Common-cause Failures

2.8 Root-cause Analysis

References

Chapter 3: Failure States

3.1 Overt and Covert Failures

3.2 Directed Failures

3.2.1 Failure Direction

3.3 Directed Failure States

3.4 What Failure States Indicate

Chapter 4: Logical/Analytical Troubleshooting Frameworks

4.1 Logical/Analytical TroublEshooting Framework

4.2 Specific Troubleshooting Frameworks

4.3 How a Specific Troubleshooting Framework Works

4.4 Generic Logical/Analytical Frameworks

4.5 A Seven-step Procedure

4.5.1 STEP 1: Define the Problem

4.5.2 STEP 2: Collect Information Regarding the Problem

4.5.3 STEP 3: Analyze the Information

4.5.4 STEP 4: Determine Sufficiency of Information

4.5.5 STEP 5: Propose a Solution

4.5.6 STEP 6: Test the Proposed Solution

4.5.7 STEP 7: The Repair

4.6 An Example of How to Use the Seven-step Procedure

4.6.1 STEP 1: Define the Problem

4.6.2 STEP 2: Collect Information Regarding the Problem

4.6.3 STEP 3: Analyze the Information.

4.6.4 STEP 4: Determine Sufficiency of Information

4.6.5 STEP 5: Propose a Solution

4.6.6 STEP 6: Test the Proposed Solution

4.6.7 STEP 7: Repair

4.7 Vendor Assistance Advantages and Pitfalls

4.8 Why Troubleshooting Fails

4.8.1 Lack of Knowledge

4.8.2 Failure to Gather Data Properly

4.8.3 Failure to Look in the Right Places

4.8.4 Dimensional Thinking

Chapter 5: Other Troubleshooting Methods

5.1 Why Use Other Troubleshooting Methods?

5.2 Substitution Method

5.3 Fault Insertion Method

5.4 "Remove and Conquer" Method

5.5 "Circle the Wagons" Method

5.6 Trapping

5.7 Complex to Simple Method

5.8 Consultation

5.9 Intuition

5.10 Out-of-the-Box Thinking

Chapter 6: Safety

6.1 General Troubleshooting Safety Practices

6.2 Human Error in Industrial Settings

6.2.1 Slips or Aberrations

6.2.2 Lack of Knowledge

6.2.3 Overmotivation and Undermotivation

6.2.4 Impossible Tasks

6.2.5 Mindset

6.2.6 Errors by Others

6.3 Plant Hazards Faced During Troubleshooting

6.3.1 Personnel Hazards (Electrical)

6.3.2 General Practices When Working With or Near Energized Circuits

6.3.3 Static Electricity Hazards

6.3.4 Mechanical Hazards

6.3.5 Stored Energy Hazards

6.3.6 Thermal Hazards

6.3.7 Chemical Hazards

6.4 Troubleshooting in Electrically Hazardous (Classified) Areas

6.4.1 Classification Systems

6.4.2 Area Classification Standards

6.4.3 Troubleshooting in Electrically Hazardous Areas

6.5 Protection, Procedures, and Permit Systems

6.5.1 Operations Notification

6.5.2 Maintenance Procedures

6.5.3 Work Permits

6.5.4 Loop Identification and System Interaction

6.5.5 Safety Instrumented Systems

6.5.6 Critical Instruments

Chapter 7: Tools and Test Equipment.

7.1 Hand Tools

7.2 Contact-type Test Equipment

7.2.1 Volt-Ohm Meters (VOM)

7.2.2 Digital Multimeters

7.2.3 Oscilloscopes

7.2.4 Voltage Probes

7.2.5 Thermometers

7.2.6 Insulation Testers

7.2.7 Ground Testers

7.2.8 Contact Tachometers

7.2.9 Motor/Phase Rotation Meters

7.2.10 Circuit Tracers

7.2.11 Vibration Monitors

7.2.12 Protocol Analyzers

7.2.13 Test Pressure Gauges

7.2.14 Portable Recorders

7.3 Noncontact Test Equipment

7.3.1 Clamp-on Amp Meters

7.3.2 Static Charge Meters

7.3.3 Magnetic Field Detectors

7.3.4 Noncontact Proximity Voltage Detectors

7.3.5 Magnetic Field/Current Detectors

7.3.6 Circuit and Underground Cable Detectors

7.3.7 PhotoTachometers and Stroboscopes

7.3.8 Clamp-On Ground Testers

7.3.9 Infrared Thermometer Guns and Imaging Systems

7.3.10 Leak Detectors

7.4 Simulators/Process Calibrators

7.5 Jumpers, Switch Boxes, and Traps

7.6 Documenting Test Equipment and Tests

7.7 Accuracy of Test Equipment

Chapter 8: Troubleshooting Scenarios

8.1 Mechanical Instrumentation

8.1.1 Mechanical Field Recorder, EXAMPLE 1

8.1.2 Mechanical Field Recorder, EXAMPLE 2

8.1.3 Mechanical Field Recorder, EXAMPLE 3

8.2 Process Connections

8.2.1 Pressure Transmitter, EXAMPLE 1

8.2.2 Pressure Transmitter, EXAMPLE 2

8.2.3 Temperature Transmitter

8.2.4 Flow Meter (Orifice Type)

8.3 Pneumatic Instrumentation

8.3.1 Pneumatic Transmitter, EXAMPLE 1

8.3.2 Pneumatic Transmitter, EXAMPLE 2

8.3.3 Pneumatic Transmitter, EXAMPLE 3

8.3.4 Pneumatic Transmitter, EXAMPLE 4

8.3.5 Pneumatic Transmitter, EXAMPLE 5

8.3.6 I/P (Current/Pneumatic) Transducer

8.4 Electrical Systems

8.4.1 Electronic 4-20 mA Transmitter

8.4.2 Computer-Based Analyzer

8.4.3 Plant Section Instrument Power Lost.

8.4.4 Relay System

8.5 Electronic Systems

8.5.1 Current Loops

8.5.2 Voltage Loops

8.5.3 Control Loops

8.5.4 Ground Loops

8.6 Valves

8.6.1 Valve Leak-By, EXAMPLE 1

8.6.2 Valve Leak-By, EXAMPLE 2

8.6.3 Valve Oscillation

8.7 Calibration

8.7.1 Low Reading on Flow Transmitter

8.7.2 Inaccurate Pay Meters

8.7.3 Plant Material Balance Off

8.8 Programmable Electronic Systems

8.8.1 PLC

8.8.2 PLC Card

8.8.3 PLC Pump Out System

8.9 Communication Loops

8.9.1 RS-232, EXAMPLE 1

8.9.2 RS-232, EXAMPLE 2

8.9.3 RS-485, EXAMPLE 1

8.9.4 RS-485, EXAMPLE 2

8.9.5 Fieldbus

8.9.6 Programmable Logic Controller, Remote Input-Output (PLC RIO)

8.9.7 Communication Loop Has Noise Problems

8.9.8 Communication Loop Has Noise Problems

8.10 Transient Problems

8.10.1 DCS with PC Display

8.10.2 PC Cathode-Ray Tube (CRT)

8.10.3 Printer Periodically Goes Haywire

8.11 Software

8.11.1 PLC-Controlled Machine Trips

8.11.2 PLC Relay "Race" Problem

8.11.3 FORTRAN Interface Program

8.12 Flow Meters

8.12.1 Flow Meter, EXAMPLE 1

8.12.2 Flow Meter, EXAMPLE 2

8.13 Level Meters

8.13.1 Level Meter (D/P), EXAMPLE 1

8.13.2 Level Meter (D/P), EXAMPLE 2

8.13.3 Level Meter (Radar)

8.13.4 Level Meter (Ultrasonic Probe)

Chapter 9: Troubleshooting Hints

9.1 Mechanical Systems

9.2 Process Connections

9.3 Pneumatic Systems

9.4 Electronic Systems

9.5 Grounding

9.6 Calibration Systems

9.7 Tools and Test Equipment

9.8 Programmable Electronic Systems

9.9 Serial Communication Links (Loops)

9.9.1 General Considerations

9.9.2 Modbus

9.9.3 Communication Information Sources

9.10 Safety Instrumented Systems (SIS)

9.11 Critical Instrument Loops

9.12 Electromagnetic Interference

9.13 Valves

9.14 Miscellaneous

Chapter 10: Aids to Troubleshooting.

10.1 Introduction

10.2 Maintainability

10.2.1 Safety

10.2.2 Accessibility

10.2.3 Testability

10.2.4 Reparability

10.2.5 Economy

10.2.6 Accuracy

10.3 Drawings

10.4 Tagging and Identification

10.5 Equipment Files

10.6 Manuals

10.7 Maintenance Management Systems

10.8 Vendor Technical Assistance

10.9 Direct Vendor Access

10.10 Maintenance Contracts

Appendix A: Answers to Quizzes

Appendix B: Relevant Standards

Appendix C: Glossary

Index

EULA.

Notes:

Bibliographic Level Mode of Issuance: Monograph

Description based on publisher supplied metadata and other sources.

ISBN:

1-394-43851-6

1-394-44204-1

1-941546-21-8

1-60119-336-X

OCLC:

1530374482