TROUBLESHOOTING A TECHNICIAN S GUIDE 2ND EDITION. William L. Mostia, Jr., P. E. ISA TECHNICIAN SERIES

Transcription

1 TROUBLESHOOTING A TECHNICIAN S GUIDE 2ND EDITION William L. Mostia, Jr., P. E. ISA TECHNICIAN SERIES

2 TABLE OF CONTENTS Chapter 1 Learning to Troubleshoot Experience Information and Skills Diversity and Complexity Learning from Experience Apprenticeships Mentoring Classroom Instruction Individual Study Logic and Logic Development Summary Quiz Chapter 2 The Basics of Failures A Definition of Failure How Hardware Fails Measures of Reliability The Wear-out Period How Software Fails Environmental Effects on Failure Rates Temperature Corrosion Humidity Exceeding Instrument Limits Functional Failures Systematic Failures Common-cause Failures Root-cause Analysis Summary Quiz References Chapter 3 Failure States Overt and Covert Failures Directed Failures Failure Direction

3 viii Table of Contents 3.3 Directed Failure States What Failure States Indicate Summary Quiz References Chapter 4 Logical/Analytical Troubleshooting Frameworks Logical/Analytical TroublEshooting Framework Specific Troubleshooting Frameworks How a Specific Troubleshooting Framework Works Generic Logical/Analytical Frameworks A Seven-step Procedure STEP 1: Define the Problem STEP 2: Collect Information Regarding the Problem STEP 3: Analyze the Information STEP 4: Determine Sufficiency of Information STEP 5: Propose a Solution STEP 6: Test the Proposed Solution STEP 7: The Repair An Example of How to Use the Seven-step Procedure STEP 1: Define the Problem STEP 2: Collect Information Regarding the Problem STEP 3: Analyze the Information STEP 4: Determine Sufficiency of Information STEP 5: Propose a Solution STEP 6: Test the Proposed Solution STEP 7: Repair Vendor Assistance Advantages and Pitfalls Why Troubleshooting Fails Lack of Knowledge Failure to Gather Data Properly Failure to Look in the Right Places Dimensional Thinking Summary Quiz References

4 Troubleshooting ix Chapter 5 Other Troubleshooting Methods Why Use Other Troubleshooting Methods? Substitution Method Fault Insertion Method Remove and Conquer Method Circle the Wagons Method Trapping Complex to Simple Method Consultation Intuition Out-of-the-Box Thinking Summary Quiz Chapter 6 Safety General Troubleshooting Safety Practices Human Error in Industrial Settings Slips or Aberrations Lack of Knowledge Overmotivation and Undermotivation Impossible Tasks Mindset Errors by Others Plant Hazards Faced During Troubleshooting Personnel Hazards (Electrical) General Practices When Working With or Near Energized Circuits Static Electricity Hazards Mechanical Hazards Stored Energy Hazards Thermal Hazards Chemical Hazards Troubleshooting in Electrically Hazardous (Classified) Areas Classification Systems Area Classification Standards Troubleshooting in Electrically Hazardous Areas Protection, Procedures, and Permit Systems Operations Notification Maintenance Procedures

5 x Table of Contents Work Permits Loop Identification and System Interaction Safety Instrumented Systems Critical Instruments Summary Quiz References Chapter 7 Tools and Test Equipment Hand Tools Contact-type Test Equipment Volt-Ohm Meters (VOM) Digital Multimeters Oscilloscopes Voltage Probes Thermometers Insulation Testers Ground Testers Contact Tachometers Motor/Phase Rotation Meters Circuit Tracers Vibration Monitors Protocol Analyzers Test Pressure Gauges Portable Recorders Noncontact Test Equipment Clamp-on Amp Meters Static Charge Meters Magnetic Field Detectors Noncontact Proximity Voltage Detectors Magnetic Field/Current Detectors Circuit and Underground Cable Detectors PhotoTachometers and Stroboscopes Clamp-On Ground Testers Infrared Thermometer Guns and Imaging Systems Leak Detectors Simulators/Process Calibrators Jumpers, Switch Boxes, and Traps Documenting Test Equipment and Tests Accuracy of Test Equipment Summary

6 Troubleshooting xi Quiz References Chapter 8 Troubleshooting Scenarios Mechanical Instrumentation Mechanical Field Recorder, EXAMPLE Mechanical Field Recorder, EXAMPLE Mechanical Field Recorder, EXAMPLE Process Connections Pressure Transmitter, EXAMPLE Pressure Transmitter, EXAMPLE Temperature Transmitter Flow Meter (Orifice Type) Pneumatic Instrumentation Pneumatic Transmitter, EXAMPLE Pneumatic Transmitter, EXAMPLE Pneumatic Transmitter, EXAMPLE Pneumatic Transmitter, EXAMPLE Pneumatic Transmitter, EXAMPLE I/P (Current/Pneumatic) Transducer Electrical Systems Electronic 4-20 ma Transmitter Computer-Based Analyzer Plant Section Instrument Power Lost Relay System Electronic Systems Current Loops Voltage Loops Control Loops Ground Loops Valves Valve Leak-By, EXAMPLE Valve Leak-By, EXAMPLE Valve Oscillation Calibration Low Reading on Flow Transmitter Inaccurate Pay Meters Plant Material Balance Off Programmable Electronic Systems PLC PLC Card PLC Pump Out System

7 xii Table of Contents 8.9 Communication Loops RS-232, EXAMPLE RS-232, EXAMPLE RS-485, EXAMPLE RS-485, EXAMPLE Fieldbus Programmable Logic Controller, Remote Input-Output (PLC RIO) Communication Loop Has Noise Problems Communication Loop Has Noise Problems Transient Problems DCS with PC Display PC Cathode-Ray Tube (CRT) Printer Periodically Goes Haywire Software PLC-Controlled Machine Trips PLC Relay Race Problem FORTRAN Interface Program Flow Meters Flow Meter, EXAMPLE Flow Meter, EXAMPLE Level Meters Level Meter (D/P), EXAMPLE Level Meter (D/P), EXAMPLE Level Meter (Radar) Level Meter (Ultrasonic Probe) Chapter 9 Troubleshooting Hints Mechanical Systems Process Connections Pneumatic Systems Electronic Systems Grounding Calibration Systems Tools and Test Equipment Programmable Electronic Systems Serial Communication Links (Loops) General Considerations Modbus Communication Information Sources Safety Instrumented Systems (SIS)

8 Troubleshooting xiii 9.11 Critical Instrument Loops Electromagnetic Interference Valves Miscellaneous Chapter 10 Aids to Troubleshooting Introduction Maintainability Safety Accessibility Testability Reparability Economy Accuracy Drawings Tagging and Identification Equipment Files Manuals Maintenance Management Systems Vendor Technical Assistance Direct Vendor Access Maintenance Contracts Summary Quiz Appendix A Answers to Quizzes Appendix B Relevant Standards Appendix C Glossary Index