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Troubleshooting : a technician's guide /

Detalles Bibliográficos
Clasificación:	Libro Electrónico
Autor principal:	Mostia, William L.
Formato:	Electrónico eBook
Idioma:	Inglés
Publicado:	Research Triangle Park, NC : ISA, ©2006.
Edición:	2nd ed.
Colección:	ISA technician series.
Temas:	System failures (Engineering) Pannes.
Acceso en línea:	Texto completo

Tabla de Contenidos:

Machine derived contents note: Table Of Contents
Chapter 1 Learning to Troubleshoot 1
1.1 Experience 1
1.1.1 Information and Skills 2
1.1.2 Diversity and Complexity. 2
1.1.3 Learning from Experience 2
1.2 Apprenticeships 3
1.3 Mentoring 3
1.4 Classroom Instruction 3
1.5 Individual Study 4
1.6 Logic and Logic Development 4
Summary 5
Quiz. 5
Chapter 2 The Basics of Failures. 7
2.1 A Definition of Failure. 7
2.2 How Hardware Fails 8
2.2.1 Measures of Reliability 9
2.2.2 The Wear-out Period 10
2.3 How Software Fails 11
2.4 Environmental Effects on Failure Rates 12
2.4.1 Temperature 13
2.4.2 Corrosion 13
2.4.3 Humidity 13
2.4.4 Exceeding Instrument Limits 14
2.5 Functional Failures 14
2.6 Systematic Failures 14
2.7 Common-cause Failures 15
2.8 Root-cause Analysis 15
Summary 16
Quiz. 17
References 17
Chapter 3 Failure States 19
3.1 Overt and Covert Failures 19
3.2 Directed Failures 20
3.2.1 Failure Direction 20
viii Table of Contents
3.3 Directed Failure States 21
3.4 What Failure States Indicate 22
Summary 24
Quiz. 24
References 25
Chapter 4 Logical/Analytical Troubleshooting Frameworks 27
4.1 Logical/Analytical TroublEshooting Framework. 27
4.2 Specific Troubleshooting Frameworks. 28
4.3 How a Specific Troubleshooting Framework Works . 33
4.4 Generic Logical/Analytical Frameworks 35
4.5 A Seven-step Procedure 37
4.5.1 STEP 1: Define the Problem 37
4.5.2 STEP 2: Collect Information Regarding
the Problem 39
4.5.3 STEP 3: Analyze the Information 40
4.5.4 STEP 4: Determine Sufficiency of
Information 43
4.5.5 STEP 5: Propose a Solution 47
4.5.6 STEP 6: Test the Proposed Solution 47
4.5.7 STEP 7: The Repair. 48
4.6 An Example of How to Use the
Seven-step Procedure 48
4.6.1 STEP 1: Define the Problem 49
4.6.2 STEP 2: Collect Information Regarding
the Problem 49
4.6.3 STEP 3: Analyze the Information 49
4.6.4 STEP 4: Determine Sufficiency of
Information 49
4.6.5 STEP 5: Propose a Solution 49
4.6.6 STEP 6: Test the Proposed Solution 49
4.6.7 STEP 7: Repair 50
4.7 Vendor Assistance Advantages and Pitfalls 50
4.8 Why Troubleshooting Fails 50
4.8.1 Lack of Knowledge 51
4.8.2 Failure to Gather Data Properly. 51
4.8.3 Failure to Look in the Right Places 51
4.8.4 Dimensional Thinking 55
Summary 56
Quiz. 56
References 58
Troubleshooting ix
Chapter 5 Other Troubleshooting Methods. 59
5.1 Why Use Other Troubleshooting Methods? 59
5.2 Substitution Method. 60
5.3 Fault Insertion Method 60
5.4 ¿Remove and Conquer¿ Method. 61
5.5 ¿Circle the Wagons¿ Method 61
5.6 Trapping 63
5.7 Complex to Simple Method 64
5.8 Consultation 65
5.9 Intuition 65
5.10 Out-of-the-Box Thinking 66
Summary 67
Quiz. 67
Chapter 6 Safety 69
6.1 General Troubleshooting Safety Practices 69
6.2 Human Error in Industrial Settings 71
6.2.1 Slips or Aberrations 71
6.2.2 Lack of Knowledge 71
6.2.3 Overmotivation and Undermotivation 72
6.2.4 Impossible Tasks 72
6.2.5 Mindset. 72
6.2.6 Errors by Others 72
6.3 Plant Hazards Faced During Troubleshooting 73
6.3.1 Personnel Hazards (Electrical). 73
6.3.2 General Practices When Working With
or Near Energized Circuits 76
6.3.3 Static Electricity Hazards. 77
6.3.4 Mechanical Hazards 77
6.3.5 Stored Energy Hazards 79
6.3.6 Thermal Hazards 79
6.3.7 Chemical Hazards 79
6.4 Troubleshooting in Electrically Hazardous
(Classified) Areas 81
6.4.1 Classification Systems 81
6.4.2 Area Classification Standards. 85
6.4.3 Troubleshooting in Electrically
Hazardous Areas. 93
6.5 Protection, Procedures, and Permit Systems 95
6.5.1 Operations Notification 95
6.5.2 Maintenance Procedures 96
x Table of Contents
6.5.3 Work Permits 97
6.5.4 Loop Identification and System Interaction. 99
6.5.5 Safety Instrumented Systems 99
6.5.6 Critical Instruments. 101
Summary 102
Quiz. 102
References 105
Chapter 7 Tools and Test Equipment. 107
7.1 Hand Tools 107
7.2 Contact-type Test Equipment 108
7.2.1 Volt-Ohm Meters (VOM) 108
7.2.2 Digital Multimeters 109
7.2.3 Oscilloscopes. 110
7.2.4 Voltage Probes. 112
7.2.5 Thermometers 112
7.2.6 Insulation Testers 113
7.2.7 Ground Testers 114
7.2.8 Contact Tachometers 115
7.2.9 Motor/Phase Rotation Meters 115
7.2.10 Circuit Tracers 115
7.2.11 Vibration Monitors 116
7.2.12 Protocol Analyzers 116
7.2.13 Test Pressure Gauges 116
7.2.14 Portable Recorders 116
7.3 Noncontact Test Equipment 118
7.3.1 Clamp-on Amp Meters 118
7.3.2 Static Charge Meters 119
7.3.3 Magnetic Field Detectors 119
7.3.4 Noncontact Proximity Voltage Detectors 119
7.3.5 Magnetic Field/Current Detectors 120
7.3.6 Circuit and Underground Cable Detectors . 120
7.3.7 PhotoTachometers and Stroboscopes 120
7.3.8 Clamp-On Ground Testers 121
7.3.9 Infrared Thermometer Guns and
Imaging Systems 121
7.3.10 Leak Detectors 122
7.4 Simulators/Process Calibrators 122
7.5 Jumpers, Switch Boxes, and Traps 123
7.6 Documenting Test Equipment and Tests 125
7.7 Accuracy of Test Equipment 125
Summary 126
Troubleshooting xi
Quiz. 126
References 128
Chapter 8 Troubleshooting Scenarios 129
8.1 Mechanical Instrumentation. 129
8.1.1 Mechanical Field Recorder, EXAMPLE 1 129
8.1.2 Mechanical Field Recorder, EXAMPLE 2 130
8.1.3 Mechanical Field Recorder, EXAMPLE 3 130
8.2 Process Connections 130
8.2.1 Pressure Transmitter, EXAMPLE 1 130
8.2.2 Pressure Transmitter, EXAMPLE 2 131
8.2.3 Temperature Transmitter 131
8.2.4 Flow Meter (Orifice Type) 131
8.3 Pneumatic Instrumentation 132
8.3.1 Pneumatic Transmitter, EXAMPLE 1 132
8.3.2 Pneumatic Transmitter, EXAMPLE 2 132
8.3.3 Pneumatic Transmitter, EXAMPLE 3 133
8.3.4 Pneumatic Transmitter, EXAMPLE 4 133
8.3.5 Pneumatic Transmitter, EXAMPLE 5 134
8.3.6 I/P (Current/Pneumatic) Transducer. 134
8.4 Electrical Systems 134
8.4.1 Electronic 4-20 mA Transmitter 134
8.4.2 Computer-Based Analyzer 135
8.4.3 Plant Section Instrument Power Lost. 136
8.4.4 Relay System. 136
8.5 Electronic Systems. 138
8.5.1 Current Loops 138
8.5.2 Voltage Loops 140
8.5.3 Control Loops 141
8.5.4 Ground Loops 142
8.6 Valves 144
8.6.1 Valve Leak-By, EXAMPLE 1 144
8.6.2 Valve Leak-By, EXAMPLE 2 145
8.6.3 Valve Oscillation. 145
8.7 Calibration 145
8.7.1 Low Reading on Flow Transmitter. 145
8.7.2 Inaccurate Pay Meters. 146
8.7.3 Plant Material Balance Off 146
8.8 Programmable Electronic Systems 147
8.8.1 Plc 147
8.8.2 PLC Card. 147
8.8.3 PLC Pump Out System 147
xii Table of Contents
8.9 Communication Loops 148
8.9.1 Rs-232, Example 1 148
8.9.2 Rs-232, Example 2 148
8.9.3 Rs-485, Example 1 149
8.9.4 Rs-485, Example 2 149
8.9.5 Fieldbus 150
8.9.6 Programmable Logic Controller,
Remote Input-Output (PLC RIO) 150
8.9.7 Communication Loop Has Noise Problems . 150
8.9.8 Communication Loop Has Noise Problems . 151
8.10 Transient Problems. 151
8.10.1 DCS with PC Display 151
8.10.2 PC Cathode-Ray Tube (CRT) 152
8.10.3 Printer Periodically Goes Haywire 152
8.11 Software. 153
8.11.1 PLC-Controlled Machine Trips. 153
8.11.2 PLC Relay ¿Race¿ Problem. 154
8.11.3 FORTRAN Interface Program 154
8.12 Flow Meters 154
8.12.1 Flow Meter, EXAMPLE 1 154
8.12.2 Flow Meter, EXAMPLE 2 155
8.13 Level Meters 155
8.13.1 Level Meter (D/P), EXAMPLE 1. 155
8.13.2 Level Meter (D/P), EXAMPLE 2. 156
8.13.3 Level Meter (Radar). 156
8.13.4 Level Meter (Ultrasonic Probe) 157
Chapter 9 Troubleshooting Hints 159
9.1 Mechanical Systems. 159
9.2 Process Connections 159
9.3 Pneumatic Systems 160
9.4 Electronic Systems.
161
9.5 Grounding 162
9.6 Calibration Systems 163
9.7 Tools and Test Equipment 163
9.8 Programmable Electronic Systems 163
9.9 Serial Communication Links (Loops) 165
9.9.1 General Considerations 165
9.9.2 Modbus. 168
9.9.3 Communication Information Sources 169
9.10 Safety Instrumented Systems (SIS) 169
Troubleshooting xiii
9.11 Critical Instrument Loops 170
9.12 Electromagnetic Interference 170
9.13 Valves 172
9.14 Miscellaneous 173
Chapter 10 Aids to Troubleshooting 175
10.1 Introduction. 175
10.2 Maintainability 175
10.2.1 Safety. 176
10.2.2 Accessibility 176
10.2.3 Testability 176
10.2.4 Reparability 177
10.2.5 Economy 177
10.2.6 Accuracy. 177
10.3 Drawings 177
10.4 Tagging and Identification 181
10.5 Equipment Files 182
10.6 Manuals 182
10.7 Maintenance Management Systems 182
10.8 Vendor Technical Assistance 183
10.9 Direct Vendor Access 183
10.10 Maintenance Contracts 183
Summary 184
Quiz. 184
Appendix A Answers to Quizzes 187
Appendix B Relevant Standards 189
Appendix C Glossary 191
Index 211.

Troubleshooting : a technician's guide /

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