Table of Contents:
“...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....
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