Perform Advanced Preventive, Predictive and Corrective Maintenance of Field Instruments
This popular course offers a combination of practical information and hands-on experience, covering proper maintenance, calibration and troubleshooting of electronic, pneumatic, and smart instruments. You will examine characteristics of electronic control systems; techniques for all type of maintenance (preventive, predictive and corrective) of field instruments; and procedures for configuring and calibrating transmitters, transducers, and controllers.
This course covers correct technology, operation, and maintenance of pneumatic instruments employed in modern process facilities. The emphasis is on valves, valve positioners, controllers, and transmitters.
Also presents a systematic approach to troubleshooting and start-up of single and multi-loop control loops. You'll see how pressure, level, flow, and temperature loops operate to maintain good process control systems.
By the end of this course the participant will:
Learn types of field instruments maintenance.
Understand employ proper safety practices during maintenance, calibration, and troubleshooting procedures.
Learn how to connect wiring in an electronic control loop.
Be familiar with the documents used to define instrument and control systems, including: Process Flow Diagrams, Piping & Instrumentation Drawings, Instrument Lists, Specification Forms, Logic Diagrams, Location Plans, Installation Details, Loop Diagrams.
Be able to select and operate test equipment to measure electrical properties and calibrate instruments.
Learn how to calibrate electronic, pneumatic, and smart transmitters and controllers.
Recognize the importance of maintenance in the proper operation of instruments and control systems.
Use P&ID, wiring, schematic, and installation detail drawings to install, calibrate, and verify proper operation of instruments.
Discuss performance characteristics and identify errors associated with the operation of pneumatic measurement and control instruments.
Develop a systematic approach to troubleshooting.
Follow specified procedures for proper loop check-out.
Verify, locate, and identify performance problems and the causes of the problems.
Take or recommend appropriate follow-up procedures to minimize problem recurrence.
Identify the common causes of sensor, transmitter, controller, and final control element problems.
Discuss applications and procedures to troubleshoot conventional analog control systems.
1- INTRODUCTIONS & DEFINITIONS
2- FUNDAMENTAL PRINCIPLES
3- INSTRUMENTATION AND CONTROL SYSTEMS DOCUMENTATION.
4- ELECTRICAL AND ELECTRONIC FUNDAMENTALS
5- MAINTENANCE MANAGEMENT AND ENGINEERING
6- INSTRUMENT MAINTENANCE: Corrective/Preventive/Predictive
7- CALIBRATION PRINCIPLE
8- CALIBRATION PROCEDURES AND TOOLS
9- INSTRUMENTS CALIBRATION
10- BASIC TROUBLESHOOTING TECHNIQUES
11- LOGICAL/ANALYTICAL TROUBLESHOOTING FRAMEWORKS
12- SINGLE-LOOP AND MULTI-LOOP CONTROL SYSTEMS TROUBLESHOOTING
13- TOOLS AND TEST EQUIPMENT
14- TROUBLESHOOTING SCENARIOS
15- LOOP CHECKING
17- APPLICATIONS AND CASE STUDIES
Introductions & Definitions
• Corrective/preventative/predictive maintenance of instruments
• History of Instrumentation and Control Maintenance
• Need for Instrumentation and Control Maintenance and Engineering
• Maintenance Personnel
• Electronic Field Instrumentation
• Why Maintain?
• Maintenance vs. Troubleshooting
• Designed with Maintenance
• Planned maintenance
Instrumentation and Control Systems Documentation
• Process Flow Diagram
• Piping and Instrumentation Drawing
• Instrument List & Specification Forms
• Logic Diagrams
• Loop Diagrams
• Installation Details and Location Plans
• Typical Control Schemes
Electrical and Electronic Fundamentals
• Direct and Alternating Current
• Inductance and Capacitance
• Diode/Silicon Controlled Rectifier (SCR)/Triac
• Digital logic
• Analog/Digital conversion
• Sensing Devices
• Schematic symbols used for electrical and electronic devices
Maintenance Management and Engineering
• Maintenance Philosophy
• Maintenance Management Organization
• Basic Requirements for a Maintenance Department
• Planning and Scheduling
• Work Order System
• MTTF, MTTR, and Availability
• Computerized Maintenance Management Systems
• Maintenance Engineering
• Engineering Assistance
• The High Maintenance System
• Service/Contract Maintenance
• New Systems Installations and Checkout
Instrument Maintenance: Corrective, Preventive, Predictive
• Pressure Transmitters
• Differential Pressure Technology
• Flow Transmitters
• Level Transmitters
• Temperature Devices
• Panel and Transmitting Instruments
• Discrete Switches
• Smart Transmitters
• Primary Elements and Final Control Devices
• Control Valves
• Pneumatic Instruments
• What Is Calibration?
• What Are the Characteristics of a Calibration?
• Why Is Calibration Required?
• Who Performs Calibrations?
• Types of Calibration
Calibration procedures and tools
• Multifunction Calibrators
• Digital Calibrators
• Thermocouple and RTD Simulators
• Current, Resistance, and Millivolts
• Calibration Procedures
• Temperature Instrument Calibration
• Pressure Instrument Calibration
• Level Instrument Calibration
• Flow Instrument Calibration
• Final Control Devices Calibration
• Process Analytical Instrument Calibration
Basic Troubleshooting Techniques
• The Basics of Failures
• How Hardware Fails
• How Software Fails
• Common-cause Failures
• Failure States
Logical/Analytical Troubleshooting Frameworks
• Specific Troubleshooting Frameworks.
• Generic Logical/Analytical Frameworks
• A Seven-step Procedure
• Why Troubleshooting Fails
• Other Troubleshooting Methods
Single-Loop and Multi-Loop Control Systems Troubleshooting Tools and Test Equipment
• Hand Tools
• Contact-type Test Equipment
• Noncontact Test Equipment
• Jumpers, Switch Boxes, and Traps
• Documenting Test Equipment and Tests
• Accuracy of Test Equipment
• Mechanical Instrumentation.
• Process Connections
• Pneumatic Instrumentation
• Electrical, Electronic Systems
• Programmable Electronic Systems
• Communication Loops
• Transient Problems
• field instruments
• Process Control Example
• Loop Checking Considerations
• Control Loop Design Guidelines
• The Factory Acceptance Test (FAT)
• Test Planning
• Performing the FAT
• Process Simulation
• Loop Check Plan
• Instrumentation Commissioning
• Site Acceptance Testing (SAT)
• Initial Equipment Start-Up Activities
• Documenting the Start-up Process
• Start-Up Team Organization
• Tuning Control Loops
Applications and Case Studies