2
Purpose of Troubleshooting
3
Bottom Line Goals
No unscheduled downtime
4
Bottom Line Goals - Impact Statement
5
Wasted Effort
6
What Are You Expected to Troubleshoot?
Process
Loop
Device
Discrete components
Pneumatic equipment
Electronic equipment
Digital systems
Networks
Analytical systems
Computers
Board or module
Process equipment
Operation procedures
7
Skills Beneficial for Troubleshooting
8
Troubleshooting Skills Dependent On
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Verify That Something is Wrong
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Identify and Locate the Problem
Once you feel the problem has been isolated, develop a plan to
repair the problem
13
Verify that the Problem Is Fixed
14
Follow Up to Minimize Future Problems
Upgrade PM program
15
Documentation for Troubleshooting
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Troubleshooting Framework Review
Verify something
is wrong
Question,
confirm
Follow-up
Document,
or changes
17
Pneumatic Test Equipment
Pressure Module
DVM
(True RMS)
mA Clamp Meter HART Hand Held
Process Calibrator
Process Calibrator
Low Cost
Pressure IR Temp
Dry Blocks HART Smartphone
Calibrator
+ blue tooth
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Digital Test Equipment
LAN Trouble
Shooter Wireless Kit ProfiTrace Analyzer
WhatsApp
Skype
You Tube Google
Box.com
Bar Code Scanner Drive
Bubble Level
Strobe Light
Sound Meter
Red Laser PdaNet
Camera
Flash Light
Quick Office
EsFile Explorer
Wifi File Explorer
Notes
Cam-Scanner
Convert Pad Pictures
Math Calculators
Ohms Law Calculator Instruction Books
Instrument Range Calculator
RTD/TC Calculators Notes
E&H Instrument Lookup
Books
HART Calibrators
Loop Tuners
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Process Control
DISTURBANCES
CONTROLLED
MANIPULATED
PROCESS Or
VARIABLES
MEASURED
VARIABLES
CONTROLLER
22
Instruments in a Feedback Control Loop
Upsets or Disturbances
Manipulated Controlled
Variable Process Variable
Indicator
Alarms
Interlocks
23
Current Loop Characteristics
D/P + 24Vdc
Trans - Current Flow
Controller
250
+ 124.5 +
+ 1-5Vdc -
250
1-5Vdc 46.8 Iout Load
H L -
A
M
MAN ALM
-
0-750
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Other Current Loop Characteristics
Comparison of Voltages at Load and Transmitter (PS = 24vDC)
Rload = Rload = Rload = Rload =
% mA Tx V Tx V Tx V Tx V
250 100 62 5
100 20.0 5v 19v 2v 22v 1.24v 22.76v 0.1v 23.9v
Functional identification
Instrument numbering
Functional locations
Signal transmission
Measuring element symbols
Final control element symbols
Example P&ID
26
Example Balloons and Tags
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Instrument to Instrument Connection Symbols
HYDRAULIC SIGNAL
CAPILLARY TUBE
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Flow Measuring Element Symbols
a) T b)
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Piping & Instrumentation Drawing (P&ID)
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Example Loop Diagram
31
Portable Training Lab
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Portable Training Lab Instrument Air Diagram
0-60
PSI 0-60
PI
PSI
TP-2
PCV
Air
Supply
TP-1
0-60
PSI
I/P
FI 20 PSI
FY
Supply
0-60
In H2O V-3
DP - High DP - Low I/P
Output
PV
PCV FV
Atmos
V-2
Variable
Orifice
V-1
DP -Test
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Troubleshooting Safety
Electrical hazards
Test equipment
34
HART Systems Review
35
HART COMMANDS : OVERVIEW
Read PV and units Write damping time constant Start, stop or clear totalizer
Read current output and percent of
Write device range value R/W density calibration factor
range
Read predefined dynamic variables Calibrate (set zero, set span) Choose PV (mass, flow, or density)
R/W materials or construction
R/W tag, descriptor, date Set fixed output current
information
R/W 32 character message Perform self-test Trim sensor calibration
Read range values, units, and
Perform master reset PID enable
damping time constant
R/W final assembly number Trim PV, zero Write PID set point
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Tree Maps