Troubleshooting
Instrumentation & Control
Systems
Don Lovell
International Society of Automation
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Reasons for Troubleshooting
Something not functioning properly
You don't know what's wrong
Equipment down or product out of specifications
Isolate problems between the equipment and the process
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Purpose of Troubleshooting
Maintain Safety of Personnel and Plant Equipment
Identify the problem
Minimize down time
Improve plant efficiency
Improve product quality
3
Bottom Line Goals
No unscheduled downtime
Product running at specifications
All instruments, controls, etc. are operating properly
Reduce maintenance cost
Minimize troubleshooting time
Improve employee efficiency
4
Bottom Line Goals - Impact Statement
The global process industry loses $20 billion, or five percent of
annual production, due to unscheduled downtime and poor
quality.*
ARC estimates that almost 80 percent of these losses are
preventable and 40 percent are primarily the result of the
operator or human in the loop. *
ARC estimates unplanned downtime accounts for the
equivalent of 20% of all production in the process industries. A
single unplanned shutdown can wipe out your plant profit for
the year. **
* 2009 Fieldbus Foundation - FFIEUC-Mumbai Conference
** NAMUR NE 107 recommendations come to the United States Larry OBrian
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Wasted Effort
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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
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Skills Beneficial for Troubleshooting
Certain skills can be helpful in troubleshooting
Logical or methodical approach
Ability to learn from past experiences
Curiosity
Patience
Self-motivated
Knowledge of information location
Use of computer based information
Drawings
Spare parts
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Troubleshooting Skills Dependent On
Your level of expertise
Familiarity with your instrumentation or equipment
What test equipment you have & familiarity with it
Your companys philosophy
Access to information resources
What parts you have available (for repair)
What time frame you have
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Steps to Logical Analysis Troubleshooting
Whatever troubleshooting method is used, a logical approach
should be taken to identify and repair a problem
Verify that something is wrong
Identify and locate the problem
Fix the problem
Verify the problem is fixed
Follow-up to prevent future problems
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Verify That Something is Wrong
Ask the operator
Observe for yourself
Is the process being operated under normal conditions and
productions rates
Begin with and test with the assumption that the
instrumentation and controls are not the problem
Familiarize yourself with the loop
Make sure you understand how the controls are supposed to
function when operating properly
Make sure you understand the associated equipment and how
it can influence the operation of the suspect equipment
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Identify and Locate the Problem
Confirm whether the instrumentation and control or something
else is causing the problem
Make the easiest checks first
Can the desired control be achieved with the control loop in manual?
Could the measuring instrument be correct and actually showing that
something has changed in the process?
Isolate the problem to the instrumentation and controls or to something
else (process, equipment, etc.)
Inform Production of the steps that you are taking that could cause an
upset, alarm, etc.
Work to isolate the source of the problem using one of 3 methods
History
Input/Output
Series
Divide and Conquer
Develop a plan for how to proceed to locate and confirm cause
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Fix the Problem
Once you feel the problem has been isolated, develop a plan to
repair the problem
Inform Production of your repair plan
Repair or recommend the repair of the problem
Follow production area safety procedures and manufacturer
specifications and procedures during repair
Communicate closely with Production
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Verify that the Problem Is Fixed
Confirm that all repaired and associated parts of the system
operate correctly, including
Measurements
Control
Alarms
Interlocks
Confirm that the Operator is satisfied with the performance of
the repaired system and understands how it is to operate under
all conditions
14
Follow Up to Minimize Future Problems
Document in history file
Suggest changes, if needed
Upgrade PM program
Submit changes to update all documentation (As built)
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Documentation for Troubleshooting
Current documentation is as important a troubleshooting tool
as any test equipment or other tools
Process & Instrument Diagrams P&ID
Instrument loop diagram
Instrument maintenance records
Instrument specifications and manuals
Electrical motor control schematics
Interlock and alarm information
System drawing
Operational logs/procedures and data
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Troubleshooting Framework Review
Verify something
is wrong
Question,
confirm
Identify and locate 1. Equipment procedures
2. Develop a plan
the problem 3. Select method Other methods
Method? Substitution
Fault insertion
Repair Equipment History Remove and conquer
the problem Circle the wagons
Input/Output Serial Trapping
Develop a plan
Complex-to-simple
to repair Input/Output Consultation
Divide and Conquer Intuition
Verify the
Out-of-the-box
repair Shot Gun Vendor assistance
Confirm
Follow-up
Document,
or changes
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Pneumatic Test Equipment
Calibration Gauge Pressure Gauge
Dead Weight Tester
Pressure Module
Dead Weight Tester
Electronic Calibration Kit
Pressure
Calibration Pump Calibrator/Recorder
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Electronic Test Equipment
DVM
(True RMS)
mA Clamp Meter HART Hand Held
Process Calibrator
Torque Screwdriver HART USB Modem
Process Calibrator
Low Cost
Pressure IR Temp
Dry Blocks HART Smartphone
Calibrator
+ blue tooth
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Digital Test Equipment
RJ-45 Tester/Wire Mapper Fieldbus Monitor
Profibus PA Monitor Wiring Validator
LAN Trouble
Shooter Wireless Kit ProfiTrace Analyzer
Wire Mapper Digital/Storage Scopes
Cable Tester
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Old Smart Phones
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
The regulation or manipulation of variables influencing the
conduct of a process in such a way as to obtain a product of
desired quality and quantity in an efficient manner
DISTURBANCES
CONTROLLED
MANIPULATED
PROCESS Or
VARIABLES
MEASURED
VARIABLES
CONTROLLER
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Instruments in a Feedback Control Loop
Upsets or Disturbances
Manipulated Controlled
Variable Process Variable
Final Control Sensor
Element
Setpoint
Signal Controller Transmitter
Transducer
Recorder
Indicator
Alarms
Interlocks
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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
Standard Signal Values (250 ohm)
4mA = 1 vDC = 0%
8mA = 2 vDC = 25%
12mA = 3 vDC = 50%
16mA = 4 vDC = 75%
20 mA= 5 vDC = 100%
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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
75 16.0 4v 20v 1.6v 22.4v 0.992v 23.00v 0.08v 23.92v
50 12.0 3v 21v 1.2v 22.8v 0.744v 23.26v 0.06v 23.94v
25 8.0 2v 22v 0.8v 23.2v 0.496v 23.5v 0.04v 23.96v
0 4.0 1v 23v 0.4v 23.6v 0.248v 23.75v 0.02v 23.98v
NAMUR Standard NE-43
>22.0 mA Wiring Problem (short)
20.5 22.0 mA Transmitter Failure
20.0 20.5 mA Normal Over Range
4.0 20.0 mA Normal Operation
3.8 4.0 mA Normal Under Range
3.6 3.8 mA Transmitter Failure
0 3.6 mA Wiring Problem (open)
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Instrument Symbols & Identification
Functional identification
Instrument numbering
Functional locations
Signal transmission
Measuring element symbols
Final control element symbols
Example P&ID
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Example Balloons and Tags
Flow Flow Flow
Transmitter Controller Valve
In Field In BPCS In Field
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Instrument to Instrument Connection Symbols
INSTRUMENT SUPPLY OR CONNECTION TO PROCESS
UNDEFINED SIGNAL
PNEUMATIC SIGNAL
ELECTRONIC SIGNAL
HYDRAULIC SIGNAL
CAPILLARY TUBE
ELECTROMAGNETIC SIGNAL (GUIDED)
ELECTROMAGNETIC (WIRELESS) SIGNAL (UNGUIDED)
COMMUNICATIONS LINK BETWEEN SYSTEM DEVICES
COMMUNICATIONS LINK TO/FROM SMART (HART) DEVICE
COMMUNICATIONS LINK TO/FROM INTELLIGENT (FIELDBUS) DEVICE
COMMUNICATIONS LINK BETWEEN TWO SYSTEMS (e.g. DCS and SIS)
Refer to ISA5.1 Table 5.3.2 for additional symbols
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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
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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
Compressed air hazards
Test equipment
Working with energized (live) equipment
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HART Systems Review
Highway addressable remote transducer
A hybrid analog/digital technology
An instruments primary variable is transmitted via 4-20ma
A de facto standard for field communication
Communication is modulated as an AC signal superimposed
onto the 4-20mA signal
Uses frequency shift keying (FSK)
Utilizes a device description (DD) language
Enables asset management
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HART COMMANDS : OVERVIEW
Universal Common Practice Device Specific
Read device type Read dynamic variables Read /write low-flow cut-off
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
Write polling address Write PV unit Valve characterization
Trim DAC zero and gain Valve set point
Write transfer function (square
Travel limits
root/linear)
Write sensor serial number User units
R/W dynamic variable assignments Local display information
(Note: this is a partial list of HART commands)
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DCS Troubleshooting Features
Process graphic display
Loop display and Detailed Loop Displays
Real time trends and Historical Data Collection
Alarms and alarm summary
Event logger
Operator action journal
Sequence of events
System management
Sequence Of Events
Function block details
Control strategy configuration
Intelligent field device configuration
Change management
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NAMUR NE 107
Requirements regarding self-monitoring and diagnosis in field
instrumentation and classification of diagnostic events
Provides improved operator, engineering and asset management
Device Status Condition Output Status HMI Color Status
Device OK Normal Valid output signal Green
Comm OK Normal Valid output signal Green
Maintenance Maintenance
Output signal is still valid Blue
Required Required
Warning Maint Maintenance
Output signal is still valid Blue
Required Required
Maintenance Out of Output signal out of the specified
Yellow
Mode Specification range
Function
Simulation Mode Temporary non-valid output signal Orange
Check
Error Failure Non-valid output signal Red
Config Error Failure Non-valid output signal Red
Comm Error Failure Non-valid output signal Red
Process Error Failure Non-valid output signal Red
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Tree Maps
Alarms & TreeMapping
Alarms & TreeMapping
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