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PREVENTIVE, PREDICTIVE & CORRECTIVE MAINTENANCE OF FIELD INSTRUMENTS

Location
Dubai, UAE
Date
From Date: 21-Apr-2025   
To Date: 25-Apr-2025
Duration
5 days
Language
ENGLISH
Discipline
INSTRUMENTATIONS, CONTROL & TELECOMMUNICATIONS
Introduction

Corrective, Preventive, Predictive and operational maintenance must be performed by qualified and experienced I&C maintenance personnel, because of the complexity of existing control systems that utilize many fields of expertise, several maintenance backgrounds are required to maintain, troubleshoot and calibrate pneumatic, electrical, electronic and computerized instruments and systems. The systems approach, which looks at the whole picture to gain an understanding of the process, is the special attribute of I& C maintenance personnel.

Good maintenance saves money. With the equipment working properly, the process quality and production will be high. When equipment fails, production normally stops, and many production personnel cannot do their jobs. With good maintenance management, spare parts are available quickly to reduce the mean time to repair (MTTR).

When the equipment is repaired quickly, the mean time between failures (MTBF) is extended. The proper frequencies of preventive maintenance should provide less downtime and the down time that occurs can be scheduled. We can become pro-active instead of reactive.

Objective

At the end of this course, participants will be able to:

  • Employ proper safety practices during installation, calibration, and maintenance procedures
  • Describe the difference between maintenance and troubleshooting
  • Apply Different types of maintenance.
  • Select and operate test equipment to measure electrical properties and calibrate instruments
  • Calibrate electronic transmitters and controllers
  • Install electronic instruments using manufacturer’s guidelines and ISA’s recommended practices and procedures
  • Use piping and instrumentation diagrams (P&IDs) and wiring, schematic, and installation detail drawings to install, calibrate, maintain and verify proper operation of instruments.
  • Describe different types of flowmeter operating principles, installation, calibration and maintenance.
  • Discuss electrical connections and grounding.
  • Discuss maintenance engineering.
  • Describe the operation of various pneumatic devices including bellows, diaphragm, Bourdon tube, flapper/nozzle mechanism, and pressure transmitters
  • Describe the specific tools used for pneumatic maintenance in a contemporary plant environment
  • Calibrate a differential pressure (D/P) transmitter for a dip tub application
  • Discuss the function of a control valve and actuator in a typical loop
  • Develop a systematic approach to troubleshooting
  • Verify, locate, and identify performance problems and the causes of the problems
  • Identify the common causes of sensor, transmitter, controller, and final control element problems
  • Troubleshoot control systems and documentation control
  • Compare general troubleshooting procedures for conventional, FIELDBUS, and HARTTM control systems
Audience

This course focuses on maintenance, calibration and troubleshooting of different instrumentation devices and systems for Engineers and Technicians.

  • Control and instrumentation
  • Control system
  • Electrical installations
  • Field technical support
  • Maintenance
  • Instrumentation Maintenance Technicians
  • Electrical Engineers and Technicians
  • Plant Operations Engineers, Supervisors and Operators
  • Maintenance Supervisors
Content

Module (01) Introduction

    1. Overview
    2. History of Instrumentation and control Maintenance
    3. Need for Instrumentation and Control Maintenance and Engineering

Module (02) Fundamental Principles

    1. Overview
    2. Electronic Field Instrumentation
    3. Why Maintain
    4. Maintenance versus Troubleshooting
    5. Calibration and Reasons to Calibrate
    6. Troubleshooting
    7. Basic Troubleshooting Technique
    8. Designed with maintenance in mind

Module (03) Diagram, Symbols and Specifications

    1. Overview
    2. P & ID
    3. Instrument Loop Diagram
    4. Logic Diagram
    5. Specifications
    6. Instrument Symbols

Module (04) Maintenance Personnel

    1. Overview
    2. Multi-Disciplined
    3. Continuous Training
    4. Training of Maintenance Workers
    5. Multi craft / Multiskilled, Multi-Discipline
    6. Knowledge Factors
    7. Skills
    8. Job Titles and Descriptions

Module (05) Maintenance Management and Engineering

    1. Overview
    2. The Need for Maintenance Management
    3. Maintenance Philosophy
    4. Maintenance Management Organization
    5. Basic Requirement for Maintenance Department
    6. Planning and Scheduling.
    7. Work Order System.
    8. MTTF, MTTR and Availability
    9. Preparing Functional Specifications
    10. Computerized Maintenance Management Systems (CMMS)
    11. Office/Shop Layout
    12. Centralized/Decentralized Shops

Module (06) Pressure and Flow Instruments

    1. Overview
    2. Pressure Transmitters
    3. Differential Pressure Technology
    4. Level Transmitters
    5. Flow Transmitters
    6. Magnetic Flowmeters
    7. Mass Flowmeters
    8. Turbine Flowmeters
    9. Positive Displacement Flowmeters
    10. Ultrasonic Flowmeters

Module (07) Maintenance Engineering

    1. Overview
    2. Engineering Assistance
    3. Maintenance involvement in new Project
    4. Successful Maintenance
    5. The High Maintenance System
    6. Documentation Control
    7. Alternative Methods of Maintenance
    8. Service / Contract Maintenance
    9. In house Maintenance versus Contract Maintenance
    10.  New Systems Installation Checkout
    11. Preventive Maintenance
    12. Predictive Maintenance
    13. Power, Grounding and Isolation Requirements
    14. Instrument Air Requirements
    15. Heating, Ventilating, Cooling and Air Conditioning System

Module (08) Temperature Devices

    1. Overview
    2. Thermocouples
    3. RTDs
    4. Thermistors
    5. Infrared Temperature Transducer
    6. Optical Fiber Thermometry
    7. Thermometers

 

Module (09) Panel and Transmitting Instruments

    1. Overview
    2. Panel and Behind Panel Instruments
    3. Panel Meters
    4. Discrete Switches
    5. Transducers
    6. Smart Transmitters

Module (10) Analytical Instruments

    1. Overview
    2. Field Analytical Instrument Systems
    3. Field Analytical Instruments
    4. Organizations
    5. Maintenance Approaches
    6. Service Factor
    7. Maintenance Workload
    8. Spare Parts
    9. Vendor Support
    10. Installation Issues

Module (11) Primary Element and Final Control Devices

    1. Overview
    2. Temperature
    3. Primary Elements
    4. Primary Element Locations
    5. Control Valves
    6. Troubleshooting Guide

Module (12) Pneumatic Instruments

    1. Overview
    2. Instrument Air Requirements
    3. Pneumatic Field Instruments

Module (13) Calibration

    1. Overview
    2. Field Calibration
    3. Calibration in Hazardous Locations
    4. In Shop Calibration

Module (14) Tuning

    1. Overview
    2. Loop Classification by Control Function
    3. Control Algorithms
    4. Loop Tuning
    5. Flow Loops

Module (15) Distributed Control Systems

    1. Overview
    2. DCS Maintenance
    3. Maintenance Goals and Objectives
    4. Programmable Logic Controllers (PLCs)

Module (16) Software and Network Maintenance

    1. Overview
    2. Computer Operating Environment
    3. 21st Century Maintenance Technology

Module (17) Safety

    1. Overview
    2. Electrical Hazards
    3. Hazardous Area
    4. Contamination
    5. Pressure and Vacuums
    6. High Voltage
    7. Moving and Rotating Machines
    8. Gases and Chemicals
    9. Heights and Confined Spaces
    10. Process Considerations
    11. Communications
    12. Standards and Recommended Practice

Module (18) Fiber Optics

    1. Overview
    2. Construction
    3. Classification
    4. Sensing Modes
    5. Advantages
    6. Disadvantages
    7. Applications
    8. Input/output Modules
    9. Sensors

 

NOTE:

Pre & Post Tests will be conducted

Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

 

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

  • 30% Lectures
  • 30% Workshops and work presentation
  • 20% Group Work& Practical Exercises
  • 20% Videos& General Discussions
Fees
• $5,500 per participant for Public Training. Fees Includes Course Materials/ Handouts, Tea/Coffee, refreshments & Lunch

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