Course Details

Objective

Upon completion of this course, participants will gain the following:

• Understand why a systematic approach to troubleshooting is most effective
• 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
• Troubleshoot control systems
• Apply DCS functions for troubleshooting
• Understand pneumatic and electronic loops
• Apply safety practices for start-up
• Check and utilize control loop documentation
• Diagnose and solve problems related to single-loop control loops
• Diagnose and solve problems with ratio, cascade, and three-element control loops
• Diagnose problems using DCS displays for information
• Construct and tune a feedback control loop
• Troubleshoot several single-loop control systems

THIS COURSE WILL COVER:

• Introduction: Purpose of Troubleshooting | Reasons for Troubleshooting
• Approaches to Troubleshooting: Equipment History | Input/Output (Serial) | Shotgun Approach | Logical Analysis
• Logical Analysis Troubleshooting: Verify | Identify | Repair | Test | Follow-up on Problems
• Review Standard Diagrams and Symbols: Process and Instrument Drawings | Loop Drawings | Safety Logic
• Single-Loop Feedback Control Troubleshooting: Measurement Concerns | Controller Operations | Signal Conditioners | Troubleshooting Simulation
• Multi-Loop Control Systems Troubleshooting: Ratio (Two Controlled Streams, Wild Stream) | Cascade | Three-Element Control | Troubleshooting Simulation
• Introduction to Digital Control Systems: Advantages | Digital Control (DDC) | Supervisory DC | Supervisory Plus DDC | Analog Back-up
• Distributed Control Functions for Troubleshooting: Elements | Displays (Graphic, Trend, Alarm)

Start-up Concerns: Safety | Documentation | Tuning Review

Content

Chapter 1: Troubleshooting

1. 1. Purpose of Troubleshooting
   2. Troubleshooting Reasons
   3. Bottom Line
   4. What Are You Expected to Troubleshoot?
   5. Troubleshooting Skills Dependent On
   6. Approaches to Troubleshooting
   7. Equipment History Approach
   8. Input/Output (Serial) Approach
   9. Input/Output Approach
   10. Shotgun Approach
   11. Steps to Logical Analysis Troubleshooting
   12. Verify Something Is Wrong
   13. Identify and Locate the Cause of the Problem
   14. Fix the Problem
   15. Verify the Problem Is Corrected
   16. Follow-Up to Minimize Future Problems
   17. Pneumatic Test Equipment
   18. Electronic Test Equipment
   19. Digital Test Equipment

Chapter 2: Review of Diagrams & Symbols

1. 1. Process Control Defined
   2. Other Instruments in a Feedback Control Loop
   3. Instrument Line Symbols
   4. General Instrument or Function Symbols
   5. Identification Letters
   6. Control Valve Body Symbols
   7. Actuator Symbols
   8. Typical Tag Numbers
   9. Actuator Symbols Fail Safe
   10. Instrument Identification

Chapter 3: Common Problems

1. 1. Pressure Measurement-Common Problems
   2. Level Measurement-Common Problems
   3. Flow Measurement-Common Problems
   4. Temperature Measurement-Common Problems
   5. Common Problems: Pneumatic Transmitters
   6. Common Problems: Transmitter Installation
   7. Common Problems: Electronic Transmitters
   8. Common Problems: Control Valves
   9. Flow Problem Discussion
   10. Temperature Problem Discussion
   11. Level Loop Problem Discussion
   12. Pressure Loop Problem Discussion

Chapter 4: System Tuning Review

1. 1. Ziegler/Nichols Closed Loop Tuning
   2. Formulas for Open Loop (in Manual)
   3. Alternate Process for Open Loop
   4. Procedure 1 (Closed Loop) Discussion
   5. Procedure 2 (Closed Loop) Discussion
   6. Procedure 3 (Open Loop) Discussion

Chapter 5: Start-Up

1. 1. Safety Start-up Concerns
   2. Start-Up Documentation
   3. Process Start-Up Familiarity

Chapter 6: Multi-Loop Control Systems

1. 1. Ratio Control Defined
   2. Ratio Control (Two Controlled Streams)
   3. Wild Stream Ratio Control
   4. General Features of a Cascade Control System
   5. Heat Exchanger: Single Loop
   6. Heat Exchanger: Cascade Control
   7. Ratio Control Problem Discussion
   8. Cascade Control Problem Discussion
   9. Three Element System Problem Discussion

Chapter 7: Digital Control Introduction

1. 1. How the Computer Works...
   2. Electronic Language - The Binary System
   3. A Comparison!
   4. Advantages of Digital Control Systems
   5. Direct Digital Control (DDC)

Chapter 8: Troubleshooting DCS

1. 1. Distributed Control System
   2. Elements of a Distributed Control System
   3. DCS Graphic Display
   4. DCS Trend Display
   5. DCS Alarm Summary
   6. DCS Distillation Control Problem Discussion
   7. DCS Batch Control Problem Discussion
   8. DCS Reactor Control Problem Discussion
   9. DCS Pressurized Vessel Problem Discussion

NOTE:

Pre & Post Tests will be conducted

Case Studies, Group Exercises, Group Discussions, Last Day Review and assessments will

be carried out.

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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