Troubleshooting

Troubleshooting: A Technician's Guide, 2nd Edition Troubleshooting loops and systems is something all technicians must do, but that few truly master. This newly revised edition draws on the author's long experience as an instrument and electrical engineer and his maintenance expertise to provide a detailed look at the skills and knowledge required for troubleshooting. Interspersed with a wealth of practical detail and real-world examples are Mostia’s no-nonsense discussions of what a good troubleshooter needs to know. He provides an in-depth discussion of the basic logical framework that underlies all troubleshooting as well as advanced troubleshooting techniques. He also explores the causes of failures and the techniques that engineers and technicians use to trace them down. This new edition covers troubleshooting methods, both basic and advanced, hints and troubleshooting aids, troubleshooting safety, basic maintenance concepts, information about training, and the developing troubleshooting skills. It also includes numerous examples of troubleshooting problems in mechanical systems, process connections, pneumatic systems, electrical systems, electronic systems, and valves. Mostia also explores test equipment, programmable electronic systems, communication circuits, transient problems, and software.

Chapter 1 Learning to Troubleshoot 1 1.1 Experience 1 1.2 Apprenticeships 3 1.3 Mentoring 3 1.4 Classroom Instruction 3 1.5 Individual Study 4 1.6 Logic and Logic Development 4 Chapter 2 The Basics of Failures 7 2.1 A Definition of Failure 7 2.2 How Hardware Fails 8 2.3 How Software Fails 11 2.4 Environmental Effects on Failure Rates 12 2.5 Functional Failures 14 2.6 Systematic Failures 14 2.7 Common-cause Failures 15 2.8 Root-cause Analysis 16 Chapter 3 Failure States 19 3.1 Overt and Covert Failures 19 3.2 Directed Failures 20 3.3 Directed Failure States 21 3.4 What Failure States Indicate 22 Chapter 4 Logical/Analytical Troubleshooting Frameworks 27 4.1 Logical/Analytical TroublEshooting Framework 27 4.2 Specific Troubleshooting Frameworks 28 4.3 How a Specific Troubleshooting Framework Works 33 4.4 Generic Logical/Analytical Frameworks 35 4.5 A Seven-step Procedure 37 4.6 An Example of How to Use the Seven-step Procedure 48 4.7 Vendor Assistance Advantages and Pitfalls 50 4.8 Why Troubleshooting Fails 50 Chapter 5 Other Troubleshooting Methods 59 5.1 Why Use Other Troubleshooting Methods? 59 5.2 Substitution Method 60 5.3 Fault Insertion Method 60 5.4 "Remove and Conquer" Method 61 5.5 "Circle the Wagons" Method 61 5.6 Trapping 63 5.7 Complex to Simple Method 64 5.8 Consultation 65 5.9 Intuition 65 5.10 Out-of-the-Box Thinking 66 Chapter 6 Safety 69 6.1 General Troubleshooting Safety Practices 69 6.2 Human Error in Industrial Settings 71 6.3 Plant Hazards Faced During Troubleshooting 73 6.4 Troubleshooting in Electrically Hazardous  (Classified) Areas 81 6.5 Protection, Procedures, and Permit Systems 95 Chapter 7 Tools and Test Equipment 107 7.1 Hand Tools 107 7.2 Contact-type Test Equipment 108 7.3 Noncontact Test Equipment 118 7.4 Simulators/Process Calibrators 122 7.5 Jumpers, Switch Boxes, and Traps 123 7.6 Documenting Test Equipment and Tests 125 7.7 Accuracy of Test Equipment 125 Chapter 8 Troubleshooting Scenarios 129 8.1 Mechanical Instrumentation 129 8.2 Process Connections 130 8.3 Pneumatic Instrumentation 132 8.4 Electrical Systems 134 8.5 Electronic Systems 138 8.6 Valves 144 8.7 Calibration 145 8.8 Programmable Electronic Systems 147 8.9 Communication Loops 148 8.10 Transient Problems 151 8.11 Software 153 8.12 Flow Meters 154 8.13 Level Meters 155 Chapter 9 Troubleshooting Hints 159 9.1 Mechanical Systems 159 9.2 Process Connections 159 9.3 Pneumatic Systems 160 9.4 Electronic Systems 161 9.5 Grounding 162 9.6 Calibration Systems 163 9.7 Tools and Test Equipment 163 9.8 Programmable Electronic Systems 163 9.9 Serial Communication Links (Loops) 165 9.10 Safety Instrumented Systems (SIS) 169 9.11 Critical Instrument Loops 170 9.12 Electromagnetic Interference 170 9.13 Valves 172 9.14 Miscellaneous 173 Chapter 10 Aids to Troubleshooting 175 10.1 Introduction 175 10.2 Maintainability 175 10.3 Drawings 177 10.4 Tagging and Identification 181 10.5 Equipment Files 182 10.6 Manuals 182 10.7 Maintenance Management Systems 182 10.8 Vendor Technical Assistance 183 10.9 Direct Vendor Access 183 10.10 Maintenance Contracts 184 Summary 184 Quiz 184 Appendix A Answers to Quizzes 187 Appendix B Relevant Standards 189 Appendix C Glossary 191 Index 211