1、TROUBLESHOOTINGA TECHNICIANS GUIDE2ND EDITIONMostia2005.book Page i Wednesday, October 12, 2005 1:25 PMMostia2005.book Page ii Wednesday, October 12, 2005 1:25 PMTROUBLESHOOTINGA TECHNICIANS GUIDE2ND EDITIONWilliam L. Mostia, Jr., P. E.ISA TECHNICIAN SERIESMostia2005.book Page iii Wednesday, October
2、 12, 2005 1:25 PMCopyright 2006 by ISA The Instrumentation, Systems and Automation Society67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved.Printed in the United States of America.1098765432ISBN 1-55617-963-4No part of this work may be reproduced, stored in a retrie
3、val system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.NoticeThe information presented in this publication is for the general education of the reader. Because neither the author nor t
4、he publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular a
5、pplication. Additionally, neither the author nor the publisher have investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular
6、 use of the information presented. Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the au
7、thor nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturers instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.Library of Congress
8、 Cataloging-in-Publication DataMostia, William L.Troubleshooting :a technicians guide / William L. Mostia.- 2nd ed.p. cm. - (ISA technician series)ISBN 1-55617-963-41. System failures (Engineering) I. Title. II. Series. TA169.5.M67 2005620.0011-dc222005029959Mostia05-frontmatter.fm Page iv Wednesday
9、, October 19, 2005 2:47 PMDEDICATIONRaymond D. Molloy, Jr. (1937-1996)The ISA Technician Series is dedicated to the memory of Raymond D. Molloy, Jr. Mr. Molloy was an ISA member for 34 years and held various Society offices, including Vice President of the ISA Publications Department. Mr. Molloy was
10、 a valued contributor to the ISA Publications Department for many years and led the Department in the introduction of many new ISA publications over the years. Ray also served as President of the New Jersey Section. He was the recipient of ISAs Distinguished Society Service and Golden Achievement Aw
11、ard and the New Jersey Section Lifetime Achievement Award.Mostia2005.book Page v Wednesday, October 12, 2005 1:25 PMMostia2005.book Page vi Wednesday, October 12, 2005 1:25 PMTABLE OF CONTENTSChapter 1 Learning to Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Experience . . . . .
12、 . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.1 Information and Skills . . . . . . . . . . . . . . . . . 21.1.2 Diversity and Complexity. . . . . . . . . . . . . . . 21.1.3 Learning from Experience . . . . . . . . . . . . . . 21.2 Apprenticeships . . . . . . . . . . . . . . . . . . . . . .
13、 . . . . . 31.3 Mentoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 Classroom Instruction. . . . . . . . . . . . . . . . . . . . . . . 31.5 Individual Study. . . . . . . . . . . . . . . . . . . . . . . . . . . 41.6 Logic and Logic Development . . . . . . . . . . . . . . . .
14、. 4Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Chapter 2 The Basics of Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 A Definition of Failure. . . . . . . . . . .
15、 . . . . . . . . . . . . 72.2 How Hardware Fails . . . . . . . . . . . . . . . . . . . . . . . . 82.2.1 Measures of Reliability . . . . . . . . . . . . . . . . 92.2.2 The Wear-out Period . . . . . . . . . . . . . . . . . 102.3 How Software Fails . . . . . . . . . . . . . . . . . . . . . . . 112.4 En
16、vironmental Effects on Failure Rates . . . . . . . . . . 122.4.1 Temperature . . . . . . . . . . . . . . . . . . . . . . 132.4.2 Corrosion . . . . . . . . . . . . . . . . . . . . . . . . 132.4.3 Humidity . . . . . . . . . . . . . . . . . . . . . . . . . 132.4.4 Exceeding Instrument Limits . . . . .
17、. . . . . . 142.5 Functional Failures . . . . . . . . . . . . . . . . . . . . . . . . 142.6 Systematic Failures . . . . . . . . . . . . . . . . . . . . . . . 142.7 Common-cause Failures . . . . . . . . . . . . . . . . . . . . 152.8 Root-cause Analysis . . . . . . . . . . . . . . . . . . . . . . . 16
18、Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Chapter 3 Failure States . . . . . . . . . . . . . . . . . .
19、. . . . . . . . . . . . . 193.1 Overt and Covert Failures . . . . . . . . . . . . . . . . . . . 193.2 Directed Failures . . . . . . . . . . . . . . . . . . . . . . . . . 203.2.1 Failure Direction . . . . . . . . . . . . . . . . . . . . 20Mostia2005.book Page vii Wednesday, October 12, 2005 1:25 PMvi
20、ii Table of Contents3.3 Directed Failure States . . . . . . . . . . . . . . . . . . . . . 213.4 What Failure States Indicate . . . . . . . . . . . . . . . . . 22Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、 . . . . . . . . . 24References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Chapter 4 Logical/Analytical Troubleshooting Frameworks . . . . . . . . 274.1 Logical/Analytical TroublEshooting Framework. . . . . 274.2 Specific Troubleshooting Frameworks. . . . . . . . . . . 284.3
22、 How a Specific Troubleshooting Framework Works . 334.4 Generic Logical/Analytical Frameworks . . . . . . . . . . 354.5 A Seven-step Procedure . . . . . . . . . . . . . . . . . . . . 374.5.1 STEP 1: Define the Problem. . . . . . . . . . . . 374.5.2 STEP 2: Collect Information Regarding the Problem .
23、 . . . . . . . . . . . . . . . . . . . . . . 394.5.3 STEP 3: Analyze the Information . . . . . . . . 404.5.4 STEP 4: Determine Sufficiency of Information . . . . . . . . . . . . . . . . . . . . . . . 434.5.5 STEP 5: Propose a Solution . . . . . . . . . . . . 474.5.6 STEP 6: Test the Proposed Solutio
24、n . . . . . . 474.5.7 STEP 7: The Repair. . . . . . . . . . . . . . . . . . 484.6 An Example of How to Use the Seven-step Procedure . . . . . . . . . . . . . . . . . . . . . . 484.6.1 STEP 1: Define the Problem. . . . . . . . . . . . 494.6.2 STEP 2: Collect Information Regarding the Problem . . . .
25、. . . . . . . . . . . . . . . . . . . 494.6.3 STEP 3: Analyze the Information . . . . . . . . 494.6.4 STEP 4: Determine Sufficiency of Information . . . . . . . . . . . . . . . . . . . . . . . 494.6.5 STEP 5: Propose a Solution . . . . . . . . . . . . 494.6.6 STEP 6: Test the Proposed Solution . . .
26、 . . . 494.6.7 STEP 7: Repair. . . . . . . . . . . . . . . . . . . . . 504.7 Vendor Assistance Advantages and Pitfalls . . . . . . . 504.8 Why Troubleshooting Fails . . . . . . . . . . . . . . . . . . 504.8.1 Lack of Knowledge . . . . . . . . . . . . . . . . . . 514.8.2 Failure to Gather Data Proper
27、ly. . . . . . . . . . 514.8.3 Failure to Look in the Right Places . . . . . . . 514.8.4 Dimensional Thinking . . . . . . . . . . . . . . . . 55Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、 56References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Mostia2005.book Page viii Wednesday, October 12, 2005 1:25 PMTroubleshooting ixChapter 5 Other Troubleshooting Methods. . . . . . . . . . . . . . . . . . . 595.1 Why Use Other Troubleshooting Methods? . . . . . . . 595
29、.2 Substitution Method. . . . . . . . . . . . . . . . . . . . . . . 605.3 Fault Insertion Method . . . . . . . . . . . . . . . . . . . . . 605.4 “Remove and Conquer” Method. . . . . . . . . . . . . . . 615.5 “Circle the Wagons” Method . . . . . . . . . . . . . . . . . 615.6 Trapping . . . . . . . .
30、. . . . . . . . . . . . . . . . . . . . . . . 635.7 Complex to Simple Method . . . . . . . . . . . . . . . . . . 645.8 Consultation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655.9 Intuition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655.10 Out-of-the-Box Thinking . .
31、 . . . . . . . . . . . . . . . . . 66Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Chapter 6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.1 General
32、Troubleshooting Safety Practices . . . . . . . . 696.2 Human Error in Industrial Settings . . . . . . . . . . . . . 716.2.1 Slips or Aberrations . . . . . . . . . . . . . . . . . 716.2.2 Lack of Knowledge . . . . . . . . . . . . . . . . . . 716.2.3 Overmotivation and Undermotivation . . . . . 726.2.
33、4 Impossible Tasks . . . . . . . . . . . . . . . . . . . 726.2.5 Mindset. . . . . . . . . . . . . . . . . . . . . . . . . . 726.2.6 Errors by Others. . . . . . . . . . . . . . . . . . . . 726.3 Plant Hazards Faced During Troubleshooting . . . . . . 736.3.1 Personnel Hazards (Electrical). . . . . . .
34、 . . . . 736.3.2 General Practices When Working With or Near Energized Circuits . . . . . . . . . . . . . 766.3.3 Static Electricity Hazards. . . . . . . . . . . . . . 776.3.4 Mechanical Hazards . . . . . . . . . . . . . . . . . 776.3.5 Stored Energy Hazards . . . . . . . . . . . . . . . 796.3.6 The
35、rmal Hazards . . . . . . . . . . . . . . . . . . . 796.3.7 Chemical Hazards. . . . . . . . . . . . . . . . . . . 796.4 Troubleshooting in Electrically Hazardous (Classified) Areas . . . . . . . . . . . . . . . . . . . . . . . . 816.4.1 Classification Systems . . . . . . . . . . . . . . . 816.4.2 Are
36、a Classification Standards. . . . . . . . . . . 856.4.3 Troubleshooting in Electrically Hazardous Areas . . . . . . . . . . . . . . . . . . . 936.5 Protection, Procedures, and Permit Systems . . . . . . 956.5.1 Operations Notification . . . . . . . . . . . . . . . 956.5.2 Maintenance Procedures . .
37、. . . . . . . . . . . . 96Mostia2005.book Page ix Wednesday, October 12, 2005 1:25 PMx Table of Contents6.5.3 Work Permits. . . . . . . . . . . . . . . . . . . . . . 976.5.4 Loop Identification and System Interaction. . 986.5.5 Safety Instrumented Systems . . . . . . . . . . 996.5.6 Critical Instrum
38、ents. . . . . . . . . . . . . . . . . 100Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Chapter 7 Tools and Tes
39、t Equipment. . . . . . . . . . . . . . . . . . . . . . 1077.1 Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077.2 Contact-type Test Equipment . . . . . . . . . . . . . . . 1087.2.1 Volt-Ohm Meters (VOM) . . . . . . . . . . . . . 1087.2.2 Digital Multimeters . . . . . . . . . .
40、. . . . . . . 1097.2.3 Oscilloscopes. . . . . . . . . . . . . . . . . . . . . 1107.2.4 Voltage Probes. . . . . . . . . . . . . . . . . . . . 1127.2.5 Thermometers . . . . . . . . . . . . . . . . . . . . 1127.2.6 Insulation Testers . . . . . . . . . . . . . . . . . . 1137.2.7 Ground Testers . . . . .
41、 . . . . . . . . . . . . . . 1147.2.8 Contact Tachometers . . . . . . . . . . . . . . . 1157.2.9 Motor/Phase Rotation Meters. . . . . . . . . . 1157.2.10 Circuit Tracers . . . . . . . . . . . . . . . . . . . 1157.2.11 Vibration Monitors . . . . . . . . . . . . . . . . 1167.2.12 Protocol Analyzers .
42、. . . . . . . . . . . . . . . 1167.2.13 Test Pressure Gauges . . . . . . . . . . . . . . 1167.2.14 Portable Recorders . . . . . . . . . . . . . . . . 1167.3 Noncontact Test Equipment . . . . . . . . . . . . . . . . 1187.3.1 Clamp-on Amp Meters . . . . . . . . . . . . . . 1187.3.2 Static Charge Meter
43、s . . . . . . . . . . . . . . . 1197.3.3 Magnetic Field Detectors. . . . . . . . . . . . . 1197.3.4 Noncontact Proximity Voltage Detectors . . 1197.3.5 Magnetic Field/Current Detectors . . . . . . . 1207.3.6 Circuit and Underground Cable Detectors . 1207.3.7 PhotoTachometers and Stroboscopes . . . .
44、 1207.3.8 Clamp-On Ground Testers . . . . . . . . . . . . 1217.3.9 Infrared Thermometer Guns and Imaging Systems . . . . . . . . . . . . . . . . . . 1217.3.10 Leak Detectors . . . . . . . . . . . . . . . . . . . 1227.4 Simulators/Process Calibrators. . . . . . . . . . . . . . . 1227.5 Jumpers, Switc
45、h Boxes, and Traps . . . . . . . . . . . 1237.6 Documenting Test Equipment and Tests . . . . . . . . 1257.7 Accuracy of Test Equipment . . . . . . . . . . . . . . . . 125Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Mostia2005.book Page x Wednesday, October 12, 2005 1:
46、25 PMTroubleshooting xiQuiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Chapter 8 Troubleshooting Scenarios . . . . . . . . . . . . . . . . . . . . . 1298.1 Mechanical Instrumentation. . . .
47、 . . . . . . . . . . . . . 1298.1.1 Mechanical Field Recorder, EXAMPLE 1 . . 1298.1.2 Mechanical Field Recorder, EXAMPLE 2 . . 1308.1.3 Mechanical Field Recorder, EXAMPLE 3 . . 1308.2 Process Connections . . . . . . . . . . . . . . . . . . . . . 1308.2.1 Pressure Transmitter, EXAMPLE 1 . . . . . . 1
48、308.2.2 Pressure Transmitter, EXAMPLE 2 . . . . . . 1318.2.3 Temperature Transmitter . . . . . . . . . . . . . 1318.2.4 Flow Meter (Orifice Type) . . . . . . . . . . . . 1318.3 Pneumatic Instrumentation . . . . . . . . . . . . . . . . . 1328.3.1 Pneumatic Transmitter, EXAMPLE 1 . . . . . 1328.3.2 Pn
49、eumatic Transmitter, EXAMPLE 2 . . . . . 1328.3.3 Pneumatic Transmitter, EXAMPLE 3 . . . . . 1338.3.4 Pneumatic Transmitter, EXAMPLE 4 . . . . . 1338.3.5 Pneumatic Transmitter, EXAMPLE 5 . . . . . 1348.3.6 I/P (Current/Pneumatic) Transducer. . . . . . 1348.4 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . 1348.4.1 Electronic 4-20 mA Transmitter . . . . . . . . 1348.4.2 Computer-Based Analyzer . . . . . . . . . . . . 1358.4.3 Plant Section Instrument Power Lost. . . . . 1368.4.4 Relay System. . . . . . . . . . . . . . . . . . . . . 1368.5 Electronic Systems. . . . .
