Maintenance of Instruments & Systems, ISA's best-selling maintenance handbook, provides comprehensive coverage of maintenance requirements for pneumatic and electrical/electronic devices as well as expanded coverage of DCS systems, analytical instrumentation, fiber optics and smart instruments. Coverage is organized by device to make finding information quick and easy, making this an excellent reference for both novice and experienced technicians. Maintenance management and engineering, as well as the personnel issues such as skill sets, training and certification/credentialing, are covered in detail.
This Second Edition clarifies the scope, responsibilities and contributions of maintenance personnel. It places a special emphasis on documentation requirements and safety issues, along with updated coverage of newly issued regulations and standards.
Table of Contents:
About the Editor and Contributors xi
Chapter 1 Introduction 1
Overview 1
History of Instrumentation and Control Maintenance 1
Need for Instrumentation and Control Maintenance and Engineering 6
Chapter 2 Fundamental Principles 9
Overview 9
Electronic Field Instrumentation 9
Why Maintain? 10
Maintenance vs. Troubleshooting 19
Calibration and Reasons to Calibrate 20
Troubleshooting 21
Basic Troubleshooting Techniques 22
Designed with Maintenance in Mind 25
Chapter 3 Diagrams, Symbols, and Specifications 31
Overview 31
Process (Piping) & Instrumentation Diagram 31
Instrument Loop Diagrams 32
Logic Diagrams 39
Highway Drawings 49
Specifications 51
Instrument Symbols 54
Instrument Symbols 58
Chapter 4 Maintenance Personnel 73
Overview 73
Multi-Disciplined 74
Continuous Training 74
Training of Maintenance Workers 74
Multicraft/Multiskilled, Multi-Disciplined 78
Knowledge Factors 80
Skills 85
Job Titles and Descriptions 88
Credentialing 91
Certification 94
Chapter 5 Maintenance Management and Engineering 97
Overview 97
The Need for Maintenance Management 98
Maintenance Philosophy 98Maintenance Management Organization 99
Basic Requirements for a
aintenance Department 100
Planning and Scheduling 102
Work Order System 102
MTTF, MTTR, and Availability 104
Training Maintenance Workers 107
Preparing Functional Specifications 109
Computerized Maintenance Management Systems 110
Office/Shop Layout 115
Centralized/Decentralized Shops 118
Chapter 6 Pressure and Flow Instruments 121
Overview 121
Pressure Transmitters 121
Differential Pressure Technology 132
Level Transmitters 138
Flow Transmitters 143
Magnetic Flowmeters 146
Mass Flowmeters 151
Turbine Flowmeters 156
Open Channel Flowmeters 158
Vortex Shedding Flowmeter 161
Vortex Shedding Meters 161
Positive Displacement Flowmeters 162
Positive Displacement Meters 164
Target Flowmeters 164
Thermal Mass Flowmeters 166
Ultrasonic Flowmeters 167Variable Area Flowmeters 168
Insertion (Sampling) Flo
meters 170
Chapter 7 Maintenance Engineering 171
Overview 171
Engineering Assistance 173
Maintenance Involvement in New Projects 174
Successful Maintenance 177
The High Maintenance System 178
Documentation Control 179
Alternative Methods of Maintenance 180
Service/Contract Maintenance 180
In-House Maintenance versus Contract Maintenance 181
New Systems Installations and Checkout 184
Preventive Maintenance 185
Power, Grounding, and Isolation Requirements 186
Instrument Air Requirements 196
Communication Requirements 197
Heating, Ventilating, Cooling, and Air Conditioning Systems 198
Chapter 8 Temperature Devices 201
Overview 201
Thermocouples 206
Resistance Temperature Devices 213
Thermistors 217
Integrated Circuit Temperature Transducer 218
Infrared Temperature Transducers 218
Optical Fiber Thermometry 220
Thermometers 220
Chapter 9 Panel and Transmitting Instruments 233
Overview 233
Panel and Behind-Panel Instruments 233
Panel Meters 241
Discrete Switches 241
Potentiometers 242
Recorders 242
Transducers 242
Smart Transmitters 244
Chapter 10 Analytical Instruments 259
Overview 259
Field Analytical Instrument Systems 259
Field Analytical Instruments 260
Organization 262
Personnel 262
Maintenance Approaches 263
Service Factor 263
Maintenance Work Load 264
Spare Parts 265
Vendor Support 265
Application Unique Issues 265
Installation Issues 266
Chapter 11 Primary Elements and Final Control Devices 267
Overview 267
Temperature 267
Primary Elements 273
Primary Element Location 276
Control Valves 277
Troubleshooting Guide 283
Chapter 12 Pneumatic Instruments 287
Overview 287
Instrument Air Requirements 287
Pneumatic Field Instruments 288
Chapter 13 Calibration 299
Overview 299
Field Calibration 300
Calibrating in Hazardous Locations 313
In-Shop Calibration 324
Other Aspects of Calibration 328
Chapter 14 Tuning 337
Overview 337
Loop Classification by Control Function 337
Control Algorithms 339
Loop Tuning 347
Flow Loops 351
Chapter 15 Distributed Control Systems 353
Overview 353
Distributed Control System Maintenance 353
Maintenance Goals and Objectives 353
Programmable Logic Controllers 368
Chapter 16 Software and Network Maintenance 373
Overview 373
Computer Operating Environment 374
21st Century Maintenance Technology 383
Chapter 17 Safety 389
Overview 389
Electrical Hazards 390
Hazardous Areas 392
Contamination 398
Pressures and Vacuums 399
High Voltage 400
Moving and Rotating Machinery 401
High and Low Temperatures 401
Gases and Chemicals 402
Heights and Confined Spaces 403
Program Changes, Software Control 404
Process Considerations 406
Communication 406
Cryogenic Considerations 406
Nuclear Plants 409
Ergonomics 412
Acknowledgment 413
Standards and Recommended Practices 413
Chapter 18 Fiber Optics 417
Overview 417
Construction 418
Classification 418
Sensing Modes 418
Advantages 419
Disadvantages 419
Applications 420
Analog Input/Output Modules 423
Sensors 423
Appendix A Glossary of Terms 427
Appendix B Bibliography 441
Index 447
About the Author :
Lawrence (Larry) D. Goettsche, Editor of ISA's first (1995) Maintenance of Instruments & Systems, part of ISA's Practical Guides Series, has added considerable new information – and significantly updated other material in the 1995 publication – for this 2nd Edition.
Mr. Goettsche has more than fifty years experience in instrumentation, measurement and automatic controls. Holder of a BS degree from New Hampshire College, he is owner of LG Process Automaton Services. During his career, he has been employed in the following capacities: Electrical and Control Designer for Kennecott Copper Environmental Engineering Projects Group, Electrical & Instrumentation Engineering at Roberts and Schaefer Company, Senior Systems Service Specialist at Johnson Yokogawa Corporation, Maintenance Engineer at Hercules Aerospace, Field Service Engineer at Leeds and Northrup Company, and Training Device Chief Petty Officer in the U.S. Navy.
