ISA Training for Instruments Maintenance and Control

Overview:

Introduction:

This class focuses on the knowledge and skill-sets required to function as an instrument maintenance technician. The electrical skill-sets possessed by a trained electrician will serve as a basis for expansion to include the skill-set required to maintain an instrument control system. Process measurement techniques, measurement, and control equipment, calibrations techniques, and calibration equipment will be discussed and utilized in numerous hands-on lab sessions. The knowledge and skill-sets gained from attending this class will lead the student to become an asset to an I&E maintenance team.

Course Objectives:

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

• Introduce students to instrument documentation for proper document interpretation
• Review physics terminology and definitions, math functions, and engineering unit assignments as used in the instrumentation field
• Introduce instrument calibration equipment and its proper utilization
• Discuss process control and measurement fundamentals and related equipment
• Discuss analog/digital transmission signals
• Relay proper use of HART communicators
• Discuss process control valve elements, makeup, and function
• Provide proper calibration techniques for transmitters and control valves
• Practice loop wiring connections, calibrations, equipment configurations/operations
• Discuss instrument troubleshooting techniques
• Discuss process control fundamentals

Targeted Audience:

• Electricians assigned the additional responsibilities of instrument maintenance
• Technicians with electrical skills cross-training into the instrument discipline
• Supervisors needing to audit/ evaluate a cross-training program for their employees

Course Outlines:

Unit 1: Fundamental Principles:

• Electronic Field Instrumentation
• Why Maintain?
• Maintenance vs. Troubleshooting
• Calibration and Reasons to Calibrate
• Troubleshooting
• Basic Troubleshooting Techniques
• Designed with Maintenance in Mind

Unit 2: Diagrams, Symbols, and Specifications:

• Process (Piping) & Instrumentation Diagram
• Instrument Loop Diagrams
• Logic Diagrams
• Highway Drawings
• Specifications
• Instrument Symbols

Unit 3: Maintenance Personnel:

• Multi-Disciplined
• Continuous Training
• Training of Maintenance Workers
• Multicraft/Multiskilled, Multi-Disciplined
• Knowledge Factors
• Skills
• Job Titles and Descriptions
• Credentialing
• Certification
• Table of Contents

Unit 4: Maintenance Management and Engineering:

• The Need for Maintenance Management
• Maintenance Philosophy
• Maintenance Management Organization
• Basic Requirements for a Maintenance Department
• Planning and Scheduling
• Work Order System
• MTTF, MTTR, and Availability
• Training Maintenance Workers
• Preparing Functional Specifications
• Computerized Maintenance Management Systems
• Office/Shop Layout
• Centralized/Decentralized Shops

Unit 5: Pressure and Flow Instruments:

• Pressure Transmitters
• Differential Pressure Technology
• Level Transmitters
• Flow Transmitters
• Magnetic Flowmeters
• Mass Flowmeters
• Turbine Flowmeters
• Open Channel Flowmeters
• Vortex Shedding Flowmeter
• Vortex Shedding Meters
• Positive Displacement Flowmeters
• Positive Displacement Meters
• Target Flowmeters
• Thermal Mass Flowmeters
• Ultrasonic Flowmeters
• Variable Area Flowmeters
• Insertion (Sampling) Flowmeters

Unit 6: Maintenance Engineering:

• Engineering Assistance
• Maintenance Involvement in New Projects
• Successful Maintenance
• The High Maintenance System
• Documentation Control
• Alternative Methods of Maintenance
• Service/Contract Maintenance
• In-House Maintenance versus Contract Maintenance
• New Systems Installations and Checkout
• Preventive Maintenance
• Power, Grounding, and Isolation Requirements
• Instrument Air Requirements
• Communication Requirements
• Heating, Ventilating, Cooling, and Air Conditioning Systems

Unit 7: Temperature Devices:

• Thermocouples
• Resistance Temperature Devices
• Thermistors
• Integrated Circuit Temperature Transducer
• Infrared Temperature Transducers
• Optical Fiber Thermometry
• Thermometers

Unit 8: Panel and Transmitting Instruments:

• Panel and Behind-Panel Instruments
• Panel Meters
• Discrete Switches
• Potentiometers
• Recorders
• Transducers
• Smart Transmitters

Unit 9: Analytical Instruments:

• Field Analytical Instrument Systems
• Field Analytical Instruments
• Organization
• Personnel
• Maintenance Approaches
• Service Factor
• Maintenance Work Load
• Spare Parts
• Vendor Support
• Application Unique Issues
• Installation Issues

Unit 8: Primary Elements and Final Control Devices:

• Temperature
• Primary Elements
• Primary Element Location
• Control Valves
• Troubleshooting Guide

Unit 9: Pneumatic Instruments:

• Instrument Air Requirements
• Pneumatic Field Instruments

Unit 10: Calibration:

• Field Calibration
• Calibrating in Hazardous Locations
• In-Shop Calibration
• Other Aspects of Calibration

Unit 11: Tuning:

• Loop Classification by Control Function
• Control Algorithms
• Loop Tuning
• Flow Loops

Unit 12: Distributed Control Systems:

• Distributed Control System Maintenance
• Maintenance Goals and Objectives
• Programmable Logic Controllers

Unit 13: Software and Network Maintenance:

• Computer Operating Environment
• 21st Century Maintenance Technology

Unit 14: Safety:

• Electrical Hazards
• Hazardous Areas
• Contamination
• Pressures and Vacuums
• High Voltage
• Moving and Rotating Machinery
• High and Low Temperatures
• Gases and Chemicals
• Heights and Confined Spaces
• Program Changes, Software Control
• Process Considerations
• Communication
• Cryogenic Considerations
• Nuclear Plants
• Ergonomics
• Acknowledgment
• Standards and Recommended Practices

Unit 15: Fiber Optics:

• Construction
• Classification
• Sensing Modes
• Advantages
• Disadvantages
• Applications
• Analog Input/Output Modules
• Sensors