This document provides a history of instrumentation and control maintenance from the 1930s to the present. It describes how maintenance evolved from pipe fitters maintaining early pneumatic systems to the development of specialized instrumentation and control technicians. With advances in technology, the required skills of maintenance personnel expanded to include electronics, computers, and various control systems. Modern plants utilize modular design, contract maintenance, and skeleton crews enabled by advanced automation. Distributed control systems are now standard, and maintenance focuses on ensuring production and preserving capital assets through effective management practices.
Installation Operation & Maintenance of 33kV & 11kV SwitchgearSheikh Nazmul Islam
In-Country Training On Operation, Maintenance, Protection & Control of 33/11 kV Substation Project Name: Design, Supply, Installation, Testing & Commissioning of 33/11 kV sub-stations with source end feeder bays. Contract No: BREB/UREDS/W-01A-001/02/2016-2017 BREB/UREDS/W-01A-002/03/2016-2017 BREB/UREDS/W-01A-004/04/2016-2017
LEAP is a unique Maintenance Tool for the
Stator Winding Insulation of Electric
Machines.
LEAP provides information on Machine
winding and expected life, and will optimize
the Machine Maintenance Plans
Isolation Procedures for Safe Working on Electrical Systems and Equipment by the JIB | solation Procedures for Safe Working on Electrical Systems and Equipment
This chart shows the safe isolation procedure that you should use when working on electrical systems and equipment.
You'll receive a printed copy of this from your Training Provider, but it's also here as a handy reference to keep electronically.
THE RULES OF SAFE ISOLATION ARE:
Obtain permission to start work (a Permit may be required in some situations)
Identify the source(s) of supply using an approved voltage indicator or test lamp
Prove that the approved voltage indicator or test lamp is functioning correctly
Isolate the supply(s)
Secure the isolation
Prove the system/equipment is DEAD using an approved voltage indicator or test lamp
Prove that the approved voltage indicator or test lamp is functioning correctly
Put up warning signs to tell other people that the electrical installation has been isolated
Once the system/equipment is proved DEAD, work can begin
Uploaded by THORNE & DERRICK LV HV Jointing, Earthing, Substation & Electrical Eqpt | Explosive Atmosphere Experts & ATEX IECEx.
Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with machine breakdowns. As one of the key pillars of the TPM Excellence framework, the goal of Planned Maintenance is to have trouble-free equipment that produce defect-free products.
Planned Maintenance achieves and sustains availability of machines at an optimum maintenance cost, reduces spares inventory, and improves reliability and maintainability of machines.
In this presentation developed by our JIPM-certified TPM Instructor, you will learn how to plan and organize the Plan Maintenance activities to strengthen the capabilities of your Maintenance department. It clarifies the roles of the Operations and Maintenance departments in supporting the TPM initiative and provides step-by-step guidance on the implementation of the Planned Maintenance pillar.
LEARNING OBJECTIVES
1. Understand what is Planned Maintenance and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Planned Maintenance activities
3. Describe the seven implementation steps of Planned Maintenance
4. Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance
CONTENTS
1. Introduction to Planned Maintenance
2. What is Planned Maintenance?
3. Planning & Organizing for Planned Maintenance
4. The 7 Steps of Planned Maintenance
5. JIPM TPM Excellence Criteria for Planned Maintenance
To download this complete presentation, goto:
https://www.oeconsulting.com.sg/training-presentations
Hello Everyone!
This is the best ppt on 'Industrial Maintenance' that you can ever find. I tried to include all the topics related to the maintenance of industry. These notes will also be helpful from university exam point of view. Go through the whole ppt and leave a feedback in the comment box. Learn and Enjoy!
Thank You!
Installation Operation & Maintenance of 33kV & 11kV SwitchgearSheikh Nazmul Islam
In-Country Training On Operation, Maintenance, Protection & Control of 33/11 kV Substation Project Name: Design, Supply, Installation, Testing & Commissioning of 33/11 kV sub-stations with source end feeder bays. Contract No: BREB/UREDS/W-01A-001/02/2016-2017 BREB/UREDS/W-01A-002/03/2016-2017 BREB/UREDS/W-01A-004/04/2016-2017
LEAP is a unique Maintenance Tool for the
Stator Winding Insulation of Electric
Machines.
LEAP provides information on Machine
winding and expected life, and will optimize
the Machine Maintenance Plans
Isolation Procedures for Safe Working on Electrical Systems and Equipment by the JIB | solation Procedures for Safe Working on Electrical Systems and Equipment
This chart shows the safe isolation procedure that you should use when working on electrical systems and equipment.
You'll receive a printed copy of this from your Training Provider, but it's also here as a handy reference to keep electronically.
THE RULES OF SAFE ISOLATION ARE:
Obtain permission to start work (a Permit may be required in some situations)
Identify the source(s) of supply using an approved voltage indicator or test lamp
Prove that the approved voltage indicator or test lamp is functioning correctly
Isolate the supply(s)
Secure the isolation
Prove the system/equipment is DEAD using an approved voltage indicator or test lamp
Prove that the approved voltage indicator or test lamp is functioning correctly
Put up warning signs to tell other people that the electrical installation has been isolated
Once the system/equipment is proved DEAD, work can begin
Uploaded by THORNE & DERRICK LV HV Jointing, Earthing, Substation & Electrical Eqpt | Explosive Atmosphere Experts & ATEX IECEx.
Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with machine breakdowns. As one of the key pillars of the TPM Excellence framework, the goal of Planned Maintenance is to have trouble-free equipment that produce defect-free products.
Planned Maintenance achieves and sustains availability of machines at an optimum maintenance cost, reduces spares inventory, and improves reliability and maintainability of machines.
In this presentation developed by our JIPM-certified TPM Instructor, you will learn how to plan and organize the Plan Maintenance activities to strengthen the capabilities of your Maintenance department. It clarifies the roles of the Operations and Maintenance departments in supporting the TPM initiative and provides step-by-step guidance on the implementation of the Planned Maintenance pillar.
LEARNING OBJECTIVES
1. Understand what is Planned Maintenance and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Planned Maintenance activities
3. Describe the seven implementation steps of Planned Maintenance
4. Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance
CONTENTS
1. Introduction to Planned Maintenance
2. What is Planned Maintenance?
3. Planning & Organizing for Planned Maintenance
4. The 7 Steps of Planned Maintenance
5. JIPM TPM Excellence Criteria for Planned Maintenance
To download this complete presentation, goto:
https://www.oeconsulting.com.sg/training-presentations
Hello Everyone!
This is the best ppt on 'Industrial Maintenance' that you can ever find. I tried to include all the topics related to the maintenance of industry. These notes will also be helpful from university exam point of view. Go through the whole ppt and leave a feedback in the comment box. Learn and Enjoy!
Thank You!
Auditing of critical parameter:- HVAC(heating, ventilation and air conditioning system) 2021; In these presentation includes the requirement of HVAC, Auditing of HVAC components, technical analysis of HVAC components, WHO-GMP audis of HVAC then
Rogert william statement on HVAC, working of HVAC systems and their components Core function of HVAC, Market trends and market analysis of HVAC, WHO guidelines on HVAC system.
Control Loop Foundation - Batch And Continous ProcessesEmerson Exchange
This presentation, by Emerson's Terry Blevins and Mark Nixon, is a guide for engineers, managers, technicians, and others that are new to process control or experienced control engineers who are unfamiliar with multi-loop control techniques.
Their book is available in the ISA Bookstore at: http://emrsn.co/1E
Application of PLC’s for Automation of Processes in IndustriesIJERA Editor
Several industries utilize sequential industrial process which is respective in nature. For such processes
industries have to depend upon use of relays, stepping drum, timers and controls, considerable difficulties
experienced in reprogramming necessitated due to change in the nature of production. Often the whole system
has to be scrapped and a redesigning is required. To overcome these problems PLC control system was
introduced. The PLC can be described as a control ladder comprising a sequence program. PLC sequence
program consists of normally open and normally closed contacts connected in parallel or in series. It also has
relay coils, which turns ON and OFF as the state of these contacts change. In this paper, about all aspects of
these powerful and versatile tools and its applications to process automation has been discussed.
An optimal general type-2 fuzzy controller for Urban Traffic NetworkISA Interchange
Urban traffic network model is illustrated by state-charts and object-diagram. However, they have limitations to show the behavioral perspective of the traffic information flow. Consequently, a state space model is used to calculate the half-value waiting time of vehicles. In this study, a combination of the general type-2 fuzzy logic sets and the modified backtracking search algorithm (MBSA) techniques are used in order to control the traffic signal scheduling and phase succession so as to guarantee a smooth flow of traffic with the least wait times and average queue length. The parameters of input and output membership functions are optimized simultaneously by the novel heuristic algorithm MBSA. A comparison is made between the achieved results with those of optimal and conventional type-1 fuzzy logic controllers.
Embedded intelligent adaptive PI controller for an electromechanical systemISA Interchange
In this study, an intelligent adaptive controller approach using the interval type-2 fuzzy neural network (IT2FNN) is presented. The proposed controller consists of a lower level proportional - integral (PI) controller, which is the main controller and an upper level IT2FNN which tuning on-line the parameters of a PI controller. The proposed adaptive PI controller based on IT2FNN (API-IT2FNN) is implemented practically using the Arduino DUE kit for controlling the speed of a nonlinear DC motor-generator system. The parameters of the IT2FNN are tuned on-line using back-propagation algorithm. The Lyapunov theorem is used to derive the stability and convergence of the IT2FNN. The obtained experimental results, which are compared with other controllers, demonstrate that the proposed API-IT2FNN is able to improve the system response over a wide range of system uncertainties.
State of charge estimation of lithium-ion batteries using fractional order sl...ISA Interchange
This paper presents a state of charge (SOC) estimation method based on fractional order sliding mode observer (SMO) for lithium-ion batteries. A fractional order RC equivalent circuit model (FORCECM) is firstly constructed to describe the charging and discharging dynamic characteristics of the battery. Then, based on the differential equations of the FORCECM, fractional order SMOs for SOC, polarization voltage and terminal voltage estimation are designed. After that, convergence of the proposed observers is analyzed by Lyapunov’s stability theory method. The framework of the designed observer system is simple and easy to implement. The SMOs can overcome the uncertainties of parameters, modeling and measurement errors, and present good robustness. Simulation results show that the presented estima- tion method is effective, and the designed observers have good performance.
Fractional order PID for tracking control of a parallel robotic manipulator t...ISA Interchange
This paper presents the tracking control for a robotic manipulator type delta employing fractional order PID controllers with computed torque control strategy. It is contrasted with an integer order PID controller with computed torque control strategy. The mechanical structure, kinematics and dynamic models of the delta robot are descripted. A SOLIDWORKS/MSC-ADAMS/MATLAB co-simulation model of the delta robot is built and employed for the stages of identification, design, and validation of control strategies. Identification of the dynamic model of the robot is performed using the least squares algorithm. A linearized model of the robotic system is obtained employing the computed torque control strategy resulting in a decoupled double integrating system. From the linearized model of the delta robot, fractional order PID and integer order PID controllers are designed, analyzing the dynamical behavior for many evaluation trajectories. Controllers robustness is evaluated against external disturbances employing performance indexes for the joint and spatial error, applied torque in the joints and trajectory tracking. Results show that fractional order PID with the computed torque control strategy has a robust performance and active disturbance rejection when it is applied to parallel robotic manipulators on tracking tasks.
Fuzzy logic for plant-wide control of biological wastewater treatment process...ISA Interchange
The application of control strategies is increasingly used in wastewater treatment plants with the aim of improving effluent quality and reducing operating costs. Due to concerns about the progressive growth of greenhouse gas emissions (GHG), these are also currently being evaluated in wastewater treatment plants. The present article proposes a fuzzy controller for plant-wide control of the biological wastewater treatment process. Its design is based on 14 inputs and 6 outputs in order to reduce GHG emissions, nutrient concentration in the effluent and operational costs. The article explains and shows the effect of each one of the inputs and outputs of the fuzzy controller, as well as the relationship between them. Benchmark Simulation Model no 2 Gas is used for testing the proposed control strategy. The results of simulation results show that the fuzzy controller is able to reduce GHG emissions while improving, at the same time, the common criteria of effluent quality and operational costs.
Design and implementation of a control structure for quality products in a cr...ISA Interchange
In recent years, interest for petrochemical processes has been increasing, especially in refinement area. However, the high variability in the dynamic characteristics present in the atmospheric distillation column poses a challenge to obtain quality products. To improve distillates quality in spite of the changes in the input crude oil composition, this paper details a new design of a control strategy in a conventional crude oil distillation plant defined using formal interaction analysis tools. The process dynamic and its control are simulated on Aspen HYSYS dynamic environment under real operating conditions. The simulation results are compared against a typical control strategy commonly used in crude oil atmospheric distillation columns.
Model based PI power system stabilizer design for damping low frequency oscil...ISA Interchange
This paper explores a two-level control strategy by blending a local controller with a centralized controller for the low frequency oscillations in a power system. The proposed control scheme provides stabilization of local modes using a local controller and minimizes the effect of inter-connection of sub-systems performance through a centralized control. For designing the local controllers in the form of proportional-integral power system stabilizer (PI-PSS), a simple and straight forward frequency domain direct synthesis method is considered that works on use of a suitable reference model which is based on the desired requirements. Several examples both on one machine infinite bus and multi-machine systems taken from the literature are illustrated to show the efficacy of the proposed PI-PSS. The effective damping of the systems is found to be increased remarkably which is reflected in the time-responses; even unstable operation has been stabilized with improved damping after applying the proposed controller. The proposed controllers give remarkable improvement in damping the oscillations in all the illustrations considered here and as for example, the value of damping factor has been increased from 0.0217 to 0.666 in Example 1. The simulation results obtained by the proposed control strategy are favorably compared with some controllers prevalent in the literature.
A comparison of a novel robust decentralized control strategy and MPC for ind...ISA Interchange
Abstract: In this work we have developed a novel, robust practical control structure to regulate an industrial methanol distillation column. This proposed control scheme is based on a override control framework and can manage a non-key trace ethanol product impurity specification while maintaining high product recovery. For comparison purposes, an MPC with a discrete process model (based on step tests) was also developed and tested. The results from process disturbance testing shows that, both the MPC and the proposed controller were capable of maintaining both the trace level ethanol specification in the distillate (XD) and high product recovery (β). Closer analysis revealed that the MPC controller has a tighter XD control, while the proposed controller was tighter in β control. The tight XD control allowed the MPC to operate at a higher XD set point (closer to the 10 ppm AA grade methanol standard), allowing for savings in energy usage. Despite the energy savings of the MPC, the proposed control scheme has lower installation and running costs. An economic analysis revealed a multitude of other external economic and plant design factors, that should be considered when making a decision between the two controllers. In general, we found relatively high energy costs favor MPC.
Fault detection of feed water treatment process using PCA-WD with parameter o...ISA Interchange
Feed water treatment process (FWTP) is an essential part of utility boilers; and fault detection is expected for its reliability improvement. Classical principal component analysis (PCA) has been applied to FWTPs in our previous work; however, the noises of T2 and SPE statistics result in false detections and missed detections. In this paper, Wavelet denoise (WD) is combined with PCA to form a new algorithm, (PCA- WD), where WD is intentionally employed to deal with the noises. The parameter selection of PCA-WD is further formulated as an optimization problem; and PSO is employed for optimization solution. A FWTP, sustaining two 1000 MW generation units in a coal-fired power plant, is taken as a study case. Its operation data is collected for following verification study. The results show that the optimized WD is effective to restrain the noises of T2 and SPE statistics, so as to improve the performance of PCA-WD algorithm. And, the parameter optimization enables PCA-WD to get its optimal parameters in an auto- matic way rather than on individual experience. The optimized PCA-WD is further compared with classical PCA and sliding window PCA (SWPCA), in terms of four cases as bias fault, drift fault, broken line fault and normal condition, respectively. The advantages of the optimized PCA-WD, against classical PCA and SWPCA, is finally convinced with the results.
Model-based adaptive sliding mode control of the subcritical boiler-turbine s...ISA Interchange
As higher requirements are proposed for the load regulation and efficiency enhancement, the control performance of boiler-turbine systems has become much more important. In this paper, a novel robust control approach is proposed to improve the coordinated control performance for subcritical boiler-turbine units. To capture the key features of the boiler-turbine system, a nonlinear control-oriented model is established and validated with the history operation data of a 300 MW unit. To achieve system linearization and decoupling, an adaptive feedback linearization strategy is proposed, which could asymptotically eliminate the linearization error caused by the model uncertainties. Based on the linearized boiler-turbine system, a second-order sliding mode controller is designed with the super-twisting algorithm. Moreover, the closed-loop system is proved robustly stable with respect to uncertainties and disturbances. Simulation results are presented to illustrate the effectiveness of the proposed control scheme, which achieves excellent tracking performance, strong robustness and chattering reduction.
A Proportional Integral Estimator-Based Clock Synchronization Protocol for Wi...ISA Interchange
Clock synchronization is an issue of vital importance in applications of wireless sensor networks (WSNs). This paper proposes a proportional integral estimator-based protocol (EBP) to achieve clock synchronization for wireless sensor networks. As each local clock skew gradually drifts, synchronization accuracy will decline over time. Compared with existing consensus-based approaches, the proposed synchronization protocol improves synchronization accuracy under time-varying clock skews. Moreover, by restricting synchronization error of clock skew into a relative small quantity, it could reduce periodic re-synchronization frequencies. At last, a pseudo-synchronous implementation for skew compensation is introduced as synchronous protocol is unrealistic in practice. Numerical simulations are shown to illustrate the performance of the proposed protocol.
An artificial intelligence based improved classification of two-phase flow patte...ISA Interchange
Flow pattern recognition is necessary to select design equations for finding operating details of the process and to perform computational simulations. Visual image processing can be used to automate the interpretation of patterns in two-phase flow. In this paper, an attempt has been made to improve the classification accuracy of the flow pattern of gas/ liquid two- phase flow using fuzzy logic and Support Vector Machine (SVM) with Principal Component Analysis (PCA). The videos of six different types of flow patterns namely, annular flow, bubble flow, churn flow, plug flow, slug flow and stratified flow are re- corded for a period and converted to 2D images for processing. The textural and shape features extracted using image processing are applied as inputs to various classification schemes namely fuzzy logic, SVM and SVM with PCA in order to identify the type of flow pattern. The results obtained are compared and it is observed that SVM with features reduced using PCA gives the better classification accuracy and computationally less intensive than other two existing schemes. This study results cover industrial application needs including oil and gas and any other gas-liquid two-phase flows.
New Method for Tuning PID Controllers Using a Symmetric Send-On-Delta Samplin...ISA Interchange
In this paper we present a new method for tuning PI controllers with symmetric send-on-delta (SSOD) sampling strategy. First we analyze the conditions that produce oscillations in event based systems considering SSOD sampling strategy. The Describing Function is the tool used to address the problem. Once the conditions for oscillations are established, a new robustness to oscillation performance measure is introduced which entails with the concept of phase margin, one of the most traditional measures of relative stability in closed-loop control systems. Therefore, the application of the proposed robustness measure is easy and intuitive. The method is tested by both simulations and experiments. Additionally, a Java application has been developed to aid in the design according to the results presented in the paper.
Load estimator-based hybrid controller design for two-interleaved boost conve...ISA Interchange
This paper is devoted to the development of a hybrid controller for a two-interleaved boost converter dedicated to renewable energy and automotive applications. The control requirements, resumed in fast transient and low input current ripple, are formulated as a problem of fast stabilization of a predefined optimal limit cycle, and solved using hybrid automaton formalism. In addition, a real time estimation of the load is developed using an algebraic approach for online adjustment of the hybrid controller. Mathematical proofs are provided with simulations to illustrate the effectiveness and the robustness of the proposed controller despite different disturbances. Furthermore, a fuel cell system supplying a resistive load through a two-interleaved boost converter is also highlighted.
Effects of Wireless Packet Loss in Industrial Process Control SystemsISA Interchange
Timely and reliable sensing and actuation control are essential in networked control. This depends on not only the precision/quality of the sensors and actuators used but also on how well the communications links between the field instruments and the controller have been designed. Wireless networking offers simple deployment, reconfigurability, scalability, and reduced operational expenditure, and is easier to upgrade than wired solutions. However, the adoption of wireless networking has been slow in industrial process control due to the stochastic and less than 100% reliable nature of wireless communications and lack of a model to evaluate the effects of such communications imperfections on the overall control performance. In this paper, we study how control performance is affected by wireless link quality, which in turn is adversely affected by severe propagation loss in harsh industrial environments, co-channel interference, and unintended interference from other devices. We select the Tennessee Eastman Challenge Model (TE) for our study. A decentralized process control system, first proposed by N. Ricker, is adopted that employs 41 sensors and 12 actuators to manage the production process in the TE plant. We consider the scenario where wireless links are used to periodically transmit essential sensor measurement data, such as pressure, temperature and chemical composition to the controller as well as control commands to manipulate the actuators according to predetermined setpoints. We consider two models for packet loss in the wireless links, namely, an independent and identically distributed (IID) packet loss model and the two-state Gilbert-Elliot (GE) channel model. While the former is a random loss model, the latter can model bursty losses. With each channel model, the performance of the simulated decentralized controller using wireless links is compared with the one using wired links providing instant and 100% reliable communications. The sensitivity of the controller to the burstiness of packet loss is also characterized in different process stages. The performance results indicate that wireless links with redundant bandwidth reservation can meet the requirements of the TE process model under normal operational conditions. When disturbances are introduced in the TE plant model, wireless packet loss during transitions between process stages need further protection in severely impaired links. Techniques such as re-transmission scheduling, multi-path routing and enhanced physical layer design are discussed and the latest industrial wireless protocols are compared.
Fault Detection in the Distillation Column ProcessISA Interchange
Chemical plants are complex large-scale systems which need designing robust fault detection schemes to ensure high product quality, reliability and safety under different operating conditions. The present paper is concerned with a feasibility study of the application of the black-box modeling method and Kullback Leibler divergence (KLD) to the fault detection in a distillation column process. A Nonlinear Auto-Regressive Moving Average with eXogenous input (NARMAX) polynomial model is firstly developed to estimate the nonlinear behavior of the plant. Furthermore, the KLD is applied to detect abnormal modes. The proposed FD method is implemented and validated experimentally using realistic faults of a distillation plant of laboratory scale. The experimental results clearly demonstrate the fact that proposed method is effective and gives early alarm to operators.
Neural Network-Based Actuator Fault Diagnosis for a Non-Linear Multi-Tank SystemISA Interchange
The paper is devoted to the problem of the robust actuator fault diagnosis of the dynamic non-linear systems. In the proposed method, it is assumed that the diagnosed system can be modelled by the recurrent neural network, which can be transformed into the linear parameter varying form. Such a system description allows developing the designing scheme of the robust unknown input observer within H1 framework for a class of non-linear systems. The proposed approach is designed in such a way that a prescribed disturbance attenuation level is achieved with respect to the actuator fault estimation error, while guaranteeing the convergence of the observer. The application of the robust unknown input observer enables actuator fault estimation, which allows applying the developed approach to the fault tolerant control tasks.
A KPI-based process monitoring and fault detection framework for large-scale ...ISA Interchange
Large-scale processes, consisting of multiple interconnected sub-processes, are commonly encountered in industrial systems, whose performance needs to be determined. A common approach to this problem is to use a key performance indicator (KPI)-based approach. However, the different KPI-based approaches are not developed with a coherent and consistent framework. Thus, this paper proposes a framework for KPI-based process monitoring and fault detection (PM-FD) for large-scale industrial processes, which considers the static and dynamic relationships between process and KPI variables. For the static case, a least squares-based approach is developed that provides an explicit link with least-squares regression, which gives better performance than partial least squares. For the dynamic case, using the kernel re- presentation of each sub-process, an instrument variable is used to reduce the dynamic case to the static case. This framework is applied to the TE benchmark process and the hot strip mill rolling process. The results show that the proposed method can detect faults better than previous methods.
An adaptive PID like controller using mix locally recurrent neural network fo...ISA Interchange
Being complex, non-linear and coupled system, the robotic manipulator cannot be effectively controlled using classical proportional integral derivative (PID) controller. To enhance the effectiveness of the conventional PID controller for the nonlinear and uncertain systems, gains of the PID controller should be conservatively tuned and should adapt to the process parameter variations. In this work, a mix locally recurrent neural network (MLRNN) architecture is investigated to mimic a conventional PID controller which consists of at most three hidden nodes which act as proportional, integral and derivative node. The gains of the mix locally recurrent neural network based PID (MLRNNPID) controller scheme are initi- alized with a newly developed cuckoo search algorithm (CSA) based optimization method rather than assuming randomly. A sequential learning based least square algorithm is then investigated for the on- line adaptation of the gains of MLRNNPID controller. The performance of the proposed controller scheme is tested against the plant parameters uncertainties and external disturbances for both links of the two link robotic manipulator with variable payload (TL-RMWVP). The stability of the proposed controller is analyzed using Lyapunov stability criteria. A performance comparison is carried out among MLRNNPID controller, CSA optimized NNPID (OPTNNPID) controller and CSA optimized conventional PID (OPTPID) controller in order to establish the effectiveness of the MLRNNPID controller.
A method to remove chattering alarms using median filtersISA Interchange
Chattering alarms are the most found nuisance alarms that will probably reduce the usability and result in a confidence crisis of alarm systems for industrial plants. This paper addresses the chattering alarm reduction using median filters. Two rules are formulated to design the window size of median filters. If the alarm probability is estimated using process data, one rule is based on the probability of alarms to satisfy some requirements on the false alarm rate, or missed alarm rate. If there are only historical alarm data available, the other rule is based on percentage reduction of chattering alarms using alarm duration distribution. Experimental results for industrial cases testify that the proposed method is effective.
PHP Frameworks: I want to break free (IPC Berlin 2024)Ralf Eggert
In this presentation, we examine the challenges and limitations of relying too heavily on PHP frameworks in web development. We discuss the history of PHP and its frameworks to understand how this dependence has evolved. The focus will be on providing concrete tips and strategies to reduce reliance on these frameworks, based on real-world examples and practical considerations. The goal is to equip developers with the skills and knowledge to create more flexible and future-proof web applications. We'll explore the importance of maintaining autonomy in a rapidly changing tech landscape and how to make informed decisions in PHP development.
This talk is aimed at encouraging a more independent approach to using PHP frameworks, moving towards a more flexible and future-proof approach to PHP development.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
A tale of scale & speed: How the US Navy is enabling software delivery from l...sonjaschweigert1
Rapid and secure feature delivery is a goal across every application team and every branch of the DoD. The Navy’s DevSecOps platform, Party Barge, has achieved:
- Reduction in onboarding time from 5 weeks to 1 day
- Improved developer experience and productivity through actionable findings and reduction of false positives
- Maintenance of superior security standards and inherent policy enforcement with Authorization to Operate (ATO)
Development teams can ship efficiently and ensure applications are cyber ready for Navy Authorizing Officials (AOs). In this webinar, Sigma Defense and Anchore will give attendees a look behind the scenes and demo secure pipeline automation and security artifacts that speed up application ATO and time to production.
We will cover:
- How to remove silos in DevSecOps
- How to build efficient development pipeline roles and component templates
- How to deliver security artifacts that matter for ATO’s (SBOMs, vulnerability reports, and policy evidence)
- How to streamline operations with automated policy checks on container images
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
DevOps and Testing slides at DASA ConnectKari Kakkonen
My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
Generative AI Deep Dive: Advancing from Proof of Concept to ProductionAggregage
Join Maher Hanafi, VP of Engineering at Betterworks, in this new session where he'll share a practical framework to transform Gen AI prototypes into impactful products! He'll delve into the complexities of data collection and management, model selection and optimization, and ensuring security, scalability, and responsible use.
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using Deplo...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
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Encryption in Microsoft 365 - ExpertsLive Netherlands 2024
Maintenance of Instruments & Systems (free chapter download)
1. Maintenance of
Instruments & Systems
2nd Edition
Lawrence D. Goettsche, Editor
Practical Guides
for Measurement and Control
2. v
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
3. Table of Contents
vi
Chapter 5 Maintenance Management and Engineering 97
Overview 97
The Need for Maintenance Management 98
Maintenance Philosophy 98
Maintenance Management Organization 99
Basic Requirements for a Maintenance 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 167
Variable Area Flowmeters 168
Insertion (Sampling) Flowmeters 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
4. Table of Contents
vii
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
5. Table of Contents
viii
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
6. Table of Contents
ix
Disadvantages 419
Applications 420
Analog Input/Output Modules 423
Sensors 423
Appendix A Glossary of Terms 427
Appendix B Bibliography 441
Index 447
7. 1
1
Introduction
Overview
The Maintenance volume is key to the Practical Guides Series and certainly a
key to the profitability of companies through ensuring that the control system is
maintained so the plant can produce its products. This volume includes some his-
tory and speculates about future advances of instrumentation and control (I&C)
system maintenance; it also covers some of the fundamental principles, vocabu-
lary, symbolism, standards, and safety. It suggests the necessary basic knowledge
required of I&C technicians and the interaction of maintenance in the retrofitting
and start-up of control systems.
History of Instrumentation and Control Maintenance
From pneumatic instrumentation to computer-controlled systems — what a
change! Is a seasoned instrument mechanic expected to troubleshoot a state-of-
the-art computer-controlled system? Should a new instrument technician be ex-
pected to maintain pneumatic instrumentation? This volume documents expe-
riences in the older types of systems as well as in the newer, state-of-the-art
systems.
1930s
Distributed control is not new. In 1938, when Chemical Processing published
its first issue, mechanisms for control were indeed distributed throughout the
plant. Process control consisted of operator adjustments to hand valves that were
based on direct readings of local gages. Control room instrumentation has taken
some dramatic turns along the way — from large-scale pneumatic recorders to
miniature analog electronic controllers to microprocessor-based digital systems.
Chemical and petroleum plants were among the first to use control systems
for their processes. Pneumatic instrumentation became the leader in automatic
control because of its safety. Pipe fitters were asked to perform maintenance on
these early pneumatic instruments. In many cases, outmoded control room hard-
ware is still operating effectively today — a tribute to the worldwide manufactur-
ers of process control instrumentation.
In the late 1930s and early 1940s, operators relied on local instrument gages
to monitor production processes. Control panels that did exist were located in the
field near process sensing points. Typically, only a handful of indicators, record-
ers, and controllers were mounted on a local panel. Often, the process fluids were
piped directly into control panels.
Where fill fluids were needed, mercury was commonly used. Control panels
served as a convenient means for improving control coordination by allowing op-
erators to adjust valves in response to visual instrument readings.
8. Introduction
2
1940s
In the 1940s the use of pneumatic proportional controllers was increasing, so
the early pipe fitters had to understand more of the theory of process and control.
New words such as integral, derivative, sensors, and final control elements were
added to their vocabularies.
By the late 1940s, a trend toward the concentration of controls in centralized
locations had begun.
1950s
In the 1950s, operating unit control rooms were built to centralize operations
and to accommodate operators assigned to monitor control boards on a full-time
basis. With the growing number and complexity of the indicators, recorders, and
controllers and the “need” to operate the plant remotely from these panels, the in-
strument mechanic was specialized to maintain the pneumatic control systems.
By the mid 1950s, electronic analog instrumentation had been formally intro-
duced but did not win industry acceptance until the late 1950s and early 1960s.
With the exception of chemical and petroleum plants, most new plants used elec-
tronic analog instrumentation because of the greater cost of tubing work between
pneumatic transmitters and controllers and the expensive pneumatic auxiliaries,
such as air compressors, filters, and dryers.
Increasing plant complexity necessitated increasing amounts of accurate, up-to-
date operating information.
Now the instrument mechanic needed to know electronics and electricity in
addition to pneumatics. Larger plants formed Electrical and Instrument (E&I), In-
strument and Electronic (I&E), or Electrical and Control (E&C) groups; some
formed an Instrument and Control (I&C) Group and had both instrument mechan-
ics and instrument technicians. The knowledge required by I&C mechanics and
technicians meant training was necessary, so vendors provided training on the
equipment they sold.
1960s
Digital computers began to appear in control rooms in the 1960s. The com-
puter’s initial role was essentially that of a data logging device from which paper
printouts could be obtained. However, the concept of direct digital control (DDC)
gained notoriety in the 1960s.
1970s
By the mid 1970s, the drawbacks to DDC had become apparent. The central
computer approach depended on the availability of a single large computer.
Highly trained computer personnel were needed to maintain the computer hard-
ware and to deal with the high-level software languages.
Single-loop analog control continued to flourish during the early 1970s.
Thousands of electronic signal wires crisscrossed central control rooms, adding
complexity to the pursuit of improved coordination. Recognizing multiple func-
tions inherent in panel instruments, split architecture systems were introduced.
Analog display stations were segregated from rack-mounted printed circuit cards
in the quest for functional modularity.
I&C groups flourished, everyone was retrofitting and updating plants, and
new plants provided more and more instrumentation requirements. Instrumenta-
tion vendors were training the instrument mechanics and electricians to maintain
their equipment.
9. History of Instrumentation and Control Maintenance
3
Standards for instrumentation were being developed, and manufacturers
started listening to ISA when developing their new instruments.
A marriage between single-loop electronic analog control and pneumatic con-
trol developed because of the need for powerful control valve actuators.
The simplicity and accuracy of electronic controllers, recorders, and indicators
made them the choice for instrument panels.
Current-to-pneumatic converters and pneumatic-to-current converters linked
electronic instruments to pneumatic instruments and sensors and actuators. Chem-
ical plants used pneumatic instruments in the hazardous areas along with signal
wires to transmit the signals to central control rooms in safe areas.
Most plants built after the mid 1970s used electronic rather than pneumatic in-
strumentation. Pneumatic valves, however, are still used almost exclusively for
throttling control and even on-off control. About the same time in this period
Honeywell® and Yokogawa® introduced the first distributed digital control sys-
tems (DDCS), now called the distributed control system (DCS). Multiple mini-
computers, geographically and functionally distributed, performed monitoring
and control tasks that had been previously handled by the central DDC computer.
Each microprocessor-based controller was shared by up to eight control loops. Se-
rial bit communication over coaxial cable linked individual system devices.
As these distributed control systems became the standard for newer chemical
and petroleum plants and the older single-loop pneumatic and electronic control-
lers were replaced, the I&C groups were trained on the new DCS. This was the
first introduction of computers to the I&C technicians, and DCS manufacturers
designed their systems to be configured and maintained by I&C groups — not
highly trained computer personnel. As a technological breakthrough, the micro-
processor accelerated advances in control system design. At the operator interface
level, distributed control contributed to an unforeseen development. For the first
time, CRT display consoles gained acceptance as the primary operator interface,
and conventional single-loop analog stations were reduced to an emergency
backup role at many early distributed control system installation sites. Long,
floor-to-ceiling panelboards were replaced with low-profile CRT workstation
consoles. Keyboards, CRTs and printers served as modern tools for seated control
room operators.
By the end of the 1970s, control system innovations had advanced beyond in-
dustry’s capacity to keep pace. Most plant sites contained an assortment of control
technologies that spanned three decades. Instrumentation and control specialists
(mechanics, technicians, and engineers) were commonplace in industry. Special
I&C groups were established, as shown in the organizational chart of Figure 1-1.
1980s
DCS operator interfaces were refined in the 1980s (see Figure 1-2). Intelligent
CRT stations utilized multiple-display formats to condense and organize exten-
sive operating information. Hierarchical arrangements of plant-, area-, group-, and
loop-level displays simplified on-screen database presentation. Real-time color
graphics added further comprehensive overviews of unit operations.
Most microprocessor-based control systems had a vast array of alarms and di-
agnostics to help operators and maintenance personnel determine if there were
any problems. Distributed control systems had many on-line and off-line diagnos-
tics, including process and input alarms, reportable events, error messages, and
hardware and software failure reporting.
10. Introduction
4
1990s
Trends for the 1990s were computer-integrated manufacturing (CIM) and
management information systems (MIS). These interfaced the real-time devices
(field devices at the machinery/process level) through distributed controllers to
multiple-station coordination, then on to scheduling, production, and management
information to the plant level for overall planning, execution, and control. Further
development of artificial intelligence and expert systems gave advanced control
new meaning.
With the introduction of computers and databases, maintenance management
systems (MMS) helped maintenance and management personnel determine repair
frequency and spare parts availability and made decisions on when to replace ob-
solete equipment.
Distributed control systems (DCS), programmable logic controllers (PLC),
computer control systems (CCS), supervisory control and data acquisition
(SCADA) and smart field devices were the norm. A digital signal was superim-
posed on the 4-20 mA signal for ranging and calibrating field devices. The Interna-
tional Organization for Standardization (ISO) Open Systems Interconnection (OSI)
model and interconnection of devices made by different manufactures has opened
systems architecture, replacing proprietary communications among devices.
2000s
Historically, factory floor maintenance methods and practices have been de-
veloped across a wide range of vertical industries, where the focus was to keep the
assembly lines and processes running rather than preserving assets. Today, manu-
facturers are focused on the long-term benefits of factory floor support practices
Figure 1-1. Typical 1970s I & C Group Organization Chart.
PROCESS
ENGINEERING
FACILITY
ENGINEERING
MECHANICAL ELECTRICALSTORES
MILLWRIGHTWAREHOUSE
PIPEFITTERSHIP/REC
LABORERSBUYERS
SHIFT 2I&C
SHIFT 3ELECTRONICS
OPERATORS
SHIFT 1ELECTRICAL PROCESSMECHANICAL
CHEMICALELECTRICAL
QUALITYI&C
OPERATIONS
MANAGER
XYZ COMPANY
11. History of Instrumentation and Control Maintenance
5
that incorporate methods and procedures which ensure production lines are opera-
tional and preserve capital assets.
Skids and modular systems became the norm in the design of new plants. New
gas electrical generating plants have been built from start to operational within a
two year period. These plants are designed to be operated with a skeleton crew of
25 to 30 personnel, including operators, maintenance crew, and supervisors.
A crew of three operate and maintain in 12 hour shifts. Major overhaul peri-
ods are contracted to the system manufacturer, and contract maintenance is re-
sponsible for calibration. Knowledge of the complete plant, including operations
and systems, are learned by all crews and supervision. Each crew member special-
izes in two or three systems.
A newer gas fired electrical generating plant organization chart is shown in
Figure 1-3 which differentiates between maintenance and production. Because
modern automation systems are installed, three units can be maintained and oper-
ated with 30 employees. Old coal-fired plants needed up to 200 people to operate
them.
With the concept of skeleton crews to operate the plant, contractor type main-
tenance programs are becoming the norm. Many of the instrumentation tasks are
completed by contract personnel. Work in the plant is becoming multi-disciplined.
Figure 1-2. Multiple-Display Distributed Control System.
12. Introduction
6
Need for Instrumentation and Control Maintenance
and Engineering
“Maintenance of instrumentation and process control systems from simple
gages to complex distributed control systems is essential for the continuation of
our industry.” Statements such as this have been repeated thousands of times by
company presidents, manufacturing directors, and production superintendents.
Maintenance personnel should be involved with new installations and upgrad-
ing older installations. They should ensure that the system is ergonomically easy
to repair and well documented. Training should be done before a new system ar-
rives so the maintenance department can help in installing and checking it out.
Equipment manufacturers provide engineering and start-up assistance. So the
majority of the new opportunities to work in the I&C field is through original
equipment manufacturers or service contract employees.
Because of the equipment’s complexity, assistance is needed from the original
equipment manufacturer. Configuration of control systems and instruments
should be done by those very familiar with the system requirements and system/
instrument capabilities.
Instrumentation tells us the process parameters in which we are operating. A
simple gage tells the temperature or pressure; the more complex instrumentation
Figure 1-3. Typical Gas Fired Electrical Generating Plant Organization Chart.
PskdjkjdidP
MAINTENANCE
MANAGER
PLANT
ENGINEER
PRODUCTION
MANAGER
ENVIRONMENTAL
AND HEALTH
(CHEMIST)
WELDER
ELECTRICIAN
I&C
MACHINIST
(M-F 8 hrs)
SHIFT
SUPERVISORS
WATER/LAB TECH.
AUX. OPERATOR
(Outside)
CONTROL
OPERATOR
12 hr shift
Rotating 24/7
PLANT
MANAGER
13. Need for Instrumentation and Control Maintenance and Engineering
7
tells much more about the process. Proper operation of all equipment is required
to make a quality product and to do it safely.
The technological advances of the past few years and the trends for more
technical and specialized equipment require better trained and educated mainte-
nance personnel. The types of equipment in control systems cover many disci-
plines: mechanical, electrical, electronic, computer science, chemical, and
environmental, among others.
The instrumentation and control field is more than electronics — it is a systems
experience. It is necessary to know the physics of heat, light, noise, and mechani-
cal advantage, as well as to have mechanical dexterity and aptitude, logical
thought, computer literacy, process knowledge, and the ability to work with others in dif-
ferent disciplines.
Because of the many different knowledge factors, the individual crafts (elec-
trician, mechanic, pipe fitter, etc.) have to work together, and finger pointing will
sometimes occur. Electrical engineers, mechanical engineers, chemical engineers,
and process engineers must understand each other and determine where their re-
sponsibilities start and stop.
The field has grown with the application of computers, artificial intelligence,
self-tuning, computer-integrated manufacturing (CIM), and so on. Larger
companies train pipe fitters to be instrument mechanics in pneumatic plants and
electricians to be instrument technicians in electronic plants. Knowledge of the
process is needed to design new systems; therefore, all engineering disciplines get
involved with the instrumentation and control system. Those who were fortunate
to get involved in early instrumentation and control systems have become the I&C
maintenance personnel and the control systems engineers of today.
The complexity of control loops and systems requires specialists. The systems
concept requires more varied knowledge and the overall concept of control rather
than component troubleshooting and replacement.
When the control system doesn't work, the plant doesn't produce. The control
system design can determine the profitability of a company. If it is maintainable
and the mechanics, technicians, and engineers are trained, the production output
of the plant will be high.
Corrective, preventive, and operational maintenance must be performed by
qualified and experienced I&C maintenance personnel.
Because of the complexity of existing control systems that utilize many fields
of expertise, several maintenance backgrounds are also required. This group is
now required to maintain, troubleshoot, and calibrate pneumatic, electrical, elec-
tronic, and computerized instruments and systems. The systems approach, which
looks at the whole picture to gain an understanding of the process, is the special
attribute of I&C maintenance personnel.
When assistance is needed, I&C personnel must have someone to go to for
help. In the past, maintenance supervisors had a broad knowledge of most of the
equipment and could make decisions on how to repair, when to repair, and so on.
A few years ago, many supervisors were instrument mechanics, but contemporary
maintenance supervisors are managers who know very little about the operation
and maintenance of the wide variety of instruments and control systems used to-
day, since most have never been instrument mechanics or technicians. In fact,
many of them know very little about pneumatics, electronics, or computers. To-
day, knowledge of the process, knowledge of the overall system, and knowledge
of the expertise of their employees is far more important than knowledge of how
to repair an individual instrument.
Who should the maintenance supervisors and managers go to for expert ad-
vice on the control system? Instrumentation and control system engineers or
maintenance engineers with an I&C background. Instrumentation and control sys-
tem engineers assist the mechanics and technicians and keep the supervisors and
14. Introduction
8
managers informed. They need to be a part of the design and start-up of the con-
trol systems.
Much money is being spent for training, fault tolerant systems, redundancy,
and new techniques. One simple but essential area that may be neglected is the ex-
perience of the past and what that may teach about the present.
We learn from our past experiences. Being involved in the problems we en-
countered and the solutions that were found yesterday helps us make better deci-
sions today. The learning technology that produces greater retention levels uses
the most senses, such as hearing, seeing, and feeling. The applications of older
systems should be used as the basis for designing newer and generally faster con-
trol systems. New problems are encountered in newer systems, but past applica-
tion experience will help solve the new problems.
Don’t neglect the knowledge
and experience gained in the
past.
Good maintenance saves money. With the equipment working properly, the
process quality and production will be high. When equipment fails, production
normally stops, and many production personnel cannot do their jobs. With good
maintenance management, spare parts are available quickly to reduce the mean
time to repair (MTTR). When the equipment is repaired properly, the mean time
between failures (MTBF) is extended. The proper frequencies of preventive main-
tenance should provide less down time, and the down time that occurs can be
scheduled. We can become pro-active instead of reactive.