course | Fault Diagnosis and Troubleshooting in Control Systems
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ICC-1052 | Fault Diagnosis and Troubleshooting in Control Systems
Course Sector : Instrumentation & Controls
| Duration | Date from | Date to | Course Venue | Course fees | Book a course |
|---|---|---|---|---|---|
| 5 Days | 2025-06-16 | 2025-06-20 | Dubai | $4,250 | Book now |
| 5 Days | 2025-08-11 | 2025-08-15 | Milan | $4,950 | Book now |
| 5 Days | 2025-12-01 | 2025-12-05 | Abu Dhabi | $4,250 | Book now |
| 5 Days | 2025-02-09 | 2025-02-13 | Riyadh | $4,250 | Book now |
Course Introduction
This course teaches a systematic approach to troubleshooting and start-up as they apply to single and multi-loop control loops. Covers how pressure, level, flow, and temperature loops operate to maintain good process control systems. Knowledge of instrumentation and control is assumed.
Course objective
- Understand why a systematic approach to troubleshooting is most effective
- Follow specified procedures for proper loop check-out
- Verify, locate, and identify performance problems and the causes of the problems
- Take or recommend appropriate follow-up procedures to minimize problem recurrence
- Identify the common causes of sensor, transmitter, controller, and final control element problems
- Troubleshoot control systems
- Apply DCS functions for troubleshooting
- Understand pneumatic and electronic loops
- Apply safety practices for start-up
- Check and utilize control loop documentation
- Diagnose and solve problems related to single loop control loops
- Diagnose and solve problems with ratio, cascade and three-element control loops
- Diagnose problems using DCS displays for information
- Construct and tune a feedback control loop
Course Outline | 01 Day One
1: Learning to Troubleshoot
- Experience
- Apprenticeships
- Mentoring
- Classroom Instruction
- Individual Study
- Logic and Logic Development
2: The Basics of Failures.
- Definition of Failure
- How Hardware Fails
- How Software Fails
- Environmental Effects on Failure Rates
- Functional Failures
- Systematic Failures
- Common-cause Failures
- Root-cause Analysis
Course Outline | 02 Day Two
3: Failure States
- Overt and Covert Failures
- Directed Failures
- Directed Failure States
- What Failure States Indicate
4: Logical/Analytical Troubleshooting Frameworks
- Logical/Analytical Troubleshooting Framework
- Specific Troubleshooting Frameworks
- How a Specific Troubleshooting Framework Works
- Generic Logical/Analytical Frameworks
- A Seven-step Procedure
- Examples of How to Use the Seven-step Procedure
- Vendor Assistance Advantages and Pitfalls
- Why Troubleshooting Fails
Course Outline | 03 Day Three
5: Troubleshooting Methods
- Why Use Other Troubleshooting Methods?
- Substitution Method
- Fault Insertion Method
- “Remove and Conquer” Method
- “Circle the Wagons” Method
- Trapping
- Complex to Simple Method
- Consultation
- Intuition
- Out-of-the-Box Thinking
6: Safety
- General Troubleshooting Safety Practices
- Human Error in Industrial Settings
- Plant Hazards Faced During Troubleshooting
- Troubleshooting in Electrically Hazardous (Classified) Areas
- Protection, Procedures, and Permit Systems
Course Outline | 04 Day Four
7: Tools and Test Equipment
- Hand Tools
- Contact-type Test Equipment
- Noncontact Test Equipment
- Simulators/Process Calibrators
- Jumpers, Switch Boxes, and Traps
- Documenting Test Equipment and Tests
- Accuracy of Test Equipment
8: Troubleshooting Scenarios
- Mechanical Instrumentation
- Process Connections
- Pneumatic Instrumentation
- Electrical Systems
- Electronic Systems
- Valves
- Calibration
- Programmable Electronic Systems
- Communication Loops
- Transient Problems
- Software
- Flow Meters
- Level Meters
Course Outline | 05 Day Five
9: Troubleshooting Hints
- Mechanical Systems
- Process Connections
- Pneumatic Systems
- Electronic Systems
- Grounding
- Calibration Systems
- Tools and Test Equipment
- Programmable Electronic Systems
- Serial Communication Links (Loops)
- Safety Instrumented Systems (SIS)
- Critical Instrument Loops
- Electromagnetic Interference
- Valves
- Miscellaneous
10: Aids to Troubleshooting
- Maintainability
- Drawings
- Tagging and Identification
- Equipment Files
- Manuals
- Maintenance Management Systems
- Vendor Technical Assistance
- Direct Vendor Access
- Maintenance Contracts
BOOST’s Professional Attendance Certificate “BPAC”
BPAC is always given to the delegates after completing the training course,and depends on their attendance of the program at a rate of no less than 80%,besides their active participation and engagement during the program sessions.
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