Quick Reference and Calculation Manual for Instrument Maintenance

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"Instrument Maintenance Quick Reference and Quick Calculation Manual" Table of Contents Chapter 1 Basic Knowledge 0011.1 Measurement Knowledge 0011.1.1 International System of Units 0011.1.2 Engineering Notation and International System Unit Conversion 0031.1.3 Relevant Knowledge of Instrument Errors 0041.1.4 Quality Indicators and Calculation of Instruments 0061.2 Basics of Electrical and Electronic Technology 0071.2.1 Definition and calculation of commonly used circuits 0071.2.2 The most basic operational amplifier circuit 0121.2.3 Related calculations of instrument power supply (with instrument gas consumption) 0151.3 Basics of instrument maintenance 0171.3.1 General instrument scale conversion formula and calculation 0171.3.2 Instrument fault inspection and judgment method 0191.3.3 Sequence and operation points of instrument maintenance 0211.3.4 Commonly used English abbreviations for instrument automatic control 023 References 029 Chapter 2 Graphical symbols of electrical and process measurement and control instruments 0302.1 Commonly used electrical graphical symbols and text codes 0302.2 Graphical symbols and text codes of commonly used process measurement and control instruments 0352.2.1 Instrument loop number and instrument tag number 0352.2.2 Reading of measured variable/initiating variable and instrument function symbol letter combination 0392.2.3 Common English abbreviations and application examples of instruments 0412.2.4 Common text codes for instrument design 0432.2.5 Graphical symbols and application examples of instrument equipment and functions 0462.2.6 Common graphic symbols for primary measuring components and transmitters of instruments 0462.2.7 Measurement annotation symbols and their meanings 0472.2.8 Graphical symbols for primary measuring components and application examples 0482.2.9 Graphical symbols for local instruments 0502.2.10 Graphic symbols for auxiliary instrument equipment and ancillary instrument equipment 0512.2.11 Graphic symbols for connection lines between instruments and processes 0522.2.12 Graphic symbols for connection lines between instruments and instruments 0522.2.13 Graphic symbols for actuators and valve bodies (final control components) 0542.2.14 Graphic symbols for signal processing functions 0562.2.15 Binary logic graphic symbols 0582.3 Application examples of instrument graphic symbols 063 References 065 Chapter 3 Temperature measuring instruments 0663.1 Conversion of temperature scale 0663.2 Thermocouple 0663.2.1 Basic characteristics of commonly used thermocouples 0663.2.2 Compensation of thermocouple reference end temperature and compensation wire 0693.2.3 Error calculation formula and calculation example of calibration thermocouple 0713.2.4 Common faults and treatments of thermocouples 0743.3 Thermal resistors 0763.3.1 Characteristics of commonly used thermal resistors 0763.3.2 Resistance-temperature relationship of thermal resistors 0773.3.3 Thermal resistor lead methods, measurement circuits and connecting cable laying parameters 0773.3.4 Error calculation formulas and calculation examples of calibrated thermal resistors 0793.3.5 Common faults and treatments of thermal resistors 0813.4 Estimation of temperature sensor protection tube and insertion depth 0823.5 Temperature transmitter 0833.5.1 Calculation formula for measurement error of calibrated temperature transmitter 0833.5.2 Wiring of temperature transmitter 0843.5.3 Maintenance and troubleshooting of temperature transmitter 087 References 089 Chapter 4 Flow measurement instrument 0904.1 Conversion table of commonly used units for flow measurement 0904.2 Common physical parameter calculation formulas for flow measurement 0934.2.1 Fluid density calculation formula 0934.2.2 Fluid viscosity calculation formula 0964.2.3 Gas isentropic index calculation formula 0974.3 Related calculations of pipelines and pipeline flows 0974.3.1 Linear expansion coefficients of some fluids, throttling parts and commonly used materials in pipelines 0974.3.2 Pipeline fluid mechanics knowledge 0994.3.3 Relevant tables and calculation formulas for Reynolds number and flow rate 0994.4 Characteristics of flow meters and conversion of measured values 1014.5 Differential pressure flow meter 1034.5.1 Some parameters of differential pressure flow meter 1034.5.2 Signal conversion calculation of differential pressure transmitter and flow transmitter 1044.5.3 Installation and technical requirements of differential pressure flow meter 1074.5.4 Calculation and calculation example of throttling device 1124.5.5 Calculation of pressure loss and energy consumption of throttling device 1174.5.6 Correction calculation of differential pressure flow meter display value 1184.6 Float (rotor) flow meter 1204.6.1 Scale, range conversion and calculation example of float flow meter 1214.6.2 Common faults and solutions of float flow meter 1254.7 Electromagnetic flowmeter 1254.7.1 Electromagnetic flowmeter installation points 1254.7.2 Inspection and treatment of common faults of electromagnetic flowmeter 1264.8 Mass flow meter 1294.8.1 Mass flowmeter installation points 1294.8.2 Related calculations of thermal mass flowmeter 1294.8.3 Common faults and treatment of mass flowmeter 1304.9 Vortex flowmeter 1344.9.1 Key points for installation of vortex flowmeter 1344.9.2 Measurement range, related calculations and calculation examples of vortex flowmeter 1354.9.3 Correction calculation of instrument coefficient of vortex flowmeter 1364.9.4 Troubleshooting and treatment of vortex flowmeter 1374.10 Turbine flowmeter 1384.10.1 Requirements for upstream and downstream straight pipe sections of turbine flowmeter 1384.10.2 Relevant calculations and calculation examples of turbine flow meters 1384.10.3 Common faults and solutions of turbine flow meters 1414.11 Ultrasonic flow meters 1414.11.1 Key points for installing ultrasonic flow meters 1414.11.2 Common faults and solutions of ultrasonic flow meters 1424.12 Positive displacement flow meters 1444.12.1 Calculation formulas of positive displacement flow meters 1444.12.2 Common faults and solutions of positive displacement flow meters 1444.13 Calculation formulas of other flow meters 145 References 146 Chapter 5 Pressure and differential pressure measuring instruments 1475.1 Related charts and calculations of pressure and pressure gauges 1475.1.1 Definition of pressure and its relationship and pressure unit conversion 1475.1.2 Allowable errors and calculations of pressure gauges 1495.1.3 The influence and calculation of ambient temperature of spring tube pressure gauge 1505.1.4 Common information on pressure instrument maintenance 1525.2 Pressure instrument with switch signal output 1545.2.1 Calibration of electric contact pressure gauge with multimeter 1545.2.2 Allowable error and adjustment of set point deviation and switching difference of electric contact pressure gauge 1555.2.3 Allowable value and adjustment of set point deviation and repetition error of pressure controller 1565.2.4 Common faults and solutions of pressure controllers 1575.3 Conversion calculation of pressure transmitter engineering quantity and output signal 1585.4 Range range, range, range ratio and allowable error of pressure and differential pressure transmitters 1595.4.1 Range range, range and range ratio of pressure and differential pressure transmitters 1595.4.2 Permissible errors and calculation of pressure and differential pressure transmitters 1595.5 Use and installation of pressure and differential pressure transmitters 1625.5.1 Corrosion resistance reference table of commonly used materials for pressure and differential pressure transmitters 1625.5.2 Relationship between power supply and load resistance of pressure and differential pressure transmitters 1655.5.3 Estimation of transmitter signal loop resistance and cable length 1665.6 Common faults and solutions of pressure and differential pressure transmitters 1675.6.1 Fault inspection and treatment of differential pressure transmitter 1675.6.2 3051 Partial fault information of the transmitter 1695.6.3 Partial fault information of EJA/EJX series transmitter 1705.6.4 HART handheld communication failure and processing method 172 References 172 Chapter 6 Liquid level measuring instrument 1746.1 Pressure level gauge 1746.1.1 Calculation formulas for commonly used pressure level gauges 1746.1.2 Zero point migration of differential pressure transmitter 1756.1.3 Zero point migration calculation of liquid level transmitter 1756.1.4 Differential pressure transmitter measurement interface 1776.1.5 Calculation of liquid level measurement by double flange differential pressure transmitter 1786.1.6 Common faults and solutions of double flange differential pressure transmitter 1806.1.7 Calculation of industrial boiler water level measured by differential pressure transmitter 1806.2 Float level gauge 1816.2.1 Calculation formula and calculation and adjustment steps of water calibration method 1826.2.2 Calculation formula and calculation and adjustment steps of hanging weight method 1846.2.3 Common faults and treatment of float level gauge 1876.2.4 FST-3000 float level gauge fault code and treatment 1886.3 Float level gauge 1896.3.1 The relationship between float level measuring range and ball rod length 1896.3.2 Common faults and solutions of float level gauge 1906.4 Inspection and treatment of common faults of magnetic flap level gauge 1916.5 Inspection and treatment of common faults of magnetostrictive level gauge 1926.6 Inspection and treatment of common faults of radar level gauge 193 References 195 Chapter 7 Regulating valves and valve positioners 1967.1 Calculation and selection of regulating valves 1967.1.1 Flow coefficient of regulating valves 1967.1.2　* * Standard regulating valve flow coefficient calculation formula and calculation examples 1967.1.3 Expansion coefficient method to calculate the regulating valve flow coefficient formula and calculation examples 2047.1.4 Empirical formula method to calculate the regulating valve flow coefficient formula and calculation examples 2067.1.5 Average gravity method to calculate the regulating valve flow coefficient formula and calculation examples 2077.1.6 Control valve flow characteristics and selection 2097.1.7 Caliber selection and calculation examples of regulating valves 2127.1.8 Selection of regulating valves 2157.1.9 Leakage and calculation of regulating valves 2187.2 Pneumatic regulating valves 2197.2.1 Relevant parameters of pneumatic actuators and unbalanced force (moment) of some regulating valves Calculation formula 2197.2.2 Selection of air opening and air closing forms of regulating valves 2217.2.3 The influence of valve flow direction on working performance and selection 2227.2.4 Fault inspection and treatment of pneumatic control valve 2237.3 Valve positioner 2267.3.1 SVP series valve positioner fault code and treatment 2267.3.2 SIPART PS2 valve positioner common faults and treatment 2277.3.3 TZID-C valve positioner debugging, fault code and treatment 2287.3.4 3730-3 Valve positioner error code and processing 2307.3.5 HVP12 valve positioner automatic detection and fault code 2327.3.6 DVC6200 valve positioner fault and processing 2337.3.7 SVI Ⅱ valve positioner self-tuning and fault processing 2347.3.8 YT-2000/3000 series valve positioner error and warning codes and processing 2357.3.9 Test of insulation resistance of electric valve positioner 2357.4 Electric control valve 2367.4.1 On-site inspection and debugging of electric actuator 2367.4.2 Common faults and treatment of electric control valve 2377.4.3 Rotork IQ3 electric actuator alarm and diagnostic status display 2417.4.4 Sichuan Instrument M8000 series electric actuator alarm and fault code 2427.4.5 DREHMO -i matic Intelligent integrated electric actuator alarm and fault code 2437.5 Solenoid valve 2477.5.1 Graphical symbol of solenoid valve and identification of main air port and control mechanism 2477.5.2 Calculation of the maximum length of solenoid valve 24V power supply line wire 2497.5.3 Combination of solenoid valve and control valve 2507.5.4 Application examples of solenoid valve under different interlock control requirements 2507.5.5 Redundant configuration of double solenoid valves 251 References 253 Chapter 8 Process Control System 2548.1 PID control knowledge 2548.1.1 PID control principle block diagram and algorithm expression 2548.1.2 Definition and calculation of proportionality, integral time, and differential time 2548.1.3 Quality indicators of the control process 2598.2 Characteristics of five common control systems and selection of control parameters 2608.2.1 Characteristics of five types of common control systems 2608.2.2 Parameter selection range of common control systems 2618.2.3 Selection of positive and negative effects of controllers in single-loop control systems 2618.3 Parameter tuning of PID controller 2628.3.1 Basics of controller parameter tuning 2628.3.2 Empirical tuning method 2648.3.3 Critical proportional method (stable boundary method) 2658.3.4 Decay curve method (attenuated oscillation method) 2668.3.5 Reaction curve method (open-loop response curve method, dynamic characteristic parameter method, ZN method) 2688.3.6 Self-tuning of PID parameters 2718.3.7 Simple control system fault inspection, judgment and processing 2718.4 Complex control system 2728.4.1 Cascade control system control rules and modes of action 2728.4.2 Parameter tuning of cascade control system controller 2748.4.3 Parameter tuning of uniform control system controller 2758.4.4 Structure of ratio control system and ratio calculation 2768.4.5 Split-range combination and calculation of split-range control system 2798.4.6 Selective control system and parameter tuning 2808.4.7 Multi-impulse control system and parameter tuning 2818.4.8 Comparison of partial control systems 283 References 283 Chapter 9 Distributed Control System (DCS) and Programmable Controller (PLC) 2849.1 Numerical system, coding and calculation 2849.2 Numerical representation of PLC analog module 2859.3 Conversion calculation of linear engineering quantities, analog quantities, and digital quantities 2879.4 Some data needed in the installation and maintenance of DCS and PLC 2899.5 Common calculation formulas for DCS configuration 2919.5.1 Calculation of the average value of two out of three analog quantities 2919.5.2 DCS temperature and pressure compensation module for common flow measurement and correction formula 2939.5.3 ECS system temperature and pressure compensation module for flow measurement and calculation formula 2949.5.4 MACS system temperature and pressure compensation module for flow measurement, calculation formula and configuration example 2969.5.5 TPS system flow measurement temperature and pressure compensation module and calculation formula 2989.5.6 CS3000 Temperature and pressure compensation module, calculation formula and configuration example for system flow measurement 2999.6 DCS debugging, maintenance and troubleshooting 3009.6.1 PID related parameters of DCS controller 3009.6.2 DCS debugging, maintenance and fault inspection and judgment methods 3019.6.3 CS3000 system FCS indicator status indication 3069.6.4 JX-300XP System control station related card status indicators and their meanings 3079.6.5 MACS system AI/AO card, DI/DO card, main control unit status indication instructions 3079.6.6 TPS system related card status indication instructions 3089.6.7 PKS system related card status indication instructions 3119.6.8 PKS system common fault inspection and processing 3139.6.9 Delta V Diagnosis and troubleshooting of system hardware and software 3149.7 PLC debugging and fault inspection and judgment methods 3219.7.1 PLC on-site debugging steps and fault judgment methods 3219.7.2 Fault in status judgment of LED lights on S7-300 series PLC 3259.7.3 Fault in status judgment of LED lights on S7-400 series PLC 3279.7.4 CPU unit LED of Omron PLC Indicator light status description 329 References 331 Chapter 10 Safety and explosion protection 33210.1 Basic logic operations 33210.2 Positive logic and negative logic 33310.3 Logical expression symbols 33410.4 Safety instrument related information 33610.4.1 Safety level and interlocking system performance requirements 33610.4.2 Safety instrument settings 33610.4.3 Various redundancy methods and structural failure status judgment 33810.4.4 Common English abbreviations for safety instruments 33910.5 Safety instrument functional testing 34010.6 Explosion-proof related information 34110.6.1 Explosion-proof types and their standard systems commonly used in the world 34110.6.2 Ambient temperature and surface temperature 34210.6.3 Explosion-proof types and explosion-proof signs of electrical equipment 34210.6.4 Combination of intrinsically safe instruments and safety barriers 34410.6.5 Calculation of the maximum laying length of instrument control cables and intrinsically safe cables 346 References 348