Fault Diagnosis for Process Manufacturing
Process manufacturing runs on pumps, valves, instrumentation and interlocked control systems where a single failed actuator or drifted instrument can stop a batch or take a process off spec. Wiresight helps process engineers diagnose these faults in a structured, repeatable way and capture the reasoning so instrumentation and control knowledge is retained.
Common equipment
- Pumps
- Motors
- Valves
- Instrumentation
- Sensors
- PLCs
- Control systems
- Conveyors
- Drives
- Interlocks
Common maintenance challenges
- Continuous processes where a stop affects the whole batch
- Instrumentation drift and calibration-related faults
- Interlock and permissive reliability
- Valve actuator and positioner failures
- Coordinating process, control and electrical causes
Common fault types
- Pump cavitation and seal failure
- Valve actuator and positioner faults
- Instrument drift and sensor fouling
- PLC analog input/output faults
- Drive trips and overload
- Interlock and permissive trips
Example diagnostic scenario: "Dosing pump stops unexpectedly"
- 1Is the safety/interlock circuit healthy and the permissive present?
- 2Does the PLC command the pump to run (output present)?
- 3Is the drive/contactor healthy and the motor receiving supply?
- 4Is the motor itself healthy and not overloaded?
- 5Are the relevant instruments (flow, level, pressure) reading sensibly?
- 6Is there a process cause — cavitation, blocked line or empty supply?
An illustrative diagnostic structure — not a substitute for site procedures or competent engineering.
How Wiresight helps
Wiresight gives process engineers structured procedures for instrumentation and control faults, log each resolution, and use captured history to surface previous occurrences — so a recurring dosing-pump stop comes with documented causes.
Relationship with your CMMS
Your CMMS holds the asset and work order; Wiresight adds the diagnostic path from instrument or interlock to cause, so process faults become traceable knowledge.
Engineering knowledge capture
Instrumentation knowledge often lives with a few engineers. Wiresight captures it as templates and history so the whole maintenance function can diagnose control and instrument faults consistently.