Introduction:
This advanced course provides comprehensive coverage of industrial process control methodologies and the corresponding instrumentation employed in typical process plants. It delves into various sensors, elucidating their working principles, specifications, design considerations, and selection criteria for measuring diverse process parameters. The course also enhances participants’ understanding of control loop components, control strategies, and the fundamentals of PID controllers, encompassing terminology, algorithms, and tuning methods. Real-life implementations, case studies, and adherence to international standards are given significant emphasis to enable participants to bridge the gap between theory and practical application in their daily work. Additionally, a concise introduction to multivariable control is included to enhance participants’ exposure to complex control systems. While primarily designed for engineers, this course also offers substantial value for operators, technicians, and supervisors.
Course Objectives:
At the end of this training, participants will be able to:
- Specify and design instrumentation systems for pressure, level, temperature, and flow.
- Understand the objectives of industrial process control
- Know the Process Control Dynamics and Transfer Functions
- Understand Open and Closed Loop Control
- Understand sensor fundamentals
- Learn various sensors used for measurement of process parameters such as temperature, flow, pressure, level, etc. covering the principle of operation, specifications, etc.
- Have knowledge on Transmitters and Intelligent Instrumentation
- Understand the working of Control Loop Components
- Gain knowledge on PID control strategy and its real-life implementation
- Know the art of PID controller tuning
- Identify a large number of industrial analytical measuring instruments.
- Describe the construction and operation of the most important analytical instruments.
- Be able to conduct the following types of measurement; pH, conductivity, turbidity, hygrometry, dissolved oxygen, total free chlorine, and on-line chromatography.
- Implement procedures for testing and calibration of analytical instruments.
- Correctly select and size control valves for any particular application.
- Troubleshoot and identify problems with instrumentation systems.
- Isolate control loops and identify a faulty instrument
Who Should Attend?
- Professionals involved in designing, selecting, sizing, specifying, installing, testing, operating and maintaining systems.
- Professionals, Technologists, Supervisory personnel, Senior Engineers engaged in the refinery operation and oil production/exploration activities, who have a considerable experience and who are required to understand and discuss issues related to their processes.
- Instrument Maintenance: Supervisors, Engineers and DCS/PLC Technicians.
- Process and Process Control Engineering, Technologists, Supervisory personnel, Senior Engineers.
- Geologists and Reservoir Engineering: Supervisors, Engineers.
- Oil and Gas Operation (Upstream/Downstream): Filed/Control Room Operators, Supervisors, Engineers.
- Mechanical, Rotating and Maintenance Planning: Supervisors, Engineers, Team Leaders and Managers.
- Laboratory Service: Technologists, Supervisory personnel, Senior Technologists.
- Health, Safety and Environment (HSE): Supervisors, Engineers, Team Leaders and Managers.
- Project Management: Supervisors, Engineers.
- Commercial, Financial and Insurance Management: Controllers, Senior Engineers engaged in the refinery operation and oil production/exploration activities.
- Business, sales, technical, and scientific personnel with limited or no broad refinery operating and oil production/exploration experience, along with technical sales personnel.
Course Outlines:
Background and Evolution of Process Control/ Automation
- Basic Concepts – Open /Close loop
- Concepts of Industrial Process Control
- Need for Automatic Process Control
- Process Control Dynamics and Transfer Functions
- Sensors and Transducer and its Characteristics
Principle of working
- Temperature Measurement
- Pressure Measurement
- Flow Measurement
- Level Measurement
- Position Sensing
- Process Parameter Switches: Pressure, Level, Flow, and
- Temperature Switches
- Feedback Control Block Diagram and Concepts
- Standard Signals, SMART Transmitter
- I to P Converter, Control Valves, Actuators and Positioner
Specifications
- Process Characteristics, Lags in Control loop
- Controllers and Control Actions: ON-OFF, Proportional,
- Integral, Derivative
- PID Controllers: Algorithms, forms, terminology, selection
- Microprocessor-based Controllers
- Tuning of Controllers
- Transforming process operating information into Controller
- Tuning
Merits and limitations
- Process Control Schematics
- Multivariable Control
- Application of Multi-Variable Control
- Cascade Control, Ratio Control
- Selective Control, Feedforward Control
Selection criteria
- Model-based Control
- Advanced Process Control Concepts
- Model Predictive Control
- Fuzzy Logic Control
- Neural Network Control