Industrial Process Control & Instrumentation / Level Two
Advanced Process Measurement & Control

Course Description

This 32-hour training program uses a hands-on approach providing students an in-depth understanding of industrial process measurement & control systems. Participants will learn to apply more comprehensive measurement and control principles, terminology, symbols and documentation standards. In addition, students will perform hands-on exercises in which they will build, test, tune and troubleshoot temperature, pressure, flow & level control systems.

Topical Outline

  • Application of ISA documentation standards
  • Elements of a Process Control Loop
    - PV-Process Variable
    - MV-Manipulated Variable
    - C-Controller
  • Other Process Measurements
    - Weight
    - pH
    - Density
    - Viscosity
    - Moisture
    - Others
  • Process Dynamics
    - Open Loop Response
    - Process Gain
    - Process Time Constant
    - Process Dead Time
  • Control Methods
    - Open Loop control (Self- regulating)
    - Manual control
    - ON/OFF control
    - Feedback control
    - Feedforward control
    - Cascade control
  • Control Tuning
    - Open vs. Closed loop methods
    - Stability vs. responsiveness
    - ¼ decay ratio
    - Simplex tuning method
    - Zeigler-Nichols tuning method
    - Auto-tuning
  • Special Cases
    - pH control
    - Nonlinear systems
  • Control Valve Selection & Sizing
    - Valve types (Globe, Ball, Butterfly & Gate)
    - Valve Characteristic (Quick opening, Linear, Equal Percentage)
    - Other Control Valve Topics (Positioners, Materials, Configuration, Actuators & Accessories)
  • Installation Best Practices
    - Wiring
    - Shielding
    - Isolation
  • Control System Troubleshooting
    - Experience Based
    - Trial & Error


PCI-100: Understanding Industrial Process Control/Level One Process Measurement & Control Fundamentals or a fundamental understanding of industrial process measurement, control system design and operation.

Course Length

36 hours




Persons successfully completing this course will be able to:

  • Create the documents used to define instruments and control systems.
  • Apply the principles, equipment and techniques for the primary industrial process measurements of temperature, pressure, level and flow.
  • Understand process response and how it affects controller operation.
  • Know and apply the proper controller tuning method.
  • Select and size the proper control valve.
  • Build, test, operate tune and troubleshoot a variable feedback control loop.