Overview
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
Prerequisites
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.
Objectives
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.
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