Session 1 – Introduction to Process Control
Importance of Process Control, Purpose of Management, Types of Displays, Process Signals, Analog Data Representation, Signal Operating Values, Signal Measurement Error, Response Time, Measurement System Deterioration, Controller Output, Transmitters, Proportionality, Pneumatic Signal Transmission, Electrical Signal Transmission, Current Pneumatic Systems, Transmission of Other Signals, Typical Control Lamps
Session 2 – Process Control Fundamentals
Industrial Process Requirements, Systems Response, On-Off Control Systems, Proportional Control, Typical Level Control Loop, Reset and Derivative, Control Loops, Cascade Control System, Tuning a Control Loop, Ratio Control Loop, Typical Industrial Loop, Transmitter Communication, Analog Signal Conditioning, Analog Signal Converters, Conversion from Analog to Digital, Digital Indicators and Recorders, Microprocessor-Based Recorders, A Complete Control System
Session 3 – PID Control Part I
Control Loops, Terminology of Control Loops, Sensor Characteristics, Controllers, Recorders, Signal Conditioners, Final Control Elements, Control Modes Classification, Digital Control Systems, Supervisory Control, Direct Digital Control (DDC), Distributed Control Systems (DCS)
Session 4 – PID Control Part II
Advanced Control, Ratio Control System, Cascade Control System, Loop Dynamics, Effects of Process Time Lag, Higher-Order Delay Lags, System Stability and Transient Response, Stability and Controller Turning, Gain and Phase Shift
Session 5 – Temperature Measurement and Control
Operation of Resistant Thermometers, Wheatstone Bridge Circuits, Lead-Wire Errors, RTD Composition and Construction, Advantages and Disadvantages of RTDs, Thermistors, Thermocouples, Extension Wires, Change in Reference-Junction Temperature and Compenstation, Advantages and Disadvantages of Thermocouples, Primary Calibration Standards, Primary Standard Instruments, Secondary Standard Instruments, Instrument Inspections, Controlled-Temperature Environments, Ice Baths, Other Temperature References, Calibration and Testing Methods
Session 6 – Level Measurement
Liquid Level and Conductivity, Measuring Levels Using Capacitance, Capacitance Probes, Capacitance Probe Electronics, Ultrasonic Level Detectors, Resistance Level Detectors, Photoelectric Level Detectors, Point Level Detection, Hydrostatic Pressure, Relative Density/Specific Gravity, Pressurized Fluids, Pressure Head, Pressure Head Instrumentation, Air Bellows, Air Purge Systems, Force-Balance Diaphragm Systems, Differential Pressure Transmitters, Density Measurement, Safety
Session 7 – Pressure Measurement
Pressure Conversion, Potentiometric Pressure Transducers, Servo Pressure Transducers, Strain Gauge Pressure Transducers, Piezoelectric Pressure Transducers, Response Comparisons, Environmental Considerations, Pressure Transmitter Components, Locating Mounting Instruments, Placing the Instruments into Service, Periodic Maintenance, Troubleshooting and Repair, Proper Equipment Requirements for Maintenance, Troubleshooting, Repair, and Calibration, Safety
Session 8 – Flow Measurement
Principles of Open-Channel Flow, Flumes, Ultrasonic and Capacitance Level Sensors, Turbine Flowmeters, Paddlewheel Flowmeters, Magnetic Flowmeters, Vortex-Precession Meters, Vortex-Shedding Meters, Mass Flow, Mass Flowmeters, Thermal Flowmeters, Heat-Transfer Meters, Hot-Wire Meters, Ultrasonic Flowmeters, Installation Procedures for Mteres
Session 9 – Working with Controllers
Types of Controllers, Automatic/Manual Control, Controller Range and Span, Direct-and Reverse-Acting Controllers, On/Off Controllers, Proportional Controllers, Tuning the Control Loop, Types of Proportional Controller Output, Current-Proportioning Control, Time-Proportioning Control, Position-Proportioning Control, Control Strategies, Hardware Option for Controllers, Auto/Manual Station, Auxiliary Outputs, Indicators, Controller Limits and Alarms
Session 10 – Electric Motor Drives
Names of Electric Motor Drives, Motor and Voltage Control, Pulse Width Modulations, AC Drive Types, Consideration of Programming, Basic Parameters, Advanced Parameters, Parameter Protection/Keypad Controls, Functionality of Inputs and Outputs, Troubleshooting Safely with Electric Motor Drives, Troubleshooting Tests and Solutions
Session 11 – Final Control Elements
Final Control Elements and Variables, Components of a Typical System with Feedback Components, Electrical Control Signals, Fluidic Control Signals, Valves, Actuators, Actuator Positioners, Solid State Relays, Proportional Control Relays
