INSTRUMENTATION, AUTOMATION AND PROCESS CONTROL
The instrumentation, automation and process control module contains the elaborated concepts on three engineering fields namely instrumentation engineering, automation engineering and process engineering. Instrumentation refers to the devices and instruments that are used in various processes. Automation refers to the automatic working of instruments. Process engineering refers to the study of processes that are carried out in any type of industry and industrial applications.
The fundamentals and selection criteria of measuring devices like pressure transducers, level transducers, temperature transducers and flow measurements are detailed. The Piping & instrument diagram and symbols for the instrumentation devices are listed and selection criteria are discussed. The process automation control and their types are incorporated with the process systems. The new technology oriented smart instruments and their data signals are further discussed. This module will disseminate information to technical professionals who would like to gain comprehensive technical, as well as practical, knowledge on instrumentation, process and automation systems.
CONTROL VALVE SIZING, SELECTION AND MAINTENANCE
In any industries, the shop floor contains many processes that are linked together to get a desired product. In order to achieve the desired product, the intermediate processes must have to be functioned in a controlled manner. These processes are designed to do their own desired task under controlled system. The control valve is the one that is used to control the independent parameters such as temperature, pressure, volume, flow rate, etc. at each sub systems in a shop floor. There are many changes/disturbances in the desired product from the designed product even after the system is controlled. The design and the proper selection and maintenance of the control valve is the only key factor that alters the product nature. In order to achieve the ideal product, the design of control valve is mandatory.
This practical task gives scope to this module on control valve sizing, selection and maintenance; this enables personnel to gain detailed study on the design of controllers, types and selection of control valves; plus calculations, performance and maintenance in context. This advanced course comes under the process engineering discipline.
PRACTICAL SCADA SYSTEMS FOR INDUSTRY
SCADA has traditionally meant a window into the process of a plant or gathering of data from devices in the field, but now the focus is on integrating this process data into the actual business and using it in real time. The emphasis today is on using open standards such as communication protocols (e.g. OPC, MODBUS, and TCP/IP) and ‘off-the-shelf’ hardware, such as industrial Ethernet to keep the costs down. This module covers the essentials of SCADA systems.
Topics include an introduction to SCADA systems, SCADA system hardware and software (including alarm management and Human Management Interface (HMI) issues) and a review of the RS-232/RS-485 interface standards and the MODBUS and DNP3 protocols.
This module continues to give a review of industrial Ethernet, TCP/IP and MODBUS/TCP, the role of Open Process Control (OPC) in plant SCADA systems, and discussion of network security, SCADA historians and troubleshooting issues.
Although the emphasis will be on practical industry topics highlighting recent developments using case studies and the latest application of SCADA technologies, the fundamentals of SCADA systems will also be covered. This module is aimed at those who want to be updated on the latest developments in SCADA systems and want to get a solid appreciation of the fundamentals of SCADA design, installation and troubleshooting.
SPECIFICATION AND TECHNICAL WRITING
Technical writing is unique because of its specialized content. It conveys technical content through specific, clear and concise writing. This fundamental module on technical writing helps the learner to assess the needs of the users and create documents that explain technical information. It also instils basic knowledge on the mechanics of good technical writing. In addition to the above, the students also learn how to build effective sentences and sections that explain information clearly and create informative content that readers will understand and use.
PROCESS AND ELECTRICAL DRAWINGS
The electrical and process drawings portion of the course will be reference through each module and is support by dedicated P&ID videos. This section makes reference to diagrams from the simple block diagram to the comprehensive engineering process line diagrams which aid in planning and fabrication of the plant. To be effective, expert knowledge is required on the use of mass and energy balances in process design. The fundamentals and principles of which, will be covered.
WHAT YOU WILL GAIN
- A fundamental understanding of industrial automation
- An introduction to instrumentation and measurement
- The key know-how to work with control valves
- An ability to configure simple PLC and SCADA systems
- An ability to work with plant documentation such as P&ID’s
WHO SHOULD COMPLETE THIS COURSE
Anybody with an interest in gaining know-how in a full range of fundamentals of measurement, instrumentation, process control, PLC’s, SCADA and P&ID, ranging from the plant secretary, to operators, trades personnel (artisans), technicians and engineers from other backgrounds – such mechanical, electrical and civil. Indeed this is an excellent course for managers from a wide variety of disciplines who are keen to understand the key workings and the future of their plants.
COURSE OUTLINE
BASIC MEASUREMENT CONCEPTS
- Performance terms and specifications – sensitivity and range and span
- Accuracy
- Precision
- Repeatability
- Range of operation
- Difference bet analog and digital
ADVANCED MEASUREMENT
- Performance terms and specifications – linearity
- Hysteresis response
- Control loop components
- Measuring instruments and control valves as part of the overall control system
P&ID SYMBOLS
- Tag description
- P&ID symbols
- Instrumentation representation on flow diagrams
- Mix of instrument signals
- Letter codes and balloon symbols
- P&ID symbols for transducers and others
SELECTION CRITERIA
- Effects of selection criteria
- Instrument selection
- Flow applications
FUNDAMENTALS OF PRESSURE MEASUREMENT
- Principles
- Types- static pressure, dynamic pressure and total pressure
- Technical terms
PRESSURE TRANSDUCERS
- Mechanical – manometer
- Bourdon tube
- Diaphragm
PRESSURE SENSORS
- Electrical – strain gauge
- Piezoelectric
- Capacitance
- LVDT
- Optical
PRINCIPLES OF LEVEL MEASUREMENT
- Point source- by visual inspection
- Gauging rod method
- Buoyancy tape systems
- Field effect level detection
- Gravimetric
- Bubbler tube
- Pressure gauge to measure level
- Installation considerations
CONTINUOUS SOURCE
- Magnetic float
- Time of flight measurement
- Echo measurement
- Selection considerations
- Continuous - pressure head
- Capacitance/resistance
- Fiscal measurement
CONTACT TYPE DEVICES – THERMOCOUPLES
- Concepts
- Average of temperatures
- J type thermocouple
- Voltage curves
- RTDs
- Concept
- PT100 resistance table
THERMISTORS AND OTHER DEVICES
- Selection and sizing
- Typical packaging
- Filled devices
- Non-contact pyrometer type
FUNDAMENTALS OF FLOW MEASUREMENT
- Basic terms and concepts
- Flow parameters – velocity
- Volumetric flow and mass flow
- Flow types
- Importance of Reynolds number
- Differential pressure flow meters
- Bernoulli’s equations
ORIFICE PLATE
- Installation
- Concentric orifice
- Application limitations
OTHER MEASURING DEVICES
- Venturimeter
- Pitot tube
- Flow over a weir
- Rotameter
- Vortex meter
- Construction of swirl meter
- Turbine flow meter
- Magnetic flow meter
- Ultrasonic measurement,
- Positive displacement – rotating vane, rotating lobe meter
- Positive displacement meter
- Mass flow rate meter
- Coriolis meter construction
- Straight through meter
- Thermal mass flow meter
CONTROL VALVES
- Introduction Control valve, classification, principles, Application function – isolation, ON-OFF valves
- Flow control, directional control, protection, overpressure
- Sliding stem valves: Plug, Globe, Cage valves, Operating conditions
- Rotary valves: butterfly, ball valves, flow characteristics
- Noise and cavitations: sources of noise, principles of cavitations and its effects
CONTROL VALVES FLOW CHARACTERISTICS
- Selection and Sizing
- Effective pressure drop
- Control valve characteristics/trim
- Components of a process control loop
PRINCIPLE OF LOOP CONTROL SYSTEMS
- Block diagram for summation and gain
- Direct & reverse controllers
- Feed forward control loop
- Cascade control
DIFFERENT TYPES OF PROCESSES OF LOOP CONTROL
- First order process and response
- Second order process and response
CLOSED LOOP PID
- Control types
- Objectives of tuning
NEW SMART INSTRUMENT AND FIELD BUS
- Fundamental concepts
- Field bus to typical control system
HYBRID TECHNIQUE – HART
- Digital messages
- Sources of noise
- Earthling configurations
COMMUNICATION SYSTEMS
- Data control and transfer protocol
- RS-423, RS-422, RS-432, RS-485
- Fibre optics
- Network topology - star, ring and bus
- Media access control methods
PLC SYSTEMS
- PLC block diagram and configuration
- Discrete DC/AC Input and Output module
- Analog input module
FUNDAMENTALS OF PLC
- PLC programming simulator
- Programming setup, languages and concept
- Function block diagram
- Instruction list
- Structured text language
- Control valve sizing, selection and maintenance
BASIC SIZING FOR LIQUIDS:
- Selection process and formulations
- Selection steps and sizing of control valves
- Valve coefficient
- Purpose,
- Pressure recovery factors
- Application of control valves
- Liquid sizing equations for determining volumetric flow rate
- Metric and SI formulae
- Valve characteristics
BASIC SIZING FOR GASES AND VAPORS:
- Selection steps and sizing of control valves for gas
- Saturated steam
- Superheated steam
- Determination of valve coefficient
- Gaseous and vapor sizing equations for determining volumetric flow rate
- Metric and si formulae
INHERENT AND INSTALLED FLOW CHARACTERISTICS
- valve characteristics
- butterfly disc shapes
- butterfly valve – inherent characteristic
- high performance characteristics
- flow characteristics
- globe valve characteristics
- cage valve characteristics
- various ball valve characteristics
- simple calculation data
- inherent characteristics
- installed characteristics
- overall process control loop
- closed loop control and controller
- importance of loop gain
- non-linear response conversion of gain to percentage of controller input range
- process pressure ratio and conclusion
ACTUATORS AND POSITIONERS
- purpose
- principles of actuators for control valves
- issues of size
- force and speed matched to valve type
- control valve design considerations
TYPES OF ACTUATORS
- Pneumatic actuator types –piston and diaphragm
- Fixed spring, rotary
- Rack and pinion
- Rotary vane
- Electrical actuators – on/off control
- Modulated control
- Solenoid type
- Hydraulic actuators for large valves
- Actuator accessories
CAVITATION AND FLASHING
- Fundamental concepts on Cavitation
- Static and dynamic pressure profiles
- Multistage pressure reduction through the valve trim
- Cavitation mechanisms
- Effects of flashing
- Damage
- Velocity and noise
- Incipient cavitation
- Diffuser plate and choke
- Trim selection guide
CAVITATION CONTROL
- problem characteristics
- Types and cavitation control parameters
- Anti-cavitation trim
- Cavitation elimination
NOISE PREDICTION AND TREATMENT
- Control valve noise Sources
- Treatment
- Prediction of noise
- Methods
- Low noise trim
- Diffuser plates
- Globe valve trim selection
- High pressure drop applications
- ED disk stack
- Low noise retainers
- Examples of noise reduction,
- Noise treatment and accessories
- Q-ball for noise attenuations and anti-cavitation
- Noise source treatment
- Chokes
- Disk stack technology
- Pressure balanced trim
MATERIALS OF CONSTRUCTION
- Control valve materials
- Overview of material selection issues
- Standard control valve body materials
- Typical materials of construction for body and valve trim
- Recognize issues of corrosion and wear, valve trim materials
- Seating materials for tight shut off vs durability
- Problems of leaks from seals
- Applications of bellows seals for toxic materials
MAINTENANCE ISSUES
- Tasks involved in valve maintenance
- Installation features relevant to good maintenance
- Recognize the setting up and testing tasks for valves
- Methods of detection of backlash and stiction in the valve drive
- Potential advantages of using smart positioners and diagnostic software tools.
PRINCIPLES OF PRESSURE
- Hazards of overpressure
- Causes and consequences,
- Basic terminology
- European standards
- Pressure types
- ASME code requirements
PRESSURE RELIEF SYSTEM
- Requirements
- Purpose
- Relief systems
- layer of protection
- use and purpose of relief system
PRESSURE RELIEF VALVES
- Safety valves- types and performance issues
- Sizing principles and equations
- Calculations with examples
- Superimposed and built – up back pressure
- Balanced pressure relief valve operation and construction
- Balanced spindle design
- Pilot operated type
- Back pressure effects on pilot operated valve
DESIGNING CONCEPTS AND ISSUES
- Outline of relief design procedure
- Sizing reliefs – determining relief rates
- Vent area
- Size of valve
- Sizing formulae and equations for gaseous and liquid flow
- Specification and installation issues
- Problem of chatter
- Rupture discs
- Rupture pins
- Prv conclusions
- Practical SCADA Systems for Industry
INTRODUCTION
- Communication architectures
- Communication philosophies
OVERVIEW OF SCADA SYSTEMS
- Hardware alternatives (RTU/PLC etc)
- Communication concentrators
- Communication alternatives
SCADA SYSTEM HARDWARE
- Hardware components
- Operation and selection issues
SCADA SYSTEM SOFTWARE
- SCADA software functions
- Response times
- Redundancy issues
- Specification and configuration issues
SCADA ALARM MANAGEMENT
- Alarm layout and organisation
- Alarm priorities
- Alarm processing and reporting
HUMAN MANAGEMENT INTERFACE (HMI)
- Ergonomic factors
- HMI organisation
- HMI screen design
COMMUNICATION PROTOCOLS
- RS-232/RS-485 interface standards
- MODBUS protocol
- DNP 3.0 protocol
INDUSTRIAL ETHERNET
- Fundamentals
- Redundancy
- TCP/IP
- Configuration
- Troubleshooting utilities
MODBUS TCP
OPEN PROCESS CONTROL (OPC)
SCADA NETWORK SECURITY
- Security issues
- SCADA firewall configuration
SCADA HISTORIAN
- Archiving plant data
- Data access
TROUBLESHOOTING ISSUES
- Testing methodology
- Noise issues
- Communications testing
- Practical SCADA Systems for Industry
INTRODUCTION TO TECHNICAL WRITING
- Technical writing- Definition, meaning and where used.
- Attributes of Technical writing
- Categories of Readers
- Expression versus Impression
THE DEVELOPMENT PROCESS
- Preparing to write a document
- Establish objective
- Identify Readers
- Perform Research
ORGANIZING THE WRITING
- Methods of development
- Outline of Technical documents
- Outlining formats
- Revising the document -Editing, Revision, Proof- reading
USE OF LANGUAGE AND WORDS
- Grammar
- Punctuation and Parts of speech
- TWR and Author’s point of view `
CLARIFICATION OF WRITING PROCESS
- Types of sentences (Simple ,Complex and Compound)
- Voice - Active Vs Passive
SOME ADDITIONAL GRAMMAR ISSUES
- Subject-Verb agreement,
- Use of British and American English
- Punctuation
- Vocabulary
- Jargon and Cliches
- Fog Index
ELEMENTS OF TECHNICAL WRITING
- Basic elements of Technical writing-Description and examples
- Organizing process description/Instruction set
- Final check
FORMATS OF TECHNICAL WRITING
- Purpose of reports
- Structure of formal report
- Terms of Reference
- What a report should contain
INTRODUCTION TO REPORT WRITING
- Main body of the report
- What to include
- Conclusion and recommendations
- Executive Summary
- Other sections
- Technical report writing Vs Report writing
MEMO REPORTS AND OTHER TECHNICAL DOCUMENTS
- Memo Reports-Types and Functions
- Basic Structure
- Other technical documents
- Technical Manual-Purpose and categories of readers
- Technical proposal-Definition and Structure
- Journal article
WRITING OF SPECIFICATION
- Purpose of Specifications
- Phases of Specification
- Equipment Specification
- Client/Purchaser Specification
CONTENTS OF SPECIFICATION
- Scope
- Standards, codes and regulations
- Definition and Terminology
CONTENTS OF SPECIFICATION - II
- Materials of Construction
- Design Basis
- Mechanical/Fabrication
- Guarantees
- Testing and Inspection
- Documentation
- Shipping
PRESENTATION ASPECTS
- Preference of Desk top publishing to other methods
- Appearance of presentation-Book binders
- Document Designing
- Use of graphs, Tables and Illustrations
ORAL PRESENTATION OF TECHNICAL DOCUMENTS
- Personal factors
- Structure of presentation-Details
- Use of various tools for oral presentation
- Importance of timing
- Conclusion
