ADVANCED INDUSTRIAL AUTOMATION - INSTRUMENTATION, AUTOMATION AND PROCESS CONTROL
Proper maintenance of equipment to reduce downtime and save money requires more than just replacing parts when they get broken. In fact, replacing a broken part with a new one is an expensive approach for maintaining equipment. To be effective, the maintenance technicians must know why a part has to change and must also have expert knowledge on the use and calibration of a device before installing any device or plant system.
This course is designed to help students to understand the principles of measurement for the proper monitoring and control of their equipment.
On completion of this course, students will have sound knowledge on how to run the plant systems and equipment efficiently and economically.

 

ADVANCED INDUSTRIAL AUTOMATION - CHEMICAL ENGINEERING
Process engineering is at the core of chemical, oil, gas, and petrochemical industries. Throughout all stages of the design of a chemical plant, engineers of many disciplines communicate by 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, chemical engineers should also have expert knowledge on the use of mass and energy balances in process design.
This course is designed to familiarize students with process and electrical drawings and also the basic concepts of fluid flow, including pumping and pipe sizing of a plant. After completing this course, students will have expert knowledge in process design and operation of the chemical industry.

 

ADVANCED INDUSTRIAL AUTOMATION - CONTROL VALVES
Piping systems, power plants and industries are fitted with valves for controlling purposes and safety requirements. Understanding the function of each valve type will have a significant reflection on the process quality, equipment and plant reliability. Technical staff should have sound knowledge on the problems associated with valves for proper diagnosis, troubleshooting and maintenance of the particular type of valve.
This course is designed to help students to understand selection, classification, application and maintenance of control valves and actuators.
After completing this course, students will have expert knowledge and skills to independently evaluate possible valve operation, selection and design solutions.
 

Advanced Industrial Automation - Plant Layout and Piping Design
Selection and construction of pipelines take up the majority of the work in the design of a process plant for transporting water, sewage, oil, gas and waste. A technical staff should have expert knowledge on piping system devices and its operation to design a more efficient piping system. This course is designed to help students to understand the fundamentals of piping system including pumps, piping hangers, reactors and heat exchangers. After completing this course, students will have sound knowledge on the latest advances in pipe design and installations that minimize risk.

 

FUNDAMENTALS OF PROFESSIONAL ENGINEERING
Professional Engineering is concerned with engineers aspiring to practice within their technical competence, for the betterment of society. This requires education, training and practice in engineering sciences and application of special knowledge of mathematics, physical and engineering sciences in professional and creative work.
This course for prospective professional engineers provides a comprehensive review of basic and advanced concepts, theories and applications. Time management, problem solving and test-taking strategies also form an integral part.
This course will greatly help in raising the overall level of engineering professionalism.

 

ADVANCED INDUSTRIAL AUTOMATION - DATA COMMUNICATIONS
Data can be exchanged from one point to another by means of electrical or optical transmission system.  In today's computing world, data communication provides electronic exchange of data or information and it is utilized in computer networking equipment such as modems, local area networks (LAN), adapters, repeaters, hubs, microwave links and wireless network access points. To be effective, technical staff should have sound knowledge on data communication media and its components to provide reliable and efficient communication.
This course is designed to help students to understand the role of IP addressing in the TCP/IP Network Reference Model in Networking, RS-232 AND 485 interface and also describes the constructional features and applications of fibre optics and copper cabling.
After completing this course, students will have expert knowledge on the basic principles of data communications and the major technologies used in modern data communication and field bus system.

 

ADVANCED INDUSTRIAL AUTOMATION - PROCESS CONTROL
Process controls are designed and implemented within the process control system to facilitate basic operation, control and automation requirements. Controllers which are not correctly configured and tuned will not perform optimally and will not reduce variability in the process as they should. Technical staff should have sound knowledge on controller design, techniques for troubleshooting control problems and optimizing control loops.
This course is designed to help students to understand the concepts and components of process control and different controller types including PID, cascade and feed forward control.
After completing this course, students will have expert knowledge on the design, tuning ratio and troubleshooting of controllers.

 

ADVANCED INDUSTRIAL AUTOMATION - TUNING OF INDUSTRIAL CONTROL LOOPS
Optimizing the process with proper setting and tuning of control loops is necessary to increase quality consistency.  Correctly setting PID control loop parameters will result in a properly controlled process with a minimum of overshoot and instability while retaining excellent control response. Technical staff should have expert knowledge on process controls to identify and correct problems with process dead time
This course is designed to help students to understand the fundamentals of open and closed loop control used in the field of process control including continuous and damped cycling method.
After completing this course, students will have sound knowledge on the tuning methods to provide a stable and controllable process, thus increasing production and reducing shutdown events.

 

Advanced Industrial Automation - Distributed Control Systems (DCS)
A distributed control system (DCS) is a control system for a process or plant, wherein control elements are distributed throughout the system. It is commonly used in manufacturing equipment and utilizes input and output protocols to control the machine. Technical staff should have expert knowledge on the design, operating characteristics, specification, selection criteria, advanced fault detection techniques of modern instrumentation and control systems, distributed control systems (DCSs) and Data Acquisition Systems (SCADA).
This course is designed to help students to understand the design, operation and control functions of a DCS including PID controllers and also the basic concepts of Advanced Process Control schemes.
After completing this course, students will have expert knowledge on the latest trends related to DCS to enhance the control system performance, reliability, robustness, speed of response and minimize wear and tear of control system components.

 

ADVANCED INDUSTRIAL AUTOMATION - DISTRIBUTED CONTROL SYSTEMS (DCS)
A programmable logic controller (PLC) is a digital computer used for automation of electromechanical processes and is used in many industries and machines. Technical staff should have expertise on the functional design, hardware configuration, programming and application of Programmable Logic Controllers (PLC).
This course is designed to help students to understand the function and the relationship between the various hardware components of a programmable logic controller including discrete I/O module and analog I/O systems.
After completing this course, students will have sound knowledge on the programming, installing equipment, purchasing or implementing cost reduction and automation programs, or maintaining and troubleshooting PLC based equipment.

ADVANCED INDUSTRIAL AUTOMATION - PLCS FOR AUTOMATION AND PROCESS CONTROL
Applications ranging from the process industries to the automotive and the communications sector are making increased use of Model Predictive Control(MPC), where a fixed control law is replaced by on-line optimization performed over a receding horizon.  The advantage is that MPC can deal with almost any time-varying process and specifications, limited only by the availability of real-time computer power.
This course is designed to help students to understand the basic principle and operation of model predictive control and its optimization.
After completing this course, students will have sound knowledge on the basic concepts of model-based control and its applications.

 

ADVANCED INDUSTRIAL AUTOMATION - ADVANCED PROCESS CONTROL FOR ENGINEERS AND TECHNICIANS
Instrumentation and controls in a boiler plant encompass an enormous range of equipment from simple industrial plant to the complex in the large utility station. The boiler control system is the means by which the balance of energy & mass into and out of the boiler are achieved. Inputs include combustion air and fuel while flue gas and steam part of the output.
This course is designed to help students to understand the basic principles of boiler control, feedwater control and draft control including burner management systems.
After completing this course, students will have excellent knowledge on the boiler design, control functions and advanced control strategies for improved boiler plant efficiency.

 

COURSE OUTLINE

BASIC MEASUREMENT CONCEPTS

• Accuracy
• Range of operation

 

ADVANCE MEASUREMENT PERFORMANCE TERMS AND SPECIFICATION

• Hysteresis
• Linearity
• Repeatability
• Response

 

P&ID SYMBOLS

• Representation on Flow diagram
• Letter code

 

A CASCADE CONTROL LOOP

• Selection criteria
• Typical Application

 

PRINCIPLE OF PRESSURE MEASUREMENT

• Total pressure

 

PRESSURE TRANSDUCERS MECHANICAL

• Bourdon tube
• Helix and spiral tubes
• Spring and bellows
• Diaphragm
• Manometer

 

PRESSURE TRANSDUCER ELECTRICAL

• Strain gauge
• Vibrating wire
• Piezoelectric
• Linear variable difference transformer
• Optical

 

LOCATION OF PROCESS CONNECTIONS

• Use of Impulse tubing
• Potential problem with impulse lines
• Use of Mono block

 

IMPULSE ARRANGEMENT FOR STEAM FLOW

• Purged flow on impulse line
• Steam flow using steal plot

 

PRINCIPLE OF MEASUREMENT

• Simple phase
• Multiple phase

 

Continuous Measurement

• Simple slight glass
• Gauging Rod method
• Wire guided float detectors
• Hydrostatic pressure

 

VOLUME MEASUREMENT

• Bubble Tube method
• Weighing method
• Ultrasonic methods
• Radar measurement

 

ELECTRICAL LEVEL MEASUREMENT

• Conductive Level Detector
• Capacitive Level Measurement
• Open Level Switch

 

CONTACT MEASUREMENT DEVICES

• Thermocouple
• RTD's
• Thermistor

 

NON-CONTACT MEASUREMENT DEVICE

• Filled devices
• Bimetallic
• Infra-Red pyrometers

 

PRINCIPLE OF FLOW

• Type of Flow
• Basic terms and concepts

 

PRIMARY ELEMENT

• Flow measurement
• Concentric Orifice plate
• Venturi tube
• Pitot tube

 

SECONDARY ELEMENTS

• Oscillatory flow measurement
• Turbine flow meter
• Variable area flow meter
• Magnetic flow meter
• Ultrasonic flow meter

 

NEW SMART INSTRUMENT AND FIELDBUS

• HART
• Application layer
• Fieldbus
• Noise and earthing

 

ELECTROSTATIC COUPLING SOURCES

• Noise Reduction
• Minimizing of Electrostatic coupling

 

MAGNETIC OR INDUCTIVE COUPLING

• Magnetic coupling
• Magnetic shield to reduce magnetic coupling
• Impedance coupling

 

COUPLING INTERFERENCES

• Electromagnetic interference
• Ground loop interference
• Single point grounding

 

SUPPRESSION TECHNIQUES

• Material Construction
• Linearization

 

INTEGRATION SYSTEM

• Selection Procedure
• Testing and Commissioning of the subsystem
• Advanced Industrial Automation - Chemical Engineering

PROCESS DRAWINGS

• Block flow diagrams
• Process flow diagrams
• Piping and Instrument diagrams
• Isometric flowchart

 

ELECTRICAL DRAWINGS

• A Series layout
• A Parallel layout

 

STOICHIOMETRY

• Molecular weight
• Periodic table of the elements
• Equation balancing

 

STOICHIOMETRY PROBLEMS

• Mol or Mass
• Ideal gas law
• Percent composition
• Mass balances
• Multiple-unit balances

 

FLUID MECHANICS

• Fluid statistics
• Laminar  and Turbulent flow
• Reynolds number

 

PIPE SIZING

• Pipe pressure drop
• Mach number
• Gauge pressure
• Differential pressure meter

 

PUMPS

• Centrifugal pumps
• Pump components
• Pump selection criteria
• Pump sizing

 

HEAT TRANSFER AND ITS APPLICATION

• Modes of Heat transfer
• Convection
• Radiation
• Heat exchangers
• Shell and tube exchangers

 

MASS TRANSFER AND ITS APPLICATION

• Modes of Mass transfer
• Distillation
• Equilibrium in Distillation
• Energy conservation in distillation
• Advanced Industrial Automation - Control Valves

 

CONTROL VALVE

• Valve selection
• Energy
• Pressure drop mechanism

 

PURPOSE OF CONTROL VALVE

• Laminar and Turbulent flow in pipes
• Flow Separation

 

PRESSURE PROFILE ACROSS A SINGLE SEAT CONTROL VALVE

• Cavitation
• Flashing
• Flow control

 

CLASSIFICATION OF VALVES

• By operation
• By function
• Various types based on energy type of the shaft actuation

 

STEM VALVES

• Cage guiding
• Stem guiding
• Post guiding
• Port guided

 

GLOBE VALVES

• Globe valve characteristics
• Different between installed and inherent characteristics

 

BUTTERFLY VALVES

• Butterfly disc shape
• Eccentric disc shape
• Bore ball valve
• Lined ball valve

 

PLUG VALVES

• Non pressure balanced plug valve
• Weir type Diaphragm valve
• Pinch valves

 

CONTROL VALVE SELECTION

• Flow coefficient
• Control valve sizing formula
• Control valve selection flow chart
• Control valve sizing formula Gas and Vapour service

 

PURPOSE OF ACTUATORS

• Size of Actuator independent
• Actuator configuration

 

PNEUMATIC ACTUATORS

• Cascade Control
• Example of Cascade control
• Positioner and Cascade control
• Positioners
• The Spool block

 

CASCADE CONTROL

• Example of Cascade control
• Positioner
• The Spool block

 

PRINCIPLES OF ACTUATORS

• Static and dynamic pressure profiles
• Multistage pressure reduction
• Time selection guide
• Anti Cavitation Trim

 

ED DISK STACK DESIGN AND TECHNOLOGY

• Diffuser plate
• Sonic choke
• High pressure drop application
• Globe valve Trim selection

 

MATERIAL SELECTION

• Packing materials
• Guide materials

 

END CONNECTIONS

• Bolted gasketed flanges
• Examples of deadband
• Examples of Stiction

 

FIRE PROOFING OF ACTUATORS

• Fire box
• Fire proof coating
• Advanced Industrial Automation - Plant Layout and Piping Design

 

APPLICATIONS OF PIPING

• Processing Facilities
• Equipment and piping in a processing facility

 

DESIGN OF PROCESS PLANTS

• Objectives
• Applications

 

PLANT LAYOUT & PIPING DESIGN

• Diagram of Plant Layout & Piping design
• Plot Plan
• Development and refinement of plot plans
• Establishment of nozzle locations
• Routing of Pipes
• Nozzles

 

DATA USED IN PLANT/PIPING DESIGN

• Net Positive Suction Head (NPSH)
• General considerations
• Minimizing Elevations
• Common Abbreviations

 

TYPES OF PLANT LAYOUT AND PIPNG DESIGN

• Feed
• Detailed design
• 3D Model
• BOM
• Physical Quantities and Units

 

PROCESS FLOW DIAGRAM (PFD)

• Chemical processing principles
• Unit operations
• Unit processes
• Refining Process
• Process flow diagram
• P&ID
• P&ID Terminology
• Instrument abbreviations
• Locally Mounted Instruments
• Local Control system
• PLC controlled system
• Service abbreviations
• Orifice meters, flange assembly and plate

 

EQUIPMENT USED IN PROCESS PLANTS

• Towers
• Towers Parameters
• Elevation of distillation tower

 

REACTORS AND HEAT EXCHANGERS

• Typical reactor
• Reactor Process vessel sketch
• Reactor Supports
• Shell and Tube HE
• Heat exchanger design
• Layout

 

PUMPS AND ITS TYPES

• Centrifugal pump
• Reciprocating Pumps
• Rotary Pumps
• NPSH
• Vapor Pressure and Cavitation
• Pump Piping

 

DOCUMENTS & TOOLS USED IN PLANT/PIPING DESIGN

• Typical equipment list
• Piping line list
• Piping specifications
• Piping codes

 

PLOT PLANS

• Types of plot plans
• Conceptual layout
• Documents used for development plot plans
• Vertical mounted structure
• Guidelines for developments
• Pipe racks

 

PIPING ISOMETRICS

• Piping Layout
• Piping Sections and Elevations
• Piping Layout
• Piping 3D Models

 

FUNDAMENTALS OF PIPE

• Pipe manufacturing methods
• Pipe joining methods
• Pipe Dimensions
• Pipe Wall thickness
• Pipe fittings
• Pipe end preparations
• Reducers
• Elbows

 

FLANGES AND GASKETS

• Flange Pressure class
• Flange facing
• Flat face flange
• Ring type joint flange
• Flange facing applications
• Flange types
• Full face gasket
• Flat ring gasket

 

PIPE MATERIALS

• Piping material properties
• Common material properties
• Valve types
• Ball Valve
• Chain operator
• Fundamentals of Professional Engineering

 

TIME MANAGEMENT

• Availability and management of time
• Indicators of poor time management
• Checklist on time management
• Time Wasters
• Peak Performance periods
• Elements of Effective Time Management                                               

 

PERSONAL PORTFOLIO AND JOURNAL

• Creating a Personal Portfolio
• Journal Entries
• Checklist for self- assessment of the learning process                            

 

PROJECT MANAGEMENT BASICS

• Basic aspects of Project Management
• Project  life cycle
• Project Plan
• Work Breakdown-Basis, Work package , Criteria ,Pitfalls

 

SCHEDULING

• Presenting the Schedule
• AON
• Gantt Chart
• PERT                                                                                

 

RISK MANAGEMENT

• Risk-Definition
• Risk sources
• Establishing Context
• Risk Identification
• Risk Assessment
• Risk treatment
• Risk Analysis-Types                                                                                      

 

COMMUNICATION

• What is effective Communication
• Total Communication
• Workplace Communication-Meetings, Discussions and Documents
• How not to Communicate
• Assertive Communication
• How to be an Assertive Communicator
• Verbal Communication- Guidelines
• Written Communication-Principles
• Communicating with Clients
• How to handle Problems
• Communicating a positive Public Image                                     

 

PROBLEM SOLVING

• What is a problem?
• Steps involved in problem solving process
• Simple Problems
• Complex Problems-Root Cause Analysis (RCA)
• Steps involved in RCA
• State problem
• Collect data
• Identify possible causal factors                                       

 

DECISION MAKING

• Steps in Decision making
• Constructive environment
• Generating good alternative solutions
• Exploring  Alternatives
• Select ion of best Alternative
• Check Decision
• Communicating  decision and taking action                                  

 

TECHNICAL WRITING AND SPECIFICATIONS

• Specification writing in general:
• What are specifications?
• Fundamentals of specifications
• Structure of Technical specifications
• Types of specifications
• Content of specification
• Taxonomy
• System-Inputs /outputs/Functions
• System Packaging
• System structure and behavior
• System environment                                                        
• Other issues
• Summary of what a system must do                                          

 

GROUP DYNAMICS

• Definition of a group
• Types of groups
• Attributes of a group
• What is group dynamics?
• Tuckman’s theory of group Development
• Group Dynamics-Positive and Negative
• Causes for Negative Group Dynamics
• Blocking roles
• Strategies to improve team Dynamics
• Benne and Sheats

 

PROJECT COSTING AND CASH FLOW

• Financial Statements-Income Statement and Balance Sheet
• Profit and Depreciation
• Depreciation Versus Cash Flow
• Cost Estimation                                                                                

 

DISCOUNTED CASH FLOW

• Time Value of Money
• Time line
• Cash Flow Representation
• Compounding, Present value(PV), Future Value(FV)
• Discounting
• Discount Rate

 

PV OF MULTIPLE CASH FLOW                                                             

• Net Present Value(NPV ) of Multiple Cash Flow
• Internal Rate of return(IRR)
• Discounted and Undiscounted Payback
• NPV method and IRR                                                                   

 

LEADERSHIP AND PROFESSIONAL CONDUCT

• Understanding what leadership is
• Management Vs Leadership
• Leadership Theories
• Leadership Models
• Guidelines on Professional Conduct

 

ETHICS OF ENGINEERING

• Introduction to Ethics
• Definition of Ethics-Professional/Engineering
• Code of Ethics
• Ethical Dilemmas in Engineering
• Ethical Theories and Tests
• Ethics Test Approach for Decision making
• Personal Liability/Legal Indemnity
• Advanced Industrial Automation - Data Communications

 

GENERAL METHODOLOGY

• Common Problems
• Methodology

 

NOISE AND COUPLING

• Definition of Noise
• Electrical coupling of Noise
• Electrostatic coupling
• Capacitive coupling
• Magnetic coupling
• Transformer coupling
• Grounding configurations
• Ingress protection

 

COPPER CABLING

• Coaxial cable
• Preferred cable types
• N-type connector
• Thin coax T piece
• BNC connector
• D-type connectors
• RJ45 connector
• M-12 connector

 

FIBRE OPTICS

• Applications of Fibre optic cable
• Fibre optic cable components
• Construction of optic fibre
• Graded index multimode fibre
• SC and ST connectors
• Splicing tray
• Fibre optic tests

 

RS-232

• RS-232 Connections
• Voltage Levels
• Asynchronous vs. synchronous transmission
• Summary of operation
• Limitation

 

RS-485

• RS – 485 Voltages
• Two wire network
• Four wire network
• Bias resistors
• RS – 485 trouble shooting

 

INTERFACE CONVERTERS

• 20mA current loop
• RS-232/RS-485 converter
• Serial interface converters

 

TCP/IP

• TCP/IP Protocol suite
• IPV4 Notation
• IPV4 Addressing concepts
• Address Classes

 

SUBNET MASK, TCP AND UDP

• IP Addressing concepts
• Prefix notation
• Private IP addresses
• IP datagram
• Establishing and terminating a connection
• User datagram protocol
• MODBUS
• Modbus serial
• Modbus transaction
• Memory address blocks
• Modbus commands
• FC01
• FC05

 

DISTRIBUTED NETWORK PROTOCOL

• Designed for SCADA
• Why use DNP3?
• Features of DNP3
• Build-up of DNP Message
• IEC 60870
• Protocol Architecture

 

MODBUS PLUS

• Frame structure
• Modbus network terminology
• Protocol structure
• Symbols used
• Normal message transfer
• HART
• Digital transmission mode
• Master Slave Mode
• Burst Mode
• Hart commands
• Commands
• Practical Demo of Modbus serials

 

DEVICENET

• Introduction
• Network specifications
• Typical open-style physical media
• ODVA troubleshooting tools
• EDS file checker
• DeviceNet assistant
• DeviceNet frame format

 

PROFIBUS

• Introduction
• Profibus stack
• DP/PA Alternatives
• IEC 61158-2
• Profibus OLM
• PA connector
• Profibus MAC
• Profibus Messages

 

FOUNDATION FIELDBUS H1

• Fieldbus
• Physical Layer
• Cable characteristics
• Foundation Technology
• Scheduling
• Power conditioner block
• Terminator

 

ETHERNET/IP

• DeviceNet
• The host to host layer
• PROFINET
• PROFINET communication
• PROFINET versions
• Comparisons

 

FOUNDATION FIELDBUS HSE

• Summary
• HSE benefits
• High speed Ethernet
• ModBus Communication Stack
• Encapsulation of MODBUS TCP/IP ADU
• Advanced Industrial Automation - Process Control

 

PROCESS CONTROL

• Economic justification of control
• Reasons for improved control
• Process modelling
• Typical block diagram of plant

 

PROCESS DYNAMIC COMPONENTS

• Process gain
• Elementary block diagram
• First order process
• Second order response

 

PROCESS CONTROL COMPONENTS

• Simple manual control
• Feedback control
• Feedforward control loop
• Open loop control
• Closed loop PID

 

CLOSED LOOP CONTROL

• Principle of Closed loop control
• Components of process control loop
• Feed heater

 

STABILITY OF CONTROL LOOP

• Consideration for critical frequency
• Instability in a closed loop
• Examples

 

IDEAL PID CONTROLLER

• Idea of a controller
• A control loop
• Industrial PID controller
• PIDs in software

 

PID CONTROLLERS

• PID variants
• Parallel or Ideal form
• Interacting or Series form

 

CASCADE CONTROL

• Single loop temperature control
• Examples of Cascade control
• Equation types

 

FEEDFORWARD CONTROL

• Manual feedforward control
• Automatic feedforward control
• Time matching feedforward control
• Feedforward modelling
• Dead time compensation
• Reaction curves for various Dead Times
• Smith predictor model
• Alarm priority bands
• Case study example
• Scan cycle
• Other Tuning Schemes
• Objectives of tuning
• Continuous Cycling – Ziegler & Nichols
• Damped cycling method
• Advanced Industrial Automation - Tuning of Industrial Control Loops

 

TUNING OF CLOSED LOOP CONTROL SYSTEM

• Types of process response
• Objectives
• Do we need to re-tune
• Objective of tuning a feedback controller

 

OPEN LOOP TUNING

• Steps of open loop tuning
• Reaction curve calculations
• Loop time constant method
• Fist order Lag

 

CLOSED-LOOP TUNING METHODS

• Continuous cycling method
• Summary

 

CONTINUOUS CYCLING METHOD

• Calculation of tuning constants
• Formula of Overshoot on start-up
• Modern 'ZN' table alternatives

 

DAMPED CYCLING METHOD

• Steps of Damped cycling method
• Calculate tuning constants
• Tuning calculations

 

QUICK AND DIRTY TUNING GUIDE

• Same caution
• Summary

 

DEADTIME

• Dominating Dead time
• Info on dead time
• Dead time dominated tuning
• Fine tuning control loops

 

TRIAL, ERROR AND SELF TUNING

• How to tune by trial and error proportional first
• Typical PID settings
• PID auto-tuners
• Gain scheduling examples
• First order process
• A complex shape tank
• Gain scheduling
• Optimizing of controller
• Advanced Industrial Automation - Distributed Control Systems (DCS)

 

CONTROL SYSTEM

• Electronic control systems
• What is network?

 

SCADA SYSTEM

• Explanation on Typical SCADA system

 

SCADA MASTER STATION

• Remote terminal unit
• Programmable logic controller
• Complicated SCADA system
• Cold and Hot standby master station

 

DCS SYSTEM RELIABILITY

• Key features
• Smart instrument
• Single ended analogue input
• Differential analogue input
• Digital/Discrete input

 

DCS MAINTENANCE

• Availability
• Reliability
• Open system
• OPC
• Safety and shutdown system

 

BASIC CONTROLLER

• Block diagram of Controller
• Micro process based control
• Typical control program
• PID Controller

 

DCS/PLC Control unit

• Memory unit
• Input/output unit

 

PROCESS CONTROL

• Continuous control
• Batch control
• Modular batch control
• Sequential control
• Ladder logic program

 

DCS CONTROL

• DCS control modes
• Basic DCS controller
• PID algorithm
• Equipment procedure
• Phase logic programming

 

ADVANCED DCS

• Digital composite point
• Functional block diagram
• Display hierarchy

 

ALARM SYSTEM

• Operator interface
• Alarm notices
• Operator activities
• Plant conditions
• Optimum conditions

 

ALARM DESIGN

• Alarm design activities
• Ergonomic factors
• Alarm classification

 

SAFETY INTEGRITY LEVEL (SIL)

• Alarm occurrence activities
• Annunciator panel

 

OVERVIEW OF CONTROL SYSTEM

• Controller display
• Self-tuning controller
• Self-tuning components
• Operator help message display

 

DCS CONFIGURATION

• DCS Engineering tool
• Project tree structure
• DCS system database
• Configuration control function

 

INDUSTRIAL COMMUNICATION

• COMMS Protocols
• TCP/IP vs. DNP3
• TCP/IP Protocol

 

NETWORK SECURITY

• Industrial network security
• Industrial vs Business network
• Bastion security model
• Pathway into control network

 

ISA-99 SECURITY STANDARDS

• Making field development simple
• Using 3 layer Architecture
• SCADA network security
• SCADA Firewall
• DMA application
• Advanced Industrial Automation - PLCs for Automation and Process Control

 

PLC HARDWARE AND CONFIGURATION

• Components of PLC system
• The scan cycle
• CPU rack

 

DISCRETE I/O MODULE

• Types of Discrete input module
• Types of Discrete output module

 

 

ANALOG I/O SYSTEMS

• Types of Analog input modules
• Types of Analog output modules

 

INSTALLATION PRACTICES

• Wiring levels
• Wiring class coding
• Good installation practices

 

INSTRUCTIONS OF PLC'S

• Basic logic instructions
• Time related general terms
• TON and TOF
• RTO
• Counter

 

PROGRAMMING LANGUAGES

• Ladder diagram
• Functional block diagram
• Instruction list
• Sequential function chart
• Structured text

 

COMPLEX FUNCTION

• MOV and MVM
• PLC programming setup
• Programming software
• Tank used to mix two liquids
• Good programming habits

 

ADVANCED CONTROL WITH PLC'S

• Control of a motor
• Coding/Decoding
• Number formats in binary

 

CONTROL SYSTEM

• Structure of Control systems
• Components of process control systems
• Continuous process
• Batch process
• Individual product production

 

CONTROL METHODS

• Open loop control system
• Open loop PLC stepper motor control system
• Closed loop control system
• Container filling closed loop process

 

CONTROLLERS

• On/Off Control
• Proportional control
• Integral control
• Derivative control
• PID control

 

RISK AND SAFETY PLC'S

• Objections to standard PLC
• Choices
• Safety separate to control
• Advanced Industrial Automation - Advanced Process Control for Engineers and Technicians

 

CONTROL BASIS

• Advance control techniques
• Multivariable
• Examples of multivariable control

 

INTERNAL MODEL CONTROL (IMC)

• IMC Structure
• IMC block diagram
• Feed forward control
• Feed forward combined with feedback control
• Ratio control

 

MODEL PREDICTIVE CONTROL (MPC)

• Optimal operation and Constraints
• What is MPC?
• Transfer function

 

MPC MODELS

• Black vs grey box models
• Causality graphs
• MPC observer
• MPC control

 

REFERENCE MODEL

• Contents
• Handling of set point controlled variables
• Rejection of measured and unmeasured disturbances
• Control problem formulation

 

MODEL PREDICTIVE CONTROL

• The Receding horizon
• Receding horizon approach
• Control problem formulation

 

DEADTIME

• Problems due to deadtime
• Deadtime compensation
• Block diagram of the compensator
• Criteria for successful implementation

 

FINAL QUADRATIC PROBLEM

• Mixed integer quadratic program
• Example-Rectification column

 

PRACTICAL EXAMPLE MPC-CONTROLLAB    

• Simulation example
• Deadtime compensation results
• From equation to block diagram

 

MPC OPTIMIZATION

• Fundamental MPC
• Steady state optimization
• Degrees of Freedom and rationale for optimization
• Submission of economic output to the setpoint
• Slogans for maximization and minimization

 

PREDICTIVE CONTROL

• The horizon for economic variables

 

ECONOMICS OF CONTROL

• Example 2: APC application in food industry-reduction in moisture variability
• How to change the control formulation problem
• Advanced Industrial Automation - Boiler Control and Instrumentation

 

BOILER PROCESSES AND THE PRINCIPLES OF BOILER CONTROLS

• Objective of boiler controls
• Boiler processes in block diagram to show key inputs and output variables
• Hazards of boiler operations
• The main control functions in boilers and furnaces

 

DRUM LEVEL AND FEED WATER CONTROLS

• Principles of Drum level measurement
• Principles of drum level controls and protection systems
• Feedwater quality and blow down control
• Steam flow measurement methods

 

FURNACE AIR AND DRAFT CONTROLS

• Pressure fired boilers
• Basic control function of Furnace draft
• Measuring Tap for Furnace draft
• Measurement and control of Furnace draft

 

AUCTIONEERING

• Control of the ID extraction rate
• Conclusion on Furnace draft

 

COMBUSTION CONTROLS

• Purpose of Combustion controls
• Terminologies
• Stoker Fired boilers
• Fuel/Air: Combustion Control basics

 

GENERAL REQUIREMENTS FOR COMBUSTION CONTROLS

• Safety requirements for combustion control
• Control strategies
• Positioning systems

 

METERING SYSTEMS

• Fuel follows Air series metering
• Parallel metering with fuel flow interlock
• Cross-limiting parallel metering control systems

 

BURNER MANAGEMENT SYSTEMS

• Safety Role of BMS
• BMS Essential functions
• Flame safety and loss of flame response
• Multiple burners
• Ignition systems
• Flame detector and monitoring system
• Flame Rod

 

STEAM PRESSURE CONTROL

• Simple pressure control in single boiler
• Series demand sharing
• Turbine following mode
• Coordinated control mode

 

STEAM TEMPERATURE CONTROL

• Temperature control strategy
• Direct contact Attemperators
• Fireside control of Superheating