Course Overview

Globalization has placed increasing demands on modern process control in terms of quality, safety, flexibility and costs. However, more efficient control can only be achieved through better measurement when the process instrumentation provides the correct information.

The field of process measurement and control is changing at a dramatic rate. Measurements and accuracies that would have been thought of as impossible to achieve are now commonplace.

This course, PRACTICAL Process control, and Instrumentation, is designed to provide engineers and technicians with the basic theoretical and practical knowledge involved in the selection, application, and installation and commissioning of industrial instrumentation and analytical instrumentation.

Course Objectives

This course offers the most up-to-date knowledge to allow you to:

  • Understand the major technologies used in the measurement of flow, temperature, pressure, and level
  • Review the construction and operation of the most important process instruments
  • Evaluate and select the appropriate instrumentation system
  • Optimize control with effective selection and installation of your process equipment
  • Calibrate and troubleshoot instrumentation systems
  • Isolate and rectify instrumentation faults
  • Appreciate the basics of chemistry and how to read chemical formula
  • Understand how analytical chemistry is applied in industry
  • Implement procedures for testing and calibration of analytical instruments
  • Understand the basics of process analysis using IR spectroscopy and chromatography
  • Understand the fundamentals of Process Control
  • Define such terms as process lag, capacitance and resistance
  • Gain an insight into the process reaction curve
  • Avoid incorrect sensor placement
  • Distinguish the effect of span on the system performance
  • Appreciate the effects of different valve characteristics on the loop performance
  • Fully appreciate the effects of proportional, integral and derivative control
  • Appreciate the effects on loop tuning using a software-based loop analysis program
  • Realize the effects of filtering on loop performance

Who Should Attend

Professionals involved Automation Engineers, Chemical Engineers, , Design Engineers, Electrical Engineers, Electricians, Installation and Maintenance Technicians, Instrument and Process Control Engineers and Technicians, Instrument Fitters, Maintenance Engineers, Mechanical Engineers and Technicians, Operations Engineers, Process Engineers, Process Operators.

Course Content

Module (01) Overview

  • Purpose of instrumentation
  • Location of control functions
  • Variables measured and controlled
  • Final control elements
  • Instrument operating medium

Module (02) Basic Measurement Concepts

  • Measured and controlled variables
  • Performance terms and specifications
  • Measurement terminology
  • P&ID symbols

Module (03) Flow Measurement

  • Basic fluid properties
  • Reynolds number
  • Flow measurement
  • Positive Displacement Meters
  • Inferential meters
  • Oscillatory Flow Meters
  • Differential Pressure Meters
  • Electromagnetic Flowmeters
  • Ultrasonic Flowmeters
  • Coriolis meters
  • Thermal mass meters
  • Open Channel Flow

Module (04) Temperature Measurement

  • Basic principles
  • Scales
  • Expansion systems
  • Thermocouples
  • Resistance thermometry
  • Thermistors
  • Radiation thermometry
  • Installation considerations

Module (05) Pressure Measurement

  • Basic principles
  • Manometers
  • Dead weight testers
  • Bourdon tubes
  • Bellow elements
  • Diaphragm elements
  • Electrical displacement sensors

Module (06) Level Measurement

  • Basic principles
  • Visual gauging systems
  • Float systems
  • Displacement systems
  • Conductive level detection
  • Capacitive level measurement
  • Hydrostatic head measurement
  • Ultrasonic level measurement
  • Radar gauging
  • Nuclear level measurement
  • Point level measurement
  • Load cells

Module (07) Basic Chemistry

  • Elements, compounds and mixtures
  • Properties of elements
  • Formation of ions
  • Bonding
  • Chemical formulae and equations
  • Atomic weight
  • Molar concentrations
  • Acids and bases

Module (08) Electrochemical Cells

  • Electrode potentials
  • Simple voltaic cell
  • Polarisation
  • Daniell cell
  • Electrolytic bridges
  • Electrochemical series

Module (09) On-line Analytical Measurement

  • Measurement of pH
  • Measurement of Redox
  • Conductivity measurement
  • Dissolved oxygen measurement
  • Chlorine measurement
  • Turbidity measurement
  • Hygrometry
  • On-line colorimetry and titration
  • Infrared Spectroscopy
  • Gas chromatography

Module (10) Basic Process Considerations

  • Definition of terms
  • Process lag, capacitance, and resistance
  • Process reaction curve
  • 1st and 2nd order reactions

Module (11) Process Measurement

  • Instrumentation cabling
  • Filtering
  • Aliasing
  • Reaction masking
  • Sensor placement
  • Correct PV
  • Effect of span

Module (12) Final Control Element

  • Choked flow
  • Pressure recovery
  • Flashing and cavitation
  • Valve construction
  • Valve characteristics
  • Inherent
  • Profiling
  • Installed
  • Cavitation control
  • Actuators
  • Diaphragm
  • Cylinder
  • Electric
  • Valve positioners
  • Deadband and hysterisis
  • Stick-slip
  • Testing procedures and analysis
  • Effect of valve performance on controllability

Module (13) Fundamentals of Process Control

  • ON/OFF control
  • Proportional control
  • Proportional band vs. proportional gain
  • Proportional offset