Advanced Process Control & Instrumentation

This course is designed to update the participants with the latest technologies in instrumentation and process control system. The course will describe the various types of sensors relating to level, pressure, flow and temperature. Also included is an in-depth look at control valves, actuators with associated accessories together with practical valve sizing and selection techniques. The topics of digital field communications and Smart transmitters form an integral part of this course.  Process Control & Instrumentation is becoming an increasingly important engineering topic, since the subject plays a crucial role in the design, operation and maintenance in areas such as power plants and chemical and industrial process plants. Control Systems have advanced dramatically during the last decade. They become more modular and more sophisticated offering a vast variety of control functions for all the systems that operate within a modern “intelligent” facility. Enhanced functionally of the automation systems also means more complexity, interactive strategies, new technologies and systems management with resulting better control and improved reliability.

In addition, this training course also utilizes an extensive collection of state-of-the-art, externally generated process management and video material concerned with all aspects of plant management, including smart wireless solutions to the collection of plant data. In addition, the subjects of digital control systems will be discussed with sessions on Distributed Control Systems (DCS) Programmable Logic Controllers (PLC), SCADA systems and Safety Instrumented Systems (SIS). A major part of the course is devoted to detailed exposition of currently used control valves, the associated terminology, valve performance, valve and actuator types, control valve accessories as well as to the correct selection and sizing of control valves for a wide range of applications. The course addresses the important issues related to valve installation and maintenance.

Who Should Attend?

Further, process engineers, electrical engineers and supervisors and those involved in the design, implementation and upgrading of industrial control systems will also benefit from practical aspects of this course. This course provides an overview for all significant aspects and considerations of basic and advanced process control and instrumentation for process control engineers and supervisors, instrumentation and control system engineers, automation engineers, instrumentation engineers and technologists.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• Acquire knowledge on Process Safeguarding including safety instrumented systems (SIS), safety integrity level (SIL) and loop safety considerations
• List down the different technologies currently in use in pressure, temperature, level flow measurement
• Determine the various process considerations for the instrumentation for industrial applications
• Apply an in-depth knowledge and skills in process control and instrumentation
• Review and apply the different types of control loop strategies and learn the features and application of Distributed Control System (DCS)
• Discuss the system components and operation of the Programmable Logic Controllers (PLC) and learn the configuration of the SCADA systems
• Identify the types of control valve and use a system approach in actuator selection
• Identify the various trends in flow calibration and apply meter proving and become acquainted with field communications

Course Outline

Day 1
Section  01:   Introduction to Process Measurement

• Why Instruments?
• Terminology and Definitions
• What types are there?
• Types of Process Control
• Where do we need it?
• Measurement Calibration
• Types of Errors
• Main applied symbols
• Intro to Quality Assurance

Section 02:   Applied Accuracy Terminology

• Accuracy, Precision, Standard Deviation & Variance
• Variability & Probability,
• “Playing Darts,
• Statistical Control & Normal Distribution,
• Repeatability and Reproducibility,
• STD & Systematic Error,

Day 2
Section 03:  Pressure Measurements

• Types of Pressure
• Types of pressure instruments
• Pressure Units
• Pressure parameters
• Pressure indicators principles
• Gauge and Diaphragm seal gauges
• Strain Gauge, Capacitance
• Piezo Electric Pressure sensors
• Pressure Transmitter

Section 04:  Temperature Measurements

• Principles
• RTD’s
• Thermistors
• Thermocouples
• Control issues
• Installation
• Non-Contact Types

Day 3
Section 05  Flow Measurements

• Flow Meter Classification
• Turbine Meter, K-factor and Accuracy Range
• Rangeability,
• Volumetric, Mass and Totalized Flow
• Positive Displacement Meters
• Categories 2 : Thermal, Differential  and Oscillatory type flowmeters,
• Orifice type ∆P measurement,
• Variable Area Meters
• Orifice Types, Advantages & Disadvantages
• Pitot type flow meters,
• Vortex type flow meter,
• Venturi Tube, Dall Tube and Nozzle,
• Categories 3:  Electromagnetic, Coriolis and Ultra Sonic flowmeters,
• Multi-beam US,
• Coriolis Mass Flow measurement,
• Doppler & Transit time US meters,
• Magnetic Flow meter,
• Turndown Ratio and Rangeability

Section 06:  Control Valves Part

• Hysteresis,
• Control Valve Terminology,
• Fail Safe positions,
• Cavitation & Flashing,
• Choked Flow,
• Flow coefficient Cv and Kv,
• Liquid Recovery Factor,
• Rotary Valves:  Butterfly, Eccentric Disc, Ball and Plug type,
• Linear type valves, Globe valves.
• Pressure Recovery Factor,

Section 07: Principles of Process Control

• Control Objectives,
• Reasons for Process Control,
• Standard Terminology & Symbols,
• Response times / Time Lags,
• Process Variables,
• Transducer / Sensor,
• Types of Errors,
• Final Control Element,
• Open and Closed Loop Control,
• Disturbances,
• Control Actions,
• Control Algorithm,
• Self-Regulating Control,
• Proportional action and Controller Gain,
• Proportional Band,
• Types of Control Algorithms,
• Process Response Curves,
• Properties of Integral Control action,
• Three mode Controlling,
• Introduction Controller Tuning?
• Derivative action and understanding,
• Specific Controller mode selection,
• Typical Control Loops,
• Feed-forward Control,
• Cascade Control,
• DCS Control systems

Day 4
Section 08:  Control Valves

• How to select the right valve,
• Changing the characteristic of a valve,
• Process inherent characteristic,
• Valve (standard) leakage rates,
• Types of Actuators,
• Cage guided Valve,
• ESD valves,
• Volume Boosters.
• Valve Positioners,

Section 09:  Level Measurement

• Buoyancy systems,
• Servo Tank Gauging systems / Honeywell Enraf,
• Applied principles for Level Measurement,
• Hydrostatic measurements,
• Open / closed vessels with Wet and Dry Leg impulse lines,
• Bubble tube measuring method,
• Displacer type level transmitter,
• Weighing method,
• Radar type method,
• Non-contact and Guided Wave systems,
• Ultra Sonic method,
• Vibrating type Detectors,
• Conductivity method,
• Capacitive method,
• Float Level Switch,
• Nucleonic Level measurement,

Section 10:  Introduction DCS systems

• Control & Monitoring,
• DCS Hierarchy, Functions & Features,
• DCS Architecture,
• Main parts and modules,
• Introduction Distributed Control,
• Properties of different DCS systems : Honeywell, Delta V, Yokogawa Centum, Foxboro I/A

Day 5
Section 11:  Programmable Logic Controllers

• Principles of Operation and features,
• Introduction,
• Current Position,
• History,
• System Components,
• Methods for Configuration.
• I/O Interfaces,

Section 12:  SCADA systems

• Control Loop
• What is a SCADA system
• Field Instrumentation
• Data Acquisition
• Supervisory Control,
• Overview of the main parts
• Remote Terminal Unit (RTU),
• SCADA Server,
• Communication Equipment,
• Operation,
• Master Terminal Unit (MTU),
• Levels of Hierarchy,
• System features,

Section 13:  Introduction Safety Instrumented Systems

• Position SIS in a total control system,
• What is IEC 61508
• System Integrity,
• Standards,
• How to compare IEC 61508 and TÜV,
• SIS Logic Solver,
• Safety Instrumented Systems: What is safety / safety system?
• SIL and Pfd,
• Proof Test of Devices,
• Redundancy for Sensors and Final Elements,
• DETT and  ETT,
• Safety PLC design,
• Safety PLC – Diagnostic features,
• Common Industrial Failure Mechanisms,
• Redundancy & Diversity,

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20       Morning Coffee / Tea
08:20 - 10:00       First Session
10:00 - 10:20       Coffee / Tea / Snacks
10:20 - 12:20       Second Session
12:20 - 13:30       Lunch Break & Prayer Break
13:30 - 15:00       Last Session