Instrumentation and Control Systems for Industrial Machinery

Introduction

Instrumentation can be viewed as the eyes and the ears of the operator in the modern plant. They are there to collect information and to assist the operator in analyzing current plant conditions. The operator is then better equipped to make the necessary decisions, pertaining to better control of the plant. Of course, not all of the control decisions falling to the domain of the plant operator. Many processes are automated. In the past, excellent analog equipment was available to do the control function. In the current digital world, modern control systems have come to the fore. These include model-based control equipment.

This Industrial Instrumentation and Modern Control Systems training course combines all of this, into one powerful, high impact, week of learning. The workshop starts off discussing aspects of transmitters, along with the modern choice of Fieldbus and HART and other communication aspects. It then delves into final control elements (many of them adjustable). This is followed by important aspects of pressure, level, temperature, and flow. The workshop then moves into process control and loop tuning, ending off with model-based control systems, and how this fits into the modern notion of process control.

Participants attending the Industrial Instrumentation and Modern Control Systems training course will develop the following competencies:

• Be able to work with and convert modern instrumentation signals
• The cognitive ability to implement a modern network-based system
• Comprehensive understanding of PID control
• Effective tuning of most modern control loops
• Implement a model-based control system
• Effectively deal with large dead times

Objectives

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

• Define the role and objectives of instrumentation in any plant
• Understand the importance of process variables, in-process control
• Develop their skills in selecting the right transmitter for an application
• Improve their skills process control strategies 
• Correctly implement loop tuning strategies (using numerous methodologies)
• Understand the concept of model-based control
• Comprehend the intricacies of IMC and MPC strategies

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This Industrial Instrumentation and Modern Control Systems training course is suitable for a wide range of professionals employed in Engineering, but it will be particularly beneficial to:

• Plant Management Personnel
• Engineers from all disciplines
• Processing Control Technicians
• Instrumentation Artisans
• Supervisors
• People involved in Projects
• People dealing with Instrumentation Equipment Selection
• Representatives from the Safety Department
• Representatives from Purchasing Departments
• Anyone with more than just a passing interest in instrumentation

Course Outline

Day 1: Introduction to Process Variable Measurement

• Sensors, Transducers and Instrumentation Systems
• Instrumentation Signals
• Instrumentation Terms and Definitions
• HART Protocol
• Fieldbus
• Digital Communication and Techniques
• A quick introduction to final control elements (including control valves, VSD and VFD)

Day 2: Pressure, Level, Temperature, and Flow Measurement

• Pressure Measurement – the principle of operation, devices, typical uses and installation considerations
• Level Measurement – the principle of operation, devices, typical uses and installation considerations
• Temperature Measurement – the principle of operation, devices, typical uses and installation considerations
• Flow Measurement – the principle of operation, devices, typical uses and installation considerations

Day 3: Process Control

• Process Dynamics
• Process Stability
• Process Responses
• Types of control that may be implemented
• The P part of PID Control
• The I part of PID Control
• The D part of PID Control
• Cascade Control

Day 4: Advanced Control and Loop Tuning Strategies using Digital Controllers

• Ratio control
• Combined feedforward and feedback control
• Open-loop tuning methods, using formulae
• Closed-loop tuning methods, using formulae
• Open-loop tuning, using trial and error
• Closed-loop tuning, using trial and error
• Dealing with processes that have large dead time

Day 5: Model-Based Control, where a PID Controller isn’t the Preferred Option

• Using a model-based controller
• Using a Smith Predictor
• Understanding Internal Model Control (IMC)
• Using a Dahlin’s Controller
• Understanding and implementing Model Predictive Control (MPC)