Process Measurement, Instrumentation and Process Control

Introduction

In an industrial situation where it is required to measure and control some aspects of a process, it is often the application of the knowledge and the ingenuity of the Engineer or Technician which is relied upon to solve the measurement and control problem. Therefore, a fundamental understanding of the principle of operation of a range of sensors/transducers and instrumentation techniques applicable in an industrial situation combined with an understanding and knowledge of Process control techniques and tuning methods equips the Engineer or Technician with the necessary skills and makes them invaluable in their workplace.

Delegates will investigate the operating principles and concepts of instrumentation and measurement systems and will acquire the knowledge relating to the characteristics and properties of the variables being measured.

Moreover, the delegate will gain an understanding of the Process Control Systems and methods used in a modern industrial system.

This is a hands-on, practical Process Measurement, Instrumentation & Process Control training course, and where applicable, theoretical studies will be supplemented with practical activities where the delegate will have the opportunity to design, develop, build, test, and evaluate their own instrumentation systems within the course room.

Some of the main topics covered include:

• Introduction to the principles and fundamentals of Process Measurement and Instrumentation systems and Process variables. Symbols and units used and sample calculations
• Principles of operation of Sensors and Transducers used for:
  • Temperature Measurement
  • Strain Measurement
  • Pressure Measurement
  • Flow Measurement
  • Level Measurement
• Ultrasonic techniques for non-invasive process measurement
• Principles of Process Control and study of the main Control strategies used, leading to an explanation of the 3-term PID controller
• Explanation of a method used to ‘tune’ a 3-term PID controller
• Practical activities to design, build, calibrate and signal condition a typical sensor application

Objectives

By the end of the course, participants will be able to:

• To give an understanding of the principles of operation of a range of sensors and transducers
• By using a hands-on approach, enable the delegate to investigate the operation of an instrumentation system through designing, building and testing a typical sensor combined with appropriate signal conditioning circuits
• To allow the delegate to become familiar and confident with a range of measurement techniques
• To understand the concepts of Process Control and acquire the knowledge relating to the characteristics and properties of a process variable being measured
• To become familiar and knowledgeable with PID control and develop the ability to ‘tune’ a process control system using PID control
• To have the confidence and knowledge to apply the above techniques and principles to solve an unfamiliar and bespoke measurement situation in the workplace

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 training course will be of benefit to:

• Electronic Engineers and Technicians
• Chemical Engineers and Technicians
• Electrical Engineers and Technicians
• Electronic Design Engineers
• Instrumentation Technicians
• Electricians
• Installation and Maintenance Technicians
• Instrument and Process Control Technicians
• Instrument Fitters
• Maintenance Engineers
• Mechanical Engineers and Technicians
• Operations Engineers
• Process Technicians
• Production Professionals
• System Integrators
• Other Professions (Engineers, Technicians) involved in the Process Industry who require an appreciation and understanding of the techniques used in Process Measurement and Control

Course Outline

DAY 1: Introduction to Sensors, Transducers and Instrumentation Systems

• Course Schedule and Layout
• Introduction to Sensors, Transducers and Instrumentation Systems
• Examples
• Terms and Definitions Associated with Instrumentation Systems, including
• Maximum Error
• Hysteresis
• Repeatability
• Sensitivity
• Resolution
• Span
• Response Time
• Examples
  • Process Variables
  • Mass Flow
  • Volumetric Flow Rate
  • Pressure
  • Viscosity
  • Turbidity

DAY 2: Strain, Pressure, and Flow Measurement (also begin practical activities)

• Principle of Strain Measurement – tension, compression, stress, strain, Youngs modulus
• Principle of Operation, Typical Uses and Installation Considerations
• Gauge Types – Principle of Operation and Configurations
• Examples
• Principles of Pressure Measurement
• Devices: Principle of Operation - Typical Uses and Installation Considerations of
• Diaphragms
• Bellows
• Capacitive Devices
• Fibre Optic Pressure Measurement Techniques
• Principles of Flow Measurement
• Reynolds Number
• Devices: Principle of Operation - Typical Uses and Installation Considerations of Invasive Types
• Coriolis Flowmeter
• Differential Pressure Type Flowmeters
• Orifice Plate
• Venturi Tube
• Flow Nozzle
• Dall Flow Tube
• Devices: Principle of Operation - Application and Installation Considerations of Non-invasive Types
• Electromagnetic Flowmeters
• Practical Activity 1: Design and Build a Liquid Level Process Measurement System

DAY 3: Temperature, Level and Non-Invasive Ultrasonic Measurement Techniques

• Temperature Scales
• Devices: Principle of Operation - Typical Uses and Installation Considerations of
• Resistance Temperature Detectors (RTD’s)
  • Thermistors
  • Thermocouples
  • Radiation Pyrometers
• Examples
• Principle of Single Point and Continuous Level Measurement Techniques
• Direct and Indirect Level Measurement Techniques
• Devices: Principle of Operation - Typical Uses and Installation Considerations of
• Ultrasonic Techniques
• Capacitive Techniques
• Pressure Techniques
• Principles and Applications of Ultrasonic Techniques for Non-invasive Measurement
• Doppler Shift and Transit Techniques
• Devices: Principle of Operation - Typical Uses and Installation Considerations of Non-invasive Flow Measurement
• Ultrasonic Flowmeters
• Practical Activity 2: Calibrate the Liquid Level Process Measurement System

DAY 4: Introduction to Process Control Engineering

• Control Strategies
• Block Diagram Representation
• Control Components
• Servomechanisms and Regulators
• Open and Closed Loop Systems
• Transfer Functions
• Negative Feedback (NFB)
• 1st and 2nd Order Systems
• Examples: Transfer Functions and Closed Loop Systems
• ON / OFF Control
• Two-Step Control Action
• Proportional Control
• Proportional Band vs. Proportional Gain
• Proportional Offset
• Reset
• Integral Action
• Integral Windup
• Derivative Action
• PID Control
• Practical Activity 3: Signal Condition the Output from the Liquid Measurement System and (if time allows) Design and Build a Strain Gauge Measurement System

DAY 5: Tuning PID Controllers

• Empirical Methods of Setting Controllers
• Open Loop Reaction Curve Method (Ziegler-Nichols)
• Default and Typical Settings
• Closed Loop Continuous Cycling Method (Ziegler-Nichols)
• Fine Tuning
• Practical Activity 4: Tuning a Control System using The Ziegler-Nichols Methods.