FG07 : Introduction to Industrial Processes, Measurement and Control

FG07 : Introduction to Industrial Processes, Measurement and Control

  • course description:

    This popular course combines lecture and hands-on labs to provide an overview of industrial measurement and control. Technicians, engineers, and managers are provided with a foundation for communication with other control system professionals. Serves as a solid fundamental course for introduction to other ISA courses.

  • course learning outcomes:

    At the end of the course, the participants will be able to;
    - Communicate with measurement and control professionals.
    - Discuss the role of measurement and control in industrial processes.
    - Differentiate between continuous, batch, and discrete control.
    - Apply specific ISA standards to interpret symbols and drawings associated with process control documentation.
    - Discuss and apply the most common methods and devices used in temperature, pressure, level, and flow measurement.
    - List control valves in a feedback control loop.
    - Discuss the fundamentals of process control.
    - Differentiate between various control system architectures.
    - Discuss trends in measurement and control technology.
    - Apply safe laboratory practices.
    - Apply hands-on skills learned in the laboratory exercises.
    - Apply basic devices and procedures for connecting and calibrating various measurement devices.
    - Operate digital controllers and smart devices.

  • Course outlines:

    - Concepts of Process Control: Typical Industries | Definitions | Continuous vs. Batch | Feedback Loop.
    - Documentation: Instrument Line Symbols | Function Symbols | Identification Letters | Piping and Instrumentation Drawing (P&ID) | Loop Diagram.
    - Industrial Measurement Systems: Process Measurement | Standard Signals | Instrument Performance Terminology | Repeatability and Accuracy | Zero, Span, and Linearity Errors | Calibration Chart.
    - Pressure Measurements: Concepts | Instruments | Differential Pressure Measurement | Pascal's Law | Absolute and Atmospheric Pressure | Relationship between Pressure and Column of Liquid | Hydrostatic Head Pressure | U-Tube and Well Manometers | Bourdon Pressure Gage | Spiral and Helical Elements | Bellows and Diaphragm Elements.
    - Level Measurement: Dip Stick Level Measurement | Basic Sight Glasses | Float and Cable Arrangements | Ultrasonic | Capacitance Probe | Radiation Point | Rotating Paddle | Radar Level System | Interface Measurement | Hydrostatic Pressure | Open Tank Level | Zero Suppression/Elevation | Air Bubbler System.
    - Flow Measurement: Types of Flow | Reynolds Number | Differential Pressure Flowmeters | Concentric and Eccentric Orifaces | Flow Nozzle | Venturi and Pitot Tubes | Target Flowmeter | Rotameter or Variable Area Meter | Magnetic, Vortex, Turbine, and Ultrasonic Flowmeter | Doppler Effect | Flow Tube Vibration and Twist | Coriolis and Thermal Mass Flowmeters | Positive Displacement Flowmeters | Rotary Vane, Oval Gear, and Nutating Disc Designs | Open Channel Flow Measurement | Weirs | Parshall Flume | Flowmeter Selection.
    - Temperature Measurement: Temperature Scales | Liquid-in-Glass, Filled Bulb, and Bimetallic Thermometers | Resistance Temperature Detectors (RTDs) | Reference Junction Compensation | Thermocouplers | Immersion and Insertion Lengths | Thermowells | Thermistors.
    - Control Valves: Types | Valve Characteristics | Inherent Flow Characteristics | Actuators | Air to Extend/Retract | Positioners | I/P Transducer.
    - Feedback Control Strategies: Control Hierarchy | Process Dynamics | Lags | Dead Time | Strategies | Direct/Reverse Acting | On-Off Control | Controller Modes | Proportional Control/Action | Level Control Offset | Integral and Derivative Action | Tuning.
    - Advanced Control Strategies: Control Hierarchy | Cascade Control | Applications: With and Without Cascade | Ratio Control | Feedforward Control.
    - Control System Hardware: Pneumatic Controller | Electronic Controller | Single Loop Controller | Distributed Control System (DCS) | Programmable Logic Controller (PLC) | Personal Computers for Control.
    - Smart Field Devices: Current Practice | Typical Smart D/P Transmitter | Smart Temperature Transmitter System | Benefits | Innovative Applications | Fieldbus Foundation - H1 & H2 | How is Fieldbus Different? | Fieldbus Control System (FCS).

  • practical aspects of the course:

    Classroom/Laboratory Exercises:
    - Calibrate process measurement devices for level, temperature, pressure, and flow using a variety of state-of-the-art calibration equipment.
    - Interpret simple P&IDs.
    - Configure smart transmitters.
    - Operate digital controllers.
    - Tune control loops using software.
    - Build and tune an actual feedback control loop.
    - Review flow measurements and pressure scales.
    A hand-held calculator should be brought to class.

  • who should attend?

    - Technicians, engineers, and managers are provided with a foundation for communication with other control system professionals.

  • duration:

    4.5 Days


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