Mastering Automation: Process Control and Instrumentation Training Course

Introduction

In modern industrial facilities, from oil refineries and chemical plants to power generation and manufacturing, efficient and safe operation relies heavily on sophisticated process control systems and precise instrumentation. These technologies enable continuous monitoring, automatic regulation, and optimization of complex processes, ensuring product quality, maximizing throughput, minimizing energy consumption, and crucially, preventing hazardous conditions. A deep understanding of how these systems work and how to apply them effectively is paramount for any technical professional in process industries.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of process control and instrumentation. From exploring the fundamental principles of measurement and control loops to mastering various control strategies, tuning techniques, and the architecture of modern control systems, you will gain the expertise to design, implement, and troubleshoot automated processes. This empowers you to optimize plant performance, enhance operational safety, reduce variability, and strategically contribute to the efficient and reliable operation of industrial facilities.

Target Audience

  • Process Engineers and Chemical Engineers.
  • Instrumentation and Control Engineers.
  • Automation Specialists and Technicians.
  • Operations Managers and Supervisors.
  • Plant Engineers and Technical Support Staff.
  • Maintenance and Reliability Engineers.
  • Project Engineers involved in Control System Upgrades.
  • Electrical Engineers working in Process Industries.

Duration: 10 days

Course Objectives

Upon completion of this training course, participants will be able to:

  • Understand the fundamental principles of process measurement and control.
  • Grasp the operation and application of various industrial instruments.
  • Analyze different control loop configurations and their components.
  • Comprehend various control strategies, including PID control and advanced control.
  • Evaluate common control system problems and apply effective troubleshooting techniques.
  • Develop practical skills in instrument calibration and control loop tuning.
  • Navigate the architecture of modern Distributed Control Systems (DCS) and PLCs.
  • Formulate robust strategies for designing, implementing, and optimizing process control systems.

Course Content

  1. Introduction to Process Control and Instrumentation
  • Definition and importance of process control in industrial operations.
  • Role of instrumentation in measurement and control.
  • Basic control loop components: sensor, transmitter, controller, final control element.
  • Benefits of effective process control: safety, quality, efficiency, cost reduction.
  • Overview of common control strategies.
  1. Principles of Process Measurement
  • Measurement variables: temperature, pressure, flow, level, composition.
  • Types of sensors and transducers for each variable.
  • Principles of operation for common instruments (e.g., thermocouples, RTDs, pressure transmitters, orifice plates, ultrasonic level sensors, pH meters).
  • Accuracy, precision, range, span, and linearity of instruments.
  • Calibration techniques and standards.
  1. Control Loop Fundamentals
  • Open-loop vs. closed-loop control.
  • Feedback control and its elements.
  • Block diagrams of control loops.
  • Types of control actions: ON/OFF, Proportional (P), Integral (I), Derivative (D).
  • Introduction to PID (Proportional-Integral-Derivative) control.
  1. PID Control and Tuning
  • Detailed understanding of P, I, and D terms and their effects.
  • PID controller algorithms and configurations.
  • Manual tuning methods: trial and error, Ziegler-Nichols.
  • Auto-tuning and adaptive tuning techniques.
  • Impact of PID tuning on control loop performance (overshoot, oscillation, offset).
  1. Final Control Elements
  • Control valves: types (globe, ball, butterfly), components, actuators.
  • Valve characteristics: linear, equal percentage, quick opening.
  • Valve sizing and selection.
  • Other final control elements: variable speed drives (VSDs), heaters, pumps.
  • Positioners and their role in control valve performance.
  1. Advanced Control Strategies
  • Feedforward control: compensating for disturbances.
  • Ratio control: maintaining consistent proportions.
  • Cascade control: improving control performance by breaking down complex loops.
  • Override control and selective control.
  • Introduction to Model Predictive Control (MPC).
  1. Distributed Control Systems (DCS) and PLCs
  • Architecture of modern DCS: controllers, operator workstations, I/O modules.
  • Functions of DCS: data acquisition, control, alarming, historical data.
  • Programmable Logic Controllers (PLCs): applications in discrete control and interlocks.
  • Human-Machine Interface (HMI) design and operator effectiveness.
  • Cybersecurity considerations for control systems.
  1. Control System Design and Implementation
  • Process and Instrumentation Diagrams (P&IDs) interpretation and development.
  • Control philosophy and strategy development.
  • Instrument specifications and selection.
  • Control system hardware and software selection.
  • Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
  1. Troubleshooting Control Systems
  • Systematic approach to diagnosing control loop problems.
  • Identifying common issues: sensor failure, valve sticking, tuning problems, process disturbances.
  • Analyzing control loop trends and historical data.
  • Root cause analysis for control system malfunctions.
  • Practical exercises in control loop troubleshooting.
  1. Digitalization and Future Trends in Process Control
  • Industrial Internet of Things (IIoT) and smart sensors.
  • Big data analytics and machine learning for predictive control and maintenance.
  • Artificial intelligence in process optimization.
  • Digital twins for real-time process simulation and control.
  • Cybersecurity threats and mitigation strategies for industrial control systems.

CERTIFICATION

  • Upon successful completion of this training, participants will be issued with Macskills Training and Development Institute Certificate

TRAINING VENUE

  • Training will be held at Macskills Training Centre. We also tailor make the training upon request at different locations across the world.

AIRPORT PICK UP AND ACCOMMODATION

  • Airport pick up and accommodation is arranged upon request

TERMS OF PAYMENT

Payment should be made to Macskills Development Institute bank account before the start of the training and receipts sent to info@macskillsdevelopment.com

For More Details call: +254-114-087-180

 

 mastering Automation: Process Control And Instrumentation Training Course in Nepal
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