Industrial Instrumentation & Modern Control Systems Selection, Applications, Operation & Diagnostics

Industrial Instrumentation & Modern Control Systems Selection, Applications, Operation & Diagnostics

Introduction 
This seminar will provide a comprehensive understanding of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, HART protocol, control valves, actuators, and smart technology. This seminar will focus on maximizing the efficiency, reliability, and longevity of these systems and equipment by providing an understanding of the characteristics, selection criteria, common problems and repair techniques, preventive and predictive maintenance.

This seminar is a MUST for anyone who is involved in the selection, applications, or maintenance of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, control valves, actuators, and smart technology because it covers how these systems and equipment operate, the latest maintenance techniques, and provides guidelines and rules that ensure their successful operation. In addition, this seminar will cover in detail the basic design, operating characteristics, specification, selection criteria, advanced fault detection techniques, critical components and all preventive and predictive maintenance methods in order to increase the reliability of these systems and equipment and reduce their operation and maintenance cost.

This seminar will provide the following information for modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, control valves, actuators, and smart technology:

• Basic Design
• Specification
• Selection Criteria
• Sizing Calculations
• Enclosures and Sealing Arrangements
• Codes and Standards
• Common Operational Problems
• All Diagnostics, Troubleshooting, Testing, and Maintenance

Practical applications of smart instrumentation, SCADA, and Distributed Control Systems, control valves, actuators, etc in the following industries will be discussed in detail:

Chemical and petrochemical

• Power generation
• Pulp and paper
• Aerospace
• Water and sewage treatment
• Electrical power grids
• Environmental monitoring and control systems
• Pharmaceutical plants

The instructor will guide the delegates during the seminar to do the following:

• Design control systems for the chemical, petro-chemical, and power generation industries
• Select the components for these control systems
• Tune and troubleshoot these control systems

The seminar will focus on the following:

• Strategies used to enhance the performance of modern control systems and reduce their capital and operation and maintenance costs
• Techniques used to increase the reliability of modern control systems and reduce the failure rate of the components and plant downtime
• Methods used to minimize plant upsets and failures due to control system instabilities

Following the seminar, individuals will be able to do the following:

• Design modern control systems for all industrial applications
• Select all the smart instrumentation and equipment required for all control systems including Distributed Control Systems
• Tune all control systems
• Operate, diagnose, troubleshoot and repair all control systems equipment including smart instrumentation, Distributed Control Systems, SCADA, control valves, actuators, positioners, transducers, etc

COURSE OUTLINE 

Feedback Control and Proportional-Integral-Derivative Algorithm, Correlations  for Tuning Constants

• Introduction to Feedback Control Systems
• Process and Instrument Elements of the Feedback Loop
• Control Performance Measures
• Integral Error Measures, Decay ratio, Period of Oscillation, Manipulated-Variable Overshoot
• Selection of Variables for Control
• Feedback Control Algorithm
• Proportional Control
• Integral Control
• Derivative Control
• Proportional-Integral-Derivative Controller
• Determining Tuning Constants that Give Good Control Performance
• Controlled-Variable Performance (Integral Absolute Error)
• Good Control Performance with Model Errors
• Manipulated-Variable Behavior
• Correlations for Tuning Constants

Proportional-Integral-Derivative Controller Tuning for Dynamic Performance,  Distributed Control Systems (DCS), Supervisory Control and Data Acquisition
(SCADA) System

• Fine-Tuning the Controller
• Stability of Control Systems
• Controller-Tuning Based on Stability
• Effect of Process Dynamics on Tuning
• Types of Control Systems
• Continuous and Discrete Data Control Systems
• Cascade Control Systems
• Structure of the Distributed Control System (DCS)
• Discrete Proportional-Integral-Derivative (PID) Control Algorithm
• Effect of Digital Control on Stability
• Tuning and Performance
• Smart Sensors
• Controller Algorithms
• Monitoring and optimization
• Distributed Control System (DCS) Architecture and Advantages
• Distributed Control Systems Components and Features
• Supervisory Control and Data Acquisition (SCADA) System
• Advantages of Distributed Control System (DCS)
• Microprocessors and Microcomputers
• Microprocessor Architecture
• Microcomputer System

Intelligent (Smart) Transmitters, Controllers, Sizing and Selection of Control
Valves, Positioners, and Actuator for Compressible and Non-Compressible
Fluids, Control Valve Flashing, Cavitation and Noise Control, Control System
Troubleshooting and Diagnostics

• Smart Systems
• Intelligent (Smart) Transmitters
• Microprocessor-Based Transmitters (Smart Transmitters)
• Smart (Intelligent) Pressure Transmitters
• Advantages of Intelligent Instrumentation
• Comparison Between Intelligent and Non-Intelligent Instrumentation
• Stand-Alone Controllers
• Self-Tuning, Sequencing, and Networking
• HART Protocol
• Valve selection
• Linear valves
• Rotary valves
• Valve selection considerations
• Valve maintenance
• Basics of valve design (seats and seals)
• Sealing the valve stem
• Leakless valves
• Valve materials
• Preventing valve material failure
• Nonmetallic valves
• General categories of control valves
• Rangeability, end connections, shutoff capability
• Valve sizing
• Choked flow
• Gas and steam sizing
• Sizing and selection of control valves and actuators
• Information required to select a control valve
• Control valve body materials
• Control valve trim material
• Pressure-temperature ratings for all control valve materials
• Class designation and PN numbers for control valves
• Face-to-face dimensions of most types of control valves
• Wear and galling resistance of control valve material
• Control valve seat leakage classification
• Control valve trim material temperature limit
• Service temperature limitations for control valve elastomers
• Ambient temperature corrosion information for most fluids used in control valves
• Control valve elastomer information
• Compatibility of elastomer material with control valve fluids
• Control valve flow characteristics
• Selection of control valve flow characteristic
• Control valve sizing
• Sizing valves for liquid applications
• Detailed calculations for sizing valves liquid applications
• Liquid sizing sample problem
• Sizing valves for compressible fluids
• Compressible fluid sizing sample problem No. 1
• Compressible fluid sizing sample problem No. 2
• Sizing coefficients for single-ported globe style valve bodies
• Sizing coefficients for rotary shaft valves
• Actuator sizing
• Packing friction
• Actuator force calculations
• Rotary actuator sizing
• Torque equations
• Breakout torque
• Dynamic torque
• Maximum rotation
• Non-destructive test procedures
• Magnetic Particle (surface examination)
• Liquid penetrant (surface) examination
• Radiographic (volumetric) examination
• Ultrasonic (Volumetric) examination
• Cavitation and flashing
• Choked flow causes flashing and cavitation
• Valve selection for flashing service
• Valve selection for cavitation service
• Noise prediction
• Aerodynamic and hydrodynamic
• Noise control
• Noise summary
• Packing selection
• Packing selection guidelines for sliding-stem valves
• Packing selection guidelines for rotary valves
• Control valve selection process
• Control valve cavitation
• Control valve noise
• Pneumatic actuators
• Piston actuators
• Electric actuators
• Hydraulic actuators
• Positioners
• Live loading
• Diagnostic testing of control loops
• Air-operated valves diagnostics
• Motors-operated valves diagnostics