Process Measurement, Instrumentation & Process Control

Process Measurement, Instrumentation & Process Control

OBJECTIVES

• 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 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

WHO SHOULD ATTEND?

• 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
• 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