:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

MAINTAIN PROCESS CONTROL SYSTEMS

Location

London, UK

Date

From Date: 04-Nov-2024
To Date: 08-Nov-2024

Duration

5 days

Language

ENGLISH

Discipline

PROCESS ENGINEERING

Introduction

The importance of the control system in a plant’s process safety, quality, environmental controls, cycle times, and production rates—basically the heart of the process operations.

Process control technology is the ability to monitor and control a continuous process in real time and for systems with large dead times, interactions, and multiples constraints, the ability to provide the necessary patience, anticipation, and forecast of future, for moving the operation to its optimum. This allows the process conditions to be adjusted faster and responsively, and avoids the dead time associated with monitoring the finished goods.

The importance of measurement instrumentation as input to the controllers should have reproducibility and repeatability to meet the process control purpose. The sensor information is combined and processed using controllers of the process.

Programmable Controllers are used in every aspect of industry to expand and enhance production; It uses digital and analog I/O modules to interface to sensors, actuators and other equipment which can be made available in redundant or triplicated configuration

This course applied process control and ESD safety system philosophy and its major components, theory of operations, types and applications, fundamental of instrumentation and control principles, attendees will learn about field measurement devices, types of signals, final control element, closed loop, control mode of operation, DCS components and operation, Safety Instrumented System (SIS) for process industries using IEC 61508 & IEC 61511, High integrity Pressure Protection System (HIPPS), Systems integration, Process troubleshooting & Alarm management system (alarm &trip), Fire and Gas system types, components and operations.

Participants will gain a better understanding of process control components and systems.

Objective

By the end of the course, participants will be provided with the basic theoretical and practical understanding of:

The impact of modern instrumentation
Signal Category, Standard Ranges
The major technologies used in the measurement of Flow, Level, pressure and temperature principle of operation.
Control system basics
Feedback control strategies, control hierarchy, process dynamic,
On-Off control, controller modes, proportional, integral and derivative
Applications with Cascade control, ratio control and feedforward control

Recognize and Understand the objectives of principal PLC functions
Identify the basic components of PLC and where they are utilized.
Identify the Programmable logic controllers' basic architecture.
Power supply module function and circuits.
Input / Output modules types and function.
Processor module typical function.
Memories and memory allocation.
Programming devices.
PLC programming languages.
Identify the basic IEC 611313 programming languages: Relay Ladder Diagram (RLD), Structured Text (ST), Function Block Diagrams, Instruction List (IL) and sequential Function Chart (SFC)

DCS components and operation, system architecture, redundancy concept and hardware configuration, HMI, types of display, reporting and trending
Alarm management system and process troubleshooting
Safety Instrumented System (SIS) and HIPPS.
Fire & Gas system technology, types of sensors, theory of operations and applications

TOPICS COVERED

What is control system?
Purpose of instrumentation
Variables measured and controlled
Final control elements
Basic measurement concepts
Flow measurement
Level measurement
Pressure measurement
Temperature measurement
Basic Control Theory
Closed Loop Control
PLC components, architectures and applications
DCS components and operation
Safety Instrumented System (SIS)
High Integrity Pressure Protection System (HIPPS)
Alarm management system
Process troubleshooting

Audience

Process Control Engineers
Safety Engineers
Control Systems Engineers
Instrumentation Engineers
Operations Managers
Maintenance Technicians
Plant Managers
Safety Analysts

Content

INTRODUCTION TO INSTRUMENTATION AND CONTROL SYSTEM

Measured and controlled variables

Performance terms and specifications
Measurement terminology
P&ID symbols

FLOW MEASUREMENT

Basic fluid properties
Reynolds number
Flow measurement and rangeability
Flow measuring sensors types
Differential pressure flowmeters
Mechanical flowmeters
Ultrasonic flowmeters
Mass flow-meters, Coriolis.

LEVEL MEASUREMENT

Basic principles
Float systems
Displacement systems
Conductive level detection
Ultrasonic level measurement
Radar gauging

PRESSURE MEASUREMENT

Basic principles
Bourdon tubes
Diaphragm elements
Electrical displacement sensors

TEMPERATURE MEASUREMENT

Basic principles
Thermocouples
Resistance thermometry
Thermistors
Radiation thermometry

FUNDAMENTALS OF PROCESS CONTROL

Process Dynamic
ON/OFF control
Proportional control
Proportional offset
Integral action
Integral windup
Stability
Derivative action
PID control
Control algorithms
Load disturbances and offset
Feedforward control, cascade and ratio control

FUNDAMENTALS OF TUNING

Basic principles
Open loop reaction curve method (Ziegler-Nichols)
Default and typical settings
Closed loop continuous cycling method (Ziegler-Nichols)

BASIC VALVE THEORY

Valve types
Control valve characterization
Defining the valve flow coefficient, Cv
Inherent characteristics
Valve testing and diagnostics

FUNDAMENTALS OF PLC HARDWARE

PLC hardware configurations
Electrical wiring for inputs and outputs
Electrical Ladder Diagrams and wiring symbols
Block diagram of typical PLC
PLC processor module – memory organization
Input and output sections - module types, Power supplies

PLC PROGRAMMING

Programming languages
Types of PLC languages
Ladder Diagram Format
Ladder relay instructions
Timers and Counters
Methods of representing Logic, Boolean Algebra, instruction code and graphical presentation
Fundamental ladder logic instruction set

DATA COMMUNICATION & PROTOCOLS

RS-232 interface standard
RS-485 interface standard
Data high way plus DH+
Network topology and Protocols
Local area network (LAN)
Ethernet
Token path

INTRODUCTION TO IEC 61131-3 Standard

Concepts
Common elements
Programming languages: Ladder Diagram
Function block diagrams

DISTRIBUTED CONTROL SYSTEM (DCS)

System architecture
Major component
Controllers
I/O System
Communication
Human Machine Interface (HMI)
Types of display, Trends, Alarms and overview.
DCS management of abnormal conditions
System integration
Troubleshooting from operation prospective.

SAFETY INSTRUMENTED SYSTEM

What is Safety Instrumented System?
Main components associated with an SIS
Risk reduction
Required Safety Integrity level (SIL)

HIGH INTEGRITY PRESSURE PROTECTION SYSTEM (HIPPS)

Device integrity and architecture
Process sensors
Logic solver
Final element
Diagnostic
Testing frequency
Common cause failures
Operations and troubleshooting

ALARM MANAGEMENT SYSTEM

Introduction
History of alarm system
Definitions
Alarm basics
Alarm management costs and design
Alarm management and safety instrumentation
Alarm set point
Alarm presentation
Alarm processing
Improving the plant's alarm management
Symptoms of alarm management problems
The tools and elements of A.M
A.M improvement and rationalization
Emergency shutdown procedure

FIRE & GAS SYSTEM

System choices and considerations
Smoke detectors, types, principle of operations and applications
Thermal sensors
Gas detection, Combustible Gas detectors, and toxic gas detectors
Fire detection, optical flame sensors, UV, IR, UV/IR, dual IR, Multi-IR
System architecture
Logic Solver, input / output device interface with logic solver.
Typical triplicated system example for tricon controller in fire & gas system

NOTE:

Pre & Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

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Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences. Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

30% Lectures
30% Workshops and work presentation
20% Group Work& Practical Exercises
20% Videos& General Discussions

Course Details