Course Overview

Process control comprises the fundamental principles important in the application of physicochemical systems often stumbled upon by chemical engineers, which includes chemical reactors, heat exchangers, and mass transfer equipment.

Who uses process control system?

It is one of the duties of engineers to design, construct and operate a physical system to perform in a particular and desired manner. Therefore, in the performance of this responsibility, there must be proper maintenance of the system to suit a particular condition, and this is where process control comes in.

 What is process control engineering?

Simply put, process control refers to the regulation of all processes undertaken in process industries. For instance, controlling level, temperature, pressure, and flow is expedient in several process applications.

It is for this reason that Zoe Talent Solutions is undertaking a course in this field to break into tidbits the concept of process control in industries, its importance, and the different mediums employed to carry out precise control and the various forms of instrumentation employed to perform tasks for temperature, pressure, flow and level.

 Course Objectives

The objectives of this Zoe course are to primarily empower professionals to-

• Understand the concepts of process control and relevant information on the characteristics and properties of the measurement of a process variable
• Solve unfamiliar and rare measurement situations in the workplace by putting to practice the techniques and principles highlighted in this course
• Become conversant with various control systems such as PID Control and maintain a process control system using PID Control
• Be familiar with the various concepts, characteristics, and properties of a process control system
• Possess the necessary skill set to maintain the operation of instrumentation and designing, building, testing sensors, and signal conditioning circuits

Training Methodology

With the aid of well-selected experts in the field, this course is taught by employing several strategies such as online classroom lessons, snap tests, 3D Animations, the performance of calculations by trainees using sample systems, tasks on designing of instrumentation system, illustration of process control employing dynamic simulators.

Zoe Talent Solutions applies this training method for all its courses. It is referred to as the Do-Review-Learn-Apply Model.

Organisational Benefits

With the personnel of corporate organisations engaging in this course, they are bound to receive the following benefits:

• Confident and sound personnel with appropriate knowledge of the use of sensors and instrumentation systems
• An improved skill set, which would have a positive ripple effect on the company
• Increased productivity and efficiency in the performance of process control through the use of their skills and proper implementation of principles governing sensors and transducers
• Ability to provide advisory aid on the installation of a new system concerning sensor choice, specification, and circuit design
• An improved dependence on suitable in-house technologies employed in plant process and instrumentation systems, thus reducing the attachment to external vendors
• A reduction in financial cost and expenses and ensure an improved fiscal savings system

Personal Benefits

Individuals undertaking this course promptly and diligently would obtain several benefits for their good and the organisation they are involved with. These benefits include:

• An in-depth understanding of the rudiments of process control and instrumentation to boost one’s career in the process industry
• Ability to comprehend the key terms and perspectives of process control such as Process Variable (PV), Set Point (SP), Operating Point (OP), Error, Offset
• Discovery of the various control loops and the ability to differentiate their separate tasks.
• An improved understanding of the operation of sensors, transducers and instrumentation techniques
• An equipped skillset of process control techniques and tuning
• Becoming conversant with the various process control systems and the methods employed in a modern industrial system.
• Ability to select and gauge the suitable sensor technology for a particular instrumentation system
• Proper identification of components and characteristics of a process control system.
• Engaging in the calibration and signal condition of a process control system and taking its measurements
• Proper comprehension of the risk and limitations accrued to the open-loop systems and risks associated with closed-loop negative feedback systems
• Ensure optimum control by tuning a system with the aid of a particular system

Who Should Attend?

• Control, process, chemical, and design engineers
• Electrical and electronics engineers who work in the oil and gas sector, production plants, and industry
• Production professionals
• Technical operations and maintenance professionals who are tasked with the care and maintenance of system operators in process control
• Installation and maintenance engineers
• System integrators
• Consultants and sales professionals who are in the manufacturing of foods, products
• Persons interested in learning the rudiments of process control and instrumentation
• Personnel involved in other professions but need an understanding of the techniques used in process control and measurement

Course Outline

Module 1: Overview of Process Control

• Introduction of Process Control system
• Functions
• Importance
• Procedures involving Process Control
• Implementation of Process Control
• Documentation of Process Control
• Process Control Strategies

Module 2: Terminologies

• Process Design
• Measurements
• Final Elements
• Control Structure
• Control Calculations

Module 3: Principles of Operation of Sensors and Transducers

• Temperature Measurements
• Strain Measurements
• Pressure Measurements
• Flow Measurements
• Level Measurements

Module 4: Instrument Loops

• Functions
• Components
• Types of Signals
• Labelling of Conventions and Symbolisations

Module 5: Sensors & Transmitters

• Measurement and Detection of Pressure, Temperature, Level and Flow
• Principles
• Selection Process

Module 6: Control Valves

• Technologies
• Accessories
• Limit Switches
• Solenoid valves
• Specification process

Module 7: Process Control

• Introduction to Advanced Process Control
• Functions of Controller and Performance Process
• ON/OFF and PID Controller
• Split-range, cascade, ratio, override, feed-forward

Module 8: Control and Safety Systems

• Introduction to Safety Instrumented Systems
• Functions, Role of a Distributed Control Systems (DCS)
• Separation of Control and Safety Systems

Module 9: System Integration, Present Practices and Process Considerations

• Fibre optic cables
• Linearisation
• Commissioning of Subsystems
• Selection Considerations
• Smart Instruments and Fieldbus
• Construction Materials

Module 10: Programmable Logic Controllers

• Output Systems/ Digital Input
• Output Systems/ Analog Input
• Fundamentals of PLC

Module 11: Level Measurement

• Principles
• Buoyancy tape systems
• Hydrostatic pressure
• Ultrasonic measurement
• Radar measurement
• Density measurement

Module 12: Temperature Measurement

• Thermocouples
• Thermistors
• Humidity
• Resistance temperature detectors (RTDs)
• Selection tables
• Temperature technologies

Module 13: Flow & Mass Measurement

• Principle of flow measurement
• Differential pressure flowmeters
• Positive displacement
• Mass Flowmeters
• Selection tables
• Installation consideration
• Magnetic flowmeters

Module 14: Fundamental Control Philosophies

• Open loops
• Closed loops
• Cascade control
• Tuning Rules
• Adaptive and self-tuning controllers

Module 15: Diagrams & Numbering

• P& ID Symbols
• Selection Criteria
• Typical applications