Customized - Introduction to instrumentation and process control

Overall objectives

• Acquire an overview of automated systems
• Develop important concepts like: open and closed loops, feedback, PID controllers, transmitters, pneumatic valves, mass, weight, velocity, heat, temperature, energy, etc.
• Set industrial process control in a factory context
• Distinguish the role and functions of equipment
• Describe the performance of major types of transmitters and final control elements
• Use devices such as: transmitters, recorders, calibrators, controllers, valves, etc
• Explain inlet/outlet circuits of various components
• Troubleshoot a simple loop
• Install and hook-up control loop devices
• Use industrial final control elements and actuators
• Correctly adjust PID industrial controller parameters
• Read and interpret plans, schematics, and block diagrams

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Specific objectives

General

• Study the basic principles
• Distinguish between open, closed loops
• Choose the appropriate performance criteria
• Describe tuning objectives, types of processes
• Recognize process flaws and models
• Alarms

Signals

• Discern the roles of components, standards, symbols
• Calculate and convert standard signals
• Pneumatic signals, electric (I, V, and F), numerics
• Explain the performance of inlet/outlet circuits of analog and numeric components
• Calculate the impedance in a measurement loop using conventional transmitters (active transmitters, 4-wire transmitters) or self-powered types (passive transmitters, 2-wire transmitters)

Reading of plans and symbols

• ISA standards 5.1, 5.2, 5.3, 5.4, and 5.5
• Other types of plans: hook-ups, SAMA, etc.
• Block diagrams

Metrology

• Explain the statistical characteristics and dynamics of measurement, dead band, and systematic errors
• Compare mechanical/electrical conversion methods
• Enumerate measurement techniques of mass, weight, pressure, level, flow, and temperature
• Compare measurement methods
• Know installation techniques, hook-ups, maintenance and calibration of industrial components

Final control elements

• Classify control valves based on: actuators, relationship open/close vs flow, position at rest, security, number of ports, characteristics, type (gate, globe, etc.), etc.
• Justify the use of a positioner on control valves
• Enumerate valve parts and explain valve construction
• Define volumetric co-efficient CV
• Draw a block diagram of electropneumatic, pneumatic and electric positioners
• Explain the performance of I/P transducers and to determine characteristics for proper applications
• Use a positioner in a control loop and carry-out appropriate tuning
• Use of power supplies

Tuning

• Process modeling using step tests
• Differentiate types of processes: self-regulating, integrator, run-away
• Recognize process flaws
• Define on/off action, proportional, integral, and derivative
• Discern PID functions and recognize the effects of each
• Convert controller tuning units from one model to another (standard, serial, parallel)
• Adjust time constants of filters and regulators
• Choose direct or inverse action
• Tune repetitively PID industrial controller parameters
• Know principles of PID controller tuning methods
• Troubleshoot and diagnose problems of simple loops
• Start-up a simple loop
• Interpret technical documentation (French and English)

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Contents

Introduction

• Control loops
• Noise, disturbances, load
• Performance criteria
• Tuning objectives
• Alarms and other automated system functions

Signals

• Standard signals: 4-20ma, 1-5V, 0-5V, 0-10V, frequency, 3-15PSI, 20-100Kpa, other
• Advantages and disadvantages
• Engineering units
• Conversions
• Calculations

Symbols

• ISA symbols 5.1 to 5.5
• Bubbles
• Labels
• Main schematics
• Hook-up schematics
• Transmitter hook-ups - 2-wire and conventional
• SAMA symbols

Metrology

• Measurement chain
• Pressure, level, temperature, and flow measurement
• Mass and weight
• Velocity
• Flow (volumetric, mass, velocity) - liquid and gas
• Pressure
• Temperature
• Calibrators, calibration
• Transmitters
• Transducers

Final control elements

• Economical aspects
• Importance of final control elements
• Noise, flashing, cavitation
• CV
• Performances and characteristics
• Specifications
• Standards
• Actuators
• Positioners
• Installation and maintenance
• Other final control elements

Controller

• Simple process models
• Types of processes
• Process flaws

Controllers

• Proportional
• Integral
• Derivative
• Filters, units, effects of each

Tuning

• Intuitive tuning
• Traditional tuning methods: step test, natural frequency, intuitive by repetition
• Advantages and disadvantages of each method
• Importance of delay
• Limits of traditional methods

Conclusion

• Role of each component
• Installation
• Functions of technical personnel
• Calibration
• Security

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Schedule

• On-site training
• Exact training date determined by involved parties
• Participants need a laptop (groups of 2)
• The course usually lasts four days, but it is possible to eliminate or reduce certain elements and cover the course in three days

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Manual used

• Ruel, Michel. Introduction to instrumentation and process control, Levis, self-published 1993, 552p. Manufacturer's documentation
• Industrial plans

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Labs

• Exercises using your components: controllers, temperature and flow indicators, thermocouples, transmitters, calibrators, PLCs, etc.
• Exercises using PID software
• Exercises using strategic software
• Exercises using simulated processes by electronic circuits

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Instructors

• Training experience combined with experienced technicians
• Work experience in pulp and paper
• Solid experience in theory and practice
• Will use manuals adapted to training
• Will use existing equipment found in your lab
• Credible, flexible, competent
• Conscientious of training objectives