Control and Instrumentation

Training that covers the practical maintenance aspects of industrial instrumentation

This course is in three modules Measurement, Valves and Controllers and is designed to be progressive with each module building on the previous.

This course enables trainees to,

· Measure current loop signal
· Connect additional instruments into current loops
· Carry out calibrations involving pressure, temperature, level and flow
· Calibrate delta P and gauge pressure transmitters
· Zero and span 4 - 40mA current loops
· Calibrate I to P convertors
· Understand pneumatic valve positioners
· Set up valve positioners
· Stroke check valves
· Adjust valve actuators
· Operate single loop controllers in Manual or Auto
· Change modes using remote Setpoints
· Set alarms levels and high lo range warnings
· Adjust PID settings for loop response
· Understand Controller faceplate indications during problem solving

Training consists of three off three day training modules or similar combination to suit shift working patterns. The training delivery can be adapted to suit company's specific requirements in terms of application, hands on practice or specific customer equipment.

This is a highly practical training course focussing on industrial Instrumentation maintenance practices and fault-finding procedures with a lot of the training being hands on work directly related to the course content.

Instrumentation - Measurements (T3) Module 1

· Signals and Standards

o Pneumatic Signals

o Voltage Signals

o Current Loops

o Loop Connections

o Power Supplies

· Process Measurement

o Temperature - Resistance, Thermocouple

o Pressure - DP Cells, Gauge, Differential, Absolute

o Level - Head Pressure, Capacitive

o Flow - Orifice Plate, Magflow, Vortex

· Indication and Recording Equipment

o Digital and Analogue Indicators

· Installation and Calibration

o Zero adjustment

o Span adjustment

o Standard (calibration) equipment

o Commissioning and bringing on-line

· Smart Transmitters

o Setting up and calibrating using a Smart Transmitter

Safety procedures will be covered at each stage and practical exercises will cover the use of isolating/equalising manifolds on flow systems, the use of pockets in conjunction with temperature probes etc. The implications of working on sensors which form part of a control loop will also be covered along with recommended safe working procedures.

Instrumentation - Valves (T4) Module 2

· Pneumatic Principles

o Compressed Air

o Instrument Air Systems

o Pneumatic Signals

· Pneumatic Instrument - Components

o Flapper/Nozzle

o Air Relays

o Bellows

o Booster Relays

· Pneumatic Instrument - Equipment

o I/P Convertors

o P/I Transmitters

o P/P Transmitters

· Control Valves

o Valve types, Component Parts, Valve Flow characteristics

· Control Valve Actuators

o Direct Acting

o Reverse Acting

o Double Acting

o Motorised

· Control Valve Positioners

o Basic Operation

o Types of Positioner

o Fault-Finding

o Valve Characterisation

o Setting up the Valve, the Actuator, the Positioner

The implications of working on valves which form part of a control loop will also be covered along with recommended safe working procedures.

Instrumentation - Controllers (T5) Module 3

· Basic Principles of Closed Loop Control Systems

o The need for feedback in a control system

o Terminology in control systems - Set point, Process Variable, Output

o 3-controller operating modes - Automatic, Manual, Remote, Internal

o Basic closed loop systems and their operation

· Types of Control

o Open loop, Closed loop, Feed-forward control

· Controller Actions

o Proportional, Integral, Derivative

o Tuning a PID controller to a process

· Control Systems Configuration

o Cascade Control, Supervisory Control, Ratio Control

· Problem Solving

o Measurement techniques in a control loop

o Analysis of controller problems

o Diagnosis of faults

· Practical Exercises

o Work on simulated closed loop control loops to gain an understanding of setting P, I and D terms.

o Build a closed loop pressure control loop using techniques learned in previous courses Measurement, Valves and Controllers. Calibrate, set up and commission this control loop.