What you'll learn:
- Learn the essentials of process controls and PID controllers for a successful career in process industries
- Successfully draw the correct information from basic to advanced process control loops
- Master the intricate terminological details of process control (process variable, set point, error, offset, load disturbance...)
- Identify any process control loop and describe its main tasks and functionalities
- Describe the basic function and method of operation for the main control loop components (sensor, transmitter, controller, actuator, control valve...)
- Differentiate between feedback and feedforward control loops
- Explain the basic implementation process for each of the following types of control: Cascade, ratio, split range…
- Differentiate between On/Off, discrete, multi-step and continuous controllers
- Describe the basic mechanism, pros and cons of the following modes of control action: On/Off, Proportional (P), Integral (I), Derivative (D), PI, PID...
- Describe the general goal of PID controller tuning
- Apply the Ziegler Nicholls method to tune P, PI and PID controllers for optimum performance
- Understand control valves working principles for successful operation of your plant and piping systems
- Understand control valve construction details (bonnet, stem, disc, seat, packing, body, actuator, positioner…)
- Identify and know the principles of operation of common control valve actuators (diaphragm, piston, rack and pinion, scotch yoke)
- Dismantle and assemble various types of control valves and actuators using 3D and 2D models
- Understand how single acting and double acting pneumatic actuators work through graphics and 3D animations
- Know how to convert a single acting spring return actuator to a double acting actuator and vice versa
- Understand the concept of failure mode in control valves : Fail Open "FO", Fail Closed "FC", Fail As Is "FAI"
- Understand the concept of "Air-to-push-up" and Air-to-push-down"
- Understand the concept of "direct-acting" and "reverse-acting"
- Know how to convert a fail close actuator to a fail open actuator and vice versa
- Understand the concept of valve flow coefficient "Cv" and familiarize yourself with the various units
- Know how to determine flowrate and pressure drop through control valves for different valve lifts
- Know how to match the valve characteristics to the process
- Know how to construct the installation curve for a given control valve
- Understand the effect of selecting a control valve larger than necessary
- Understand the effect of differential pressure on the valve lift and actuator operation
- Differentiate between fast opening, linear and equal percentage valve characteristics
- Understand how valve positioners operate
- Know the different types of valve positioners (P/P, I/P, force balance, motion balance, digital…)
- Understand when a positioner should be fitted
- Understand the working principles of I/P converters and how they are used in control valves
- Understand the control of pressure in a pipe
- Understand the control of flow in a pipe
- Understand how self-acting pressure controls work and their applications
- Understand how self-acting temperature controls work and their applications
- Understand flow merging control
- Understand flow splitting control
- Understand centrifugal pump control systems (discharge throttling, variable speed drive, minimum flow…)
- Understand positive displacement pump control systems (recirculation pipe, variable speed drive, stroke adjustment…)
- Understand compressor control systems (capacity control, variable speed drive, anti-surge…)
- Understand heat exchanger control systems (direct control, bypass control, back pressure control…)
- Understand reactor temperature control systems
- Understand fired heater control systems
- Understand container and vessel control systems
- Understand electric motor control systems (ON / OFF actions)
- Know and understand the concept of Safety Instrumented Systems (SIS)
- Know and understand the concept of Alarm Systems and Interlocks
- Understand through extensive 3D animation the techniques and methods used in process industries to measure temperature, pressure, flow and level
- Put your knowledge to the test at the end of each section with a valuable technical quiz (420+ questions and solved problems)
- Get access to a set of valuable downloadable resources
Welcome to this 16 hour masterclass on process control and instrumentation.
This valuable masterclass is organized into 6 parts :
Part 1: Process Control and PID* Controllers
Part 2: The Final Control Element - Control Valves, Actuators and Positioners
Part 3: Practical Examples of Temperature, Pressure, Flow and Level Controls
Part 4: Practical Examples of Process Equipment Controls (Heat Exchangers, Pumps, Compressors, Reactors, Piping Systems…)
Part 5: Safety Instrumented Systems (SIS), Interlocks and Alarms
Part 6: Instrument Devices For Temperature, Pressure, Flow and Level Measurement
Part 1 is an essential guide to a complete understanding of process control principles and PID* controllers design and tuning. In this first module, we will break down for you all the process control principles into easily digestible concepts, like feedback controls, open loops, split range controls, self-acting controls... Useful reference data, technical recommendations, field observations and numerous process control schemes are presented in an-easy-to-understand format. This module also cautions the process control engineer that the performance of a properly designed process control system can be severely compromised when used in conjunction with incorrect PID* controller settings. In this regard, PID* controller tuning guidelines and their rationale according to the Ziegler Nicholls method are offered to ensure optimum performance. Typical tuning examples have been included to assist you in understanding how specific formulae are applied.
Part 2 focuses on the final control element of any process control system, that is the valve-actuator-positioner assembly. In this second module, you will find valuable insights into the working principles and construction details of the following control elements:
Control valves (sliding stem and rotary / fast opening, linear and equal percentage)
Mixing and diverting 3-port control valves
Diaphragm actuators ("air-to-push-up" and "air-to-push-down")
Piston actuators (Single Acting and Double Acting / Fail Open (FO) and Fail Closed (FC))
Rack-and-pinion actuators (Single Acting and Double Acting / Fail Open (FO) and Fail Closed (FC))
Scotch Yoke actuators (Single Acting and Double Acting / Fail Open (FO) and Fail Closed (FC))
Pneumatic positioners (force balance, motion balance)
Digital positioners
I/P converters
...
The module then proceeds through a series of process examples and solved problems that require you to:
Dismantle and assemble various types of control valves and actuators using 3D and 2D models
Identify the net effect of various control valve/actuator assemblies (direct acting, reverse acting, fail open, fail close...)
Convert an actuator from Single Acting to Double Acting configuration and vice versa
Convert a control valve/actuator assembly from a Fail Closed (FC) to a Fail Open (FA) configuration and vice versa
Construct the installation curve for a control valve
Determine flowrate and pressure drop through control valves for different valve lifts
Match the valve characteristics to the given application
Examine the effect of selecting a control valve larger than necessary
Examine the effect of differential pressure on the valve lift and actuator operation
Determine when a positioner should be fitted
...
This will help you develop the necessary skills to ensure your process control systems run smoothly.
Part 3 focuses on fluid properties control. This module identifies different ways in which precise control of temperature, pressure, flow and level is ensured. It provides real industrial examples of process control loops and the keys to interpret them in high quality video lectures. Both self-acting and modulating types of control are discussed in exquisite details.
Part 4 introduces you to advanced process control in process industries. It identifies different ways in which precise control is ensured for the main process equipment such as chemical reactors, pumps, compressors, fired heaters and heat exchangers just to name a few. The numerous examples outlined in this module are taken from petroleum refineries, chemical and steam boiler plants, making the knowledge gained in this section extremely valuable to practicing engineers and technicians.
Part 5 discusses the important concepts of Safety Instrumented Systems (SIS), Alarm Systems and Interlocks. It presents their anatomy, their requirement, their functions and how they are represented in engineering drawings such as Piping & Instrumentation Diagrams.
Part 6 illustrates through 3D animations and cross-sectional views the main control instrument devices to measure temperature, pressure, flow and level. These instruments include thermocouples, RTDs’, Bourdon tube pressure gauges, Coriolis flowmeters, level radars and capillary systems just to name a few...
As you proceed through the masterclass, answer the 400+ question quiz to test your knowledge and emphasize the key learning points.
The quiz includes:
True/False questions
Multi-choice questions
Images, cross-sectional views
Solved problems
And much more...
You have our promise that at after completing this masterclass, you will be an advanced process control professional, you won’t be a process control expert but you will be prepared to become one if that is what you want and persist to be. In fact, the knowledge that you will gain will help you understand all process control loops, instrumentations and safety systems so that you can draw the correct information from them. This will set you apart from your peers, whether you are a graduate student, a practicing engineer or a manager, and will give you an edge over your competitors when seeking employment at industrial facilities.
So with no further ado, check out the free preview videos and the curriculum of the course and we look forward to seeing you in the first section.
Hope to see you there
WR Training
Spread the wings of your knowledge
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* When PID is mentioned, it is with reference to Proportional (P), Integral (I) and Derivative (D) control actions
Safety note
Sizing, selection, installation and tuning of process control systems (control valves, actuators, controllers, sensors, wiring...) should not be based on arbitrarily assumed conditions or incomplete information. Merely having a control system does not make a process safe or reliable. Now, while it is obviously impossible to address every installation mistake ever made, we have included a valuable summary of the most frequent installation mistakes encountered in the field. We are confident that this valuable masterclass will help you contribute to the safety of your facility, your fellow workers and yourself.
