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Process Controls - Continuous Process

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Process Controls - Continuous Process Courses

Instrumentation Control Training

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with input field devices that perform online analyses. After completing this course, participants should be able to describe common applications and procedures that are associated with the use of online analyzers. They should also be able to describe some of the many different types of online analyzers that are used in continuous process systems.

Learning Objectives

By the end of this course, you will be able to:

  • Describe common applications of online analytical field devices in continuous process systems
  • Describe the essential components of most online process analyzers
  • Describe general concerns associated with the installation, operation, and maintenance of online analyzers
  • Describe common types of electrochemical analyzers that use property- or compound-specific sensors for online analyses in continuous process systems
  • Describe one type of flammable vapor analyzer that is commonly used in continuous process systems
  • Describe common maintenance concerns associated with electromagnetic analyzers
  • Describe optical analyzers that are commonly used for online analyses in continuous process systems
  • Describe mass spectrometers that are commonly used for online analyses in continuous process systems
  • Describe nuclear devices that are commonly used for online analysis of density
  • Describe common maintenance concerns associated with electromagnetic analyzers
  • Describe chromatographs that are commonly used for online analyses in continuous process systems
  • Describe common maintenance concerns associated with gas chromatographs

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with input field devices that sense and monitor temperature, pressure, or weight. After completing this course, participants should be able to describe the basic operation of various types of temperature, pressure, and weight transducers and transmitters.

Learning Objectives

By the end of this course, you will be able to:

  • List typical temperature, pressure, and weight applications
  • Explain how thermocouples, RTDs, and thermistors work
  • Explain reference junction compensation
  • Explain RTD lead length compensation
  • Explain how load cells work
  • Explain absolute, gauge, and differential pressure measurement
  • Explain the function of set points
  • Describe transmitter operating parameters, and define the following terms: range, LRL, URL, LRV, URV, span, turndown ratio, engineering units, PV, and SV
  • Explain how transmitter accuracy can be specified
  • Identify and describe common transmitter configuration options
  • Describe the ways that transmitters communicate signal information
  • Describe how to set up a traditional transmitter
  • Explain how to communicate with, configure, and test a smart transmitter

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with some of the basic material, process, and system characteristics that can affect process control. After completing this course, participants should be able to identify and describe some basic factors that affect process control. They should also be able to describe common process control methods and the operation of loops that control critical process variables.

Learning Objectives

By the end of this course, you will be able to:

  • Identify variables that are routinely monitored and controlled by process control systems
  • Describe basic material properties and fluid flow characteristics
  • Describe the relationship between temperature and pressure in fluids
  • Describe the basic principles and methods of heat transfer
  • Identify and describe some basic factors that affect process control
  • Describe on/off, proportional, integral (reset), derivative (rate), and proportional-integral-derivative (PID) control algorithms
  • Identify and describe pressure, temperature, level, flow, and pH control loops in a typical boiler system

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with basic procedures for configuring traditional and “smart” analog field devices. After completing this course, participants should be able to explain how to set zero and span and perform a calibration procedure on a traditional analog transmitter. They should also be able to explain the basics of how to configure a smart analog field device using a portable communicator or a laptop PC.

Learning Objectives

By the end of this course, you will be able to:

  • Define “analog” as it relates to process control signals
  • Explain how analog field devices function in process control systems
  • Explain how to set zero and span on a traditional electronic transmitter
  • Explain how to perform a calibration procedure on a non-smart transmitter
  • Explain the relationship between the value of a process variable and a transmitter’s 4-20 milliamp output signal
  • Identify the basic configuration parameters for smart transmitters
  • Calculate a process measurement from a smart transmitter’s analog signal output
  • Explain how to configure a smart field device with a portable communicator
  • Explain how to configure a smart field device with a laptop PC

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with basic procedures for using a distributed control system (DCS) to configure digital field devices. After completing this course, participants should be able to explain how to use the Honeywell TDC 3000 and the Fisher-Rosemount DeltaV to configure a digital field device.

Learning Objectives

By the end of this course, you will be able to:

  • Explain how digital field devices differ from analog field devices
  • Describe how a DCS is used to monitor and control a process
  • Identify and describe the information that is provided on the point detail screens of a typical DCS
  • Describe a basic procedure for using a DCS to configure a digital field device
  • Describe the basic operating principles and architecture of fieldbus technology
  • Describe a basic procedure for using the DeltaV to configure a field device

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with input field devices that sense and monitor level or flow. After completing this course, participants should be able to describe the basic operation of various types of level measurement and flow measurement devices.

Learning Objectives

By the end of this course, you will be able to:

  • Define the following terms: level, point level measurement, continuous level measurement, direct level measurement, and indirect level measurement
  • Identify common examples of point, continuous, direct, and indirect level measurement devices
  • Identify factors that determine the type of level measurement device used for a particular application
  • Define the following terms: density, specific gravity, and hydrostatic pressure
  • Describe how pressure gauges, differential pressure transmitters, bubblers, and displacers provide level measurements
  • Describe common applications and limitations associated with pressure gauges, differential pressure transmitters, bubblers, and displacers
  • Describe factors that must be considered during the configuration of pressure gauges, differential pressure transmitters, bubblers, and displacers
  • Describe how capacitance, or radio frequency (RF) devices, and conductance devices measure level
  • Describe common applications and limitations associated with capacitance and conductance devices
  • Describe factors that must be considered during the configuration of capacitance and conductance devices
  • Describe how radar, ultrasonic, laser, and nuclear level measurement devices work
  • Describe common applications and limitations associated with radar, ultrasonic, laser, and nuclear level measurement devices
  • Describe how tuning fork sensors and weight devices provide level measurements
  • Describe common applications and limitations associated with tuning fork sensors and weight devices
  • Describe how differential pressure flow meters provide flow measurements
  • Identify common primary flow elements that are used in differential pressure measurement
  • Describe common problems that can affect the operation of differential pressure flow meters
  • Describe how positive displacement flow meters measure flow
  • Describe how turbine flow meters measure flow
  • Describe applications and limitations associated with positive displacement flow meters and turbine flow meters
  • Describe how magnetic, vortex, and ultrasonic flow meters measure flow
  • Describe applications and limitations associated with magnetic, vortex, and ultrasonic flow meters
  • Describe how Coriolis flow meters and thermal flow meters work
  • Describe applications, limitations, and installation considerations for Coriolis flow meters and thermal flow meters

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with basic procedures for using field communicators to configure “smart” analog field devices. After completing this course, participants should be able to explain how to configure smart analog transmitters using a HART communicator, a Honeywell communicator, a Yokogawa communicator, and the Foxboro Local Display Module.

Learning Objectives

By the end of this course, you will be able to:

  • Explain how to use the HART communicator to perform the basic configuration of a magflow transmitter
  • Explain how to use a Honeywell SFC to perform the basic configuration of a differential pressure transmitter
  • Explain how to use the Yokogawa BT200 to perform the basic configuration of a pressure transmitter
  • Explain how to use the Foxboro Local Display Module

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with the basic operation and use of multiple loop control. After completing this course, participants should be able to explain the basic operation of multiple single loops, cascade control, ratio control, feed-forward control, and special connections that are used with multiple loop control. They should also be able to use a piping and instrumentation diagram (P&ID) to trace boiler control functionally.

Learning Objectives

By the end of this course, you will be able to:

  • Explain typical interactions between single control loops
  • Explain several types and applications of cascade control
  • Explain several types and applications of ratio control
  • Describe computational components that are typically used in multiple loop control
  • Explain how limiters, interlocks, override controls, and selective controls are used
  • Explain the difference between feedback control and feed-forward control
  • Describe the advantages, problems, and applications of feed-forward control
  • Identify the main boiler control components and connections on a P&ID
  • Trace boiler control functionality

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with the basic operation, maintenance, and calibration of components in a pneumatic control system. After completing this course, participants should be able to describe how to service the various devices that help dry and filter the air and how to check pressure control devices in the system for proper operation. They should also be able to describe the basic operation and maintenance of some typical control components in a pneumatic system.

Learning Objectives

By the end of this course, you will be able to:

  • Describe the operation and maintenance of air supply components that dry and filter compressed air in a pneumatic control system
  • Describe the operation and maintenance of pressure control components in a pneumatic control system
  • Describe the operating principles of pneumatic control components
  • Identify the basic types of pneumatic sensor-transmitters
  • Describe the operation and maintenance of sensor-transmitters
  • Identify and describe common types of pneumatic receiver-controllers
  • Describe basic calibration procedures for a typical receiver-controller
  • Identify and describe common types of pneumatic actuators
  • Describe procedures involved in testing, calibrating, and maintaining pneumatic actuators

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with the basic operation and use of single control loops. After completing this course, participants should be able to explain the basic operation of a feedback control loop, describe how the proportional-integral-derivative (PID) control algorithm works, and identify and describe features that may be used to enhance the performance of a PID controller.

Learning Objectives

By the end of this course, you will be able to:

  • Describe a typical feedback control loop
  • Describe how the PID control algorithm works
  • Identify and describe features that are commonly used to enhance the performance of a PID controller
  • Describe a typical single-loop pressure control system
  • Describe a typical single-loop temperature control system
  • Describe a typical single-loop level control system
  • Describe a typical single-loop flow control system
  • Describe a typical single-loop pH control system

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with the operation and use of smart controllers. After completing this course, participants should be able to describe basic procedures for installing, configuring, operating, and tuning smart controllers.

Learning Objectives

By the end of this course, you will be able to:

  • Describe the purpose of a smart controller
  • Describe a smart controller’s common control options
  • Explain how to install and wire a new or replacement smart controller
  • Explain how to configure a smart controller
  • Explain how to operate a smart controller
  • Explain how to tune a smart controller for optimum performance
  • Describe the procedures for troubleshooting a single loop process controlled by a smart controller
  • Describe the procedures for tuning a single-loop process controlled by a smart controller

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with basic procedures for troubleshooting the inputs and outputs of a distributed control system (DCS). After completing this course, participants should be able to explain how to gather information about a DCS I/O problem, identify possible causes of the problem, test the possible causes, and finish up the troubleshooting procedure.

Learning Objectives

By the end of this course, you will be able to:

  • Explain how to gather information about a DCS I/O problem
  • Explain how to eliminate possible causes of a DCS I/O problem
  • Explain how to prioritize possible causes of a DCS I/O problem
  • Explain how to test possible causes of a DCS I/O problem in a logical order
  • Explain how to complete the procedures for troubleshooting a DCS I/O problem

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with basic procedures for troubleshooting control loop problems. After completing this course, participants should be able to explain how to use a systematic troubleshooting procedure to troubleshoot problems in control loops.

Learning Objectives

By the end of this course, you will be able to:

  • Explain how to gather information about a control loop problem
  • Explain how to eliminate components or functional elements as possible causes of a control loop problem
  • Explain how to prioritize possible causes of a control loop problem
  • Explain how to test possible causes of a control loop problem in a logical order
  • Describe the steps that should be taken to complete the troubleshooting of a control loop problem
  • Describe a basic procedure for troubleshooting a discrete control loop
  • Describe a basic procedure for troubleshooting a single analog control loop
  • Describe considerations in troubleshooting a multiloop control system

Duration: 2.00 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course is designed to familiarize participants with the basic principles of tuning control loops. After completing this course, participants should be able to describe how to prepare for tuning a loop and how to tune a loop manually using a systematic trial and error method, the Ziegler-Nichols open loop method, and the Ziegler-Nichols closed loop method. They should also be able to describe how tuning can be accomplished by the auto-tune function, by artificial intelligence features, and by tuning software.

Learning Objectives

By the end of this course, you will be able to:

  • Describe tuning in relation to loop response
  • Describe the types of process upsets
  • Explain process delays.
  • Describe the effects of gain, reset, and rate on response curves
  • Explain how to identify and assess asymmetry, non-linearity, and noise
  • Explain how to correct or reduce hysteresis, stiction, and noise
  • Distinguish between random tuning and systematic trial and error tuning
  • Describe the precautions necessary when tuning by trial and error
  • Explain the procedure for tuning using the Z-N open loop method
  • Explain the procedure for tuning using the Z-N closed loop, or ultimate gain, method
  • Describe how the auto-tune function tunes
  • Describe artificial intelligence (fuzzy logic) tuning features
  • Explain how to connect and run tuning programs
  • Describe the options tuning programs may provide
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