Topic outline

  • Basics of Control and Automation

    This course provides a basic overview of all significant aspects and considerations of control and automation for engineering managers, instrumentation and control engineers, process control and automation engineers, design engineers and consulting engineers, process control engineers, electrical engineers, management, engineering and supervision staff who are responsible on PLC, superintendents, supervisors, DCS, SCADA and PLC personnel, process control staff, trades staff working with or near PLC’s and other technical staff
    • Training Methodology & Objectives

      Training Methodology

      This Trainee-centered course includes the following training methodologies:-

      • Talking presentation Slides (PPT with audio)
      • Simulation & Animation
      • Exercises
      • Videos
      • Case Studies
      • Gamification (learning through games)
      • Quizzes, Pre-test & Post-test

      Course Objectives

      After completing the course, the employee will:-

      Apply and gain a basic knowledge on control and automation Discuss the fundamentals of instrumentation including the terminology for home heating control
      Explain the motivation for automatic process control and recognize the terminology for home heating control Describe the fundamentals of instrumentation and process control and identify the modes of closed loop control
      Employ manual control, on-off control, PID control, time proportion control and cascade control Identify the basic elements of process control and the dynamic process behavior
      Describe graphical modelling of dynamic process data, process and controller action Recognize the standard instrumentation signals, pneumatic scaling and current loop scaling
      Employ digital communications, configuration, signal conditioning and self-diagnosis Determine instrument properties that affect a process covering range and span, measurement resolution, accuracy, precision and instrument dynamics
      Discuss input aliasing and correct sampling frequency as well as determine the correct sampling interval Identify instrument noise and temperature including thermocouples, thermocouple junctions, linearization, gain, types and etc.
      Define pressure and describe pressure absolute, gauge and differential Recognize common level sensing technologies-non-contract comprising of ultrasonic, radar/microwave, nuclear level measurement, hydrostatic pressure, RF/capacitance and guided wave radar
      • Course Description

        This E-learning course is designed to provide participants with a basic overview of control and automation. It covers the fundamentals of instrumentation and the terminology for home heating control; the motivation for automatic process control; the fundamentals of instrumentation and process control; the modes of closed loop control; the manual control, on-off control, PID control, time proportion control and cascade control; the basic elements of process control and the dynamic process behavior; and the graphical modelling of dynamic process data, process and controller action
        During this course, participants will learn the standard instrumentation signals, pneumatic scaling and current loop scaling; the digital communications, configuration, signal conditioning and self-diagnosis; the instrument properties that affect a process covering range and span, measurement resolution, accuracy, precision and instrument dynamics; the range and span, measurement resolution, accuracy, precision and instrument dynamics; the input aliasing and correct sampling frequency and the correct sampling interval; the instrument noise and temperature; the thermocouples, thermocouple junctions, linearization, gain, types and etc.; the pressure absolute, gauge and differential; and the common level sensing technologies-non-contract
        • Module 1 - Fundamentals of Instrumentation & Process Control

          Contents:
            • Motivation for Automatic Process Control 
            • “Loose” Control Costs Money 
            • “Tight” Control is More Profitable 
            • Terminology for Home Heating Control 
            • What is Process Control 
            • What is a Process 
            • What is Process Control 
            • Module Quiz
          • Module 2 - What is Open Loop Control

            Contents:
              • What is Closed Loop Control 
              • What are the Modes of Closed Loop Control 
              • Basic Elements of Process Control 
              • Module Quiz
            • Module 3 - Understanding Dynamic Process Behavior

              Contents:
                • Dynamic Process Behavior and Controller Tuning 
                • Graphical Modeling of Dynamic Process Data 
                • Modeling Dynamic Process Behavior 
                • The FOPDT Model is All Important 
                • Step Test Data and Dynamic Process Modeling 
                • Process Gain (Kp) from Step Test Data 
                • Process Gain (Kp) for Gravity-Drained Tanks 
                • Additional Notes on Process Gain
                • Process Time Constant from Step Test Data 
                • Time Constant for Gravity-Drained Tanks 
                • Process Dead-Time (Өp) from Step Test Data 
                • Dead-Time (Өp) is the Killer of Control
                • Dead-Time (Өp) for Gravity Drained Tanks 
                • The FOPDT Model Parameters 
                • Hands-On Workshop 
                • Processes have Time Varying Behavior 
                • Processes have Nonlinear Behavior 
                • What is a Nonlinear Process 
                • What is Process Action 
                • Fundamentals of Instrumentation & Process Control Interactive Training Workshop
                • Introduction to Instrumentation 
                • What are Sensors and Transducers 
                • What are Standard Instrumentation Signals 
                • What are Smart Transmitters 
                • What Instrument Properties Affect a Process 
                • What is Input Aliasing 
                • Workshop Lab: Input Aliasing 1
                • What is Input Aliasing 
                • Workshop Lab: Input Aliasing 2
                • What is Instrument Noise 
                • Workshop Lab: Noise Filtering
                • What is Temperature 
                • What Temperature Instruments Do We Use 
                • Video: Dynamic Behavior and Input Types in Process Control
                • Module Quiz
              • Module 4 - Fundamentals of Instrumentation & Process Control

                Contents:
                  • What is Pressure 
                  • What is Pressure Absolute, Gauge and Differential 
                  • Section Assessment: Pressure
                  • Common Level Sensing Technologies 
                  • Common Level Sensing Technologies Non-Contact: Ultrasonic 
                  • Common Level Sensing Technologies Non-Contact: Radar/Microwave 
                  • Common Level Sensing Technologies Non-Contact: Nuclear Level Measurement 
                  • Common Level Sensing Technologies Contact: Hydrostatic Pressure 
                  • Common Level Sensing Technologies Contact: RF/Capacitance 
                  • Common Level Sensing Technologies Contact: Guided Wave Radar 
                  • Section Assessment: Level
                  • What is Flow?
                  • Factors Affecting Flow Measurement 
                  • Factors Affecting Flow Measurement Viscosity 
                  • Factors Affecting Flow Measurement Viscosity Conversion Chart 
                  • Factors Affecting Flow Measurement Viscosity of Common Fluids 
                  • Factors Affecting Flow Measurement Fluid Type 
                  • Factors Affecting Flow Measurement Reynolds Number 
                  • Factors Affecting Flow Measurement Laminar Flow 
                  • Factors Affecting Flow Measurement Turbulent Flow 
                  • Factors Affecting Flow Measurement Transitional Flow 
                  • Factors Affecting Flow Measurement Flow Irregularities 
                  • Common Flowmeter Technologies 
                  • Common Flowmeter Technologies Volumetric Flow 
                  • Common Flowmeter Technologies Volumetric Flow: Positive Displacement 
                  • Common Flowmeter Technologies Volumetric Flow: Magnetic 
                  • Common Flowmeter Technologies Volumetric Flow: Orifice Plates 
                  • Common Flowmeter Technologies Mass Flow 
                  • Common Flowmeter Technologies Mass Flow: Coriolis 
                  • Common Flowmeter Technologies Flowmeter Turndown 
                  • Common Flowmeter Technologies Installation and Calibration 
                  • Section Assessment: Flow
                  • Introduction to Final Control Elements 
                  • What is a Control Valve 
                  • What is an Actuator
                  • Additional Photos of Actuators 
                  • What is a Positioner 
                  • What is Cv 
                  • What are Valve Characteristics 
                  • What is Valve Deadband 
                  • What is Stiction 
                  • What are the Types of Valves 
                  • Section Assessment: Valves
                  • What is a Centrifugal Pump 
                  • What is Pump Head 
                  • Why Do We Use Pump Head and not PSI 
                  • What is a Pump Curve 
                  • What is a System Curve 
                  • What is the System Operating Point 
                  • What is a Positive Displacement Pump 
                  • How Does a PD Pump Differ from a Centrifugal Pump 
                  • Positive Displacement Pump 
                  • Section Assessment: Pumps
                  • Good Practice and Troubleshooting
                  • Video: Process control loop Basics - Instrumentation technician
                  • Module Quiz
                • Module 5 - Programmable Logic Controller (PLC)

                  Contents:
                    • Description
                    • Introduction to PLCS
                    • PLC Origin
                    • Historical Background
                    • Programmable Controller Development
                    • Programmable Logic Controllers (Definition according to NEMA standard ICS3-1978)
                    • Leading Brands of PLC
                    • Areas of Application
                    • PLC Size
                    • Tank Used to Mix Two Liquids
                    • Major Components of a Common PLC
                    • Programming Device
                    • I/O Module
                    • Discrete Input
                    • Analog Input
                    • Digital Output
                    • Analog Output
                    • Processor
                    • Memory Map Organization
                    • Memory Designs
                    • PLC Operation
                    • PLC Communications
                    • Specifications
                    • Selecting a PLC
                    • A Detailed Design Process
                    • Specifications
                    • PLC Status Indicators
                    • Troubleshooting
                    • Programming
                    • Coils
                    • Boxes
                    • And Operation
                    • OR Operation
                    • Not Operation
                    • Module Quiz
                  • Module 6 - Device Management Protocols

                    Contents:
                      • 4–20 mA Process Control Loops 
                      • Control Loops
                      • The Key Advantages of The current Loop Are:
                      • Current Loop
                      • History of Control Signals
                      • The HART Protocol Current Loop The Classical Solution for Analog Values
                      • Field Device: Example Differential Pressure Transducer 
                      • 4-20 mA Loop - the Conventional, Analog Standard (Recall) 
                      • HART 
                      • HART - Principle 
                      • Installation 
                      • The Round Card 
                      • HART - Protocol 
                      • HART - Commands 
                      • HART Commands Summary 
                      • Device Description 
                      • Device Access 
                      • Device Description Language 
                      • Device Description Usage 
                      • Video:  What is HART Protocol
                      • Module Quiz
                    • Module 7 - Industrial Control Systems

                      Contents:
                        • Automation Defined 
                        • Program of Instructions 
                        • Work Cycle Program 
                        • Control System
                        • Control Architecture 
                        • Automatic Control - Level 0 and 1 
                        • Sensors – Level 0
                        • Actuators – Level 0
                        • Advanced Automation Functions
                        • Safety Monitoring 
                        • Maintenance and Repair Diagnostics 
                        • Error Detection and Recovery 
                        • Industrial Control Systems 
                        • Process vs. Discrete Industries 
                        • Variables and Parameters 
                        • Types of Control  
                        • Types of Continuous Process Control 
                        • Regulatory Control 
                        • Regulatory Control 
                        • Feedforward Control 
                        • Feedforward Control Combined with Feedback Control 
                        • Steady-State Optimization 
                        • Steady State (Open-Loop) Optimal Control 
                        • Adaptive Control 
                        • Video: Industrial Control Systems - Understanding ICS Architectures 
                        • On-Line Search Strategies 
                      • Module 8 - Distributed Control System (DCS)

                        Contents:
                          • DCS Overview 
                          • DCS
                          • Why DCS System is Required?
                          • What Does DCS System Consist of?
                          • How Does it Work?
                          • How Process Control Loop Works
                          • The Basic Plant Areas Classified as Follows:
                          • DCS - Components and Inter faces 
                          • Components of DCS:
                          • Interface DCS:
                          • Human – Machine Interface
                          • DCS - Communication Facilities, Requirements, Architecture Model
                          • Communication System Requirements:
                          • DCS Communication Architecture:
                          • Channel Structure:
                          • Levels of Subnetworks:
                          • DCS System Layout and its Different Parts 
                          • DCS System Layout
                          • System Cabinets
                          • Marshalling Cabinets
                          • Operator WorkStation
                          • Engineering WorkStation
                          • Switch
                          • Communication Media and Protocols
                          • Types of System Architecture Used in Industrial Automation
                          • Architecture #1
                          • Architecture #2
                          • Architecture #3
                          • Architecture #4
                          • Architecture #5
                          • Architecture #6
                          • File Transfer
                          • Recommended System Architectures
                          • Example of Hybrid Architecture Implementation
                          • Module Quiz
                        • Module 9 - What is SCADA? How Does SCADA Work?

                          Contents:
                            • SCADA Systems Concepts
                            • Human Machine Interface
                            • SCADA Hardware
                            • Remote Terminal Unit (RTU)
                            • Supervisory Station
                            • SCADA Operational Philosophy
                            • Communication Methods and Infrastructure
                            • SCADA Architectures
                            • Networked: The Third Generation
                            • SCADA Security Issues
                            • Applications of SCADA:
                            • Module Quiz
                          • Module 10 - Know, Read & Understand Your Piping & Instrumentation Diagrams (P&ID’s)

                            Contents:
                              • What is Piping and Instrumentation Diagram (P&ID)?
                              • Contents and Function
                              • List of P&ID Items
                              • Piping and Instrumentation Diagram Example 
                              • Anatomy of a Drawing
                              • The Title Block
                              • First Area of the Title Block
                              • Second Area of the Title Block
                              • Third Area of the Title Block
                              • Categories of Drawings
                              • P&ID Guidelines for Pumps Drawings
                              • P&ID Guidelines for Control Valves
                              • P&ID Guidelines for Storage Tanksc
                              • P&ID Guidelines for Centrifugal Compressor Systems
                              • Identify Process Variables in P&ID 
                              • Instrumentation Diagrams Multiple Choice Questions
                            • Post-Test

                              Kindly complete the post-test to assess your knowledge about the topic after the course.