Course Details
Your Growth, Our Mission
Course Description
This 5-day course focuses on a fast-paced review of the knowledge required to properly install and maintain standard measurement and control instrumentation. It is designed specifically for practicing technicians preparing for the Level Certified Control Systems Technician (CCST) examination.
The Training Course Will Highlight ?
Training Objective
Target Audience
- Instrumentation and control system Technicians
- Instrumentation and control system Junior Supervisors
- Instrumentation and control system Junior Engineers
- Automation Engineers, Instrumentation Technologists and Engineers
Training Methods
This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include:
- Lectures
- Workshop & Work Presentation
- Case Studies and Practical Exercise
- Videos and General Discussions
Daily Agenda
Concepts of Process Control
- Definition of a Process
- Types of Process
- Typical Industries
- Continuous vs. Batch Processing
- Typical Continuous Processes
- Continuous Process Example
- Typical Batch Processes
- Batch Process Example
- Process Control
- The Process Control System (Loop)
- Industrial Process Example
- Control Loop on P & I Drawings
- Process Dynamics (Response to Change)
- First Order Lag plus Dead Time
Basic Measurement Units
- Pressure and Level Measurement Units
- Relationship between Pressure Terms
- Density
- Specific Gravity
- Viscosity
- Pressure of Fluids
- Liquid Head Measurement
- Effect of S.G. on Liquid Head Measurement
- Unit Systems - Flow Measurement
- Flow Measurement of Fluids
- Flow Terms
Test & Calibration Equipment
- Temperature Scales
- Hydraulic Dead Weight Tester
- U-Tube Manometers
- Well Manometer
- Schematic of Low Pressure Pneumatic Calibrator
- Typical Digital Multimeter
- Voltage Measurement
- Current Measurement
- Resistance Measurement
- Electro-Pneumatic Calibrator
Instrument Performance
- Range and Span
- Suppressed and Elevated Zero Range
- Range and Span Terminology
- Span and Range Calculation Practice
- Accuracy
- Repeatability
- Importance of Accuracy
- Linearity
- Hysteresis and Dead Band
Calibration Principles & Procedures
- Calibration
- Verification: Without Adjustment
- Calibration Block Diagram
- Shop Calibration - DP Transmitter
- RTD Calibration Arrangement
- Thermocouple Calibration Arrangement
- Hierarchy of Standards
- Five-Point Calibration Check
- Calibration Chart
- In-Shop or Field Calibration
Advancing Technology
- Standard Practice
- Industry’s changing Needs
- Smart Devices
- Smart Transmitters
- Digitizing a Measurement
- The Microprocessor
- Smart Instrument Characterization
- Smart Transmitter Functions
- Smart Transmitter Operation
- Configuration vs. Calibration
- Re-ranging
- Characterization and Digital Trim
Controller Actions and Modes
- Control Hierarchy
- Controllers and Control Strategies
- Direct Acting Controller
- Reverse Acting Controller
- Direct or Reverse Acting?
- Direct or Reverse Acting?
- On-Off Control of Heating
- Proportional Control
- Proportional Action
- Proportional Control of a Continuous Process
- Proportional Action
- Offset with Proportional Control
- Level Control Offset Example
- Integral Action
- Proportional + Integral Control
- Integral Control
- Derivative Action
- Derivative (Rate) Control Action
- Proportional + Integral + Derivative Control
- Characteristics of Controller Modes
Tuning Methods
- Objectives of Tuning
- Trial & Error Tuning
- Tuning Map - Gain and Reset
- The Effect of Adding Derivative
- Tuning by Open Loop Testing
- Ziegler-Nichols (Z-N) Open Loop Method
- Open Loop Considerations
- Tuning by Closed Loop Testing
- Z-N Closed Loop Method
- Closed Loop Considerations
Advanced Control Strategies
- Ratio Control - Wild Stream
- Ratio Control - Both Streams Controlled
- Automatic Ratio Set: Example
- Cascade Control: Diagram
- Application: Without Cascade
- Application: With Cascade
- Inner and Outer Loops
- Cascade Control Considerations
- Feedforward Control
- Feedforward Control Concepts
- Feedforward Control Loop
- Feedforward Control of Heat Exchanger
Loop Checking Concepts
- Loop Check Considerations
- Loop Check Process
- Loop Check Procedure
Instrument Installation
- Instrument Installation
- Installation Detail
- Installation Details
- Instrument Location Plan
- Installation Practices
- Manufacturer’s Requirements
- Instrument Air Quality Considerations
- Instrument Air Supply System
Troubleshooting Considerations
- Purpose of Troubleshooting
- Why Troubleshoot?
- Bottom Line
- What Are You Expected to Troubleshoot?
- Troubleshooting Skills
- Troubleshooting Productivity
- Approaches to Troubleshooting
- Equipment History Approach
- Input/Output (Serial) Approach
- Input/Output Approach
- Halving Approach
- Shotgun Approach
- Logical Analysis Troubleshooting
- Verify something is wrong
- Identify and Locate the Cause of the Problem
- Fix the Problem
- Verify the Problem is corrected
- Follow up to Minimize Future Problems
Final Control Elements
- Control Valves
- A Typical Control Valve with Actuator
- Globe Valves
- Other Linear Motion Valves
- Rotary Motion Valves
- Valve Characteristics (Trim)
- Inherent Flow Characteristics
- Cavitation
- Cv - Valve Coefficient of Flow
- Actuators
- Direct (Air-to-Extend)
- Reverse (Air-to-Retract)
- Positioners
- Typical Motion-Balance Positioner
- I/P Transducer
- Other Final Control Elements
Common Problems
- Pressure
- Level
- Flow
- Temperature
- Valves
- Actuators
- Positioners
- Dampers
- Variable Speed Drives
Troubleshooting with DCS
- Distributed Control System
- Elements of a Distributed Control System
- DCS Graphic Display
- DCS Trend Display
- DCS Alarm Summary
Instrument Maintenance
- What is Instrument Maintenance?
- Importance
- Types
Programmable Electronic Systems
- Basic PLC System
- Numbering Systems
- Decimal Number
- Binary Number
- Octal Number
- Hexadecimal Number
- Conversion Practice
- Ladder Logic Programming
- Typical Ladder Logic Format
- Relay Type Instructions
- Start/Stop Ladder Logic
- Input Wiring Diagram
- Output Wiring Diagram
Fieldbus
- Fieldbus Definition
- What is a Fieldbus?
- Bus Hierarchy
- Why Use a Fieldbus?
- Foundation Fieldbus H1 Bus Segment
- Device Descriptions
- Fieldbus Summary Slide
Start-Up Concerns
- Start-Up Safety Concerns
- Start-Up Documentation
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.
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