Participant will be able to:

1. Cite principles and theory that explain measurement and control instrument functions
2. Describe procedures required to properly maintain the function of measurement and control instrumentation
3. Understand the procedures and safety requirements for loop checking and its purpose
4. Perform calculations and other analysis of information related to the calibration and troubleshooting of measurement and control instruments and systems
5. Describe procedures required to safely start-up and shut-down a new or existing process
6. Understand the education, experience, and examination requirements for becoming a CCST
7. Identify important knowledge and skill requirements of a practicing CCST
8. Describe the procedures involved in taking the CCST Level exam
9. Identify any need for further study or training in specific knowledge areas

• Instrumentation and control system Technicians
• Instrumentation and control system Junior Supervisors
• Instrumentation and control system Junior Engineers
• Automation Engineers, Instrumentation Technologists and Engineers

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

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

Reranging

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

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.