Purpose of Seminar:
Proper troubleshooting and maintenance of plant systems & equipment to reduce downtime and save money requires more than just replacing parts when they get broken. In fact, a “replace-part-when-broken” strategy for maintaining equipment is frequently the most expensive approach you can take. To be effective, maintenance technicians who fix equipment must know why a part needs to be changed out in the first place. Perhaps the real problem isn’t what he thinks it is!
In this seminar students will learn what, where and how to measure parameters for the proper monitoring and control of their equipment. When something breaks, they’ll now know why. With this understanding, they will be able to work much more efficiently on the industrial systems and processes for which they are responsible. A sound knowledge in instrumentation and control is certain to result in better-qualified technicians and less equipment failures. This course is designed to provide workers with the knowledge they need to keep your plant up and running as efficiently and inexpensively as possible.
Who should take this course?
This seminar is a must for anyone who works with manufacturing or process equipment in industrial settings. General maintenance personnel, workers in cross-training programs, electricians and engineers will find this course extremely valuable. Attendees come from a variety of industries, skill-levels, company sizes, and job titles, so if you're not sure you will fit in or will benefit from the class, don't worry - you will - as long as your job involves instrumentation, and process measurement & control! Some of the people who will benefit from attending this seminar include...
Maintenance Personnel In:
- Manufacturing Plants
- Food, Beverage & Meat Processing Plants
- Compressed Gasses
- Packaging Plants
- Building Facilities
- Oil Refineries
- Utilities
- Power Plants
- Pulp & Paper
- Metals & Mining
- Water Treatment Plants
- Space & Defense
Including:
- Electricians
- Mechanics
- Engineers
- Apprentices
- Electronic Technicians
- Machine Operators
- Control Technicians
- Schedule/Planners
- HVAC Technicians
- High Performance Work-team Members
- Instrumentation Technicians
- Plant Managers & Supervisors
- and ANYONE involved in Multi-craft & Cross
Learning Objectives
- Determine manipulated, controlled, and measured variables of typical industrial processes.
- Convert pressure, level, flow, or temperature variables into pneumatic or electrical values.
- Identify electrical variables that are used by instruments to determine values.
- Use and calibrate a variety of instruments and transmitters using ISA industrial consensus standard techniques.
- Identify and use the ANSI/ISA-S5.1 consensus industrial standard process symbols.
- Troubleshoot to the device level using the Process and Instrumentation Diagram and/or the Instrument Loop Diagram.
- Perform required calculations to find typical process control parameters using a single loop controller configured in Proportional, Proportional and Integral, Proportional and Derivative, or Proportional and Integral and Derivative modes.
- Use several different strategies to effectively tune a process controller.
Course Outline / Agenda
INTRODUCTION TO PROCESS CONTROL
- On/Off
- Proportional
- Integral
- Derivative
PNEUMATIC CONTROL
- Operation of the nozzle and flapper value
- Bellows receiver unit
ELECTRONIC CONTROL
- Resistance
- Capacitance
- Inductance
- Voltage
MEASUREMENT OF “PRESSURE”
- Units and Pressure Standards
- Construction and Operation of typical industrial pressure instruments
- Calibration of pressure transducers and transmitters
MEASUREMENT OF “LEVEL”
- Units and Level Standards
- Construction and Operation of typical industrial level instruments
- Calibration of level transducers and transmitters
MEASUREMENT OF “FLOW”
- Units and Flow Standards
- Construction and Operation of typical industrial flow instruments
- Calibration of flow transducers and transmitters
MEASUREMENT OF “TEMPERATURE”
- Units and Temperature Standards
- Construction and Operation of typical industrial temperature instruments
- Calibration of temperature transducers and transmitters
SELECTED ANALYTICAL MEASUREMENTS
- Electrical Conductivity
- Chemistry 101
- Acids
- Bases
- pH
- Redox Potentials
- ORP Measurement
- Ion Activity Measurement
INDUSTRIAL PROCESS CONTROL SYMBOLS
- Understanding ANSI/ISA-S5.1 process control symbols
- Understanding and Drawing Process and Instrumentation Diagrams
- Understanding and Drawing Instrument Loop Diagrams
- Using process control diagrams to troubleshoot industrial control systems
CONTROL VALVES
- Purpose and use of control valves, actuators, and positioners.
- Significance of valve coefficients and sizing considerations.
PROPORTIONAL CONTROL CONCEPTS
- First Order Lag calculations
- How to calculate Dead Time
- Adding Manual Reset to Proportional Control
- Case Studies
PROPORTIONAL & INTEGRAL CONTROL CONCEPTS
- Additional Process Dynamics
- The dynamic behavior of control valves
- Tuning PI controllers
- Case Studies
PID CONTROLERS
- Open Loop Tuning Methods
- Closed Loop Tuning Methods
- Case Studies
COMMON INDUSTRIAL APPLICATIONS & CASE STUDIES
APPLICATIONS FOR USE IN YOUR FACILITY
Continuing Education Units (CEUs)
All students attending our seminars receive a personalized Certificate of Completion and .8 CEUs
(Continuing Education Units) per day of training. Over 40,000 employers and government agencies who
have sent their employees to our classes accept American Trainco CEUs for continuing education
requirements. Our administration and record keeping practices meet or exceed the standards of ACE
(American Council on Education) and we are able to provide transcripts of all classes attended and
tests taken by individual students. Please contact us if our CEUs are not yet accepted by your authority.
We will initiate an application to get the approval process started.