This course is for participants who need to have a practical knowledge of selection, installation

and commissioning of industrial instrumentation and control valves. In many respects a clear understanding

and application of these principles is the most important factor in an efficient process control system.

You can only achieve excellent control of your process when your instrumentation provides the correct

information. The course is for those individuals primarily involved in achieving effective results for the industrial processes they are responsible for. This would involve the design, specification and implementation of control and measurement equipment.

The course focuses on real applications, with attention to special installation considerations and application limitations when selecting or installing different measurement or control equipment.

At the end of the program Learners should be able to:

1. Describe the control principles in the Industrial Process System application.
2. Perform the measurement for the temperature, pressure, fluid flow and level.
3. Tune the PID with the right techniques for optimization of the system.

1. INTRODUCTION, BASIC TERMS AND DEFINITIONS

• Basic measurement and control concepts
• Basic performance terms and conditions
• Advanced performance terms and conditions
• Definitions

2. DIAGRAMS AND NUMBERING

• P & ID symbols, selection and criteria
• Typical sources

3. PRESSURE MEASUREMENTS

• Principles of pressure measurement
• Pressure sources
• Mechanical transducers and elements
• Electrical transducers and elements
• Installation considerations, impact on the overall control loop, selection tables
• Future pressure technologies

4. LEVEL MEASUREMENT

• Principles of level measurement
• Simple sight glasses and guiding rods
• Buoyancy tape measurement, hydrostatic pressure
• Ultrasonic measurement, radar measurement
• Vibration switches
• Radiation measurement, electrical measurement, density measurement
• Future level technologies

5. TEMPERATURE MEASUREMENT

• Principles of temperature measurement
• Thermocouples, Resistance Temperature Detectors (RTDs), thermistors
• Liquid-in-glass, filled and bimetallic
• Non-contact pyrometers, humidity
• Installation considerations, impact on the overall control loop, selection tables
• Future temperature technologies

6. FLOW AND MASS MEASUREMENT

• Principle of flow measurement
• Differential pressure flowmeters
• Open channel flow measurement
• Variable area flowmeters
• Oscillatory flow measurement
• Magnetic flow meters
• Positive displacement
• Ultrasonic flow measurement
• Mass flow meters
• Installation considerations, impact on overall control loop, selection tables

7. CONTROL VALVES

• Principles of control valves
• Sliding stem valves, rotary valves
• Control valve selection and sizing
• Control valve characteristics / trim
• Control valve noise and cavitation
• Actuators and positioners
• Valve benchset and stroking
• Impact on overall control loop
• Selection tables, future technologies

8. BASIC CONTROL PHILOSOPHIES

• Open loops, closed loops
• Feed forward and ration control,
• Feedback control
• Overview of different tuning rules available
• Cascade control
• Good practice in troubleshooting
• Adaptive and self-tuning controllers

9. INTEGRATION OF THE SYSTEM, MODERN TRENDS AND OTHER PROCESS CONSIDERATIONS

• Calculation of individual instruments and total error for the system
• Selection considerations
• Testing and commissioning of sub-systems
• RS 232, RS 422, RS 423, RS 485, etc.
• Fiber optic cables
• New smart instruments and fieldbus
• Noise and earthing considerations
• Materials of construction
• Linearisation

10. PROGRAMMABLE LOGIC CONTROLLERS – INTRODUCTION TO THE PLC

• Digital Input / Output systems
• Analog Input / Output systems
• Fundamentals of PLC programming

11. ISO, HAZOPS, RELIABILITY CENTERED MAINTENANCE, SPARE PARTS ANALYSIS, TESTING AND PANEL DESIGN

• ISO 9001:2000 in depth, HAZOP analysis
• Reliability centered maintenance and spare parts analysis
• Acceptance Testing (FAT and SAT)
• Electrical design of assorted panels

12. HMI, SCADA AND DCS SYSTEMS

• System hardware and software, components, design and layout, alarms and reporting

• Lectures
• Practical exercises

Mulungushi University certificate will be provided