Training Certificate

Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees.

Course Introduction

The control of processes in today’s oil, gas and chemicals industries requires accurate knowledge of process conditions and this in turn means accurate measurement of those conditions. Without measurement there can be no control and no information as to the state of the process.

A greater understanding of the measuring equipment and the instruments can improve the performance of the operator and this in turn will improve plant performance. Better knowledge of how equipment is selected and how it is constructed and how it works also helps an operator to identify the cause of problems and prevent the recurrence, Hence, the economic benefits of properly trained and informed operators can be readily quantified.

The course is designed to provide an overview of industrial measurement and control which includes process measurement (Flow, Level, Pressure and Temperature), transmitter, controller, process control (basic control theory, closed loop, Process dynamic, time constant, process gain, PID Control , practical logic and control system hardware,  (UPS, DCS, PLC, and SCADA), alarm and trip system.

The course covers the major components and subsystems of a gas chromatographic system and its accessories, including inlets, columns and detectors. It presents operating principles, set-up procedures, and failure modes for each along with practical examples.

The course will cover also the use of best practices in troubleshooting and diagnose of equipment operation problem.

Course Objective

By the end of the course, participants who are almost all operatorI and OperatorII in production operations, should become able to:  

• Explain theory behind measurement and control skills
• Describe the common control loop: elements, types of signals, response time, etc
• Discuss  logic in DCS operation, alarm and shutdown signals
• Diagnose equipment operations problems
• Use best practices in troubleshooting
• Explain GC control philosophy
• Explain theory behind measurement and control skills
• Describe the common control loop: elements, types of signals, response time, etc
• Discuss  logic in DCS operation, alarm and shutdown signals
• Discuss key elements of an emergency response action plan, the impact of modern instrumentation, Signal Category, Standard Ranges, Linearity
• Discuss the major technologies used in the measurement of temperature, pressure, level and flow etc.
• Discuss the theory behind measurement and control skills, the common control loop: elements, types of signals, response time, etc.
• Discuss the logic in DCS operation, alarm and shutdown signals
• Discuss PLC, UPS and SCADA
• Diagnose equipment operations problems
• Explain GC control philosophy, Principle of chromatography, Calibration and signal processing
• Explain the key elements of an emergency response action plan
• Identify different types of industrial analytical measuring instruments
• Troubleshoot and identify problems with instrumentation systems and equipment
• Explain the fundamentals of process control
• Explain the effects of proportional, integral and derivative control
• Explain the process loops and how this can be applied to optimize process control.
• To give an understanding of the principles and practice of the following elements:
  • Flow Measurement
  • level Measurement,
  • Pressure Measurement
  • Temperature Measurement,
  • Control Valves

• Familiar and confident with a range of measurement techniques
• Explain the concepts of Process Control and acquire the knowledge relating to the characteristics and properties of a process variable being measured
• Disseminate and share experience and knowledge with other delegates through open session discussions hence broadening the knowledge base of all
• Familiar and knowledgeable with PID control and develop the ability to ‘tune’ a process control system using PID control

Suitable For

• Operator I
• Operator II

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work & Practical Exercises
• 20% Videos & General Discussions

Course Content

INTRODUCTION TO INSTRUMENTATION AND CONTROL SYSTEM

• Measured and controlled variables
• Performance terms and specifications
• Measurement terminology
• P&ID symbols

FLOW MEASUREMENT

• Basic fluid properties
• Reynolds number
• Flow measurement and rangeability
• Flow measuring sensors types    
• Differential pressure flowmeters  
• Mechanical flowmeters
• Electronic flowmeters
• Mass flow-meters, Coriolis. 

LEVEL MEASUREMENT

• Basic principles
• Float systems
• Displacement systems
• Conductive level detection
• Ultrasonic level measurement
• Radar gauging

PRESSURE MEASUREMENT

• Basic principles
• Bourdon tubes
• Diaphragm elements
• Electrical displacement sensors

TEMPERATURE MEASUREMENT

• Basic principles
• Thermocouples
• Resistance thermometry
• Thermistors
• Radiation thermometry

 FUNDAMENTALS OF PROCESS CONTROL

• ON/OFF control
• Proportional control
• Proportional offset
• Integral action
• Integral windup
• Stability
• Derivative action
• PID control
• Control algorithms
• Load disturbances and offset

FUNDAMENTALS OF TUNING

• Basic principles
• Open loop reaction curve method (Ziegler-Nichols)
• Default and typical settings
• Closed loop continuous cycling method (Ziegler-Nichols)

DAY 2

BASIC VALVE THEORY

• Valve types
• Control valve characterization
• Defining the valve flow coefficient, Cv
• Inherent characteristics
• Valve testing and diagnostics

DCS, PLC & SCADA

• Introduction
• System architecture
• Major component
• Controllers
• I/O System
• Master Unit
• Remote Terminal Unit (RTU)
• Communication
• System hardware and software
• Human Machine Interface (HMI)
• Operator console
• Types of display, Trends, Alarms and overview
• System integration
• Troubleshooting from operation prospective

GAS CHROMATOGRAPH

INTRODUCTION

BASIC CHROMATOGRAPHIC INSTRUMENTATION

COMPONENTS OF A PROCESS GAS CHROMATOGRAPH

• Analyzer
• Oven
• Valves
  • Rotary Valve
  • Sliding Plate
  • Diaphragm
• Columns
  • Packed Columns
  • WCOT (Capillary) Columns

COLUMN AND VALVE CONFIGURATIONS

• Hardware
  • Sample Injection
  • Backflush
  • Heart-cutting

DETECTORS

• Thermal Conductivity Detector
• Flame Ionization Detector
• Flame Photometric Detector
• Pulsed Flame Photometric Detector
• Orifice-Capillary Detector
• Photoionization Detector
• Electron Capture Detector
• Discharge Ionization Detectors

CARRIER GAS FLOW CONTROL

• PROGRAMMER-CONTROLLER
• Programmer
• Peak Processor
• Data Acquisition
  • Input–Output
• Communication
• Operator Interface
• Alarms and Diagnostics
• Quantitative

SAMPLE HANDLING

• Sample Probe
• Sample Transport
• Sample Conditioning
• Multistream Analysis
• Sample Disposal

INSTALLATION AND MAINTENANCE

DAY 3

WASTEWATER TREATMENT CONTROLS

Introduction

• General Considerations
• Industrialwastewater treatment

Chemical Oxidation

• Cyanide Destruction Process
  • Batch Cyanide Control
  • Continuous Cyanide Control
  • Chlorinator, Sulfonator, and other Controls
  • Cyanide Destruction by Ozonation

CHEMICAL REDUCTION

• Reduction of Hexavalent Chromium
• Other Reduction Processes

NEUTRALIZATION CONTROLS

• Equalization Tanks
  • Valve Rangeability Required
  • Sequenced Valves
  • Reaction Rates and Tank Sizing
• Single Reagent Control
• Two Reagent Control Systems
• Ratio Control
• Cascade Control
• Feedforward Control

Flared Gas Recovery System

• Introduction
• Schematic of Flare Gas Recovery System