Process Control & Instrumentation 16 Hour Masterclass

Know & understand process control PID controllers control valves actuators positioners & instrumentation like a pro

What you'll learn

Learn the essentials of process controls and PID controllers for a successful career in process industries

Successfully draw the correct information from basic to advanced process control loops

Master the intricate terminological details of process control (process variable, set point, error, offset, load disturbance…)

Identify any process control loop and describe its main tasks and functionalities

Describe the basic function and method of operation for the main control loop components (sensor, transmitter, controller, actuator, control valve…)

Differentiate between feedback and feedforward control loops

Explain the basic implementation process for each of the following types of control: Cascade, ratio, split range…

Differentiate between On/Off, discrete, multi-step and continuous controllers

Describe the basic mechanism, pros and cons of the following modes of control action: On/Off, Proportional (P), Integral (I), Derivative (D), PI, PID…

Describe the general goal of PID controller tuning

Apply the Ziegler Nicholls method to tune P, PI and PID controllers for optimum performance

Understand control valves working principles for successful operation of your plant and piping systems

Understand control valve construction details (bonnet, stem, disc, seat, packing, body, actuator, positioner…)

Identify and know the principles of operation of common control valve actuators (diaphragm, piston, rack and pinion, scotch yoke)

Dismantle and assemble various types of control valves and actuators using 3D and 2D models

Understand how single acting and double acting pneumatic actuators work through graphics and 3D animations

Know how to convert a single acting spring return actuator to a double acting actuator and vice versa

Understand the concept of failure mode in control valves : Fail Open "FO", Fail Closed "FC", Fail As Is "FAI"

Understand the concept of "Air-to-push-up" and Air-to-push-down"

Understand the concept of "direct-acting" and "reverse-acting"

Know how to convert a fail close actuator to a fail open actuator and vice versa

Understand the concept of valve flow coefficient "Cv" and familiarize yourself with the various units

Know how to determine flowrate and pressure drop through control valves for different valve lifts

Know how to match the valve characteristics to the process

Know how to construct the installation curve for a given control valve

Understand the effect of selecting a control valve larger than necessary

Understand the effect of differential pressure on the valve lift and actuator operation

Differentiate between fast opening, linear and equal percentage valve characteristics

Understand how valve positioners operate

Know the different types of valve positioners (P/P, I/P, force balance, motion balance, digital…)

Understand when a positioner should be fitted

Understand the working principles of I/P converters and how they are used in control valves

Understand the control of pressure in a pipe

Understand the control of flow in a pipe

Understand how self-acting pressure controls work and their applications

Understand how self-acting temperature controls work and their applications

Understand flow merging control

Understand flow splitting control

Understand centrifugal pump control systems (discharge throttling, variable speed drive, minimum flow…)

Understand positive displacement pump control systems (recirculation pipe, variable speed drive, stroke adjustment…)

Understand compressor control systems (capacity control, variable speed drive, anti-surge…)

Understand heat exchanger control systems (direct control, bypass control, back pressure control…)

Understand reactor temperature control systems

Understand fired heater control systems

Understand container and vessel control systems

Understand electric motor control systems (ON / OFF actions)

Know and understand the concept of Safety Instrumented Systems (SIS)

Know and understand the concept of Alarm Systems and Interlocks

Understand through extensive 3D animation the techniques and methods used in process industries to measure temperature, pressure, flow and level

Put your knowledge to the test at the end of each section with a valuable technical quiz (420+ questions and solved problems)

Get access to a set of valuable downloadable resources

Requirements

Some engineering or field knowledge is preferable but not mandatory. All the concepts are explained in depth using an-easy-to-understand language to allow students to build their knowledge from the ground up

Please note that the mathematics in the PID tuning and control valve sizing sections are undemanding. All the work can be done with a hand-held calculator

Description

Welcome to this 16 hour masterclass on process control and instrumentation.This valuable masterclass is organized into 6 parts :Part 1: Process Control and PID* ControllersPart 2: The Final Control Element - Control Valves, Actuators and PositionersPart 3: Practical Examples of Temperature, Pressure, Flow and Level ControlsPart 4: Practical Examples of Process Equipment Controls (Heat Exchangers, Pumps, Compressors, Reactors, Piping Systems…)Part 5: Safety Instrumented Systems (SIS), Interlocks and AlarmsPart 6: Instrument Devices For Temperature, Pressure, Flow and Level MeasurementPart 1 is an essential guide to a complete understanding of process control principles and PID* controllers design and tuning. In this first module, we will break down for you all the process control principles into easily digestible concepts, like feedback controls, open loops, split range controls, self-acting controls… Useful reference data, technical recommendations, field observations and numerous process control schemes are presented in an-easy-to-understand format. This module also cautions the process control engineer that the performance of a properly designed process control system can be severely compromised when used in conjunction with incorrect PID* controller settings. In this regard, PID* controller tuning guidelines and their rationale according to the Ziegler Nicholls method are offered to ensure optimum performance. Typical tuning examples have been included to assist you in understanding how specific formulae are applied.Part 2 focuses on the final control element of any process control system, that is the valve-actuator-positioner assembly. In this second module, you will find valuable insights into the working principles and construction details of the following control elements:Control valves (sliding stem and rotary / fast opening, linear and equal percentage)Mixing and diverting 3-port control valvesDiaphragm actuators ("air-to-push-up" and "air-to-push-down")Piston actuators (Single Acting and Double Acting / Fail Open (FO) and Fail Closed (FC))Rack-and-pinion actuators (Single Acting and Double Acting / Fail Open (FO) and Fail Closed (FC))Scotch Yoke actuators (Single Acting and Double Acting / Fail Open (FO) and Fail Closed (FC))Pneumatic positioners (force balance, motion balance)Digital positionersI/P converters…The module then proceeds through a series of process examples and solved problems that require you to:Dismantle and assemble various types of control valves and actuators using 3D and 2D modelsIdentify the net effect of various control valve/actuator assemblies (direct acting, reverse acting, fail open, fail close…)Convert an actuator from Single Acting to Double Acting configuration and vice versaConvert a control valve/actuator assembly from a Fail Closed (FC) to a Fail Open (FA) configuration and vice versaConstruct the installation curve for a control valveDetermine flowrate and pressure drop through control valves for different valve liftsMatch the valve characteristics to the given applicationExamine the effect of selecting a control valve larger than necessaryExamine the effect of differential pressure on the valve lift and actuator operationDetermine when a positioner should be fitted…This will help you develop the necessary skills to ensure your process control systems run smoothly.Part 3 focuses on fluid properties control. This module identifies different ways in which precise control of temperature, pressure, flow and level is ensured. It provides real industrial examples of process control loops and the keys to interpret them in high quality video lectures. Both self-acting and modulating types of control are discussed in exquisite details.Part 4 introduces you to advanced process control in process industries. It identifies different ways in which precise control is ensured for the main process equipment such as chemical reactors, pumps, compressors, fired heaters and heat exchangers just to name a few. The numerous examples outlined in this module are taken from petroleum refineries, chemical and steam boiler plants, making the knowledge gained in this section extremely valuable to practicing engineers and technicians.Part 5 discusses the important concepts of Safety Instrumented Systems (SIS), Alarm Systems and Interlocks. It presents their anatomy, their requirement, their functions and how they are represented in engineering drawings such as Piping & Instrumentation Diagrams.Part 6 illustrates through 3D animations and cross-sectional views the main control instrument devices to measure temperature, pressure, flow and level. These instruments include thermocouples, RTDs’, Bourdon tube pressure gauges, Coriolis flowmeters, level radars and capillary systems just to name a few…As you proceed through the masterclass, answer the 400+ question quiz to test your knowledge and emphasize the key learning points.The quiz includes:True/False questionsMulti-choice questionsImages, cross-sectional viewsSolved problemsAnd much more…You have our promise that at after completing this masterclass, you will be an advanced process control professional, you won’t be a process control expert but you will be prepared to become one if that is what you want and persist to be. In fact, the knowledge that you will gain will help you understand all process control loops, instrumentations and safety systems so that you can draw the correct information from them. This will set you apart from your peers, whether you are a graduate student, a practicing engineer or a manager, and will give you an edge over your competitors when seeking employment at industrial facilities.So with no further ado, check out the free preview videos and the curriculum of the course and we look forward to seeing you in the first section.Hope to see you thereWR TrainingSpread the wings of your knowledge–––––––––––-* When PID is mentioned, it is with reference to Proportional (P), Integral (I) and Derivative (D) control actionsSafety noteSizing, selection, installation and tuning of process control systems (control valves, actuators, controllers, sensors, wiring…) should not be based on arbitrarily assumed conditions or incomplete information. Merely having a control system does not make a process safe or reliable. Now, while it is obviously impossible to address every installation mistake ever made, we have included a valuable summary of the most frequent installation mistakes encountered in the field. We are confident that this valuable masterclass will help you contribute to the safety of your facility, your fellow workers and yourself.

Overview

Section 1: Introduction to controls

Lecture 1 Introduction to controls

Lecture 2 Do we need to control at all ?

Lecture 3 Control terminology

Lecture 4 Elements of automatic control

Lecture 5 Assessing Safety Stability & Accuracy

Lecture 6 Summary of terminology

Lecture 7 Elements of a temperature control system

Lecture 8 Automatic process control

Lecture 9 Components of an automatic control

Lecture 10 Before proceeding to the next section

Section 2: Basic control theory

Lecture 11 Modes of control

Lecture 12 On/Off control

Lecture 13 Continuous control

Lecture 14 Proportional control (P)

Lecture 15 Proportional temperature control example

Lecture 16 The concept of gain

Lecture 17 Reverse vs direct acting control signal

Lecture 18 Industrial Example - The FOXBORO 43AP Pneumatic Indicating Controller

Lecture 19 Gain line offset - Proportional effect

Lecture 20 Manual reset

Lecture 21 Integral control (I): Auto reset action

Lecture 22 Integral control (I): Overshoot and wind-up

Lecture 23 Derivative control (D)

Lecture 24 Summary of modes of control: P / PI / PD / PID

Lecture 25 Time constant

Lecture 26 Hunting

Lecture 27 Practical Example: The effect of hunting on a steam system

Lecture 28 Lag

Lecture 29 Rangeability

Lecture 30 Before proceeding to the next section

Section 3: Control loops

Lecture 31 Introduction

Lecture 32 Control loops

Lecture 33 Open loop controls

Lecture 34 Closed loop controls

Lecture 35 Feedback control

Lecture 36 Feed-forward control

Lecture 37 Single loop control

Lecture 38 Multi-loop control

Lecture 39 Cascade control

Lecture 40 Ratio control

Lecture 41 Split range control

Lecture 42 Operations on control signals

Lecture 43 Before proceeding to the next section

Section 4: Introduction to process dynamics

Lecture 44 Introduction

Lecture 45 Process reactions

Lecture 46 Before proceeding to the next section

Section 5: Choices and selection of process controls

Lecture 47 Introduction to choices and selection of process controls

Lecture 48 Application

Lecture 49 Self-acting controls

Lecture 50 Pneumatic controls

Lecture 51 Electric controls

Lecture 52 Electropneumatic controls

Lecture 53 What you should remember

Lecture 54 What type of controls should be installed ?

Lecture 55 What type of valves should be installed ?

Lecture 56 Controllers

Lecture 57 Before proceeding to the next section

Section 6: Installation and commissioning of process controls

Lecture 58 Valves

Lecture 59 Actuators and sensors

Lecture 60 Power and signal lines

Lecture 61 Electrical wiring

Lecture 62 Controllers

Lecture 63 Setting up a controller: The Ziegler-Nicholls method

Lecture 64 Bumpless transfer

Lecture 65 Self-tuning controllers

Lecture 66 Before proceeding to the next section

Section 7: Computers in process control

Lecture 67 Introduction

Lecture 68 History

Lecture 69 More on Fieldbus

Lecture 70 Benefits of Fieldbus

Lecture 71 Before proceeding to the next section

Section 8: Control valve functions and basic parts

Lecture 72 Learning objectives

Lecture 73 Introduction

Lecture 74 Valve body

Lecture 75 Valve bonnet

Lecture 76 Trim

Lecture 77 Plug and seat

Lecture 78 Stem

Lecture 79 Actuator

Lecture 80 Packing

Lecture 81 Before you proceed to the next section

Section 9: Control valve configurations

Lecture 82 Control valves

Lecture 83 Trim arrangement

Lecture 84 Direction of action

Lecture 85 Control valve 3D dismantling

Lecture 86 Control valve 2D dismantling

Lecture 87 Before you proceed to the next section

Section 10: General considerations

Lecture 88 Introduction

Lecture 89 Two-port valves

Lecture 90 Shut-off tightness

Lecture 91 Balanced single seat

Lecture 92 Slide valves - Spindle operated

Lecture 93 Rotary valves

Lecture 94 Options

Lecture 95 Two-port valves summary

Lecture 96 Three-port valves

Lecture 97 Process examples of three-port valves

Lecture 98 Before you proceed to the next section

Section 11: Control valve capacity

Lecture 99 Introduction

Lecture 100 Valve flow coefficient Cv

Lecture 101 Use of flow coefficient Cv for piping and components

Lecture 102 Before you proceed to the next section

Section 12: Control valve characteristics

Lecture 103 Flow characteristics

Lecture 104 Fast opening

Lecture 105 Linear

Lecture 106 Equal percentage

Lecture 107 Example: Determining flowrate for different valve lifts

Lecture 108 Matching the valve characteristic to the process

Lecture 109 Example: A water circulating heating system

Lecture 110 Example: A boiler water level control system

Lecture 111 Example: Constructing the installation curve

Lecture 112 Example: Comparing linear and equal percentage

Lecture 113 Example: Temperature control of a steam application

Lecture 114 Example: The effect of selecting a control valve larger than necessary

Lecture 115 Before you proceed to the next section

Section 13: Control valve sizing for water systems

Lecture 116 Introduction

Lecture 117 Pumps

Lecture 118 Circulating system characteristics

Lecture 119 Actual performance

Lecture 120 Three-port valves

Lecture 121 Two-port valves

Lecture 122 Valve authority

Lecture 123 Before proceeding to the next section

Section 14: Control valve sizing for steam systems

Lecture 124 Introduction

Lecture 125 Saturated steam flow through a control valve

Lecture 126 Critical pressure

Lecture 127 Noise

Lecture 128 Checking noise

Lecture 129 Erosion

Lecture 130 Sizing equations

Lecture 131 The concept of "hunting"

Lecture 132 The effect of "hunting" on a steam system

Lecture 133 Sizing globe valves

Lecture 134 Reminder

Lecture 135 EXAMPLE: Sizing a control valve for a steam heating application

Lecture 136 Sizing on an arbitrary pressure drop

Lecture 137 The higher the pressure drop the better ?

Lecture 138 EXAMPLE: Saturated steam for a critical pressure drop application

Lecture 139 EXAMPLE: Saturated steam for a NON-critical pressure drop application

Lecture 140 EXAMPLE: Finding the pressure drop across a control valve

Lecture 141 EXAMPLE: Superheated steam application

Lecture 142 Before proceeding to the next section

Section 15: Control valve actuators and positioners for a continuous control action

Lecture 143 Introduction

Lecture 144 Piston actuators

Lecture 145 Piston actuators (double acting) - 3D animation

Lecture 146 Piston actuators (single acting) - Dismantling

Lecture 147 Diaphragm actuators

Lecture 148 Actuator valve combinations

Lecture 149 Effect of differential pressure on the valve lift

Lecture 150 What are valve positioners ?

Lecture 151 Force balance positioners

Lecture 152 Motion balance positioners

Lecture 153 Example of positioners

Lecture 154 Positioners: What you should remember

Lecture 155 Positioners: When should a positioner be fitted

Lecture 156 P/P positioners

Lecture 157 I/P positioners

Lecture 158 About I/P converters

Lecture 159 Digital positioners

Lecture 160 Summary: Selecting a pneumatic valve and actuator

Lecture 161 Before you proceed to the next section

Section 16: Control valve actuators and position indicators for an ON/OFF control action

Lecture 162 Pneumatic actuators

Lecture 163 Example 1 : Single acting / spring return actuators : Components & Operation

Lecture 164 Example 2 : Single acting / spring return actuators : Components & Operation

Lecture 165 Example 3 : Double acting actuators : Components & Operation

Lecture 166 Example 4 : Double acting actuators : Components & Operation

Lecture 167 From single acting to double acting actuator

Lecture 168 From Fail Close (FC) to Fail Open (FO) - Scotch Yoke actuators

Lecture 169 From Fail Close (FC) to Fail Open (FO) - Rack and Pinion Actuators

Lecture 170 Rack and Pinion vs Scotch Yoke

Lecture 171 Valve position indication

Lecture 172 Before you proceed to the next section

Section 17: Controllers and Sensors

Lecture 173 Controllers

Lecture 174 Sensors

Lecture 175 Filled system sensors

Lecture 176 Resistance Temperature Detectors RTDs'

Lecture 177 Thermistors

Lecture 178 Thermocouples

Lecture 179 Electrical communication signals

Lecture 180 Digital addressing

Lecture 181 Before proceeding to the next section

Section 18: Self-acting temperature controls

Lecture 182 Principles of operation

Lecture 183 Vapor tension systems

Lecture 184 Liquid self-acting temp. control valves

Lecture 185 Required force for actuation

Lecture 186 Bellows balanced valves

Lecture 187 Double-seated control valves

Lecture 188 Three-port control valve

Lecture 189 Typical examples

Lecture 190 Ancillaries

Lecture 191 Environments and applications

Lecture 192 Before proceeding to the next section

Section 19: Self-acting pressure controls

Lecture 193 Why reduce fluid pressure?

Lecture 194 Direct acting control valves

Lecture 195 Pilot operated control valves

Lecture 196 Selection and installation

Lecture 197 Summary of pressure reducing valves

Lecture 198 Pressure maintaining valves

Lecture 199 Pressure surplussing valves

Lecture 200 Before proceeding to the next section

Section 20: Examples of pressure control systems

Lecture 201 Introduction

Lecture 202 Self-acting pressure reducing valves: Bellows type

Lecture 203 Self-acting pressure reducing valves: Diaphragm type

Lecture 204 Self-acting pressure reducing valves: Pilot-operated

Lecture 205 Pneumatic pressure reduction

Lecture 206 Electropneumatic pressure reduction

Lecture 207 Electric pressure reduction

Lecture 208 Series and parallel pressure reduction

Lecture 209 Pressure reduction example: Steam desuperheater

Lecture 210 Controlling pressure to control temperature

Lecture 211 Differential pressure control

Lecture 212 Surplussing control

Lecture 213 Cascade pressure control: Example #1

Lecture 214 Cascade pressure control: Example #2

Lecture 215 Before proceeding to the next section

Section 21: Examples of temperature control systems

Lecture 216 Introduction

Lecture 217 Why control temperature

Lecture 218 Self-acting temperature control

Lecture 219 Pilot-operated temperature control

Lecture 220 Pneumatic temperature control

Lecture 221 Electropneumatic temperature control

Lecture 222 Electric temperature control

Lecture 223 Parallel temperature control

Lecture 224 High temperature fail safe control

Lecture 225 Before proceeding to the next section

Section 22: Examples of level control systems

Lecture 226 Introduction

Lecture 227 Methods of achieving level control

Lecture 228 Non-adjustable On/Off control

Lecture 229 Adjustable On/Off level control

Lecture 230 Modulating level control

Lecture 231 Before proceeding to the next section

Section 23: Examples of flow control systems

Lecture 232 Introduction

Lecture 233 Flow control system

Lecture 234 Supply pressure variation

Lecture 235 Using mass flowmeter differential pressure transmitter

Lecture 236 Before proceeding to the next section

Section 24: Control systems installation

Lecture 237 Sensors

Lecture 238 Controllers

Lecture 239 Valves and actuators

Lecture 240 Radio Frequency Interference (RFI)

Lecture 241 Installation best practices to limit RFI

Section 25: Miscellaneous process control examples from refineries and chemical plants

Lecture 242 Learning objectives

Lecture 243 Why do we need to control ?

Lecture 244 How to control ?

Lecture 245 Pipe control: Example #1

Lecture 246 Pipe control: Example #2

Lecture 247 Pipe control: Example #3

Lecture 248 Pipe control: Example #4

Lecture 249 Flow control: Example #1

Lecture 250 Flow control: Example #2

Lecture 251 Pump control: Example #1

Lecture 252 Pump control: Example #2

Lecture 253 Pump control: Example #3

Lecture 254 Pump control: Example #4

Lecture 255 Pump control: Example #5

Lecture 256 Pump control: Example #6

Lecture 257 Pump control: Example #7

Lecture 258 Compressor control: Example #1

Lecture 259 Compressor control: Example #2

Lecture 260 Compressor control: Example #3

Lecture 261 Heat transfer equipment control: Example #1

Lecture 262 Heat transfer equipment control: Example #2

Lecture 263 Heat transfer equipment control: Example #3

Lecture 264 Heat transfer equipment control: Example #4

Lecture 265 Heat transfer equipment control: Example #5

Lecture 266 Heat transfer equipment control: Example #6

Lecture 267 Chemical reactor temperature control

Lecture 268 Fired heater control: Example #1

Lecture 269 Fired heater control: Example #2

Lecture 270 Container and vessel control: Example #1

Lecture 271 Container and vessel control: Example #2

Section 26: Safety Instrumeneted Systems, Interlocks and Alarms

Lecture 272 Learning objectives

Lecture 273 Safety strategies

Lecture 274 Concepts of Safety Instrumented Systems (SIS)

Lecture 275 SIS actions and types

Lecture 276 SIS extent

Lecture 277 SIS requirements

Lecture 278 Anatomy of SIS

Lecture 279 SIS element symbols

Lecture 280 SIS primary elements sensors

Lecture 281 SIS final elements

Lecture 282 Switching valve actuator arrangements

Lecture 283 Valve position validation

Lecture 284 Merging switching and control valves

Lecture 285 SIS logic

Lecture 286 Showing safety instrumented functions on P&IDs

Lecture 287 Discrete control

Lecture 288 Alarm systems

Lecture 289 Anatomy of alarm systems

Lecture 290 Alarm requirements

Lecture 291 Alarm system symbology

Lecture 292 Concept of common alarms

Lecture 293 Fire and Gas Detection Systems (FGS)

Lecture 294 Electric motor controls

Lecture 295 Electric motor controls 2/3

Lecture 296 Electric motor 3/3

Lecture 297 A typical example of an electric motor control system

Section 27: A couple of comments

Lecture 298 Before you proceed to process instrumentation sections

Section 28: How process instruments work: Temperature measurement

Lecture 299 Introduction

Lecture 300 Local indicators

Lecture 301 Bulb instruments for remote transmission

Lecture 302 Thermocouples

Lecture 303 Resistance Temperature Detectors (RTDs)

Section 29: How process instruments work: Pressure measurement

Lecture 304 Hydrostatic manometers

Lecture 305 Bourdon tube pressure gauges

Lecture 306 Bellows pressure gauges

Lecture 307 Strain pressure gauges

Lecture 308 Piezoelectric pressure gauges

Lecture 309 Capacitive pressure gauges

Section 30: How process instruments work: Flow measurement

Lecture 310 Orifice, Nozzles & Venturi tubes

Lecture 311 Pitot tubes

Lecture 312 Annular probes

Lecture 313 Rotameters

Lecture 314 Vortex flowmeters

Lecture 315 Ultrasound flowmeters

Lecture 316 Electromagnetic flowmeters

Lecture 317 Coriolis mass flowmeters

Section 31: How process instruments work: Level measurement

Lecture 318 Introduction

Lecture 319 Glass level gauges

Lecture 320 Float level gauges

Lecture 321 Float switches

Lecture 322 Reed chain float sensors

Lecture 323 Magnetic level gauges

Lecture 324 Hydrostatic level gauges

Lecture 325 Bubble tubes

Lecture 326 Optoelectronic switches

Lecture 327 Capillary systems

Lecture 328 Ultarsonic sensors

Lecture 329 Radars

Lecture 330 Radiometric sensors

Personnel needing to learn the essentials of process control, PID controllers and instrumentation,Control, Process, Chemical and Design engineers & technicians,Instrumentation engineers & technicians,Maintenance engineers & technicians,Experienced personnel as a refresher course and to broaden their knowledge,Instructional designers and those involved in writing manuals and operational procedures,Anyone else with an interest in how process control and PID controllers should be designed, tuned and used in process industries