INDUSTRIAL INSTRUMENTATION AND MODERN CONTROL SYSTEMS Selection, Applications, Operation and Diagnostics TOPICS COVERED. Expert Course Faculty Leader

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1 INDUSTRIAL INSTRUMENTATION AND MODERN CONTROL SYSTEMS Selection, Applications, Operation and Diagnostics 3 for 2 Bundle Offer. SGD 2040 each for Team of 3! TOPICS COVERED Equipment Operation Equipment Diagnostics and Inspection Equipment Testing Equipment Maintenance and Troubleshooting Expert Course Faculty Leader Our key expert has more than 32 years of practical engineering experience with Ontario Power Generation as an Engineering Supervisor and Training Manager, has conduct courses and seminars, to more than 4,000 working engineers and professionals who consistently ranked him as "Excellent" or "Very Good". He has also wrote 5 books for working engineers from which three have been published by McGraw-Hill, New York. Equipment Repair and Refurbishment Efficiency, Reliability, and Longevity Equipment Sizing Another Quality Training By

2 Introduction This seminar will provide a comprehensive understanding of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, HART protocol, control valves, actuators, and smart technology. This seminar will focus on maximizing the efficiency, reliability, and longevity of these systems and equipment by providing an understanding of the characteristics, selection criteria, common problems and repair techniques, preventive and predictive maintenance. This seminar is a MUST for anyone who is involved in the selection, applications, or maintenance of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, control valves, actuators, and smart technology because it covers how these systems and equipment operate, the latest maintenance techniques, and provides guidelines and rules that ensure their successful operation. In addition, this seminar will cover in detail the basic design, operating characteristics, specification, selection criteria, advanced fault detection techniques, critical components and all preventive and predictive maintenance methods in order to increase the reliability of these systems and equipment and reduce their operation and maintenance cost. This seminar will provide the following information for modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, control valves, actuators, and smart technology: Basic Design Specification Selection Criteria Sizing Calculations Enclosures and Sealing Arrangements Codes and Standards Common Operational Problems All Diagnostics, Troubleshooting, Testing, and Maintenance Practical applications of smart instrumentation, SCADA, and Distributed Control Systems, control valves, actuators, etc in the following industries will be discussed in detail: Chemical and petrochemical Power generation Pulp and paper Aerospace Water and sewage treatment Electrical power grids Environmental monitoring and control systems Pharmaceutical plants The instructor will guide the delegates during the seminar to do the following: 1. Design control systems for the chemical, petro-chemical, and power generation Industries 2. Select the components for these control systems 3. Tune and troubleshoot these control systems The seminar will focus on the following: 1. Strategies used to enhance the performance of modern control systems and reduce their capital and operation and maintenance costs 2. Techniques used to increase the reliability of modern control systems and reduce the failure rate of the components and plant downtime 3. Methods used to minimize plant upsets and failures due to control system instabilities

3 Following the seminar, individuals will be able to do the following: 1. Design modern control systems for all industrial applications 2. Select all the smart instrumentation and equipment required for all control systems including Distributed Control Systems 3. Tune all control systems 4. Operate, diagnose, troubleshoot and repair all control systems equipment including smart instrumentation, Distributed Control Systems, SCADA, control valves, actuators, positioners, transducers, etc Seminar Outcomes Equipment Operation: Gain a thorough understanding of the operating characteristics of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Diagnostics and Inspection: Learn in detail all the diagnostic techniques and inspections required of critical components of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Testing: Understand thoroughly all the tests required for the various types of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Maintenance and Troubleshooting: Determine all the maintenance and troubleshooting activities required to minimize the downtime and operating cost of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, control valves, actuators, and smart technology Equipment Repair and Refurbishment: Gain a detailed understanding of the various methods used to repair and refurbish modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Efficiency, Reliability, and Longevity: Learn the various methods used to maximize the efficiency, reliability, and longevity of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Sizing: Gain a detailed understanding of all the calculations and sizing techniques used for modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Design Features: Understand all the design features that improve the efficiency and reliability of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Selection: Learn how to select modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial instrumentation, control valves, actuators, and smart technology by using the performance characteristics and selection criteria that you will learn in this seminar Equipment Enclosures and Sealing Methods: Learn about the various types of enclosures and sealing arrangements used for modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Commissioning: Understand all the commissioning requirements for modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Equipment Codes and Standards: Learn all the codes and standards applicable for modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial

4 Equipment Causes and Modes of Failure: Understand the causes and modes of failure of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial System Design: Learn all the requirements for designing different types of modern control systems, digital control, distributed control systems (DCSs), supervisory control and data acquisition (SCADA) systems, industrial Who Should Attend Engineers of all disciplines Managers Technicians Maintenance personnel Other technical individuals Training Methodology The instructor relies on a highly interactive training method to enhance the learning process. This method ensures that all the delegates gain a complete understanding of all the topics covered. The training environment is highly stimulating, challenging, and effective because the participants will learn by case studies which will allow them to apply the material taught to their own organization. This training course has a limited attendance for up to 20 participants only. Sessions commence at 9am on all days, with short intervals at 10.30am and 3.30pm respectively. Refreshments will be provided in the short intervals. Lunch will be provided at 12:30pm for 1 hour. Sessions will end at 5pm on all days.

5 Your Expert Faculty Our expert has been a teacher at University of Toronto and Dalhousie University, Canada for more than 25 years. In addition, he has taught courses and seminars to more than four thousand working engineers and professionals around the world, specifically Europe and North America. He has been consistently ranked as "Excellent" or "Very Good" by the delegates who attended his seminars and lectures. He wrote 5 books for working engineers from which three have been published by McGraw-Hill, New York. Below is a list of the books authored by him: 1. Power Generation Handbook: Gas Turbines, Steam Power Plants, Co-generation, and Combined Cycles, second edition, (800 pages), McGraw-Hill, New York, October Electrical Equipment Handbook (600 pages), McGraw-Hill, New York, March Power Plant Equipment Operation and Maintenance Guide (800 pages), McGraw-Hill, New York, January Industrial Instrumentation and Modern Control Systems (400 pages), Custom Publishing, University of Toronto, University of Toronto Custom Publishing (1999). 5. Industrial Equipment (600 pages), Custom Publishing, University of Toronto, University of Toronto, University of Toronto Custom Publishing (1999). Furthermore, he has received the following awards: 1. The first "Excellence in Teaching" award offered by PowerEdge Asia Training center, Singapore, December The first "Excellence in Teaching" award offered by the Professional Development Center at University of Toronto (May, 1996). 3. The "Excellence in Teaching Award" in April 2007 offered by TUV Akademie (TUV Akademie is one of the largest Professional Development centre in world, it is based in Germany and the United Arab Emirates, and provides engineering training to engineers and managers across Europe and the Middle East). 4. Awarded graduation With Distinction from Dalhousie University when completed Bachelor of Engineering degree (1983). 5. Entrance Scholarship to University of Ottawa (1984). 6. Natural Science and Engineering Research Counsel (NSERC) scholarship towards graduate studies Master of Applied Science in Engineering ( ). Our specialist performed research on power generation equipment with Atomic Energy of Canada Limited at their Chalk River and Whiteshell Nuclear Research Laboratories. He also has more than 32 years of practical engineering experience with Ontario Power Generation (OPG - formerly, Ontario Hydro - the largest electric utility in North America). He retired from OPG in November While working at Ontario Hydro, he acted as a Training Manager, Engineering Supervisor, System Responsible Engineer and Design Engineer. During the period of time, he worked as a Field Engineer and Design Engineer, he was responsible for the operation, maintenance, diagnostics, and testing of gas turbines, steam turbines, generators, motors, transformers, inverters, valves, pumps, compressors, instrumentation and control systems. Further, his responsibilities included designing, engineering, diagnosing equipment problems and recommending solutions to repair deficiencies and improve system performance, supervising engineers, setting up preventive maintenance programs, writing Operating and Design Manuals, and commissioning new equipment. Later, he worked as the manager of a section dedicated to providing training for the staff at the power stations. The training provided by him covered in detail the various equipment and systems used in power stations. Lastly, he was awarded his Bachelor of Engineering Degree "with distinction" from Dalhousie University, Halifax, Nova Scotia, Canada. He also received a Master of Applied Science in Engineering (M.A.Sc.) from the University of Ottawa, Canada. He is also a member of the Association of Professional Engineers in the province of Ontario, Canada.

6 3 Day Course Outline Day 1 Feedback Control and Proportional-Integral-Derivative Algorithm, Correlations for Tuning Constants, Proportional- Integral-Derivative Controller Tuning for Dynamic Performance Introduction to Feedback Control Systems Process and Instrument Elements of the Feedback Loop Control Performance Measures Integral Error Measures, Decay ratio, Period of Oscillation, Manipulated-Variable Overshoot Selection of Variables for Control Feedback Control Algorithm Proportional Control Integral Control Derivative Control Proportional-Integral-Derivative Controller Instrument Society of America (ISA) Standards and Codes for Algorithms Recommended Algorithms for Different Applications Determining Tuning Constants that Give Good Control Performance Controlled-Variable Performance (Integral Absolute Error) Good Control Performance with Model Errors Manipulated-Variable Behavior Correlations for Tuning Constants Determining the Values of Proportional, Integral, and Derivative Algorithms Control Loop Tuning Exercises for Different Applications of Loop Tuning Fine-Tuning the Controller Stability of Control Systems Controller-Tuning Based on Stability Effect of Process Dynamics on Tuning Types of Control Systems Continuous and Discrete Data Control Systems Cascade Control Systems Day 2 Distributed Control Systems (DCS), Supervisory Control and Data Acquisition (SCADA) System, Intelligent (Smart) Transmitters, Controllers, Sizing and Selection of Control Valves Structure of the Distributed Control System (DCS) Discrete Proportional-Integral-Derivative (PID) Control Algorithm Effect of Digital Control on Stability Tuning and Performance Smart Sensors Controller Algorithms Monitoring and optimization Distributed Control System (DCS) Architecture and Advantages Distributed Control Systems Components and Features Supervisory Control and Data Acquisition (SCADA) System Advantages of Distributed Control System (DCS) Differences between SCDA and DCS DCS communications with other control systems Microprocessors and Microcomputers Microprocessor Architecture Microcomputer System Application of Alarm Management System Manage the Design of an Alarm System to increase its usability Instrument Society of America (ISA) Standards and Codes for Industrial Instrumentation Smart Systems Intelligent (Smart) Transmitters Microprocessor-Based Transmitters (Smart Transmitters) Smart (Intelligent) Pressure Transmitters Advantages of Intelligent Instrumentation Comparison Between Intelligent and Non-Intelligent Instrumentation Stand-Alone Controllers Self-Tuning, Sequencing, and Networking HART Protocol Valve selection Linear valves Rotary valves Valve selection considerations Valve maintenance Basics of valve design (seats and seals) Sealing the valve stem Leakless valves Valve materials Preventing valve material failure Nonmetallic valves General categories of control valves Rangeability, end connections, shutoff capability Valve sizing Choked flow Gas and steam sizing Sizing and selection of control valves and actuators Information required to select a control valve Control valve body materials Control valve trim material Pressure-temperature ratings for all control valve materials Class designation and PN numbers for control valves Face-to-face dimensions of most types of control valves

7 Wear and galling resistance of control valve material Control valve seat leakage classification Control valve trim material temperature limit Service temperature limitations for control valve elastomers Ambient temperature corrosion information for most fluids used in control valves Control valve elastomer information Compatibility of elastomer material with control valve fluids Control valve flow characteristics Selection of control valve flow characteristic Day 3 Sizing of Control Valves, Positioners, and Actuator for Compressible and Non-Compressible Fluids, Control Valve Flashing, Cavitation and Noise Control, Control System, Commissioning of Instrumentation and Control System Packages, Troubleshooting and Diagnostics Control valve sizing Sizing valves for liquid applications Detailed calculations for sizing valves liquid applications Liquid sizing sample problem Sizing valves for compressible fluids Compressible fluid sizing sample problem No. 1 Compressible fluid sizing sample problem No. 2 Sizing coefficients for single-ported globe style valve bodies Sizing coefficients for rotary shaft valves Actuator sizing Packing friction Actuator force calculations Rotary actuator sizing Torque equations Breakout torque Dynamic torque Maximum rotation Non-destructive test procedures Magnetic Particle (surface examination) Liquid penetrant (surface) examination Radiographic (volumetric) examination Ultrasonic (Volumetric) examination Cavitation and flashing Choked flow causes flashing and cavitation Valve selection for flashing service Valve selection for cavitation service Noise prediction Aerodynamic and hydrodynamic Noise control Noise summary Packing selection Packing selection guidelines for sliding-stem valves Packing selection guidelines for rotary valves Control valve selection process Control valve cavitation Control valve noise Pneumatic actuators Piston actuators Electric actuators Hydraulic actuators Positioners Live loading Commissioning of Instrumentation and Control System Packages Minimum Documents Needed for Accepting Instrumentation and Control Systems Packages Factory Acceptance Test (FAT) Site Acceptance Test (SAP) Speed Response Test Commissioning Procedures and Checklists I/O Lists Alarm and Trips Lists Hook-up Drawings Proportional Integral and Derivative Algorithms Control Loop Diagrams Instrumentation and Control System Manuals Liquified Natural Gas (LNG) Instrumentation and Control Systems Instrumentation and Control Systems Used in Chemical, Petrochemical, and Power Generation Industries Diagnostic testing of control loops Air-operated valves diagnostics Motors-operated valves diagnostics Troubleshooting Methods of Industrial Instrumentation and Control SystemsHands on Exercise on System Controllers Hands on Exercises on System Controllers

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