Master Series - Instrumentation & Control

ABOUT THE MASTERS SERIES

This is four hard hitting days of intensive training, the instrumentation and control master series has proved an outstanding success. It delivers a critical blend of knowledge and skills, covering technology in control and instrumentation, industry analysis and forecasts, leadership and management – everything that is relevant to a modern control and instrumentation engineer. You will be exposed to four high impact days where you will hear from an outstanding expert and undertake practical hands-on sessions and exercises.

A key element of the master series is the ongoing case study conducted throughout the four days that pitches the delegates (in teams of four each) against each other in the design costing of a state-of-the-art plant. The case study is exciting, intense, useful and fun. You will however require every ounce of ingenuity to come up with control and instrumentation solutions appropriate to the design of this process plant.

WHO SHOULD ATTEND?

This master series course is for those from a control and instrumentation background. It has been developed for those whose time is limited and who work in a critical role or situations where a lengthy time away for study is impossible. Those who would benefit most include:

  • Automation engineers
  • Chief engineers
  • Control and instrumentation engineers
  • Electrical engineers
  • Engineering managers
  • Process control engineers
  • Senior technologists and technicians
  • Superintendents

CONTENT SUMMARY

MODULE 1: “SETTING THE SCENE”

This initial module sets the tone for the four days and defines project objectives, administrative issues, timing, instructors and protocols to be followed during the exercises. Participants will be introduced to each other and their assigned team.

MODULE 2: “I&C STANDARDS, DRAWINGS AND DOCUMENTATION”

As built plant documentation is at best 90% accurate on handover; from this point it degrades rapidly to 50 to 75% accuracy in two years. This session will reinforce why it is so important to keep looking at the plant documentation as a whole in order to solve a problem and to adhere to best practice drawing standards and documentation. This will hopefully create the awareness that an engineer's greatest resource is not only his toolbox, but rather his drawing office, databases and plant documentation.

  • Introduction to plant design
  • Process diagrams
  • Instrumentation documentation
  • Electrical documentation
  • Vendor packages
  • Change control

MODULE 3: “PROCESS CONTROL”

This session reviews the essentials of process control and tools to optimise the operation of your plant or process, including the ability to perform effective loop tuning. You will be able to identify and apply the essential building blocks in automatic control with a focus on PID control.

  • Basic control concepts
  • Principles of control systems
  • Stability and control modes
  • Tuning of closed loop control
  • Cascade control
  • Feedforward control
  • Long dead time in closed loop systems

MODULE 4: “ADVANCED PROCESS CONTROL”

In today's competitive environment, every plant manager is looking for the best quality products at minimum operating and investment costs. Advanced Process Control (APC) is essential in this race. Small differences have large effects on profitability; get it right and profits continue to grow; get it wrong and red ink appears everywhere. Most applications of APC have pay out time well below one year, but this cannot be totally outsourced. It requires good knowledge of the plant to design it and some follow up along the life or modification of the plant.

  • Economic justification of advanced control
  • An overview of control problems
  • Internal model control
  • Model Predictive Control (MPC)
    • Model representations
    • Model identification
    • Observers
    • Control
  • Control formulation problem
  • MPC steady state optimisation
  • Application to the control of two different units on a process simulator

MODULE 5: “INDUSTRIAL DATA COMMUNICATIONS AND WIRELESS”

Best practice in designing, installing, commissioning and troubleshooting industrial data communications systems. With so many different communication standards on the market today, the debate is not about what is the best – be it Foundation Fieldbus, Profibus, DeviceNet or industrial Ethernet – but rather in selecting the most appropriate technology for the application and to take advantage of the newer technologies such as Wireless in a low risk way.

  • Introduction
  • Fundamentals
  • Copper/fibre
  • Physical layer standards – RS-232/RS-485/IEC 61158-2
  • Industrial networks – industrial Ethernet; ASi; Foundation Fieldbus; HART; ProfiNet; HSE
  • Industrial protocols – TCP/IP, Modbus, Modbus/TCP
  • Wireless fundamentals
  • Radio telemetry
  • Selection methodologies
  • Installation methodologies
  • Commissioning/testing and troubleshooting
  • Industrial network security

MODULE 6: “SAFETY INSTRUMENTATION AND MACHINERY SAFETY”

For project managers and engineers involved with hazardous processes, this session focuses on the management, planning and execution of automatic safety systems in accordance with IEC 61511 and IEC 61508. Safety authorities are now expecting companies to work to established international standards and often insist on compliance with them.

This session will provide an essential grounding in these safety standards.

  • Overview of safety instrumented systems
  • Introduction to IEC 61508
  • Overview of IEC 61511
  • Principles of risk reduction and safety allocation
  • Practical SIS configurations
  • Selection of sensors and actuators for safety duties
  • Reliability analysis
  • Selection of safety controllers
  • System integration and application software
  • Machinery safety principles
  • Guide to regulations with machinery safety

MODULE 7: “HAZOPS”

This session encourages a multi-discipline approach to the design and ongoing operation of safe process plants. It seeks to give practical experience to those who may be required to participate in a HAZOP and to those who need practice in HAZOP team leadership. It gives managers an appreciation of the strengths and capabilities of HAZOPs as a safety management tool. HAZOP is widely used for identifying hazards in an industrial process and for assessing the potential consequences where there are risks of harm to persons, the environment or to assets. The HAZOP technique is fully recognised and recommended throughout industry by professional engineering institutions, government regulators and insurance companies. It is one of the principle risk management tools required by most government regulators for industrial processes worldwide.

  • Preparations for and conduct of a HAZOP workshop
  • Team member responsibilities
  • Good HAZOP workshop records
  • Hazard identification and risk management
  • Quality HAZOP reports and action files
  • Cost considerations
  • Alternatives to HAZOPs

MODULE 8: “BUDGETING, ROI AND FINANCE OF I&C PROJECTS”

Management approval for your next automation project depends unfortunately not merely on its technical merits but it has to pay for itself. There is a range of financial criteria to consider once you have completed the engineering part of your proposal. This will enable you to put strong financial submissions in for an automation project and communicate more effectively with financial managers and understand how your work affects the profitability of a project and your firm.

  • Introduction
  • Basic accounting concepts
  • Budget preparation and control
  • Understanding cash flow
  • Estimation and costing
  • Time value of money and discount rates
  • Investment appraisal methods
    • DCF
    • Payback
    • NPV
    • IRR
  • Capital budgeting
  • Decision making
  • Tax
  • Risk and uncertainty

MODULE 9: “HAZARDOUS AREAS AND INTRINSIC SAFETY”

This session provides you with an understanding of the hazards involved in using electrical equipment in potentially explosive atmospheres. It is based on the newly adopted IEC79 series of standards that are now slowly replacing the older national standards.

  • Background to hazardous areas
  • Zones and definitions
  • Flameproof concept Ex D
  • Intrinsic safety concept Ex I
  • Increased safety concept Ex E
  • Non sparking concept Ex N
  • Purge and pressurisation
  • Concept Ex P
  • Combined and other methods of protection
  • Electrical hazards, earthing and bonding
  • Standards and codes of practice
  • Maintenance, fault finding and repairs

MODULE 10: “SCADA, PLC AND DCS SYSTEMS”

A SCADA system has traditionally meant a window into the process and gathering of data and then control of the plant. However the focus is now on integrating this process data into the actual business and using it in real time. The emphasis is on using open standards and off the shelf technology rather than the proprietary standards as in the past. Programmable Logic Controllers (PLC) have also evolved significantly into being tightly integrated in the plant in terms of industrial communications, improved analogue control capability and with unified tagging architectures. Distributed Control Systems (DCS) systems have also opened up significantly in terms of communications and taking advantage of the new fieldbus systems. Alarm management is an often neglected area in the use of these systems and this will be examined in detail in this session.

  • Fundamentals
  • SCADA software
  • Distributed Control Systems (DCS)
  • Distributed vs localised I/O
  • PLCs and PACs - the battle of acronyms
  • OPC a bridge between PLCs, DCSs and SCADA systems
  • Optimal alarm management
  • Integration with business systems

MODULE 11: “PROJECT MANAGEMENT OF I&C PROJECTS”

Project managers can only be effective if the nominated project manager and people working on the project understand the critical factors for successful achievement of project objectives. You must have the practical skills necessary to plan and control the project through the various phases. Instrumentation and control projects have some peculiar issues which need to be addressed and this will be examined in this session.

  • Fundamentals of project management
  • Time management
  • Cost management
  • Integrated cost and time management
  • Construction contracts
  • Management of the project team
  • Risk management
  • Contract law
  • Project planning
  • Application to instrumentation and control

MODULE 12: “PREPARATION FOR PRESENTATIONS”

Each team will prepare for the presentations on the next day. The instructors will spend time with each group to ensure that their materials are presented as effectively and practically as possible.

MODULE 13: “INSTRUMENTATION AND VALVE DEVELOPMENTS”

This reviews the latest developments in instrumentation and valve technology to ensure that you are applying the hottest technologies to your plant. Instrumentation and valve selection is one of the core skills of all instrumentation and control specialists and proficiency in this area needs to be jealously maintained.

  • Pressure measurement
  • Level measurement
  • Temperature measurement
  • Flow measurement
  • Analytical instrumentation
  • Control valves
  • Integration of the system

MODULE 14: “DELEGATE PRESENTATIONS”

Throughout the technical modules, participants operating in small teams, complete a series of exercises based on constructing a new plant. Time will be set aside to collate the exercises into a presentation. During this session, each team will present its plans to the other teams.

MODULE 15: “REVIEW OF EXERCISES AND CASE STUDY”

A review will be made on the exercises and submissions and builds on previous sessions. The instructors will participate here.

MODULE 16: “FORECASTS AND PREDICTIONS”

With the swift technical developments in MES/wireless and SCADA systems and the higher risk business environment there is no doubt that enormous pressures are being placed on instrumentation and control technical personnel. This session will endeavour to make sense of the conflicting data and information from so many different sources and provide some clear signposts of the way ahead. This will enable you to make more considered decisions.

  • Main technology trends
  • Conflicting data
  • How to resolve
  • Technical skills squeeze
  • Outsourcing
  • The China challenge
  • Market predictions

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