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BNI2-SP Industrial Instrumentation and Control for Non-Instrument Personnel

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  • Investment: US$ 899
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Content

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Advanced Industrial Automation - Chemical Engineering

Description

Instrumentation, Automation and Process Control
The instrumentation, automation and process control module contains the elaborated concepts on three engineering fields namely instrumentation engineering, automation engineering and process engineering. Instrumentation refers to the devices and instruments that are used in various processes. Automation refers to the automatic working of instruments. Process engineering refers to the study of processes that are carried out in any type of industry and industrial applications.
The fundamentals and selection criteria of measuring devices like pressure transducers, level transducers, temperature transducers and flow measurements are detailed. The Piping & instrument diagram and symbols for the instrumentation devices are listed and selection criteria are discussed. The process automation control and their types are incorporated with the process systems. The new technology oriented smart instruments and their data signals are further discussed.

This module will disseminate information to technical professionals who would like to gain comprehensive technical, as well as practical, knowledge on instrumentation, process and automation systems.

Control valve sizing, selection and maintenance
In any industries, the shop floor contains many processes that are linked together to get a desired product. In order to achieve the desired product, the intermediate processes must have to be functioned in a controlled manner. These processes are designed to do their own desired task under controlled system. The control valve is the one that is used to control the independent parameters such as temperature, pressure, volume, flow rate, etc. at each sub systems in a shop floor. There are many changes/disturbances in the desired product from the designed product even after the system is controlled. The design and the proper selection and maintenance of the control valve is the only key factor that alters the product nature. In order to achieve the ideal product, the design of control valve is mandatory.

This practical task gives scope to this module on control valve sizing, selection and maintenance; this enables personnel to gain detailed study on the design of controllers, types and selection of control valves; plus calculations, performance and maintenance in context. This advanced course comes under the process engineering discipline.


Practical SCADA Systems for Industry
SCADA has traditionally meant a window into the process of a plant or gathering of data from devices in the field, but now the focus is on integrating this process data into the actual business and using it in real time. The emphasis today is on using open standards such as communication protocols (e.g. OPC, MODBUS, and TCP/IP) and ‘off-the-shelf’ hardware, such as industrial Ethernet to keep the costs down. This module covers the essentials of SCADA systems.

Topics include an introduction to SCADA systems, SCADA system hardware and software (including alarm management and Human Management Interface (HMI) issues) and a review of the RS-232/RS-485 interface standards and the MODBUS and DNP3 protocols.

This module continues to give a review of industrial Ethernet, TCP/IP and MODBUS/TCP, the role of Open Process Control (OPC) in plant SCADA systems, and discussion of network security, SCADA historians and troubleshooting issues.

Although the emphasis will be on practical industry topics highlighting recent developments using case studies and the latest application of SCADA technologies, the fundamentals of SCADA systems will also be covered. This module is aimed at those who want to be updated on the latest developments in SCADA systems and want to get a solid appreciation of the fundamentals of SCADA design, installation and troubleshooting.


Specification and Technical Writing
Technical writing is unique because of its specialized content. It conveys technical content through specific, clear and concise writing.

This fundamental module on technical writing helps the learner to assess the needs of the users and create documents that explain technical information. It also instils basic knowledge on the mechanics of good technical writing.

In addition to the above, the students also learn how to build effective sentences and sections that explain information clearly and create informative content that readers will understand and use.


Process and Electrical Drawings
The electrical and process drawings portion of the course will be reference through each module and is support by dedicated P&ID videos. This section makes reference to diagrams from the simple block diagram to the comprehensive engineering process line diagrams which aid in planning and fabrication of the plant. To be effective, expert knowledge is required on the use of mass and energy balances in process design. The fundamentals and principles of which, will be covered.


What You Will Gain

  • A fundamental understanding of industrial automation
  • An introduction to instrumentation and measurement
  • The key know-how to work with control valves
  • An ability to configure simple PLC and SCADA systems
  • An ability to work with plant documentation such as P&ID’s

 

WHO SHOULD COMPLETE THIS COURSE
Anybody with an interest in gaining know-how in a full range of fundamentals of measurement, instrumentation, process control, PLC’s, SCADA and P&ID, ranging from the plant secretary, to operators, trades personnel (artisans), technicians and engineers from other backgrounds – such mechanical, electrical and civil. Indeed this is an excellent course for managers from a wide variety of disciplines who are keen to understand the key workings and the future of their plants.

 

COURSE OUTLINE
BASIC MEASUREMENT CONCEPTS

  • Performance terms and specifications – sensitivity and range and span
  • Accuracy
  • Precision
  • Repeatability
  • Range of operation
  • Difference bet analog and digital

ADVANCED MEASUREMENT

  • Performance terms and specifications – linearity
  • Hysteresis response
  • Control loop components
  • Measuring instruments and control valves as part of the overall control system

P&ID SYMBOLS

  • Tag description
  • P&ID symbols
  • Instrumentation representation on flow diagrams
  • Mix of instrument signals
  • Letter codes and balloon symbols
  • P&ID symbols for transducers and others

SELECTION CRITERIA

  • Effects of selection criteria
  • Instrument selection
  • Flow applications

FUNDAMENTALS OF PRESSURE MEASUREMENT

  • Principles
  • Types- static pressure, dynamic pressure and total pressure
  • Technical terms

PRESSURE TRANSDUCERS

  • Mechanical – manometer
  • Bourdon tube
  • Diaphragm

PRESSURE SENSORS

  • Electrical – strain gauge
  • Piezoelectric
  • Capacitance
  • LVDT
  • Optical

PRINCIPLES OF LEVEL MEASUREMENT

  • Point source- by visual inspection
  • Gauging rod method
  • Buoyancy tape systems
  • Field effect level detection
  • Gravimetric
  • Bubbler tube
  • Pressure gauge to measure level
  • Installation considerations

CONTINUOUS SOURCE

  • Magnetic float
  • Time of flight measurement
  • Echo measurement
  • Selection considerations
  • Continuous -  pressure head
  • Capacitance/resistance
  • Fiscal measurement

CONTACT TYPE DEVICES – THERMOCOUPLES

  • Concepts
  • Average of temperatures
  • J type thermocouple
  • Voltage curves
  • RTDs
  • Concept
  • PT100 resistance table

THERMISTORS AND OTHER DEVICES

  • Selection and sizing
  • Typical packaging
  • Filled devices
  • Non-contact pyrometer type

FUNDAMENTALS OF FLOW MEASUREMENT

  • Basic terms and concepts
  • Flow parameters – velocity
  • Volumetric flow and mass flow
  • Flow types
  • Importance of Reynolds number
  • Differential pressure flow meters
  • Bernoulli’s equations

ORIFICE PLATE

  • Installation
  • Concentric orifice
  • Application limitations

OTHER MEASURING DEVICES

  • Venturimeter
  • Pitot tube
  • Flow over a weir
  • Rotameter
  • Vortex meter
  • Construction of swirl meter
  • Turbine flow meter
  • Magnetic flow meter
  • Ultrasonic measurement,
  • Positive displacement – rotating vane, rotating lobe meter
  • Positive displacement meter
  • Mass flow rate meter
  • Coriolis meter construction
  • Straight through meter
  • Thermal mass flow meter

CONTROL VALVES

  • Introduction Control valve, classification, principles, Application function – isolation, ON-OFF valves
  • Flow control, directional control, protection, overpressure
  • Sliding stem valves: Plug, Globe, Cage valves, Operating conditions
  • Rotary valves: butterfly, ball valves, flow characteristics
  • Noise and cavitations:  sources of noise, principles of cavitations and its effects

CONTROL VALVES FLOW CHARACTERISTICS

  • Selection and Sizing
  • Effective pressure drop
  • Control valve characteristics/trim
  • Components of a process control loop

PRINCIPLE OF LOOP CONTROL SYSTEMS

  • Block diagram for summation and gain
  • Direct & reverse controllers
  • Feed forward control loop
  • Cascade control

DIFFERENT TYPES OF PROCESSES OF LOOP CONTROL

  • First order process and response
  • Second order process and response

CLOSED LOOP PID

  • Control types
  • Objectives of tuning

NEW SMART INSTRUMENT AND FIELD BUS

  • Fundamental concepts
  • Field bus to typical control system

HYBRID TECHNIQUE – HART

  • Digital messages
  • Sources of noise
  • Earthling configurations

COMMUNICATION SYSTEMS

  • Data control and transfer protocol
  • RS-423, RS-422, RS-432, RS-485
  • Fiber optics
  • Network topology - star, ring and bus
  • Media access control methods

PLC SYSTEMS

  • PLC block diagram and configuration
  • Discrete DC/AC Input and Output module
  • Analog input module

FUNDAMENTALS OF PLC

  • PLC programming simulator
  • Programming setup, languages and concept
  • Function block diagram
  • Instruction list
  • Structured text language
  • Control valve sizing, selection and maintenance

BASIC SIZING FOR LIQUIDS:

  • Selection process and formulations
  • Selection steps  and sizing of control valves
  • Valve coefficient
  • Purpose,
  • Pressure recovery factors
  • Application of control valves
  • Liquid sizing equations for determining volumetric flow rate
  • Metric and SI formulae
  • Valve characteristics  

BASIC SIZING FOR GASES AND VAPORS:

  • Selection steps  and sizing of control valves for gas
  • Saturated steam
  • Superheated steam
  • Determination of valve coefficient
  • Gaseous and vapor sizing equations for determining volumetric flow rate
  • Metric and si formulae

INHERENT AND INSTALLED FLOW CHARACTERISTICS

  • valve characteristics
  • butterfly disc shapes
  • butterfly valve – inherent characteristic
  • high performance characteristics
  • flow characteristics
  • globe valve characteristics
  • cage valve characteristics
  • various ball valve characteristics
  • simple calculation data
  • inherent characteristics
  • installed characteristics
  • overall process control loop
  • closed loop control and controller
  • importance of loop gain
  • non-linear response conversion of gain to percentage of controller input range
  • process pressure ratio and conclusion

ACTUATORS AND POSITIONERS

  • purpose
  • principles of actuators for control valves
  • issues of size
  • force and speed matched to valve type
  • control valve design considerations

TYPES OF ACTUATORS

  • Pneumatic actuator types –piston and diaphragm
  • Fixed spring, rotary
  • Rack and pinion
  • Rotary vane
  • Electrical actuators – on/off control
  • Modulated control
  • Solenoid type
  • Hydraulic actuators for large valves
  • Actuator accessories

CAVITATION AND FLASHING

  • Fundamental concepts on Cavitation
  • Static and dynamic pressure profiles
  • Multistage pressure reduction through the valve trim
  • Cavitation mechanisms
  • Effects of flashing
  • Damage
  • Velocity and noise
  • Incipient cavitation
  • Diffuser plate and choke
  • Trim selection guide

CAVITATION CONTROL

  • problem characteristics
  • Types and cavitation control parameters
  • Anti-cavitation trim
  • Cavitation elimination

NOISE PREDICTION AND TREATMENT

  • Control valve noise Sources
  • Treatment
  • Prediction of noise
  • Methods
  • Low noise trim
  • Diffuser plates
  • Globe valve trim selection
  • High pressure drop applications
  • ED disk stack
  • Low noise retainers
  • Examples of noise reduction,
  • Noise treatment and accessories
  • Q-ball for noise attenuations and  anti cavitation
  • Noise source treatment
  • Chokes
  • Disk stack technology
  • Pressure balanced trim

MATERIALS OF CONSTRUCTION

  • Control valve materials
  • Overview of material selection issues
  • Standard control valve body materials
  • Typical materials of construction for body and valve trim
  • Recognize issues of corrosion and wear, valve trim materials
  • Seating materials for tight shut off vs durability
  • Problems of leaks from seals
  • Applications of bellows seals for toxic materials

MAINTENANCE ISSUES

  • Tasks involved in valve maintenance
  • Installation features relevant to good maintenance
  • Recognize the setting up and testing tasks for valves
  • Methods of detection of backlash and stiction in the valve drive
  • Potential advantages of using smart positioners and diagnostic software tools.

PRINCIPLES OF PRESSURE

  • Hazards of overpressure
  • Causes and consequences,
  • Basic terminology
  • European standards
  • Pressure types
  • ASME code requirements

PRESSURE RELIEF SYSTEM

  • Requirements
  • Purpose
  • Relief systems
  • layer of protection
  • use and purpose of relief system

PRESSURE RELIEF VALVES

  • Safety valves- types and performance issues
  • Sizing principles and equations
  • Calculations with examples
  • Superimposed and built – up back pressure
  • Balanced pressure relief valve operation and construction
  • Balanced spindle design
  • Pilot operated type
  • Back pressure effects on pilot operated valve

DESIGNING CONCEPTS AND ISSUES

  • Outline of relief design procedure
  • Sizing reliefs – determining relief rates
  • Vent area
  • Size of valve
  • Sizing formulae and equations for gaseous and liquid flow
  • Specification and installation issues
  • Problem of chatter
  • Rupture discs
  • Rupture pins
  • Prv conclusions
  • Practical SCADA Systems for Industry

INTRODUCTION

  • Communication architectures
  • Communication philosophies

OVERVIEW OF SCADA SYSTEMS

  • Hardware alternatives (RTU/PLC etc)
  • Communication concentrators
  • Communication alternatives

SCADA SYSTEM HARDWARE

  • Hardware components
  • Operation and selection issues

SCADA SYSTEM SOFTWARE

  • SCADA software functions
  • Response times
  • Redundancy issues
  • Specification and configuration issues

SCADA ALARM MANAGEMENT

  • Alarm layout and organisation
  • Alarm priorities
  • Alarm processing and reporting

HUMAN MANAGEMENT INTERFACE (HMI)

  • Ergonomic factors
  • HMI organisation
  • HMI screen design

COMMUNICATION PROTOCOLS

  • RS-232/RS-485 interface standards
  • MODBUS protocol
  • DNP 3.0 protocol

INDUSTRIAL ETHERNET

  • Fundamentals
  • Redundancy
  • TCP/IP
  • Configuration
  • Troubleshooting utilities

MODBUS TCP

  • Overview

OPPEN PROCESS CONTROL (OPC)

  • Overview

SCADA NETWORK SECURITY

  • Security issues
  • SCADA firewall configuration

SCADA HISTORIAN

  • Archiving plant data
  • Data access

TROUBLESHOOTING ISSUES

  • Testing methodology
  • Noise issues
  • Communications testing
  • Practical SCADA Systems for Industry

INTRODUCTION TO TECHNICAL WRITING

  • Technical writing- Definition, meaning and where used.
  • Attributes of Technical writing
  • Categories of Readers
  • Expression versus Impression                                                    

THE DEVELOPMENT PROCESS

  • Preparing to write a document
    • Establish objective
    • Identify Readers
    • Perform Research                                                                   

ORGANIZING THE WRITING

  • Methods of development
  • Outline of Technical documents
  • Outlining formats
  • Revising the document -Editing, Revision, Proof- reading                                

USE OF LANGUAGE AND WORDS

  • Grammar
  • Punctuation and Parts of speech
  • TWR and Author’s point of view                                                  `

CLARIFICATION OF WRITING PROCESS    

  • Types of sentences  (Simple ,Complex and Compound)
  • Voice - Active Vs Passive                                         

SOME ADDITIONAL GRAMMAR ISSUES

  • Subject-Verb agreement,
  • Use of British and American English
  • Punctuation                                                                     
  • Vocabulary
  • Jargon and Cliches
  • Fog Index                                                               

ELEMENTS OF TECHNICAL WRITING

  • Basic elements of Technical writing-Description and examples
  • Organizing process description/Instruction set
  • Final check                                                                                       

FORMATS OF TECHNICAL WRITING

  • Purpose of reports
  • Structure of formal report
  • Terms of Reference
  • What a report should contain                                         

INTRODUCTION TO REPORT WRITING                    

  • Main body of the report
  • What to include
  • Conclusion and recommendations
  • Executive Summary
  • Other sections
  • Technical report writing Vs Report writing                     

MEMO REPORTS AND OTHER TECHNICAL DOCUMENTS

  • Memo Reports-Types and Functions
  • Basic Structure
  • Other technical documents
  • Technical Manual-Purpose and categories of readers
  • Technical proposal-Definition and Structure
  • Journal article                                                                

WRITING OF SPECIFICATION

  • Purpose of Specifications
  • Phases of Specification
  • Equipment Specification
  • Client/Purchaser Specification                                      

CONTENTS OF SPECIFICATION

  • Scope
  • Standards, codes and regulations
  • Definition and Terminology                                            

CONTENTS OF SPECIFICATION - II

  • Materials of Construction
  • Design Basis
  • Mechanical/Fabrication
  • Guarantees
  • Testing and Inspection
  • Documentation
  • Shipping                                                                            

PRESENTATION ASPECTS

  • Preference of Desk top publishing to other methods
  • Appearance of presentation-Book binders
  • Document Designing
  • Use of graphs, Tables and Illustrations                              

ORAL PRESENTATION OF TECHNICAL DOCUMENTS

  • Personal factors
  • Structure of presentation-Details
  • Use of various tools for oral presentation
  • Importance of timing
  • Conclusion

 

Investment

Plan Name Investment
Unlimited Access for 2 Years: US$ 899

Instructor

John Piperides

BE Electrical

 

John is a professional electrical engineer with over 25 years experience in industrial maintenance, production, management, sales and improvement. He has held management positions in several manufacturing and sales companies. His diverse responsibilities have included contract negotiation, authoring and responsibility of departmental budgets, daily management of over 20 reports, practice of cGMP, auditing in a pharmaceutical plant, and system administration and programming of diverse IT and embedded systems. He has been directly involved with industries including building management, pest control, mining, power utilities, food, pharmaceutical, steel, building products, sugar, paper and pulp, rail and airports.

John has completed many years of further education including developing, writing and delivering many work based courses and seminars. He has spent 10 years as a part time teacher at TAFE in electrical engineering, and 15 years delivering structured courses in thermography, power quality, instrument safety, motor drive theory, PLC, SCADA, and pest inspection

Courses by this presenter

Name Level Release Date
SX-SP Practical SCADA Systems for Industry 14-09-2015
LA-SP Engineering Leadership 21-09-2015
AU-SP PLC's for Automation and Process Control 22-10-2015
PJ-SP People Management Skills for Engineers and Technicians 03-11-2015
COG-SP Electrical and Instrumentation Engineering in Oil and Gas 17-12-2015
CAW-SP Australian and New Zealand Electrical Wiring Standards - AS3000:2007 05-01-2016
LT-SP Tuning of Industrial Control Loops 15-01-2016
PM-SP Project Management 15-01-2016
SS-SP Safety Instrumentation Systems and Functional Safety for the Process Industries 28-01-2016
DIA1-SP Advanced Industrial Automation - Instrumentation, Automation and Process Control 12-02-2016
DIA7-SP Advanced Industrial Automation - Process Control 16-02-2016
BNI2-SP Industrial Instrumentation and Control for Non-Instrument Personnel 16-02-2016
DIA8-SP Advanced Industrial Automation - Tuning of Industrial Control Loops 16-02-2016
BSQ-SP Fundamentals of Instrumentation, Process Control, PLCs and SCADA for Plant Operators and Other Non-Instrument Personnel 17-02-2016
DIA10-SP Advanced Industrial Automation - PLCs for Automation and Process Control 18-02-2016
DIA11-SP Advanced Industrial Automation - Advanced Process Control for Engineers and Technicians 18-02-2016
DIA-SP Specialized Engineering (Industrial Automation) 25-02-2016
BAU-SP Advanced Programmable Logic Controllers for Industry 25-02-2016
MCD1-SP Fundamentals of Process Measurement 25-02-2016
BCIIP-SP Relay Theory and Basic System Protection 16-03-2016
MCD4-SP Process Measurement - Hazardous Areas 04-05-2016
MCD2-SP Process Measurement - Use and calibration 04-05-2016
SAK-SP Swiss Army Knife of Videos on Engineering Skills 08-06-2016
LA2-SP Engineering Leadership - Personal leadership 21-09-2015
LA5-SP From Engineer to Leader - Conflict Management Skills 21-09-2015
LA6-SP From Engineer to Leader - Creativity and Problem Solving 21-09-2015
PJ4-SP People Management Skills - The Four Behavioural Styles 03-11-2015
PJ8-SP People Management Skills - Team Motivation 03-11-2015
PJ6-SP People Management Skills - Effective Communication 03-11-2015
PJ9-SPPeople Management Skills - Effective Time Management 03-11-2015
CAW3-SP Regulations of AS NZS 3000-2007 05-01-2016

Frikkie Marx

Pr Eng, B Sc (Eng) Senior Engineer

Frikkie has over 20 years of experience in the fields of Power Systems from design to industrialisation. He started his career on the Power System Protection side, then migrated to EMC and Power Supply Systems. Frikkie's portfolio of achievements includes the design of Power Systems, Switch Mode Power Supplies, UPS, high precision Servo Amplifiers, battery and Inverter Design for solar panel applications, vehicle management, specialised computer systems and high current starter for vehicle plants. Lecturer and course developer of Industrial  and Power electronics for Technikon SA (UNISA). Project Manager/System engineer for the development of Electro-optical systems which include video systems for UAV’s and a high resolution Infra-Red Camera. Other activities include the mentorship programs of Kentron, Industrial electronics, rockets and robots training programme for the Denel Youth Foundation Bridging Program as well as training consultant.

Roland Green

Mechanical Engineer / Estimator 

Roland brings more than 20 years’ experience in engineering and estimating fields, gained mostly in South Africa. He has worked on many projects spanning the minerals industry, including power stations, coal stockyards and manganese. The past two years Roland has being extensively involved with major projects across Western Australia ranging from $460 Mil to projects of more than a few Billion dollars.

Key projects include:

  • Kusile Power Station Coal Stockyard
  • Kalagadi Manganese
  • Medupi Power Station
  • Minproc RIO TINTO Ramp Conveyor

Geoff Bottrill

HNC, DMS, MIEE

Senior Hazardous Areas Engineer

Used: HZ Nov 12

Geoff has been working in the instrumentation, measurement and control fields for over twenty-five years and has spent the past fifteen years specialising in Hazardous Areas, Intrinsic Safety and Instrumentation Drawings. Geoff began his career at Kent Instruments, as a service engineer working in both the UK and East Africa. His experience ranges from systems design functions and on-site trouble shooting to technical and commercial customer support.

Recently Geoff has taken on the responsibility of mentoring engineers in training, in addition to the presentation of engineering workshops in the process control and measurement field. His positive interactive approach to teaching has made him popular with workshop attendees worldwide.

Eugene Coetzee

Pr. Eng, BSc (Elec Eng)

Used AV Sept 14 SA  

 

Eugene is an electronic engineer with 20 years experience in software development specialising in industrial networks for control systems and corporate IT applications. He started his career at the engineering division of Sasol, Sastech Secunda, where he did control system design, PLC software design and SCADA configuration on the Honeywell, Hartmann & Braun and Siemens DCS/PLC systems.

 

He moved on to develop serial network drivers for the Wonderware SCADA system on Windows NT as an independent contractor. Subsequently, Eugene worked as a senior electronic engineer in the electronic development lab of the NWU (North-West University) where he designed and developed building management systems on RS485 and Ethernet networks and developed networking software for TCP/IP based access control equipment.

 

Eugene is an experienced course presenter, and has provided training for large international clients across several industries, including a recent training initiative for one of the largest metal and mining companies in Africa. He is currently a consultant engineer on various large projects which includes fire detection systems, emergency evacuation systems, access control systems, CCTV systems and integrated Ethernet/IP based building management. He also lectures part-time at North West University’s Electronic Engineering School presenting courses in industrial network communications, database design and C++ programming.

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Duration
Advanced Industrial Automation - Chemical Engineering

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