PROCESS CONTROL INSTRUMENTATION, TROUBLESHOOTING AND PROBLEM SOLVING TRAINING

Introduction to Process Control: Basics of process control, feedback loops, and control strategies. Importance of accurate and reliable process measurements.

Instrumentation Devices and Sensors: Overview of various sensors (pressure, temperature, level, flow, etc.). Selection, calibration, and installation of instrumentation devices.

Control Valves and Actuators: Types of control valves and their functions in regulating fluid flow. Actuators, positioners, and control valve tuning.

PID Control and Tuning: Understanding Proportional-Integral-Derivative (PID) control. Tuning PID controllers for optimal performance.

Process Analyzers and Measurements: Analytical instruments for measuring chemical composition and quality. pH, conductivity, gas analyzers, and chromatography.

Data Acquisition and SCADA Systems: Introduction to Supervisory Control and Data Acquisition (SCADA) systems. Data logging, visualization, and remote monitoring.

Instrumentation Calibration and Maintenance: Calibrating and maintaining instrumentation devices. Ensuring accuracy and reliability of measurements.

Troubleshooting Techniques: Strategies for identifying and diagnosing process control issues. Root cause analysis and fault detection.

Problem Solving Methods: Applying problem-solving methodologies to resolve control system issues. Fishbone diagrams, fault trees, and cause-and-effect analysis.

Human-Machine Interface (HMI): Designing intuitive and user-friendly HMIs for process monitoring and control. Alarm management and operator interfaces. Safety Instrumented Systems (SIS): Principles of safety instrumented systems and their role in process safety. Functional safety standards (IEC 61508/61511) and SIL assessment.

Process Optimization and Performance Improvement: Identifying opportunities for process optimization and efficiency improvement. Adjusting control strategies for better performance.

Remote Diagnostics and Maintenance: Implementing remote diagnostics and predictive maintenance for control systems. Cloud-based monitoring and remote troubleshooting.

Communication Protocols and Networks: Understanding industrial communication protocols (Modbus, Profibus, etc.). Networking considerations for process control systems.

Case Studies and Real-world Scenarios: Analyzing real-life process control challenges and their solutions. Learning from practical experiences in troubleshooting.