Process Instrumentation

The RCAM Process Instrumentation Series provides 71 hours of job related instruction in a convenient online format. These courses are designed to develop the fundamental instrumentation skills of the 21st century industrial chemical processing environment. Developed by TPC Training Systems, and managed by the experienced RCAM staff, this package delivers improved technical skills needed for the complex industrial environment.

To apply these skills, RCAM has developed hands-on instrumentation labs designed to put the knowledge into practice. These labs are conducted by experienced maintenance professionals who have proven track records in the industrial instrumentation environment.

To complete a comprehensive training program, the RCAM staff can assist your organization in the development of structured on-the-job (OJT) training that aligns with your job specific training needs.

For more information, contact the RCAM Programs & Services Coordinator at 423.354.5275.

Course#

Course Name and Description

Number
of
Lessons

PROCESS CONTROL INSTRUMENTATION (Series 270)

 

271

Introduction to Process Control

6

 

Covers the function of basic devices for measuring and controlling different kinds of variables in process control. Introduces closed-loop control and PID functions. Introduces analog and digital devices and programmable logic controllers (PLCs). ISA and SAMA instrumentation symbols and interpretation and use of process diagrams are covered.

 

273

Pressure Measurement

5

 

Covers units of pressure and discusses Boyle's and Charles' laws to explain relationships among pressure, volume, and temperature. Describes sensor operation of manometers, bourdon tubes, diaphragms, and bellows. Explains the operation of potentiometric, capacitive, reluctive, servo, strain-gauge, and piezoelectric transducers. Describes devices used in low-pressure control. Discusses proper and safe methods for installing and servicing pressure instruments.

 

274

Force, Weight, Motion Measurement

5

 

Covers force, stress, and strain and explains the operation of strain-gauge systems. Relates weight to mass and scales to balances. Explains the operation of load-cell scales. Describes belt-scale, nuclear-scale, and weigh feeder operation. Covers position measurements by means of proximity detection, air gauging, LVDT gauges, synchros, code disks, and other devices. Explains machine tool control and accelerometer operation. Describes the measurement of angular velocity and acceleration, vibration detection, and machinery balancing.

 

275

Flow Measurement

10

 

Covers principles of fluid flow and how primary devices affect fluid flow. Describes flow measurement using several kinds of secondary devices. Discusses rotameters and other variable-area instruments. Explains how weirs, flumes, and other arrangements measure open-channel flow. Compares many kinds of positive-displacement meters and explains the operation of several kinds of turbine and magnetic flowmeters. Describes less-common flowmeters (including vortex-precession, mass flow, and ultrasonic devices) and instruments that meter the flow of solids. Provides guidelines for safe installation and maintenance of flow devices.

 

276

Level Measurement

5

 

Covers principles governing various methods of measuring level. Explains operation of conductive, capacitive, resistive, ultrasonic, and photoelectric devices. Compares the operation of several kinds of pressure-head instruments. Explains the measurement of solids by ultrasonic, microwave, radiation, and other methods. Discusses several special-application devices for both continuous and point level measurement.

 

277

Temperature Measurement

5

 

Covers units in thermal measurement and operation of RTDs (and wheatstone bridges), thermistors, and thermocouples and thermometers. Includes principles of pyrometry and operation of narrowband, broadband, and bandpass pyrometers. Discusses calibration standards, typical calibrating methods, and instrument testing.

 

278

Analytical Instrumentation

5

 

Covers principles, installation, calibration, and maintenance of conductivity probes, and methods of stack gas monitoring. Includes how to install, calibrate, and maintain pH and ORP measurement instruments and operation, installation, calibration, and maintenance of several optical analyzers. Discusses principles and safe practices governing sensors used in measuring oxygen, carbon monoxide, carbon dioxide, and other products of combustion. Concludes with operation, calibration, and system components in liquid and gas chromatography.

 

279

Final Control Elements

5

 

Covers how elements in a closed-loop system affect final control element. Describes components in final control subsystems. Discusses operations of solenoids, motors, relay systems, and PLCs. Explains pneumatic actuators and positioners. Describes mechanical advantage in several hydraulic control systems. Compares construction, characteristics, and applications of eight control valves. Traces operation of each element in typical feedwater, turbine, and robotic control systems.

 

280

Safety, Calibration, and Testing Procedures

5

 

Covers the responsibilities of employer, employee, and regulatory agencies in maintaining safety. Discusses ways of identifying and handling chemical, electrical, biological, radiation, and mechanical hazards. Discusses importance of maintenance (including calibration) and proper record keeping. Describes use of common electrical and electronic test instruments. Offers guidelines for handling heavy equipment, decontaminating and servicing pneumatic and hydraulic equipment, and troubleshooting.

 

PROCESS CONTROL SYSTEMS (Series 280)

 

281

Working with Controllers

5

 

Covers the purposes and kinds of controllers and their relationship to other components in process control systems. Explains the concepts of current-, position-, and time-proportioning control. Compares the operation of several kinds of controllers. Describes the operation of proportional, integral, and derivative modes, and discusses tuning procedures for each. Discusses cascade, feedforward, ratio, and auctioneering control systems as well as other operations. Describes ways to eliminate or reduce controller problems.

 

282

How Control Loops Operate

5

 

Covers definition of control loop terms and characteristics. Includes specific examples of operation of control loops of many kinds. Discusses proportional, integral, and derivative modes in detail. Describes advanced control methods by means of four strategies with specific examples. Examines the effects of loop dynamics on system stability.

 

283

Data Transmission

5

 

Covers mechanical, hydraulic, pneumatic, and telemetric data transmission methods. Discusses indicators, other devices, and methods used for electrical/electronic data transmission in detail. Compares methods and standards for parallel and serial digital data transmission. Describes optical isolation and the operation of optical data transmission systems in detail. Provides specific methods for preventing common kinds of data transmission interference.

 

284

Computers in Process Control

5

 

Covers the evolution of today's process control computer systems. Compares smart components to older conventional system devices. Covers the architecture (hardware and software), configuration, and operation of distributed control systems in depth (two entire lessons) by using as an example a typical DCS controlling an ice cream plant. Defines common terms used in today's integrated plant and discusses the integration of discrete and continuous processes with plant business functions.

 

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