About the Course

Process instrumentation plays a critical role in maintaining the safety, efficiency, and productivity of industrial and manufacturing processes. By continuously monitoring and controlling process variables, manufacturers can optimise their operations, reduce downtime, and improve product quality, achieving excellent process control when instrumentation provides the correct information.

This 5-day Process Instrumentation training course will ensure that engineers and technicians gain the highest level of Process Instrumentation & Field Instruments Servicing knowledge and skills. It introduces industrial processes measurement and principles of measurement of process plants and sets up process transmitters, digital Indicators, gauges, and switches to measure pressure, flow, level, temperature, and analytical. It analyses the instruments and control systems used in the process industry, including terminology, process variables, symbology, control loops, and basic troubleshooting. Also, it allows the setting up of process control loops and "P&ID" process and instrumentation diagrams.

The training program provides complete training (operation, installation, calibration, configuration, maintenance, and troubleshooting), enabling delegates to enhance and refine their operating and maintenance knowledge so that they can keep the field measurements at their best performance. Delegates will gain knowledge and could practice in operation, installation calibration, configuration testing, commissioning, instrumentation systems, and equipment.

Core Objectives

The delegates will achieve the following objectives:

• Understand the instruments and systems used in the process industry, including terminology, process variables, symbology, and control loops 
• Know how to set up process transmitters, digital indicators, gauges, and switches to measure process variables such as pressure, flow, level, temperature, and analytical
• Understand the 4-20mA control loop and how to test and troubleshoot analog input problems effectively
• Prepare to operate, install, calibrate, configure, program, troubleshoot, and repair various types of process field instruments 
• Apply basic devices and procedures for connecting various measurement devices
• Know how to set up, configure, test, and calibrate typical smart transmitters using modern calibration equipment and HART communicators
• Identify problems with instrumentation systems
• Learn to utilise standard instrumentation test and calibration equipment such as process meters, calibrators, and HART communicators
• Apply practical skills for testing, maintaining, and modifying process field instruments (smart electronic and pneumatic)
• Understand the operation of modern SMART transmitters and gain familiarity with the common functionality, mistakes, and misconceptions associated with them
• Develop skilled maintenance professionals who understand operating principles and capabilities of process instrumentation and know-how to install, commission, service, operate, and troubleshoot field process instruments
• Gain skills for selecting appropriate devices for process measurement of parameters like level temperature, pressure, flow, and analytical
• Understand servicing and troubleshooting field instruments
• Design and install instrumentation measurement systems to get accurate feedback from production processes 

Training Approach

This training course is delivered through presentation, using animations, graphics, audio, video, and interactive exercises to augment and intensify. Theoretical content is delivered by informal lecture and discussion and supplemented where appropriate with tutorial sessions using worked examples. Delegates are allowed to perform their calculations based on sample systems.

An essential part of the program is the hands-on aspect. Approximately a quarter of the total time will be devoted to practical activities. Delegates will acquire the skills to design their instrumentation system from a given sensor(s) and specification and develop the skills to 'tune' a process control system using relevant software.

The Attendees

This training course suits technicians and engineers who want to gain practical experience in operating, installing, calibrating, configuring, and troubleshooting industrial instrumentation.

Likewise, it will be valuable to the professionals but not limited to the following:

• Instrument and Process Control Engineers & Technicians
• Engineers and Technicians from all disciplines
• Instrumentation Technicians
• Service and Maintenance Technicians
• Process Technicians
• Installation and Maintenance Technicians
• Operations Technicians and Engineers

Daily Discussion

DAY ONE: PROCESS INSTRUMENTATION BASICS AND PRESSURE MEASUREMENT

• Fundamentals of Industrial Instrumentation
• Terminology of Process Instrumentation Systems
• Definitions Instrumentation Calibration Parameters:
  • Range
  • Span
  • Zero
  • Linearity

• Process Instrumentation Signals
• A Piping and Instrumentation Diagram or P&ID
• Pressure Measurements Overview: Pressure Definition and Units
• Operation and Installation of Pressure Gauges
• Calibration of Pressure Gauges and Configuration of Smart Gauges
• Process Pressure Transmitters – Smart, Electronic and Pneumatic
• Operation, Installation, and Wiring
• Pressure Transmitter Calibration Procedures (Pneumatic and Electronic)
• Configuration of Smart Pressure Transmitters
• Pressure Switches (Calibration, Set, and Reset)
• Applications of Pressure Instruments in Control Systems

DAY TWO: LEVEL MEASUREMENT

• Principles of Level Measurement
• Level Gauges – Magnetic Level Gauges
• Displacer Transmitters
• Hydrostatic Level Measurement
• Differential Pressure Transmitter
• Smart Differential Pressure Transmitter
• Submersible Probes for Level and Fill Measurement
• Open Tank Level Calculation
• Closed Tank Level Calculation (Wet Leg)
• Interface Level Measurement
• Ultrasonic Level Measurement & Transmitter
• Programming Ultrasonic Level Transmitter
• Radar Level Transmitter
• Level Switches – Operation, Application, and Calibration (Set and Reset)

DAY THREE: TEMPERATURE MEASUREMENT

• Principles of Temperature Measurement
• Types of Temperature Measurement Instrument
• Thermocouple
• Temperature Transmitter Calibration and Configuration
  • Thermocouple Reference Tables
  • Resistance Temperature Detector (RTD)
  • Temperature Transmitters RTD (Pt100) and Calibration

• RTD (Pt100) Reference Tables
• Practical RTD and Thermocouple Measurement
• Temperature Calibrator
• Temperature Switch
• Test and calibration of Temperature Switch
• Infrared Temperature Measurement Devices

DAY FOUR: FLOW MEASUREMENTS

• Introduction to Flow Measurement
• Classification of Flow Measurement Methods
• Differential Pressure (DP) Flowmeters:
  • Orifice Flow Meters: Detailed Specifications
  • Sizing Orifice Plate Design and Calculation
  • DP Flow Transmitter Re-Ranging Calculation
  • Differential Pressure Flow Meters Applications
  • Advantages and Disadvantages of Differential Pressure Flow Meter

• Magnetic Flowmeters:
  • What are Electromagnetic Flow Meters?
  • Choosing an Electromagnetic Flow Meter
  • Magnetic Flowmeters Operation, Installation, Wiring, and Configuration

• Mass Flowmeters: Coriolis Mass Flowmeters
  • Coriolis Flowmeter Operation and Installation
  • Wiring, Configuration, and Troubleshooting

• Thermal Flowmeters: Construction and Operating Constraints
• Open Channel Flow Measurement: Weirs & Flumes

DAY FIVE: FLOW MEASUREMENTS AND PROCESS ANALYZER  

• Ultrasonic Flowmeters:
  • Ultrasonic Flow Meter Working Principle
  • Installation and Wiring Considerations
  • Ultrasonic Flowmeter Applications
  • Configuration, Setting Flow Range, and Total

• Positive Displacement Flowmeters: Piston Helica, Gear, and Nutating Disc 
• Turbine Flowmeters – Installation Calibration
• Analytical Analyser
  • pH Measurement
  • Conductivity Measurement
  • Concentration Measurement

• Applications Process Control Loops (Pressure, Level, Temperature, and Flow)
• Troubleshooting of Process Field Instruments