PROCESS CONTROL INDUSTRIAL MAINTENANCE TECHNICIAN CERTIFICATE

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1 PROCESS CONTROL INDUSTRIAL MAINTENANCE TECHNICIAN CERTIFICATE Process Control (T5552) Course 1 Introduction to Process Control Course 2 Instrument Tags Course 3 Piping and Instrumentation Diagrams Course 4 Loop Controllers Course 5 Final Control Elements Course 6 Level Measurement Course 7 Liquid Level Control Course 8 Methods of Automatic Control Course 9 Basic Flow Measurement and Control Course 10 Control Loop Performance Ultrasonic Level Measurement and Control (T5552-L1) Course 11 Ultrasonic Liquid Level Smart Flow Transmitter (T5552-F1) Course 12 Differential Pressure Flow Measurement and Control Page 1 of 11

2 T5552 PROCESS CONTROL SYSTEM COURSE 1 INTRODUCTION TO PROCESS CONTROL Activity PROCESS CONTROL CONCEPTS Define process control Describe three common process control s Define three basic process control terms and explain their importance Describe five common process variables and give an of each Define two types of process variables: controlled and manipulated Determine the manipulated and controlled variables given process descriptions Define a process instrument and give an example Define an open loop process control system and give an advantage Define a closed loop process control system and give an advantage T5552 System familiarization SAFETY Describe six rules for safe dress when working with process control equipment Describe 14 basic rules of process safety Describe the function of lockout/tagout Describe how to perform a lockout/tagout on a process control system Perform a lockout of process control equipment MANUAL CONTROL Describe the function of manual control and give an Describe the operation of open loop manual control and give an Describe the operation of closed loop manual control Manually control the liquid level in a tank using open and closed loop methods SIGHT GAGES Describe two functions of level and give an Describe the function of a sight gage and give an example Describe the operation of a float-type sight gage and give an Describe the operation of a sight glass and give an Describe how to read a slight glass Use a sight glass to determine liquid level COURSE 2 INSTRUMENT TAGS BLOCK DIAGRAMS Describe the function of a block diagram Describe the function of the three basic symbols of a block diagram Draw a block diagram for a given INSTRUMENT TAG FUNDAMENTALS Describe the function of an instrument tag Define the six types of information described by an instrument tag Describe five types of instrument tags Page 2 of 11

3 SKILL 5 0 SKILL 6 1 SKILL 7 Identify the type of device using an instrument tag Describe how an instrument tag identifies the location of a device Identify the location of a device using an instrument tag INTERPRETING INSTRUMENT TAGS Describe how to use an instrument tag to identify a measured or initiated variable Identify the measured variable using an instrument tag Describe how an instrument tag identifies the function of a device Identify the function of a device given its instrument tag Describe how to identify the area where a device is located given its instrument tag Describe how to identify the loop in which a device is connected given its instrument tag Identify the loop and area in which a device is connected given its instrument tag Describe how to draw an instrument tag given device information Draw an instrument tag given device information COURSE 3 PIPING AND INSTRUMENTATION DIAGRAMS SKILL SKILL 6 SKILL 7 SECTION SKILL 8 LINE SYMBOLS Describe the function of a P&ID Describe the function of a loop diagram Describe ten line symbols used in P&IDs Describe how to represent binary signals in a P&ID Identify P&ID line symbols VALVE AND PUMP SYMBOLS Define 11 P&ID valve symbols Define four P&ID valve actuator symbols Identify P&ID valve and actuator symbols Describe three P&ID pump symbols Identify pump symbols given a P&ID LEVEL AND FLOW SENSING ELEMENT SYMBOLS Describe 10 P&ID liquid level sensing element symbols Identify P&ID level sensing element symbols Describe 11 P&ID flow sensing element symbols Identify P&ID flow sensing element symbols PRESSURE AND TEMPERATURE ELEMENT SYMBOLS Describe two P&ID pressure sensing element symbols Describe two P&ID temperature sensing element symbols Identify P&ID pressure and temperature sensing element symbols Draw a P&ID given an actual process control system INSTRUMENT INDEX Describe the function of an instrument index Describe how to interpret the information contained in an instrument index Interpret instrument data using an instrument index COURSE 4 LOOP CONTROLLERS Page 3 of 11

4 0 1 2 LOOP CONTROLLERS Describe two categories of loop controllers and give an of each Describe four functions of an electronic loop controller Describe the construction of an electronic loop controller Describe how to power up a UDC 3300 Honeywell controller and test the display Power up a UDC 3300 Honeywell controller and perform a display and key test Describe the two display modes of the UDC 3300 Honeywell controller Describe how to navigate a Honeywell loop controller menu system Navigate a Honeywell loop controller menu system LOOP CONTROLLER PARAMETERS Describe five types of loop controller parameters Describe how to view and interpret controller process variables Describe how to enter a loop controller parameter Change Honeywell loop controller parameters MANUAL OPERATION Describe the operation of an electronic loop controller in manual mode Describe how to connect a loop controller to a final control element Describe how to operate a loop controller in manual open loop mode Operate a loop controller in the manual mode COURSE 5 FINAL CONTROL ELEMENTS I/P CONVERTER OPERATION Describe the function of a current-to-air pressure (I/P) converter Describe the construction of an I/P converter Describe the operation of an I/P converter Connect and operate an I/P converter I/P CONVERTER CALIBRATION Describe the function of control loop component calibration and explain its importance Describe how to calibrate an I/P converter using a multimeter Calibrate an I/P converter using a multimeter or loop calibrator PROPORTIONAL CONTROL VALVES Describe the function of two types of proportional valves and give an of each Describe the operation of a diaphragm actuator proportional valve Describe two types of diaphragm actuator valve configurations and give an of each Connect and operate a diaphragm actuator proportional valve Describe how to adjust the spring of a diaphragm actuator proportional valve Adjust the spring of a diaphragm actuator proportional valve COURSE 6 LEVEL MEASUREMENT LEVEL SENSOR OPERATION Describe the functions of two parts of a sensor: the transducer and the transmitter Page 4 of 11

5 0 1 2 SKILL SKILL 6 APPENDIX A Describe two types of analog transmitter signal outputs Describe four methods of sensing level and give an of each Describe how to measure liquid level using a pressure sensor and give an Describe how to measure liquid level using a bubbler and give an Describe the operation of a variable capacitance pressure sensor Describe how to use a multimeter to measure a pressure sensor output signal Connect and operate a variable capacitance pressure sensor LEVEL SENSOR SIGNAL MEASUREMENT Define specific gravity and describe its affect on level Describe how to convert liquid level units to fluid pressure units Convert liquid level units to fluid pressure units Define sensitivity and explain its importance Describe how to convert pressure sensor output signals to pressure units Convert pressure sensor output signals to pressure units Describe how to convert liquid level units to sensor output signal units Convert liquid level units to sensor output signal units Use a multimeter to test pressure sensor operation DISPLAY SCALING Define display scaling Describe the function of a process meter Describe the operation of a process meter Describe how to configure a Simpson Hawk 3 process meter to display a process variable Configure a Simpson Hawk 3 process meter to display a process variable SPECIFIC GRAVITY OF VARIOUS LIQUIDS COURSE 7 LIQUID LEVEL CONTROL RELAY BASED ON/OFF CONTROL Describe the operation of an on/off process control system and give an advantage Describe the operation of relay-based on/off process control systems Control the level in a tank using on/off control Design an on/off level control system PROCESS METER ON/OFF CONTROL Describe how to program a Simpson Hawk 3 process meter s discrete outputs to control alarms Program a Simpson Hawk 3 process meter s discrete outputs as alarms Describe how to program a Simpson Hawk 3 process meter to perform on/off control Program a Simpson Hawk 3 process meter s discrete outputs to perform on/off control CLOSED LOOP LIQUID LEVEL CONTROL Describe the operation of a closed loop liquid level control system Describe the effect of two types of disturbances on a closed loop system Describe how to configure and operate a UDC 3300 Honeywell controller based closed loop system Page 5 of 11

6 SKILL 5 Configure and operate a UDC 3300 Honeywell controller based closed loop liquid level system DISCRETE INPUT/OUTPUT FUNCTIONS Describe the function of loop controller alarm outputs and give an Describe how to connect and operate the alarm outputs on a UDC 3300 Honeywell controller as alarms SKILL 6 Connect and operate alarm outputs on a UDC 3300 Honeywell controller 0 Describe the function of loop controller discrete inputs and give an 1 Describe how to configure and operate the discrete inputs on a UDC 3300 Honeywell controller SKILL 7 Connect and operate discrete inputs on a UDC 3300 Honeywell controller COURSE 8 METHODS OF AUTOMATIC CONTROL PERFORMANCE CONCEPTS Define steady and transient control system states Define gain and explain its importance Define closed loop stability and explain its importance Define open loop gain and explain its importance PROPORTIONAL CONTROL Describe the operation of a proportional closed loop control system and give an Define proportional band and explain its importance Define reset constant Describe how to use a Honeywell controller to control a process using closed loop control Use a Honeywell controller to control a process using proportional control PROPORTIONAL-INTEGRAL CONTROL Describe the operation of integral (reset) control Define reset time and reset rate and explain their importance Define reset wind-up and explain its importance Describe the operation of proportional-integral control and give an Use a Honeywell controller to control a process using PI control PROPORTIONAL-INTEGRAL-DERIVATIVE CONTROL Describe the operation of derivative or rate control Describe the operation of proportional-derivative control and give an Use a Honeywell controller to control a process using PD control Describe the operation of PID control and give an Use a Honeywell PID controller to control a process using PID control COURSE 9 BASIC FLOW MEASUREMENT AND CONTROL FLOW MEASUREMENT UNITS Describe the basic function of flow and give an Define three flow units Describe how to convert between velocity and volumetric flow rates Page 6 of 11

7 0 1 SKILL 5 APPENDIX APPENDIX A APPENDIX B Convert between velocity and volumetric flow rates Describe how to convert between volumetric and mass flow rate units Convert between volumetric and mass flow rates FLOW SENSORS Describe four categories of flow sensors and give an of each Describe the operation of a turbine flow sensor Describe the operation of a paddlewheel flow sensor FLOW MEASUREMENT Describe the operation of a digital flow transmitter Describe the calibration parameters of a digital flow transmitter Describe how to configure a +GF+ SIGNET digital flow transmitter Configure a +GF+ Signet flow transmitter Measure flow using a paddlewheel flow sensor BASIC FLOW CONTROL Describe the operation of a closed loop flow control system Operate a flow control loop using a paddlewheel sensor Standard Pipe Size Table Density of Common Fluids COURSE 10 CONTROL LOOP PERFORMANCE RESOLUTION Define control loop optimization and explain its importance Define instrument resolution and explain its importance Describe how to calculate instrument resolution in units of the measured parameter Calculate resolution in units of the measured parameter ACCURACY AND REPEATABILITY Define instrument accuracy and explain its importance Describe five methods of expressing accuracy Calculate instrument accuracy Define repeatability and explain its importance OPEN-LOOP TUNING Define loop tuning and explain its importance Define open-loop tuning and give an Describe how to tune a loop using the process reaction curve open-loop method Tune a control loop using the process reaction curve method Describe the function of tuning software and give an CLOSED-LOOP TUNING Define closed-loop tuning and give an Describe how to tune a loop using the ultimate gain closed-loop method Tune a control loop using the Ziegler-Nichols ultimate gain method Page 7 of 11

8 T5552-F1 SMART FLOW TRANSMITTER COURSE 12 DIFFERENTIAL PRESSURE FLOW MEASUREMENT AND CONTROL Activity ORIFICE PLATE FLOW SENSORS Describe how differential pressure is used to measure flow Describe the function of differential pressure flow sensors and name four types Describe the operation of an orifice plate flow sensor Describe three types of orifice plates Differential Pressure Flow Sensor Familiarization DIFFERENTIAL PRESSURE FLOW TRANSMITTERS Describe the function of a differential pressure flow transmitter Describe the operation of a differential pressure flow transmitter Describe how to bleed the manifold of a differential pressure flow transmitter Describe how to calibrate a differential pressure flow transmitter Measure flow using an orifice plate flow sensor and a differential pressure flow transmitter COMMON DIFFERENTIAL PRESSURE FLOW SENSORS Describe the operation of a flow nozzle Describe the operation of a venturi tube Measure flow using a venturi tube flow sensor and a differential pressure flow transmitter Describe the operation of a pitot tube Measure flow using a pitot tube flow sensor and a differential pressure flow transmitter FLOW CONTROL USING DIFFERENTIAL PRESSURE FLOW MEASUREMENT Describe the operation of a closed loop flow system using a differential pressure flow sensor Construct and operate a flow control loop using a differential pressure sensor Page 8 of 11

9 T5552-L1 ULTRASONIC LIQUID LEVEL LEARNING SYSTEM COURSE 11 ULTRASONIC LEVEL MEASUREMENT AND CONTROL ULTRASONIC LEVEL MEASUREMENT Describe the function of an ultrasonic level sensor and give an Describe the operation of an ultrasonic level sensor Describe how to wire an ultrasonic level sensor for non-inverted Describe how to wire an ultrasonic level sensor for inverted Connect and operate an ultrasonic level sensor ULTRASONIC LEVEL SENSOR CALIBRATION Describe how to calibrate an ultrasonic level sensor for non-inverted Describe how to calibrate an ultrasonic level sensor for inverted Calibrate an ultrasonic level sensor LEVEL CONTROL Describe the operation of a closed loop level control system that uses an ultrasonic sensor Operate a closed loop system that uses an ultrasonic level sensor Page 9 of 11

10 T5552-F1 SMART FLOW TRANSMITTER COURSE 12 DIFFERENTIAL PRESSURE FLOW MEASUREMENT AND CONTROL Activity ORIFICE PLATE FLOW SENSORS Describe how differential pressure is used to measure flow Describe the function of differential pressure flow sensors and name four types Describe the operation of an orifice plate flow sensor Describe three types of orifice plates Differential Pressure Flow Sensor Familiarization DIFFERENTIAL PRESSURE FLOW TRANSMITTERS Describe the function of a differential pressure flow transmitter Describe the operation of a differential pressure flow transmitter Describe how to bleed the manifold of a differential pressure flow transmitter Describe how to calibrate a differential pressure flow transmitter Measure flow using an orifice plate flow sensor and a differential pressure flow transmitter COMMON DIFFERENTIAL PRESSURE FLOW SENSORS Describe the operation of a flow nozzle Describe the operation of a venturi tube Measure flow using a venturi tube flow sensor and a differential pressure flow transmitter Describe the operation of a pitot tube Measure flow using a pitot tube flow sensor and a differential pressure flow transmitter FLOW CONTROL USING DIFFERENTIAL PRESSURE FLOW MEASUREMENT Describe the operation of a closed loop flow system using a differential pressure flow sensor Construct and operate a flow control loop using a differential pressure sensor Page 10 of 11

11 T5552-L1 ULTRASONIC LIQUID LEVEL LEARNING SYSTEM COURSE 11 ULTRASONIC LEVEL MEASUREMENT AND CONTROL ULTRASONIC LEVEL MEASUREMENT Describe the function of an ultrasonic level sensor and give an Describe the operation of an ultrasonic level sensor Describe how to wire an ultrasonic level sensor for non-inverted Describe how to wire an ultrasonic level sensor for inverted Connect and operate an ultrasonic level sensor ULTRASONIC LEVEL SENSOR CALIBRATION Describe how to calibrate an ultrasonic level sensor for non-inverted Describe how to calibrate an ultrasonic level sensor for inverted Calibrate an ultrasonic level sensor LEVEL CONTROL Describe the operation of a closed loop level control system that uses an ultrasonic sensor Operate a closed loop system that uses an ultrasonic level sensor Page 11 of 11

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