Process Instrumentation, Control & Safeguarding Systems

Introduction: Process Control Automation is a critical service in the Oil & Gas downstream sector, where precise regulation of process variables is essential for converting crude oil into various refined products, including Liquid Petroleum Gas (LPG), Diesel, Kerosene, Petrol, and more. This complex transformation relies on advanced technology-based control systems that integrate various components to monitor and control chemical processes effectively.
Key Components of Control Systems:
1. Sensors:
o Sensors are devices that detect changes in physical, electrical, mechanical, or chemical properties, producing electrical outputs in response.
o Commonly measured physical properties include level, temperature, flow, pressure, speed, pH, and conductivity.
2. Controllers:
o Controllers determine the process specifications, handling either digital or analog inputs and outputs.
o Types of control systems include:
§ Classic Control (Relay Logic Control)
§ Programmable Logic Controllers (PLC)
§ Distributed Control Systems (DCS)
o Control methods such as Open Loop, Closed Loop, and Cascade Loop are employed to achieve desired outcomes.
3. Final Control Elements:
o These elements execute the controller’s commands to achieve the target process variable, including:
§ Pumps and Motors
§ Heaters
§ Control Valves (e.g., linear and rotary types)
Course Objectives: By the end of this course, participants will be able to:
• Understand the fundamental principles and components of control systems.
• Gain insights into different types of control systems used in industry.
• Learn about the functions of sensors, controllers, and final control elements.
• Explore process automation in Oil & Gas, focusing on measurement techniques for pressure, temperature, flow, and level.
• Differentiate between gauge, switch, and transmitter functions.
• Understand the importance of safety instrumented systems (SIS) and their integrity levels.
• Learn about calibration methods for various instrumentation.
Who Should Attend:
• Instrumentation Engineers
• Instrumentation Technicians
• Electrical Engineers
• Electrical Technicians
• Maintenance Personnel
• Operators and Supervisors
Training Methodology: This comprehensive training course blends theoretical knowledge with practical applications, including:
• Pre- and post-test evaluations to assess knowledge gains.
• Individual assessments and group discussions.
• Hands-on practical exercises to reinforce learning.
Course Outline:
• Day 1: Introduction to Instrumentation and Control
o Overview of manual and automated control
o Detailed discussion on sensors (pressure, temperature, level, flow)
o Examination of control systems and final control elements
o Introduction to P&ID (Piping and Instrumentation Diagram) reading
• Day 2: Pressure Measurements
o Types of pressure measurements: gauge, absolute, and differential
o Overview of primary elements (Bourdon tube, diaphragm, etc.)
o Pressure measurement devices, selection, troubleshooting, and calibration
• Day 3: Temperature and Level Measurements
o RTD and Thermocouple principles, wiring, and calibration
o Exploration of various level switch types and level transmitters
• Day 4: Flow Measurements
o Obstructive and non-obstructive flow measurement techniques
o Selection, installation, and calibration of different types of flowmeters
• Day 5: Safety Instrumented Systems (SIS)
o Importance of SIS in preventing industrial disasters
o Differences between SIS and Basic Process Control Systems (BPCS)
o Overview of IEC standards and layers of protection analysis
This course is designed to provide a thorough understanding of process instrumentation and control systems, equipping participants with the knowledge and skills necessary to excel in the Oil & Gas industry.