Process Control Instrumentation
TPC Training Systems’ Process Control Instrumentation training series describes the safe operation and maintenance of sensors, transducers, controllers, final control elements, and other devices used in process control. Courses included in this series explain the principles and practices governing many kinds of devices used to control pressure, temperature, flow, and level. The training also describes the proper use of analytical instrumentation and devices that measure and control force, weight, and motion.
This course 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 maintenance of analog and digital devices and programmable logic controllers (PLCs). ISA and SAMA instrumentation symbols and interpretation and use of process diagrams are covered.
Lesson 1 – The Nature of Process Control
Lesson 2 – Elements of Process Control
Lesson 3 – Process Control Signals
Lesson 4 – Process Measurement Fundamentals
Lesson 5 – Principles of Transducer Operation
Lesson 6 – Basic Process Measurement Systems
Covers basic principles of measurement and defins process control terms. Describes several kinds of signals and displays and traces the path of a signal through a system. Explains the operation of transducers, transmitters, signal conditioners, converters and recorders. Discusses specification details, conversion between English and SI units, calibration methods, and the maintenance of records.
Lesson 1 – Introduction to Process Measurement
Lesson 2 – Principles of Transducer Operations
Lesson 3 – Basic Process Measurement Systems
Lesson 4 – System Standards and Instrument Calibration
Lesson 5 – Maintaining System Quality
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.
Lesson 1 – Principles of Pressure in Liquids and Gases
Lesson 2 – Pressure Sensor
Lesson 4 – Low-Pressure Measurement
Lesson 5 – Installation and Service
This course covers force, stress, and strain and explains the operation of strain-gauge systems. Relates weight to mass and scales to balances. The course 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.
Lesson 1 – Force, Stress, and Strain
Lesson 2 – Weight and Mass Measurement
Lesson 3 – Weighing Materials in Motion
Lesson 4 – Position Measurements
Lesson 5 – Acceleration, Vibration, and Shock
Covers principles of fluid flow and how primary devices affect fluid flow. Describes flow measurement using several kinds of secondary devices. The course goes on to Discuss 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.
Lesson 1 – Properties of Fluid Flow
Lesson 2 – Primary Measuring Devices
Lesson 3 – Secondary Measuring Devices
Lesson 4 – Variable-Area Instruments
Lesson 5 – Open-Channel Flow Devices
Lesson 6 – Positive-Displacement Meters
Lesson 7 – Turbine and Magnetic Flowmeters
Lesson 8 – Specialized Flowmeters
Lesson 9 – Metering the Flow of Solid Particles
Lesson 10 – Installation and Maintenance of Flow Instruments
Covers principles governing various methods of measuring level. This course explains the operation of conductive, capacitive, resistive, ultrasonic, and photoelectric devices. Compares the operation of several kinds of pressure-head instruments and their maintenance. Explains the measurement of solids by ultrasonic, microwave, radiation, and other methods. Discusses several special-application devices for both continuous and point level measurement.
Lesson 1 – Principles of Level Measurement
Lesson 2 – Electrical Instruments
Lesson 3 – Pressure Head Instruments
Lesson 4 – Solid Level Measurement
Lesson 5 – Other Level Measurement Instruments
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.
Lesson 1 – Temperature Measurement Principles and Indicators
Lesson 2 – Bimetallic & Fluid-Filled Temp. Instruments
Lesson 3 – Electrical Instruments
Lesson 4 – Pyrometry
Lesson 5 – Temp. Instrument Maint. & Calibration
The Analytical Instrumentation course covers principles, installation, calibration, and maintenance of conductivity probes, and methods of stack gas monitoring. The course 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.
Lesson 1 – Measuring Conductivity
Lesson 2 – Measuring pH and ORP
Lesson 3 – Optical Measurements
Lesson 4 – Measuring Products of Combustion
Lesson 5 – Chromatography
Covers how elements in a closed-loop system affect final control element. Describes components in final control subsystems. Discusses operations and maintenance of solenoids, motors, relay systems, and PLCs. Explains pneumatic actuators and positioners. The course goes on to describe 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.
Lesson 1 – Final Control Elements in Process Loops
Lesson 2 – Electric Actuators
Lesson 3 – Pneumatic and Hydraulic Actuators
Lesson 4 – Control Valves
Lesson 5 – Final Control Element Applications
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.
Lesson 1 – Safety Standards and Practices
Lesson 2 – Servicing Fundamentals
Lesson 3 – Pneumatic and Hydraulic Stations
Lesson 4 – Electrical and Electronic Stations
Lesson 5 – Troubleshooting
Lesson 6 – Systems Specifications and Instrument Calibration