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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.

Unit 271: Introduction to Process Control ($100)

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

Unit 272: Foundations Of Measurement Instrumentation ($100)

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

Unit 273: Pressure Measurement ($100)

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

Unit 274: Force, Weight, and Motion Measurement ($100)

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

Unit 275: Flow Measurement ($100)

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

Unit 276: Level Measurement ($100)

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

Unit 277: Temperature Measurement ($100)

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

Unit 278: Analytical Instrumentation ($100)

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

Unit 279: Final Control Elements ($100)

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

Unit 280: Safety, Calibration, and Testing ($100)

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