IE0038 : Process Control, Instrumentation, Troubleshooting & Problem Solving

This practical and highly-interactive course
includes various practical sessions and
exercises. Theory learnt will be applied using
one of our state-of-the-art simulators.
Production processes consist of many complex
apparatuses involving both moving and static parts
as well as interconnecting pipes, control
mechanisms and electronics, mechanical and
hermal stages, heat exchangers, waste and side
product processing units, power ducts and many
others. Bringing such a complicated unit online and
ensuring its continued productivity requires
substantial skill at anticipating, detecting and solving
acute problems. Failure to identify and resolve these
problems quickly can lead to lost production, offspec
product, equipment loss, and even catastrophic
accidents. Therefore, the ability to troubleshoot
process operations is one of the most valuable skills
operations personnel can possess.
Troubleshooting is the process used to diagnose the
fault safely and efficiently, decide on corrective
action and prevent the fault from reoccurring.
Process engineering, especially troubleshooting, is
different from most other branches of technology in
another respect: It is not advancing very quickly.
The principles of distillation, hydraulics, phase separation, and heat transfer, as they
apply to process applications, have been well known for quite some time. The
challenge in troubleshooting consists of untangling the influence that human error,
mechanical failure, and corrosion have on these well-known principles. The aspect of
the job that makes it so difficult is that most process problems are initiated by human
error – a never-ending source of surprise.
Process control is becoming an increasingly important engineering topic, since the
subject plays a crucial role in the design, operation and maintenance in areas such as
power plants and chemical and industrial process plants. Control systems have
advanced dramatically during the last decade. They become more modular and more
sophisticated offering a vast variety of control functions for all the systems that operate
within a modern "intelligent" facility. Enhanced functionality of the automation systems
also means more complexity, interactive strategies, new technologies and systems
management with resulting better control and improved reliability.
This course is designed to provide instruction in process control, instrumentation and
the different types of troubleshooting techniques, procedures, and methods used to
solve process problems. Participants will use existing knowledge of equipment,
systems and the instrumentation to understand the troubleshooting process operations
of an entire unit in a facility. Participants study concepts related to troubleshooting
commissioning, normal startup, normal operations, normal shutdown, turnarounds, and
abnormal situations, as well as the Process team role in performing tasks associated
with these concepts within an operating unit.
A major part of the course is devoted to a detailed exposition of currently used control
valves, the associated terminology, valve performance, valve and actuator types,
control valve accessories as well as to the correct selection and sizing of control valves
for a wide range of applications. The course addresses the important issues related to
valve installation and maintenance. In addition, this training course also utilizes an
extensive collection of state-of-the-art, externally generated process management and
video material concerned with all aspects of plant management, including smart
wireless solutions to the collection of plant data. In addition, the subjects of digital
control systems will be discussed with sections on Distributed Control Systems (DCS),
Programmable Logic Controllers (PLC) and SCADA systems.