COURSE OVERVIEW:

Advanced Process Control and Instrumentation represents the critical intersection of sophisticated mathematical algorithms and high-precision field hardware within modern industrial environments. This course delves into the complex dynamics of closed-loop systems, focusing on how integrated instrumentation architectures facilitate real-time data acquisition and autonomous decision-making. By exploring the synergy between sensing elements and final control elements, participants will understand how to stabilize volatile processes while maximizing throughput and ensuring rigorous safety standards across various industrial sectors.

The scope of this training encompasses the technical evolution from basic Proportional-Integral-Derivative (PID) control to more complex strategies such as Model Predictive Control (MPC) and Feedforward mechanisms. Participants will examine the physical principles governing advanced sensors, the nuances of signal conditioning, and the integration of digital communication protocols like Foundation Fieldbus and HART. The curriculum is designed to bridge the gap between theoretical control logic and the practical realities of hardware limitations, noise interference, and non-linear process responses found in chemical, oil, and gas facilities.

This comprehensive program covers the entire lifecycle of a control system, ranging from initial instrument selection and sizing to the tuning of complex loops and the implementation of multivariable control strategies. It provides detailed coverage of smart instrumentation, final control element performance, and the diagnostic capabilities of modern Distributed Control Systems (DCS). Through a detailed analysis of process variability and response times, the course ensures that attendees can identify inefficiencies, perform root-cause analysis on system failures, and implement optimization techniques that result in measurable improvements in operational efficiency and product quality.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Analyze the fundamental principles of advanced process dynamics and their impact on loop stability.
• Evaluate and select appropriate primary sensing elements based on specific fluid properties and environmental conditions.
• Implement Feedforward, Cascade, and Ratio control strategies to handle complex process disturbances.
• Configure and calibrate smart field instruments using HART and Foundation Fieldbus protocols.
• Master the techniques for tuning PID controllers in non-linear and time-delayed environments.
• Perform detailed sizing and selection of control valves to prevent cavitation, flashing, and noise.
• Identify the architectural differences between Distributed Control Systems (DCS) and Programmable Logic Controllers (PLC).
• Integrate safety instrumented systems (SIS) with basic process control functions to ensure layered protection.
• Utilize advanced diagnostic tools for predictive maintenance of instrumentation and final control elements.
• Develop comprehensive loop diagrams and P&ID documentation for complex industrial processes.
• Optimize energy consumption through the precise regulation of combustion and heat transfer processes.
• Troubleshoot complex instrumentation loops using a systematic, evidence-based approach.

TARGET AUDIENCE:

This course is designed for Process Engineers, Instrumentation and Control Engineers, Automation Specialists, Plant Maintenance Managers, and Technical Supervisors who are responsible for the design, operation, and maintenance of sophisticated control systems in industrial environments.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.