COURSE OVERVIEW:

The purpose of this course is to provide a comprehensive technical understanding of hybrid control systems that utilize both compressed air and electronic signals to manage industrial processes. While modern plants are increasingly digital, the sheer force and reliability of pneumatic actuators remain essential, necessitating a "bridge" between electronic controllers and pneumatic final elements. This program focuses on the synergy between these two media, ensuring that participants can manage the conversion of millivolt or milliamp signals into precise mechanical movement.

The scope of this training encompasses the hardware components found in hybrid loops, including Current-to-Pressure (I/P) transducers, pneumatic controllers, and smart positioners. Participants will explore the physics of compressed air, the mechanics of diaphragm actuators, and the electronic logic that governs their operation. The curriculum is specifically designed to address the maintenance of older pneumatic "legacy" systems while integrating them with modern electronic Distributed Control Systems (DCS) or Programmable Logic Controllers (PLC).

Coverage includes the practical aspects of air quality management, signal calibration, and the troubleshooting of leaks or mechanical stiction. Attendees will learn how to tune pneumatic controllers, calibrate electronic-to-pneumatic converters, and ensure the safety of fail-safe systems. By focusing on the intersection of air and electricity, the course ensures that participants can maintain the high-torque, high-reliability control loops common in oil, gas, and chemical manufacturing environments.

COURSE OBJECTIVES:

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

• Analyze the advantages and disadvantages of pneumatic versus electronic control.
• Identify the components of a hybrid Pneumatic-Electronic control loop.
• Execute calibration of Current-to-Pressure (I/P) and Pressure-to-Current (P/I) transducers.
• Understand the operation of pneumatic PID controllers and relays.
• Configure and calibrate "Smart" digital valve positioners.
• Manage instrument air quality and filtration requirements.
• Troubleshoot leaks, blockages, and contamination in pneumatic lines.
• Identify different types of pneumatic actuators: Diaphragm, Piston, and Vane.
• Execute fail-safe testing on pneumatic control valves.
• Interpret pneumatic and electronic symbols on loop diagrams.
• Adjust "Bench Set" and "Seat Load" on pneumatic control valves.
• Adhere to safety protocols for high-pressure pneumatic systems.

TARGET AUDIENCE:

This course is intended for Instrumentation Technicians, Mechanical Maintenance Staff, Control Room Operators, and Facility Engineers.

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.