Pneumatic and Field Instruments Supply and Installation 14th – 18th July, 2025

Introduction:

The Basic Field and Control Layer Process Control Course is a training program designed to introduce participants to the foundational principles and techniques used in the automation and control of industrial processes. It covers the essential elements involved in monitoring and controlling process variables (such as temperature, pressure, flow, and level) within industries like manufacturing, oil and gas, chemicals, power generation, etc.

The Basic Field and Control Layer Process Control course typically focuses on introducing participants to the fundamentals of process control systems, including the various components involved in managing industrial processes. This course is essential for professionals in industries like manufacturing, oil and gas, chemicals, power generation, and others that rely on automated systems for controlling processes.

Course Objectives:

1. Understand Process Control Basics:

• Introduction to the basic principles of process control and automation.

• Overview of the importance of maintaining process stability, quality, and efficiency.

2. Field Instrumentation:

• Learning about different types of sensors, transmitters, and actuators used to monitor process variables such as temperature, pressure, level, and flow.

• Understanding signal transmission methods (analog vs. digital).

3. Control Layers:

• Differentiating between different control layers: field, control, and supervisory layers.

• Familiarity with the hierarchy of control systems, from basic local control loops (e.g., PID controllers) to higher-level control strategies (e.g., DCS, SCADA).

4. Control Strategies:

• Exploration of different control techniques such as feedback, feedforward, cascade, ratio, and multi-loop control.

• Introduction to control loop tuning and performance optimization (e.g., PID tuning methods).

5. Programmable Logic Controllers (PLC) and Distributed Control Systems (DCS):

• Overview of PLCs and DCS systems used in the control layer.

• Understanding how control logic is implemented using ladder diagrams or function block programming.

• Introduction to Human-Machine Interface (HMI) and supervisory control.

6. Process Monitoring and Alarms:

• Basics of process monitoring and alarm management.

• Understanding alarm types and their roles in ensuring process safety

7. Troubleshooting and Maintenance:

• Developing skills for diagnosing issues within field instruments and control systems.

• Maintenance techniques for improving system reliability and uptime.

8. Case Studies and Practical Applications:

• Real-world applications of field and control layer process control.

• Hands-on exercises to simulate control system operation and troubleshooting.

Course Contents:

1. Introduction to Process Control:

• The role of automation in process industries.

• Overview of process variables (temperature, pressure, flow, level).

2. Field Instrumentation and Devices:

• Sensors, transducers, and actuators.

• Signal conditioning and transmission (4-20 mA, HART, wireless systems).

3. Control Systems Overview:

• Control loop fundamentals (open-loop, closed-loop).

• Types of controllers (on/off, proportional, integral, derivative).

4. Control Layer Architecture:

• Local control loops vs. centralized control systems.

• Introduction to PLC and DCS.

• HMI and SCADA for process visualization and control.

5. Control Strategies:

• PID controllers: theory and tuning.

• Cascade, ratio, and feedforward control.

• Advanced control strategies (model predictive control, adaptive control).

6. Process Safety and Alarms:

• Safety systems in process control (SIS, ESD systems).

• Alarm philosophy and management strategies.

7. PLC/DCS Configuration and Programming:

• Basic programming concepts for PLCs and DCS.

• Developing simple control programs.

8. Field Maintenance and Troubleshooting:

• Diagnosing common field instrument issues.

• Calibration and routine maintenance of sensors and actuators.

9. Practical Sessions and Simulation:

• Hands-on exercises with PLC or DCS.

• Simulation-based control loop tuning and system troubleshooting.

This course provides a strong foundation in process control, from understanding field instruments to configuring advanced control systems, making it ideal for beginners and intermediate-level professionals.