Process Instrumentation and Control for Engineers, Operators, and Technicians Course

Lesson 1 • Signal Standards and Transmission

Introduces 4–20 mA, HART, fieldbus, and pneumatic signal standards used to transmit measurement data. Links signal type selection to installation and compatibility decisions.

Lesson 2 • Instrument Documentation and Drawings

Explains P&IDs, instrument loop diagrams, and instrument index sheets as the primary engineering documents. Students read and interpret standard instrumentation drawings.

Lesson 3 • Instrument Classification and Terminology

Categorizes instruments by function: sensors, transmitters, indicators, recorders, and controllers. Provides the naming conventions used throughout the course.

Lesson 4 • Process Variables and Their Significance

Defines temperature, pressure, flow, level, and analytical variables and explains why each is measured. Establishes the measurement context for all subsequent instrument study.

Lesson 1 • Electronic Pressure Transmitters

Examines capacitive, piezoresistive, and resonant-frequency sensing technologies used in smart transmitters. Connects electronic sensing to 4–20 mA and digital output signals.

Lesson 2 • Pressure Instrument Installation and Calibration

Details impulse line design, isolation valves, and calibration procedures for pressure instruments. Prepares students to commission and verify pressure measurement loops.

Lesson 3 • Mechanical Pressure Sensing Elements

Covers Bourdon tubes, diaphragms, bellows, and capsules as elastic sensing elements. Explains how mechanical deformation is converted to a readable output.

Lesson 4 • Differential Pressure Applications

Applies differential pressure measurement to flow, level, and filter monitoring. Demonstrates how a single DP transmitter serves multiple process measurement functions.

Lesson 1 • Resistance Temperature Detectors

Covers PT100 and PT1000 RTD construction, 2-wire, 3-wire, and 4-wire connection methods, and linearization. Highlights RTD advantages in accuracy and stability over thermocouples.

Lesson 2 • Thermistors and Filled-System Thermometers

Examines NTC and PTC thermistors and liquid-filled, gas-filled, and vapor-pressure thermometers. Positions these devices within their appropriate application niches.

Lesson 3 • Thermocouples: Principles and Types

Explains the Seebeck effect, reference junction compensation, and common thermocouple types (J, K, T, E, R, S). Enables correct thermocouple selection for temperature range and environment.

Lesson 4 • Non-Contact and Thermowell Installation

Introduces infrared pyrometers and thermal imagers for non-contact measurement and covers thermowell design and insertion depth. Completes temperature sensor selection and installation knowledge.

Lesson 1 • Flow Meter Installation and Calibration

Details upstream and downstream straight-run requirements, flow conditioners, and in-situ vs. bench calibration. Ensures students can commission flow meters to specification.

Lesson 2 • Flow Fundamentals and Fluid Properties

Reviews continuity equation, Reynolds number, laminar vs. turbulent flow, and fluid viscosity effects. Provides the hydraulic foundation needed to evaluate flow meter performance.

Lesson 3 • Differential Pressure Flow Meters

Covers orifice plates, venturi tubes, flow nozzles, and annubars as primary elements with DP transmitters. Explains beta ratio, discharge coefficient, and permanent pressure loss.

Lesson 4 • Positive Displacement and Mass Flow Meters

Covers gear, oval-gear, and diaphragm PD meters alongside Coriolis and thermal mass flow meters. Addresses custody transfer accuracy and direct mass measurement advantages.

Lesson 1 • Level Measurement Principles

Distinguishes direct, inferential, and indirect level measurement approaches and their underlying physics. Frames the selection criteria used throughout the chapter.

Lesson 2 • Ultrasonic, Radar, and Guided Wave Radar

Examines non-contact ultrasonic and radar and contact guided wave radar for level measurement. Addresses beam angle, false echoes, and dielectric constant effects.

Lesson 3 • Level Switches and Point Detection

Reviews vibrating fork, capacitance, conductance, and float-type level switches for point detection. Connects switch selection to safety and alarm functions in process plants.

Lesson 4 • Float, Displacer, and Sight Glass Devices

Covers float switches, displacer transmitters, and sight glasses as mechanical level measurement devices. Explains torque tube operation and buoyancy force calculations.

Lesson 1 • Actuators and Positioners

Covers pneumatic diaphragm, piston, and electric actuators and the role of valve positioners in accuracy. Explains split-range, digital positioner configuration, and bench-set procedures.

Lesson 2 • Control Valve Construction and Types

Covers globe, ball, butterfly, and rotary plug valve bodies and their trim configurations. Establishes the mechanical basis for understanding valve performance and selection.

Lesson 3 • Valve Flow Characteristics

Explains inherent linear, equal-percentage, and quick-opening characteristics and installed characteristic distortion. Guides characteristic selection to match process gain requirements.

Lesson 4 • Control Valve Sizing

Applies Cv and Kv flow coefficient equations to liquid, gas, and steam service sizing. Ensures students can size valves to avoid cavitation, flashing, and choked flow.

Lesson 1 • PID Tuning Methods

Applies Ziegler-Nichols, Cohen-Coon, and IMC-based tuning rules to calculate initial PID parameters. Compares tuning methods by robustness, speed, and ease of application.

Lesson 2 • PID Algorithm Modes and Equations

Derives proportional, integral, and derivative modes mathematically and explains their individual control effects. Covers ideal, series, and parallel PID forms used in industrial controllers.

Lesson 3 • Controller Performance Assessment

Uses IAE, ISE, and ITAE performance indices and trend analysis to evaluate and refine controller tuning. Identifies oscillation, sluggishness, and windup as common performance defects.

Lesson 4 • Process Dynamics and Response

Covers process gain, dead time, and time constant as the three dynamic parameters governing controllability. Explains step-test methods to identify process dynamics from plant data.

Lesson 1 • Override and Split-Range Control

Covers selector logic for override control and split-range valve sequencing for wide-range control. Addresses windup prevention in override control schemes.

Lesson 2 • Cascade Control Configuration

Explains the primary and secondary loop structure of cascade control and its advantage over single-loop control. Covers tuning sequence: inner loop first, then outer loop.

Lesson 3 • Model Predictive Control Overview

Introduces MPC concepts: prediction horizon, control horizon, and constraint handling for multivariable processes. Positions MPC as the advanced alternative to PID for complex unit operations.

Lesson 4 • Ratio and Feedforward Control

Applies ratio control to maintain proportional flow relationships and feedforward to reject measurable disturbances. Combines feedforward with feedback for improved disturbance rejection.