At the end of this course participants will be able to:

• Specify a controller action for various situations
• Describe the need for feedback control and explain its imposition.
• Describe open and closed loop methods of controller tuning
• Calculate steady state gain for a single loop controller
• Describe dynamic gains for a single loop controller
• Describe process dead-time
• Describe the gain and phase of dead-time
• Implement control loops for each type of controller: P, P+I and P+I+D
• Describe the limits for each type of control
• Describe the tuning of a cascade control loop

• Process models
• Understanding control
• PID control, bringing it all together
• Controller design
• New tuning methods
• Other control methods
• Tuning a cascade control loop

Day 1

Process Models

• Static models
• Dynamic models
• Step response models
• Frequency response
• Parameter estimation
• Disturbance models
• Understanding Control
• Negative feedback
• Steady-state response of a system
• Dynamic response of a control system
• Loop gain
• Gain and dead time
• Process dead time
• Reverse and direct acting controllers
• Two-step control
• Two-step control with deadband
• Proportional control action
• Integral control action

Day 2

PID Control, Bringing it all Together

• The feedback principle
• PID control
• PID algorithms
• Integral windup
• Commercial controllers
• When can PID control be used?

Day 3

Controller Design

• Specifications
• Ziegler Nichols and related methods
• Loop shaping
• Analytical tuning methods
• New Tuning Methods
• Step response method
• Frequency response methods
• Open loop methods
• Closed loop methods
• The process reaction method

Day 4

Other Control Methods

• Cascade control
• Ratio control
• Applications of ratio control
• Fuzzy logic, what is it?
• Neural networks, what are they?

Day 5

Tuning a Cascade Control Loop

• A written procedure for loop tuning
• Identifying the master and slave controllers in a cascade control system
• Why is cascade control used? What are its advantages and disadvantages?

At the end of this course, participants will be able to

• Understand instrumentation terms, concepts, diagrams, and symbols
• Implement an instrument and wiring number system1
• Understand level measurement and the basics associated with it
• Identify flow measurement techniques
• Know new technologies such as smart instrumentation and field bus
• Integrate a complete system (considering instrumentation and total errors) as well as selection criteria, commissioning, and testing

• Introduction
• Categories of measurements
• Basic analog DC meters
• Bridge circuits
• Comparison measurements
• Oscilloscope
• Sensors and transducers

Day 1

Introduction

• Significant figures scientific notation
• Average
• Decibels
• Basic of measurement
• Categories of Measurements
• Making measurements
• Accuracy & precision
• Resolution
• Measurement errors and distribution analysis

Day 2

Basic Analog DC Meters

• Taut band meter movement
• Using basic DC meters
• Voltage measurement from DC current meters
• DC analog ohmmeter
• Analog AC meters
• Analog multimeters
• Day 3
• Bridge Circuits
• DC wheatstone bridge
• Bridge application
• DC bridge
• AC bridge
• DC null indicators
• Phase detectors

Day 4 and 5

Comparison Measurements

• Potentiometers
• Potentiometers circuits and operation
• Digital circuits
• Oscilloscope
• CRT oscilloscope
• Oscilloscope specification
• Storage oscilloscope
• Sensors and Transducers
• Strain gauge
• Temperature transducers
• Thermistars & thermocouples
• Inductive transducers

At the end of this course, participants will be able to

• Understand the fundamentals of hazardous area classifications and the hazardous result from energy librated from electrical equipment
• Understand the fundamentals of gas grouping and temperature classifications to avoid hazards
• Understand the different methods for explosion protection
• Understand routine maintenance, modifications, and fault diagnostics
• Understand safety working practices

• Basic concepts
• Classification
• Methods of protection
• Fieldbus
• Maintenance

Day 1

Basic Concepts

• Introduction to hazardous areas
• Flammable materials
• Fire triangle
• Explosive limits
• Ignition energy
• Dust hazards

Day 2

Classification

• Classification concepts
• Area calcification of gas
• Area calcification of dust
• Group classification
• Temperature classification
• Classification of hazardous locations
• Steps to area classification for gases and vapors

Day 3

Methods of Protection

• Overview of protection philosophy
• Explosion proof fundamentals
• Explosion proof advantages and disadvantages
• Intrinsic safety fundamentals

Day 4

Fieldbus

• Field bus in hazardous areas
• Field with traditional explosion proof methods
• Non-incendive protection
• Fieldbus bus powered devices
• Fieldbus using intrinsic safety
• Topologies FNICO

Day 5

Maintenance

• Introduction
• Maintenance –general guidelines
• Inspection
• Maintenance of explosion-proof instruments
• Maintenance of increased safety equipment

At the end of this course participants will be able to

• Be familiar to instrumentation systems
• Understand and maintain instrument devices
• Read P& ID and symbols
• Calibrate instruments devices

• Fundamental principles
• Diagrams, symbols, and specifications
• Maintenance management and engineering
• Pressure and flow instruments
• Temperature devices
• Panel and transmitting instruments
• Analytical instruments
• Calibration

Day 1

Fundamental Principles

• Maintenance vs. troubleshooting
• Calibration and reasons to calibrate
• Troubleshooting
• Diagrams, Symbols, and Specifications
• P& ID
• Instrument loop diagrams
• Logic diagram
• Instrument symbols

Day 2

Maintenance Management and Engineering

• Maintenance philosophy
• Planning and scheduling
• Preventative maintenance
• Alternative methods of maintenance

Day 3

Pressure and Flow Instruments

• Level, flow, pressure transmitters
• Magnetic, mass, vortex and ultrasonic flow meters
• Temperature Devices
• Thermocouples and thermistors
• Integrated circuits, temperature and infrared transducers

Day 4 and 5

Panel and Transmitting Instrument

• Panel meters
• Potentiometers
• Recorders, transducers and smart transducers
• Analytical Instruments
• Field analytical instruments
• Maintenance approaches
• Installation issues
• Calibration
• Field calibration
• Calibration in hazardous location

At the end of this course participants will be able to

• Understand the fundamentals of process control and new techniques
• Tune PID control loops
• Correct stability problems
• Understand cascade loops and feed forward control
• Identify and correct problems with dead time in the process

• Basic control concepts
• Introduction to sensors and transmitters
• Introduction to control valves
• Basic principles of control systems

Day 1 and 2

Basic Control Concepts

Introduction to Sensors and Transmitters

• Types of transmitters
• Types of sensors
• Field bus application
• Field network standards and communication protocol

Day 3

Introduction to Control Valves

• Classification of valves and types
• Control valve performance

Day 4 and 5

Basic Principles of Control Systems

• Modelling of systems, block diagrams, signal flow graphs
• Transient and steady-state analysis of continuous-time linear time invariant systems, system stability
• Natural and forced response, forced performance
• Root locus analysis and design
• Frequency domain analysis and design (Nyquist’s plots)
• State-space analysis and design
• Digital control analysis and design
• Analog PID controller design for the LTI process
• Digital PID controller design
• Control hardware components

At the end of this course participants will be able to

• Understand the different types of pumps, compressors and turbines
• Operate pumps, compressors and turbines as close as possible to the design efficiency
• Monitor pump compressor and turbine efficiency, availability and reliability
• Know selection, operation and maintenance strategies
• Troubleshoot pump, compressor and turbine problems

• Types of compressors
• Types of pumps
• Types of energy generators
• Troubleshooting of compressors, pumps and energy generators

Day 1 and 2

Types of Compressors

• Introduction
• Hazard assessment
• Operating requirements
• Maintenance requirements
• Control

Day 3

Types of Pumps

• Introduction
• Hazard assessment
• Operating requirements
• Maintenance requirements
• Control

Day 4

Introduction

• Hazard assessment
• Operating requirements
• Maintenance requirements
• Control

Day 5

Troubleshooting of Compressors, Pumps and Energy Generators

Gas Turbine Maintenance

• Air inlet filtration
• Compressor blades erosion
• Compressor fouling
• Compressor tip clang
• Inspection schedules
• Safety precautions
• Bore-scope inspections
• Cracks testing
• Bearings

Compressor Maintenance

• Motor will not run
• Oil in discharge gas
• Knocks or rattles
• Gas delivery has dropped off
• Relief valve vents pressure
• Motor overload trips
• Compressor runs excessively hot
• Compressor doesn’t come up to seed

Pump Maintenance

• Not enough water delivered
• Pump takes too much power
• Pump leaks excessively at stuffing box
• Not enough pressure
• Pump too noisy
• Pump works for a while then quits

At the end of this course participants will be able to

• Examine the major components of a common PLC1
• Interpret PLC specifications
• Apply troubleshooting techniques
• Convert conventional relay logic to a PLC language
• Operate and program a PLC for a given application

• PLC hardware
• I/O signals, and modules
• Memory mapping and addressing
• Programme upload and download procedures and precautions
• Ladder programming
• Case studies, and examples applying PLC from different manufacturers; installation and practical aspects

Day 1

PLC Hardware

• Introduction to PLC functions
• PLC types
• PLC architectures
• Redundancy

Day 2

I/O Signals and Modules

• Digital contact/voltage modules
• Digital sinking/sourcing modules
• Analogue 4- 20 mA modules
• Analogue hart-field bus modules

Day 3

Memory Mapping and Addressing

• I/O addressing
• Software contact, relays, times and counters allocation in memory

Day 4 and 5

Programme Upload and Download Procedures and Precautions

• Ladder Programming
• Timers’ instructions
• Counters’ instructions
• Comparison instructions
• Moving instructions
• Case studies, and Examples Applying PLC from Different Manufacturers; Installation and Practical Aspects
• PLC sizing and selection
• Safety consideration
• Installing in hazard industries
• Power supply

At the end of this course participants will be able to

• Identify challenges and defines solutions
• Assure operational integrity of these mission-critical networked services
• Assess and mitigate security vulnerabilities
• Understand where unique-to-SCADA approaches are necessary

• Open systems issues push the agenda
• Points of vulnerability
• SCADA network protocols
• Encryptian
• Firewalls and perimeter security
• Intrusion detection and prevention
• Wireless security issues

Day 1

Introduction

• Security challenges are universal
• Increased vulnerability due to open systems trend
• Increased vulnerability from motivated, knowledgeable attackers
• Some documented SCADA security failure incidents
• Oil & gas sector benefits from electrical power industry initiatives
• Open Systems Issues Push the Agenda
• Protocols of the internet architecture
• Ethernet and other IT-derived networks
• Fieldbus standards
• IEC standards
• Ethernet/IP and CIP
• Computer operating systems; Windows and Unix/Linux

Day 2

Points of Vulnerability

• The IT infrastructure
• Leased and shared infrastructure
• The sensor/fieldbus networks
• Wireless LAN systems
• Rogue (undocumented) dial and wireless links
• Infected/compromised portable equipment
• Network management systems
• SCADA Network Protocols
• Features common to most SCADA networks
• The MODBUS protocol and its lack of security
• Demonstration/lab: MODBUS dialog
• The DNP3 protocol and its security limitations
• The near-universal trend to ethernet-based networks

Day 3

Encryptian

• Starting with a secure physical environment
• The traditional purpose of assuring privacy is a minor issue
• Traditional symmetric key cryptography
• Public key cryptography and RSA
• Protecting field networks from intrusion with encryption

Day 4

Firewalls and Perimeter Security

• Firewall design objectives
• Survey of firewall types
• Network address translation
• Creating and populating a SCADA DMZ
• Field-level firewalls in the SCADA network
• Intrusion Detection and Prevention
• NIDS principles and features
• Deployment scenarios
• Packet signature and traffic pattern analysis
• Strategies for dealing with the volumes of data

Day 5

Wireless Security Issues

• Wireless technology offers, compelling advantages
• Early misadventures with wireless security
• TKIP and the WPA/IEEE 802111i WiFi standards
• Private point-to-point wireless services
• Cellular/mobile data networks; benefits and risks

At the end of this course participants will be able to

• Know an intensive, systematic treatment of classical solutions, and new developments in SCADA technology
• Have an up-to-date view of emerging trends in this critical industry segment

• Features of industrial computing applications
• Telecommunications services and link protocols
• Local area networks in station and in field switches
• Full duplex ethernet
• Core principles of the TCP/IP
• Architecture
• Reliability, redundancy and safety issues
• Features of RTU
• Automatic local control process
• Instrument and equipment
• Security

Day 1

Summary Features of Industrial Computing Applications

• A prototype view of SCADA systems
• SCADA, PLC, and DCS systems as used in the oil & gas industry
• Networked computing issues that apply to SCADA
• Data communications and computing
• Telecommunication Services and Link Protocols
• Types of SCADA networks
• Communication media and signals
• Wireless systems concepts
• Modern types and features
• Functions and examples of data

Day 2

Local Area Networks in the Station and in the Field

• Ethernet networks and configurations
• Industrial adaptations to Ethernet
• Hub-oriented LAN configurations
• Intelligent and switching hubs
• LAN connectivity: bridges, routers and switches
• Solving Distance and Capacity Problems with Full Duplex Ethernet

Day 3

Architecture

• Features of the internet computing architecture
• Key elements of The Internet Protocol
• Transmission control protocol concepts
• Web-based industrial computing applications
• Reliability, Redundancy, and Safety Issues
• Reliability and availability definitions
• System reliability models
• Failure modes
• Intrinsic safety and electrical hazards

Day 4

Features of RTU

• Oil/gas wellhead example: typical data points
• Data representation formats
• Real time operations: requirements and features
• Role and typical features of the RTU
• Packaging issues and designs
• Automatic Local Control Process
• Open- and closed-loop control concepts
• Relay logic and ladder diagrams
• Programmable logic controllers
• The Fieldbus/Modbus architecture
• Ethernet Industrial Protocol (Ethernet/IP)

Day 5

Instruments and Equipment

• Traditional computer interfaces
• Balanced and unbalanced wiring configurations
• RS-485 bus architecture features
• Cross-over cables
• Analog interfaces and instrument concepts
• Security
• Sampler of oil & gas security incidents
• Points of vulnerability
• Overview of encryption and firewalls
• Access control and intrusion detection
• Unique challenges of wireless systems