Professional Certificate of Competency in the

Fundamentals of Process Plant Layout & Piping Design

Plant layout fundamentals and work flow procedures

Terminology and symbols used in plant layout

Plot plans, elevations and 3-D models

Fundamental principles of chemical process technology

Process flow diagrams (PFDs)

Equipment used in process plants

Instrument symbols and abbreviations

Piping and instrumentation diagrams (P&IDs)

Piping design and engineering principles

Terminology, symbols and abbreviations used in piping design

Piping materials

Piping specifications and piping codes

Components of piping systems - fittings, flanges and valves

Piping isometrics and bill of material

Overview

Process plants, such as refineries and petrochemical plants, are complex facilities consisting of
equipment, piping systems, instruments, electrical systems, electronics, computers, and control
systems. The design, engineering and construction of process plants involves a multidisciplinary
team effort. Plant layout and design of piping systems constitutes a major part of the design and
engineering effort. The goal is to design safe and dependable processing facilities in a cost
effective manner. The fact is that there are very few formal training programs that focus on design
and engineering of process plants and piping systems. Therefore, most of the required skills are
acquired while on the job, reducing productivity and efficiency.

The objective of this course is to provide the delegates the basic knowledge and skills in this
discipline to facilitate faster learning curves while on the job. This course will cover the
fundamental principles and concepts used in process plant layout and piping design. Upon
completion of this course the delegates will have a clear understanding of the design and
engineering principles used in plant layout and piping design.
Course Outline

MODULE 1: Introduction to Process Plant Layout and Piping Design

Plant layout fundamentals

Procedures and workflow

Physical quantities and units

MODULE 2: Introduction to Chemical Processing Methods

Unit operations and unit processes

Process Flow Diagrams (PFDs)

Heating and cooling utilities used in process plants

Typical equipment specifications

MODULE 3: Equipment Used in Process Plants - I

Process equipment

- Reactors

- Towers

- Exchangers - Furnaces

- Vessels

Mechanical equipment

- Pumps

- Compressors

- Turbines

Equipment foundations and supports

MODULE 4: Equipment Used in Process Plants - II (Documents)

Equipment data sheets

Equipment sketches

Equipment drawings
Equipment nozzle specifications

Equipment foundation drawings

MODULE 5: Plant Layout and Plot Plans

Plant layout specifications

Codes and safety considerations

Development of plot plans

Plot plan use by disciplines

Sample plot plans and equipment arrangement drawings

Layout case studies

MODULE 6: Piping Materials and Material Specifications

Material properties

Classification of materials

Material specifications (ASTM)

Common piping materials

Piping specifications

Material selection

Material testing, inspection and QA

MODULE 7: Piping and Instrumentation Diagrams (P&IDs) - I

P&ID basics

Use of P&IDs by different disciplines

Information contained in P&IDs

Instruments and instrument symbols

MODULE 8: Piping and Instrumentation Diagrams (P&IDs) - II

Local control, DCS and PLC

Discussion of a sample P&ID

Control valve manifolds

Meter runs

MODULE 9: Plant Layout and Piping Design Documentation and Tools - I

Piping codes

Piping specifications

Equipment lists

Piping line lists

MODULE 10: Plant Layout and Piping Design Documentation and Tools - II

Stress isometrics

Piping isometrics and Bill of Materials

PFDs, plot plans, and P&IDs

3D models

MODULE 11: Fundamentals of Pipe and Pipe Fittings

Pipe dimensions and pipe representation

Use of pipe data tables

Pipe joining methods

Pipe fittings

- Elbows

- Tees

- Reducers

- End caps

Fitting dimensions and tables

MODULE 12: Piping System Components

Basics of flanges

- Flange ratings and flange types

Flange data tables and their use

Different types of valves and their applications

Valve data tables

Piping restraints

 Fundamentos de diseño de planta y procedimientos de flujo de trabajo.

 Terminología y símbolos utilizados en el diseño de la planta.
 Planos de trama, elevaciones y modelos 3-D
 Principios fundamentales de la tecnología de procesos químicos.
 Diagramas de flujo de proceso (PFD)
 Equipos utilizados en plantas de proceso.
 Símbolos de instrumentos y abreviaturas
 Diagramas de tuberías e instrumentación (P e ID)
 Diseño de tuberías y principios de ingeniería.
 Terminología, símbolos y abreviaturas utilizados en el diseño de tuberías.
 Materiales de tuberías
 Especificaciones de tuberías y códigos de tuberías
 Componentes de los sistemas de tuberías: accesorios, bridas y válvulas.
 Isometría de tuberías y lista de materiales
Visión general

Las plantas de proceso, como las refinerías y las plantas petroquímicas, son instalaciones
complejas que consisten en equipos, sistemas de tuberías, instrumentos, sistemas eléctricos,
electrónicos, computadoras y sistemas de control. El diseño, ingeniería y construcción de plantas
de proceso implica un esfuerzo de equipo multidisciplinario. El diseño de la planta y el diseño de
los sistemas de tuberías constituyen una parte importante del diseño y el esfuerzo de ingeniería. El
objetivo es diseñar instalaciones de procesamiento seguras y confiables de manera rentable. El
hecho es que hay muy pocos programas formales de capacitación que se centren en el diseño y la
ingeniería de plantas de proceso y sistemas de tuberías. Por lo tanto, la mayoría de las habilidades
requeridas se adquieren en el trabajo, lo que reduce la productividad y la eficiencia.

El objetivo de este curso es proporcionar a los delegados el conocimiento básico y las habilidades
en esta disciplina para facilitar curvas de aprendizaje más rápidas mientras están en el trabajo.
Este curso cubrirá los principios y conceptos fundamentales utilizados en el diseño de la planta de
proceso y el diseño de tuberías. Al finalizar este curso, los delegados comprenderán claramente
los principios de diseño e ingeniería utilizados en el diseño de la planta y el diseño de las tuberías.
Esquema del curso
MÓDULO 1: Introducción al diseño de planta de proceso y diseño de tuberías

Fundamentos del diseño de la planta

Procedimientos y flujo de trabajo

Cantidades físicas y unidades

MÓDULO 2: Introducción a los métodos de procesamiento químico

Operaciones unitarias y procesos unitarios

Diagramas de flujo de proceso (PFD) Servicios de

calefacción y refrigeración utilizados en plantas de proceso

Especificaciones de equipos típicos

MÓDULO 3: Equipo utilizado en plantas de proceso - I

Equipos de proceso

- Reactores

- Torres

- Intercambiadores - Hornos

- Recipientes

Equipamiento mecánico

- Bombas

- Compresores

- Turbinas

Fundaciones y soportes de equipos.

MÓDULO 4: Equipo utilizado en plantas de proceso - II (Documentos)

Hojas de datos del

equipo Bocetos del

equipo Planos del

equipo Especificaciones de la boquilla del equipo Planos del

cimiento del equipo

MÓDULO 5: Diseño de planta y planos de parcela

Especificaciones de diseño de planta

Códigos y consideraciones de seguridad

Desarrollo de planos de

parcela Uso del plan de parcela por disciplinas

Planos de parcela de muestra y planos de disposición de equipos

Estudios de caso de diseño

MÓDULO 6: Materiales de tuberías y especificaciones de materiales

Propiedades

del material Clasificación de materiales

Especificaciones de materiales (ASTM)

Materiales de tuberías comunes

Especificaciones de tuberías

Selección de

materiales Prueba de materiales, inspección y control de calidad

MÓDULO 7: Diagramas de tuberías e instrumentos (P e ID) - I

Conceptos básicos

de P&ID Uso de P & ID por diferentes disciplinas

Información contenida en P & ID

Instrumentos y símbolos de instrumentos

MÓDULO 8: Diagramas de tuberías e instrumentos (P e ID) - II

Control local, DCS y PLC

Discusión de una muestra P&ID

Colectores de válvulas de control

Mediciones de funcionamiento

MÓDULO 9: Herramientas y documentación de diseño de planta y diseño de tuberías - I

Códigos de

tuberías Especificaciones de tuberías

Listas de equipos Listas de

líneas de tuberías

MÓDULO 10: Documentación y herramientas de diseño de planta y tuberías - II

Isométricos de tensión Isométricos de

tuberías y

PFD de lista de materiales , planos de trazado y P & ID

Modelos 3D

MÓDULO 11: Fundamentos de tuberías y accesorios de tubería

Dimensiones de tubería y representación

de tubería Uso de tablas de datos de

tubería Métodos de unión de

tubería Accesorios de tubería

- Codos

- Tees

- Reductores

- Tapas finales
Dimensiones de montaje y mesas

MÓDULO 12: Componentes del sistema de tuberías

Conceptos básicos de bridas

- Clasificaciones de bridas y tipos de bridas

Tablas de datos de bridas y su uso

Diferentes tipos de válvulas y sus aplicaciones

Tablas de datos de válvulas Restricciones de

tuberías

- Soportes, anclajes y guías.

diagramas de flujo de proceso (PFD)

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https://www.eit.edu.au/cms/courses/data-comms-industrial-it

https://www.eit.edu.au/cms/courses/engineering-management

https://www.eit.edu.au/cms/courses/electronic-engineering

https://www.eit.edu.au/cms/courses/electronic-engineering/advanced-diplomas/52705wa-
advanced-diploma-of-biomedical-engineering

School of Industrial Automation, Instrumentation and

Process Control
In order to meet the exacting demands of the oil and gas, mining, manufacturing and
downstream processing industries, modern plants are equipped with systems and devices
which are needed to measure and regulate variables such as temperature, pressure, flow,
humidity, liquid level, velocity and density. Industrial Automation provides the technology to
control and monitor a process plant using such concepts as feedback, cascade,
feedforward and advanced process control. Here at the Engineering Institute of
Technology (EIT), we have developed industry-focused programs in the form of
vocational advanced diplomas, all the way up to Masters level in the higher education
sector.
There is a critical shortage of automation, instrumentation and control engineers,
technicians and technologists around the world now due to the retirement, restructuring
and rapid growth in new technologies and industries. The respected International Society
of Automation (ISA) organization estimated that at least 15,000 new automation engineers
are needed annually in the USA alone.
In keeping with the philosophy of EIT, students in this school are exposed to the practical,
up-to-the-minute knowledge and skills demanded by leading industries worldwide, with
online instrumentation courses. EIT does not just cater to a generic student body, instead
all of our online instrumentation courses are specific to industry. The programs cover a
large range of topics and are suited to anyone needing an intensive and practical look at
all facets of industrial automation, instrumentation and process control.
Students in EIT's School of Industrial Automation, Instrumentation and Process Control
study subjects which include: process control, instrumentation, control valves, process
plant layout and piping design, tuning of process loops, SCADA, PLCs, advanced process
control (APC), boiler control, hazardous areas, safety instrumentation (IEC 61511 and IEC
61508), HAZOPs, industrial data communications, networking, deviceNet and Fieldbus,
industrial wireless, radio telemetry systems, shielding/EMC/EMI, and noise reduction.

52677WA - Advanced Diploma of Remote Engineering, Mechatronics and Robotics

52684WA - Advanced Diploma of Electrical and Instrumentation (E&I) Engineering for Oil and Gas Facilities

52708WA - Advanced Diploma of Industrial Automation

52727WA - Advanced Diploma of Electrical and Instrumentation (E&I) Engineering in Mining

Bachelor of Science (Industrial Automation Engineering)**

Master of Engineering (Electrical and Instrumentation in Oil and Gas)

Master of Engineering (Industrial Automation)**

Master of Engineering (Safety, Risk and Reliability)**

On Campus - Bachelor of Science (Industrial Automation Engineering)**

On Campus - Master of Engineering (Industrial Automation)**

Professional Certificate of Competency in Allen Bradley Controllogix/ Logix5000 PLC Platforms

Professional Certificate of Competency in Control Valve Sizing, Selection and Maintenance

Professional Certificate of Competency in Hazardous Areas and Intrinsic Safety for Engineers and
Technicians

Professional Certificate of Competency in IEC 61850 based Substation Automation

Professional Certificate of Competency in Instrumentation Automation and Process Control

Professional Certificate of Competency in Programmable Logic Controllers (PLCs) & SCADA Systems

Professional Certificate of Competency in Safety Instrumentation Systems for Process Industries

https://www.eit.edu.au/cms/courses/industrial-automation-instrumentation-process-control

School of Industrial Automation, Instrumentation and Process Control study subjects

which include: process control, instrumentation, control valves, process plant layout and
piping design, tuning of process loops, SCADA, PLCs, advanced process control (APC),
boiler control, hazardous areas, safety instrumentation (IEC 61511 and IEC 61508),
HAZOPs, industrial data communications, networking, deviceNet and Fieldbus, industrial
wireless, radio telemetry systems, shielding/EMC/EMI, and noise reduction.

https://www.eit.edu.au/cms/courses/electrical-engineering

Escuela de Automatización Industrial, Instrumentación y Control de Procesos del EIT

estudian temas que incluyen: control de procesos, instrumentación, válvulas de control,
diseño de planta de proceso y diseño de tuberías, ajuste de bucles de proceso, SCADA,
PLC, control avanzado de procesos (APC), control de calderas , áreas peligrosas,
instrumentación de seguridad (IEC 61511 e IEC 61508), HAZOP, comunicaciones de
datos industriales, redes, DeviceNet y Fieldbus, sistemas inalámbricos industriales,
sistemas de radio telemetría, blindaje / EMC / EMI y reducción de ruido.
Prescribed and Recommended Readings
Required textbook

 King M. (2011) Process Control: A Practical Approach Published by John Wiley & Sons Ltd,
UK and available in electronic form and in print form: ISBN-13: 978-0470975879

Recommended Reference Materials

 Engineering Standard ANSI/ISA-88 Part 1 or IEC 61512-1

 Engineering Standard ANSI/ISA-95 Part 1 or IEC 61512-1
 Examples of journals include

a. Journal of Process Control

b. Control (Electronic access via ControlGlobal.com)

Unit Content
One topic is delivered per contact week, with the exception of part-time 24-week units, where
one topic is delivered every two weeks.

Topic 1
Control systems and their relationship to process operations

1. Introduction to the purposes of industrial control systems and the role of the control system in
achieving business objectives.
2. Characteristic control system features in various industry sectors
3. Input/output relationships of typical process equipment modules: Tanks, Heat exchangers,
reactors.

Topic 2

1. Process unit operations, flowcharts and the depiction of the control system.
2. Outline of process industry equipment units and material flows (mass, temperature, pressure).
3. Linear differential equations and Introduction to process dynamics
4. Pressure and flow characteristics in pipelines and the role of control valves.

Topic 3
Characteristics and dynamics of continuous processes

1. Laplace transform
2. 1st and 2nd order processes.
3. Block diagram modeling for process models and feedback control.
4. Feedforward Control

Topic 4
Fundamentals of feedback control

1. Process variables, MVs and set points

2. Sensing and actuation using instrumentation
3. Feedback control characteristic responses of 3 term controllers
4. Principles of digital control and sampled data systems.
5. Introduction to multivariable systems

Topics 5 and 6
Advanced Analysis and design of feedback control systems
(Lab demonstrations and application software tools should be used (MATLAB Control System
Toolbox) in association with this topic.

1. Frequency domain analysis

2. Stability and dynamic behaviour of linear systems in feedback control.
3. Impacts of non-linearity and time delay in feedback control
4. Digital control algorithms and their effects on control response.
5. Loop tuning techniques for industrial controllers.

Topic 7
MATLAB Demos & Control Overview

1. Tuning a Controller with MATLAB

2. The Nyquist Criterion
3. Feed Forward Control Overview
4. Other Control Problems

Topic 8
Characteristics of industrial process control equipment

1. Single loop digital controllers

2. PLC based loop and sequence control.
3. Distributed control systems outline

Topic 9
Automation system functions

1. Introduction to safety critical control systems (Details in ME 508).

2. Principles of batch process control based on ANSI/ISA-88)
3. Introduction to Enterprise-Control System Integration (ANSI/ISA-95)
Topics 10 and 11
Developing the control system specification for a project

1. Understanding the process and its control and operability requirements

2. Functional specifications for plant control systems. Alarms, process management, safety trips
and emergency shutdown systems.
3. Role of operators and the design of the control room
4. Developing the control system architecture
5. Control system specification
6. Project planning and deliverables

Topic 12
Project and Course Review
In the final week, students will have an opportunity to review the contents covered so far.
Opportunity
will be provided for a review of student work, to clarify any outstanding issues, and to work on
finalizing the major assessment report.
https://www.eit.edu.au/cms/masters-core-units/me/me503

Prescribed and Recommended Readings

Required textbook(s)

 Holman, J., 1978, Experimental Methods for Engineers (Mcgraw-Hill Series in Mechanical
Engineering) – ISBN: 978-0073529301
 Patranabis D., 2010, Principles of Industrial Instrumentation 3rd Edition: Tata McGraw-Hill –
ISBN: 978-0070699717
 EIT course notes
 Engineering Standard ANSI/ISA Instrument Symbols and Identification

Recommended textbook(s)

 Dunn, W., 2005, Fundamentals of Industrial Instrumentation and Process Control: McGraw-Hill
Education – ISBN: 978-0071457354
 Morris, A. S., 2001, Measurement and Instrumentation Principles, 3rd Edition: Butterworth-
Heinemann – ISBN: 978-0750650816
 Du, W. Y., 2014, Resistive, Capacitive, Inductive, and Magnetic Sensor Technologies: CRC
Press – ISBN: 978-1439812440
 Lipták, B. G., 2005, Instrument Engineers' Handbook, 4th Edition, Volume Two - Process
Control and Optimization: CRC Press – ISBN: 978-0849310812

Reference Materials
 Number of journals and websites (advised during lectures).
 Examples of journals including the International Journal of Instrumentation

Unit Content
One topic is delivered per contact week, with the exception of part-time 24-week units, where one
topic is delivered every two weeks.

Topic 1
Introduction to instrumentation and measurement systems
1. The generalized measurement system and its relationship to control systems
2. Dimensions, SI units and reference standards
3. Introduction to instrumentation systems as used in industry.

Topic 2
Measurement principles

1. Measurement ranges, linearity and sensitivity.

2. Measurement error and uncertainty analysis
3. Statistical methods for measurement
4. Analogue instruments and measurement principles
5. Digital measurement principles
6. Dynamic measurements and response factors.

Topic 3
Electrical measurement principles

1. Electromagnetic forces and waveform measures

2. Basic analog and digital meters
3. Principles of differential and operational amplifiers
4. Signal conditioning, filtering and noise reduction methods

Topic 4
Transducer principles

1. Potentiometers and inductive sensors

2. Piezo-electric sensors
3. Photoelectric sensors
4. Capacitance and vibration sensors
5. Other sensors

Topic 5
Signal processing and signal transmission
1. Principles of signal processing for measurement
2. Data acquisition systems
3. Principles of industrial transmitters and analogue signal transmission methods
4. Microprocessors and intelligent transmitters, HART digital transmission systems
5. Introduction to Fieldbus and wireless data transmission for industrial applications

Topic 6
Force and pressure measurements

1. Principles of force and mass measurement

2. Elastic elements and strain gauges
3. Overview of pressure measurement methods.
4. Diaphragm gauges and sensors
5. Thermal conductivity methods

Topics 7 and 8
Industrial flow measurement techniques

1. Principles of fluid flow

2. Flow-obstruction methods (orifice, flow nozzle, venturi)
3. Pitot tubes and their applications)
4. Leading process flow metering methods (Vortex, Magnetic, Ultrasonic, Thermal)
5. Integration and selection of flowmeters for process automation

Topic 9
Control valves and actuators

1. Introduction to pipeline flow and the role of the control valve

2. Installed flow characterization of control valves
3. Valve sizing for liquids, gases and steam flow control
4. Comparative features of variable speed pumps versus control valves for fluid flow control.

Topic 10
Level measurement techniques for liquids and solids

1. Introduction to level measuring challenges in industry.

2. Liquid level by hydrostatic head
3. Microwave and radar methods for solids
4. Ultrasonic and radiation methods
5. Storage tank gauging and linearization
6. Mass measurements using load cells

Topic 11
Temperature measurement techniques

1. Physical principles
2. Resistance temperature detectors and thermocouples
3. IR and UV radiation temperature sensing.

Topic 12
Instrument systems engineering

1. Instrumentation project scope in support of automation

2. Instrumentation symbols, notations and numbering systems
3. Industrial installation practices and standards
4. Remote monitoring and diagnostics in process instrumentation

https://www.eit.edu.au/cms/masters-core-units/me/me504

Prescribed and Recommended Readings

Required textbook(s)
C. J. Geankoplis, Transport Processes and Separation Process Principles, 4th edition, Prentice Hall,
UK, 2003
M. Smith and H.C. Van Ness, Introduction to Chemical Engineering Thermodynamics , Seventh
Edition, Mc Graw-Hills

Reference Materials
Number of peer-reviewed journals and websites (advised during lectures). Some examples are
listed below.

 N.P. Chopey, Handbook of Chemical Engineering Calculations, 3rd edition, McGraw Hill, 2004
 R,K. Sinott, Coulson and Richardson’s Chemical Engineering volume 6 – Design, Pergamon
Press, 1995
 Perry’s Chemical Engineers Handbook, 8th edition, McGraw Hill
 Number of peer-reviewed journals and websites (advised during lectures) [some examples
below]
a. Chemical Engineering Journal
b. Journal of Chemical and Engineering Data
c. Oil and Gas Journal
d. Chemical Engineering
e. EIT notes

Unit Content
One topic is delivered per contact week, with the exception of part-time 24-week units, where
one topic is delivered every two weeks.
Topic 1
Introduction to Process Engineering

1. Definition of a process, process modelling and design

2. Commonly encountered process operations
3. Concept of process integration
4. Walk-through typical processes
5. Process measurement and control – instrumentation, measurement, control and material of
construction.

Topic 2
Principles of Chemical Engineering Thermodynamics-I

1. The laws of Thermodynamics

2. Thermodynamics processes

Topic 3
Principles of Chemical Engineering Thermodynamics-II

1. Carnot Efficiency
2. Common Cycles (e.g. Rankine, Brayton)

Topic 4
Principles of Chemical Engineering Thermodynamics-III

1. Equations of state – Major, Cubic and Non Cubic

2. Thermodynamics calculations

Topic 5
Flow Phenomena and momentum transfer-I

1. Statics and hydraulics

2. Flow through a pipe

Topic 6
Flow Phenomena and momentum transfer-II

1. Laminar and turbulent flow. Flow around objects.

2. Flow through Packed Beds and Fluidized Beds
3. Particle flow
4. Multiphase flow
5. Momentum transfer
6. Flow equipment and measurement
Topic 7
Fundamentals of heat and mass transfer-I

1. Concepts of heat and mass transfer

2. Mass transfer coefficients
3. Steady state conduction through simple and composite flat walls
4. Convective heat transfer, finned walls
5. Heat and mass transfer equipment’s

Topic 8
Fundamentals of heat and mass transfer-II

1. Heat and mass transfer equipment’s (Contd.)

2. Stoichiometry and chemical process calculations
3. Design Concepts
4. Application to instrumentation and control

Topic 9
Fundamentals of heat and mass transfer-III

1. Design Concepts
2. Application to instrumentation and control

Topic 10
Chemical kinetics-I

1. Introduction to chemical reaction engineering

2. Rates and kinetics
3. Catalysis

Topic 11
Chemical kinetics-II

1. Fundamentals of reactor design - Batch and continuous processes, mixed processes, Plug
flow, mean residence time, Residence time distribution.
2. Typical reaction process (e.g. steam reforming of natural gas)

Topic 12
Plant layout
Overview of plant layout, emphasising the process engineering aspects.

1. Considerations in laying out a process plant

2. Preservation of process intent, controllability
3. Safety
https://www.eit.edu.au/cms/masters-core-units/me/me505

https://www.eit.edu.au/cms/courses/industrial-automation-instrumentation-process-
control/bachelors-degree/bachelor-of-science-industrial-automation-engineering

https://www.eit.edu.au/cms/courses/industrial-automation-instrumentation-process-
control/bachelors-degree/bachelor-of-science-industrial-automation-engineering

https://www.eit.edu.au/cms/courses/industrial-automation-instrumentation-process-
control/advanced-diploma/52684wa-advanced-diploma-of-electrical-and-instrumentation-e-i-
engineering-for-oil-and-gas-facilities

https://www.eit.edu.au/cms/courses/industrial-automation-instrumentation-process-
control/advanced-diploma/52708wa-advanced-diploma-of-industrial-automation

https://www.eit.edu.au/cms/courses/industrial-automation-instrumentation-process-
control/bachelors-degree/bachelor-of-science-industrial-automation-engineering

Prescribed and Recommended Readings

Suggested Textbook
• Singh, SK 2010, Industrial Instrumentation and Control, 3rd edn, Tata McGraw, ISBN-13: 978-
0070678200
Reference Materials
• Whitt, MD 2012. Successful Instrumentation and Control Systems Design, 2nd edn, ISA, ISBN
978-1-62198-550-1 Online version available at:
http://app.knovel.com/hotlink/toc/id:kpSICSDE06/successful-instrumentation/successful-
instrumentation

• Meier, FA. Meier, CA.2011. Instrumentation and Control Systems Documentation. (2nd edn. ISA.
Online version available at:
http://app.knovel.com/hotlink/toc/id:kpICSDE006/instrumentation-control/instrumentation-control
• Peer reviewed Journals
• Knovel library: http://app.knovel.com
• IDC Technologies publications
• Other material and online collections as advised during the lectures

Unit Content
Topic 1
Introduction to Measurement Science
1. Fundamentals of measurement science (static characteristics calibration, accuracy, precision,
repeatability; dynamic characteristics (response speed, lag, dynamic error, and etc.)
2. Statistical analysis
3. Units and standards

Topics 2, 3 and 4
Pressure, Level, Temperature and Flow
1. Pressure units, characteristics and types of pressure (Gauge, absolute, vacuum, and etc.)
2. Methods of pressure measurement, calibration (manometers, force balance, and etc.)
3. Level measurement (direct and indirect methods, sight glass, float-type air bellows, calibration,
maintenance and repair, and etc.)
4. Temperature scales, fixed points
5. Methods, characteristics, calibration (Thermometers, electrical temperature measurement,
Pyrometers, fibre optic systems, and etc.)
6. Flow measurement (inferential, quantity, mass)
7. Inferential flow methods and characteristics (variable head, magnetic, target, turbine, thermal,
ultrasonic, and etc.)
8. Quantity methods and characteristics (positive displacement, metering)
9. Mass flow methods and characteristics, calibration, maintenance and repair

Topic 5
Control Valve Sizing, Selection and Maintenance
1. Control valves theory
2. Valve types, materials and characteristics
3. High-pressure drop applications, and sizing
4. Actuators and positioners
5. Installation and maintenance
6. Quality standards (ASME, NACE, ISO9000, and etc.)

Topics 6, 7 and 8
Fundamentals of Control
1. Basic concepts of control (on/off, modulation, feed-forward, feedback, PID)
2. Stability in closed loops (causes, PID control modes)
3. Compare alternative closed loop configurations (cascade, feedforward, combined feedback and
feed-forward)

Topic 9
Introduction to Matlab Control Toolbox and Simulink
1. Principles of Matlab and exercises in scripting
2. Block diagram models and transfer function manipulation
3. Frequency response testing methods

Topics 10 and 11
Tuning Control Loops
1. Fundamentals of tuning loops (PID controllers and modes, load disturbances and offsets, speed
and stability issues, and etc.)
2. Tuning rules (Pessen, Ziegler Nichols, simplified lambda, and etc.)
3. Tuning value controllers (Hysteresis, striction)
4. Automated tuning (Self-tuning, adaptive control)
5. Tuning complex systems (Multivariate, ratio, feed-forward, cascade and interactive loops)
Topic 12
Unit Review
In the final week students will have an opportunity to review the contents covered so far.
Opportunity will be provided for a review of student work and to clarify any outstanding issues.

Prescribed and Recommended Readings

Textbook

• N. S. Nise, Control Systems Engineering, 7th ed. Wiley, 2015 – ISBN: 978-1118170519
Reference
• B. Barraclough, K. Dutton, S. Thompson, The Art of Control Engineering. Prentice Hall, 1997 –
ISBN-13: 978-0201175455
• L. Ferrarini, C. Veber, Modeling, Control, Simulation, and Diagnosis of Complex Industrial and
Energy Systems. ISA, 2009 – ISBN 978-1-62870-506-5.
Online version available at: http://app.knovel.com/hotlink/toc/id:kpMCSDCIE3/modeling-control-
simulation/modeling-control-simulation
Notes and Reference Texts
IDC notes and reference texts as advised.
Other material advised during the lectures

Unit Content
Topics 1 and 2
Introduction to Process Dynamics and Mathematical Models
1. Review of 1st and 2nd order linear differential equations
2. Representation of physical processes by linear differential equations
3. Examples of linearity and non-linearity in physical processes
4. Representation of dynamic processes using transfer functions
5. Derivation of Laplace transforms for impulse, step, and ramp functions
6. The transfer function in block diagram models

Topic 3
Time Response Modelling
1. Block diagram notations and examples
2. Representation of process dynamics by 1st and 2nd order transfer functions
3. Transfer functions for time delays in the process response
4. Determination of time responses to pulse, step, and ramp inputs
5. Modelling of feedback control systems
6. Higher order dynamic models and their simplification to approximate 2nd order plus dead time
Topics 4 and 5
Modelling of process characteristics in Matlab
1. Steady state process model representations to identify inputs, outputs, and disturbance
influences
2. Development of a 1st order model from typical physical process such as a stirred hot water tank
3. Development of a 2nd order model from a spring and weight model, and from a cascaded water
tank process
4. Development of a feed heater model with disturbances
5. Detailed application model of a feedback control loop applied to a 1st order process

Topic 6
PID control and Frequency domain analysis
1. PID Control
2. Frequency response plots and their interpretation
3. Bode diagrams
4. Root locus diagrams

Topics 7 and 8
Stability analysis of single loop feedback controllers (SISO)
1. Stability criteria for feedback control
2. Nyquist Diagrams
3. Compensation by lead-lag elements to achieve stability
4. Configuration and tuning of feedback controllers using S plane models
5. Feed forward control techniques and benefits for disturbance rejection

Topic 9
Modelling, control, design and analysis of SISO systems using Matlab™
1. Case studies and exercises with Matlab to:
a. model, tune, and analyze 1st and 2nd order systems
b. verify stability and response of controllers

Topic 10
Advanced Process Control
1. Advanced vs classical control
2. Internal Model Control - IMC
3. Model Predictive Control - MPC
4. Reference models and Control model formulation

Topic 11
Digital (Discrete) Control System Fundamentals
1. Digital vs Analogue
2. Modelling a digital sampler and Zero-order Hold
3. The z-transform and transfer functions
4. Digital compensator and digital PID control

Topic 12
Project and Unit Review
In the final week, students will have an opportunity to review the contents covered so far.
Opportunity will be provided for a review of student work and to clarify any outstanding issues.
Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Modeling, Control, Simulation, and

Diagnosis of Complex Industrial and Energy
Systems
Veber, Modeling, Control, Simulation, and Diagnosis of Complex Industrial and Energy Systems

Thompson, The Art of Control Engineering.

Nise, Control Systems Engineering

myke king process control a practical approach pdf

 1. Remote Supervision Center for Enel Combined Cycle Plants

 2. Pickling Line Modeling for Advanced Process Monitoring and Automation
 3. Modeling, Simulation and Predictive Control of a Gasoline Engine
 4. Dynamic Principal Component Analysis Applied to the Monitoring of a
Diesel Hydrotreating Unit
 5. A Simulation Study of the Flue Gas Path Control System in a Coal-Fired
Power Plant
 6. Automatic Diagnosis of Valve Stiction by Means of a Qualitative Shape
Analysis Technique
 7. Monitoring and Controlling Processes with Complex Dynamics Using
Soft Sensors
 8. Estimation of a Ternary Distillation Column via a Tailored Data
Assimilation Mechanism
 9. A Prediction Error-Based Method for the Performance Monitoring of
Model Predictive Controllers
 10. An Intelligent/Smart Framework for Real-Time Process Monitoring and
Supervision
 11. Quality Monitoring through a Dynamic Neural Software Sensor
 12. Wind Generation and Flexible Electric Load Management Issues for
System Operation in Crete
 13. A Fuzzy Inference System Applied to Quality Control in the Paper
Industry
 14. Innovative Load Shedding and Demand Side Management
Enhancements to Improve the Security of a National Electrical System
 Index

https://app.knovel.com/web/toc.v/cid:kpMCSDCIE3/viewerType:toc//root_slug:modeling-control-
simulation/url_slug:modeling-control-simulation
Aspectos geométricos de las ecuaciones diferenciales ordinarias 3 de 4

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