9/2/13

CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

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CERTIFICATE IN AUTOMATION ENGINEERING (CAE)

CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)
MODULE 2: System Design and Development with PLC, HMI/SCADA,DCS (ISA CAP Domain III & IV) Section 2.1Working with Applicable Standards e.g. ISA S84, S5.1, IEC 61508, 21 CFR Part 11, NFPA, NEC,EPA, NEMA, UL, IEC 61131 Section 2.2Electrical & Instrumentation Systems Section 2.3PLC Systems Section 2.4HMI/SCADA Systems Section 2.5Distributed Control Systems (DCS) Section 2.6Process Automation (DCS Production Plant Operation & Performance Management of Process Models) Section 2.7Industrial Communication System SECTION 2.1 Working with Applicable Standards ISA S84, S5.1, IEC 61508, 21 CFR Part 11, NFPA, NEC, EPA, NEMA, UL, IEC 61131
OVERVIEW The aim of this section is to provide trainees with the knowledge to perform safety and hazard analysis, security analysis and regulatory compliance assessments by highlighting key issues in order to conform to applicable standards, policies and regulations. It also helps them to produce standards, templates and guidelines applicable to automation systems using the information gathered in the definition stage and considering human factor effects in order to satisfy customer design criteria and preferences.

COURSE CONTENT LESSON 1 Applicable standards (e.g., ISA S84, IEC 61508, 21 CFR Part 11, NFPA) Environmental standards (EPA) Electrical, electrical equipment, enclosure, and electrical classification standards (e.g., UL/FM, NEC, NEMA)

LESSON 2 Process Industry Practices (PIP) (Construction Industry Institute) IEC 61131 programming languages
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CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

Customer standards Vendor standards Template development methodology Field devices Control valves Electrical standards (NEC) Instrument selection and sizing tools ISA standards (e.g., S88)

SECTION 2.2 Electrical & Instrumentation Systems

OVERVIEW This module is designed for instrumentation specialists involved in the definition and specification of instrumentation and control systems using the SmartPlant Instrumentation software and for IT specialists and support personnel who are responsible for installation and system administration of SmartPlant Instrumentation. Students will learn how to define the instruments using SmartPlant Instrumentation as per the specifications of project deliverables, software and hardware requirements, system, supporting RDBMS installation, overview of database structure, database maintenance and overview of customization. The training program will also focus on the concepts and characteristics associated with industrial processes, process variables and Basic process control. Participant will have hand-on experience with a simple control system as well as process and controller simulators.

COURSE CONTENT Variable Frequency Drives (VFDs)

i. ii. iii.

vIntroduction to VFD/VSD Operations vVFD selection & Parameterization vLoad analysis Rated voltage Rated current Rated RPM
i. ii. iii. iv. v.

i.

vCommissioning, No Load Test vPLC-VFD Interface vPID Tuning vSpeed modulation vON/OFF Command

vTrip vi. vInTools Instrumentation Design System and Project Administration Overview Instrument Index, Control loops, Specifications,

User Report Interface ( Browser Module) Process Data Definition Loop Diagrams Wiring Hookups (Installation Details) Specifications Calculations Instrumentation Operation & Maintenance i. vClose loop control ii. vUnderstanding operation of instruments/field device in general iii. vIdentifying instruments vendor and specification iv. vInstallation of field devices/instruments v. vWorking with Instrument and Process variables vi. vWorking with different instrument operation systems vii. vPneumatic System operation On/Off Solenoids valves Piston displacement Control valves
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CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

i. ii. iii. v. vi. vii. viii.

Actuators

vHydraulic System operation vWorking with actuators

vPumps, valves, compressors, heaters, filters, boilers etc iv. vInstrument calibration vSelection of Measurement and Control Devices vRepair modes and records; Failure mode analysis; vMaintenance, calibration modes, and records; Calibration seals; Tools and equipment. vTroubleshooting and maintenance of instruments I/P Convertor Level Transmitters Flow Transmitters Proximity Sensors Pressure Transmitters Temperature Transmitters/RTDs

SECTION 2.3 Programmable Logic Controller, PLC Systems

OVERVIEW Programmable Logic Controllers (PLCs) are the main engine behind most discrete control systems in many industries. This class aims to introduce the principles of operations, maintenance techniques, basic troubleshooting techniques and thorough understanding of overall machine design concepts using PLCs. Focus will also be on PLC based control system project development including specification/parameter analysis, control system design, field devices selection, I/O configuration, PLC selection, project development and implementation. Participants will have hands-on experience with different projects on live PLC including plant alarm systems, sequential control systems feed forward systems, data logging & extraction and many more. The class training will be complemented by class workshops, discussion on industry best practices and ISA videos on PLCs. Students will be issued a certificate at the end of the training. Trainees will be trained on the following PLC brands: Siemens, Allen Bradley, GE Fanuc, Mitsubishi, Omron, ABB etc.

COURSE CONTENT Introduction to Automation & Control System Engineering PLC System Architecture Working with PLC Hardware / Installation PLC Wiring Relay Logic Controls PLC Operation Cycle PLC Configuration/Set ups PLC Communication/Interfacing/Networking/Remote IO Configuration Digital & Analog I/O Addressing Techniques PLC Programming
i.

vLadder & Function Block Programming - Bit, Byte & Word Instructions -Timers & Counters -PID Mode Programming -Comparison / Mathematical Instructions -Analog Signal Processing (ASP) -Subroutines Programming -Interrupts Programming -Forcing inputs & outputs -Program Debugging

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CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

-Downloading/uploading PLC Status Troubleshooting HMI Interface

SECTION 2.4 Human Machine Interface/Supervisory Control & Data Acquisition, HMI/SCADA Systems
OVERVIEW The aim of this module is to build a good understanding about the basics of supervisory control and data acquisition (SCADA) and human machine interface (HMI). A special emphasis on real life implementations, case studies and international standards would ensure participants to co-relate the theory with their day-to-day practice. The class training will be complemented by class workshops, discussion on industry best practices. Students will be issued a certificate at the end of the training.

Trainees will be trained on the following software: Wonderware Intouch, Simantic WinCC, Intellution Ifix etc.

COURSE CONTENT Introduction to HMI/SCADA Communication Protocols Database & DDE Connection (Server, I/O Drivers) Interface with PLC and field devices Data acquisition from field devices Operator Screen Interface Design (Statics) Object Functionality Definition Tag Creation, Addressing & Configuration Animation of Objects (Dynamics Properties Movement, Filling, Visibility, Display Type, Blinking etc) Alarms/Events Configuration Real-time & Historical Trends Interface with PLC and field devices SCADA/HMI Systems Administration User account set up Security profile/access right set up Engineering & Operator station configurations

SECTION 2.5 Distributed Control Systems, DCS

OVERVIEW The training provides an understanding of the fundamentals of Distributed Control Systems (DCS). The evolution of computer control systems is discussed and the architecture of contemporary DCS is described in detail. The lesson covers hardware, configuration, data communications, user interface and I/O devices.

COURSE CONTENT Introduction to DCS operation DCS System Architecture DCS CPU-Processor Hardware Configuration I/O Modules Communication Modules I/O Wiring Techniques Profibus Master / Slave Optical Module Bus
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Distribution node A-Configuration Distribution node B-Configuration

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CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

DCS CPU Programming Instruction set programming CPU Settings CPU Addressing Nodes Addressing Downloading/uploading Functional System Monitoring

- System Diagnosis Operator Interface Working with Navigations SCADA portal Detailed designing Face/points Alarm/Trends/Events OPC/ODBC Controller Interface Screen Designing Controller Interface

HMI System Design & Programming

- Upload/Download Communication Protocols PAC Hardware configuration I/O Modules I/O Wiring Troubleshooting Simple & Complex Programming CPU Addressing I/O Addressing Upload & download Monitoring/fault finding Positioning functions High speed counter Ethernet Modbus Profibus Optical Module bus Fieldbus

- PID Control Real time interface Process control 2-Axis motion control

- Servo drive/motor - Encoder

SECTION 2.6 Process Automation (DCS Production Plant Operation & Performance Management of Process Models)
OVERVIEW Day by day monitoring of plant performance is very important in a process control system. Because of inherent risk common on production and manufacturing plants, more especially when the process variables and values are tampered with, operators find it difficult to be trained on live plant. Process simulation software is therefore a substitute. This course provides an understanding of the fundamentals of Process Control Systems, Process Variables & Values, Instrumentation, and Distributed Control Systems (DCS) i.e. Process monitoring and Control with Yokogawa CS3000 operator station. Processes like the following, amongst others stated in the contents bellow will be covered; Distillation Column, Gas & Steam Plant monitoring, Centrifugal compressor, Crystallizer, Fixed Bed Reactor, etc.
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CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

COURSE CONTENT Introduction to Process Control Systems and Instrumentation. Introduction to Process Variables and Process Values. Architecture of DCS. Field control stations Safety control stations Advantage of DCS over PLC Scope of DCS in the field of Automation. Human interface stations & engineering stations Basic Process Models o Centrifugal compressor o Crystallizer o Cyclone separator o Distillation column o Evaporator o Flash drum o Gas turbine o Heat exchanger o Heater o Plug flow reactor o Centrifugal pump o CSTR o Fixed bed reactor o Superheated steam generator
o Co-generation

boiler

Control Models On off level controller On off temperature controller P & PI controller on flow Pressure controller Level transmitter and controller Direct and cascade control Split range pressure control Ratio control Feed backward and forward control Three element boiler control Control valve characteristics Characteristics coefficient of control valve Study of rangeability of control valve Interacting and non-interacting level system basic instrumentation troubleshooting system

SECTION 2.7 Industrial Communication System

OVERVIEW This course will show the ideas and basis that support the communications between Industrial Digital Devices, mainly between them and field devices or supervisory systems.

COURSE CONTENT Concept of Data Communication Serial Communication- Technologies and Applications LAN Technologies Process Control Network and Data Security Working with communication protocols: RS232/485, MODBUS, OPC, PROFIBUS, ETHERNET, CONTROLNET, DEVICENET, etc Proprietary PLC/DCS Networks
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CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

Databases Plant Information Security System Wireless Data Transmission Class Exercise

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