Modern Distributed Control System (DCS) and PPB Maintenance Course

Introduction:

This lesson introduces the general maintenance requirements of a distributed control system (DCS). It covers troubleshooting techniques using DCS self-diagnosis and the various diagnostic displays available to the technician as well as safe and proper component replacement procedures for cards, modules, and power supplies. The lesson also covers DCS peripheral equipment including disk and tape drives and uninterruptible power supplies (UPS).

Course Objectives:

By attending this online training course, the delegates will be able:

• Identify proper tools and test equipment for troubleshooting
• Interpret diagnostic software from the operating console and the engineering workstation
• Demonstrate proper troubleshooting methods
• Identify typical communication malfunctions
• List symptoms of communication faults
• Identify a proper cable connection
• List indications of power supply failure
• Check power supply voltages

Who Should Attend?

This course is designed to provide Knowledge of automation using distributed control. Control Engineers, Electronic Engineers. Instrumentation Engineers, Electrical Engineers, Process Engineers Technologists, and technicians in supervisory positions would benefit from the material presented. The course is a high level and covers the broad spectrum of distributed control system technologies and implementations. High-level troubleshooting will be possible from the knowledge gained from this course. 

Course Outlines:

Review of Process Control and Introduction to DCS

• Review of sensors, instrumentation, and process control systems
• Control Algorithms
• Proportional (P)
• Proportional and Integral (PI)
• Proportional, Integral, and Derivative (PID)
• Distributed Control Systems: Introduction
• Overview, Features, Advantages, Were used
• Functions, Architecture, I/O, components,
• Hardware, software, system interfacing
• Programmable Logic Controller (PLC) – a brief overview
• supervisory control and direct digital control
• Supervisory Control and Data Acquisition (SCADA) – a brief overview
• DCS, PLC, and SCADA compared

DCS Configuration and Networking

• Distributed Control Systems: Structure and Configuration
• DCS block diagrams, components, architecture, redundancy concepts
• DCS hardware configuration
• DCS Hardware & Software Internals
• Process variables, software variables, tags
• Human Machine Interface (HMI)
• Alarms, Trends
• Databases
• Basic DCS Controller Configuration
• Sequential Controllers for Batch Processing
• Controllers for Continuous Processes: Function Blocks
• Hierarchical Structure of control systems: ISA-95
• Data Communications and Networking
• Signal Transmission
• Physical Network Structures
• Logical Network Structures
• Communication Standards
• Fieldbus Operation: Foundation Fieldbus, Profibus
• Wide Area Network (WAN) communications: Modbus
• Control in the Field (CIF)
• DCS applications and case study (Oil & Gas)

HMI, Alarms, and DCS Operation

• Human Machine Interfaces: Introduction, features, requirements
• Plant mimic and animation
• DCS Operator Stations
• Interface Categories
• Recorders, Loggers, Trend Displays, and Data Archiving
• HMI in the Control Room and in the Field: Mobile and remote devices
• Alarm Management
• Key Requirements
• Alarm System Functions
• Alarms philosophy, control & Management
• Development and Applications, Logs, trends, and reports
• DCS Operation
• Operational view of DCS
• Role of operators
• Integration and Optimization of DCSs
• DCS Configuration
• DCS Integration

Maintenance and Troubleshooting

• Maintenance Considerations
• Maintenance Requirements: System and Components
• Procedure for Checking Control Loop Calibration
• Identify proper tools and test equipment for troubleshooting
• Proper troubleshooting methods
• Identify typical communication malfunctions and faults
• Identifying failures, malfunctions, and faults
• Diagnostics through DCS Modules, and Programs (code)
• Diagnostics through Internal internal Variables and Bits of DCS
• Diagnostics of Communication faults

Process Control

• Advanced Process Controllers
• Feedforward Control
• Cascade Control
• Statistical Process Control
• Basics of advanced process control and optimization
• Latest DCS Trends
• Monitoring and control in the Field
• Industrial Internet
• Internet of Things
• Mobile and remote devices
• Monitoring and control in the Cloud
• Cloud Processing