CPAE - Cipprap.incipprap.in/details/images/download/CPAE.pdfCentrifugal Compressor Centrifugal Pump Heat Exchanger Flash Drum Gas Turbine Furnace Evaporator CSTR Plug Flow Reactor

INDEX

2 Brands of PLCs

(Keyence & AB)

1 Brands of SCADA

(Wonderware Intouch)

Pneumatics & Field Instruments

PROCESS AUTOMATION

Distillation Column

Superheated Steam Generator

Centrifugal Compressor

Centrifugal Pump

Heat Exchanger

Flash Drum

Gas Turbine

Furnace

Evaporator

CSTR

Plug Flow Reactor

Fixed Bed Reactor

Cogeneration Boiler

CPAE

CERTIFIED PROCESS AUTOMATION ENGINEER

Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:

9551232896

Basic Introduction & Evolution of automation

Discussion about automation in industry

History of automation

Futures and application of automation

Automation tools explanation

Basic hardwire relay logic development & real time practice

Automation HEART DEVICE control of relay concept

Electrical concept of hardwire relay logic development

Live practice on hardwire logic in relay panel

Assignment based on digital logic and Boolean equations using relay

Introduction of PLC architecture and input / output system in various industries

General block diagram of PLC architecture

Explain input / output field instrument in industries

Explain various standard PLC and software used in industries

Explain various PLC programming method used in industries

Derive the ladder logic program using hard wire relay logic concept

Digital logics gates & Boolean concept

Flip-flops & latching

concepts in ladder Programming based on k-map rules

Assignment based on real time applications

Online Exams on above Topics

COURSE CONTENT

BASIC AUTOMATION INTRODUCTION AND HARDWIRE RELAY LOGIC DEVELOPMENT



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Introduction of Keyence PLC software [ladder builder] and addressing of

Input / output system

Specification and features of Keyence PLC

Addressing of input / output system and memory mapping

Live practice on Keyence PLC programming tools software [ ladder builder ]

Assignment based on real time applications

Explain the application of timer [delay function] in automation industries

Explain the role of timer in industries

Various type of timer and its application

Programming based on timer and live practice in Keyence PLC software

Assignment based on timer applications

Explain the usage of counter function in automation industries

Differentiate the timer & counter function in PLC software and its usage

Various type counter and its application

Programming based on timer / counter and live practice in Keyence PLC software

Assignment based on counter applications

Upload / download the program and online monitoring in Keyence PLC panel

Communication detail between Keyence PLC and programming tool software in PC

Procedure of upload / download the program in Keyence PLC

Online monitoring and practice of programming tools software in Keyence PLC panel

Assignment based on Keyence PLC series and its evolution

Industrial standard of PLC panel Erection, commissioning & Trouble Shooting

Basic requirement of PLC panel designing and its apparatus tools

Draw the electrical wiring diagram of Keyence PLC panel and trouble shooting

Explain the [ source/sink ] type of digital input /output

Assignment based on electrical wiring on PLC panel used in industrial application

PLC PROGRAMMING DEVELOPMENT AND CONTROLS PANEL ERECTION & COMMISSIONING

TROUBLESHOOTING USING KEYENCE & OMRON PLC

KEYENCE PLC



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Live practice on PLC panel wiring and application development

Examining the field input devices to PLC panel

Verifying the field output devices from the PLC panel

Design and development of real time industrial projects

Assignment based on complete PLC project solution


AB PLC:

Industrial & Evolution of AB PLC and its programming tool software practice

Evolution and specification of AB PLC

Addressing Input / Output and memory mapping in AB PLC

Working in AB PLC programming tools software

Configuration of timer & counter and its application practice

Live practice on AB PLC panel explain Special Instruction sets & application development

Draw the electrical wiring diagram of AB PLC panel and troubleshooting

Practice on special instrument in AB PLC programming tool software

Procedure of upload / download and communication details between AB PLC panel and

programming tools software

Assignment based on real time application development in AB PLC panel

Overview of Industrial Field Instrument and explain field pneumatic control

System

Evolution of analog control system in industry

Explain pneumatic control system and its application usage in industry

Tools requirement of pneumatic control system and erection and commissioning

Connection between pneumatic field device to AB PLC panel and its configuration

Live practice on pneumatic control application using level control system

(PID control Algorithm)

Configuration of analog Input / Output module in AB PLC panel

Explain discrete of continuous control method used in level control system

Describe PID control algorithm and its configuration in AB PLC panel

Live demo on tank level control system interface with AB PLC panel and practice



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Level / Temperature / Pressure

Process Control Using AB PLC

Special input module configuration (RTD, Thermocouple) in AB PLC and its real time

application development and practice

Explain various temperature measuring instrument in industry and its feature

Configuration of special Input module [RTD, Thermocouple] in AB PLC panel

Explain temperature controlling method in industry and its application development in AB PLC

panel

Assignment based on temperature control loop in AB PLC panel and SCADA design in

Wonderware INTOUCH

Interfacing of operation work station in AB PLC with SCADA Wonderware INTOUCH and

application development

Interfacing between AB PLC and Wonderware INTOUCH and its drives configuration and

addressing

Live practice and online testing of tag signal in Wonderware INTOUCH to AB PLC panel

Designing of operator workstation in Wonderware INTOUCH SCADA for tank level control

system and temperature control loop in industry

Assignment based on continuous process application in industry


Feed Forward Method

Feed Back Method

Cascade

Ratio

Introduction of Wonderware INTOUCH SCADA system & design the industrial

Application development

Introduction of Wonderware INTOUCH SCADA system and its live demo application

Create tag name & data base and graphical object properties

Explain real time PLC I/O drive and configuration

Assignment based on application design

LIVE INDUSTRIAL PROJECT

INTOUCH SCADA



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Historical & real time trends monitoring and alarm events configuration

Explain alarm event configuration

Explain real time trend display

Explain historical display configuration

Assignment based historical display application

SCADA script programming and ODBC [using MS-ACCESS] & DDE [using MS-EXCEL]

Connectivity in INTOUCH SCADA

Explain SCADA script programming

Explain DDE [Dynamic Data Exchange using MS-EXCEL] connectivity

Explain ODBC [Open Database Connectivity MS-ACCESS] connectivity

Assignment based on DDE & ODBC connectivity

Recipe management and I/O drive configuration

Explain recipe management system and configuration

Live practice & assignment based on recipe management system

I/O drive configuration and its procedure

Various example of industrial application using recipe management system

Interfacing of AB PLC panel to Wonderware INTOUCH SCADA SYSTEM

Communication parameter setting between AB PLC and Wonderware INTOUCH

AB PLC input /output and memory mapping for real time tag creation in Wonderware

INTOUCH

Communication cable details and protocol information

Assignment based on industrial application

Live project development and practice on AB PLC & Wonderware INTOUCH SCADA

SYSTEM

Explain various project used in AB PLC

Explain how to make project documentation

Live project development and practice




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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a distillation system

To provide opportunity in identifying the main equipments associated with distillation

systems.

To describe the operation of Depropanizer column.

To learn about the startup and shutdown process.

To respond safely and efficiently for disturbances and malfunctions in the process.

To understand how temperature and pressure affect the operation of a distillation tower.

CONTROL SCHEME

Depropanizer Feed Flow Controller

Depropanizer Reflux Feed Flow Controller

Depropanizer Top Product Feed Flow Controller

Depropanizer Level Controller

Reflux Drum Level Controller

Depropanizer Pressure Controller

Depropanizer Bottom Temperature Control

PROCESS DISTURBANCES

Change in Depropanizer Feed Flow

Change in Feed Composition

Change in Feed Temperature

Change in Reboiler Steam Flow

Change in Depropanizer Pressure

Change in Depropanizer Reflux Flow


PROCESS AUTOMATION

DISTILLATION COLUMN



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a Superheated Steam Generator.

To describe about the operation of Boiler

To learn about the startup and shutdown process

To respond safely and efficiently for disturbances and malfunctions in the process

To know how temperature and pressure affect the operation of Superheated Steam

Generator.

CONTROL SCHEME

Feed Drum Level Controller

Deaerator Pressure Controller

Deaerator Level Controller

Three Element Boiler Control


Change in FG and FO supply Pressure

Change in Steam header Pressure

Boiler Feed Water Supply ( to Deaerator ) Pump failure

Boiler Feed Water Supply ( to Steam Drum ) Pump failure

Water Supply ( from mud drum to steam drum ) Pump failure


SUPERHEATED STEAM GENERATOR



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TRAINING OBJECTIVE

To teach trainees and to recognize understand the operating fundamentals of a Compressor.

To describe about the operation of Compressor.

To learn about the startup and shutdown of the process using documented procedures.

To respond safely and efficiently to disturbances and malfunctions in the process.

CONTROL SCHEME

Important control scheme available in this unit is Anti-surge controller which creates a spill

back from the outlet of the compressor to the inlet to avoid compressor surge.


Feed Gas Failure

Compressor Failure

Fail Cooling water supply

Change in Feed Gas Temperature

Change in Molecular weight

Change in Feed Supply Pressure

Change in Compressor RPM


CENTRIFUGAL COMPRESSOR



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a Centrifugal Pump.

To create a virtual environment for the trainees to understand various functional aspects of

the equipment, normal operating conditions.

To learn about the changes in the input parameters and their corresponding response in the

output.


CONTROL SCHEME

Feed Water Level Controller in the Drum

Minimum Recirculation Line flow Controller


Change in Vapour Pressure of feed

Change in Specific Gravity of Feed

Change in Pump RPM

Change in Discharge of Pump to Head

Change in Pressure of the Tank on Head


CENTRIFUGAL PUMP



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a heat exchanger

To portray all the design parameters and variation of them with respect to process

conditions.

CONTROL SCHEME

The Temperature Controller to maintain the hot fluid outlet temperature of the heat

exchanger


Change in type of Cold and Hot fluid (Deg API & Boiling Point)

Change in Inlet Temperature ( Cold and Hot side)

Change in Dirt factor ( Cold and Hot side)

Change in Specific Gravity ( Cold and Hot side)

Change in Inner Diameter ( Shell and Tube side)

Change in Baffle Spacing (Shell and Tube side)

Change in Number of passes ( Shell and Tube side)

Change in Tube Pitch

Change in Length of Tube

Change in Number of Tubes

Change in Flow area per Tube

Change in Surface Area per Linear Length


HEAT EXCHANGER



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TRAINING OBJECTIVE

To teach the trainees the operating fundamentals of the Flash drum.




output and design.

CONTROL SCHEME

A Pressure controller is used to maintain the Flash drum pressure.

A Level Controller to maintain the level of the Flash Drum.


Change in Inlet feed flow rate

Change in feed composition


FLASH DRUM



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a gas turbine system.

To provide opportunity in identifying the main equipments associated with gas turbine.


To respond safely and efficiently for disturbances and malfunctions in the process.

To understand how temperature and pressure affect the operation of a gas turbine unit.

CONTROL SCHEME

Load Speed Controller to maintain the speed of the governor in power transmission unit.

Steam Temperature Controller in Desuperheater.

Steam Flow Controller in Desuperheater.

Water Level Controller in Steam Drum.


Change in Ambient Temperature

Change in GT Oil and Gas supply Pressure

Change in Grid KV and Frequency

Change in Feed water supply Pressure and Temperature

HRSG Fuel Burner failure

Lube Oil pump trips

Diesel Engine Starter failure

GT Fuel Burner failure

Circuit Breaker and Exciter failure


GAS TURBINE



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a heater.

To portray all the design parameters and variation of them with respect to process

conditions.

To respond safely and efficiently to disturbances and malfunctions in the process

CONTROL SCHEME

Furnace outlet Temperature Controller

Fuel Gas Supply Pressure Controller

Air Supply Hand Controller


Change in Feed Gas Temperature

Change in Feed flow

Change in Fuel Gas Calorific Value


FURNACE



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TRAINING OBJECTIVE

To teach the students about various operating fundamentals and the design of an Evaporator.




output and design.

CONTROL SCHEME

A Temperature Controller is used to regulate the flow of steam depending upon the

temperature of the outlet sugar syrup.

A Pressure Controller is used to regulate the flow of vapor generation.

A Hand Controller is used to increase or decrease the feed flow.


Change in Feed Inlet temperature

Change in Feed flow rate

Change in Inner Diameter (ID)

Change in Outer Diameter (OD)

Change in Tube Pitch

Change in Number of Tubes

Change in Number of Passes

Change in Length of the Tube

Change in Flow Area per Tube


EVAPORATOR



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a Continuous Stirred Tank Reactor



To learn about the startup and shutdown process.


output.


CONTROL SCHEME

Reactor Temperature Controller

Reactor Level Controller

Reactant A supply Hand Controller

Reactant B supply Hand Controller


Change in Inlet Pressure of Reactor

Change in Cooling Water Supply

Change in Order of reaction

Change in feed inlet temperature

Change in feed flow ( A & B)


CSTR



9551232896

TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a Plug Flow Reactor.

To provide opportunity in identifying the main equipments associated with Plug Flow

Reactor




Change in Conversion (Adiabatic)

Change in Order of the reaction (Isothermal)

Change in Feed Flow Rate (Isothermal)

Change in Inlet Temperature (Adiabatic and Isothermal)

Change in Initial Concentration (Adiabatic and Isothermal)


PLUG FLOW REACTOR



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TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a Fixed Bed Reactor.

To provide opportunity in identifying the main equipments associated with Fixed Bed

Reactor


CONTROL SCHEME

Two Temperature Controllers to maintain the Bed Temperature


Change in Hydrogen Flow

Change in Catalyst Activity

Change in Feed inlet Temperature


TRAINING OBJECTIVE

To teach trainees the operating fundamentals of a Co Generation Boiler



To know how temperature and pressure affect the operation of Co-Generation Boiler

CONTROL SCHEME

Feed Drum Level Controller

Deaerator Pressure Controller

Deaerator Level Controller

Three Element Boiler Control

FIXED BED REACTOR

COGENERATION BOILER



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Change in FG and FO supply Pressure

Change in Steam header Pressure

Boiler Feed Water Supply ( to Deaerator ) Pump failure

Boiler Feed Water Supply ( to Steam Drum ) Pump failure

Water Supply (from mud drum to steam drum) Pump failure


Documents

CPAE - Cipprap.incipprap.in/details/images/download/CPAE.pdfCentrifugal Compressor Centrifugal Pump Heat Exchanger Flash Drum Gas Turbine Furnace Evaporator CSTR Plug Flow Reactor