1.   Process Control System (3 days)

 

§  Control System Concept

§  Instrumentation

Pressure Measurement

Temperature Measurement

Flow Measurement

Level Measurement

Speed Measurement

Position Measurement

Weigh Measurement

• Controller
• Actuator
• Fault Tracking
• Calibration Planning

 

2.   Electrical and Instrumentation Maintenance  (3 days)

§  Introduction

§  Control Base Monitoring (CBM)

§  Inspection Running

§  PM Stop, Scheduled Service

§  Breakdown Maintenance

§  Electrical System : Electrical Current, Transmission & Distribution, Motor Maintenance

§  Instrumentation Maintenance : Control Process Concept, DCS, Instrumentation Activities

 

3.   Generator and Motor Maintenance (3 days)

 

§  Introduction Motor Category

§  Construction of Winding Machine

§  Three Phase Induction Motor

§  Squirrel Cage Induction Motor

§  Slip Ring Motor

§  DC Motor

§  Maintenance Program

§  Stop Inspection for Motor

§  Running Inspection for Motor

§  Motor's Vibration

§  Carbon Brush Performance

§  Generator Synchrony Concept & Category

§  Inspection for Generator Sinkron

 

4.   PLC and DCS (3 days)

 

PLC

§  Control Task Definition

§  Control Strategy

§  Implementation Guidelines

§  The IEC-61131-3 Standard and Programming language

§  Program Organization  and Implementation

§  Discrete I/O Control Programming (Example)

§  Implementation

 

      DCS

• Controller

o   Logic

o   Sequencing

o   Regulatory control (including self tuning, adaptive control)

o   Positioning

o   Weighing

o   Motor Control

 

• Operating Station (HMI/MMI)
• I/O System

o   Digital Input (24VDC, 48 VDC, 220VAC, Etc)

o   Digital Output (24VDC, 48VDC, 220VAC, Free Contact Relay, Etc)

o   Analog Input and Output (0..20mA, 4..20mA, 0..10VDC)

o   Counter Input

o   Weighing

 

• Networking

o   Plant Network (TCP/IP)

o   Control Network (MasterBus300)

o   Field Network (Master FieldBus)

 

• Engineering Station
• Information system

 

5.   Electrical Engineering Maintenance (3 days)

§  Detail process of control system

§  Interlocking System

§  Working Principle of Electric High Tension Equipment

§  Transmission, Motor, Transformer, Switch Gear

§  Working Principle of Electric Low Tension Equipment

§  Distribution

§  Motor

§  Transformer

§  Lighting

§  Air Conditioners

§  Cable Routing

§  Cable tunnel

§  Cable Rack system

§  Wiring Installation

§  Lightning Protection

§  Working principle of Programmable Logic Control (PLC)

§  Controller, Modules, Standard Signal, Programming

§  Working principle of Distributed Control System (DCS

§  Work Station, Operate Station, Field Control Station,

§  Instrumentation and electrical measurement

§  Designing Instrumentation system

§  Mechanical and Electronic System

§  Electrical Distribution System Protection

§  Electrical Power System Analysis

§  Equipment Related Safety Considerations

 

6.   Instrument Configuration and Calibration (3 days)

§     Calibration of transmitters for: weight, T,P, level, and flow

§     Selection of test instruments for a given calibration

§     PID Loops

§     Tuning of PID regulators

§     Development of instrumentation history plans

§     Create a proactive maintenance plan

§     Controlling and changing parameters on programmable transmitters via an instrument bus.

§     Conforming to relevant HSE regulations in connection with calibrations.

§     Analyses

 

7.   Plant Automation and Motor Control (3 days)

 

§     Automation and Motor Control

o        Reliability

o        Quality

o        Energy saving

o        Manpower saving

o        Maintenance

o        Environment

§     Areas of Automation in a Cement Plant

§     Process Automation

§     Process Automation  Components

§     Process Automation  Systems

§     PLC

o        Introduction, History

o        Hardware of Programmable Controllers

o        Structure of a PLC

o        Software of Programmable Controllers

o        Programming a PLC

o        Programmable controller: language presentation

§     Selection Criteria of an Automation and PLC-Control System

§     Automation system

§     Criteria governing the Choice of PLC

 

 

8.   Electrical Practice (3 days)

§  Electrical Theory

§  High Voltage Theory and Practice

§  Design

§  Troubleshooting

§  Maintenance

§  Repair

§  Assembly

§  Equipment Related Safety

9.   Electronics Practice (3 days)

§  Electronics/ Instrument (PLC, DCS)

§  PLC Programming

§  Maintenance of PLC programs

§  Development of new or modifications to, code

§  Computers setting up and interfacing

§  TIS

§  Equipment Related Safety

 

10.       Inspection Techniques and Methodologies (3 days)

§  Basic Inspections Techniques

§  Setting up Inspection Schedules

§  Patrol Inspections of Operation Condition

§  Troubleshooting

§  Equipment Related Safety

 

11.       Control Technique (3 days)

 

§  The Control Loop

§  Dynamic Behavior Of The Process

o        Proportional Factor of the Process

o        Dead Time Element

o        Delay Element

o        Combinations

§  Controllers

o        Different Types of Controllers

o        PID - Controller

o        Analog and Digital Controller

o        Terminology

§  Optimal Settings Of The Controller

o        Stabilization Point

o        Adjustments of the PID Settings

o        Optimal Settings of the Controller

12.       Control Maintenance (3 days)

 

§     Process Control and Process Control Equipment

§     Machinery Surveillance/Protection Measurements

§     Transmission and Signal Handling Principles

§     Process Computers

§     Process Computer Diagnostics

§     Bus Systems

§     Distributed Control Systems

§     Performing required maintenance procedures in routine maintenance, preventive maintenance, and breakdown repair/replacement.

§     Evaluating part replacement and/or repair