Process control and automation training Training solutions · Process control and automation training ... practical simulation of a wide variety of instrumentation ... • The meaning

Process control and automationtrainingTraining solutions

Products Solutions Services

Training Solutions

3Contents

Contents

4 Introduction

5 Our facilities

6 Main training area

9 Outline of training courses and modules

10 Training courses and modules: TC1001



16 Customised training courses

17 Getting to Endress+Hauser

18 Course schedule

Introduction

4 Training solutions

In today’s competitive marketplace, a well-trained and motivated work force is vital. Investing in employees ensures the continued success of your company.

Training within Endress+Hauser focuses on LEARNING, not on TEACHING. “The goal is NOT that the trainees just participate in a training course, but that they really learn something.”

Situated in our purpose-built Sandton offices, our new training centre and programs are ready to offer technical training courses to industry and educational establishments.

Whether it’s helping your staff understand the measurement principles, installation requirements, set up of instruments at commission time or teaching advanced diagnostics and long term asset management, we have the facilities and the expertise to work with you to meet all of your training requirements.

Research of learning theory for adults shows several criteria which

help to improve the knowledge retention rate during a training course. One major aspect is active training methods rather than just lecture style presentation. Thus, the training courses focus on an active participation of the trainees whereby all the theoretical modules are supplemented by hands-on workshops and discussions. On-going assessments give the participant timely feedback on his or her progress and / or any weaknesses.

Endress+Hauser is launching a series of standard training courses. The content is designed to help at all levels, ensuring that your staff are knowledgeable and competent to work on the valuable asset represented by your instrumentation and control equipment.

As well as offering standard training courses at our office in Sandton we can offer customised courses to suit your own particular requirements plus our training team can come to you if required.

Chris GimsonTraining ManagerEndress+Hauser (Pty) Ltd

[email protected]+27 11 262 8087+27 60 9766 380

Our facilitiesWhat we offer at our offices in Sandton

• A 98-seater auditorium fitted with state-of-the-art audio-visual equipment.

• Additional training rooms with full audio-visual equipment

• An environment where you can learn to maintain, diagnose faults and reprogram instruments at your own pace with a wide range of individual process instruments including power supplies, test equipment and measurement evaluation tools

• Product demonstration plinths

• wazzup Café refreshment area and meeting room facilities.

• Secure car parking

• Facilities for the physically disabled

5Facilities

Main training area


A Universal Training Rig (UTR) that is designed to simulate a real process environment

7Universal Training Rig (UTR)

several level meters including interface measurement to show the differences in handling and performance. A pH dosing station can change the pH value in the mixing tank. From the mixing tank the emulsion can either be pumped around a loop or into a gravity separator, and back to the storage tanks.

The fully equipped rig is designed to allow the trainee to understand the operation of different measurement technologies under real-life conditions. Also the appropriate selection, sizing, and installation of the field instruments to suit the application are of importance and are extensively covered in the theoretical training.

Extensive setup and programming of the field instruments will be carried out creating an understanding of the different parameterisation requirements for different measuring technologies not only under “ideal” but also under difficult process conditions.

The three process control techniques (PID) can be demonstrated individually and combined through various exercises with control loops on the rig: pressure, temperature, level, flow, density.

Instrumentation The UTR is equipped with a variety of process measuring sensor technologies in order to offer the trainees the possibilities of different hands-on experiences.

Control system The processes are controlled by an embedded Programmable Logic Controller (PLC) and communication between the field instruments and control system is a mixture of 4-20 mA and digital signals, collected by a remote input/output system and then transmitted to the PLC via Profibus DP.

Control Loops The level in the mixing tank can be controlled by different level instruments, selectable via the PLC screen. Flow from the storage tanks to the mixing tank canbe controlled via a Coriolis flow meter for oil and an Electromagnetic flow meter (Mag Meter) forwater acting on the relevant pumped line.

The UTR is a purpose-built completely functional and practical simulation of a wide variety of instrumentation and measuring processes. The design has included as many different field sensors and corresponding control loops as possible. The UTR does not emulate a production process of any specific industry, but includes the frame conditions in a way to offer a variety of training topics relevant to most industries.

The basic concepts of the rig are a mixing application of water and oil with a subsequent separation of the two media or to simply utilise either of the liquids singularly. As the rig consists of two tanks holding the water and the oil, both liquids can be pumped separately or together, according to a definable density, into the mixing tank.

To simulate entrained gas in the liquid, compressed air can be injected into the fluid. The mixing tank is equipped with

Software The Human Machine Interface (HMI) is part of the PLC and offers visual information about the process conditions as well as the option to change set-points or to select different instruments for control. An alarm server is also part of this HMI.

The oil/water ratio can be controlled by a cascade controller and the density of the emulsion either via a Coriolis flow meter or a vibrating fork device, both of which are acting on the oil line.

The temperature in the mixing tank is controlled by a temperature sensor linked to a heating element. The pH value in the mixing tank can be controlled by a pH

sensor either in the pipe or in the vessel and the dosing point of caustic and acid can be selected between the pipe and the vessel.

The pressure in the pipe to the mixing tank can be controlled by a pressure device acting on a control valve.

Content focus The “Universal Training Rig” used throughout the course is designed to present the operation of different measurement technologies under real-life conditions. Also in real life, the appropriate selection, sizing, and installation of the field instruments are of critical importance for successful operation. Extensive setup and programming of the field instruments is therefore carried out creating an understanding of the different parameterisation requirements for different measuring technologies not only under “ideal” but also under difficult process conditions.

The different features ofLife Cycle management(LCM) will bedemonstrated withthe Internet based toolof the W@M suite i.e.operation activities aswell as maintenance andrepair.

Training methodology All courses consists of both theoretical lessons and hands-on exercises focusing on a learner centered approach to ensure a high and sustained impact of the training session. For this reason the maximum number of participants is limited to 6.

Theoretical and practical assessments as part of the training course ensure that the training objectives are met.


9Outline of training courses and modules

Outline of training courses and modulesProcess measurement and instrumentation

TM2000

TM2000

TM2005

TM2020

TM2005

TM2001

TM2001

TM2007

TM2031

TM2007

TM2002

TM2002

TM2008

TM2032

TM2008

TM2003

TM2003

TM2009

TM2009

2 hours

2 hours

2 hours

2 hours

2 hours

2 hours

2 hours

1 day

1 hour

1 day

2 days

2 days

1 day

2.25 hours

1 day

2 days

2 days

1 day

1 day

P&ID Diagrams

P&ID Diagrams

Temperature Measurement

Thermocouple & RTD sensor types

Temperature Measurement

Software tooling (Applicator & FieldCare)

Software tooling (Applicator & FieldCare)

Control

Temperature transmitters

Control

Level Measurement

Level Measurement

Oil Application

Temperature sensors and thermowells: practical selection guide and common mistakes

Oil Application

Flow Measurement

Flow Measurement

Density Measurement

Density Measurement

TC1001 – Total duration 5 days




5 CPD points

4 CPD points

2 CPD points

9 CPD points

Title

Title

Title

Title

Duration

Duration

Duration

Duration

Module reference

Module reference

Module reference

Module reference

Custom training courses can be created using the above individual modules to suit your own requirements (minimum 4 trainees).

Contact Chris [email protected] discuss your requirements

TM2004

TM2004

TM2010

TM2033TM2034

TM2010

2 hours

2 hours

3 hours

1 hour3 hours

3 hours

Pressure Measurement

Pressure Measurement

Digital Communications & Plant Asset Management

Calibration, PER & other value added servicesBuild your own temperature sensor

Digital Communications & Plant Asset Management

TC1001: Process measurement and instrument configuration I

Learning objectives

Pre-requisite for course Delegates should have some basic experience of their plant processes and instrumentation used.

Target Groups Project engineers and management, Instrument technicians, Factory engineers and management, Quality technicians and management.

Benefit Get a comprehensive view of different measurement technologies, their strengths, weaknesses and selection criteria. Study the different components and learn their specific characteristics with the help of working models. Practical exercises in reading P&I diagrams will enable you to discuss the best selection of technology and field devices in relation to the “best fit for purpose” with users in an automation project.

Course content This course involves all elements of process instrumentation, basic measuring principle,selection, installation, setup, operation and device exchange. The course layout is designed so that the participant receives both practical experience with hands on exercises and theoretical knowledge via class room tutorials. Even during the theoretical session we useactive teaching methods to integrate the training in an effective way.

Course format The course is delivered as one block of 5 days, or 2 blocks of 2 and 3 days respectively

Pipe & Instrument Diagrams (P&ID):• P&ID: Flow chart, P&I diagrams• The meaning of the flow diagram• The meaning of the P&ID symbols• The meaning of the P&I diagram• Determination of all of the main components of the training rig• Determination of all of the control loops on the training rig• Identification of each measuring point and measuring principle on

the training rig

Software tooling (Applicator and FieldCare):• Know and understand the FDT/DTM (Field Device Tool / Device Type

Manager) technology • Features of the Endress+Hauser software tool FieldCare• The differences between local configuration at the display and

remotely via FieldCare• Configuration of a field device using FieldCare• Selection of the correct measuring principle and instrument for

a particular application using the Endress+Hauser software tool Applicator

• The features of Applicator and how to use them• How to determine the correct sizing for a flow meter in a specific

application using Applicator

Ref. TM2000

Ref. TM2001

@-computer mouseApplication:Website links

PersonApplication:Personnel messages, personal portraits

Info-iApplication:Infoboxes

Play ButtonApplication:Video clips

Exclamation markApplication:Important notices/information

ArrowApplication:Links to other sections or publications

Check markApplication:Product advantages

Speech bubbleApplication:Interviews, quotes


Level measurement:• Capacitive, hydrostatic, ultrasonic, radar, vibronic• The different technologies for level measurement• The different applications for level measurement• The different technologies being employed on the UTR• The characteristics of these technologies and their strength and

weaknesses• The importance of the application and process conditions for the

selection of the correct measurement technology• The installation of a sensor in the field• The assessment of whether a device is installed correctly• The configuration of a hydrostatic level meter directly via the display

& keyboard and remotely via FieldCare, for different mounting positions

• The configuration of a “time of flight” level meter directly via the display and keyboard and remotely via FieldCare, with different obstacles in the measuring beam

• How to determine the important application parameters

Flow measurement:• Coriolis, ultrasonic, electromagnetic, vortex, thermal and differential

pressure (dp). Each measurement principle and the limitations of each technology

• The importance of the application and process conditions as it pertains to the selection of the correct measurement technology; determining which technology fits the application

• The configuration of a flow device directly via the display and keyboard and remotely via FieldCare

Calibration • What is normative basis?• What is calibration?• The differences between accuracy, linearity and uncertainty• The differences between repeatability and reproducibility• The relevant international standards and what they mean• The meaning of accreditation• The differences between national, reference and working standards• The meaning of traceability

Pressure:• The basics of pressure measurement and the available sensor

technologies• The differences between absolute, gauge, differential and

hydrostatic pressure• The differences between ceramic and metallic sensor cells• Configuration of a pressure device directly via the display and

keyboard and remotely via FieldCare • Determination of the most suitable installation position

Ref. TM2002

Ref. TM2003

Ref. TM2004

11Training course TC1001

TC1002: Process measurement and instrument configuration II

Learning objectives

Pre-requisite for course Successful completion of course TC1001.

Target Groups Project engineers and management, Instrument technicians, Factory engineers and management, Quality technicians and management.

Benefit Building on the first course, the different measuring technologies of Temperature pH and Density are examined, their strengths and weaknesses and instrument selection criteria. You will study the different components and learn their specific characteristics with the help of working models employing PID and fixed term control elements with flow, level, pH, temperature and interface measurements. Practical exercises in reading P&I diagrams will enable you to discuss the best selection of technology and field devices in relation to the “best fit for purpose” with users in an automation project. You will be introduced to the concept and practicalities of Plant Asset

Management, an often overlooked aspect of managing plant maintenance and planning existing and future requirements.

Course content The course modules involve all of the elements of process instrumentation, basic measuring principles, selection, installation requirements, setup, operation and device exchange (maintenance and repair). The course layout is designed so that the participant receives both practical experience with hands on exercises and theoretical knowledge via class room tutorials. Even during the theoretical sessions, the trainers use active teaching methods using the UTR and follow through with assessments to maximise the impact of the theoretical content and reinforce its absorption by the trainee.

Temperature:This module introduces temperature sensors and a temperature control loop. • Resistive temperature detectors (RTD) and thermocouple sensor

types and their basic operating principles• Configuration of a temperature transmitter directly via the display

and keyboard or remotely via the Endress+Hauser software tool FieldCare

• Common temperature sensor selection problems and how to avoid them

Pressure II. Ref. TM2007This module introduces a pressure control loop

Control loop• The different components of a control loop• How to analyze the dynamic of a system (step response)• The difference between open and closed control loops and the

difference between self-regulating and non-self-regulating systems• The different elements of a PID controller and be able to do a basic

tuning of a PID control loop (tangent method)

Control valve• The basic operation principle of a control valve

Frequency inverter• The basic operation principle of a frequency inverter• How to determine when a control valve or a frequency inverter

should be used

Ref. TM2005

Ref. TM2007

Course format The course is delivered as one block of 4 days, or 2 blocks of 2 days










Oil application:This module offers the possibility to add an oil layer on the water for interface measurement in the mixing tank. In addition with a cascade control, a water/oil mixture can be produced – first the flow of water will be selected and then the required ratio of oil.• The influences of different media on the device configuration• Configure a guided radar sensor for interface measurement

Density:• Density measurement with different techniques: Coriolis, vibronic,

gamma• Configuration of a density measurement loop with Coriolis• How different application conditions influence the measurement and

selection of the measurement principle• Comparison between a density measurement system with the

Vibronic technique and Coriolis flow meter

Plant Asset Management:

Digital communication• The most important digital communication protocols used in process

industries• The most important advantages and disadvantages of each

technology

Life Cycle Management (LCM)• The different communication options from FieldCare• The meaning of Plant Asset Management• The meaning of Life Cycle Management• Finding the necessary system documents by using W@M

Ref. TM2008

Ref. TM2009

Ref. TM2010


TC1004: Understanding of temperature measurement principles and sensor selection

Learning objectives

Pre-requisite for course Delegates should have some basic experience of their plant processes and instrumentation used.

Target Groups Project engineers, Instrument technicians, Plant engineers, buyers and quality technicians.

Benefit Our Production Centre in Benoni, Johannesburg houses our local Centre of Competence for Engineered Temperature Solutions as well as a wide range of standard products, including a SANAS approved calibration laboratory.

Course content• Introduction to basic temperature measurement • RTD’s • Thermocouples• Introduction to temperature transmitters • Products • Technologies • Benefits of transmitters• Process discussions • Understanding product make up • Materials of construction • Process connections • Specifications and measurements of a thermowell • Sizing of thermowell• Understanding calibrations and accuracy requirements• Build your own sensor and gain an understanding of the

manufacturing processes.

By attending this course you will learn the basic principles of operation of RTD’s and thermocouples, leading to an increased understanding of application suitability.

You will increase your knowledge of sensor construction, including selecting of correct lengths and dimensions for inserts and thermowells, diameters of sensors, process connections, housings, terminations and many other attributes of a temperature sensor.

Gain insight into how the sensor signal is transformed into an analogue or digital signal for retransmission. Also increase your knowledge of temperature transmitters and when to use which type.

Finally, gain insight into the accuracy of sensor and transmitter, an understanding of sensor-transmitter matching and also understand the necessity for calibration.

Build your own sensorAs part of the course assessment you will be required to “build your own sensor” by putting theory into practise. This will reinforce what you have learnt during the two days, and provide you with the opportunity to build your own sensor which you can take away with you.

Course format The course is delivered as one block of 2 days










Venue details Endress+Hauser Pyrotemp,Cnr. Rotterdam Rd and Milan Place,Apex extension 3, Benoni

GPS coordinatesDigital -26.211586, 28.331553DMS S26° 12’ 41” E28° 19’ 53”


People provide an essential contribution to your company’s overall performance. This is all the more true for people who are invested in production processes and maintenance.

Endress+Hauser trainers put all of their expertise at your disposal, helping you to produce more, at a higher quality, in a safe and profitable manner. Apart from the scheduled standard training courses with the Universal Training Rig, additional customised training is available for subjects according to your specific needs.

Training is essential to fulfil your commitments: • It allows you to get the best from your measurement

devices and thereby optimising your investment• Thanks to a better knowledge of the instrumentation’s

behaviour, your technicians will be able to minimise downtime

• A better knowledge of appropriate maintenance methods will contribute to make your assets durable

• Contributes to the up-skilling of your maintenance team

We conduct training sessions to your needs and where it is most convenient (at your site, in your local Endress+Hauser branch or in specialised training centers in Johannesburg). Competent and totally equipped, our trainers ensure an efficient knowledge transfer to your teams.

The training programme will be pre-defined according to your requirements and the entry level expertise and experience of the participants, who will receive supplementary literature and a certificate of attendance. It is recommended that a trainee attends one or more standard training courses before embarking on a higher level customised course.

We provide training for: • Engineers and instrumentation technicians and artisans• Instrumentation plant operators• Maintenance engineers

Basic and advanced training topics include: • Product overview, operating principles and hands-on

knowledge • Parameters, Installation advice • Start-up and maintenance diagnostics • Diagnosing errors and troubleshooting tips • Software tooling for product communication and

practical exercises • Communication protocols such as Profibus PA/DP,

Foundation Fieldbus, HART and WirelessHART (note Profibus and Foundation Fieldbus are non-certified)

Customised training coursesMastering instrumentation and fieldbus networks to maintain your competitive edge

Please contact Marc Piscaer for further discussions regarding your customised training

Marc PiscaerPhone +27 11 262 8051Mobile +27 79 741 [email protected]


Getting to Endress+Hauser

GPS coordinatesDigital -26.090283, 28.075017DMS S26° 05’ 25” E28° 04’ 30”

DistancesFrom OR Tambo International Airport27km, using the highway

From the Marlboro turn-off from the N3 highway4.5km

From Sandton CBD4.9km, via Rivonia Road

GautrainGauteng’s premier high-speed rail service, the Gautrain, runs at regular intervals between Pretoria, Johannesburg and the airport, including a stop in Sandton. A bus from the Sandton station stops on Katherine Street, right up the road from Endress+Hauser. www.gautrain.co.za

Bus route from Sandton stationS2: Gallo Manor. Stop S2-6 or S2-14(Corner Bowling Avenue and Commerce Crescent)

Direction to our offices in Sandton

17Cutomised training

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South Africa

Endress+Hauser (Pty) Ltd 5 Commerce Crescent WestEastgate Ext. 13Sandton, 2090 Tel: +27 (0) 11 262 8000 Fax: +27 (0) 11 262 [email protected]

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Process control and automation training Training solutions · Process control and automation training ... practical simulation of a wide variety of instrumentation ... • The meaning