PRT 140: Industrial Process Instrumentation I

Industrial Process Instrumentation I is a comprehensive course that identifies the equipment utilized to control process variables and the theory behind their physical operation. Students will learn how these primary measurements are utilized to control physical properties required to safely operate the equipment found in process industries. Students will also learn the basic theories of control logic including proportional control, integral timing, automatic reset and derivative action.


Course Information

Credits: 3

Prerequisites: DEVM 105 Intermediate Algebra or permission of instructor

Instructional Goals

  1.  Identify the role of a process technician with instrumentation and controls.
  2. Explain the terminology utilized by process technicians in describing instrumentation and controls.
  3. Explain safety issues related to process instrumentation and controls.
  4. Explain and demonstrate variables used and measured in process systems.
  5. Explain and demonstrate pressure sensing equipment.
  6. Explain and demonstrate flow sensing equipment.
  7. Explain and demonstrate temperature sensing equipment.
  8. Explain and demonstrate level sensing equipment.
  9. Explain and demonstrate control loops and controllers
  10. Explain and demonstrate basic instrumentation troubleshooting

Student Outcomes

Student Outcomes
Upon successful completion of the course, the student will be able to do the following:
Assessment Procedures
This outcome will be assessed by one or more of the following:
Discuss the historical significance of process control in industry.Performance answering identified test questions.
Describe how process variables are measured and utilized in the process industry.Performance answering identified test questions
Describe/ identify how pressure is measured and transmitted.Performance answering identified test questions
Observed performance identifying
Describe/ identify how flow is measured and transmitted.Performance answering identified test questions
Observed performance identifying
Describe/ identify how temperature is measured and transmitted.Performance answering identified test questions
Observed performance identifying
Describe/ identify how level is measured and transmitted.Performance answering identified test questions
Observed performance identifying
Describe the function and role of analytical instruments in the process industry.Performance answering identified test questions
Observed performance identifying
Describe the role of primary sensors, transmitters, controllers and controlled elements in a controlled loop.Performance answering identified test questions
Calculate relationships between process variables, and perform basic calculations used for instrument calibration and analysis.Performance answering identified test questions
Observed performance of calibration
Identify the appropriate terminology and drawing symbols for the instruments studied.Performance answering identified test questions

Course Outline

  1. Introduction to Instrumentation
    1. Importance of instrumentation to process industries
    2. Instrumentation terminology
    3. Major process variables
    4. Relationships between process variables
    5. Variable change effects on accurate measurements
  2. Process Variables, Elements and Instruments – Pressure
    1. Pressure and pressure instrumentation terminology
    2. Components that affect force
    3. Common types of pressure sensing/measuring instruments
    4. Purpose of pressure sensing in a process
    5. Pressure conversions/scales
  3. Process Variables, Elements and Instruments – Temperature
    1. Temperature and temperature instrumentation terminology
    2. Heat energy and temperature scales
    3. Common types of temperature sensing/measuring instruments
    4. Purpose of temperature sensing in a process
    5. Temperature conversions/scales
  4. Process Variables, Elements and Instruments – Level
    1. Level and level instrumentation terminology
    2. Common types of level sensing/measuring instruments
    3. Purpose of level sensing in a process
    4. Hydrostatic head pressure and reference pressure in relation to level
    5. Relationship between temperature and level control/fluid density
    6. Relationship between temperature and level control/volume
  5. Process Variables, Elements and Instruments – Flow
    1. Flow and flow instrumentation terminology
    2. Common types of flow sensing/measuring instruments
    3. Purpose of flow sensing in a process
    4. Difference between total volume flow and flow rate
    5. Flow conversions/scales
  6. Process Variables, Elements and Instruments – Analytical
    1. Analytical and analytical instrumentation terminology
    2. Common types of flow sensing/measuring instruments
    3. Purpose of analytical sensing in a process
    4. How analytical instrumentation affects the role of the process technician
    5. Process technicians role in analytical instrumentation performance
  7. Miscellaneous Measuring Devices
    1. Terminology associated with measuring devices
    2. Load cells
    3. Vibration measurement
    4. Proximity switches
    5. signal conversions/scales
  8. Introduction to Control Loops
    1. Description of process control
    2. Function of a control loop
    3. Components of a control loop
    4. Open and closed control loops
    5. Signal transmission types
  9. Introduction to Control Loops – Controllers
    1. Terminology associated with controllers
    2. Types of controller functions
    3. Applications of controller types/functions
    4. Controller operations
    5. Controller bumpless transfers
  10. Control Valves and Final Control Elements
    1. Terminology associated with valves and final control elements
    2. Components of a control valve
    3. Applications of control valve types/elements
    4. Role of the final control element in the control loop
    5. Control valve actuators/operation
  11. Instrumentation Troubleshooting
    1. Facility practices related to process technician troubleshooting
    2. Typical malfunctions of sensing elements and transmitters
    3. Importance of process knowledge in troubleshooting
    4. Proper use of tools and meters
    5. Purpose of instrument calibration

Suggested Text

Instrumentation
By CAPT(Center for the Advancement of Process Tech)
Pearson, 2010
ISBN # 978-0-13-700413-3

Bibliography

DACUM Research Chart for Mill Operator
Produced for Teck Alaska Inc. Red Dog Mine – June 2015
Prepared by John P. Hakala
Apprenticeship USA United States Department of Labor

PRT 110: Introduction to Occupational Safety, Health and Environmental Awareness

This course is an overview of the field of safety, health and environment within the process industry. Covers plant hazards, safety, and environmental systems and equipment, and applicable government regulations and industry standards.


Course Information

Credits: 3

Prerequisites: None

Instructional Goals

  1.  Identify the role of an operator technician in safety, health, and environmental issues.
  2. Explain the terminology utilized by operator technicians with safety systems.
  3. Explain safety issues related to Health
  4. Explain safety issues related to Environmental Awareness.
  5. Explain and demonstrate Hazard Recognition as applied by OSHA.
  6. Explain and demonstrate Hazard Classification as applied by OSHA.
  7. Explain safety permit systems
  8. Explain safety issues related to fires and firefighting.
  9. Explain safety issues related to electrical hazards.
  10. Explain safety issues related to chemical hazards.
  11. Explain the roles of Regulatory Agencies

Student Outcomes

Student Outcomes
Upon successful completion of the course, the student will be able to do the following:
Assessment Procedures
This outcome will be assessed by one or more of the following:
Identify the role of a process technician within a modern safety systemPerformance answering identified test questions
Understand and explain the terminology utilized by individuals and agencies involved in a modern safety, health and environmental system.Performance answering identified test questions
Understand and explain the importance of PPEPerformance answering identified test questions
Observed performance identifying PPE
Understand and explain the role of regulating agencies the process industry.Performance answering identified test questions
Explain the hazard identification and classification system.Performance answering identified test questions

Observed performance identifying and classifying a hazard
Explain the difference between engineering and administrative safety controls.Performance answering identified questions

Observed performance identifying administrative and engineering safety controls
Describe the role of Process Safety Management, M.O.C. and risk assessment in the process industries.Performance answering identified test questions

Observed performance demonstrating proper (general) safety practices required of an operator

Course Outline

  1.  Introduction to Process Safety
    1. The significant events of the safety movement
    2. The safety roles and responsibilities of process technicians
    3. The basic principles of safety
    4. The general safety rules used in the industry
    5. The difference between the terms process safety and occupational safety and health
  2. Hazard Classification
    1. Describe the hazard classification system
    2. Apply the methods of hazard recognition and classification
    3. Compare acute and chronic hazards
    4. Describe the physical hazards associated with chemicals
    5. Explain the principles of accident prevention
  3. Routes of Entry and Environmental Effects
    1. The attitudes and behaviors for safe and environmentally sound work habits
    2. How hazardous chemicals can enter the human body
    3. Principles of classification
    4. The dose response relationship
    5. Key elements of environmental awareness training
  4. Gases, Vapors, Particulates, and Toxic Metals
    1. The physical and health hazards associated with gases and vapors
    2. The physical and health hazards associated with particulates
    3. Common poisonous metals and describe the hazards associated with each
    4. The hazards associated with compressed gas cylinders
    5. The flammable gases that will mix easily with air
    6. Special precautions used when working with particulates, dust, and gases
  5. Hazards of Liquids
    1. The physical and health hazards associated with liquids
    2. The physical and health hazards associated with solvents
    3. The hazards associated with paints and adhesives
    4. Acids and caustics
    5. The PPE used in handling acids and caustics
  6. Hazard Chemical Identification: Hazcom, Toxicology, and DOT
    1. The Hazard Communication standard
    2. The physical properties and hazards associated with handling, storing, and
    3. transporting chemicals
    4. The key elements of a material safety data sheet
    5. Hazardous chemical inventory list
    6. Safety signs, tags, and warning labels utilized by process technicians
  7. Fire and Explosion
    1. The principles of fire prevention, protection, and control
    2. The chemistry of fire
    3. The fire classification system
    4. The various types of fire-fighting equipment
    5. Flammable and explosive materials
  8. Electrical, Noise, Heat, Radiation, Ergonomic and Biological Hazards
    1. The hazards associated with electricity
    2. The hazards associated with the operation and maintenance of electrical equipment
    3. The hazards of working with noise, heat, and radiation
    4. The hazards connected to confined space entry
    5. The effects of noise on hearing
  9. Safety Permit Systems
    1. The different types of permit systems in the processing industry
    2. Energy isolation and lockout/tagout (CFR 29 1910.147).
    3. The confined space entry procedure (CFR 29 1910.146).
    4. Hot work permits (CFR 29 1910.119).
    5. Cold work permits
  10. Personal Protective Equipment
    1. Personal protective equipment found in a plant
    2. General limitations of PPE equipment
    3. Purpose of respiratory protection
    4. Methods of hazard exposure prevention
    5. Engineering/environmental controls and PPE
  11. Engineering Controls
    1. Key elements of risk evaluation
    2. Basic pressure relief devices
    3. Interlocks and automatic shutdown devices
    4. “noise abatement.”
    5. Deluge and explosion suppression systems
  12. Administrative Controls
    1. The key elements of administrative control
    2. The steps used in performing a job safety analysis
    3. Essential parts of the Hazards and Operability Study (HAZOP)
    4. The process hazards analysis PHA system and HAZOP
    5. The importance of good housekeeping
  13. Regulatory Overview: OSHA, PSM, EPA
    1. The process safety management (PSM) standard.
    2. The written procedures requirement of the PSM standard
    3. The employee training issues contained in the PSM standard
    4. The audit section of PSM
    5. The Occupational Safety and Health Act
  14. HAZWOPER
    1. The HAZWOPER first responder, awareness level
    2. The HAZWOPER first responder, operations level
    3. The Incident Command System
    4. Fall protection system
    5. Emergency response.
  15. Process System Hazards
    1. The operating hazards found in industry
    2. The hazards associated with pump and compressor system operations
    3. The hazards associated with steam generation and furnace operation
    4. Hazards associated with the principles of reaction and distillation
    5. The principles of fluid flow in process equipment

Suggested Text

Introduction to Process Technology Safety, Health and Environmental
Charles E. Thomas
ISBN:  9781111036355
3rd Edition, Delmar Cengage Learning, 2012

Biboliography

DACUM Research Chart for Mill Operator
Produced for Teck Alaska Inc. Red Dog Mine – June 2015
Prepared by John P. Hakala
ApprenticeshipUSA United States Department of Labor