Pipes

Process Control

Process control is a versatile and vital part of major industries like:power generation; petrochemicals; food processing and bottling; chemical manufacturing; bio-technology; pharmaceuticals; and refineries.

Because of the wide application of this key component, Amatrol has developed the largest and most in-depth offering of industrial process control training options available. Amatrol offers four major process control systems, each covering a different process control application: level and flow, temperature, analytical, and pressure. Amatrol also offers a variety of training options for related process control applications such as HART communication protocol, Foundation Fieldbus, and SCADA. This in-depth offering of process control training solutions fit within various Amatrol programs like:

For more in-depth explanations and applications of Process Control, please reference the following article:

Level / Flow Process Control

This program teaches two of the most common types of process control systems, flow and liquid level, and the basic concepts on which other systems are based. This process control system allows learners to calibrate, adjust, install, operate, and connect process control systems in industrial applications.

Process control systems provide precise control of liquids and gases in industrial areas including power generation, petrochemicals, food processing, and manufacturing. These systems control liquid and gas variables like flow rate, pressure, temperature, liquid level, density, and pH levels. Amatrol’s Level and Flow Process Control training system (T5552) covers two types of process control systems, flow and liquid level. Learners use this process control training system to study process control concepts and practice hands-on process control skills like calibrating, adjusting, installing, operating, and connecting process control systems in industrial applications.

This level and flow process control simulator includes a bench-top workstation, process control network, control panel, and an interactive online process control training course. The workstation is constructed of heavy-duty, welded steel. Industrial quality components are mounted and plumbed in a closed loop circuit to control the water flow between two 

tanks or the liquid level in one tank. All components are connected to banana jacks on the control panel, allowing students to measure signals and connect devices in a variety of control configurations.

This process control training system offers three types of controllers: relay control, standard, and two options: PID controller and PLC control. This allows students to study a wide range of process control methods. The relay control includes manual input switches, control relays, solenoid valves, and float switches to perform automatic on/off liquid level control. The PID controller option enables variable electronic control of either liquid level or flow and the PLC controller option enables both on/off and PID control of the system. Manual valves are used to switch between the PID and on/off control methods.

The process control training simulator offers a wide variety of transducers and control valves, enabling students to study a full range of process instrumentation technology. Optional transducers and valves can be quickly interchanged with the standard ones via hand-tightened pipe unions and plug-in electrical connections.

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    Level/Flow Process Control

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    Level/Flow Process Control Troubleshooting

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    Versatile Differential Pressure Flowmeter Sensor

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    Foundation Fieldbus Process Control

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    HART Communications Protocol

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    Process Visualization Control 1

Level & Flow Training | Hands-On Process Control Skills in Portable Case

Amatrol’s Portable Process Control Learning System – Level and Flow (990-PC1) covers two of the most common types of process control systems, flow and liquid level, by providing eLearning curriculum and hands-on training for subjects like process control equipment safety, loop controllers, level measurement and control, control loop performance, and more! Process control is used in a variety of industrial areas including power generation, petrochemicals, food processing, and manufacturing. This system is durable, portable, and offers process control training on a space as small as a conference room table or shop floor desk.

This Portable Process Control training system features two portable consoles featuring a PID controller, operator controls, process meter, flow transmitter, water tanks, gauges, and more! Learners will use these components along with the multimedia curriculum to study topics like process control safety, interpreting instrument tags, valve and pump symbols, loop controllers, proportional control valves, display scaling,

closed loop liquid level control, proportional control, flow sensors, and open-loop tuning. Amatrol uses industry-standard components that allow learners to practice real-world skills using equipment that they’ll see in advanced manufacturing environments.

Practice Hands-On Process Control Skills with a Portable Training Solution

This Portable Process Control training system includes portable consoles, liquid tanks, centrifugal pump, a piping network with valves, and a PLC interface. Learners will practice hands-on skills with these components to gain an understanding how process control equipment works. Skills highlighted by this system include connecting and operating loop controllers and diaphragm actuator proportional valves, using a multimeter to test pressure sensor operation, connecting and operating alarms on a controller, controlling a process using PI control, measuring flow using a paddlewheel flow sensor, and tuning a control loop using the process reaction curve method.

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    Portable Level/Flow Process Control

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    Portable L/F Process Control Troubleshooting

Temperature Process Control

This program allows learners to study and practice calibrating, adjusting, installing, operating, and tuning thermal process control systems in industrial applications. Major topic areas include: basic temperature control elements; loop controllers; final control elements; temperature sensors; temperature transmitters; basic temperature control; methods of automatic control; and control loop performance.

Amatrol’s Temperature Process Control Learning System (T5553) teaches learners how to install, calibrate, operate, adjust, and tune thermal process control systems in a wide variety of industrial applications, including food processing, chemical manufacturing, and bio-technology. Process control systems provide precise control of liquids and gases.

The Temperature Process Control training system features a heavy-duty, welded-steel workstation with industrial-quality components, which are mounted and plumbed in two water flow circuits, a process loop, and a heating loop that controls the temperature of water flowing in the process loop. All electrical components are connected to the control panel to allow learners to measure signals and connect the devices in a wide variety of control configurations, including PID control, on/ off control, and manual control.

Practice Temperature Process Control Skills with Real-World Equipment

Amatrol’s Temperature Process Control training system features an impressive variety of real-world components, including: a chiller that mechanically refrigerates the process fluid; three types of temperature sensors: thermocouple, thermistor, and RTD; a heating loop network; and an operator interface station. The system allows learners to observe what is happening inside the system, so they can evaluate the effects of external disturbances and their own adjustments. Learners will practice a variety of real-world skills, such as: control water temperature using a sensing bulb thermostat; connect and operate a loop controller in the manual mode; calibrate an I/P converter; connect and configure a temperature transmitter for a thermocouple; and configure and operate discrete inputs on a Honeywell UDC 3500 controller.

In-Depth Temperature Process Control Curriculum

The Temperature Process Control training system includes an in-depth, comprehensive curriculum that provides a strong foundation in temperature process control, including these major topics: process control concepts and safety; instrument tags; piping and instrumentation diagrams; thermal energy; basic temperature control elements; loop controllers; final control elements; temperature sensors; temperature transmitters; basic temperature control; methods of automatic control; and control loop performance. The curriculum also features over 50 hands-on skills to prepare learners for real-world situations. The curriculum is also available in a convenient eBook format with enhanced features like keyword searches and zoom controls that enable users to quickly locate and view information.

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    Temperature Process Control

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    Three-Channel Data Acquisition

Analytical Process Control

This program covers major topics and skills involved with controlling and modifying the chemical properties of a substance. The Analytical Process Control Learning System covers topics like pH electrodes, pH meters and transmitters, and loop controllers and vital theoretical process control knowledge including: describing the function of a process hazard analysis; defining pH and explaining its importance; learning five common types of loop controller parameter groups; and configuring a Honeywell UDC 3500 for continuous pH control.

Amatrol’s Analytical Process Control Learning System (T5554) teaches knowledge and skills essential for controlling and modifying the chemical properties of a substance, which is important to industries such as pharmaceutical companies, beverage companies, and refineries. The system allows learners to explore a wide range of topics, including analytical process control, pH electrodes, pH meters and transmitters, loop controllers, and more!

The Analytical Process Control training system includes a tabletop workstation with a control panel, PLC interface, and industrial pumps, tanks, and piping. Learners will use these components to perform hands-on skills, such as manually setting and controlling an electronic metering pump, testing the pH of a solution using pH test strips, and connecting and operating a continuous loop pH control system. These skills will prepare learners for industrial process applications they’ll encounter on the job.

Practice Analytical Process Control Skills with Real-World Equipment

Amatrol’s Analytical Process Control training system features an impressive variety of real-world components, including: a PLC interface panel, metering pump, injector pump, continuous stirred tank reactor (CSTR), pH transmitter, pH probe, two reagent tanks, and a piping by-pass network. Learners will practice a variety of real-world skills, such as: manually controlling the liquid flow rate in a process; setting the injection ratio control for an educator pump; installing and connecting a combination glass electrode; calibrating a Honeywell DL421 pH sensor module; and calculating resolution in units of the measured parameter.

In-Depth Analytical Chemical Process Control Curriculum

The Analytical Process Control training system includes an in-depth, comprehensive curriculum that provides a strong foundation in analytical process control, including these major topics: process control concepts and safety; instrument tags; piping and instrumentation diagrams; pH electrodes; pH meters and transmitters; and loop controllers. The curriculum also features important hands-on skills to prepare learners for real-world situations, such as configuring a Honeywell UDC 3500 for continuous pH control. The curriculum is also available in a convenient eBook format with enhanced features like keyword searches and zoom controls that enable users to quickly locate and view information.

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    Temperature Process Control

Pressure Process Control

This program offers the ability to control liquid level and tank pressure simultaneously using a human machine interface (HMI), programmable automation controller (PAC), and variable frequency drive (VFD). This functionality allows learners to study important industrial gas blanket applications as well as gain valuable hands-on experience in practicing a broad range of pressure process operations in both manual and automatic modes. The Pressure Process Control Learning System explores major topics like loop control devices, HMI panel operation, pressure control systems, process system alarms, automatic control methods, performance concepts, control loop performance, and open- and closed-loop tuning.

Amatrol’s T5555 Pressure Process Control Learning System offers the ability to control liquid level and tank pressure simultaneously using a human machine interface (HMI), programmable automation controller (PAC), and variable frequency drive (VFD) that are found in real-world industrial fields such as pharmaceutical, bio-technology, and power generation! This functionality allows learners to study important industrial gas blanket applications as well as gain valuable hands-on experience in practicing a broad range of pressure process operations in both manual and automatic modes.

Amatrol’s T5555 Pressure Control training simulator features an exposed component layout built to enhance a learner’s understanding of a pressure process control system’s operation. This training simulator is compact enough to fit through a standard door, yet broad enough to offer all of the skills and topics a learner needs. Additional industrial-grade components on this learning system include: level sensors, which learners can use to set alarms; a centrifugal pump for producing liquid flow; and several valves to show their function and operation in a loop control system.

 

Control Liquid Level and Tank Pressure Simultaneously!

This process control training system is capable of controlling liquid level and tank pressure simultaneously by utilizing components including a differential pressure sensor and proportional valves. Using an industrial-grade variable frequency drive-controlled (VFD) centrifugal pump, learners can directly practice gas blanket applications in manual or automatic modes for this and similar applications. In manual mode, the HMI is used to adjust the percentage that each of two proportional flow controls are open and to control the flow rate from the centrifugal pump. The simulator’s pump draws water from a 6 gallon industrial pressure vessel to guarantee resilience in this top quality product. The system’s reservoir tank assembly also includes a strainer, filter/regulator, and a safety lockout valve.

Practice Real-World Pressure and Level Control using an Industrial-Grade PAC

Hands-on skills for process instrumentation can only be achieved using real-world industrial components.  Therefore, this process control simulator is operated by the powerful Siemens Simatic S7-1200 programmable automation controller (PAC), which provides human machine interface (HMI) for process visualization and control. All electrical components on the T5555 are connected to the control panel so learners can measure signals and connect devices in a wide variety of configurations to practice industry-applicable skills. This exposed layout allows for easy observation and evaluation of system operation and performance.

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    Pressure Process Control

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