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Control Systems-CAO Course Details 

PS3090 PID CONTROL LOOP TUNING

2 Days
Location: SRTCC or Customer's site
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This workshop provides information and practice at finding and setting the correct values for control loop parameters. Correctly set PID control loop parameters will result in a properly controlled process with a minimum of overshoot and instability while retaining excellent control response.

Designed For

This workshop is recommended for Senior Process Operators, Process Operators, ACR Technicians, CAO Technicians and Production or Operations Managers, and others who need to interact with process control loops.

Prerequisite

None

Objectives

Continuing efforts by Engineering and Operations to improve process efficiency is resulting in more numerous and more sophisticated controls. The standard control system is the PID system. Knowledge of how to find the correct settings and implement them on process controls will result in a more stable and controllable process, thus increasing production and reducing shutdown events.

Outline

  1. INTRODUCTION TO PID CONTROL LOOP PRINCIPLES
    1. Proportional Control
    2. Integral Control
    3. Derivative Control
  2. HANDS-ON CONTROL SESSIONS WITH LEVEL CONTROLS
    1. Proportional Control Only - Lab Exercise
    2. Integral Control Added - Lab Exercise
    3. Derivative Control Added - Lab Exercise
  3. CONTROL LOOP TUNING PRINCIPLES
    1. System Delays and Time Response
    2. Actuator Delays and Deadbands
    3. Hands-On Tuning Practice
    4. Loop Tuning Software
  4. HANDS-ON CONTROL SESSIONS WITH GAS FLOW RATE CONTROLS
    1. Proportional Control - Tuning Parameters
    2. Integral Control Added - Tuning Parameters
    3. Derivative Control Added - Tuning Parameters
  5. WORKSHOP SUMMARY AND WRAP-UP

PS3089 PRODUCTION OPTIMIZATION UTILIZING ELECTRONIC CONTROLS

5 Days
Location: SRTCC
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This workshop provides the technical background and hands-on experience with electronic controls so the participant can fully participate in multidisciplinary teams working to increase well and platform production rates. In addition, the participant will develop skills to assess and contribute to decisions regarding equipment, procedures, and controls tuning. Techniques and terminology used in the analysis and setup of microprocessor-, PLC-, and DCS-based controls will be covered, as well as operating characteristics of equipment brands like Foxboro, Allen-Bradley, Moore, Rosemount, Taylor, Fisher, and others. The production, electrical, and controls systems labs at the Robert Training Center will be used to provide working models of gas-lift injection controls and vessel liquid level controls through the use of proportional control valves and variable speed drives.

Designed For

Sr. Process Operators, Process Operators, Technicians, Team Leaders, and Operations and Production Managers desiring information and hands-on experience using the latest generation electronic control systems as a tool to increase oil and gas production from existing wells and facilities by optimizing the throughput of processes and decreasing unplanned shutdowns.

Prerequisites

None

Objectives

Today's economic environment no longer allows well and facilities to be produced at less-than-optimal rates. Careful analysis and control of vessel pressures, vessel levels, and injection rates can improve production rates 3% to 20% or more. The increase in production does not come easily though. Precise and detailed procedures must be used to determine the "sweet spot" and then proper controls utilized to hold process values tightly within that range.

Upon completion of this course, the student should be able to:

  • Fully participate in teams working on improving and optimizing production rates.
  • Work with vendors and Control Systems Engineering to set up and configure controllers.
  • Recognize and evaluate process conditions that could benefit from control tuning.
  • Monitor and evaluate effectiveness of current controls.
  • Understand and configure PID loop controllers.
  • Understand the concepts and uses of advanced controls like "fuzzy logic" and "neural nets".

Outline

  1. PRODUCTION OPTIMIZTION - AN OVERVIEW
  2. ELECTRONIC CONTROLS - AN OVERVIEW
  3. CLASIC PID CONTROLS
    1. Explanation of PID Control
    2. PID Controls on PLC, DCS, and Local Controllers
  4. GETTING PROCESS INFORMATION FROM THE FIELD
    1. Pressure, Level, Flow, and Temperature Transmitters
  5. CONTROLLABLE PROCESS DEVICES - PUMPS AND VALVES
  6. PRINCIPLES OF DCS SYSTEMS - FOXBORO I/A SYSTEM
    1. Field Device Wiring and Processor
    2. Operator Interfaces
  7. LIQUID LEVEL OPTIMIZATION
  8. GAS INJECTION RATE OPTIMIZATION
  9. PROCESS PERFORMANCE INDICATORS
    1. Separators and Treaters
    2. Glycol Systems
    3. Heat Exchangers
  10. HANDS-ON SESSIONS
  11. WORKSHOP WRAP-UP

PS2306 PLC MAINTENANCE & TROUBLESHOOTING - I

4 Days
Location: SRTCC
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This "learn-by-doing" workshop is the first in a four-part series that covers the setup, use, programming, troubleshooting, and maintenance of the Allen-Bradley PLC-5 family of programmable logic controllers. Lab exercises cover field devices, input/output modules, wiring, fusing, and processor programming leading to in-depth troubleshooting and maintenance of the equipment. The exercises are performed on actual equipment setups and are applicable to process control, motor control, level control, and safety interlocking.

Designed For

This course is recommended for Production Technicians, Maintenance Specialists, and Engineering Technicians who desire a hands-on approach to understanding and troubleshooting the Allen-Bradley line of PLC's. Some background in basic electrical principles is helpful but not a strict requirement. Minimal coverage of theory and mathematical principles is provided with an emphasis on hands-on use of the actual equipment.

Prerequisites

Basic Electrical Course or equivalent.

Objectives

Upon completion of this course, the student should be able to:

  • Understand PLC Control Principles and Applications with Field Devices
  • Connect and Wire Field Devices to PLC Inputs and Outputs
  • Understand and use basic Ladder Logic Programming
  • Use and Configure a Delay Timer and Counter in a Controller
  • Connect a Power Device Using an Interposing Relay
  • Identify Allen-Bradley PLC-5 Hardware Components and Equipment
  • Connect a Programming Terminal to the PLC; KT Card, KE Card, and PCMK Card
  • Use the Programming Terminal to Troubleshoot Failed Field Devices
  • Determine Address Names for Input and Output Points
  • Add Comments to Instructions and Rungs for Program Documentation
  • Use Symbolic Addressing to Speed Development and Troubleshooting
  • Use Address and Function Searches within the Program
  • Save Ladder Logic Ladders and Data Files from the PLC to a Floppy Disk
  • Restore Ladder and Data Files to a Processor from a Programming Terminal
  • Print Reports and Documentation of the PLC System and Program
  • Use the Force Function to Troubleshoot and Maintain Equipment Operation
  • Troubleshoot Failed Input and Output Field Devices, Power Supplies, and Processors

Outline

  1. INTRODUCTION TO CONTROL SYSTEMS
    1. An introduction to control systems and ladder logic is provided by building relay logic circuits using batteries, relays, switches, lights, and connecting wires. Fundamental PLC principles are established as the participants work together to perform the functions of a PLC wired with input and output devices.
  2. ALLEN-BRADLEY HARDWARE AND LADDER LOGIC PROGRAMMING
    1. The components of an A-B PLC5 programmable logic controller are covered noting their function and use. Participants attach input switches and output lights to a PLC system and write basic ladder logic to control their operations. Normally open contacts (XIC), normally closed contacts (XIO), output coils, timers, and counters are used to build and/or motor starter, and safety monitoring circuits.
  3. USING A PROGRAMMING TERMINAL TO MONITOR AND EDIT
    1. The use of 6200 series software to monitor and edit control systems is the focus as participants practice the use of KE, KT, and PCMK modules to establish communications between their PC and the PLC. After locating the proper address on the Data Highway, participants log on to the appropriate PLC and check data and program file operation.
  4. SYSTEM TROUBLESHOOTING USING THE PROGRAMMING TERMINAL
    1. The programming terminal can shorten the time required to locate and repair failed components. Participants practice using the terminal to locate contacts that are preventing equipment operation, locate the addresses in field hardware, verify proper voltages and current levels, and isolate and repair failed devices.
  5. SYSTEM UTILITIES FOR MAINTENANCE AND REPAIR
    1. Steps required to create backup copies of the ladder logic in a PLC and the steps to restore a program to a PLC in the event of a hardware failure or power upset are covered. In addition, practice with utilities like printing ladder logic and status reports to a printer is provided. Also included are forcing inputs and outputs, adding symbols and comments to ladder logic, and moving from data files to ladder files while troubleshooting.
  6. PUMP CONTROL OPERATIONS
    1. The use of the PLC as a controller for pumps and other electrical and safety equipment is studied. Typical ladder logic as used on offshore platforms is used to demonstrate control and safety principles. Participants will view existing code and have the opportunity to build and enhance control systems during the hands-on sections of the course. 

PS2307 PLC MAINTENANCE & TROUBLESHOOTING - II

4 Days
Location: SRTCC
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This "learn-by-doing" workshop is the second in a four-part series and provides experience in the setup, maintenance, and troubleshooting of discrete, analog input, and analog output devices on the Allen-Bradley PLC-5 family controllers. Within SOI, analog devices are handled with "Configurable Code" RTU5 ladder logic. Participants will practice addressing, block transfer instructions, indirect addressing, subroutine jumps, analog module configuration, and coding examples that lead to an understanding of RTU5 code and how to enter information into the data files for configuration.

Designed For

This course is recommended for Production Technicians, Specialists, Engineering Technicians, CAO Technicians, Electrical Technicians, and others who need to interact with the PLC/CAO system on their platform.

Prerequisites

PLC Maintenance & Troubleshooting - 1 or equivalent.

Objectives

Upon completion of this course, the student should be able to:

  • Review programming terminal connections to PLC with KE, KT, and PCMK interface cards
  • Configure KE and/or KT module and set up communications protocols
  • Configure DIP switch settings for chassis, processor, and remote I/O adapters
  • Configure Flex I/O - install terminal bases, modules, and assemble system
  • Understand and utilize indirect addressing - develop ladder logic code utilizing indirect addressing
  • Using A-B documentation, set jumpers on 1771-IFE card for 4-20mA input signals on all channels.
  • Install, configure, and attach field devices to analog input and output cards
  • Write ladder logic including Block Transfers to handle analog input and output modules
  • Understand philosophy of RTU5 "Configurable" ladder logic
  • Study RTU5 file layout for analog input modules
  • Study indirect addressing examples and use in RTU5
  • Troubleshooting practice with RTU5 and PLC5 hardware

Outline

  1. REVIEW PLC-BASED CONTROL SYSTEMS INCLUDING SAFETY CIRCUITS AND PUMP CONTROL LOGIC
    1. Look at troubleshooting techniques for field devices, I/O modules, remote I/O adapters, chassis, and processors. Find and replace failed PLC components and test the system for proper and safe operation. Review hardware addressing, data file structures, and ladder logic file structures. Study ladder logic code including contacts, outputs, timers, and counters.
  2. INSTALL AND CONFIGURE ANALOG MODULES FOR HANDLING PROCESS TRANSMITTERS
    1. Set module DIPswitches to the Shell standard 0-20 mA module configuration to handle the 4-20 mA process transmitters. Set up ladder logic with Block Transfer instructions to configure the intelligent module and retrieve the analog values.
  3. INSTALL AND CONFIGURE FLEX AND BLOCK REMOTE I/O MODULES
    1. Set up DIPswitches and configure ladder logic code to make them operational. Troubleshoot and repair faulty field devices, fuses, connections, terminal bases, flex modules, block modules, and remote I/O connections.
  4. STUDY RTU5 "CONFIGURABLE CODE" LADDER LOGIC USED AS THE BASIS FOR PLATFORM CONTROL SYSTEMS
    1. Understand how to use the documentation to determine data files needed for configuration of platform systems. Enter the data into the data files and study the ladder code to determine proper system operation. Troubleshoot and repair field device and PLC system errors using the RTU5 code.

PS2310 PLC MAINTENANCE & TROUBLESHOOTING - III

4 Days
Location: SRTCC
Contact:  SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This "learn-by-doing" workshop covers the electronic safety shutdown system (SSDS) as used on many SOI Shelf and Deepwater platforms. Data file structure and ladder logic is covered with practice at equipment point setup and testing. Troubleshooting practice and hands-on experience with the system is emphasized. Each participant may choose to work with either RTU5 version 2 or 3 depending on what system is installed on their platform.

Designed For

This course is recommended for Production Technicians, Maintenance Specialists, and Engineering Technicians who desire a hands-on approach to understanding and troubleshooting the Allen-Bradley based Electronic Safety Shutdown System.

Prerequisites

PLC Maintenance & Troubleshooting - 2 or equivalent.

Objectives

Upon completion of this course, the student should be able to:

  • Review ladder logic instructions and data file structures in PLC5 systems
  • Troubleshoot discrete and analog I/O modules
  • Review block-transfer instructions
  • Study shut-down Classes: A, B, C, and C/B and alarm-only points
  • Handle shut-down inputs (SDI's): configure and monitor equipment subroutines
  • Handle equipment shutdowns: configure and monitor valves, pumps, and wells
  • Study local panel (LCP) functions: bypass, horn silence/inhibit, and reset
  • Understand the bit structure to the input point status word in PLC
  • Configure a Redi-Panel as a local control panel (LCP)
  • Practice with data file structures and shutdown input point setup
  • View and understand SSDS Shared Data Message (Token) and message command
  • Review Data Highway Plus and technical specifications - troubleshooting procedures
  • Master status panel operation and setup
  • Troubleshoot and repair SSDS system problems of all types

Outline

  1. Review of A-B PLC hardware and ladder logic, field device connections for analog and discrete process monitoring and control devices, and wiring/cabling/fusing schemes for various I/O module configurations. Review of programming terminal use for system troubleshooting and repair.
  2. Use and operation of the Local Control Panels (LCP's) to view first outs, acknowledge first outs, view cascaded outs, silence horn, and engage bypass modes. Difference between Class A, Class B, Class C, and Class C with B override type shutdowns. Use of LCP to monitor bypass state.
  3. Use and operations of Master Status Panel (MSP) to view first out LCP, cascaded LCP's, bypassed LCP's, Summary Process Alarms, Individual Process Alarms, Miscellaneous Shutdown Inputs, Valves Output Status, and Pumps Output Status.
  4. Use of the platform "Safe Chart" to determine Shutdown Inputs that apply to each valve or pump to be turned off in the event of detection of an unsafe condition.
  5. Configuration of the data files and ladder logic files in the SSDS PLC's to provide system operation in accordance with the Safe Chart. Use of the RTU5-based ladder logic code for troubleshooting and repair operations. Use of RTU5 Version 2 for those working on Electronic SSDS systems installed before 1994. Version 3 of RTU5 applies to installations after 1994.
  6. Advanced system troubleshooting techniques including the Shared Data Message (Token) traveling on the Data Highway Plus, Data file and status word bit structures, information flow from one SSDS PLC to another, and output shutdown management.

PS2312 PLC MAINTENANCE & TROUBLESHOOTING - IIII

4 Days
Location: SRTCC
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This "learn-by-doing" workshop provides Production Technicians and Electrical Specialists with background and experience in the setup, maintenance, and troubleshooting of discrete and analog input and output devices on the Allen-Bradley SLC 500 family PLC's and with new Block and Flex I/O. Within SOI, SLC 500's have been installed since early 1996 and will likely be extensively used in future projects and updates. This course looks at the hardware and software from the perspective of maintaining and troubleshooting an installation with a SLC 500 as the controlling PLC.

Designed For

This course is intended for Production Technicians, Maintenance Specialists, and Engineering Technicians who have a solid background in PLC's are desire to update and refresher their skills on newer hardware, software, and troubleshooting techniques. This session is primarily self-paced and the participant can choose to invest the most time in those areas that are most helpful in his/her daily work.

Prerequisites

PLC Maintenance & Troubleshooting - 2, 3, or equivalent.

Objectives

Upon completion of this course, the student should be able to:

  • Expand Participants Skills base to include SLC500 Hardware to new PLC-5 I/O Hardware
  • Learn to use APS (Advanced Programming System) Software for Programming the SLC500
  • Set up and use DH-485 and DH+ Peer Communications Connections
  • Connect Discrete Field Devices (Switches and Lights) to SLC500 I/O Modules
  • Connect Analog Inputs/Outputs (Transmitters, Proportional Valves, and VSD's) with SLC500's
  • Connect and program all functions for Block I/O Hardware for discrete and analog devices
  • Connect and program all functions for Flex I/O Hardware for discrete and analog devices

Outline

  1. SLC500 FAMILY PROCESSORS
    1. System Installation and Configuration
    2. Connecting a Programming Terminal via DH-485 and DH+
    3. Installing and Using I/O Modules
    4. Running APS Programming Software
    5. Maintenance and Troubleshooting Procedures
  2. BLOCK I/O
    1. System Installation and Configuration
    2. Connecting to Processor via Remote I/O Links
    3. Installing and Using I/O Modules
    4. Addressing and Multiple Remote I/O Drops
    5. Maintenance and Troubleshooting Procedures
  3. FLEX I/O
    1. System Installation and Configuration
    2. Connecting to Processor via Remote I/O Links
    3. Installing and Using I/O Modules
    4. Addressing and Multiple Remote I/O Drops
    5. Maintenance and Troubleshooting Procedures
    6. Special Considerations for Analog Input Modules
  4. RTU5 VERSIONS 2 AND 3
    1. Background and History of RTU5
    2. Configurable Code-What's the Advantage?
    3. Data Files and Ladder Files
    4. Configuring RTU5 for your Platform
    5. Troubleshooting and Maintenance Tricks and Techniques
  5. SSDS AND DAS SYSTEMS
    1. Safety Shutdown System Overview
    2. Data Acquisition System Overview
    3. Advanced Troubleshooting and Maintenance Techniques

PS2406 PLC MAINTENANCE & TROUBLESHOOTING - V

4 Days
Location: SRTCC
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

Introduction to using ALLEN BRADLEY'S CONTROLLOGIX PLC'S for process control and shutdowns. Emphasis on Commissioning, Maintenance and Troubleshooting issues for Technicians and Operators.

Designed For

 

Prerequisites

PLC Maintenance & Troubleshooting - 2, 3, 4, or equivalent.

Objectives

Upon completion of this course, the student should be able to:

 

Outline

  1.  

 

PS3092 RSLogix5 ENHANCED TROUBLESHOOTING SOFTWARE FOR PLC's

2 Days
Location: SRTCC
Contact:  SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

The current software (called 6200 Series) for programming PLC's is no longer supported by Allen-Bradley and is DOS-based. It runs poorly on NT machines and lacks many of the features of the newer, windows-based software. In addition, many versions of the 6200 Series software have Year 2000 problems. Each facility will need to upgrade to the new software over the next year, and training is required, as the new software is significantly different.

Designed For

Technicians and Operators who work with Allen-Bradley PLC controls and Shell's electronic safety shutdown systems.

Prerequisites

None

Objectives

This workshop provides information and practice in utilizing the advanced troubleshooting tools available with Rockwell Software's (Allen-Bradley) new PLC programming package. Several features of the new software can significantly reduce the time to troubleshoot failed systems and return the platform to service.

Outline 

  1. RSLogix5 - OVERVIEW OF FEATURES AND SCREENS
  2. INSTALLATION ON WIN '95 OR NT COMPUTERS
  3. USE OF RSLinx FOR COMMUNICATION ON THE DH+
  4. TRANSFERRING DOCUMENTATION AND LADDER LOGIC FOR EXISTING PROGRAMS
  5. MONITORING ON-LINE LOGIC
  6. SIMULTANEOUS VIEWING OF LOGIC AND DATA FILES
  7. BUILDING CUSTOM TROUBLESHOOTING SCREENS
  8. BUILDING CUSTOM GRAPHING SCREENS
  9. PERFORMING ROUTINE BACKUP OF PROCESSOR FILES
  10. EMERGENCY!
    1. Restoring Ladder Files to Faulted Processors
    2. Troubleshooting Ladder Faults
    3. Troubleshooting Process Transmitters
  11. TROUBLESHOOTING PRACTICE
    1. CAO PLC's
    2. SSDS System PLC's
  12. COURSE WRAP-UP

PS4554 TURBOTRONIC (2.0/3.0) CONTROL SYSTEM LOGIC, LEVEL ONE

5 Days
Location: SRTCC/Customer Site, or Solar Training Center
Contact: SRTCC Staff, Dannie Smith, 504-728-1225

Course Overview

This course provides in-depth instruction on the operation of Turbotronic hardware and software, the use and interpretation of electrical/software drawings and documentation, and the control algorithm operational philosophy and start sequence logic. Students gain a familiarization with employing electrical/software drawings and documentation to apply basic diagnostic techniques.

Designed For

Personnel involved in troubleshooting and repairing electrical control systems for Solar turbines.

Prerequisites

Participants should have successfully completed a Solar Operation and Routine Maintenance Course for their specific equipment package and PLC-1.

Objectives

Upon completion of this course, the student will demonstrate:

  • The ability to interpret specific Turbotronic 2.0/3.0 electrical and software drawings and documentation to perform basic troubleshooting for Turbotronic 2.0/3.0 equipped turbomachinery packages.

Outline

  1. TURBOTRONIC 2.0/3.0 CONTROL SYSTEM ELECTRICAL SYSTEM, DRAWINGS AND SOFTWARE (PLC 5 SERIES) DOCUMENTATION
  2. DISPLAY/INFORMATION SYSTEMS OF THE TURBOTRONIC 2.0/3.0 CONTROL SYSTEM
  3. TURBOTRONIC PLC 5 SERIES PROCESSOR, CHAIS, INPUT, OUTPUT, AND SPECIAL MODULES
  4. DOCUMENTATION-BASED TROUBLESHOOTING AND DIAGNOSTIC TECHNIQUES
  5. START SEQUENCE LOGIC AND CONTROL ALGORITHM OPERATIONS

Reference Material

Students receive a comprehensive workbook, a full set of wiring diagrams, a set of package logic block flow diagrams, and hardware and software information. These materials are designed for classroom use and for reference purposes on the job.

02/19/2008