AEST: Automation Engineering Survival Training

Starts:  Oct 10, 2022 08:00 AM (CT)
Ends:  Oct 14, 2022 05:00 PM (CT)
Associated with  Houston

ISA Automation Engineering Survival Training (AEST)

Do you have what it takes to survive in the world of process automation?

Sharpen your process automation know-how with this intensive week of expert-led lecture and hands-on exercises covering practical, real-world automation survival skills.

Automation Engineering Survival Training is a unique process automation engineering experience designed to hone your process automation knowledge and skills. This intensive technical training boot camp for automation engineers combines lecture and hands-on labs with bonus features, including a plant tour to maximize your learning experience.

ISA's seasoned "Survival Expert" will guide you through a fast-paced and rigorous course of topics from process measurement fundamentals through advanced automation, and everything in between! This course also serves as a solid introduction to other ISA engineering courses that can assist in the advancement of your process engineering career.

Who Should Attend?

  • New automation, control system, or process control engineers
  • Recent process engineering and other engineering graduates
  • Seasoned engineers looking to refresh their process automation knowledge and skills
  • Individuals wanting to learn more about process automation

Intensive Hands-On Training Curriculum

Days: 4.5

CEUs: 3.6

PDHs: 36

DAY 1: Measurement Basics & Documentation

You Will Cover:

  • Concepts of Process Control: Typical Industries | Definitions | Continuous vs. Batch | Feedback Loop
  • Documentation: Instrument Line Symbols | Function Symbols | Identification Letters | Piping and Instrumentation Drawing (P&ID) | Loop Diagram
  • Industrial Measurement Systems: Process Measurement | Standard Signals | Instrument Performance Terminology | Repeatability and Accuracy | Zero, Span, and Linearity Errors | Calibration Chart
  • Control System Hardware: Pneumatic Controller | Electronic Controller | Single Loop Controller | Distributed Control System (DCS) | Programmable Logic Controller (PLC) | Personal Computers (PC) for Control
  • Temperature Measurement: Temperature Scales | Liquid-in-Glass, Filled Bulb, and Bimetallic Thermometers | Resistance Temperature Detectors (RTDs) | Reference Junction Compensation | Thermocouplers
  • Pressure Transducers: Pressure Elements | Signal Generation | Pressure/Force Relationships | Selection
  • Flowmeters: DP | Magnetic | Mass | Other 

Classroom/Laboratory Exercises:

  • Develop diagrams for flow, level, temperature, and pressure loops
  • Interpret simple P&IDs
  • Evaluate level instrument performance and accuracy
  • Determine upstream and downstream piping considerations
  • Select flowmeters for a variety of specific applications and specify installation and calibration requirements


You Will Be Able To:

  • Discuss the role of measurement and control in industrial processes
  • Differentiate between continuous, batch, and discrete control
  • Discuss the fundamentals of process control
  • Apply specific ISA Standards to interpret symbols and drawings associated with process control documentation
  • Discuss and apply the most common methods and devices used in temperature, pressure, level, and flow measurement 


DAY 2: Control Valves & Strategies

You Will Cover:

  • Introduction: Valve in Loop | Valve | Actuator | Positioner
  • Basic Valve Types: Globe | Ball | Plug | Butterfly
  • Installation: Performance | Safety | Other
  • Valve Sizing: Manual | Computer
  • Review of Feedback Control Concepts and Components: History of Control Operation | Concepts
  • Control Modes: Proportional | Integral | Derivative
  • Dynamic and Steady State Considerations: Gain | Dead Time | Time Constant
  • Tuning Control Systems: Closed Loop Tuning Using Ziegler Nichols Method | Evaluation and Control Criteria
  • Advanced Regulatory Control: Feedback Penalty | Challenges in Feedback Control | Real-World Control 


Classroom/Laboratory Exercises:

  • Size valves manually and with software
  • Specify valves, actuators, and auxiliaries for specific applications
  • Tune feedback control loops via a number of different methods
  • Tune using PC-based simulation software

You Will Be Able To:

  • Compare various types of final control elements
  • Size valves for any flow condition likely to be found in a process plant
  • Define the concepts of PID control
  • Explain the operation of the components in a closed loop control system including static and dynamic functions
  • Use three methods to tune a control system for stated quality control
  • Apply the operation and function of ratio control systems
  • Identify real-world control problems as the basis of need for advanced control 


DAY 3: Safety & Operator Effectiveness

You Will Cover:

  • Graphics and Controls: HMI Hierarchy Design | Classes of Displays | Navigation
  • Human Engineering: Human Factors in Console Design 
  • The Common Problems in Alarm Systems
  • The Alarm Management Lifecycle
  • Location Classification Standards
  • Protection Techniques Standards
  • Explosion Proof Enclosures
  • Intrinsic Safety
  • General SIS Design Considerations: Design Life Cycle | Separation of Control and Safety
  • Failure Rates and Modes: Safe vs. Dangerous | Failure Mode vs. Technology | Failure Rates | Test Intervals
  • System Technologies: Pneumatic | Relays | Microprocessors
  • Operations and Maintenance: Installation | Bypassing | Testing  


Classroom/Laboratory Exercises:

  • Alarm prioritization
  • Area classification
  • Calculate device failure rates 


You Will Be Able To:

  • Design a graphical hierarchy for navigation
  • Explain best practices in HMI
  • Develop an Alarm Management Philosophy
  • Discuss rationalization, classification, and prioritization of alarms
  • Describe and use procedures for electrical classification
  • Describe the basic principles of protection
  • Select explosion proof apparatus for specific applications
  • Select the appropriate protective techniques for different hazards
  • Differentiate between process control and safety control
  • Analyze the performance of different logic system technologies
  • Specify and select safety instrumented systems (SIS) 


DAY 4: Industrial Security & Project Management


You Will Cover:

  • What is Data Communications?: ISO/OSI Reference Model | Terminology Basics
  • TCP/IP Basics: Is Ethernet Ready for the Plant Floor? | Industrial Ethernet Design Techniques
  • Data Exchange: Using OPC for Inter-System Data Exchanges
  • How Cyberattacks Happen: Understanding the Threat Sources | The Steps to Successful Cyberattacks
  • Standards and Models: ANSI/ISA95 Standards | MESA International Model | WBF B2MML XML Schemas
  • Information Model: Production Resources | Process Segments | Product Definition and Capability | Production Schedules | Production Performance
  • Types of Projects: Facility Update | Addition to Existing Process | Technology Replacement | New Facility
  • Fundamentals: Activity/Phase Concept | Best Practices | Phase Interaction | What to Do/How to Do it | Do it
  • Project Development: Schedule Preparation | PERT | CPM | GANT | Cost 


Classroom/Laboratory Exercises:

  • Conduct security threat analysis
  • Identify key business processes and objects
  • Identify process segment definitions
  • Practice project scheduling techniques 


You Will Be Able To:

  • Identify Local Area Network (LAN) topologies and protocols
  • Define the different Ethernet varieties and which are best for industry
  • Discuss the principles behind creating an effective long-term security program
  • Define the basics of risk and vulnerability analysis methodologies
  • Specify the requirements for an enterprise-control integration solution
  • Explain the business drivers involved in integration
  • Identify project types and overall goals and objectives
  • Explain the four important objectives critical to automation projects vs. the three objectives typical of other projects 


DAY 5: Advanced Process Automation

You Will Cover:

  • Physical Model: Process Cells | Units | Equipment Modules | Control Modules
  • Recipe Information Categories: Header | Procedure | Formula | Equipment Requirements
  • Procedural Control Model: Procedure | Unit | Operation | Phase
  • Modes and States: Exception Handling | Allocation and Arbitration
  • Control Activity Model: Recipe Management | Production Planning and Scheduling | Production Information Management | Process Management | Unit Supervision | Process Control | Personnel and Environmental Protection
  • Integration: Communications | Manufacturing Execution System (MES) | Network Security
  • Workflow and Project Leadership: Opportunity Identification and Project Justification | Communications and Team Processes 


Classroom/Laboratory Exercises:

Develop procedural elements using the ANSI/ISA88 procedural control model and test those procedural elements against the equipment entities 


You Will Be Able To:

  • Specify the requirements for a batch control system
  • Effectively structure and subdivide equipment entities
  • Describe modes and states and how they are applied at the equipment level
  • Describe the interfaces that are needed between batch control and other systems within an enterprise
  • Apply the critical areas of automation opportunity identification and project justification
  • Interpret the best practice methodology for automation project execution


15995 N Barkers Landing Rd #143
Houston, TX 77079