Distributed Control System (DCS) Training

The rugged workstation is built for intensive hands-on experimentation, with stainless steel piping and concealed wiring for added durability.

Workstation equipment

• Large touch panel display
• Stainless steel piping
• Water tank
• Two acrylic columns
• Two centrifugal pumps with variable-frequency drives
• Valves: ball valves, globe valve, check valve, pneumatic actuator globe valve, proportional pressure control valve, solenoid valve, angle-seat control valve with pneumatic actuator
• Over 20 pressure measurement ports
• Manometer and rotameter for flow and pressure monitoring
• Electrical and control components housed in a rear cabinet

Smart field instrumentation

• Pressure switch
• Differential pressure transmitter (high-range)
• Temperature transmitter (Pt100 RTD)
• Temperature transmitter (J-type thermocouple)
• Magnetic flow transmitter
• Radar level transmitter with remote display
• Differential pressure transmitter with 3-valve manifold (flow, Venturi)
• Differential pressure transmitter (level, low-range)

Provide essential hands-on instrumentation and process control experience via a DCS through:

• Structured hands-on labs covering calibration, configuration, commissioning, and operation of a distributed control system
• Core process fundamentals, including key process variables, system dynamics, centrifugal pumps, and fluid mechanics
• Instrumentation & control: identifying, configuring, and calibrating primary measuring devices and final control elements
• Industrial communication: setting up and troubleshooting HART, Modbus, and common industrial networks
• Process control & optimization: tuning control loops, managing alarms, and optimizing process performance
• Process simulations and operator shadowing to connect measurements, control actions, and real process outcomes
• Troubleshooting scenarios with staged electrical, instrumentation, and process faults under time pressure, including root-cause analysis
• Documentation & communication exercises, such as reading piping and instrumentation diagrams (P&IDs), writing shift logs, creating concise fault reports, and performing handovers

Build tailored learning paths while saving time: The ready-to-use course “DCS Learning System (PCS neo)” provides a rich pool of teaching and learning material with comprehensive topic coverage. Discover the course outline:

Learning Unit 1 — Process Control Systems

• Key topics: DCS (SIMATIC PCS Neo) overview, process variables, operations, DCS vs PLC, DCS architecture, P&ID, standards, HMI (menus, alarms, emergency), communication networks, sequencers (Levels, Batch), start-up & shutdown procedures.
• Experiments: Exercise 1‑1 — Introduction to the DCS Learning System (SIMATIC PCS Neo): HMI navigation, alarms, levels sequencer, batch sequencer, start/stop sequences.

Learning Unit 2 — Introduction to Measurement

• Key topics: fundamentals of measurement, units, observable variables, instrument characteristics (accuracy, precision, errors), loop error, dynamic characteristics, dead time, response curves, time constant.

Learning Unit 3 — Pressure Measurement

• Key topics: fluid properties, hydrostatic pressure, Pascal’s law, pressure units, static pressure head.
• Exercises: Exercise 3‑1 — Pressure Sensing Devices: manometers, Bourdon tube gauges, strain-gauge transmitters, pressure switches, installation & bleeding, pressure measurement in piping and pump systems, digital pressure switches.

Learning Unit 4 — Introduction to Flow

• Key topics: volume flow rate, mass flow rate, fundamentals of flow measurement.
• Exercises: Exercise 4‑1 — Rotameters: design, reading technique, pros & cons, flow measurement with rotameters.

Learning Unit 5 — Pressure Versus Flow

• Key topics: fluid dynamics, Bernoulli equation & applications, laminar vs turbulent flow, Reynolds number, pressure types.
• Exercises: Exercise 5‑1 — Centrifugal Pumps: pump types, operation, performance curves, cavitation, NPSH, head vs speed; Exercise 5‑2 — Pressure Loss: major/minor losses, K-factor and equivalent length methods; Exercise 5‑3 — Control Valves: solenoid & proportional valves, valve characteristics, pneumatic actuators, positioners, valve sizing & commissioning.

Learning Unit 6 — Flow Measurement

• Key topics: primary flow elements (orifice plates, Pitot tubes), differential-pressure fundamentals.
• Exercises: Exercise 6‑1 — Venturi Flow Elements & Electromagnetic Flow Meters: Venturi operation, flow calculations, installation, pressure loss; electromagnetic meter principles, commissioning, advantages/limitations, manifold operation for DP transmitters.

Learning Unit 7 — Level Measurement

• Key topics: level measurement principles, hydrostatic level, suppressed/elevated zero ranges, differential pressure for level.
• Exercises: Exercise 7‑1 — Differential Pressure Level Meters: configuration, zeroing, level in pressurized vessels; Exercise 7‑2 — Radar Level Meters: guided vs non‑guided radar, echo analysis, dielectric effects, linearization, mapping, commissioning, volume readings.

Learning Unit 8 — Temperature Measurement & Heat Transfer

• Key topics: temperature scales, thermodynamics, heat transfer mechanisms (conduction, convection, radiation), specific & latent heat.
• Exercises: Exercise 8‑1 — Temperature Probes: RTDs, thermocouples, wiring, noise sensitivity, transmitters, time-constant measurements.

Learning Unit 9 — Process Characteristics

• Key topics: open-loop vs closed-loop, dynamic systems, block diagrams, process dynamics (resistance, capacitance, inertia), single‑capacitance models, time constant, process gain.
• Exercises: Exercise 9‑1 — Determining Dynamic Characteristics of a Process: open-loop response analysis, process order/gain, graphical and numerical methods (2%–63.2%, 28.3%–63.2%), pressure process characterization.

Learning Unit 10 — Feedback Control

• Key topics: feedback fundamentals, on‑off control, PID control (P, PI, PID), controller tuning, controller structures (parallel, interacting, non‑interacting), effects of controller actions.
• Exercises: Exercise 10‑1 — Tuning and Control of a Pressure Loop: trial-and-error tuning, P/PI modes; Exercise 10‑2 — Tuning and Control of a Flow Loop: ultimate cycle tuning, Q‑decay; Exercise 10‑3 — Tuning and Control of a Level Loop: open-loop Ziegler‑Nichols, fine tuning; Exercise 10‑4 — Cascade Control of a Level/Flow Process: cascade setup and tuning.

Learning Unit 11 — Batch Control

• Key topics: batch process control concepts, functions, standards, batch vs continuous processes, optimization.
• Exercises: Exercise 11‑1 — Tuning a Batch Control System: batch loop control and parameter tuning.

Learning Unit 12 — Troubleshooting of a Process Control System

• Key topics: systematic troubleshooting, 7‑step method, plant shutdown scenarios, guided vs non‑guided troubleshooting, projects and transversal skills.
• Exercises: Exercise 12‑1 — Guided Process Control Troubleshooting; Exercise 12‑2 — Non‑Guided Process Control Troubleshooting and project work.