Know About Your Trainer
Our Consultant is a Self-motivated team player with proven experience as CTO/ Engineering Management/ Technical leadership/ Automation Consultancy/Engineering Management/ Project Management/ Project execution as Lead/ Maintenance/ Training, ability to deliver quality results under pressure and willing to learn more. Having 15.5+ years of International experience. I have worked with most major brands of Robotics/IOT/ PLC/ DCS/ ESD or SIS/ F&G/ SCADA/ Instrumentation/ Turbomachinery/ Electrical Systems and Automation Communication Protocols-Media. I have experience in all major industries, like Automobile, Fertilizer, Chemical, Tobacco, Nuclear, Water treatment, Food and Beverages, Personal care products, Petrochemical, and mainly Oil and gas (upstream, midstream, downstream, green/ brown field projects, Onshore and offshore) and Academia/ Research. As a Robotics and Industrial Automation engineer with proven experience.
Achievements and Highlights
• In 2017, CTO (Chief Technology Officer) /Training Specialist for Robotics and Automation, Services Syndicate (Pvt) Limited.
• In 2016, Engineering Manager and CTO (Chief Technology Officer) /Training Specialist, Devrim Technologies for Robotics and Industrial Automation Technical Leadership and Business Development/ trainings
• In 2009 onwards, Executed PALL Chevron/ QATAR Petroleum Projects as Project Manager.
• In 2007, Project Manager/ Commissioning HIMA F&G system, Qatar Petroleum, HIMA ESD sys, OGC, Oman
• In 2005, Worked in UAE, Dubai and Sharjah, FPSO /MOPU DCS/ ESD/ F&G Honeywell Experion R201/ R210 and FSC Projects
Benefits For Attending This Training
PLC and DCS
control system technologies become the back bone of any factory or industry or a process plant. The attendees will learn about the basics of PLC and DCS. Also the differences between PLC and DCS and the similarities. Also trainees will learn the history of PLC/ DCS and future evolution of these technologies.
Attendees of this training will gain understanding on different types of documentation for PLC/ DCS and related equipment. Without referring to such documentation it is not possible to maintain control system of any number of Input & outputs. These documents are updated when ever there is changes done to software/ hardware/ network, wiring or changes in the field instrumentation or JB wiring.
Attendees will be exposed to international standards related to PLC/ DCS/ HMI and real life career experiences from International Projects and maintenance experience on mega projects etc.
Attendees will be introduced to real life experiences of the trainer related to control system and instrumentation and related to challenges faced in design, testing, commissioning and maintenance at international level clients like Saudi Aramco, Chevron, Shell, OMV and others.
Attendees will be competent Control system maintenance professionals in the field of Maintenance of PLC, DCS, HMI, related Networks and related instrumentation.
Key Objectives For Training Module-1 PLC
Module -1 PLC
The trainee Should become conversant with PLC and all related technologies.
Should be able the access relevant documentation End user, system integrator, vendor
Select the all hardware components of PLC system
PLC Software and programming languages,
Regulatory and Discrete instructions and algorithms
Network software, Emulation Software
PLC networks
HMI/ SCADA
Maintenance and troubleshooting on Controller/Communication/ Power Supply, IO Cards and Software level PLC/ HMI (Upto 10 or more Special Topics related to PLC/ HMI control system Life cycle based on Trainer vast Experience
Simulator will be provided for duration of training
Module -2 DCS
The trainee Should become conversant with DCS and all related technologies.
Should be able the access relevant documentation End user, system integrator, vendor
Select the all hardware components of DCS system
DCS Software and programming languages,
Regulatory and Discrete instructions and algorithms
Network software, Emulation Software
DCS networks
HMI/ SCADA
Maintenance and troubleshooting on Controller/Communication/ Power Supply, IO Cards and Software level DCS/ HMI
(Upto 10 or more Special Topics related to DCS/ HMI control system Life cycle based on Trainer vast Experience
Simulator will be provided for duration of training
Course Outline
DAY ONE
Session One:
-
• PLC
• Basic concepts of PLC
• PLC, DCS and SCADA comparison
• PLC specifications, advantages, features and selection criteria
Case Study / Activity
-
• Control system Desired Specifications from End User-1
PLC HARDWARE BUILDING BLOCKS
-
• Control system and security hierarchy
• Input, Output, Control, Communication and Redundancy Modules
• Selection of all PLC hardware Controller and IO Racks, Power Supplies, Cables like power cable, IO card cable, IO card Terminal Blocks, Etc POWER QUERY SYNTAX
- Control system Desired Specifications from End User-2
Session Two:
-
• PLC SOFTWARE ENVIRONMENT AND BASIC USAGE TO CREATE PROGRAMS
• PLC Software Environment
• PLC Creating a new Project
• PLC Software environment
• PLC Programming Languages
• PLC Programming languages as per International Standard IEC-61131-3
• PLC Instruction Set BASIC
• PLC Instruction Set INTERMEDIATE
• PLC Instruction Set ADVANCED
• Review of PLC Instruction Set and how to configure basic instructions in different languages
• Review of Control Algorithms (Proportional, Integral and Derivative (PID)) control,
• Tuning methods like hit and trial, and other mathematical methods. Also covering other types of regulatory control blocks
Case Study / Activity
- • Control System Design Documents from Control system vendor (Principal or system integrator)-1
PLC DATA COMMUNICATIONS,
NETWORKING, REDUNDANCY-
Data Communications and Networking
Common types of Networks DH+, DH-485, Ethernet, Ethernet/IP, Modbus-RTU, Modbus-TCP, OPC
• Physical, Logical and Communication Network Structures and Standards Difference between Physical and Logical layer of Network commonly used Standards in Communication
• Hardware security and redundancy how is Hardware Security implemented redundancy, purpose, layers of redundancy Power Supply/ CPU/ Communication/ Rack/ IO Card Level etc.
Case Study / Activity
-
Control System Design Documents from Control system vendor (Principal or system integrator)-2
DAY TWO
Session One:
-
PLC LOGIC SOFTWARE ADVANCED, HMI INTRODUCTION, ENTERPRISE LEVEL
PLC Software (Control system, controller and Function Block) configuration and programming.
Review of Control system Architecture Function Block Configuration and Programming
User Defined Data Types User Defined Function Blocks (Add-on Instructions)
EXERCISE
-
Human Machine Interfaces (Introduction, features and requirements).
• HMI Basic Concepts
• HMI Tags and connectivity with PLC
Software environment intro Creating a project
Making graphic screens
Making animated objects
Making HMI tags
Linking Hmi Tags to PLC tags
Testing PLC with HMI is simulated/ Emulated environment
advanced features of HMi like Trends, Alarms, Security, Etc.
EXERCISE
• Enterprise Level communication
- OPC, Historian, ERP level software
- this involves OPC and Historian Software.
- OPC level software collects Realtime data from PLC and related equipment
- the historian software collects data from OPC and makes a record at a defined frequency. this software can also provide business analytics.
- The enterprise level software like ERP gets data from OPC/ Historian and provide Realtime and historical data to plant/ factory production management
EXERCISE Case Study / Activity
- Maintenance related special topics
Session Two:
-
PLC MAINTENANCE AND TROUBLESHOOTING OF HARDWARE AND SOFTWARE
• Maintenance and Troubleshooting for CPU/ RACK POWER SUPPLY
Finding Datasheets from Vendor website and locating the diagnostic/ LED status
EXERCISE
• Maintenance and Troubleshooting for All Other Hardware Including IO cards Communications, Cards, signal and communication Wiring Etc.
Types of hardware maintenance, like Hot Swappable, and other types finding Datasheets from Vendor website and locating the diagnostic/ LED status
EXERCISE Maintenance and Troubleshooting for Software. Online software modification, online editing of Logic and HMI
Finding Datasheets from Vendor website and locating the diagnostic/ LED status also how to access diagnostics related info from software
EXERCISE Case Study / Activity
- • Special topics Books and other online resources for continuous Learning
DAY THREE
Session One:
-
BASICS OF DCS
• Basic concepts of DCS
EXERCISE
DCS, PLC and SCADA comparison
EXERCISE
DCS specifications, advantages, features and selection criteria
EXERCISE
• Laboratory work: Project creation and project common definition
• FCS configuration Case Study / Activity
- • Control system Desired Specifications from End User-1
Session Two:
-
DCS HARDWARE BUILDING BLOCKS
•Control system and security hierarchy
EXERCISE
• Input, Output, Control, Communication and Redundancy Modules
EXERCISE
• Selection of all DCS hardware
• I/O module configuration
•Software switches configuration
•Message definition
Controller and IO Racks, Power Supplies, Cables like power cable, IO card cable, IO card Terminal Blocks, Etc.
EXERCISE
Case Study / Activity
- • Control system Desired Specifications from End User-2
DAY FOUR
Session One:
-
DCS SOFTWARE ENVIRONMENT AND BASIC USAGE TO CREATE PROGRAMS
DCS SOFTWARE ENVIRONMENT AND FIRST STEPS IN Creating a Project, Configuring Hardware and software settings
PLC Software Environment
PLC Creating a new Project
PLC Software environment
PLC Programming Languages
PLC Programming languages as per International Standard IEC-61131-3
EXERCISE
-
DCS Instruction Set BASIC
DCS Instruction Set INTERMEDIATE
DCS Instruction Set ADVANCED
Review of PLC Instruction Set and how to configure basic instructions in different languages
EXERCISE
-
• Review of Control Algorithms (Proportional, Integral and Derivative (PID)) control
• Laboratory work: FCS configuration, I/O module definition, Regulatory control generation
• Sequence control function
• Laboratory work: Regulatory control and Sequence control exercises Tuning methods like hit and trial, and other mathematical methods. Also covering other types of regulatory control blocks
Case Study / Activity
-
Control System Design Documents from Control system vendor (Principal or system integrator)-1
Session Two:
- DCS DATA COMMUNICATIONS, NETWORKING, REDUNDANCY
• Data Communications and Networking Common types of Networks V-NET, V-NET/IP, Ethernet, Ethernet/IP, Modbus-RTU, Modbus-TCP, OPC
EXERCISE
• Physical, Logical and Communication Network Structures and Standards Difference between Physical and Logical layer of Network commonly used Standards in Communication
EXERCISE
Hardware security and redundancy How is Hardware Security implemented redundancy, purpose, layers of redundancy Power Supply/ CPU/ Communication/ Rack/ IO Card Level etc.
EXERCISE Case Study / Activity
- • Control System Design Documents from Control system vendor (Principal or system integrator)-2
DAY FIVE
Session One:
-
DCS LOGIC SOFTWARE ADVANCED, HMI INTRODUCTION, ENTERPRISE LEVEL
DCS Software (Control system, controller and Function Block) configuration and programming.
• HIS configuration
• Window configuration/ Test function
• Laboratory work: HIS builder function
Review of Control system Architecture
Function Block Configuration and Programming
User Defined Data Types
User Defined Function Blocks (Add-on Instructions)
EXERCISE
Human Machine Interfaces (Introduction, features and requirements).
• DCS has same tag database for controller and HMI, how does this work?
• Graphic builder
• Laboratory work: Graphic generation
Software environment intro
Creating a project
Making graphic screens
Making animated objects
Selecting Tags from Controller Database
Linking Controller Tags to HMI Objects
Testing DCS with HMI is simulated/ Emulated environment
advanced features of HMi like Trends, Alarms, Security, Etc.
EXERCISE • Enterprise Level communication
OPC, Historian, ERP level software
- this involves OPC and Historian Software.
- OPC level software collects Realtime data from PLC and related equipment
- the historian software collects data from OPC and makes a record at a defined frequency. this software can also provide business analytics.
- The enterprise level software like ERP gets data from OPC/ Historian and provide Realtime and historical data to plant/ factory production management Case Study / Activity
- Maintenance related special topics
Session Two:
-
DCS MAINTENANCE AND TROUBLESHOOTING OF HARDWARE AND SOFTWARE
Maintenance and Troubleshooting for CPU/ RACK POWER SUPPLY
Finding Datasheets from Vendor website and locating the diagnostic/ LED status
EXERCISE
• Maintenance and Troubleshooting for All Other Hardware Including IO cards Communications, Cards, signal and communication Wiring Etc.
Types of hardware maintenance, like Hot Swappable, and other types finding Datasheets from Vendor website and locating the diagnostic/ LED status
EXERCISE
Maintenance and Troubleshooting for Software. Online software modification, online editing of Logic and HMI
Finding Datasheets from Vendor website and locating the diagnostic/ LED status also how to access diagnostics related info from software
EXERCISE Case Study / Activity
- • Special topics Books and other online resources for continuous Learning