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Standards

Certification

Education and Training

Publishing

Conferences and Exhibits

ISA Seminars on the WebLive Experts on Hot Topics

Standards

Certification

Education and Training

Publishing

Conferences and Exhibits

CSE PE Exam Review:Control Systems

EN00W4 Version 1.4 2011

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Seminar Logistics

Seminar materials Downloadable presentation

Question and Answer session (audio and email)

Survey

Earn 1 Professional Development Hour (PDH)

Seminar length

60 minute presentation

Three 10-minute question and answer sessions

Audio Instructions

As a participant, you are in a listen-only mode.

You may ask questions via the internet, using your keyboard, atany time during the presentation. However, the presenter maydecide to wait to answer your question until the next Q&ASession.

If you have audio difficulties, press *0.

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Audio Instructions for Q&A Sessions

Questions may be asked via your telephone line.

Press the *1 key on your telephone key-pad.

If there are no other callers on the line, the operator willannounce your name and affiliation to the audience and thenask for your question.

If other participants are asking questions, you will be placedinto a queue until you are first in line.

While in the queue, you will be in a listen-only mode until theoperator indicates that your phone has been activated. Theoperator will announce your name and affiliation and then

ask for your question.

Introduction of Presenter

Gerald Wilbanks, P.E. Vice President ofDocumentation and Engineering Services inBirmingham, Alabama has over 40 years ofexperience in engineering, management,consulting, and design in heavy industry. He is aregistered professional engineer in 4 states, amember of NSPE, ASQ, and an InternationalFormer President (1995) of ISA. Gerald is agraduate of Mississippi State University with aBachelors Degree in Electrical Engineering andwas recognized as the Engineer of the Year in1991 by the Engineering Council of Birmingham.He is a Distinguished Engineering Fellow ofMississippi State University and is a Life Fellowmember of ISA. He has served as an instructorin many courses, seminars, and othereducational sessions for ISA and in his ownbusiness.

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Key Benefits of Seminar

Identify areas of focus for more effective studying to assist inpassing the PE examination

Explain control system functionality

List Control System applications

Discuss system documentation and standards used

Review Control Loop Tuning

Control Systems represents 18 problems or 22% of the CSEPE exam

Section 1: Control Loops

Loop Definitions

Controller Actions

Loop Examples

Proportional Mode

Integral Mode

Derivative Mode

Controller Characteristics

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Process Control

The regulation or manipulation of variables influencing theconduct of a process in such a way as to obtain a product ofdesired quality and quantity in an efficient manner

PROCESSMANIPULATED

VARIABLESMEASURED

VARIABLE

CONTROLLER

CONTROLLED

VARIABLE

DISTURBANCES

The Process Control System (Loop)

PROCESS

TRANSMITTED

SIGNAL

SENSOR

TRANSMITTERCONTROLLER

FINALCONTROLELEMENT

MANIPULATED

VARIABLE

CONTROLLED

VARIABLE

SET POINT

Signal basedon error ordeviation andeffects of controlmodes

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Controller Actions and Modes

Direct and reverse actions

On-Off control

Proportional control

Integral control

Derivative control

CORPORATE LEVEL CONTROLS

SCHEDULING AND OTHER

Ratio, Cascade, Feedforward

ADVANCED REGULATORY CONTROL

Feedback

BASIC REGULATORY CONTROL

OPTIMIZATION

SAFETY CONTROLS

PROCESS

Control Hierarchy

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Controllers and Control Strategies

Set Point

Disturbances

ProcessMeasurement

Algorithm(Control Law)

FinalControlElement

Process

Controller Output

Direct Acting Controller

CONTROLLAW

ErrorSet Point

Measurement

ControllerOutput

Increase in MeasurementCauses

Increase in Controller Output

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Reverse Acting Controller

CONTROLLAW

ErrorSet Point

Measurement

ControllerOutput

Increase in MeasurementCauses

Decrease in Controller Output

Direct or Reverse Acting - Example

Steam

Air-to-Open

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Proportional Control

Proportional Control Algorithm

Gain

Closed

Open

Setpoint

Valve

100

90

80

70

60

50

403020

100

m = Kce + Bias

e

KC

KCe

e m

Proportional Action

Proportional band

The amount of input change that will produce 100% output change.

Always expressed as a percentage

Gain

A unit-less number that defines the ratio of the change in output, due to

proportional control action, to the change in input

PB G

200% --------------------------------- .5

100% -----------------------------------1

50% ------------------------------------2

in

outG

=

PBG

100=

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Integral Action

Integral (reset): Control action in which the output is proportional to thetime

integral of the input

Reset action is adjusted in repeats/minutes or minutes/repeat

Minutes/Repeat (Ti) Repeats/Minute (Tr)

2 ------------------------- .5

1 ------------------------- 1

.5 ------------------------- 2

Proportional + Integral Control

Proportional - Plus - Integral (PI):

Integral (Reset) Action: mT

e dt

i

= 1

BiasdteT

eKm

i

c+

+= 1

Gain

Closed

Open

Setpoint

Valve

100

908070

6050403020

100

Reset

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Derivative Action

Derivative (rate): Control action in which the output is proportional to the rate of change

in the input

Derivative (Rate) Control Action

m Td

dte

d=

Control action in which the output is proportionalto the rate of change in the input

Error Signal

-5

0

+5

75

80

85Temperature

Rate ofChange Over Time

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Proportional + Integral + Derivative Control

Gain

Closed

Open

Setpoint

Valve

10090807060

5040

302010

0

Reset

Rate

P + I + D + Biasm K eT

edt T d

dte

c

i

d= + +

1

edt

dTAction(Rate)Derivative D ==m

Characteristics of Controller Modes

Proportional

Simple

Inherently stable when properly tuned

Easy to tune

Experiences offset at steady state

Proportional-plus-reset

No offset

Better dynamic response than reset alone

Possibilities exist for instability due to lag introduced

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Characteristics of Controller Modes (contd)

Proportional-plus-rate

Stable

Less offset than proportional alone (use of higher Kc possible)

Reduces lags, i.e., more rapid response

Proportional-plus-reset-plus-rate

Most complex

Rapid Response

No offset

Difficult to tune

Best control if properly tuned

Process Dynamics (Response to Change)

INPUT CHANGE OUTPUT RESPONSE

PROCESSDEAD TIME PLUS

FIRST ORDER LAG

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Dead Time

DEAD TIME

CHANGEIN INPUT

INPUT CHANGE INITIATED

PROCESS

Process Variable Measurement

Time

Time Constant

FIRST TIMECONSTANT

TIME

100%

63.2%

0%

CHANGE IN INPUT

PROCESS

OUTPUTCHANGE%

Process Variable Measurement

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First Order Lag

0 1 2 3

TIME CONSTANTS

INPUT

OUTPUT

4 5

Input

Output

Dead Time

Product Out

Td

TIC

Steam

Product In

Condensate

Time

Steam In

Outlet Temperature

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First Order Lag plus Dead Time

0 1 2 3

TIME CONSTANTS

INPUT

OUTPUT

4

Td

Tuning Methods

Objectives of Tuning

Trial & error

Open-loop test

Closed-loop test

Improving as found tuning

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Objectives of Tuning

Adjustment of gain, reset, and rate to achieve good processcontrol

CHANGE / DISTURBANCE

PROCESS

CONTROL

SYSTEM

GOOD PROCESS CONTROL

Acceptable response to a set point change

1. ONE-QUARTER DECAY RATIO

A BB

A

1

4

2. MINIMIZE OVERSHOOT

Objectives of Tuning (contd)

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Tuning Map - Gain and Reset

Increasing Reset Action

FAST RESET(More Repts/Min)

(Less Min/Repeat)

NO RESET(Small Repts/Min)

(Large Min/Repeat)

IncreasingProportionalAction

HIGHGA

IN

(NARROW

PB)

LOWG

AIN

(WIDEPB)

Tuning by Open Loop Testing

Process near normal operating point

Controller in MANUAL

Step change the controller output

Approximate the observed response by a simplified process model

From the model parameters, use somebodys correlation todetermine controller tuning parameters

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Z-N Open Loop Test Method

TIMETd

K = PROCESS GAIN =p

T =d DEAD TIME

TIME CONSTANT

Tangent - drawn at pointof steepest process rise

VALVE

MEASVALVE

MEAS 63.2%MEAS

=

=

=

Open Loop Method (contd)

TUNING PARAMETERS

P PI PID

K

T

T

I

D

C

K Tp d

K Tp d

K Tp d

0.9 1.2

3.33 Td 2.0 Td

0.5 Td

(Gain)

(Minutes/Repeat)

(Minutes)

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Problems with Open Loop Method

Sensitive to parameter estimation error (especially dead time)

Simplified form of process model may not match the actualprocess

Controller not in normal operating mode

Limitations on step size may make it difficult to interpret theresponse - especially in the presence of noise

Closed loop response may not be acceptably damped for a setpoint change

Tuning by Closed Loop Testing

Process near normal operating point

Controller in AUTOMATIC

GAIN only; no RESET nor DERIVATIVE

Induce sustained oscillation by gradually increasing controller gain

Note the ultimate period (Pu) and ultimate gain (Kcu)

Use correlation to determine controller tuning parameters

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Z-N Closed Loop Method

uP

Increase Kc

Decrease Kc

K = Kcu c

Closed Loop Method (contd)

TUNING PARAMETERS

P PI PID

K

T

T

I

D

C 0.6 K cu

0.83 P 0.5 P

0.125 P

u u

u

0.45 K cu0.5 K cu

(Gain)

(Minutes/Repeat)

(Minutes)

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Problems with Closed Loop Method

May not be possible to drive process into oscillating condition

May require several tests - longer testing time - than open loopmethod

Cannot guarantee how much the PV - nor the controller output- will swing

Good Points with Closed Loop Test

Controller is operating in its normal mode (automatic)

No artificial form of the process model imposed

Minimal uncertainty in the data

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Review of Key Points

The controller action works together with the control valveoperation

Controller law or algorithm determines the output from thecontroller in response to loop error

Control modes must be selected based on the processcharacteristics and response

Three mode control is not always the most effective selection

The control modes are interactive and dynamic

Live Question and Answer Session

During Q&A, questions may be asked via your telephone line.

Press the *1 key on your telephone key-pad.

If there are no other callers on the line, the operator will announceyour name and affiliation to the audience and then ask for yourquestion.

If other participants are asking questions, you will be placed into aqueue until you are first in line.

While in the queue, you will be in a listen-only mode until the operatorindicates that your phone has been activated. The operator will

announce your name and affiliation and then ask for your question.

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Section 2: System Documentation

Process and Instrument Diagrams

ISA Standards for Documentation

Loop Numbering Conventions

Loop Diagram Symbology

Instrument Lists

Installation Details

Process and Instrumentation Diagram

FIC

FIC

PIC

LIC

VENT

FEED

O2

FIFCV

FCVLCV

PCV

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Identification Letters

FIRST LETTER SUCCEEDING- LETTERS

Measured orInitiating Variable Modifier

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

Analysis

Burner, Combustion

Users Choice

Users Choice

Voltage

Flow Rate

Users Choice

Hand

Current (Electrical )

Power

Time, Time Schedule

Level

Users Choice

Users Choice

Users Choice

Differential

Ratio (Fraction)

Scan

Time Rate ofChange

Momentary

Readout orPassive Function

Alarm

Users Choice

Sensor (Primary)Element

Glass, Gauge

Viewing device

Indicate

Light

Users Choice

Orifice,Restriction

Output

Function

Users Choice

Control

Control Station

Users Choice Users Choice

Users Choice

Modifier

High

Low

Close

Deviation

Middle

Open

Identification Letters (contd)

FIRST LETTER SUCCEEDING-LETTERS

Measured or

Initiating Variable ModifierReadout or

Passive Function

Output

FunctionModifier

P Pressure, Vacuum Point Connection

Q Quantity Integrate

R Radiation Record

S Speed, Frequency Safety Switch

T Temperature Transmit

U Multivariable Multifunction Multifunction Multifunction

V Vibration, Mechan.

Analysis

Valve, Damper,

Louver

W Weight, Force Well

X Unclassified X Axis Unclassified Unclassified Unclassified

Y Event, State Y Axis Relay, Compute

Z Position, Dimension Z AxisDriver, Actuator,

Final Element

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General Instrument or Function Symbols

Instrument to Instrument Connection Symbols

INSTRUMENT SUPPLY OR CONNECTION TO PROCESS

UNDEFINED SIGNAL

PNEUMATIC SIGNAL

ELECTRONIC SIGNAL

CAPILLARY TUBE

HYDRAULIC SIGNAL

ELECTROMAGNETIC SIGNAL (GUIDED)

INSTRUMENT SUPPLY OR CONNECTION TO PROCESS

UNDEFINED SIGNAL

PNEUMATIC SIGNAL

ELECTRONIC SIGNAL

CAPILLARY TUBE

HYDRAULIC SIGNAL

ELECTROMAGNETIC SIGNAL (GUIDED)

COMMUNICATIONS LINK BETWEEN SYSTEM DEVICES

COMMUNICATIONS LINK TO/FROM SMART (HART) DEVICE

COMMUNICATIONS LINK TO/FROM INTELLIGENT (FIELDBUS) DEVICE

ELECTROMAGNETIC (WIRELESS) SIGNAL (UNGUIDED)

COMMUNICATIONS LINK BETWEEN TWO SYSTEMS (e.g. DCS and SIS)

Refer to ISA5.1 Table 5.3.2 for additional symbols

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Example #1 Adding Signal Transmission Lines

Example #2 Adding Signal Transmission Lines contd

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Actuator Action and Power Failure

Flow Measuring Element Symbols Orifice plate or restriction orifice Pitot tube Turbine flowmeter Vortex shedding flowmeter

b)Ma) Magnetic flowmeter

Ta) b) Thermal mass flowmeter Positive displacement flowmeter

Cone flowmeter

Coriolis mass flowmeterSonic flowmeter

Open channel flowmeterRefer to ISA5.1 Table 5.2.3 for additional symbols

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Level Measuring Element Symbols

Displacer internally mounted in vessel

Ball float internally mounted in vessel

Sonic or Single point Radiation

Dip Tube and other primary element

Probe inserted in vessel

Radar

Refer to ISA5.1 Table 5.2.3 for additional symbols

Typical Transmitters Flow

Orifice plate andorifice flanges withflange taps, differentialpressure transmitter,pneumatic transmission

Orifice plate andflanges, taps aremade in pipe,differential pressuretransmitter, electronictransmission

Venturi tube, tapsare in tube,differential pressuretransmitter withindicator, electronictransmission

Pitot tube,connections are intube, differentialpressure transmitter,electronic transmission

FE99

FT99

FE1

FT1

FE100

FIT100

FT15

FE15

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Level using Differential Pressure Transmitter

Differential pressure typetransmitter, electronicsignal

VESSELLIT99

ISA Standards used for Documentation

ISA5.1-2009, Instrumentation Symbols and Identification

ISA5.4-1991, Instrument Loop Diagrams

ISA5.5-1985, Graphic Symbols for Process Displays

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Other Documentation

Loop diagrams

Process flow diagrams

Instrument lists

Instrument installation

Piping specifications

Review of Key Points

Control systems can be documented in a logical and standardmanner

Each drawing has a specific purpose and conveys information to avariety of people

The P&I Diagram is the central most important document to portraythe overall control function

Calculations and device selection is based on the documents for thesystem function

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Live Question and Answer Session

During Q&A, questions may be asked via your telephone line.

Press the *1 key on your telephone key-pad.

If there are no other callers on the line, the operator will announceyour name and affiliation to the audience and then ask for yourquestion.

If other participants are asking questions, you will be placed into aqueue until you are first in line.

While in the queue, you will be in a listen-only mode until theoperator indicates that your phone has been activated. Theoperator will announce your name and affiliation and then ask foryour question.

Section 3: Control Types/Characteristics

Ratio control

Cascade control

Feedforward control

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Ratio Control - Wild Stream

RATIO CONTROL:Flow rate of one streampaces the flow rate of asecond stream

FFC

FT

FT

Wild Flow

FY

FY

Controlled

Flow

Ratio Control - Both Streams Controlled

Air

Hydrocarbon

Air

MIXINGTEE TO

REACTOR

FC

FF

FC

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Automatic Ratio Set: Example

TT

TICFC

FTFT

FC

O C2 O T2

AIR FUEL

Cascade Control: Diagram

CASCADE CONTROL:

When one feedback controllersets the set point of anotherfeedback controller

FIC

FT

TIC

Primary

Controller

Secondary

Controller

FY

TT

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Application: Without Cascade

TIC

T

SteamCold In

Hot Out

Process Flow

TT

Disturbance: Drop in Steam Header Pressure

Consequence: Feedback Penalty Paid at

Temperature Controller

Application: With Cascade

FIC

FT

TIC

Primary

Controller

Secondary

Controller

T

Steam

Cold In

Hot Out

Process Flow

TT

Disturbance: Drop in Steam Header Pressure

Consequence: Feedback Penalty Flow Controller;

Minimal Effect at Temperature Controller

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Inner and Outer Loops

Primary Secondary InnerProcess

MainProcess

Disturbance Disturbance

INNER LOOP

OUTER LOOP

Feedforward Control: Definition

FEEDFORWARD CONTROL:

The final control device (valve or set point oflower level flow controller) is manipulated by ameasurement of the process disturbance, ratherthan by the output of a feedback controller

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Feedforward Control: Requirements

The disturbance must be measurable

We must know what to do to compensate for the disturbance

We must know when (i.e., on what time schedule) to take thecompensating action

Feedforward Control Loop (contd)

SETPOINTDISTURBANCE

FEEDFORWARDCONTROLLER

SENSOR

PROCESSMANIPULATED CONTROLLED

VARIABLE VARIABLE

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Feedforward Control of Heat Exchanger

LIQUID IN

LIQUID OUT

STEAM

FC

FI

TRC

TI

TRAP

T

T

W

F

T

T

T

SP

SP

SP

0

F =Wc ( )

H

T TSPP ii

ADJUSTING THE SETPOINT

Level Control Strategy Functional Diagram

LT

T AA

PI

f(x)Feedwater Control

Valve (Valve A)

Steam Drum Level(Device C)

Single Element Control

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Level Control Strategy Functional Diagram

FT

T AA

SUM

f(x)

Feedwater Flow(Device B)

Three Element Control

PI

FTSteam Flow(Device E)

PI

LT

Steam Drum Level(Device C)

Feedwater ControlValve (Valve A)

Review of Key Points

Blending and mixing can be done with ratio control systems

Cascade control is when the output of one feedback controller isthe set point for another controller

The inner loop of a cascade system should have a much fasterspeed of response than the primary control loop

Feedforward control may be used with feedback control toprovide correction in anticipation of a disturbance.

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Live Question and Answer Session

During Q&A, questions may be asked via your telephone line.

Press the *1 key on your telephone key-pad.

If there are no other callers on the line, the operator will announceyour name and affiliation to the audience and then ask for yourquestion.

If other participants are asking questions, you will be placed into aqueue until you are first in line.

While in the queue, you will be in a listen-only mode until theoperator indicates that your phone has been activated. Theoperator will announce your name and affiliation and then ask foryour question.

How Many People Are at Your Site?

Poll Slide

Click on the appropriate number indicating the number ofpeople that are at your site.

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Sample Exam Question - #1

According to ISA Standard 5.1, Instrumentation Symbolsand Identification, the terms record or recording canapply to which of the following:

I. Graphical data in a strip or circular chart

II. A table of numerical data in a computer memory

III. A listing of alarms by a control computer

A. I and II

B. II and III

C. I and III

D. I, II, and III

Sample Exam Question - #2

The control algorithm for a flow control loop is underconsideration. It is determined that the flow must bemaintained near set point with little or no offset and the signalwill be rapid response and noisy. The best choice of controlmodes for this loop will be:

A. Proportional Mode

B. Integral plus Derivative

C. Proportional plus Integral

D. Proportional plus Integral plus Derivative

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Sample Exam Question - #3

A secondary steam distribution system is being used to controlthe heat input to a heat exchanger. It has been determined thata control problem will exist since the varying steam headerpressure will be a major disturbance. Define the primarycontrolled variable and what control scheme could beemployed to provide the best response with the least amount ofmeasured variable offset.

A. Product outlet temperature with header pressure feedforward control

B. Steam header pressure with outlet temperature adjusting set point

C. Product outlet temperature with temperature cascading steam flow

D. Product outlet temperature with direct feedback control.

Sample Exam Question - #4

Compared to a control loop with no dead time (pure timedelay), a control loop with an appreciable dead time tends torequire:

A. Less proportional gain and less integral action

B. More proportional gain and less integral action

C. More proportional gain and more integral action

D. Less proportional gain and more integral action

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Related Courses from ISA

Understanding and Applying Standard Instrumentation and ControlDocumentation (FG15)

Tuning Advanced Controllers (TC05C2)

Understanding Industrial Process Measurement and Control (FG05)

All ISA courses are available any time as on-site training

For more information: www.isa.org/training or (919) 549-8411

Other Related Resources from ISA

Instrument Engineers Handbook, 3rdEdition(Bela Liptak) fromISA Press

Fundamentals of Process Control Theory(Paul Murrill) fromISA Press

The Condensed Handbook of Measurement and Control, 2nd

Edition(N. Battikha) from ISA Press

ISA5.1-2009 Instrumentation Symbols & Identification

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Other Related Resources from ISA

ISA Membership is just $100 per year, which includes freemembership in two Technical Divisions (a $20 value) - onefrom each Department: Automation and Technology andIndustries and Sciences.

For more information: http://www.isa.org/membership/meminfo or(919) 549-8411

ISA Certifications

Certified Automation Professionals (CAP )

www.isa.org/CAP

Certified Control Systems Technician (CCST)

www.isa.org/CCST

Please visit us online for more information on any of theseprograms, or call (919) 549-8411.

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