Lesson 1 - History and Overview

Topics:

SCADA; Microprocessor-based instruments; Distributed control; Personal computers; PLCs; Artificial intelligence; Expert systems; Fuzzy logic; Integrated control systems

Learning Objectives:
– Discuss the history of the application of computers to continuous and batch process control.
– Describe the function of an RTU in a SCADA system.
– Describe the development of distributed control systems from microprocessor-based instruments, including programmable logic controllers.
– Compare the hardware, operating systems, software, and applications of a PC with a household VCR.
– Compare the concepts of artificial intelligence, expert systems, and fuzzy and crisp logic.

Lesson 2 - Small Computers in Process Control

Topics:

Smart sensors, transmitters, signal conditioners, and final elements; Single and multiloop controllers; Networks; PLCs

Learning Objectives:
– Describe the various kinds of small computers used in process control.
– Explain how a "smart" device differs from its conventional counterpart.
– Discuss the similarities between microprocessor-based instruments and conventional instruments and list several advantages of microprocessor-based instruments.
– Describe the roles of two kinds of PCs (programmable controllers and personal computers) in process control.

Lesson 3 - DCS Architecture

Topics:

Distributed control system hardware and software; Workstations; Remote processing units; Host/guest computers; Transmission systems; What is Fieldbus?

Learning Objectives:

– Describe the elements of a typical workstation.
– Discuss the functions of remote processing units and host/guest computers in DCSs.
– Compare star, hub, and ring network topologies and token-passing, contention, and polling protocols.
– Explain why today's DCS users must be more computer literate than previously.
– Discuss ways of calculating and ensuring DCS reliability.
– Describe the functions of six typical DCS peripherals. 
– List advantages and disadvantages of all-digital process control systems, such as fieldbus. 

Lesson 4 - DCS Configuration and Operation

Topics:

Configuring distributed control systems; Hierarchical displays; Configuring operating and auxiliary displays; Operation

Learning Objectives:
– Describe the basics of a simple configuration process.
– Discuss the preparatory steps required for configuration.
– Describe a typical hierarchical display arrangement and discuss the progression of the configuration process from level to level.
– Discuss the automatic configuration of auxiliary displays.
– Discuss the DCS functions for which the operator is and is not responsible.

Lesson 5 - Systems and Application Integration

Topics:

Total business operation; Discrete processes and manufacturing systems; Flexible manufacturing; Materials control; Statistical process control

Learning Objectives:
– Discuss the development of integration in industry.
– Describe how continuous and discrete processes fit into the concept of total business integration.
– Describe the purposes of MAP and OSI.
– Discuss the functions of CAD, CADD, CAE, CAM, and cell control in discrete processes.
– Discuss the importance of FMS, MRP, JIT, and MMS in today's integrated industrial plant.
– Explain how SPC ensures quality control in open-loop processes.
– Discuss the advantages of integrating batch, continuous, and discrete processes throughout a plant.