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INDEX
2 Brands of PLCs
(Keyence & AB)
1 Brands of SCADA
(Wonderware Intouch)
Pneumatics & Field Instruments
PROCESS AUTOMATION
Distillation Column
Superheated Steam Generator
Centrifugal Compressor
Centrifugal Pump
Heat Exchanger
Flash Drum
Gas Turbine
Furnace
Evaporator
CSTR
Plug Flow Reactor
Fixed Bed Reactor
Cogeneration Boiler
CPAE
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
Basic Introduction & Evolution of automation
Discussion about automation in industry
History of automation
Futures and application of automation
Automation tools explanation
Basic hardwire relay logic development & real time practice
Automation HEART DEVICE control of relay concept
Electrical concept of hardwire relay logic development
Live practice on hardwire logic in relay panel
Assignment based on digital logic and Boolean equations using relay
Introduction of PLC architecture and input / output system in various industries
General block diagram of PLC architecture
Explain input / output field instrument in industries
Explain various standard PLC and software used in industries
Explain various PLC programming method used in industries
Derive the ladder logic program using hard wire relay logic concept
Digital logics gates & Boolean concept
Flip-flops & latching
concepts in ladder Programming based on k-map rules
Assignment based on real time applications
Online Exams on above Topics
COURSE CONTENT
BASIC AUTOMATION INTRODUCTION AND HARDWIRE RELAY LOGIC DEVELOPMENT
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
Introduction of Keyence PLC software [ladder builder] and addressing of
Input / output system
Specification and features of Keyence PLC
Addressing of input / output system and memory mapping
Live practice on Keyence PLC programming tools software [ ladder builder ]
Assignment based on real time applications
Explain the application of timer [delay function] in automation industries
Explain the role of timer in industries
Various type of timer and its application
Programming based on timer and live practice in Keyence PLC software
Assignment based on timer applications
Explain the usage of counter function in automation industries
Differentiate the timer & counter function in PLC software and its usage
Various type counter and its application
Programming based on timer / counter and live practice in Keyence PLC software
Assignment based on counter applications
Upload / download the program and online monitoring in Keyence PLC panel
Communication detail between Keyence PLC and programming tool software in PC
Procedure of upload / download the program in Keyence PLC
Online monitoring and practice of programming tools software in Keyence PLC panel
Assignment based on Keyence PLC series and its evolution
Industrial standard of PLC panel Erection, commissioning & Trouble Shooting
Basic requirement of PLC panel designing and its apparatus tools
Draw the electrical wiring diagram of Keyence PLC panel and trouble shooting
Explain the [ source/sink ] type of digital input /output
Assignment based on electrical wiring on PLC panel used in industrial application
PLC PROGRAMMING DEVELOPMENT AND CONTROLS PANEL ERECTION & COMMISSIONING
TROUBLESHOOTING USING KEYENCE & OMRON PLC
KEYENCE PLC
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
Live practice on PLC panel wiring and application development
Examining the field input devices to PLC panel
Verifying the field output devices from the PLC panel
Design and development of real time industrial projects
Assignment based on complete PLC project solution
Online Exams on above Topics
AB PLC:
Industrial & Evolution of AB PLC and its programming tool software practice
Evolution and specification of AB PLC
Addressing Input / Output and memory mapping in AB PLC
Working in AB PLC programming tools software
Configuration of timer & counter and its application practice
Live practice on AB PLC panel explain Special Instruction sets & application development
Draw the electrical wiring diagram of AB PLC panel and troubleshooting
Practice on special instrument in AB PLC programming tool software
Procedure of upload / download and communication details between AB PLC panel and
programming tools software
Assignment based on real time application development in AB PLC panel
Overview of Industrial Field Instrument and explain field pneumatic control
System
Evolution of analog control system in industry
Explain pneumatic control system and its application usage in industry
Tools requirement of pneumatic control system and erection and commissioning
Connection between pneumatic field device to AB PLC panel and its configuration
Live practice on pneumatic control application using level control system
(PID control Algorithm)
Configuration of analog Input / Output module in AB PLC panel
Explain discrete of continuous control method used in level control system
Describe PID control algorithm and its configuration in AB PLC panel
Live demo on tank level control system interface with AB PLC panel and practice
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
Level / Temperature / Pressure
Process Control Using AB PLC
Special input module configuration (RTD, Thermocouple) in AB PLC and its real time
application development and practice
Explain various temperature measuring instrument in industry and its feature
Configuration of special Input module [RTD, Thermocouple] in AB PLC panel
Explain temperature controlling method in industry and its application development in AB PLC
panel
Assignment based on temperature control loop in AB PLC panel and SCADA design in
Wonderware INTOUCH
Interfacing of operation work station in AB PLC with SCADA Wonderware INTOUCH and
application development
Interfacing between AB PLC and Wonderware INTOUCH and its drives configuration and
addressing
Live practice and online testing of tag signal in Wonderware INTOUCH to AB PLC panel
Designing of operator workstation in Wonderware INTOUCH SCADA for tank level control
system and temperature control loop in industry
Assignment based on continuous process application in industry
Online Exams on above Topics
Feed Forward Method
Feed Back Method
Cascade
Ratio
Introduction of Wonderware INTOUCH SCADA system & design the industrial
Application development
Introduction of Wonderware INTOUCH SCADA system and its live demo application
Create tag name & data base and graphical object properties
Explain real time PLC I/O drive and configuration
Assignment based on application design
LIVE INDUSTRIAL PROJECT
INTOUCH SCADA
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
Historical & real time trends monitoring and alarm events configuration
Explain alarm event configuration
Explain real time trend display
Explain historical display configuration
Assignment based historical display application
SCADA script programming and ODBC [using MS-ACCESS] & DDE [using MS-EXCEL]
Connectivity in INTOUCH SCADA
Explain SCADA script programming
Explain DDE [Dynamic Data Exchange using MS-EXCEL] connectivity
Explain ODBC [Open Database Connectivity MS-ACCESS] connectivity
Assignment based on DDE & ODBC connectivity
Recipe management and I/O drive configuration
Explain recipe management system and configuration
Live practice & assignment based on recipe management system
I/O drive configuration and its procedure
Various example of industrial application using recipe management system
Interfacing of AB PLC panel to Wonderware INTOUCH SCADA SYSTEM
Communication parameter setting between AB PLC and Wonderware INTOUCH
AB PLC input /output and memory mapping for real time tag creation in Wonderware
INTOUCH
Communication cable details and protocol information
Assignment based on industrial application
Live project development and practice on AB PLC & Wonderware INTOUCH SCADA
SYSTEM
Explain various project used in AB PLC
Explain how to make project documentation
Live project development and practice
Online Exams on above Topics
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a distillation system
To provide opportunity in identifying the main equipments associated with distillation
systems.
To describe the operation of Depropanizer column.
To learn about the startup and shutdown process.
To respond safely and efficiently for disturbances and malfunctions in the process.
To understand how temperature and pressure affect the operation of a distillation tower.
CONTROL SCHEME
Depropanizer Feed Flow Controller
Depropanizer Reflux Feed Flow Controller
Depropanizer Top Product Feed Flow Controller
Depropanizer Level Controller
Reflux Drum Level Controller
Depropanizer Pressure Controller
Depropanizer Bottom Temperature Control
PROCESS DISTURBANCES
Change in Depropanizer Feed Flow
Change in Feed Composition
Change in Feed Temperature
Change in Reboiler Steam Flow
Change in Depropanizer Pressure
Change in Depropanizer Reflux Flow
Online Exams on above Topics
PROCESS AUTOMATION
DISTILLATION COLUMN
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a Superheated Steam Generator.
To describe about the operation of Boiler
To learn about the startup and shutdown process
To respond safely and efficiently for disturbances and malfunctions in the process
To know how temperature and pressure affect the operation of Superheated Steam
Generator.
CONTROL SCHEME
Feed Drum Level Controller
Deaerator Pressure Controller
Deaerator Level Controller
Three Element Boiler Control
PROCESS DISTURBANCES
Change in FG and FO supply Pressure
Change in Steam header Pressure
Boiler Feed Water Supply ( to Deaerator ) Pump failure
Boiler Feed Water Supply ( to Steam Drum ) Pump failure
Water Supply ( from mud drum to steam drum ) Pump failure
Online Exams on above Topics
SUPERHEATED STEAM GENERATOR
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees and to recognize understand the operating fundamentals of a Compressor.
To describe about the operation of Compressor.
To learn about the startup and shutdown of the process using documented procedures.
To respond safely and efficiently to disturbances and malfunctions in the process.
CONTROL SCHEME
Important control scheme available in this unit is Anti-surge controller which creates a spill
back from the outlet of the compressor to the inlet to avoid compressor surge.
PROCESS DISTURBANCES
Feed Gas Failure
Compressor Failure
Fail Cooling water supply
Change in Feed Gas Temperature
Change in Molecular weight
Change in Feed Supply Pressure
Change in Compressor RPM
Online Exams on above Topics
CENTRIFUGAL COMPRESSOR
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a Centrifugal Pump.
To create a virtual environment for the trainees to understand various functional aspects of
the equipment, normal operating conditions.
To learn about the changes in the input parameters and their corresponding response in the
output.
To respond safely and efficiently for disturbances and malfunctions in the process
CONTROL SCHEME
Feed Water Level Controller in the Drum
Minimum Recirculation Line flow Controller
PROCESS DISTURBANCES
Change in Vapour Pressure of feed
Change in Specific Gravity of Feed
Change in Pump RPM
Change in Discharge of Pump to Head
Change in Pressure of the Tank on Head
Online Exams on above Topics
CENTRIFUGAL PUMP
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a heat exchanger
To portray all the design parameters and variation of them with respect to process
conditions.
CONTROL SCHEME
The Temperature Controller to maintain the hot fluid outlet temperature of the heat
exchanger
PROCESS DISTURBANCES
Change in type of Cold and Hot fluid (Deg API & Boiling Point)
Change in Inlet Temperature ( Cold and Hot side)
Change in Dirt factor ( Cold and Hot side)
Change in Specific Gravity ( Cold and Hot side)
Change in Inner Diameter ( Shell and Tube side)
Change in Baffle Spacing (Shell and Tube side)
Change in Number of passes ( Shell and Tube side)
Change in Tube Pitch
Change in Length of Tube
Change in Number of Tubes
Change in Flow area per Tube
Change in Surface Area per Linear Length
Online Exams on above Topics
HEAT EXCHANGER
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach the trainees the operating fundamentals of the Flash drum.
To create a virtual environment for the trainees to understand various functional aspects of
the equipment, normal operating conditions.
To learn about the changes in the input parameters and their corresponding response in the
output and design.
CONTROL SCHEME
A Pressure controller is used to maintain the Flash drum pressure.
A Level Controller to maintain the level of the Flash Drum.
PROCESS DISTURBANCES
Change in Inlet feed flow rate
Change in feed composition
Online Exams on above Topics
FLASH DRUM
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a gas turbine system.
To provide opportunity in identifying the main equipments associated with gas turbine.
To learn about the startup and shutdown process
To respond safely and efficiently for disturbances and malfunctions in the process.
To understand how temperature and pressure affect the operation of a gas turbine unit.
CONTROL SCHEME
Load Speed Controller to maintain the speed of the governor in power transmission unit.
Steam Temperature Controller in Desuperheater.
Steam Flow Controller in Desuperheater.
Water Level Controller in Steam Drum.
PROCESS DISTURBANCES
Change in Ambient Temperature
Change in GT Oil and Gas supply Pressure
Change in Grid KV and Frequency
Change in Feed water supply Pressure and Temperature
HRSG Fuel Burner failure
Lube Oil pump trips
Diesel Engine Starter failure
GT Fuel Burner failure
Circuit Breaker and Exciter failure
Online Exams on above Topics
GAS TURBINE
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a heater.
To portray all the design parameters and variation of them with respect to process
conditions.
To respond safely and efficiently to disturbances and malfunctions in the process
CONTROL SCHEME
Furnace outlet Temperature Controller
Fuel Gas Supply Pressure Controller
Air Supply Hand Controller
PROCESS DISTURBANCES
Change in Feed Gas Temperature
Change in Feed flow
Change in Fuel Gas Calorific Value
Online Exams on above Topics
FURNACE
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach the students about various operating fundamentals and the design of an Evaporator.
To create a virtual environment for the trainees to understand various functional aspects of
the equipment, normal operating conditions.
To learn about the changes in the input parameters and their corresponding response in the
output and design.
CONTROL SCHEME
A Temperature Controller is used to regulate the flow of steam depending upon the
temperature of the outlet sugar syrup.
A Pressure Controller is used to regulate the flow of vapor generation.
A Hand Controller is used to increase or decrease the feed flow.
PROCESS DISTURBANCES
Change in Feed Inlet temperature
Change in Feed flow rate
Change in Inner Diameter (ID)
Change in Outer Diameter (OD)
Change in Tube Pitch
Change in Number of Tubes
Change in Number of Passes
Change in Length of the Tube
Change in Flow Area per Tube
Online Exams on above Topics
EVAPORATOR
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a Continuous Stirred Tank Reactor
To create a virtual environment for the trainees to understand various functional aspects of
the equipment, normal operating conditions.
To learn about the startup and shutdown process.
To learn about the changes in the input parameters and their corresponding response in the
output.
To respond safely and efficiently for disturbances and malfunctions in the process
CONTROL SCHEME
Reactor Temperature Controller
Reactor Level Controller
Reactant A supply Hand Controller
Reactant B supply Hand Controller
PROCESS DISTURBANCES
Change in Inlet Pressure of Reactor
Change in Cooling Water Supply
Change in Order of reaction
Change in feed inlet temperature
Change in feed flow ( A & B)
Online Exams on above Topics
CSTR
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a Plug Flow Reactor.
To provide opportunity in identifying the main equipments associated with Plug Flow
Reactor
To learn about the startup and shutdown process
To respond safely and efficiently for disturbances and malfunctions in the process
PROCESS DISTURBANCES
Change in Conversion (Adiabatic)
Change in Order of the reaction (Isothermal)
Change in Feed Flow Rate (Isothermal)
Change in Inlet Temperature (Adiabatic and Isothermal)
Change in Initial Concentration (Adiabatic and Isothermal)
Online Exams on above Topics
PLUG FLOW REACTOR
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a Fixed Bed Reactor.
To provide opportunity in identifying the main equipments associated with Fixed Bed
Reactor
To respond safely and efficiently for disturbances and malfunctions in the process
CONTROL SCHEME
Two Temperature Controllers to maintain the Bed Temperature
PROCESS DISTURBANCES
Change in Hydrogen Flow
Change in Catalyst Activity
Change in Feed inlet Temperature
Online Exams on above Topics
TRAINING OBJECTIVE
To teach trainees the operating fundamentals of a Co Generation Boiler
To learn about the startup and shutdown process
To respond safely and efficiently for disturbances and malfunctions in the process
To know how temperature and pressure affect the operation of Co-Generation Boiler
CONTROL SCHEME
Feed Drum Level Controller
Deaerator Pressure Controller
Deaerator Level Controller
Three Element Boiler Control
FIXED BED REACTOR
COGENERATION BOILER
CERTIFIED PROCESS AUTOMATION ENGINEER
Technocrat Automation, #122, 2nd Floor, Opportunity Tower (opp to IDBI Bank), Nelson Manickam Road, Chennai - 600 029.Ph: No:
9551232896
PROCESS DISTURBANCES
Change in FG and FO supply Pressure
Change in Steam header Pressure
Boiler Feed Water Supply ( to Deaerator ) Pump failure
Boiler Feed Water Supply ( to Steam Drum ) Pump failure
Water Supply (from mud drum to steam drum) Pump failure
Online Exams on above Topics
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