p a c t school of chemical engineering and advanced materials process automation msc, diploma and...

P A C TSchool of Chemical Engineering and Advanced Materials

Process Automation

MSc, Diploma and IGDS Modules


A Question

A fact: Process automation includes the immediate objectives of process control but also underpins all aspects of enterprise management: that is operability, quality, reliability, safety, sustainability and viability.

A question to ponder on:Where are the engineers with the relevant expertise and experience going to come from?

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Newcastle University

A redbrick university (Victorian origins: mid/late 1800s): ● approx 19,000 students.

Three faculties: SAgE, HASS and Medicine, ● Science, Agriculture and Engineering (SAgE) has nine Schools, one of which is CEAM.

Chemical Engineering and Advanced Materials (CEAM); ● has 54 full-time academic and support staff: ● approx 250 undergraduate students, ● approx 100 full-time MSc & PhD students, ● consistently ranked in top 6 for teaching & research.

Six academics with expertise in process control.

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P A C TSchool of Chemical Engineering and Advanced Materials 4


Aim of the IGDS

Integrated Graduate Development Scheme (IGDS) in process automation: ● it is a scheme or programme.

Aim:“…. to broaden and deepen the expertise and experience of personnel concerned with process automation, either in the design and development of control and related systems, in their application, or in the operation and the management thereof.”

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What is the IGDS?

The IGDS is aimed at, and designed around the needs of, personnel employed in the chemical and process industries.

It is a national scheme based in Newcastle: Consists of a suite of modules:

● provided within framework of an MSc degree, ● organised on a part-time Continuing Professional Development (CPD) basis.

Flexible: take whole or part modules as short courses:● credit accumulation for an MSc/Diploma.

Accredited by IChemE, IET and InstMC for CEng status.

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Aim of the PACT

Partnership in Automation and Control Training (PACT): ● it is an organisation.

Aim“…to enable companies in the UK chemicals and process sector to maintain and improve their competitive edge by creating a supply of personnel who understand and are able to effectively apply modern automation techniques.”

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What is the PACT?

The PACT was originally established in 1992: It consists of Newcastle University and a consortium of

companies in the process sector. A healthy mix of end-users, contractors and suppliers.

● ABB, AMT, BP, Emerson, Invensys, Honeywell, Jacobs, Genzyme, RWE npower, SABIC, Sellafield Ltd.

PACT responsible for developing and supporting the IGDS on behalf of the industry.

The IGDS is delivered by and through the PACT. It is based in CEAM.

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What is the LMC?

Local Management Committee (LMC). The LMC consists of representatives of the University and

each of the PACT companies. Uniquely: ● the LMC has delegated authority, not window dressing,● the LMC determines policy regarding all aspects of operation of the IGDS and control over finances, ● majority are industrialists, chaired by an industrialist.

LMC members are actively involved in course design, delivery, management and quality assurance: ● that involvement underpins the relevance and usefulness of the Scheme. .

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Where does it fit in?

Faculty Teaching Committee (FTC)

EPSRC

Local Management Committee (LMC)

ExamBoard

QualityCttee

Finance Cttee

information

CEAM PGBoS

qualityassessment business plan

AMRoverall

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Who are the Delegates?

IGDS designed for people working in process automation. Delegates must be involved in the design and

development of control systems, their application, operation, support and management.

May be employed by suppliers, contractors or end users. Mix ensures quality interaction with/between delegates. Spectrum of ages (typically 25-55), experience and

responsibility. All delegates are sponsored by their companies. Not diluted by undergraduate of full-time MSc students.

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Admissions Policy

Entry to MSc requires:2.2 Hons BEng, BSc, etc in chem/elec/mech engineering or appropriate science,+ employment in chemical/process sector,+ sponsorship by company.

Entry to Diploma requires:as above but HND/HNC+ significant relevant industrial experience, ● transfer to MSc depends upon progress.

Entry to single modules on an ad-hoc basis depends on likelihood of benefiting from doing so.

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Some Statistics

Breakdown of delegates by registration: ● 38 alumni to date (33 MSc, 5 Diploma).● 20 active MSc & Diploma registrations. ● 9 suspended MSc & Diploma registrations.● 18 active IGDS Modules delegates. ● 225 former IGDS Modules delegates.

A significant proportion of the UK process control community has either been through or engaged with the Scheme.

Correct: end Jan 2010

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Delegate Backgrounds

Breakdown of delegates by disciple & qualifications:

28% chemical engineers. 38% electrical engineers. 11% inst & control engineers. 23% other engineers & scientists.

30% MEng, MSc, PhD 43% BSc, BEng, (2.2 Hons). 27% HNC, HND, etc, with relevant industrial experience.

Correct: July 2002 to Nov 2006

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Nature of the Modules

Modules are generic, focus on principles and technology. Close involvement of industry in design and delivery. Independent training: neither vendor nor product specific. High academic standard & quality of content: no apology. Strike sensible balances between breadth & depth,

technique & technology, conventional & advanced, theory & practice, information & understanding, etc.

Examples and applications of a process nature. Emphasis on international standards. 16 modules covering spectrum of process automation.

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P A C T

Process Analytics

Instrument’n & Meas’t

Chem Eng Principles

Mathematics & Matlab

Schemes& Strategies

Modelling &Simulation

ClassicalCS Design

ModernCS Design

Manag’t ofAuto Projects

Batch ProcAutomation

Adv Process Automation

Adv Process Control

IndustrialProject

Optimisation& Scheduling

Control ofDistillation

Fuzzy Neural Expert Sys

Control SysTechnology

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Module Content

List of some of the techniques and technology taught: AIN, ALARP, AMS, APC, ARMAX, ANN, ASM, ATEX,

BLS, CHAZOP, CIM, COOP, CPD, CSTR, DCF, DCS, DDC, DDL, DFS, DOC, DPMO, ELS, ES, ESD, FAT, FF, FIR, FLC, FMEA, FTA, GA, GAMP, GC, GLC, GLS, GPC, HART, HIPS, HR, IEC, JIT, KBS, KPI, LAN, LEL, LVDT, MCC, MCS, MEI, MILP, MIMO, MIS, MLP, MLR, MPC, MRP, MSPC, MTBF, MV, MVC, NPV, ODE, OLE, OLTF, OPC, PCA, PFD, PID, PLC, QA, QP, RBF, RGA, RLS, RTOS, SCADA, SIL, SISO, SEX, SFC, SPC, SQL, SQP, SSO, STC, S88, TCP/IP, TQM, UAL, URS, ZOH, etc.

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Pattern of Study

Module is 1-week full-time intensive study at Newcastle: ● mix of lectures, tutorials, labs, case studies, demos, etc.● plus assignment (over 2 months) and written exam.● approx 3 months per module.

Typically 2-3 modules per year per delegate.● some 3-4 years to complete 8 modules for MSc.● plus 1-2 years to complete industrial project. ● upper limit of 5 years.

Delegates choose modules subject to:● availability, interest, needs, funding, order and cycle.

Cycle of some18 months for 16 modules.

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Industrial Project

Equivalent to 3 month’s full-time effort (45 credits):● lapsed time of 1-2 years.

Done on an in-company basis. Must be of sufficient: ● importance to company to justify time & resources,● challenge and relevance to justify MSc degree.

Most projects have led to significant benefits: ● one generated >£400K/year of savings in fuel costs,● good payback on investment in training by any yardstick.

Dissertation covered by confidentiality agreement.

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Industrial Project cont’d

Some examples of projects completed: ● fuzzy logic ratio trim on coal fired boilers (RWE npower)● prototype protection system design (BNG),● high speed bar code verification system (Muller), ● model predictive controller on exothermic reactor (BP),● control loop performance techniques evaluation (ABB), ● repetitive control for bulging compensation (Corus),● optimisation of benzene recovery plant (Ineos),● stabilisation & optimisation of cement kiln fuel (Cemex),● constrained linear quadratic controller (SABIC), ● performance monitoring of fiscal metering system (BP).

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Process Control Laboratory

Investment in lab worth £200-250K: ● teaching and project facility.

Pilot plant scale rigs:● designed around different process operations.● demonstrate variety of control strategies.

Industrial instrumentation with many types of signals:● interfaced to Honeywell Experion system.

Rigs enable a variety of hands-on practical work:● reconciling P&I diagrams ● loop tracing & fault finding ● calibration ● operation ● tuning ● dynamic response ● model testing ● APC.

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RigProcess Operation Measurements

Basic controlstrategy

Strategy for future dev’t

Dolly

Molly

Polly

Sally

Nelly

Desorption

Humidification

Neutralisation

Blending

Pneumatic conveying

Flow, speed &dissolved O2

Flow &dew point

Flow & pH

Flow &conductivity

Level &weight

Cascade & feedback

Ratio & feedback

Feedforward& feedback

Multivariable& feedback

Sequencecontrol

Optimalcontrol

Fuzzy logic

Adaptivecontrol

Model predictive

Scheduling

Holly Heat transfer Flow, pressure& temperature

Feedback & multiple loops

Multivariable


Cooling

Vent/overflow LegendShared display,shared control

Discrete instruments,field mounted

Signal

Process stream

PV68

P67

FV69

TV65

Steam

V60

V63

V66

67TT

67FT

60PI

68PT

60TT

64TT

63TT

V67

Top up water

Drain

Drain

61TT

63PI

62PI

62TT

69FT

V62

water

68PI

69FC

67TC

65TC

60TC

68PC

XH

XC

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Drawn by Jonathan Love

Heat Transfer Rig: P&I Diagram

Revised by April 2010

Title Reference Holly

J Love


Benefits to Delegates

Self improvement: deeper expertise and broader experience through study and work experience.

Interaction: both with lecturers (academic and industrial) and delegates from other companies.

Alternatives: exposed to new/different ideas and practices.

Recognition: the IGDS has an established reputation in the industry and is of a high standard.

Demanding: delegates are stretched intellectually, but in a way that relates to their work.

Satisfying: opportunities to apply theory to practice. Flexibility: delegates can tailor scheme to suit themselves.

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Benefits to Companies

Usefulness: employees are more knowledgeable about and have deeper understanding of control & automation.

Credibility: employer can demonstrate to clients that staff are well qualified and being developed.

Reward: demonstrates employees’ worth to company through investment in staff development.

Motivation: involvement in IGDS stimulates delegates’ interest in and enthusiasm for work.

Loyalty: sponsorship over 5 years commits delegates to company.

Confidence: scheme is designed to meet the needs of industry, is relevant and up-to-date.

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Fees

£1,800 per module, £3,600 for industrial project. Payment on lump-sum basis costs £16,200,

ie 10 modules for the price of 9. ● lump-sum in two instalments: 1st upon starting, 2nd is sooner of 2 years or 6th module, ● note 2nd lump is subject to fee increase in between.

Payment for MSc (8 modules + project) on a module-at-a-time basis costs £18,000.● many pay on module-at-a-time basis despite discount.● discount on sliding scale for transfer of basis.

With effect from 1st Jan 2011

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Further Information

Thankyou for listening.

Detailed information about the IGDS on the website:

http://www.ncl.ac.uk/pact Enquiries to Jonathan Love:

School of Chemical Engineering and Advanced MaterialsNewcastle UniversityMerz Court, Claremont Rd, Newcastle upon Tyne, NE1 7RU, UK [email protected]

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p a c t school of chemical engineering and advanced materials process automation msc, diploma and...

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question n

n flexible

pact n partnership

n pact responsible

c t aim

advanced materials ceam

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