PCI-200: Understanding Industrial Process Control/Level Two Advanced Process Measurement & Control Fundamentals

Course Description

This 36 hour, 4.5 day training program uses a hands-on approach providing students an in-depth understanding of industrial process measurement & control systems. Participants will learn to apply more comprehensive measurement & control principles, terminology, symbols & documentation standards. In addition students will perform hands-on exercises in which they will build, test, tune & troubleshoot temperature, pressure, flow & level control systems.

Topical Outline

  • Application of ISA documentation standards
  • Elements of a Process Control Loop: PV-Process Variable, MV-Manipulated Variable & C-Controller
  • Other Process Measurements: Weight, pH, Density, Viscosity, Moisture & Others
  • Process Dynamics: Open Loop Response, Process Gain, Process Time Constant & Process Dead Time
  • Control Methods: Open Loop control (Self-regulating), Manual control, ON/OFF control, Feedback control, Feedforward control & Cascade control
  • Control Tuning: Open vs. Closed loop methods, Stability vs. responsiveness, ¼ decay ratio, Simplex tuning method, Zeigler-Nichols tuning method & Auto-tuning
  • Special Cases: pH control & Nonlinear systems
  • Control Valve Selection & Sizing: Valve types (Globe, Ball, Butterfly &  Gate), Valve Characteristic (Quick opening, Linear, Equal Percentage) & Other Control Valve Topics  (Positioners, Materials, Configuration, Actuators &  Accessories)
  • Installation Best Practices: Wiring, Shielding & Isolation
  • Control System Troubleshooting: Experience Based & Trial & Error


Persons successfully completing this course will be able to:
  • Create the documents used to define instruments & control systems.
  • Apply the principles, equipment & techniques for the primary industrial process measurements of temperature, pressure, level & flow
  • Understand & process response & how it affects controller operation.
  • Know & apply the proper controller tuning method.
  • Select & size the proper control valve.
  • Build, test, operate tune & troubleshoot a various feedback control loops.


PCIC-101: Understanding Industrial Process Control/Level One Process Measurement & Control Fundamentals or a fundamental understanding of industrial process measurement & control system design & operation.



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