PROCESS CONTROL SYSTEMS
Graduate Diploma of Engineering (Electrical and Instrumentation in Oil and Gas)
Duration: 1 year
Master of Engineering (Electrical and Instrumentation in Oil and Gas) Duration: 2 years
Grad Dip total course credit points = 24 (3 credits x 8 (units))
Masters total course credit points = 48
(12 credits (Thesis) + 3 credits x 12 (units))
Mode of Delivery
Combination of modes: Online synchronous lectures; asynchronous discussion groups, videos, remote and cloud-based labs (simulations); web and video conferencing tutorials. High emphasis on personal and group self-study.
Delivery/ Contact Hours per week
Student workload including “contact hours” = 10 hours per week: Lecture 1 hour
Tutorial Lecture 1 hours
Practical / Lab 1 hour (where relevant) Personal Study recommended - 7 hours
Students will be provided with Blackboard Collaborate (or similar) for video and web conferencing. This will allow them to attend lectures, interact with lecturers and fellow students, and use the Remote Lab facility. Students will be required to download the latest version of Java and .NET in order to use these packages.
For ease of communicating with peers and lecturers, installation of this package is recommended.
It is recommended that students install at least a 2007 version of the Microsoft Office. Older versions will work, but sometimes create issues with file compatibility. If individuals are reluctant to use these, they can also use Open Office (www.openoffice.org).
As students are co-operating with people from throughout the world with a multitude of different PCs, it is recommended that they have good quality up-to-date virus detection software installed. The free version of AVG is sufficient. A thorough automated scan of computers at least once a week is recommended.
EIT uses a state-of-the-art learning management system (Moodle) for lecturing and interacting with lecturers and fellow students. Students can chat, socialize, and collaborate on projects with similarly motivated and enthusiastic course participants.
Computing resource requirements
Students’ computers should have an Intel Core Duo CPU and 2 Gigabytes of RAM. Hard disk space available should be at least 2 Gigabytes free. If necessary the built-in hard drive can be augmented with an inexpensive USB drive. No particular special graphics card is required. The operating system should be Windows with Windows 7 Service Pack 1 as a minimum.
An ADSL Internet connection with a minimum speed of 128 kbps down and 64 kbps up is recommended.
Students will require a good quality stereo headset with analogue or USB connectors. In addition, a low-cost USB webcam is recommended. Students should budget in the order of
$30 for a headset and $20 for a webcam. This will vary from country to country.
For difficulties with other online materials the lecturer should be contacted. Technical material will be accessible 24/7 through the online portal.
This unit provides the students sufficient depth of practical understanding of the principles, design, configuration, testing, installation, commissioning and maintenance of process control systems in the context of the oil and gas industry.
The underlying principles of process control and system requirements (functional and technical arising from end user, process control, separation of process control from safety instrumented functions, system architecture, communication networks, power, earthing, and environmental) will provide the student with an understanding of how to systematically identify and apply these principles to control system design based on commercially available systems (Distributed Control Systems, Programmable Logic Controllers and SCADA Systems). Practical aspects of overall project development and the impact on process control system design development and integration will be addressed as will control system operation and maintenance.
On successful completion of this Unit, students are expected to be able to:
Identify and analyse principles of Process Control System Engineering to onshore and offshore Oil & Gas facilities.
Evaluate disciplined and practical engineering processes to enhance the lifecycle performance of process control systems.
Analyse and Apply sound engineering practices, and demonstrate understanding of process control hardware and design.
Evaluate and apply principles for interfacing packaged equipment control systems.
Recommend and apply principles for incorporating design information into the system design development.
Completing this unit will add to students professional development/competencies by:
Fostering the personal and professional skills development of students to:
Be adaptable and capable 21st century citizens, who can communicate effectively, work collaboratively, think critically and innovatively solve complex problems.
Equipping individuals with an increased capacity for lifelong learning and professional development.
Planning and organising self and others
Instilling leadership qualities and a capacity for ethical and professional contextualization of knowledge
Enhancing students’ investigatory and research capabilities through:
Solving complex and open-ended engineering problems
Accessing, evaluating and analysing information
Processes and procedures, cause – effect investigations
Developing the engineering application abilities of students through:
Labs / practical / case studies / self-study (where applicable)
Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes.
A. Effective Communication
Learning Outcomes (Refer to 2.2)
A1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience.
A2. Ability to engage effectively and appropriately across a diverse range of international cultures.
B. Critical Judgement
B1. Ability to critically analyse and evaluate complex information and theoretical concepts.
B2. Ability to innovatively apply theoretical concepts, knowledge and approaches with a high level of accountability, in an engineering context.
C. Design and Problem Solving Skills
C1. Cognitive skills to synthesise, evaluate and use information from a broad range of sources to effectively identify, formulate and solve engineering problems.
C2. Technical and communication skills to design complex systems and solutions in line with developments in engineering professional practice.
C3. Comprehension of the role of technology in society and identified issues in applying engineering technology ethics and impacts; economic; social; environmental and sustainability.
D. Science and Engineering Fundamentals
D1. Breadth and depth of knowledge of engineering and understanding of future developments.
D2. Knowledge of ethical standards in relation to professional engineering practice and research.
D3. Knowledge of international perspectives in engineering and ability to apply Australian and International Standards.
E. Information and Research Skills
E1. Application of advanced research and planning skills to engineering projects.
1, 4, 5, A, B
E2. Knowledge of research principles and methods in an engineering context.
1, 4, 5, B
(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))
When assessed (eg Week 5)
Weighting (% of total unit marks)
Learning Outcomes Assessed
Type: Multi-choice test Word length: n/a
Topic examples: Fundamental concepts of process control system design, installation and maintenance
Type: Report (Midterm Project)
[This will include a progress report; literature review, hypothesis, and proposed solution with concept workings]
Word length: 1000
Topic examples: process control system design development considerations
1, 2, 3
Type: Report (Final Project)
[If a continuation of the midterm, this should complete the report by adding sections on: workings, implementation, results, verification/validation, conclusion/challenges and recommendations/future work. If this is a new report, all headings from the midterm and the final reports must be included.]
Word length: 4000
Topic examples: process control system specification for a long field life Floating Production Storage Offtake (FPSO) vessel or as specified by the lecturer
1, 2, 3, 4, 5
May be in the form of quizzes, class tests, practical assessments, remote labs, simulation software or case studies: E.g. Simulation of control system
3, 4, 5
King, Process Control: A Practical Approach, Prentice Hall, UK, 2011.
ISA-95 / IEC 62264
ISA-18 (alarms) and ISA-101 (HMI)
IEEE Introduction to Industrial Control Networks
SP 800-82 Rev. 2 (May 2015) Guide to Industrial Control Systems (ICS) Security
ISA-99 and IEC-62443 (cyber security)
IDC Practical Process Control for Engineers and Technicians
IDC Design of Industrial Automation Functional Specifications for PLCs, DCSs and SCADA systems
IDC Best Practice in Industrial Data Communications
IDC Practical Fieldbus, DeviceNet and Ethernet for Industry
IDC Practical Alarm Management for Engineers and Technicians
Number of peer-reviewed journals and websites (advised during lectures) [some examples below]:
Journal of Process Control
Introduction to Process Control Systems
Introduction to the purposes of process control systems and their role in achieving business objectives
History and development of process control systems
Typical control system architectures and characteristic features used in the Oil & Gas industry
Current state of technology and key challenges
Weeks 2, 3 and 4
Process Control Engineering
Principles of digital control and sampled data systems
1st and 2nd order processes, Laplace transforms, Nyquist plots
Process unit operations, flowcharts and control system depiction
Sensing and actuation using field instrumentation
Process controller: process variables, manipulated variable, set points, loop tunning
Control schemes (eg feedback, feed forward, cascade), characteristic responses of three term controllers, motor control interfacing, typical DCS controller configuration,
Principles of control valves and their impact on controller performance
Introduction to multivariable systems and advanced process control
Defining control requirements, use of forms such as natural language control narratives, cause & effect, functional logic diagrams, bubble diagrams and SAMA logic.
Weeks 5 and 6
Industrial process control equipment
Single loop digital controllers
Programmable logic controllers
Distributed control systems
Plant wide communications networks, IT and network design (switches, network levels, security)
Human Machine Interface key principles, display graphics development, use of international standards such as ISA-18 and ISA-101
Design considerations: segregation (cable, cabinet, FieldBus segments, Independent Protection Layers, unit operation and equipment sparing for controller and I/O design),power, earthing, EMI, environmental control), system back-up and recovery, instrumentation failure modes
Weeks 7 and 8
Process Control System Interfaces
Fieldbus, DeviceNet, HART, Ethernet, Wireless, Asset Management Software
Safety Instrumented Systems overview, interfacing, set-points, alarms, controller modes, operational overrides (MOS, OMO, SUO etc). Details of SIS are covered in MOG 506.
Packaged controls, interfacing to and integrating with the plant control system
Enterprise system and control system integration (ANSI/ISA-95)
Process control system security and cyber security (SP 800-82, ISA-99 and IEC-62443)
Weeks 9, 10 and 11
Process Control System Development
V-model system development process
Process control system procurement process
Project lifecycle, contracting strategies, MIV concept, evolution of design information and third party vendor data
Lifecycle requirements, user requirements, system functional specification (Clear, concise, unambiguous, defined fault/failure modes), project planning
System configuration: I/O and controller database, graphical interface, applications, alarm management (alarm objective analysis, masking etc), data historian, security
System operations and maintenance
Project and Revision
In the final weeks students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.