Trainer Controls
Stand-alone Control Panel: Each process trainer can be constructed with its own control cabinet either directly mounted on the process skid or with an umbilical cord for remote location. The control cabinet will contain all the necessary power switching, PID loop controllers, recording devices and an alarm annunciator.
Distributed Control System (DCS): One or more process trainers may be connected to a DCS. The DCS then provides all the necessary control for process operation. Typically, the DCS control consoles will be located in a control room setting. The DCS capacity can be increased to include more than one trainer. For example, Distillation, Gas Absorption and Three-phase Separation all are well suited to DCS control. The incremental cost of adding more trainer units is relatively small. Where two or more trainers will be controlled by a single Distributed Control System, multiple operator stations are provided, each one dedicated to one trainer and protected by software "firewalls".
Hybrid Control Systems: It is possible to configure the control system so that one or more process trainers have both DCS and a local control cabinet. While this option is more expensive, it provides options for training representative of different industry environments. Note that with this option the trainer is only operable from one control station at a time and transfer is not "bump-less".
Diverse Field Instrumentation: Since this equipment is designed for a variety of training activities, it may be desired to include a variety of control system technology. It is also possible and advisable where multiple trainers are in use, to provide different types of field instrumentation on each unit to provide trainees with the maximum exposure of available technology. Different types can include standard 4 to 20 mA, Smart (Hart Protocol), Foundation Fieldbus or other digital bus technologies.
Marshalling Cabinet: For each trainer unit, all input and output signals will be wired into a marshalling cabinet ready for hard-wiring to the DCS upon installation at the customer’s site. It shall include all necessary termination strips, an alarm indicator light, shut-down switch, power switches and indicators. Motor starters will also be located in the high voltage zone of this cabinet. Remote trainers will connect to the DCS cabinet with an umbilical cable(s).
DCS Cabinet: The DCS cabinet will be mounted on one selected Trainer, and be pre-wired to that unit’s marshalling cabinet. The control cabinet will contain all the necessary power, switching, input/output modules, DCS control modules, control-room cabling interfaces etc. for the process trainer. A separate DCS module carrier will be provided for each trainer unit.
Instrumentation Standards: Our standard designs utilize Emerson (Fisher-Rosemount) control devices e.g. transmitters, control valves etc. Our standard communication protocol is 4 to 20 mA, (Hart Protocol). Our standard DCS is Emerson DeltaV. The use of Foundation Fieldbus or other digital bus technologies is recommended only on selected trainers due to the physical size of bus components.
Specific Component Suppliers: The process measurement or control component equipment can be customized to include specific manufacturers to reflect local industry practices. Use of alternate suppliers may result in revised costs due to additional engineering and configuration required.
Control Stations: A separate computer station will be provided as the operator station for each trainer. The Distillation station will also serve as the DCS engineering station. Each station shall include the necessary computer hardware, software and a 19" color (or larger) flat-screen monitor. Dual screens can be provided on request.
Software: All software required for configuration and operation shall be included and custom configuration specific to the processes is included:
- Operating System
- Configuration
- Graphic Display
- Graphic Configuration
- Trending
- Control and Alarm functions
- Configuration and Graphical Displays: All shall be functions fully configured. Graphical Displays shall closely resemble the PFD and physical layout of the process training unit.
Redundancy: Not required for training purposes.
Skid Instrumentation: Skid instruments shall be industry quality Emerson (Rosemount pressure, level and flow transmitters; Fisher/Bauman control valves) compatible with standard 4 to 20 mA, Protocol. Alternate manufacturers can be supplied (e.g: Foxboro, Siemens, etc.).
Control Room Consoles: Industry-typical control room consoles may be provided to mount the operator stations and associated computers if this option is selected.
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