Process control systems maintain precise control of liquid and gas variables, such as liquid level, flow rate, pressure, temperature, and pH. These multifaceted systems are a critical part of major industries like power generation, refineries, petrochemicals, chemical manufacturing, pharmaceuticals, biotechnology, and food processing and bottling.

DAC Worldwide’s Smart Process Plant Training System (603-SP) is a fully-functional, industrial-quality fluid process system that provides hands-on training in the measurement and control of five of the most common process variables: level, pressure, temperature, flow, and pH. The system groups these process control elements into one complete piping system, which allows it to teach multiple configurations of flow loops, controls, and communications.

The system incorporates both new and legacy technologies so that users are prepared for anything they might encounter on the job. These technologies work together to form a 3-level communication architecture:

• Device Level: Smart sensors monitor Level, Flow, Temperature, Pressure, and pH. They are connected via either IO-Link and Ethernet communication or HART communication.
• Control Level: A DCS and various PLCs and PIDs allow for operation and control of the system’s components.
• Enterprise Level: The DCS software provides Supervisory Control with data analytics for monitoring smart production, smart maintenance, etc.

The Smart Process Plant uses a Distributed Control System (DCS) that features a Supervisory Control software. This software is Rockwell Automation’s PlantPAx, and it acts as the backbone of the system. It gathers and organizes data and creates dashboards that represent the real-time status of the processes being carried out by the system.

Industry-Standard Components Provide Realistic, Hands-On Training

Technical training is most effective when learners can gain hands-on practice with industry-standard components they’ll encounter on the job. The Smart Process Plant Training System features a wide variety of common, industrial-quality components and instruments to provide learners with a realistic training experience that will build skills that translate easily to the workplace.

Hands-On Exercises

The Smart Process Plant includes multiple experiments, which simulate both continuous and batch process control loops that are widely used in many process industries. These experiments include:

• Bioreactor Application
• Clean-In-Place (CIP) Skid Application
• Boiler Drum Level Application
• Wastewater Treatment Application

With these experiments, learners will explore a wide variety of fundamental process control topics, including: temperature, level, flow, pressure, and pH ratio control; agitation; sequence control; continuous control; 3-element control; feed forward/cascade control; and pump lead/lag demand.