Process Control and Instrumentation Training by DAC Worldwide
Process control and instrumentation skills are foundational to careers in power generation, oil and gas, refining, chemical processing, pharmaceutical manufacturing, food and beverage production, and every other industry that depends on continuous or batch processes. Operators and instrument technicians who can calibrate transmitters, configure and tune PID controllers, install and maintain control valves, and work confidently across flow, level, pressure, and temperature loops are among the most valued and highest-compensated technical workers in those industries.
The challenge for training programs is that process control skills cannot be learned in the abstract. A technician who has read about PID tuning but never configured a real controller and watched a process loop respond is not prepared for the job. The same is true for transmitter calibration, control valve characterization, and every other instrumentation skill that forms the core of a process control technician's competency.
DAC Worldwide's process control and instrumentation training line gives learners the hands-on, real-equipment experience they need, through fully functional fluid process systems, specialized single-topic trainers, and a comprehensive line of instrumentation cutaways covering the field instruments found throughout industrial facilities.
Klein Educational supplies DAC Worldwide process control and instrumentation training equipment to process technology programs, industrial maintenance programs, community colleges, and workforce development centers across California, Oregon, Washington, Arizona, Nevada, Hawaii, and Alaska. We help programs find the right systems for their curriculum and budget.
What DAC Worldwide process control training covers
DAC Worldwide's process control and instrumentation product line spans comprehensive multi-variable training systems, single-topic focused trainers, and instrumentation cutaways and dissectibles. The training systems are fully functional fluid process systems built with industrial-quality components and instruments that give learners realistic hands-on experience with the exact types of control loops, field instruments, and controller configurations they will encounter in operating facilities.
The flagship: 4-Variable Advanced Process Control Training System
The 4-Variable Advanced Process Control Training System is DAC Worldwide's most comprehensive process control training platform and one of the most capable process control training systems available for any program. The system provides hands-on training in the measurement and control of all four of the most fundamental process variables: flow, level, pressure, and temperature. It is a fully functional industrial-quality fluid process system with a tubular steel frame, two integral 19-inch instrument mounting racks, two centrifugal pumps, clear acrylic tanks, transparent PVC piping, a heat exchanger, a water heater with storage tank, thermowells, RTDs, thermocouples, rotameters, control valves, solenoid valves, and a 44-gallon primary reservoir.
Up to six learners can use the system simultaneously, and the open architecture design allows for the creation of one complex multi-variable process loop or, with an optional dual-loop PID, two independent process systems. The system comes with an Endress and Hauser instrument and control package including differential pressure transmitters, a PID controller, temperature transmitter panel, I/P converter panel, 4-channel strip chart recorder, square root extractor, bubbler assembly, and U-tube manometer.
The training system supports a comprehensive curriculum covering process instrumentation terminology, process control theory, thermocouple and RTD characteristics, transmitter calibration for pressure, level, flow, and temperature, closed loop integral and proportional control in all four variable types, and notch, ultimate, and open loop tuning methods. It can also be configured for feed-forward, feedback, split range, ratio, cascade, and three-element control loops, making it suitable for both introductory and advanced instrumentation programs. The 4-Variable Advanced Process Control Training System Plus adds an economy standard test and calibration equipment package to this system for an even more complete training package.
3-Variable Process Control Training System
For programs that want comprehensive multi-variable process control training at a more accessible scale, the 3-Variable Process Control Training System provides hands-on training in level, pressure, and flow measurement and control in a large-scale working fluid process system. The system uses an Endress and Hauser instrument and control package including two PID controllers, differential pressure transmitter, I/P converter panel, gauge pressure transmitter, digital multimeter, bubbler assembly, U-tube manometer, square root extractor, and pressure switch. Standard or user-specified instruments from any brand can be installed on a mounting stanchion or built-in 19-inch instrument rack. The 3-Variable Process Control Training System Plus adds a calibration test and equipment package for an expanded training experience.
Single-topic process control trainers
DAC Worldwide offers a focused line of single-topic process control trainers for programs that want to address specific instrumentation skills in dedicated, task-specific systems.
The Control Valve Characteristics Training System is a working fluid process system for hands-on training in the design, calibration, and testing of common control valves, including provision for mounting valves of different designs by a variety of manufacturers. A magnetic flow meter and two pressure sensors demonstrate performance at different flow rates using multiple valve plug and trim designs, and field calibration of valves and positioners can be practiced using a high-quality regulator and test gauge.
The Flow Measurement Training System is a large-scale working flow process system for hands-on training in the installation, calibration, and maintenance of process flow measurement instruments. The system includes a 15-gallon reservoir and a three-quarter-inch pipe diameter process loop with a removable spool section that accepts orifice plates, a Pitot tube, and a Venturi tube, covering the three most common differential pressure flow measurement approaches in a single system. Open architecture allows optional instruments of various designs and manufacturers to be installed in the replaceable spool section. The Flow Measurement Training System Plus adds a differential pressure transmitter and pressure gauge for a more complete measurement package.
The Analytic Process Control Training System provides realistic hands-on analytical process control training covering the measurement and control of analytical process variables found in water treatment, chemical processing, and pharmaceutical applications. The Calibration Training System provides focused hands-on practice in instrument calibration procedures. The PID Controller Trainer provides dedicated training in PID controller configuration, tuning, and application.
Process control and instrumentation cutaways
DAC Worldwide's process control cutaway line covers the field instruments that process operators and instrument technicians encounter, calibrate, and maintain throughout their careers, giving learners a direct view inside components that are otherwise completely sealed during operation.
The Bourdon Tube Pressure Gauge Cutaway exposes the internal Bourdon tube, rotary geared movement, and dial face of the most common type of industrial pressure gauge, showing learners how the mechanical pressure sensing mechanism works. The Pressure Gauge Cutaway, Low Pressure covers the diaphragm-type pressure gauge used in low-pressure and differential pressure applications where Bourdon tube gauges lack the required sensitivity.
The Control Valve Positioner Cutaway depicts a common industrial valve positioner that has been sectioned to show internal components and operating principles, helping learners understand how positioners improve control valve response and accuracy. The Constant-Differential Relay Air Cutaway covers the control-type constant pressure regulator used throughout pneumatic instrument air systems. The Ball Float Air Vent Valve Cutaway and Ball Float Drain Valve Cutaway cover two common steam and condensate system accessories.
Process control dissectibles include the Liquid Level Gauge Sample Dissectible, Sight Flow Indicator Sample Dissectible, Variable Area Flow Meter Dissectible, Control Valve Dissectible, Enhanced Control Valve Dissectible, and Pressure Control Switch and Pressure Switch dissectibles, giving learners hands-on component experience with the most frequently encountered field instruments in process facilities.
What students and trainees learn
DAC Worldwide's process control training systems and cutaways support a comprehensive curriculum covering the knowledge and hands-on skills that instrument technicians and process operators need throughout their careers:
Process control theory and terminology including process variables, control modes, and loop terminology
Thermocouple and RTD temperature measurement principles, characteristics, and calibration
Pressure transmitter calibration and pressure gauge calibration
Level measurement installation and calibration including bubbler assemblies and differential pressure methods
Flow transmitter calibration and square root extraction
Orifice plate, Pitot tube, and Venturi tube flow measurement installation and comparison
PID controller configuration, tuning using notch, ultimate, and open loop methods
Closed loop integral and proportional control in temperature, pressure, level, and flow applications
Feedback, feed-forward, split range, ratio, cascade, and three-element control loop configuration
Control valve design, calibration, positioner operation, and characteristics testing
Field instrument installation, maintenance, and troubleshooting
Pressure switch setting and adjustment
Analytical process variable measurement and control
Who uses DAC Worldwide process control training equipment
DAC Worldwide's process control and instrumentation training products are used by process technology programs at community colleges, petrochemical and refinery instrument technician training departments, power generation facility training programs, oil and gas company training centers, and workforce development programs preparing learners for careers as process operators and instrument technicians across continuous process industries.
How Klein Educational supports your program
Klein Educational is more than an equipment supplier. We work with program directors, department heads, and workforce administrators from the first conversation through delivery and beyond. That includes needs assessment, system selection, and support to ensure your program gets the right process control training equipment for your curriculum.
We have direct access to the full DAC Worldwide product line and support infrastructure, which means faster service and deeper product knowledge for programs across our seven-state region.
Frequently asked questions
What process control training does DAC Worldwide offer? DAC Worldwide offers a comprehensive line including the 4-Variable Advanced Process Control Training System covering flow, level, pressure, and temperature, a 3-Variable Process Control Training System, single-topic trainers for control valve characteristics, flow measurement, analytic process control, calibration, and PID control, and a line of process control cutaways and dissectibles covering pressure gauges, control valve positioners, regulators, and field instruments.
What is the 4-Variable Process Control Training System? The 4-Variable Advanced Process Control Training System is a fully functional industrial fluid process system that provides hands-on training in all four fundamental process variables: flow, level, pressure, and temperature. It supports up to six learners simultaneously and can be configured for simple or advanced control loop configurations including feedback, feed-forward, cascade, and three-element control.
What instrumentation brand is included with the process control systems? The standard instrument packages use Endress and Hauser components, including differential pressure transmitters, PID controllers, temperature transmitters, I/P converters, and strip chart recorders. The open architecture design also allows for installation of instruments from other manufacturers.
What flow measurement devices does the Flow Measurement Training System include? The system includes orifice plate, Pitot tube, and Venturi tube flow measurement spools in a removable spool configuration, covering the three most common differential pressure flow measurement approaches. The system also accepts optional instruments of various designs from multiple manufacturers.
Who is DAC Worldwide? DAC Worldwide is a world leader in technical training solutions for industrial skills with more than 35 years of experience, and a sister company of Amatrol within the Amatrol family of technical training solutions, based in Swedesboro, New Jersey.
Does Klein Educational help with system selection? Yes. Klein works with programs from needs assessment through system selection and delivery to ensure programs get the right process control training equipment for their curriculum and learner population.
What states does Klein Educational serve? We serve California, Oregon, Washington, Arizona, Nevada, Hawaii, and Alaska.
Ready to Build or Expand Your Process Control Training Program?
Whether you are starting a new instrumentation and process control program or adding hands-on training systems to an existing curriculum, our team will help you find the right DAC Worldwide training equipment for your needs and budget.