Strategies for Improving Learner Outcomes in Energy Systems Instrumentation and Controls Education

1. Strategies for Improving Learner Outcomes in Energy Systems Instrumentation and Controls Education Lawrence Beaty Idaho State University Pocatello, Idaho Friday, July 22, 2011

2. ESTEC Premise: Energy workforce development is a complex, dynamic process shaped by: Technology, Economics, Education, Regulation, Demographics, Politics, Competition, Public Perception

3. ESTEC Partners Operating Partners guide the strategic direction of the Center The Energy Systems Technology and Education Center

4. Why was ESTEC Created? • ESTEC was created to address a growing shortage in the energy workforce

5. Key Segments in Decline Percent Growth in U.S. Workforce by Age: 2000-2020 Age of Workers Source: U.S. Census Bureau

6. 1970-2010 2010-2050 Decreasing Workforce Growth will Increase Global Competition for STEM workers Mexico Brazil India China South Australia Canada US Netherlands Spain France UK Russia Italy Japan Germany Korea Source: Deloitte Research/UN Population Division (http://esa.un.org/unpp/) It’s 2008: “Do You Know Where Your Talent Is?” Why Acquisition and Retention Strategies Don’t Work, p.6

7. Deficiency in Workforce Planning – Despite the Evidence! Extent to Which Retiring Boomers Cause Changes in Hiring, Retention, Management Practice and Policy Preparation for Potential Labor Shortage Due to Baby Boomer Retirement (n=314) (n=368) Have agreed internally on a plan to change policies and management practices 5% Have implemented specific policies and management practices 11% To a very large extent 5% To no extent at all 38% Have proposed specific policy and management practice changes 7% To some extent 26% Just becoming aware of the issue 38% Beginning to examine internal policies and management practices 39% To a very small extent 31% Baby Boomers defined as people born from 1945 to 1964. The number of workers 55 or older is expected to grow 50 percent by 2012, according to the federal Bureau of Labor Statistics. (SHRM) Source: 2005 Future of the U.S. Labor Pool Survey Report, Society for Human Resource Management

8. Students favor the social sciences

9. What is ESTEC and what does it do? • A partnership between Idaho State University, Idaho National Laboratory and Partners for Prosperity. • Focus on engineering technician education and training for the energy market sector. • Three initial degree programs: • Instrumentation and Control Engineering Technology • Electrical Engineering Technology • Mechanical Engineering Technology • Secured $600K National Science Foundation ATE Grant for development of an Energy Systems Instrumentation and Controls program • Secured $2M DoL Community-based Job Training Grant • Secured $1.5 M DoL State Energy Sector Partnership grant for renewable energy. • Secured a U.S. DoE Nuclear Energy University Program grant to crate a Nuclear Operations program for unlicensed operators

10. Instrumentation and Controls Industry needs • Participating Companies: • Idaho Power • Idaho National Engineering Laboratory • PacifiCorp • EPRI • Entergy • Progress Energy • Tri-State Generation and Transmission • URS

11. Identified Attributes, Skills and Knowledge • Soft Skills • Basic Job Skills • Human Interaction Skills • Technical Knowledge • Mathematics • Electricity, Mechanics • Sciences • General Industry Knowledge • Discipline Specific Knowledge

12. WWW.CEWD.ORG • Formed in March 2006, the Center for Energy Workforce Development (CEWD) is a non-profit consortium of electric natural gas and nuclear utilities and their associations - Edison Electric Institute, American Gas Association, Nuclear Energy Institute, and National Rural Electric Cooperative Association. CEWD was formed to help utilities work together to develop solutions to the coming workforce shortage in the utility industry. It is the first partnership between utilities, their associations, contractors and unions to focus on the need to build a skilled workforce pipeline that will meet future industry needs.

17. Introductory Course (Taken by all Energy Systems students) • ESET 0100 Engineering Technology Orientation 1 credit. An introduction to the opportunities and responsibilities of an engineering technician. Exposure to the various fields of technology through field trips, movies and guest lectures. Introduction to materials, techniques, and college services, which will assist the student in completing a technology program.

18. AC and DC Electricity and Electronics • ESET 0101 Electrical Circuits I 5 credits. Includes measurements and calculation of current, voltage, resistance and power in series, parallel and combination circuits with DC and AC power sources. Voltage and current in resistive-capacitive (R-C) and resistive-inductive (R-L) circuits during switch transitions, AC power circuits including reactance and transformation. Voltage and current in non-resonant and resonant AC circuits and filters. • ESET 0101L Electrical Circuits I Laboratory 5 credits. Electrical circuits are analyzed, designed and constructed using various DC and AC theories and electrical quantities are measured using appropriate test equipment.

19. Semiconductors, amplifiers and digital electronics • ESET 0102 Electrical Circuits II 5 credits. Continuation of electrical circuit study introducing the fundamentals of semiconductors, amplifier theory, digital logic and logical devices. • ESET 0102L Electrical Circuits II Laboratory 5 credits. Laboratory applications and experiments in troubleshooting of semiconductor devices and circuits, digital logic and logic device application.

21. Summer (a transition course) • ESET 0200 Applications of Electronic, Electrical, and Power Systems Control Fundamentals and Safety 6 credits. Overview and application of electronic sensors, thyristor power control circuits, and networks. Electrical motor control, relays, timers, PLCs, and computer software used to design and verify motor control circuits.  Basic process control print reading and device calibration methods. Includes troubleshooting techniques and safety practices.

22. Electrical Systems • ESET 0210 Principles of Power Generating Systems 2 credits. Transmission lines, generator and transformer characteristics, and fault detection and correction. Emphasis on circuit performance addressing voltage regulation, power factor, and protection devices. Lecture/Laboratory. • ESET 0211 Sensors and Control Devices 2 credits. Theory and application of control devices, sensors, timers, relays.  • ESET 0212 Electrical Systems Documentation and Standards 1 credit. Introduction to print reading, technical specifications, print annotation, report writing and electrical codes

23. ESET 0213 Motors, Generators and Industrial Electrical Systems 2 credits. The construction, design aspects and theory of operation of DC, single and poly-phase motors, variable frequency motor control, electrical switch-boards and electrical distribution systems.   • ESET 0214 Motor Control Laboratory 1 credit. Applications of AC and DC motor control theory and motor protection systems. • ESET 0215 Controller Laboratory 1 credit. Applications of Programmable Logic Controls and DCS including I-O configuration, Ladder logic design and function block use. • ESET 0216 Sensors and Control Device Laboratory 1 credit. Laboratory applications of sensors (including photoelectric and proximity types), relay and timer circuits, and application of automation devices. • ESET 0217 Motor, Generator and Electrical Systems Laboratory 2 credits. Installation, setup, control, maintenance, and troubleshooting of AC and DC motors, electrical device installations and industrial safety and proper tool usage.

24. Heat Transfer, Fluid Flow and Applications • ESET 0220 Thermal Cycles and Heat Transfer 2 credits. Introduction to the Rankin, Carnot, and Brayton cycles. Includes principles of  heat transfer and fluid flow and thermodynamic principles.  • ESET 0221 Boiler, Reactor, and Turbine Principles 2 credits. Survey of various boiler types and principles of combustion, overview of reactor principles and steam generation, turbine types and principles of operation. 

25. Process Control • ESET 0222 Process Control Theory 3 credits. Electronic instruments-sensors, indicators, transmitters, computing relays, electro-optics, electronic controllers, ratio control, cascade control, recorders, analytical equipment, troubleshooting.   • ESET 0223 Digital Control Theory 2 credits. Digital systems, digital control, analog-to-digital and digital-to-analog interfacing, signal conditioning, programmable controllers, computer application.  • ESET 0224 Measurement Theory 2 credits. Calibration calculations, pressure scales, level considerations, specific gravity, elevation suppression, closed and open systems, temperature scales, thermocouple and RTD values, bulb and capillary devices, heat transfer, flow with square root linearization, gas flow measurement calculations, mass flow, humidity measurements, pH measurements.

26. ESET 0225 Instrument Calibration Laboratory 1 credit. Use of test equipment, power supplies, current and volt measurements, use of oscilloscope, capacitor checker, decade box, Wheatstone bridge, transmitter simulator, manometers, pressure calibration devices.  • ESET 0226 Process Control Devices Laboratory 1 credit. Set up, maintenance and troubleshooting of electronic sensors, indicators, transmitters, relays recorders, and controllers, transmission with twisted pair, fiber optics, smart systems, and analytical equipment.  • ESET 0227 Digital Control Systems Laboratory 1 credit. Computer and programmable controller interfacing with transmitters and final elements, PID loops, auto tuning, set up to complete control loops, computer graphics.  • ESET 0228 Measurements Laboratory 1 credit. Calibration of transmitters, simulation of process variables, temperature, pressure, level flow, and humidity control loops.

27. Objective Based Learning • Classroom and Laboratory Objectives were derived from industry needs and characterized for general instruction • Evaluation is based on the students ability to explain, describe or define concepts and the ability to perform tasks to specified standards • Multiple choice knowledge testing or completion of task standards are not used for evaluation

28. Example: Pressure Module Classroom Objectives • EXPLAIN how an electronic pressure transmitter produces an output signal including: • a. Method of detection • b. Method of signal generation • Given a basic block diagram of a pressure transmitter, STATE the purpose and EXPLAIN the function of the following blocks: • a. Sensing element • b. Transducer • c. Pressure detection circuitry • d. Pressure indication

29. Example: Pressure Module Laboratory Objectives • Given a pressure transmitter, test equipment, technical manuals and system data, • CALULATE the require calibration of the transmitter • PERFORM and as found check on the transmitter • PERFORM a calibration of the transmitter • WRITE a complete work report documenting the work performed

30. Introduced Factors • Evaluations are timed • Test equipment and transmitter settings are defaulted to non-standard setting • Unit conversions are required for calculation of calibration settings

31. 4-20 mA Transmitter in Current Loop

32. Smart Transmitters with HART Communicator

33. Transmitters in flow loop

34. Flow Loop

35. Additional Activities • Industry Contemporary affairs reports • Safety related Incidents • Regulatory News • Plant Trips • Lab projects • Field Trips

39. Discussion