Practical Process Control and Tuning of Industrial Control Loops
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Practical Process Control and Tuning of Industrial Control Loops Course
Introduction:
This 5-day course is designed to give you a solid understanding of the essentials of Process Control and skill you and/or your staff, in the latest procedures for the tuning of Industrial Control Loops using a minimum of mathematics and formulas. A clear review of the principles and essentials of Process Control is given thus allowing you to gain the skills to tune a wide variety of controllers. Tuning controllers is an exact science that requires precise configuring of the process controller using the correct procedures. When the controller is set up correctly this is called tuning.
Course Objectives:
By completing this training course, participants will be able to:
- Understand the fundamentals of Process Control
- Know the fundamentals of tuning loops - both open and closed-loop
- Get the best PID settings right first time
- Know where to troubleshoot to achieve optimally tuned control loops
- Be able to apply step-by-step descriptions of the best field-proven tuning procedures
- Know the typical procedures for troubleshooting tuning problems
- Tune more control loops in less time with consistently excellent results
- Be able to apply the practical rules of thumb for tuning systems
- Be proficient at tuning with a detailed knowledge of Open Loop Tuning and Closed Loop Tuning (including such classics as Ziegler Nichols Tuning and Lambda Tuning)
- Be able to determine the minimum settling time for a control loop
- Know the optimum amount of filtering or dampening to apply to the measurement
- Know why and how to size valves for best control loop performance
- Be able to handle problems such as valve hysteresis, stiction, and non-linearities
- Be able to tune complex loops ranging from cascade to feedforward
- Know when to use derivative control for the best-tuned loop
- Understand cascade loops and feedforward control
- Be able to identify and correct problems with dead time in the process
- Apply the fundamentals of Process Control
- Set up efficient Process Control systems
- Set up cascade and feedforward systems
- Tune loops effectively
- Apply open and closed-loop tuning rules
- Deal with stiction, hysteresis, and non-linearities
- Correct problems with dead time
- Troubleshoot tuning problems
Who Should Attend?
This course is intended for all Instrumentation & Control Engineers, Process Control Engineers, Mechanical Engineers & Technicians, System Integrators, Consultants, Operators Monitoring & Controlling Processes, Installation & Maintenance Technicians as well as Energy Management Consultants, Electrical Engineers, Electricians, and Automation Engineers.
Course Outlines:
Introduction & BASIC CONTROL CONCEPTS
- Typical Manual Control
- Feedback and Feedforward Control
- Block Diagrams
INTRODUCTION TO INSTRUMENTATION
- Selection and Specification of devices
- Pressure Measurement
- Flow Measurement
- Level Measurement
- Temperature Measurement
Introduction to Control Valves
- Basic Principles
- Rotary Control Valves
- Ball Valves
- Characteristics and Specifications
FUNDAMENTALS OF PROCESS CONTROL
- Processes, controllers, and tuning
- PID controllers - P, I and D modes of operation
- Load disturbances and offset
- Speed, stability, and robustness
- Gain, dead time and time constants
- Process noise
- Feedback controllers
- How to select feedback controller modes
- Practical Session
Fundamentals of Tuning
- Open-loop characterization of process dynamics
- Default and typical settings
- General-purpose closed-loop tuning method
- Quick and easy-open loop method
- Fine-tuning for different process types
- Simplified lambda tuning
- Practical Session
THE DIFFERENT TUNING RULES
- Ten different rules compared
- Tables of typical tuning settings
- When to use them/when not to use them
- Rules of thumb in tuning
- Practical Session
TUNING OF VALVES
- Hysteresis
- Stiction
- Practical Session
AUTOMATED TUNING
- Self-tuning loops
- Adaptive control
- Practical Session
TUNING OF MORE COMPLEX SYSTEMS
- Cascade systems - tuning of them
- Feedforward, ratio, multivariable systems
- Interactive loops tuning
- Deadtime compensation
- Practical limitations
- Practical Session
GOOD PRACTICE
- Good practice for common loop problems
- Flow control loop characteristics
