Practical Process Control & Tuning of Industrial Control Loops

THE WORKSHOP

This workshop 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.

The aim of this workshop is to provide and/or enhance the skills required to tune a controller for optimum operation. An optimally tuned processed loop is critical for a wide variety of industries ranging from food processing, chemical manufacturing, oil refineries, pulp and paper mills, mines and steel mills. Although tuning rules are designed to give reasonably tight control, this may not always be the objective. Some thought needs to be given when retuning a loop as to whether the additional effort is justified as there may be other issues which are the cause of the poor control. By the end of this workshop you will have the skills to troubleshoot and tune a wide variety of process loops.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

  • Automation engineers
  • Consultants
  • Electrical engineers
  • Electricians
  • Energy management consultants
  • Installation and maintenance technicians
  • Instrumentation and control engineers
  • Mechanical engineers and technicians
  • Operators monitoring and controlling processes
  • Process control engineers
  • System integrators

CONTENT SUMMARY

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

FUNDAMENTALS OF TUNING

  • Open loop characterisation 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

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

TUNING OF VALVES

  • Hysteresis
  • Stiction

AUTOMATED TUNING

  • Self tuning loops
  • Adaptive control

ADVANCED TUNING STRATEGIES FOR MORE COMPLEX SYSTEMS

  • Cascade systems – tuning of them
  • Feedforward, ratio, multivariable systems
  • Interactive loops tuning
  • Dead time compensation
  • Practical limitations

GOOD PRACTICE

  • Good practice for common loop problems
  • Flow control loop characteristics
  • Level control loop characteristics
  • Temperature control loop characteristics
  • Pressure control loop characteristics
  • Other less common loops

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