Practical Tuning of Industrial Control Loops

THE WORKSHOP:

This workshop is designed to train you and/or your staff, in the configuration and tuning of industrial control loops using a minimum of mathematics and formulas. Controllers need to be carefully matched to the process to work optimally; this matching procedure is called tuning. Controllers that are not correctly configured and tuned will not perform optimally and will not reduce variability in the process as they should.

The aim of this workshop is to provide and/or enhance the skills required to configure and 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. These issues will be discussed in some detail in the workshop. At 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
  • Control and instrumentation engineers
  • Electrical engineers
  • Electricians
  • Electronic engineers
  • Energy management consultants
  • Facility managers
  • Mechanical engineers
  • Installation and maintenance technicians
  • Technicians

CONTENT SUMMARY

FUNDAMENTALS OF LOOP TUNING

  • 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

  • Different rules compared
  • Typical tuning settings
  • When to use them/when not to use them
  • Rules of thumb in tuning

TUNING OF VALVES

  • Hysteresis
  • Stiction
  • Characteristic selection and correction
  • Positioner configuration and tuning

AUTOMATED TUNING

  • Self tuning loops
  • Adaptive control

TUNING OF 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

 

PRACTICAL SESSIONS

This is a practical, hands workshop enabling you to work through practical exercises which reinforce the concepts discussed. Practical sessions include:

  • Model response
  • Trial and error tuning
  • Ziegler Nichols tuning
  • Open loop step analysis
    • Self regulating process
    • Integrating process
  • Protuner analysis
    • Self regulating analysis
    • Integrating analysis
  • Protuner data acquisition
  •  Feed forward
  •  IMC tuning

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