Process Control Analysis and Tuning Workshop Course Description
Overview
This workshop is aimed at professionals who are charged with optimizing
the performance of their process control strategies and controller tuning.
The unique thing about the material is that most of the high-level
mathematics has been stripped away and distilled into practical exercises
and simple algebra.
The Control Analysis and Tuning workshop provides delegates with basic
revision of the PID algorithm and its digital implementation (e.g. PLC or
DCS) and progresses through an examination of all the common industrial
processes. There is a section on measurement and control hardware and the
effects of poorly designed or maintained equipment when trying to optimize
a control system. Building on this knowledge the delegates will learn all
the skills to analyze and tune the majority of control loops in their own
plants and have the knowledge to implement many enhanced control techniques.
Objectives
On successful completion of the Workshop attendees will be able to:
- Identify different dynamic process types.
- Design a basic control strategy for the different dynamic process types.
- Understand the theory of using analytical methods to tune PID controllers.
- Understand the basic techniques of enhanced Process Control.
- Have basic skills in the use of ProcessACT, Prototyping and Control Software.
- Have basic skills in the use of Techmation Protuner Control Loop Tuning Software.
- Have basic skills in the use of instrumentation/actuator principles and how they relate to Process Control.
Abstract
The course is divided into modules. Each module will build on the previous
one so that learning is done in an organized and structured format.
Module 1: The Digital PID Controller - In this module you
will investigate the finer points of the PID controller and their
implementation in the digital form (i.e. PLC and DCS). The controller algorithms,
units, error reference constants are all explained and reinforced through
the use of some innovative simulation. The course material contains information
on dozens of different vendors’ PID loop configuration.
Module 2: Industrial Processes - In this module the concept
of open and closed loop control is discussed and an explanation of what
constitutes an industrial process. The concept of Integrating and Self-Regulating
processes is raised and examples of where these are found.
Module 3: Process Dynamics - This module introduces the
concept of the transfer function or how a process is described mathematically
between its input and output. The inexorable link between the transfer
function of a process and controller tuning is made. Terms such as Process
Gain, Lags and Delays are explained.
Module 4: Measurement and Control - In this module basic
instrumentation and final control element technology is discussed and the
reason why the correct selection, implementation and maintenance of these
components is essential to optimized control.
Module 5: Control Loop Analysis and Tuning - This module
examines the techniques to analyze closed loop data to help formulate subsequent
loop testing and analysis. Open loop testing and analysis methods are covered
and controller tuning based on these tests is learned. Manual methods are
taught prior to introducing the Protuner loop analysis software. There are
many practical exercises where different processes are constructed, tested
and tuned so the delegates gain a good feel for the theory.
Module 6: Control System Performance Assessment - This module
explains the notion of benchmarking controller performance and developing a
continuous performance monitoring program. Alarm data gathering and analysis
is discussed.
Module 7: Enhanced Control Techniques - This module examines
some of the inherent weaknesses of the conventional PID algorithm and explores
a number of strategies that mitigate these problems as well as improving the
control of difficult processes. Some of the strategies covered in this module
include Cascade, Feedforward, Decoupling, IMC, drum level and dual cross limiting.
The cases are all reinforced with practical exercises.