Process controls are designed and implemented within the process control system to facilitate basic operation, control and automation requirements. Controllers which are not correctly configured and tuned will not perform optimally and will not reduce variability in the process as they should. Technical staff should have sound knowledge on controller design, techniques for troubleshooting control problems and optimizing control loops.
This course is designed to help students to understand the concepts and components of process control and different controller types including PID, cascade and feed forward control.
After completing this course, students will have expert knowledge on the design, tuning ratio and troubleshooting of controllers.

WHO SHOULD COMPLETE THIS COURSE

• Design Engineers
• Project Managers
• Construction Foremen
• Public Works Engineers
• Construction Managers
• Soil Testing Personnel
• Pipeline Owners
• Contractors
• Specification Writers
• Construction Inspectors
• Piping fabricators

 

COURSE OUTLINE

PROCESS CONTROL

• Economic justification of control
• Reasons for improved control
• Process modeling
• Typical block diagram of plant

 

PROCESS DYNAMIC COMPONENTS

• Process gain
• Elementary block diagram
• First order process
• Second order response

 

PROCESS CONTROL COMPONENTS

• Simple manual control
• Feedback control
• Feedforward control loop
• Open loop control
• Closed loop PID

 

CLOSED LOOP CONTROL

• Principle of Closed loop control
• Components of process control loop
• Feed heater

 

STABILITY OF CONTROL LOOP

• Consideration for critical frequency
• Instability in a closed loop
• Examples

 

IDEAL PID CONTROLLER

• Idea of a controller
• A control loop
• Industrial PID controller
• PIDs in software

 

PID CONTROLLERS

• PID variants
• Parallel or Ideal form
• Interacting or Series form

 

CASCADE CONTROL

• Single loop temperature control
• Examples of Cascade control
• Equation types

 

FEEDFORWARD CONTROL

• Manual feedforward control
• Automatic feedforward control
• Time matching feedforward control
• Feedforward modeling
• Dead time compensation
• Reaction curves for various Dead Times
• Smith predictor model
• Alarm priority bands
• Case study example
• Scan cycle
• Other Tuning Schemes
• Objectives of tuning
• Continuous Cycling – Ziegler & Nichols
• Damped cycling method