Process Control Analysis and Tuning

Course Outline

This workshop is aimed at professionals who are charged with optimising 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 relatively 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. A section on measurement and control explains the effects of poorly designed or maintained equipment on the performance of your control system. Building on this knowledge the delegates will learn all the skills to analyse and tune the majority of control loops in their own plants and have the knowledge to implement many enhanced control techniques. The workshop is conducted over three days in a class room environment with a mix of theory and practical exercises using realistic simulators. The course learning can be consolidated with further testing, analysing and tuning controllers on your operating plant by engaging us to extend the workshop.

Course Facilitator

Graham Jefferson (Asia Pacific)

Graham is a principal consultant specialising in process control optimisation and combustion safety systems. He is a TÜV certified functional safety engineer and has designed and implemented many boiler and furnace systems. Graham has over forty years’ experience in the area of industrial instrumentation and process control applications with an international patent for the design of a specialised burner control strategy.

Course Synopsis

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. An in-depth explanation of the client’s particular control system is undertaken.

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 are essential to optimised control.

Module 5 – Control Loop Analysis and Tuning

This module examines the techniques to analyse 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 ProtunerPlus 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 programme. 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.