Advanced Process Control For Engineers & Technicians

Introduction

Advanced Process Control and Loop Tuning and Analysis is designed to provide engineers and technicians with the basic theoretical and practical underKanding of the process loop and how this can be applied to optimize process control in terms of quality, safety, flexibility and costs.

Objectives

Upon successful completion of this course, the delegates will be able to:

• Fundamentals of process control
• The effect of   P.I.D tuning
• Recognize different control algorithm
• Understand cascade and feed-forward control
• Lead lag and ratio control
• How to decouple the interacting loop
• Appreciate the effects of different valve characteristics on the loop performance
• Analyze such problems as valve hysteresis, stiction, and non-linearities
• Fully appreciate the effects of proportional, integral and derivative control
• Correctly apply both open and closed Loop Tuning according to Ziegler Nichols
• Understand cascade and feed-forward control
• Appreciate the rationale for using Ratio control and Adaptive control systems

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This course is intended for all engineers & technicians in the field of Instrument and control, Automation, Chemical, Consulting, Design & Project, Electrical, Maintenance, and Operations.

Course Outline

Day 1: Introduction

• Control objective
• Closed control loop
• Control strategies
• Feedback control
• Feedforward control

The basic components control system

• Sensor and transmitters
• Controller, the action of controllers
• Final control element
• Control valve gain
• Windup reset control

Day 2: Process control fundamental

• ON/OFF control
• Proportional control
• Proportional band vs. proportional gain
• Proportional offset
• Reset
• Integral action
• Integral windup
• Stability
• Derivative action
• PID control
• Load disturbances and offset

Advanced control Algorithm

• Feedforward control
• Cascade Control loop
• Self-tuning
• Ratio control
• Split range control 

Day 3: Loop Tuning

• Basic principles
• Open-loop reaction curve method (Ziegler – Nichols)
• Default and typical settings
• Closed-loop continuous cycling method (Ziegler – Nichols)
• Override and selective control
• Ratio and feedforward control

Control Algorithm

• Stability consideration
• Two-level cascade
• Three-level cascade
• Fine-tuning
• Tuning for load rejection vs. set-point rejection
• Tuning for different vs. robustness
• Surge control

Elements of the advanced control loop

• Smart transmitter it, advantage
• Final control elements with smart positioning
• The microprocessor or based controller
• Organization of control element to have a feedback control system
• The disadvantage of a feedback control system
• How to overcome the disadvantage of feed back control system

Day 4: Advanced control algorithms

• Why we choose the advanced control system
• Stage of development of advanced control system
• Difference between feedback & feedforward control system
• Cascade control system
• Feedforward control system
• Ratio control system
• How to combine the advantage of feedback and feedforward
• Adaptive and self-tuning control loops

Multivariable Controls

• Interacting loops (severity of interaction)
• Relative gain array calculation
• Decoupling interactive multivariable control loops
• Statistical analysis

Day 5: Final control element

• Pressure recovery
• Flashing and cavitation’s
• Valve construction
• Valve characteristics
• Inherent
• Installed
• Cavitation’s control
• Actuators
• Diaphragm
• Cylinder
• Electric
• Valve positioners
• Deoband and hysteresis
• Stick-slip
• Testing procedures and analysis
• Effect of valve performance on controllability

Digital Control System

• Communication fundamental
• Migration to expersion
• Introduction to Fieldbus, Profibus
• Application of control system
• Case studies
• Boiler control
• Level drum control
• Single element
• Two element
• Three element

Ratio Control

• Series limited control
• Parallel limited control
• Lead lag firing

 Fractionator Control

• The reflux rate
• The reboiler heat input
• The fractionators pressure
• The feed rate
• The feed temperature