MK-PCAT-2 - Process Control Analysis and Tuning Workshop

Overview

This workshop is aimed at professionals who are in charge of optimizing the performance of their process control strategies and controller tuning. Most of the high-level mathematics has been stripped away and distilled into practical exercises and simple algebra.

The workshop provides you 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, you will learn all the skills to analyze and tune the majority of control loops in your own plant and have the knowledge to implement many enhanced control techniques.

Objectives

This workshop will allow you to:

Cost

$1490.00 USD.

Professional Development Hours

14 hours.

Pre-Requisites

An understanding of the basics of process control.

Learning Environment

The workshop will be held in a computer lab where each participant is given dedicated use of a computer for the duration of the course. The course includes presentations, examples, demonstrations, and hands-on exercises. Participants are encouraged to discuss current alarm and event issues they face.

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 is made. The concept of Integrating and Self-Regulating processes is raised and examples are presented.

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.