PID Controller Tuning & Advanced Process Control Techniques
Class Description
Class material is targeted for engineers and technicians and includes basic terminology and building blocks of process control and advanced process control techniques. The class consists of classroom and lab time. Attendess will use software tools to tune loops and implement advanced controls.
Overview
This class covers how to set up, maintain, and tune a PI or PID controller, for tighter control, improved product quality, and reduced scrap, with better and easier maintenance work.
Topics Covered
- Fundamentals of process control — Recognize the differences of each process loop. Learn the different process types, effect of noise, and the pros and cons of open loop tests and closed loop tests – all elements critical to tuning success.
- PID control algorithms — How they work
- Defining objectives for controller performance — How to adjust tuning strategy depending on your objectives
- PID controller tuning techniques — Discussion of various tuning techniques such as Ziegler-Nichols Tuning, Cohen-Coon Method, and IMC based tuning.
- Lab time — Practicing tuning techniques with example applications
- Recognizing When Adaptive Tuning is Required — The benefits of adaptive tuning and non-intrusive loop diagnostics for different process loops.
Applications Reviewed
Standard Applications
- Temperature
- Pressure
- Flow
- Level
Difficult Applications
- Inline Blending
- Cascade PID Loops
- Long Deadtime
Details
You will learn the fundamentals of PID control, its variations, things that are important to know in evaluating the health and tuning of PID loops, and the practical ways to tune a PID controller.
The class culminates in an easy-to-use 3-step approach for tuning any PID loop and the ability to understand when tuning is not the root cause issue.
PID loops will be simulated and demonstrated using software-based process simulation in class. Hands-on exercises will allow attendees to practice these techniques in real-time simulation.
Required: Laptop computer with USB drive and WiFi enabled.
Overview
This class will cover advanced process control techniques beyond PID control, such as multi-layer cascades, override control, gain scheduling, feedforward compensation, design, and tuning.
Topics Covered
- Cascade Control — what it is, when to use, and techniques for tuning
- Feedforward Control — what it is, when to use, and techniques for tuning
- Gain Scheduling — what it is, when it's required
- Override Control — how to implement
- What to do with processes that have long time delays
- How to implement controls on processes with highly interactive loops
- Lab Time: Implementing techniques discussed in class and identifying the improvements in performance achieved by using these advanced techniques
- Model Predictive Control — What it is, examples where Model-based Controls outperform PID controllers
Applications Reviewed
Standard Applications
- PID Control
- Model-Based Control
- Feedforward Control
- Gain Scheduling
- Heat/Cool Split Range
- Override Control
Difficult Applications
- Interacting PID Loops
- Long Deadtime Processes
- Multi-Output Control
- Extruder Control
Details
You will learn when each technique is appropriate along with the common implementation pitfalls that often produce less than desirable results.
Each techniqe will be simulated and demonstrated using software-based process simulation in class. Instructor will use both a PowerPoint presentation and real process simulation during these training classes. As on Day 1, hands-on exercises will allow attendees to practice these techniques in real-time simulation.
Required: Laptop computer with USB drive and WiFi enabled.
Overview
This class provides an overview of all critical boiler control loops and control methods, as well as step-by-step techniques for tuning each application area. We will also discuss common difficulties, pitfalls, and special considerations that often make proper boiler tuning so challenging. Hands-on exercises throughout the training will help attendees better understand boiler tuning principles.
Topics Covered
- Boiler Control
- Load Demand Control
- Boiler-Following Mode
- Turbine-Following Mode
- Coordinated Control
- Lab time — Hands-on exercise tuning unit master controls
- Main Boiler Control Loops
- Unit Master (MW and Throttle Pressure)
- Feedwater Flow
- Drum Level Control
- Fuel Flow Control
- Air Flow Control
- SH/RH Steam Temperature Control
- Furnace Pressure Control
- Excess O2 Control
- Pollution Controls (NOx, SOx, Opacity)
- Trim Control Principles and Uses
- Function Generators Characterization
- Specifc Tuning Principles and Step-by-Step Procedures for:
- Feedwater Flow / Drum Level Control
- Air Flow / Excess O2 Control
- Fuel Flow Control
- Primary Air Flow, & Fuel / Air Temperature Control (as needed per boiler and fuel type)
- Superheat and Steam Attemperation Control
- Unit Master Control Tuning or Boiler- and Turbine-Master
Details
Required: Laptop computer with USB drive and WiFi enabled.
Upcoming Classes
Onsite Classes
We also offer this training onsite, at your location.