COURSE OVERVIEW:

The purpose of this course is to provide a deep technical understanding of the principles and practices required to achieve stable and efficient process control. Industrial control loops are the fundamental units of plant automation, and their performance directly impacts product quality, energy consumption, and equipment longevity. This program focuses on the mathematical and practical aspects of PID (Proportional-Integral-Derivative) control, ensuring that participants can transform unstable processes into steady-state operations.

The scope of this training encompasses the identification of process dynamics, the selection of appropriate control strategies, and the rigorous application of tuning methodologies. Participants will explore the diverse characteristics of flow, level, pressure, and temperature loops, each requiring a unique approach to parameter adjustment. The curriculum is specifically designed to address real-world challenges such as dead time, hysteresis, and non-linear process behavior that often confound theoretical models.

Coverage includes the practical aspects of loop testing, the use of tuning software, and the implementation of advanced control structures like cascade and feed-forward. Attendees will learn how to conduct "bump tests," analyze process response curves, and determine optimal PID gains to minimize overshoot and settling time. By focusing on the practical application of control theory, the course ensures that participants can maximize the performance of every loop in the facility, leading to enhanced operational stability and safety.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Analyze the components of a closed-loop control system.
• Identify process characteristics, including gain, dead time, and time constant.
• Differentiate between Proportional, Integral, and Derivative actions.
• Execute standardized tuning methods like Ziegler-Nichols and Cohen-Coon.
• Tune flow, level, pressure, and temperature loops for optimal stability.
• Implement Cascade control to manage secondary disturbances.
• Utilize Feed-forward control to preemptively correct for load changes.
• Troubleshoot loops with significant dead time using Smith Predictors.
• Identify and correct mechanical issues like valve friction and stiction.
• Use digital tuning tools and loop analyzers to verify performance.
• Manage "reset windup" and other common controller malfunctions.
• Document tuning parameters and maintain a loop performance database.

TARGET AUDIENCE:

This course is intended for Process Engineers, Instrumentation Technicians, Control Room Operators, and Maintenance Staff.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.