COURSE OVERVIEW:

The purpose of this course is to provide a comprehensive technical understanding of how industrial processes are stabilized and optimized through automated control loops. In any modern facility, thousands of loops work simultaneously to maintain variables like temperature, pressure, and flow within strict limits. This program focuses on the technical logic of the PID (Proportional-Integral-Derivative) algorithm, which remains the global standard for industrial automation.

The scope of this training encompasses the entire lifecycle of a control loop, from the initial identification of process dynamics to the final optimization of controller parameters. Participants will explore the diverse mathematical behaviors of process "Gain," "Dead-time," and "Time-constants" that dictate how a system responds to changes. The curriculum is specifically designed to address the practicalities of loop tuning, moving beyond theoretical formulas to provide hands-on techniques for field application.

Coverage includes the practical aspects of standardized tuning methods, the implementation of advanced control strategies, and the systematic troubleshooting of unstable loops. Attendees will learn how to conduct step tests, analyze response curves, and eliminate steady-state errors without inducing oscillations. By focusing on the intersection of process physics and controller logic, the course ensures that participants can maximize the stability and efficiency of any automated industrial system.

COURSE OBJECTIVES:

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

• Analyze the functional components of an industrial control loop.
• Differentiate between Open-loop and Closed-loop control systems.
• Identify process dynamics: Gain, Time Constant, and Dead-time.
• Explain the specific roles of Proportional, Integral, and Derivative actions.
• Execute standardized tuning methods: Ziegler-Nichols and Cohen-Coon.
• Implement Lambda tuning for smooth and robust process response.
• Tune flow, level, pressure, and temperature loops effectively.
• Manage "Reset Windup" and other common controller malfunctions.
• Implement Cascade and Feed-forward control structures.
• Troubleshoot "Hunting" and oscillations in control loops.
• Utilize software tools for loop analysis and performance auditing.
• Document tuning parameters and maintain a performance database.

TARGET AUDIENCE:

This course is intended for Process Engineers, Instrumentation Technicians, Control Room Operators, and Automation Specialists.

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.