COURSE OVERVIEW:

The purpose of this course is to provide advanced technical expertise in the optimization of industrial control loops through sophisticated tuning and control strategies. While basic PID control handles most applications, complex processes with non-linearities, long dead-times, or high interaction require a higher level of engineering. This program focuses on the technical mastery of the PID algorithm and the implementation of advanced architectures to achieve world-class process stability.

The scope of this training encompasses the rigorous mathematical and practical application of feedback, feed-forward, and cascade control. Participants will explore the behavior of "Integrating" processes, such as tank levels, and "Self-regulating" processes, like flow, to apply the correct tuning laws for each. The curriculum is specifically designed to address the challenges of multi-variable interactions where the adjustment of one loop adversely affects another.

Coverage includes the practical aspects of loop response analysis, the use of specialized tuning software, and the implementation of model-based control concepts. Attendees will learn how to handle "Reset Windup," optimize "Dead-time" compensation using Smith Predictors, and implement "Override" control for equipment protection. By focusing on advanced tuning, the course ensures that participants can drive process efficiency to its theoretical limits while maintaining maximum safety and quality.

COURSE OBJECTIVES:

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

• Analyze complex process dynamics including High-order and Non-linear systems.
• Differentiate between PID controller forms (Ideal, Parallel, and Series).
• Execute advanced tuning methods like Lambda and IMC (Internal Model Control).
• Tune Level loops for "Surge" vs. "Tight" control objectives.
• Implement and tune Cascade control to isolate upstream disturbances.
• Design Feed-forward strategies to preemptively correct for load changes.
• Troubleshoot loops with dominant Dead-time using specialized predictors.
• Manage "Controller Interaction" in multi-loop processes.
• Implement Ratio and Split-range control for specialized applications.
• Utilize automated loop tuning software and frequency response tools.
• Identify and eliminate "Valve Stiction" effects through tuning and logic.
• Document performance metrics (IAE, ISE) to verify optimization success.

TARGET AUDIENCE:

This course is intended for Control Engineers, Senior Instrumentation Technicians, Process Optimization Specialists, and Plant Managers.

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.