Course Details
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Course Description
Efforts at improving process control are one of the best investments that an operating company in the refining and petrochemical industry can make. The capital investment for the plant has already been made, and improved process control can many times provide substantial economic benefit with little or no capital investment. Operators and technicians with the proper training can troubleshoot control loops, tune PID control loops, and identify opportunities for advanced PID applications. To effectively apply these skills, the operators and technicians must understand the hardware (control computers, control valves, and sensors) associated with control loops, have a command of the fundamentals of PID and advanced PID control, and most importantly understand the operation of their process. This course is designed to provide operators and technicians with these skill sets.
The Training Course Will Highlight ?
The course covers the key elements associated with the application of process control to the hydrocarbon and chemical processing industries. The course will begin with an introduction to process control that demonstrates the primary economic benefits associated with improved process control.
The control-relevant aspects of control computers, actuator systems, and sensor systems commonly found in the hydrocarbon and chemical processing industries will be addressed next. Then, the forms and characteristics of PID controllers are studied, as well as the proper selection of the mode of the PID controller. Industrially relevant tuning of PID controllers for fast and slow responding control loops is presented and practiced using simulation software. A systematic approach for troubleshooting a PID controller is also demonstrated.
When and how to apply advanced PID control options is considered next. Then, an overview of multivariable control is presented. Finally, the specifics of PID control applied to heat exchangers, reactors, distillation columns, and pH are covered.
Training Objective
The course covers the key elements associated with the application of process control to the hydrocarbon and chemical processing industries. The course will begin with an introduction to process control that demonstrates the primary economic benefits associated with improved process control.
The control-relevant aspects of control computers, actuator systems, and sensor systems commonly found in the hydrocarbon and chemical processing industries will be addressed next. Then, the forms and characteristics of PID controllers are studied, as well as the proper selection of the mode of the PID controller. Industrially relevant tuning of PID controllers for fast and slow responding control loops is presented and practiced using simulation software. A systematic approach for troubleshooting a PID controller is also demonstrated.
When and how to apply advanced PID control options is considered next. Then, an overview of multivariable control is presented. Finally, the specifics of PID control applied to heat exchangers, reactors, distillation columns, and pH are covered.
Target Audience
Operators and technicians working in the petrochemical, oil, and gas process industries with a need to understand and use process control.
Training Methods
This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include:
- Lectures
- Workshop & Work Presentation
- Case Studies and Practical Exercise
- Videos and General Discussions
Daily Agenda
Day 1
Introduction
- Importance of process control
- Economic benefit of improved process control
- Terminology of process control: an everyday example of process control
- Typical process control loops
- Control and optimization
Control Loop Hardware
- Controllers (pneumatic, electronic, DCS, and fieldbus)
- Control valves
- Sensors
Day 2
- Forms of the PID controller
- Fundamental characteristics of P, I and D action
- Selecting the mode of a PID controller
- Analysis of commonly encountered control loops (flow, level, pressure, temperature, and composition loops)
PID controller tuning
- Conventional tuning methods and their limitations
- Recommended tuning approach
Day 3
Simulation In-Class Exercises
- Visual basic controller tuning exercises
Controller Troubleshooting
- General approach and expected performance specifications
- Actuator system
- Sensor system
- Controller
Advanced PID Control
- Cascade control
- Ratio control
- Feed-forward control
Day 4
Advanced PID Control
- Inferential control
- Scheduling of controller tuning parameters
- Computed manipulated variable control
- Constraint control
Multivariable Control
- Configuration selection
- Tuning multivariable PID controllers
- Model predictive control
Day 5
Case Studies
- Control of heat exchangers
- Control of exothermic and endothermic reactors
- Distillation control
- pH control
Overview Wrap-up of Course
Exercises
- Exercise 1 - Evaluation of installed valve characteristic
- Exercise 2 - Selection of reverse- or direct-acting PID controller
- Exercise 3 - Selection of PID mode for a particular process
- Exercise 4 - Field tuning exercise for level process
- Exercise 5 - Field tuning exercise for temperature mixing process
- Exercise 6 - Auto-tune exercise for heat exchanger
- Exercise 7 - Auto-tune exercise for CSTR control
- Exercise 8 - Troubleshooting exercise
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.
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