Myke King’s Process Control – Advance Process Control Techniques – Part 1

Instructor: Myke King (view profile)

Upcoming Session: Bogor, 9-13 May 2016

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Course Overview
The practical application of advanced control can have a significant impact on process performance. In many processes it can double profitability. Course delegates will learn not only the importance of process control but also how it is applied. Successful implementation depends also on the awareness of others of the benefits and the efforts involved in installation. The courses are of value not only to those directly involved in implementation but also to process management and other technical support groups who have responsibility for maintaining and improving process profitability. Delegates would include control engineers, process engineers, mechanical engineers, instrument engineers, instrument technicians and plant supervisors.

The courses stress the practical application of basic and advanced control techniques, using the minimum of control theory. They comprise a number of relatively short classroom sessions each followed by more lengthy ‘hands-on’ work. Delegates work in small groups on a process simulated on a PC.


I.1. Introduction

  • course introduction
  • benefits of improved control
  • regulatory control
  • constraint control
  • closed loop optimization
  • terminology
  • hierarchy of control
  • case study description

I.2. Process Dynamics

  • process gain, dead time and lag
  • concept of order
  • simplifying approximations
  • obtaining dynamics from plant tests
  • linearity
  • non-self-regulating process

I.3. PID Algorithm

  • development of control algorithm
  • tuning by trial and error
  • tuning criteria
  • published tuning methods
  • tuning for set point and load changes
  • use of proportional on PV algorithm
  • manipulated variable response
  • cascade control
  • split-ranging and dual acting control
  • anti-reset windup

I.4. Signal Conditioning

  • linearization
  • pressure compensation of distillation temperatures
  • dealing with steam drum (swell)
  • gas flow compensation
  • heating value compensation
  • filtering noise
  • impact on controller tuning

I.5. Level Control

  • importance of correct level control
  • tight versus averaging control
  • determining vessel working volume
  • tuning methods
  • error squared algorithm
  • gap control
  • linearity
  • problem of noise

I.6. Feedforward Control

  • use and advantages
  • ratio and bias algorithms
  • types of decoupler
  • tuning feedforward controller
  • impact on feedback controller
  • compensation for changing process gain
  • dealing with noise
  • manipulated variable movement

II.1. Dead time Compensation

  • use of predictive techniques
  • Smith Predictor
  • Dahlin Algorithm
  • Internal Model Control (IMC)
  • tuning
  • impact of modeling error
  • limitations

II.2. Non-linear Control

  • limitations of linear algorithms
  • gain scheduling
  • programmed adaptive control
  • process variable linearization
  • application to pH control

II.3. Constraint Control

  • types of constraint
  • PID based techniques
  • single input, single output controllers
  • multi-input, multi-output controllers
  • use of signal selectors
  • incremental versus full position algorithms
  • 2×2 decoupling
  • multivariable techniques

 Watch Myke King’s Process Control Video