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DCS450

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DCS450: Function Blocks for APC Implementation in DCS/PLC

Contact Us Today: info@PiControlSolutions.com, Tel: (832) 495 6436

Duration: 3 Days Classroom or 20 hours Online
Audience: Process Control Engineers, DCS Maintenance Technicians, Instrument Engineers.
Prerequisites: Some control room exposure is desirable, but not required.
Course Material: PowerPoint Slides, DCS screens, Industrial Data,
Calculation Procedures and Data Analysis.

Course Description and Objectives: This course teaches you how to conceive, design and implement process control schemes inside a DCS or even a PLC.  There are many DCS and PLC vendors and this course builds skills that are useful for all types and models of any DCS or PLC.  Whether you work in a chemical, petrochemical, pharmaceutical, polymer, electric power, paper or really any manufacturing process, this course will teach you the skills to come up with new advanced process control ideas and schemes.  The knowledge will also help in the design of controls for safer and smoother plant operation and to run the plant better, smoother and with reduced chance of mistakes, shutdowns and human error.  The knowledge will help to maximize production rates, minimize utilities, speed up product grade transitions and improve key performance indicators.  In an era of a lot of approaching retirees in industry and the entry of new personnel in the control room, this course is a must for any process control engineer, DCS engineer, PLC engineer or process control technician.

Learning Outcomes

This course teaches the main components of a DCS and even a PLC.  It describes the DCS and PLC architecture.  It explains all DCS and PLC control functions.  It teaches standard and custom DCS logic blocks.  It covers batch, sequential, continuous and semi-batch control schemes.  It teaches how to design and implement control schemes.  It explains how to design and implement various standard function blocks available in most DCSs and PLCs.  The various standard function blocks are listed below.  With knowledge from PID100, APC200, this course is a perfect continuation to build the process control skills and knowledge and be more in the realm of what is available in DCSs and PLCs.  After completion of this course, the student will be ready to build new APC tags inside a DCS or PLC.  The following topics are covered in this course:

  • Process Control Nomenclature and Basic Definitions
  • SAMA Standard Diagrams and Symbols
  • PID Control
  • PID Related Peripheral Algorithms
  • PIDFF – PID with Feedforward
  • Transfer Function
  • Nonlinearity
  • SMOOTH Filtering for Noisy Signals
  • Dead Time and TRANSPORT Algorithm
  • LEADLAG Algorithm
  • Monitoring Algorithms
  • Boolean Logic Algorithms
  • Timers and Counters
  • Input and Output Algorithms
  • Multiple Signal Algorithms
  • Calculation Algorithms and Programs
  • Smith PREDICTOR Algorithm
  • PID Tuning Procedures
  • Procedures for Testing, Commissioning & Troubleshooting
  • DCS/PLC algorithms covered:
DCS450

DCS450 Question & Answers

The DCS450 course is designed to teach process control engineers and technicians how to conceive, design, and implement advanced process control (APC) schemes within a Distributed Control System (DCS) or Programmable Logic Controller (PLC). The course equips you with the skills to maximize plant performance and reduce errors and shutdowns.

This course is ideal for process control engineers, DCS maintenance technicians, instrument engineers, and anyone designing or maintaining control systems for industries such as chemical, petrochemical, pharmaceutical, and manufacturing.
The DCS450 course covers process control nomenclature, PID control, function blocks, nonlinearity, algorithms, and procedures for designing and implementing control schemes. It also includes essential topics like dead time, transport algorithms, and Smith predictors.
The DCS450 course is available as a 3-day classroom session or 20 hours of online training, providing flexibility to accommodate different schedules.
While some control room experience is helpful, it is not mandatory. This course is designed to provide essential skills for both beginners and those looking to expand their knowledge in advanced process control and DCS/PLC systems.
You'll learn to design and implement process control schemes, including standard and custom DCS function blocks, PID control, Boolean logic algorithms, and advanced control strategies. The course also covers commissioning and troubleshooting procedures.
By mastering function blocks and control schemes, DCS450 helps reduce human errors, optimize production rates, minimize utilities, and improve key performance indicators. This leads to smoother plant operation with fewer shutdowns and increased efficiency.
PID control is a core topic of the DCS450 course. You’ll learn how to design and tune PID controllers, implement PID with feedforward (PIDFF), and apply various PID-related algorithms for effective process control.
The DCS450 course teaches both standard and custom DCS/PLC function blocks, including algorithms for timers, counters, multiple signal processing, and calculation procedures. These blocks are key to designing complex control schemes in various industries.
DCS450 provides the knowledge needed to design and implement advanced APC systems using function blocks. This includes the use of monitoring algorithms, transfer functions, and nonlinearity compensation, ensuring effective and optimized plant control.
Industries such as chemical, petrochemical, pharmaceutical, polymer, power generation, and paper manufacturing can greatly benefit from DCS450 training. The course provides skills applicable to any process-oriented industry.
By completing the DCS450 course, you will be equipped to design and implement control schemes using DCS/PLC function blocks. You'll also understand advanced topics like PID tuning, transfer functions, nonlinearity, and troubleshooting procedures.
DCS450 teaches control techniques that reduce human error, enhance process stability, and improve the response time to operational issues. By mastering function blocks, you'll be able to implement more reliable control systems, minimizing the risk of mistakes and shutdowns.
The course recommends some exposure to control room environments, but it is not a strict requirement. Beginners in process control or those with basic knowledge of DCS/PLC systems can benefit from the course.
To learn more about the DCS450 course or to register, contact PiControl Solutions at info@PiControlSolutions.com or call (832) 495 - 6436. Our team is happy to assist with any inquiries and registration details.
Yes. DCS450 provides structured methods and naming conventions that help teams implement standardized function block logic across units, improving maintainability and reducing inconsistencies across shifts or teams.
Yes. The course includes strategies to work around platform-specific limitations in older DCS/PLC systems using combinations of available blocks and custom calculations to meet modern APC goals.
Yes. The course includes documentation samples, block diagrams, and example logic sequences that can be adapted for your plant’s implementation post-training.
DCS450 trains you in using diagnostic and monitoring blocks, such as RATECHANGE, QUALITYMON, and LOWMON, to pinpoint issues quickly and take preemptive action before process deviations become critical.
Yes. Many principles in the course—such as transfer functions, filtering, and nonlinear modeling—are applicable in simulation environments used for digital twin design, process emulation, and operator training.
Absolutely. DCS450 teaches how to reverse-engineer existing control logic and redesign it using modern function blocks, making it valuable for upgrade planning or migrating from one vendor platform to another.
Yes. Upon completion, participants receive a PiControl DCS450 Certificate, which is recognized by clients and employers across industries as evidence of advanced APC and control logic expertise.

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