APC275: Control Scheme Implementation
Contact Us Today: info@PiControlSolutions.com, Tel: (832) 495 6436
Duration: 3 Days Classroom or 21 hours Online
Audience: Process Control Engineers, Advanced Process Control Engineers, Instrument Engineers, Lab Technicians, DCS/PLC Technicians, Managers and Supervisors.
Prerequisites: 2-year or 4-year degree in engineering or operations. A few months of plant/ engineering experience is desirable, but not required.
Course Material: Software Products used in Course – Pitops, Simcet and Training Slides.
Course Description: This course starts with important basic knowledge about process control nomenclature, primary process control, process dynamics. It then moves into the design of control schemes and implementation inside a DCS or PLC. It covers PID control and transfer functions more concisely compared to PID100 and APC200 courses but spends more time on how to design and implement control schemes inside a DCS or PLC. Knowledge from this course will help any engineer on technician working with any DCS or PLC manufactured from any vendor worldwide. The teaching and concepts are generic and not vendor specific. The course covers how to design and implement both standard and custom function blocks inside any DCS or PLC. This includes batch control, continuous control, sequence control, single PID, Cascade PID, Multiple Cascades and Multiple Slaves, Feedforward Control (lead/lag/dead time/delay), startup/bump-less initialization, PV and SP/OP tracking, Simple Selectors, Constraint Override Control Selectors, Fan-Out Blocks, Ratio Control, Summers/Multipliers/Dividers, Split-Range Control, Safety Shutdown Control Logic, Math Function Blocks, Model-Based Control, Inferential Control, Adaptive Control, Flow Compensation, Linearization, Control Valve Characterization, Totalizers, Ramp and Soak, Switches, Clamps, Anti-Windup Protection, Signal Validation, Safe Design of Control Schemes and Operator Alerts and Advisory.
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At the end of this course, students will have the skills to design and build both continuous and batch control schemes inside any DCS or PLC. Students will have the ability to look at a process flow diagram or P&ID and based on the goals, needs and objectives of the operations or process group, design and implement the appropriate control schemes inside any DCS or PLC. Students will also have the skills to mathematically compute the various tuning parameters and control parameters for the control schemes. The course also teaches good process control habits to avoid making mistakes in the design and avoid plant upsets and shutdowns. Poorly designed control schemes can be dangerous and can cause upsets, shutdowns or even dangerous operating conditions including environmental releases. The course teaches the design of safe control schemes that will take into account operator mistakes, instrument failures and prevent bad things from happening. The course teaches how to provide automation to stabilize the process operation, how to maximize production, minimize cheaper byproducts, minimize utilities, minimize environmental emissions, increase the profit margins and improve key performance indicators.
- Process control terminology and definition
- Need and Benefits of Process Control
- DCS and PLC Function Blocks
- Batch control, Continuous control and Sequence control
- First Order Transfer Functions
- Zero and Second Order Transfer Functions
- Single PID Control
- Advanced PID functions
- Cascade PID Control
- Multiple Cascades and Multiple Slaves
- Startup / Bump-Less Initialization
- PV and SP/OP tracking
- Anti-Windup Protection
- How to build correct DCS Configuration for Long Chain
- Control Schemes Startup and Chain Activation Procedure
- Identification of process dynamics using transfer functions
- Feedforward Control (lead/lag/dead time/delay)
- Simple Selectors
- Averaging Control
- Constraint Override Selector Control Procedures and Calculations
- Fan-Out Blocks
- Ratio Control
- Split-Range Control
- Safety Shutdown and Process Critical Control Logic Design
- Math Function Blocks
- Inferential and Model-Based Control
- Linearization, Adaptive Control, Gain Scheduling and Control Valve Characterization
- Ramp and Soak Blocks
- Flow Compensation
- DCS Clamps- SP, OP and Operator Entry Validation
- Signal Validation and use in Closed-Loop Control Schemes
- Safe Design of Control Schemes
- Operator Alerts and Advisory.
- Practical Troubleshooting Rules and Tips for PID and APC Schemes
- Model-based Control, Bias Update, Empirical Models and Mass Balance Control