TRAINING COURSES
DCS450: DCS/PLC Advanced Process Control Design and Implementation
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.
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Learning Outcomes
This course teaches the main components of a DCS and even a PLC. It describes the DCS and PLC architecture. It explains process control network and the concept of L0 – L5 control levels. 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 shows the safe and correct way of starting up advanced control schemes. It explains how to design and implement PID control, cascade PID control, feedforward control, ratio control, model-based control, adaptive control, constraint override control, production maximizing control, virtual sensors, and closed-loop control using online analyzers. There are numerous industrial examples illustrating process control problems, followed by the design and implementation.
Day 1
- DCS and PLC overview
- DCS and PLC control architecture and control network
- Definition and examples of primary and advanced process control
- Standard function blocks available inside DCS or PLC
- Custom function blocks available inside DCS or PLC
- Building continuous control strategies
- Building discrete control strategies
- MODBUS and OPC interfaces and connectivity to DCS
- Ethernet and coax-based networks
- Process Control Terminal Server
- DCS/PLC remote access and process control security
- Dual redundant and triple redundant control schemes, 2 out of 3 voting
- Programming languages used in DCSs
- Selection of scan rates for different types of tags
- Naming convention tips and recommendations
Day 2
- Designing advanced process control schemes inside a DCS or PLC
- Lube Oil Plant APC design and implementation
- Polyethylene APC design and implementation
- Distillation APC design and implementation
- Quarry production maximization design and implementation
- Gas composition mass balance control design and implementation
- Reactor heat balance calculations and yield prediction
- Use of online analyzers and analyzer multiplexing
- Design and implementation of furnace feedforward control
- Design and implementation of ratio control and summer control
- Design and implementation of closed loop cascade control using online analyzers
- Compressor surge control
- Control valve characterization and gain scheduling
- Determining transfer function parameters
- Calculating DCS tuning parameters for APC schemes based on transfer function parameters
- Signal validation, frozen data alarms and spike detection and rejection
Day 3
- Median signal PV calculation
- Consideration of safety and abnormal situations
- Design of safe process control schemes
- How to avoid mistakes and design robust control schemes
- HAZOP review procedures
- Safety shutdown control logic and design
- Design and procedure for conducting FAT (factory acceptance tests)
- Safe procedure for activating long chains of control schemes
- eMOC – electronic management of change procedures
- Design and implementation of batch sequence control schemes
- Designing logic for automatic activation and startup of advanced control schemes
- Mixing of batch control and continuous control logic for maximum effectiveness
- Tips and ideas to achieve high onstream factor on DCS and PLC based control schemes
- Protecting control schemes from fault, errors and problems
- Enhanced alarms and user alerts
- Alarm management and event analysis
- Adaptive control design and implementation
- Inferential control design and implementation