PID Control and Loop Tuning

Overview

Most process plants have hundreds of control loops, and studies regularly find that a large share of them perform poorly: they oscillate, respond too slowly, or run in manual because operators no longer trust them. Every poorly tuned loop costs energy, product quality and operator attention. This course gives instrument and process engineers the practical skills to tune PID loops properly and keep them performing. Participants learn how processes behave dynamically, how proportional, integral and derivative actions work in different controller algorithms, and how to tune loops using open-loop and closed-loop methods. The programme covers flow, pressure, level and temperature loops, and advanced structures such as cascade, ratio, feedforward and override control. It also explains how to diagnose valve problems that no amount of tuning will fix.

Objectives

• Characterise process dynamics from step tests
• Explain PID algorithms and controller settings in common DCS platforms
• Tune loops using open-loop and closed-loop methods
• Apply suitable tuning strategies for flow, pressure, level and temperature loops
• Design cascade, ratio, feedforward and override schemes
• Diagnose valve stiction, deadband and sizing problems
• Assess and monitor control loop performance

Who should attend

Training methodology

More than half of the course is spent tuning simulated loops. Participants perform step tests, identify process models, calculate settings with several methods and compare the results on a dynamic simulator that reproduces typical oil and gas processes. Real trend data from plants is used to diagnose oscillation, sluggish response and valve problems. Each participant tunes a full set of loops for a separator and compressor system during the week. A practical tuning assessment completes the course.

Programme outline

Dates and fees

Fees are in GBP. per delegate.

Certificate

Frequently asked questions