MODULE DETAILS

Process Control and Tuning of Industrial Control Loops DIAPCT607

Nominal duration: 60 hours total time commitment

This time commitment includes the structured activities, preparation reading, and attendance at each webinar, completing exercises, practical assessments and proctored assessments.

It is also expected that students spend additional time on readings, personal study, independent research and learning, practicing on remote labs and required software and working on any projects and assignments.

This module covers the basics of process control, closed loops, loop tuning, tuning rules, valve controllers, automated tuning features, and consideration of application to more complex systems.

MODULE PURPOSE

The purpose of the module is for participants to develop knowledge of modern theory and good practice for control systems and be able to manage and apply effective procedures for tuning control loops.

MODIFICATION HISTORY

Original module approved in 2007 (51935); June 2011 (52403WA); 2014 (52708WA).  This version: V4.0

PREREQUISITE AND/OR CO‑REQUISITE MODULES

Modules that must be delivered and assessed before this module:

Process Plant Layout and Piping Design DIAPPL605

Modules that must be delivered concurrently with this module:

None

SUMMARY OF LEARNING OUTCOMES

On successful completion of this module students will be able to:

1. Explain basic process control concepts
2. Identify and correct stability issues in closed loops
3. Compare alternative closed loop configurations

4.    Outline peripheral issues in process control

1. Explain the fundamental concepts of loop tuning
2. Evaluate tuning rules
3. Explain characteristics of the process for tuning valve controllers
4. Outline effective procedures for automated tuning

9.    Outline the considerations in tuning complex systems

LEARNING OUTCOMES

ASSESSMENT CRITERIA

Learning outcomes specify what students will be able to do as a result of the learning.

Assessment criteria provide the criteria by which achievement of the learning outcomes will be judged.

1

Explain basic process control concepts

1.1

Explain, using examples, the following basic control concepts:

(a) On/off control

(b) Modulation control

(c) Feed-forward control

(d) Feedback control

(e) PID control

2

Identify and correct stability issues in closed loops

2.1

Identify and outline stability issues in control systems, with specific reference to:

(a) Causes of instability

(b) Methods to improve stability

(c) Changing of stability through PID control modes

2.2

Perform optimization of a PID temperature control loop by means of stability analysis

3

Compare alternative closed loop configurations

3.1

Compare the following closed loop control configurations:

(a) Cascade control

(b) Feed-forward control

(c) Combined feedback and feed-forward control

4

Outline peripheral issues in process control

4.1

Describe the problem of long dead time in closed loop control

4.2

Outline common considerations relating to alarm handling

4.3

Evaluate commercially-available process control equipment

4.4

Compare and contrast the use of PLCs as alternatives to dedicated PID controllers

4.5

Explain the characteristics and applications of self-tuning controllers

5

Explain the fundamental concepts of loop tuning

5.1

Outline the basic concepts and building blocks related to process control applicable to loop tuning, with reference to:

(a) PID controllers

(b) P, I and D modes of operation

(c) Load disturbances and offset

(d) Speed and stability issues

(e) Gain and dead time

(f) Process noise

5.2

Justify the selection of appropriate feedback controller modes

5.3

Describe the method for obtaining the open loop characterisation of a process through experimentation

5.4

Outline default settings for the following processes:

(a) Liquid level

(b) Gas pressure

(c) Reactor temperature

5.5

Compare and contrast the characteristics of the following generic closed loop tuning approaches:

(a) General purpose

(b) Quick and easy

(c) Fine

(d) Simplified Lambda

5.6

Demonstrate, using simulation software where appropriate, good practice in setting up control loops for:

(a) Flow control

(b) Pressure control

(c) Level control

(d) Temperature control

6

Evaluate tuning rules

6.1

Describe and use the basic procedures of the following tuning rules:

(a) Pessen

(b) Short cut open-loop

(c) Simplified Lambda

(d) On-line trial

(e) Ziegler Nichols

(f) Open loop reaction rate

(g) Open loop point of inflection

(h) Open loop process gain

(i) Cohen-Coon

6.2

Select, using tables, typical tuning settings for various application types

6.3

Determine the most appropriate rule for a given scenario

6.4

Outline rules of thumb used in loop tuning

7

Explain characteristics of the process for tuning valve controllers

7.1

Describe the effects of hysteresis and how to address it when tuning a loop

7.2

Describe the effect of stiction and how to address it when tuning a loop

8

Outline effective procedures for automated tuning

8/1

Outline the concept of self-tuning loops

8.2

Outline the concept of adaptive control

9

Outline the considerations in tuning complex systems

9.1

Outline and illustrate, by example, the methods to tune more complex systems such as:

(a) Cascade systems

(b) Feed-forward systems

(c) Ratio systems

(d) Multivariable systems

(e) Interactive loops

9.2

Explain the application of dead time compensation

9.3

Outline and illustrate, by example, the practical limitations of each of the approaches specified in 5.1 (a) through (e) above

DELIVERY MODE

Online and/or face-to-face

SPECIALISED RESOURCES

N/A

ASSESSMENT STRATEGY

METHODS OF ASSESSMENT

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, structured assessments, samples and questioning. This will include short answer questions on the knowledge content, the use of remote and virtual labs, and writing tasks to apply the learning to academic tasks.

CONDITIONS OF ASSESSMENT

Questioning techniques should not require language, literacy and numeracy skills beyond those required in this module. The candidate must have access to all tools, equipment, materials and documentation required.

The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Assessments may be open book assessment and may be completed off campus. Invigilation software will be used for some assessments to ensure authenticity of work completed.

Model answers must be provided for all knowledge-based assessments to ensure reliability of assessment judgements when marking is undertaken by different assessors.