MODULE DETAILS

 

Module 8: Practical Tuning of Industrial Control Loops for Engineers and Technicians

 

Nominal duration: 3 weeks (36 hours total time commitment)

 

This time commitment includes the preparation reading, attendance at each webinar (1 hour plus 15-30 minutes for discussion), and the time necessary to complete the assignments and further study.

 

MODULE PURPOSE

 

This module covers the procedures for tuning closed-loop (PID) control loops, as used in an Industrial environment, with a minimum of mathematics and formulas.

 

PRE-REQUISITES MODULE, UNITS /

 

CO-REQUISITES

 

Module 7

 

ASSESSMENT STRATEGY

 

To evaluate the achievement of the learning outcomes; written assignments, group projects and practical exercises are set.

 

SUMMARY OF LEARNING OUTCOMES

 

1. Examine the fundamentals of loop tuning

 

2. Evaluate various tuning rules

 

3. Examine the process of tuning valve controllers

 

4. Outline the procedures for automated tuning

 

5. Examine and illustrate the issues related to the tuning of more complex systems

 

Learning Outcome 1

 

Examine the fundamentals of loop tuning

 

Assessment Criteria

 

1.1

 

Examine the basic concepts and building blocks related to process control, 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

 

 

 

 

1.2

 

Examine the selection of appropriate feedback controller modes

 

 

1.3

 

Examine the method for obtaining the open loop characterization of a process through experimentation

 

 

1.4

 

Examine the default settings for the following processes:

 

(a) Liquid level

 

(b) Gas pressure

 

(c) Reactor temperature

 

 

1.5

 

Examine the following generic closed loop tuning approaches:

 

(a) General purpose (b) Quick and easy (c) Fine

(d) Simplified Lambda

 

 

1.6

 

Examine good practice in setting up control loops for: (a) Flow control

(b) Pressure control

 

(c) Level control

 

(d) Temperature control

 

 

 

Learning Outcome 2

 

Evaluate various tuning rules

 

Assessment Criteria

 

2.1

 

Examine the basics 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

 

 

2.2

 

Select typical tuning settings for various application types, from tables

 

 

2.3

 

Decide on the most appropriate rule for a given scenario

 

 

2.4

 

Apply the various rules of thumb used in loop tuning

 

Learning Outcome 3

 

Examine the process of tuning valve controllers

 

Assessment Criteria

 

3.1

 

Examine the effects of Hysteresis and how to address it when tuning a loop

 

 

3.2

 

Examine the effect of Stiction and how to address it when tuning a loop

 

Learning Outcome 4

 

Outline the procedures for automated tuning

 

Assessment Criteria

 

4.1

 

Outline the concept of self-tuning loops

 

 

4.2

 

Outline the concept of adaptive control

 

 

 

Learning Outcome 5

 

Examine and illustrate the issues related to the tuning of more complex systems

 

Assessment Criteria

 

5.1

 

Examine and illustrate 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

 

 

5.2

 

Examine the application of dead time compensation

 

 

5.3

 

Examine and illustrate the practical limitations of each of the approaches specified in 5.1 (a) through (e) above

 

Delivery mode

 

A combination of asynchronous and synchronous e-learning delivery comprising a judicious mix of interactive online web conferencing, simulation (virtual labs) software, remote online labs, online videos, PowerPoint slides, notes, reading and study materials (in PDF, HTML and Word format) accessed through the Moodle Learning Management System (LMS).

 

Software/Hardware Used

Software

  • PC-ControLAB 

  • v3

Hardware

  • Remote Lab