#1410 - Application of Feedback Controllers

Course Objective

Upon completion of this course, participants will understand basic controllers, learn how to tune controllers faster, and provide improved control of their processes.  Participants will understand the use of basic, feedback controllers in the process industries and the practical, successful methods to tune them.  This course stresses the fact that improved control will provide better productivity and efficiencies.

Who Should Attend

Technicians, engineers, operators, trainers, sales personnel, maintenance, management personnel, and scientists who are involved in the processing industries:  refineries, chemical plants, power stations, water plants, etc.  The only prerequisite is some knowledge of controllers in the process industry.

Course Description

This course presents practical, step-by-step, successful tuning methods that utilize relationships and reaction curve analysis.  No advanced mathematics will be required or used.  These methods can be easily understood and implemented by the individual immediately. 

Participants will be able to:

• Understand how a controller works and how it fits into a process
• Know the parts of a control loop
• Understand the fundamentals of controller gain or proportional band, integral and derivative actions
• Tune a controller by trial and error
• Improve on trial and error method by using special rules
• Apply the ultimate oscillation tuning method to properly tune feedback controllers
• Determine tuning constants by using modifications of the ultimate oscillation method
• Run response curves on a process
• Identify controller problems by analyzing the response curve
• Measure gain, dead time, and process lag of a process
• Determine what controller gain or proportional band, integral and derivative actions are best to control the process
• Understand the difference between set point change and load change
• Apply tuning methods to cascade controllers
• Identify when process changes may be needed for improved control

The course consists of the following main topics and subtopics.

• Relationship of controller and process
  • Four parts of a process
  • Interaction of changes to the four parts
  • Benefits of good control
• Definitions of the controller modes:  gain, integral, and derivative
• Rules for improved trial and error tuning
• Analysis of oscillation responses
  • Tuning using oscillation techniques
• Analysis of response curves
  • Tuning using a response curve generated by a step change
  • Tuning using a response curve produced by a load change
  • Working with unusual response curves
• Changes that may be required in the process to improve controllability
• Use of cascade control

The following exercises are included in this course:

• As a class, trial and error measurement will be studied and various tuning methods will be performed using a PC-based computer program
• Individual participants will calculate tuning constants using various methods based on data from handouts (Note:  Calculators are useful)

Course Duration - 1 day