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Process Control (PC)

Onsite Process Control Training. 

We will bring our  training equipment to your location and provide high quality, hands-on training that is tailored to your personnel, your schedule, your equipment & systems, and your specific training needs. 

We work with you to design a course that will achieve the desired objectives for your team. 

Our onsite training classes can be very cost-effective and result in dramatic improvements in your team's skill and performance levels. 

Some of the benefits of having training delivered at customer's location include:

  • Flexible schedules (back shifts, weekends, split-shifts to allow maintenance and production support, skill or experience level split groups, etc.)
  • Simplifies logistics and lost time for your personnel
  • Reduce travel cost of traveling to remote locations (hotels, airfare, rental cars & fuel, food, etc.)
  • Avoid potential travel delays or other problems

Our onsite training offerings can include skillset needs assessments, development of training plans & curriculum, development of standard and customized training materials and resources, remote progress checks, mentoring, and guidance for each individual or for groups, or whatever your team needs. We think out of the box to solve your training needs. Give us a call today to see how we might help your team! 

Detailed information on our Onsite Process Control Training - (Can be modified to meet customer needs and goals)

Length: 1 - 4 days
Percent Hands-on: 25 - 75%

This course takes students already have the knowledge gained in our instrumentation & controls course (IC) to the next level to begin doing detailed process control work. This course makes heavy use of process simulations with realistic controller configurations and settings and is designed for personal in roles such as controls engineer, senior instrument or controls technician, process or automation specialists, etc. This course is fast-paced and assumes personnel have knowledge equivalent to IC course and some experience working with process control loops and associated field equipment. 

Course Approach:
This course will utilize laptops with control simulations. Students will work with various fast-running simulated processes (flow, level, temperature, etc.) and trend screens that have insertable faults and problems, and variable process dynamics. Students will directly observe the impact of common control problems such as noise, process disturbances, process dynamics changes, etc., and will later analyze and determine control objectives and needs for several simulated systems, and will then setup, configure, test, and tune numerous control loops using various common methods (such as; Successive Approximation; Zeigler Nichols open/closed, Cohen-Coon, Lambda, etc.).  

This course will help high end professionals who need to analyze and solve process control problems to approach the problem in a safe and methodical way and to have insight to the issues and often overlooked details that could result in bigger problems and/or could lead them in the wrong direction. This course will also help personnel know when they are in the deep water and will help them avoid making serious mistakes that could jeopardize equipment, people, or the plant. 

Course objectives:

  • Understand process dynamics and it’s role in process control
  • Understand noise and filtering and recognize the common mistakes and problems in filtering.
  • Understand process time cycle, process lag, and deadtimes. 
  • Understand basics of proportional, integral, and derivative actions as well as the common uses and issues with each. 
  • Recognize the differences of common PID algorithms and be able to determine which algorithm your systems utilize (needed to select proper tuning approaches and thumb-rule values).
  • Be able to perform bump-test analysis of a process as part of a strategic tuning campaign. 
  • Know how to determine control objectives and compromises between fast and slow control system responses. 
  • Be familiar with common PID controller features and functions such as; bumpless transfer and bumpless tuning, variable gain selections, controller direction settings, controller bias and offsets, scaling of PV and OP, algorithm selections, ramp limiting & filtering, etc.
  • Be able to recognize common control system problems including field problems (noise, actuators/valves, etc.), controller setup issues, incorrect control objectives, etc.) 

Hands-on Exercises: 

  • Analyze impact of various process dynamics (gain, deadtime, lag, etc.)
  • Analyze impact of different controller algorithms
  • Perform a safe control system ‘test drive’ to observe and record important characteristics about the process interactions. 
  • Analyze and determine the control system performance objectives and compromises or limits for a system. 
  • Perform bump test analysis of a control system
  • Perform various methodical tuning procedures 
  •  Experiment with various controller functions and features. 
  • Solve problems and tune loops setup by instructor.
  • Troubleshoot control system issues and faults as setup by instructor.

Contact us today or submit an onsite course request form to get information and a detailed quotation for customized onsite training delivered to your team at your location!