Process Control


Outstanding Features

Theory is one thing practice is another. From PID to model-based techniques, academic process control doesn’t get to grips with process dynamics and how to match and tune the right control technique for the process. We do the opposite, understanding process dynamics before selecting and tuning the control approach.

Course Overview

In our experience, the teaching of control theory does not adequately explain the concept of process dynamics and hence many people have been introduced to control theory but don’t understand how to match the appropriate techniques with the actual process dynamics. This programme aims to provide understanding of process control through practical exercise.
We will use a range of simulation models to measure process dynamics, test and tune control techniques; just as you would do onsite. We limit the theory to what you need to know to understand the practical exercise of process control.
Your job in the real world is not to develop new control techniques, we can leave that to the many control specialists out there, your job is to apply known control techniques to get the maximum benefit in production optimization.

Target Audience

Operations engineering support teams, instrument technicians and panel operators will all benefit from this course. New control engineers will also gain from practical advice to complement the theory from school. Technicians should have at least three years field experience, engineers do not require any experience.

You Will Learn How to

This course has been prepared to meet the specific requirements of engineers, control room operators and instrument specialists who together, need to gain confidence and competence in control. You will learn how to:

Identify different aspects of Control Systems
Measure Process Dynamics
Determine Control Dynamics
Use the Control Toolkit
Tune feed back loops

Feedback Control: On/Off
Feedback Control : Proportional Only
Feedback Control : Proportional and Integral
Feedback Control : Proportional, Integral and Derivative
Feedback Control: Cascade

Tune feed forward loops

Feed forward Control: Ratio
Feed forward Control : Bias
Feed forward Control : Models

Use tuning packages
Recognize the need for model based control


Introduction to Control Systems
Role of each element of a control system
Plant control objectives
Desired response using a range of control options
PID Controller Terms
Pros and Cons of Derivative Action
Tune pressure, level, flow and temperature loops
Control Tool kits

Course Details

Day One:
The course starts with a breakdown of control systems from final element all the way back round a control loop, and then on to the architecture of control systems, including emergency shutdown and fire and gas systems. There should be no element of the system that we do not explain such that the purpose and the contribution to process and control dynamics can be understood.

Day Two & Day Three:
We then measure and compare process and control dynamics explaining how each piece of information is used to select the appropriate control technique. This whole course has been prepared to build from the concepts of process dynamics towards the application of the most appropriate control technique. The course gives a practical introduction to the application of control from the standpoint of modelling process dynamics and selecting an appropriate control technique to reflect the process dynamics.

Participants will be able to apply feed forward techniques to decouple control interactions, and will also be able to be able to tune the various control techniques from basic on off control to feed forward. The computer simulations allow us to practice tuning via a control system interface whilst the dynamic simulation runs in real time giving immediate feedback on control performance.

Day Four:
Building on a thorough understanding of the basics of control, each participant will be introduced to our concept of the ‘control toolkit’ such that they understand and can apply the appropriate control technique where basic control can’t cope with process dynamics and interaction. Computer simulations are used to give practical examples to explore control strategies.

Day Five:
At the end of the course delegates will be able to collect and analyse process data. Importantly, they will understand the ongoing demands of different control techniques, and hence understand why model based control, whilst technically interesting, is of minimal use without solid regulatory control as a basis. They will understand non-linear behaviour and be able to apply adaptive control techniques to compensate, as well as an appreciation of how to control non self-regulating processes.

We will also consider the use of automatic tuning tools and their limitations. By the end of the course participants should be able to participate in loop tuning and control discussions guiding and if necessary actively tuning control loops for optimum process performance.

Course Length

5 Days

Course Director

Howard Thomas


Upon completion, you will receive a Worley Academy Certificate of Completion.

Course Schedule

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