How You Can Train others for Tuning PID

In the modern era, machines and technologies play a very significant role in the life of people which leads the engineers, technologists, and better scientists to achieve and introduce the best quality, efficiency in the industrial machines which consume less energy and thereby provide maximum benefits/outputs.

To help you get close to this concept, we have listed three detailed steps to tune PID controllers.

3 Apparent ways to train your trainees about Tuning PID

1.    Using Two Module Courses

Module 1

The first module is the classic control which provides the training of how a PID controller works, what its parameters signify and they both should be tuned.

Ask the participants to do their own individual exercises of the PID loops.

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Module 2

The second module is the advance control process which teaches superior and advances control solutions such as override control, split range, feed-forward, and master-slave. 

2.    Provide Brief descriptions of the Modules with Course Contents

Module 1

The first module targets in teaching the participants how a PID controller works and furthermore how to deal with certain circumstances that may be encountered during the practice session. Basically here the participants learn how to identify the poorly tuned loops and the process of fixing them.

Contents:

·         The scheme of the PID controller

·         PID tuning controller

·         Tuning the PID controller

·         Examples and samples from regular practice

Module 2

The second module deals with the teaching of the advanced control process and its use in design control. Besides, they also involve the application of filters.

Contents:

·         Gain in scheduling

·         Self-learning feed-forward & feed ward

·         Control in master-slave

·         Decoupling

3.    Objectives

Module 1

·         Case studies

·         Exercises

·         Tuning of PID Loops

·         Identification of poorly tuned loops & tuning them accurately

·         Reporting the entire results

Module 2

·         Detection and selection of the correct advanced control solution

·         How to combine the control solution with the controller (PID)

·         Tuning PID

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A brief introduction to the process control solution

Manufacturing plants run by various applications and proper systems. The advancement of modern technology has been of great help in maximizing the productivity and profitability of the process plants. Process control solution being, one of the most developed creations of modern technology, is widely used in various industries.  

What is the process control solution?

Process control is the system of automatic control of an output variable. This system changes the process via process monitoring tools to derive specific results within an application. In order to generate a result with consistently high quality, implementation of the process control is required.

Understanding the basics of process control

The process control system is divided into three processes and they are-

·         Measured variable  

The measured variable is the monitored output variable that’s derived from a process. Technically, the result of the monitored output is derived within a given limit. 

·         Input or manipulated variable

 It’s basically the input variable of the process that’s generated by a control signal. The input variable is also known as a parameter. The measured variable can be controlled by changing the input variable cleverly.

·         The set or final point

The set-point is the targeted value of the output variable or parameter that’s usually monitored by a sensor. Error signals are generated by the   process control system.

Other terms related to the process control system

·         Sensors- Sensors are devices that are used to detect physical variables. For example, controlling temperature, motion or light intensity is being controlled by sensor devices.

·         Actuators- These are devices that are used to control input variables. An actuator will act as a flow-control valve that’s used to control the flow rate.

·         Controller- The controller is the heart of the process control system. It’s a hardware that’s used in performing many technical tasks. This device is also called the decision-maker of the whole process.

·         Feedback control- Feedback control is the process of comparing the generated values.

Different operations related to the process control system

The basic operations that must be implemented in the control system are-

·         Measurement (M)

·         Decision (D)

·         Action (A)

Different types of process controls

·         On/off control

·         Adaptive control

·         Cascade control

·         Feed-forward control

Bottom line

The process control solution is an integral part of the application system that’s commonly used in various industries starting from cement, alcohol, power plants, refining to petrochemicals. It’s a system that helps in running various applications effectively and efficiently.