Industrial Process Control

This comprehensive INVOLVE® interactive multimedia training program was produced in association with the Instrument Society of America. (ISA). This two individual lesson program trains participants in the concepts and principles of process control modes.

Audience: This program is an excellent entry-level course for control practitioners as well as for the multi-craft training needs of process and manufacturing facilities.

Single Loop Control


Prerequisites: This lesson is designed for participants familiar with measurement fundamentals. An understanding of algebra is also recommended.

Description: This lesson presents the principles of single-loop control and the applications of feedback control in the industrial environment. Also introduced are various control modes including on/off, proportional, integral, and derivative control.

Objectives:

  • Define and site industrial control
  • Define process variable
  • Compare manual and automatic process control
  • Adjust the set point on a pictorial representation of an industrial controller
  • Identify the controlled, measured, and manipulated variables of a heat exchanger system
  • Define deviation
  • Identify the system response for various control modes
  • Define load change
  • Identify the elements of process control
  • Identify the action of the final control element of various control systems
  • Identify the dead zone or dead band on an on/off control response curve
  • Compare and contrast the action of a final control element in an on/off control
  • System with a proportional control process
  • Identify reverse- or direct-acting control with an example of measurement and subsequent output response
  • Define proportional control in relation to response error
  • Determine the setting of the controller’s proportional band and gain on a pictorial representation of process control action
  • Identify offset on an example of proportional only control
  • Define integral control in relation to error signal
  • Identify minutes per repeat and repeats per minute with an example of the units used in integral control
  • Define reset wind-up on a process response curve for an integral controller
  • Identify the effects of reset wind up on the elements of process control on a heat exchange system
  • Define derivative process control in relation to error signal

Multiple Loop Control


Prerequisites: This lesson is designed for participants familiar with single-loop control. An understanding of pressure, temperature, level, and flow measurement as well as basic algebra is also recommended.

Description: This lesson explains the application of multiple-loop control strategies to industrial process control systems. The lesson also explains the operation of several types of digital process control systems.

Objectives:

  • Identify the benefits of advanced process control strategies
  • Compare feedback and feedforward control
  • Explain the principles and applications of a feedforward control system
  • Explain the principles and identify the benefits of cascade control
  • Discriminate between wild and controlled flows in a ratio control system
  • Explain the principles and applications for ratio control
  • Explain the principles and application of adaptive and selective control
  • Identify the method of process control used in direct digital, supervisory, and distributed control systems