Practical Process Control Monitoring and Diagnostics

Chemical plants can have anywhere from about 50 PIDs in small plants to over 2000 PIDs in large refineries and integrated petrochemical complexes. In addition to simple PIDs, there are cascades, override controllers, model-based controllers, and multivariable controllers.

As time goes by, even well-tuned PIDs and other controllers can slowly start to deteriorate. As deterioration progresses, process oscillations can start with small amplitudes and can grow large over time costing the plant significant monetary and/or quality losses. Or conversely, PIDs could become sluggish because of changes in process and operating conditions, once again causing the control quality to deteriorate.

This course covers the technology and application of a control performance monitoring software (Apromon) that identifies poorly controlling PIDs (including single, cascade, override and complex PIDs). Apromon runs online using OPC and calculates several control criteria and generates control quality reports. Integrated with Apromon is a novel, breakthrough algorithm called TAD (True Amplitude Detection) that accurately isolates oscillating or sluggish controllers. This course shows how to improve and maintain the plant’s primary and advanced control system and increase the plant’s profits.

This course explains how to identify control problems in an online/real-time manner and take immediate corrective action using online adaptive control. The course also shows how to implement true adaptive control inside the DCS by connecting the control quality monitoring software using OPC technology to the DCS/PLC and by designing special DCS/PLC-resident logic for triggering automatic control action.

Learning Outcomes:

At the end of the course, attendees will be skilled in understanding process control quality monitoring criteria and statistics. They will be skilled in the application, installation, and use of real-time software products for process control quality monitoring at any plant.

Attendees will also be skilled in the application of online adaptive control technology using the control quality monitoring software and then linking it with closed-loop DCS based-adaptive control schemes. Using the knowledge, attendees on their own can build closed-loop adaptive control schemes at their plant inside the DCS/PLC using OPC connectivity.

Attendees will be able to significantly improve control quality at their plants, and move the plant more stably and reliably in the direction of increasing profits with fewer shutdowns and fewer abnormal events. The plant will also see a reduction in the number of alarms and a reduced need for operator intervention.

Our MON300 (Practical Process Control Monitoring and Diagnostics) training course is very practical, and easy to understand for everyone: engineers, technicians, operators, and students – both new and experienced. That is why our customers consider us the best.
This training course covers the basics of practical industrial continuous process control (PID and APC), measuring sensors, and final control element performance monitoring and diagnostics, all in the time domain. Our course is more hands-on than any competitor. Students can download and install process control software products on their personal laptops for use during our process control training. The software products are full-blown industrial process control software applications used by the industry. This level of hands-on approach tremendously aids the learning process and mastering process control theory and practicals.

Our instructors have over 30 years of industrial experience and process control training experience. They not only have the technical process control knowledge but also skills to make sure participants are fully engaged and able to concentrate on the material.

As part of the Udemy MON300 training course you will only get the possibility to install the following two powerful software products on your own computers (7-day free trial):

• APROMON – Online Process Control Performance Monitoring and Diagnostics software

• PiOPCServer – Real-time OPC server with PID Control Loop embedded

For installation and activation please contact us at info@picontrolsolutions.com. The usage of the above software packages is only limited to educational purposes, not for any industrial or commercial use.

If you would like to participate and enroll in more detail and a full-blown course on Practical Process Control Monitoring and Diagnostics and beyond, please contact us directly at info@picontrolsolutions.com. In our wider training course, in addition to Udemy topics, you will understand the need for process control monitoring and diagnostics, learn about statistical quality criteria, statistical control charts, data distribution characterization, and confidence intervals,

data transformation and smoothing and many other related topics.

After competition of our full-blown MON300 training course, you will get an international diploma as a process control expert in the field of process control monitoring and diagnostics, and you will get also possible to install our simulation, monitoring, and diagnostics process control software for the time period of more than one month. For more information, please contact us at info@picontrolsolutions.com.

Thank you,

PiControl Solutions

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Frequently Asked Questions

How long do I have access to the course materials?

You can view and review the lecture materials indefinitely, like an on-demand channel.

Can I take my courses with me wherever I go?

Definitely! If you have an internet connection, courses on Udemy are available on any device at any time. If you don’t have an internet connection, some instructors also let their students download course lectures. That’s up to the instructor though, so make sure you get on their good side!