Process Education on Demand - targeted, customizable training

Featuring "New" eLearning: Control Loop

Foundations

Photography & Video Recording Policy

Photography and audio/video recording is not permitted in any sessions or in the

exhibition areas without press credentials or written permission from the Emerson

Exchange Board of Directors. Inquiries should be directed to:

EmersonExchange@Emerson.com

Thank you.

Presenters

Mike Brouse, Mgr. Global

Learning Solutions

(Educational Services)

Terry Blevins

Introduction

This workshop describes online educational services that provide easy 24 /7

access to the training and knowledge resources you need. We will review:

Educational Services Strategy

Blended Learning (online and live classes)

Coming soon - e9025 – Control Loop Foundations

– Intended Audience

– Course Outline

– Example – a “typical” lesson

– Supporting materials – book, website

New learning management system (LMS)

Summary & questions

Where To Get More Information

Remove the Barriers to Learning

Reduce the complexity in learning about products, applications technologies and industry solutions

– Fast pace of new products & technologies

– New features and capabilities

Be more proactive and consultative with our customers regarding their training & education requirements

Provide customized “blended learning solutions” that address major shifts in learning needs:

Changing demographics

Just-in-time training

Globalization

Customer Feedback About Learning

Content & solutions should include:

– High quality online content (live & on-demand)

– High quality classroom training (hands-on)

– Ability to personalize learning for a specific audience

Easily accessible learning - flexible deployment

– LMS website – 24 / 7 learning opportunities

• Intuitive, informative, easy self-service

• Online searchable course catalog

• Online registration, reports, & payment

• Global – multi-language interface

Self Service

World Wide

Education

Blended Learning Path – I&E Technician

e9025 Control Loop Foundations (coming Jan 2014)

9000 4.5 day class - Introduction to Process Control

2375 – 2 day class - Wireless Self-Organizing Network

e475 Field Communicator Technical Training

e2353 Micro Motion Online Instrument & Electrical (pre-requisite for MMI ILT classes)

2380 2 day class – Micro Motion Comprehensive Product (field class w/ hands-on equipment training)

e1500 Introduction to Fisher Control Valves (pre-requisite for Fisher ILT classes)

1400 4.5 day class – Fisher Valve Technician I (Hands-on equipment training)

e7020 AMS Suite: Intelligent Device Manager Primer (pre-requisite for AMS ILT classes)

7020 3 day class - AMS Device Manager (Hands-on equipment training)

7018 4 day class - DeltaV Hardware and Troubleshooting (Hands-on equipment training)

7037 – 3.5 day class – Communication Interfaces with DeltaV System

e2069 Fundamentals of Vibration (Machinery Heath Management)

2031 4 day class – Basic Vibration Analysis (Hands-on equipment training)

e2300 Rosemount Flow Products

2340 - 1 day class Rosemount 8700 Series Smart Mag Flowmeter (Hands-on equipment training)

2341 - 1 day class Rosemount 8800 Series Vortex Flowmeter (Hands-on equipment training)

2326 4.5 day class – Rosemount Measurement Products I (Hands-on equipment training)

2327 3 day class – Rosemount Measurement Products II (Hands-on equipment training)

Classroom Training

Online Learning

Power of Blended Learning

LMS

Custom

Curriculum

- online content (live & on-demand)

- classroom training (hands-on)

What kind of online training is available ?

eLearning Courses – self-paced, includes testing,

tracking, & reporting

– Level 1 – informational

– Level 2 – skills based

• On-line training enables learning without travel & expenses

• Flexible training, one person at a time rather than a group

Virtual Classroom

– 25 courses

Control Loop Foundation – eLearning Course

This eLearning course is based on the book

Control Loop Foundation and addresses key

points and workshops included in the book.

All workshops and application examples in the

book are implemented using DeltaV control

capability.

The application section is designed to show how

control techniques may be combined to address

more complex process requirements

The book web site may be accessed to perform

the workshops and to obtain hands-on

experience using application example.

In E9025, the workshop’s modules are accessed

through a web browser.

Course Outline (Control Loop Foundation)

Background – Historic Perspective

Measurement – Basic Transmitter Types, Limitations

Analyzers – Examples of On-line Analyzers

Final Elements – Valves and Variable Speed Drives

Field Wiring and Communications – Traditional, HART, FF , WirelessHART

Control Strategy Documentation – Plot Plan, Flow Sheet, P&ID, Loop Diagram

Operator Graphics and Metrics – Considerations in Display Design

Process Characterization – Identifying process dynamics and gain

Control Objectives

Single Loop Control – PID basics, selecting PID structure, action

Tuning and Loop Performance – Manual and automated tuning techniques

Multi-loop Control – Feedforward, Cascade, Override, Split-range,

Ratio, Valve Position Control

Model Predictive Control – Addressing Difficult Dynamics, Interactions

Process Modeling – Process simulation for Checkout/Training

Applications – Continuous, Batch, Combustion, Distillation

Course Outline (Control Loop Foundation)

Background – Historic Perspective

Measurement – Basic Transmitter Types, Limitations

Analyzers – Examples of On-line Analyzers

Final Elements – Valves and Variable Speed Drives

Field Wiring and Communications – Traditional, HART, FF , WirelessHART

Control Strategy Documentation – Plot Plan, Flow Sheet, P&ID, Loop Diagram

Operator Graphics and Metrics – Considerations in Display Design

Process Characterization – Identifying process dynamics and gain

Control Objectives

Single Loop Control – PID basics, selecting PID structure, action

Tuning and Loop Performance – Manual and automated tuning techniques

Multi-loop Control – Feedforward, Cascade, Override, Split-range,

Ratio, Valve Position Control

Model Predictive Control – Addressing Difficult Dynamics, Interactions

Process Modeling – Process simulation for Checkout/Training

Applications – Continuous, Batch, Combustion, Distillation

Course Outline (Control Loop Foundation)

Background – Historic Perspective

Measurement – Basic Transmitter Types, Limitations

Analyzers – Examples of On-line Analyzers

Final Elements – Valves and Variable Speed Drives

Field Wiring and Communications – Traditional, HART, FF , WirelessHART

Control Strategy Documentation – Plot Plan, Flow Sheet, P&ID, Loop Diagram

Operator Graphics and Metrics – Considerations in Display Design

Process Characterization – Identifying process dynamics and gain

Control Objectives

Single Loop Control – PID basics, selecting PID structure, action

Tuning and Loop Performance – Manual and automated tuning techniques

Multi-loop Control – Feedforward, Cascade, Override, Split-range,

Ratio, Valve Position Control

Model Predictive Control – Addressing Difficult Dynamics, Interactions

Process Modeling – Process simulation for Checkout/Training

Applications – Continuous, Batch, Combustion, Distillation

Ratio Control For many processes such as blending and boiler combustion, a key objective is to

maintain the flow rates of two process streams in some proportion to one another.

FV

220 FT

220

FC

220

FFC

221

FV

221 FT

221

FC

221

FC

FC

Flow A

Flow B = Ratio * Flow A

Ratio

Control

Independent Input SP or PV of independent loop

Dependent Input SP = Ratio * Independent Input

Ratio Example Ratio

1 Flow B = Flow A

0.5 Flow B = (Flow A)/2

Ratio Input Selection

Independent Input

SP PV

IN

Ratio Block

OUT

SP * Ratio SP OUT

* Ratio SP

Ratio SP

SP

Dependent Loop

Noise

OUT

Ratio Input Selection

Independent Input

SP

IN

Ratio Block

OUT

Ratio SP

SP

Dependent Loop

Independent Loop

Ratio SP * SP

OUTPV

Ratio SP *

Ratio not maintained!

OUTSP

Ratio maintained!

SP

Example – Reactor

FT

225

FV

225

SC

226

FC

225

FC Feed

Catalyst

Reactor

Outlet

FFC

221 Ratio Control

Dependent

Independent

Example – Blending

AT

232

AC

232 Ratio SP FFC

231

Ratio Control

Target Property

(Ingredient

Concentration or

Composition)

FV

231 FT

231

FC

231

FC

FV

230 FT

230

FC

230

FC

Feedback Controller

CAS

Example – Slaker Lime Feed

FT

240 FV

240

FC

240

FFC

241

Ratio Control

SC

241

FC Green Liquor / Slaker

(sodium carbonate)

Lime

(calcium oxide)

AC

242

AT

242

Conductivity

Causticizers

Ratio Control Implementation

The Ratio block is used to implement ratio control.

The input to the Ratio block is the measurement or

setpoint of the independent flow input to the

process.

In the Ratio block, this input is multiplied by the

ratio to determine the setpoint of the dependent

flow input to the process.

Workshop – Ratio Control

A blender is used to blend two streams of different concentrations. The percent solids concentration exiting the blender is measured on-line and is the input to a concentration controller.

The concentration controller output adjusts the setpoint of the ratio controller associated with the main flow and blend.

Changes in the concentration controller setpoint cause the inlet flow ratio to change to the value needed to achieve the target outlet concentration.

Workshop – Ratio Control

Open the Ratio Control workshop using your web browser.

Step 1: Change the mode of the Ratio

block to Auto.

Step 2: Change the Ratio SP (setpoint)

over the following range: 0.3, 0.5, and

0.8. Observe the change in the blend

flow and the process outlet

concentration. Then set the Ratio SP

to 0.5 and wait for the concentration

to settle to a steady value

Step 3: Make a step change in the

Main Flow and observe the way the

ratio changes the dependent loop. Did

the concentration change?

Workshop – Ratio Control

Step 4: Change the Ratio block to Cascade mode. Change the setpoint of the analytical loop to 40% and observe the impact on the ratio setpoint. Does the measured concentration reach setpoint?

Step 5: Examine the process simulation module used in this workshop, shown here. Question: What are the advantages of structuring the process simulation as a separate module? What are the disadvantages of this approach?

Web Interface - Workshops

Use your web browser to

access the web site. The

workshops that go with

Control Loop Foundation

are displayed on the

home page.

Individual workshops and

applications are

accessed by clicking the

mouse over the name.

Exercise Information

When a selection is made

from the Workshops or

Applications interface, the web

page will change to give

information on the selected

workshop or application.

For example, if Ratio Control

is selected under Workshops,

then the interface for this

workshop would appear as

shown in this example.

The Exercise tab is shown by

default and duplicates the

book’s directions.

Process Information

To see the process that is

used in a workshop or

application, the Process

tab may be selected.

In response, the bottom

portion of the screen will

change to show a picture

of the process, as

illustrated here.

Workspace –Dynamic Simulation/Control

With the selection of the

Workspace tab, the lower

portion of the screen

changes to show an on-

line view of the function

blocks used in the control

strategy.

Changing Block Parameter Value

To change the value of a parameter,

double-click on the parameter name

in the left pane. In response, a

dialog box is displayed that allows

the parameter value to be changed

In some cases, a module parameter

is used to allow disturbances to be

introduced into the process

simulation.

To modify a parameter contained in

a module, it is only necessary to

double-click on the parameter. In

response, a dialog box is displayed

that may be used to change the

parameter value.

Accessing Chart View

The impact of a change in a block

or module parameter may be

observed by examining the

dynamic values of the block input

and output parameters that are

constantly updated based on the

simulated process.

However, it is often helpful to view

a trend of a parameter to better

judge the impact of a parameter

change. Selecting the Chart tab will

cause a trend of selected

parameters to be displayed in the

lower portion of the screen

Workshop Solution

Selecting the Solution tab opens

a video showing the exercise

solution in the lower portion of

the screen.

In the video, each step of the

exercise is shown and

discussed.

Using the controls provided in

the video area, it is possible to

regulate the sound level and to

start, stop, and replay the video.

Educational Services Website

Browse a catalog of the latest on-line

and ILT courses from many different

Emerson Process brands on a variety

of technical topics

Professional eLearning with 24x7

access that includes demonstrations,

interactive practice sessions, progress

tracking, module tests, and a

comprehensive exam.

eLearning courses are deployed using

the latest (flash based) technology.

Educational Services Web Site:

http://www2.emersonprocess.com/en-

US/brands/edservices/Pages/EducationalServices.aspx

Educational Services eStore (eLearning courses)

A growing library of

eLearning courses are

available and may be easily

ordered & taken over the

web.

Educational Services EELMS coming soon…

Conclusion

Blended learning is a cost effective solution to help train and prepare your personnel.

– eLearning courses

– Virtual Classroom – Live Instructor

– Classroom courses

The E9025 eLearning course is based on the book “Control Loop Foundation”

– Many workshops and application examples are provided

– All workshop modules are accessed through a web browser

– ETA Jan 30 - $850 / 16-20 hours of online content

Where To Get More Information

Stop by the Educational Services booth

Educational Services website:

– http://www2.emersonprocess.com/en-

us/brands/edservices/Pages/EducationalServices.aspx

email me:

– Mike.Brouse@emerson.com

Contact Educational Services:

– 641-754-3771 or 800-338-8158

– email: education@emersonprocess.com

Control Loop Foundation

– Purchase Book or eBook :

http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/Produ

ctDisplay.cfm&ProductID=11267

– Web site: http://controlloopfoundation.com/

Thank You for Attending!

Enjoy the rest of the conference.

eLearning Demos e7012 DeltaV Operator v11 - http://emersonprocess.adobeconnect.com/p58z91ss9h7/ e7014 DeltaV Operator w batch - http://emersonprocess.adobeconnect.com/p3n76drppo9/ e7046 Batch Analytics - http://emersonprocess.adobeconnect.com/p75r110i5a0/ e1500 – Intro to Fisher Control Valves - http://emersonprocess.adobeconnect.com/p7n4aa3okmy/ e2353 - Micro Motion Online Technician Training - http://emersonprocess.adobeconnect.com/p18cul59djz/ e7020 AMS Device Manager - http://emersonprocess.adobeconnect.com/p9p7aatxn7f/