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PID Maintenance, Configuration, and Troubleshooting
Length: 32 Hours

Course Number: PLC-P201
Maximum Participants: 10 Students

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Software Used: RSLogix / Studio 5000 in Windows 10
Course Description: The purpose of this course is to familiarize students with the major PID tuning methods, and to troubleshoot PID loops. We will cover both position based, and velocity based PID instructions, and the operating modes available for each instruction. As an option, the course will be delivered using the PID and PIDE instructions, or with PlantPAx.
Prerequisites: Students who take this course should have previously completed ControlLogix Level 1 and PlantPAx (if you choose that option). Equivalent knowledge and experience is sufficient.
Course Objectives:
  • Troubleshoot PID Systems
  • Configure PID Loops
  • Maintain and Tune Single Loop PID Systems
  • Maintain and Tune Cascading PID Loops
1. Introduction
  • Introduction of Students
  • Pretest
2. ControlLogix Review
  • Hardware
  • Communication
  • RSLinx
  • RSLogix
    • Local I/O
    • Remote I/O
    • Ladder Logic
    • Function Blocks
3. Analog
  • Connections to the Analog Modules (Input and Output)
  • Scaling Analog Values
4. PID Terminology
  • PID Variables
  • Dependent vs. Independent Mode
  • Forward Acting vs. Reverse Acting
  • Position Based vs Velocity Based PID
5. PID Challenges
  • Lag and Delay
  • Valve Stiction
  • Excessive Valve Movement
6. PID Tuning Methods
  • Heuristic Method
  • Ziegler-Nichols Method
7. Ladder Logic PID Instruction
  • Configuring the PID instruction
  • Practice with Proportional Gain only (observe stability)
  • Calculate and introduce Integral. (observe response curve)
  • Calculate and introduce Derivative if used. (observe output)
8. PID Lab – Practice tuning with various settings for load, lag, delay, and response time

9. Function Block PIDE (Enhanced PID)

  • Main differences between PID and PIDE instructions
  • Configure the PIDE instruction
  • Program vs. Manual Mode (switching between modes)
  • Practice tuning the PIDE instructions
  • Use plant programs to trace the source of the Process Variable
  • In a plant program, trace the Control Variable to the real world output
  • orward Feed for predictive disturbances
  • PID Deadband
  • Cascading PID loops
  • Troubleshooting and tuning Cascading PID loops
10. PlantPAX P_PIDE (if selected as an option)
  • Import and configure the P_PIDE Instruction
  • Import and configure PIDE Faceplate in FactoryTalk View
  • Navigate the PIDE Faceplates on a running project
  • Tune the P_PIDE
  • Switch between Operator, Program Control, and Manual modes
  • Forward Feed with PlantPAx
  • Cascading PID loops in PlantPAx
  • Troubleshooting PlantPAx PID
11. Tank Level Tuning -- We'll use a separate tuning formula for integrated, non-self regulating processes such as a tank level control.

12. PIDE Lab – Using the enhanced PID, tune various loops with various scenarios on the PID Simulator

13. Conclusion

  • Review
  • Post Test
  • Course Evaluations

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