PID Tuning and Loop Troubleshooting

IPC 115 focuses on developing the essential skills required for instrumentation and process control technicians to effectively manage and maintain industrial control loops. The curriculum covers foundational control theory, various tuning methodologies (including manual, Ziegler-Nichols, and auto-tuning), and advanced strategies for optimizing PID parameters in diverse process applications. Students will learn to diagnose common control loop issues, interpret process trends, and implement corrective actions using a structured troubleshooting approach. Emphasis is placed on practical, safety-conscious techniques applicable across a wide range of industrial processes, preparing students to improve system reliability and throughput in real-world settings. This course bridges theoretical understanding with hands-on application.

InstructorJacob Calhoun

Prerequisites

IPC 105 IPC 110

Course outline

Lectures, virtual labs, and graded assignments — completed in your browser.

01Lesson 1: Introduction to Process Control & Control Loop Componentslecture

02Lesson 2: Fundamentals of PID Control and Control Action Typeslecture

03Lesson 3: Process Dynamics, Dead Time, and Load Disturbanceslecture

04Hands-on Lab: Process Characterization and Open Loop Testinglab

05Lesson 5: Manual PID Tuning Methods and Rules of Thumblecture

06Lesson 6: Ziegler-Nichols and Other Algorithmic Tuning Methodslecture

07Lesson 7: Advanced Tuning Strategies: Cascade, Ratio, and Feedforward Controllecture

08Hands-on Lab: PID Tuning Practical Applications & Midterm Reviewlab

09Lesson 9: Control Loop Performance Monitoring and Metricslecture

10Lesson 10: Systematic Control Loop Troubleshooting Methodologylecture

11Hands-on Lab: Diagnosing and Resolving Common Loop Problemslab

12Lesson 12: Valve Characteristics, Stiction, and Actuator Issueslecture

13Lesson 13: Sensor Malfunctions, Transmitter Calibration, and Noise Reductionlecture

14Capstone Service Project: Optimize and Troubleshoot a Complex Control Systemassignment

Syllabus

["Week 1: Lesson 1: Introduction to Process Control & Control Loop Components","Week 2: Lesson 2: Fundamentals of PID Control and Control Action Types","Week 3: Lesson 3: Process Dynamics, Dead Time, and Load Disturbances","Week 4: Hands-on Lab: Process Characterization and Open Loop Testing","Week 5: Lesson 5: Manual PID Tuning Methods and Rules of Thumb","Week 6: Lesson 6: Ziegler-Nichols and Other Algorithmic Tuning Methods","Week 7: Lesson 7: Advanced Tuning Strategies: Cascade, Ratio, and Feedforward Control","Week 8: Hands-on Lab: PID Tuning Practical Applications & Midterm Review","Week 9: Lesson 9: Control Loop Performance Monitoring and Metrics","Week 10: Lesson 10: Systematic Control Loop Troubleshooting Methodology","Week 11: Hands-on Lab: Diagnosing and Resolving Common Loop Problems","Week 12: Lesson 12: Valve Characteristics, Stiction, and Actuator Issues","Week 13: Lesson 13: Sensor Malfunctions, Transmitter Calibration, and Noise Reduction","Week 14: Capstone Service Project: Optimize and Troubleshoot a Complex Control System"]