APC Expert Consultants, Inc.

Practical Process Control Training

Training Objectives:

Successful completion of the “Process Control Fundamentals” and “Advanced Process Control and Modeling” courses with APC Expert Consultants, Inc. provides a solid background in the field of process control.

These programs teach a strong balance between foundational and advanced concepts in process control, including:

  • PID fundamentals, loop tuning, feedforward, and anti-reset windup

  • Understanding process dynamics and their role in control strategy selection

  • Practical insights on feedforward control, inferential control, and valve stiction counteraction

  • Exploring control strategy design (constraint control, valve position control, control of integrating processes)

  • Hands-on exposure to DCS architecture, sensors, transmitters, and final control elements

  • Introduction to dynamic compensation and process simulation within a DCS environment

Training is offered at the client’s site or other preferred venue.

Each attendee receives a spiral-bound book documenting all the topics covered in the course. Many find this book invaluable for review of the material, often carrying it into the field to use as a guide for implementing the techniques learned.

Training Feedback:

Typical comments include…

  • why wasn’t this material taught in school?

  • I really enjoyed the practicals and the case studies. They assisted in helping me understand the course better.

  • The labs were excellent in promoting understanding. Really appreciate the tying up with practicality.

  • The instructor is very knowledgeable; he answered questions by leading us to the discovery of the answers. He encouraged participation and understood gaps (thus explained to our level)

  • the Test helped with learning

  • I enjoyed how complex concepts were well broken down by the instructor. It made it easier for me to grasp the logic behind them.

  • I liked the linking of every example/concept with the practical and real world. The training was not just a theoretical exercise; the application of each concept was well presented.

  • I enjoyed the modeling sections and learning of new control strategies. 

Client List:

Our clients include…

  • Chevron-Phillips Chem (multiple sites)

  • Lyondell-Basell (multiple sites)

  • Sasol (multiple sites)

  • Alcoa

  • S-Chem (Saudi Chevron Phillips)

Training Details:

The “Process Control Fundamentals” course…

  • starts from a rudimentary level

  • builds the skill level sufficiently to enable the engineer to employ sophisticated control strategies

  • covers all classical control concepts, with emphasis on understanding process dynamics to conduct proper process identification, loop tuning, and control strategy design

  • employs seven Excel-based labs that students do in the classroom to reinforce the lessons; each covers essential concepts; the labs can be retained on the student’s computer for refresher knowledge down the road

  • employs case studies, which give students the opportunity to design more involved control strategies; cases are based on actual control problems encountered in industry. Each student must design his/her own solution; then we compare and cover how the problem was solved in real life.

  • provides each student with a spiral-bound book showing all presentation slides

  • presents students with a comprehensive followup exam (open book) to reinforce the information given during the course; questions and answers are reviewed afterward


The “Advanced Process Control and Modeling” course…

  • continues development of model-based process control concepts

  • provides a deeper understanding of dynamic compensation for both self-regulating processes and integrating processes

  • introduces practical insights on dynamic process simulation within a DCS for purposes of control strategy development, testing, and operator training

  • presents students with an assignment to create a real-time simulation of a process with complex dynamics, requiring them to perform material and energy balances, holdup integration, and addition of noise to simulated measurements; this is done entirely with DCS configuration

  • assigns students to perform process step tests for model identification

  • challenges students to construct a model-based multi-variable controller through hands-on exposure to DCS configuration

  • directs students to evaluate the model-based controller performance and compare it to a well-tuned PID controller

  • provides each student with a spiral-bound book showing all presentation slides