Process Control and Process Optimization Training Course

Course Overview

Learning Objectives

• Analyze the relationship between process control, operational performance, quality, safety, energy efficiency, reliability, and cost during the course.
• Assess key process variables, operating limits, control objectives, and performance indicators for selected process systems.
• Develop process control profiles that define critical measurements, set points, control ranges, alarms, responsibilities, and escalation requirements.
• Evaluate the performance of control loops, instrumentation, automation systems, and operating procedures using practical process scenarios.
• Apply process data analysis methods to identify trends, variability, deviations, control instability, and improvement opportunities.
• Design practical optimization approaches for set points, operating windows, equipment loading, sequencing, and process constraints.
• Improve control-system reliability by identifying maintenance, calibration, instrumentation, communication, and data-quality requirements.
• Strengthen alarm management practices by assessing alarm priorities, operator response, nuisance alarms, escalation, and documentation.
• Implement structured processes for testing, validating, and monitoring optimization changes while managing operational risk.
• Assess the interaction between process control, energy use, production capacity, quality performance, maintenance, and process safety.
• Align process optimization initiatives with organizational objectives for operational excellence, compliance, sustainability, cost discipline, and business continuity.
• Develop a time-bound process control and optimization action plan for implementation after the course.

Who Should Attend

Learning Outcomes

• Explain how effective process control supports safe, stable, reliable, efficient, and high-quality operations.
• Identify critical process variables, operating limits, control objectives, and performance measures for selected systems.
• Interpret process trends, control-system data, alarms, operating records, and quality results to identify deviations and variability.
• Assess the role of instrumentation, sensors, transmitters, valves, actuators, control loops, and automation systems in process performance.
• Evaluate control-loop performance and recognize common issues, including oscillation, delay, poor tuning, sensor drift, valve problems, and unstable operating conditions.
• Develop practical control strategies that define set points, limits, alarm priorities, operator actions, and escalation arrangements.
• Identify optimization opportunities related to equipment loading, sequencing, process parameters, utility use, throughput, and operating windows.
• Apply basic process data analysis methods to support troubleshooting, root cause analysis, and continuous improvement.
• Integrate process control improvement with maintenance, calibration, inspection, reliability, process safety, and energy-management activities.
• Assess the impact of optimization changes on process safety, quality, equipment integrity, energy use, and operational risk.
• Prepare a plan for testing, validating, documenting, and sustaining process control improvements.
• Produce an initial process control and process optimization roadmap relevant to the participant’s workplace.

Course Outline