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Detailed Loop Analysis With ExperTune

Course EX-501-5E

Duration: 4 days of hands-on ExperTune training

Class Schedule

Course Objectives

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Course includes hands-on ExperTune training. Includes case studies of industrial problems and solutions.


This course will allow you to master the use of powerful control loop analysis tools provided in the ExperTune advanced PID loop optimizer package. Improve your control loop optimization skills by analyzing and diagnosing issues with real world loop simulations.

Who should attend:

Anyone with a basic knowledge of instrumentation who wishes to use loop analysis and optimization software with any vendors PID controller.


Fundamental concepts


  • Control loops
  • Noise, disturbances, load
  • Feedback–Feedforward
  • Control objectives
  • Loop Simulation


  • Simple model
  • Types of processes
  • Design issues affecting loop performance
  • Exercises


  • Proportional, integral, derivative, filter
  • Structures of industrial controllers
  • Exercises


  • Intuitive tuning
  • Performance criteria
  • Load change, Setpoint change
  • Tuning: a compromise
  • Traditional tuning methods
  • Natural frequency
  • Importance of time delay
  • Limits of traditional tuning methods
  • Exercises

ExperTune Tools

  • Basic principles
  • Acquiring the data
  • Frequency analysis, time series
  • Choice of tuning objectives
  • Bode plot, how to interpret it
  • Exercises

Data to tune a loop

  • Good data, from a controller output change (Manual)
  • Good data, from a setpoint change (Automatic)
  • Exercises

Tuning control loops using ExperTune

  • PID grid
  • Quality of frequency data
  • Filter
  • Selecting tuning parameters, Safety factor, Lambda value
  • Load rejection and setpoint tuning
  • Tuning comparison with Lambda and Ziegler/Nichols tuning
  • Simulation, response to load change, setpoint change, noise
  • Frequency response
  • Robustness plot
  • Performance: IAE, robustness, valve travel,...
  • More Loop Simulation
  • Exercises

Steps to tune a loop

  • Bump sizes, preliminaries, operator cooperation
  • Setpoint changes in both directions
  • Bump tests to check hysteresis, stiction, linearity
  • Loop analysis, design, 4 rules of 3
  • Exercises

Analyzing the data from a test in automatic mode

  • How to detect hysteresis, stiction, high process gain
  • How to detect bad tuning parameters
  • Exercises
  • Tips and tricks

Scan time

  • Aliasing
  • ExperTune and scan time to acquire data

Exercise: real cases, self regulating and integrating processes

  • Analyzing the data
  • Editing the data
  • Tuning the loop to quickly remove disturbances
  • Robustness analysis

Management-of-Change Tools

  • ExperTune standard loop report
  • Exercises with reports

Review & Discussion

  • Tuning methods comparison
  • Time to tune loops
  • Robustness and performance
  • Practical rules, tips and tricks
  • Process control and economics

Advanced Concepts

Frequency domain vs. time domain

  • Definitions
  • Terminology & Definitions
  • Frequency Response
  • Natural Frequency
  • Bode Diagram

More on Analysis

  • Valve or final element sizing
  • Noise level
  • Characterization, linearization, asymmetry
  • Filtering
  • Exercise

Advanced Tools

  • Sampling time
  • Editing data
  • Frequency domain evaluation
  • Validity of results
  • Filter selection in the frequency domain
  • Valve abuse index
  • Linearity correction with the characterization

Tuning multi-Loop Systems

  • Tuning interactive loops
  • Synchronizing loops
  • Tuning cascade systems
  • Tuning ratio controls
  • Exercises

Troubleshooting tools

  • Power spectral density
  • Cross correlation
  • Auto-correlation
  • Tips and tricks


  • Statistical Analysis
  • ISO 9000 and reporting
  • Customizing reports

Practical Exercises

  • Process optimization examples
  • Improving performance
  • Troubleshooting loops
  • Tips and tricks
  • Simple and multiple loops
  • Cascade loop
  • Interacting loop
  • Feedforward tuning

Latest Advances in Control Performance

  • Continuous loop monitoring
  • Loop performance metrics and KPIs
  • Active Model Capture
  • Process interaction detection
  • Alarm Management

Process Control, economics, and practice

  • Time to Tune Loops
  • Practical Rules
  • Good optimization and maintenance practices

Software Used


Students typically come from a wide variety of backgrounds. Some may have little or no formal education in control theory, while others have college degrees in engineering. Some may have little industrial experience, while others are veterans. The course includes refresher instruction with hands-on exercises, to get all students on solid footing before diving in to more advanced topics.

The Student must Bring a Laptop Computer with:

  • An open USB port
  • Permission to install software
  • MS Word installed

If you do not have a computer, ExperTune can arrange to rent one for you, at your cost.

All training is presented by: ExperTune's Official Training Partners. Our partners are highly trained and have extensive field experience. The average instructor has over 20 years' experience in process control.

Abbreviated Option

Contact for pricing and details.

"Instructor was expert in theory and fieldwork, which is seldom seen." I&C Training, Entergy

"Great class & well worth the $ ... Discussion of real life problems & seeing real life data." Process Engineer, Armb World

"One of the best instructors I've seen." PC&E technician, Boise

"Very good course," Manager Internal Training, Siemens

"It was a very useful training that covered the practical aspect of control theory," Validation Engineer, Merck, Sharp & Dohme

"This time Process Control theoretical principles really got a practical sense!" Controls & Computer Validation Engineer, Merck & Co.

"This course was very well done in all aspects," Systems Technician, Placid Refining

"Very good course, it is a well balance between theory and practice," Control Engineer, ECOPETROL - ICP

"I would highly recommend this course to anybody in the process industry," Instrument Tech, Terra Nova

"Excellent Course - Great Instructor. Covered material & reviewed course Materials very well. Good Text Books - Covered Basics to greater Details. I Have no Complaints. Would like to attend Troubleshooting course sometime later," Process Optimization Specialist, Weyerhaeuser

"I feel that the info will pay for course with first solution," Control System Engineer, Weyerhaeuser

"I learned a considerable amount regarding loop tuning and control in general," Process Controls Eng., Abitibi Consolidated Inc.

"I plan to utilize what I have learned from Top Control and combine that with the power of ExperTune to help place our process back on track. I am always looking for ways to save a penny and this should save a lot of money by increasing the performance of our loops," Process control engineer, Cargill Inc.

"This training made me realize just how important it is to do a preventive analysis on loops in order to avoid working in the dark and to optimize the work of our technicians," Supervisor Electricity/Instrumentation, Kruger Inc.

"An excellent class that tied all the basics of PID tuning together. I had all the tools, software and great controllers, but I wasn't necessarily using them properly. Now I will," Engineer, Bicron

"Usually a class like this isn't extremely useful, but this class is the exception. One of the few classes I truly enjoyed," Process Control Engineer, Noltex

"I learned a lot and really found the course to be helpful. Abbott labs will benefit tremendously from this class," Utilities,Abbott Labs

"Very good class for a very good piece of software," Control's Designer, IBM

"Overall good class," Control Engineer, Designer, IBM

"The course content was directed to the concerns and areas of interest of the attendees. Analysis of actual in-house processes was included during the training," Engineer, VLOC

"George did an excellent job relating crystal growth to the PID tuning with ExperTune. I learned a lot and can find this product/course quite useful to further developing my laboratory," Production Growth Engineer, VLOC

"It is an excellent course," Chief Engineer, Yokogawa Corp of America

"I thought this course was very informative with a lot of useful information. I look forward to the advanced course," Operations, Air Products

"I found this class to be extremely practical and useful. It had a good combination of theory and empirical information. We had several of our top process controls guys in this class and you really showed your expertise," Lead Project Engineer, Siemens

"Very good course. Info was related very well. An excellent time saving tool," Instr. Tech, Petro-Canada

"This was the best exposure/training I have attended in terms of practical application. The best value added I have attended in many years," Inst. Tech. (FPSO), Petro-Canada.

"Excellent course - very interesting & bound to be one of the best & most widely used tool on the Terra Nova FPSO," Instrumentation - Ops, Terra Nova Alliance

"Excellent course & would be of value to me during my job. Would like to take a course on the optimization of the plant utilizing this tool," Process Engineer, Petro-Canada

"A great overview of both ExperTune Software and tuning (PID) loops. I'm excited to get back and get more performance & less wear out of my process," Consulting Engineer, Johnson Polymer

"This has been the best course involving tuning and process control that I have taken. The software and knowledge will be able to be applied at the smelter in a practical approach to achieve better control. I would recommend this course to anyone who works in a plant and has to tune loops," Senior Process Control Engineer, Kennecott Utah Copper

"Learned a lot in a small amount of time. Many light bulbs came on during class," Regional Engineer, Sanitary Water Group

"Very pleased with course content and practical application," Senior Project Engineer, Johns Manville

"The course gave me a lot of insight and strategies to attack tuning issues in our plant." Instrumentation Tech, Weyerhaeuser Company

"Excellent class with a very knowledgeable and excellent instructor and a very good product." Process Control , Wellman Inc

"This class has a very high gain!!" Control Systems Engineer, Kennecott Utah Copper

"I really enjoyed this class. As someone who recently purchased ExperTune, this class has taught me good optimization techniques that will help me in getting the most out of our investment. Without this class, I'm sure I would have under utilized the software. Thanks for setting this up!" Staff Electrical Engineer, Armb World Industries, Inc.

"The course was very well presented. Good mixture of book and hands on training. Hank was able to relate a lot of his field experience to classroom examples. Best tuning class that I have attended." Instrument Foreman, PSNH Schiller Station

"The software is a very powerful and valuable tool. The training compliments the software and greatly increases the overall value. The training is enhanced by the fact that TOP Control field experts provide the instruction and give real-life examples and understand the issues that the students are faced with." Process Control, Wellman, Inc

"Excellent course with tons of practical application for any plant!" Senior Engineer, Johnson Polymer

"Very good course. Instructor has field experience and teaching experience and conveys information very well with real life examples." Control Systems Engineer, Precision Engineering


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