Certified Instrumentation and Process Control Technician Training Course

Why Select this Training Course?

Given the rapidly changing nature of industrial automation, the call for well-trained Instrumentation and Control Technicians is accelerating. Acquiring comprehensive skills in this field will provide you with the capabilities you need to innovate, increase productivity, and ensure safety on the plant floor. This course supplies the groundwork to help you succeed in such an environment.

What makes this course stand out?

Unlike other offerings, our students learn both the theoretical and real-world hands-on practical knowledge of systems used in the current industry. Consequently, we focus heavily on practical applications including troubleshooting, fault diagnosis and system performance.

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How will this training prepare you to handle the field challenges?

As the program deals with the latest technology in the field of instrumentation and control, we place more emphasis on gaining practical knowledge in the field of current automated systems. In other words, we will be able to provide you with the necessary learning ability to understand and trouble shoot current automated systems, as well as to adopt to new automated systems with required learning.

Who Should Attend?

Professionals poised for advancement in:

• Instrumentation
• Process Control
• Manufacturing
• Operations and Maintenance
• Automation
• Renewable Energy

What are the Course Objectives?

By the end of the training, professionals will:

• Attain proficiency in configuring and maintaining process control systems.
• Leverage industry-standard tools and techniques to improve system reliability.
• Cultivate the ability to troubleshoot complex industrial instrumentation.
• Stay abreast of emerging technologies and practices within the field.

How will this course be presented?

The course incorporates:

• Demonstrative lectures and workshops.
• Intensive lab sessions using contemporary equipment.
• Real-life case studies and problem-solving exercises.
• Interaction with industry-leading professionals.
• Peer-to-peer learning and networking opportunities.

What are the Topics Covered in this Course?

Module 1: Instrumentation Fundamentals

• Overview of measurement principles and applications.
• Sensor types, selection criteria, and performance specifications.
• Calibration and validation techniques for accuracy.
• Transmitter and transducer mechanisms.
• Loop wiring and signal conditioning.
• Understanding P&ID diagrams for instrumentation.
• Basic troubleshooting for field instruments.
• Safety practices in handling instrumentation equipment.

Module 2: Control Valve Mechanics

• Valve types and their specific applications in control.
• Actuator designs and selection guidelines.
• Valve sizing and flow coefficient calculation.
• Positioner functionality and optimisation.
• Maintenance and calibration of control valves.
• Understanding severe service conditions.
• Smart valve technology and digital valve controllers.
• Cavitation and flashing in valves, and mitigation techniques.
• Fail-safe designs and safety integrity levels (SIL).

Module 3: Process Control Systems

• Architecture of Distributed Control Systems (DCS).
• In-depth Programmable Logic Controller (PLC) programming.
• SCADA systems for centralized monitoring.
• PID control, tuning, and stability.
• Advanced control strategies (Cascade, Ratio, Feedforward).
• Batch processing and Sequential Function Chart programming.
• Alarm management and system reliability.
• Performance indicators and system optimisation techniques.
• Data acquisition, logging, and analysis.
• HMI and interactivity design principles.
• Cybersecurity in control systems.
• Integration and interfacing with Enterprise Resource Planning (ERP) systems.
• Evolution of control systems with Industry 4.0.

Module 4: Industrial Network and Data Communication

• Industrial networking fundamentals.
• Fieldbus, HART, and other communication protocols.
• Ethernet/IP networking and TCP/IP applications in industry.
• Wireless sensor networks for process automation.
• Network security and industrial cybersecurity best practices.
• Redundancy, reliability, and fault tolerance in networks.
• Configuring remote I/O and smart devices.
• Data management and integration strategies.
• IoT implementation for process optimization.

Module 5: Safety Practices and Compliance

• Regulatory standards and compliance (ISA, IEC, NEC).
• Understanding Intrinsic safety and explosion-proof classifications.
• Implementing Safety Instrumented Systems (SIS).
• Hazardous area classifications and safe installation practices.
• Functional safety management and lifecycle.

Module 6: Diagnostics and Troubleshooting Techniques

• Systematic approach to fault finding in instrumentation.
• Employing diagnostic software tools.
• Identifying and resolving common PLC and DCS system errors.
• Best practices for on-the-fly troubleshooting during operations.

Module 7: System Integration and Calibration

• Integrating measurement and control components.
• Calibration standards and execution.
• Staging, testing, and simulation of control systems.
• Ensuring interoperability across various systems and vendors.
• Batch calibration protocols and documentation.
• Understanding loop checks and field verifications.
• Coordinating system maintenance and turnaround activities.
• Upgrading and retrofitting control systems for enhanced performance.

Module 8: Process Control Optimisation

• Techniques for enhancing process efficiency.
• Utilising data analytics for control loop performance.
• Adaptive and model-based control applications
• Energy management strategies within process control.
• Optimisation in multi-variable processes and constraints.
• Operator training simulators for control optimisation.
• Leveraging Machine Learning for predictive maintenance.
• Achieving sustainability goals through control system design.
• Virtualization and digital twins in process optimisation.
• Real-time optimisation (RTO) techniques.

Module 9: Advanced Data Analysis and Industrial Informatics

• Big Data analytics in industrial process monitoring.
• Real-time processing with Edge and Cloud computing technologies.
• Implementing statistical process control for quality assurance.
• Data visualisation and interpretation for performance insights.
• Machine learning in fault detection and predictive analytics.
• Streamlining data flow from the field to enterprise-level systems.
• Data mining techniques for operational intelligence.
• Robust control and condition monitoring with IIoT platforms.
• Cloud-based data storage, access, and security considerations.
• Edge analytics for fast, localised decision-making.
• Energy data analysis and ISO 50001 implementation for systems.
• AR/VR applications in maintenance and training.
• Implementing smart sensors and IoT devices in legacy systems.

Module 10: Future Technologies and Innovations

• Embracing nanotechnology in measurement and control applications.
• Anticipating the impact of quantum computing in process optimisation.
• Exploring the potential of biomimicry in control system design.

Module 11: Renewable Energy Integration in Process Control

• Design methodologies for integrating renewable energy with process controls.
• Smart grid technology and its interaction with industrial control systems.
• Energy storage solutions and management for process stability.
• Impact of intermittent energy sources on process control.
• Utilising IoT and AI for optimising renewable energy in industry.
• Regulations and standards governing renewable integration.
• Microgrid controls and distributed energy resource management systems (DERMS).
• Case studies: Renewable energy integration in various industrial sectors.

Module 12: Robotics and Automated Systems

• Fundamentals of robotics in manufacturing and process industries.
• Collaborative robots (cobots) and their integration into existing processes.
• Advanced programming for industrial robots and automation.
• Role of artificial intelligence in automated process control.
• Vision systems and sensor integration for robotic automation.
• Safety and ethical considerations in robotic systems deployment.
• Maintenance strategies for reliability in robotic systems.
• Real-world applications and case studies of industrial robotics.

Module 13: Regulatory Compliance and Standardisation

• Navigating global and regional process control regulations.
• International standards for control and safety system compliance (IEC, ANSI/ISA).
• Role of compliance in operational excellence and process safety.
• Implementing compliant process control documentation and records.
• Auditing and gap analysis for continuous improvement in standards adherence.
• Cybersecurity compliance in control systems.
• Impact of regulatory changes on process control strategies.
• Case studies on managing regulation and compliance in different jurisdictions.

Module 14: Human Factors and Control Room Design

• Principles of ergonomic design in control system interfaces.
• Human factors engineering for optimal system performance.
• Reducing human error through effective control room layout and HMI design.
• Alarm rationalisation and management techniques.
• Stress and workload management for control room operators.
• Integrating advanced visualisation tools for enhanced situational awareness.
• Use of simulation and virtual reality for operator training.
• The future of control room design: trends and technological advancements.

Module 15: Sustainability and Environmentally Conscious Control Practices

• Environmental impact assessment for process control systems.
• Sustainable practices in instrumentation and control.
• Implementing green technology and eco-friendly control solutions.
• Waste reduction and pollution control through process optimisation.
• Metrics for measuring sustainability in control engineering.
• Corporate Social Responsibility (CSR) in process control.
• Best practices for energy-efficient control system operations.
• Case studies in sustainability improvements through advanced control techniques.