Automation & Control Systems Course

Lesson 1 • Introduction to Automation Systems

Defines automation, its industrial role, and key drivers. Establishes vocabulary used throughout the course.

Lesson 2 • System Diagrams and Documentation

Introduces block diagrams, P&ID symbols, and instrument tagging. Enables reading and interpreting standard engineering drawings.

Lesson 3 • Core Components of a Control System

Identifies sensors, actuators, controllers, and process elements. Links each component to its functional role in a control loop.

Lesson 4 • Safety and Regulatory Fundamentals

Covers hazard identification, safety integrity levels, and compliance frameworks. Grounds students in safety obligations before hands-on work.

Lesson 1 • Temperature and Pressure Sensors

Covers thermocouples, RTDs, pressure transmitters, and their selection criteria. Connects sensor choice to process requirements and environmental conditions.

Lesson 2 • Signal Conditioning and Transmission

Addresses amplification, filtering, isolation, and analogue-to-digital conversion. Prepares signals for reliable transmission to controllers.

Lesson 3 • Flow, Level, and Analytical Sensors

Examines flow meters, level detectors, and analytical instruments such as pH and conductivity sensors. Reinforces selection logic introduced in the previous section.

Lesson 4 • Measurement Principles and Accuracy

Explains measurement error, accuracy, precision, and calibration concepts. Provides the basis for evaluating sensor performance specifications.

Lesson 1 • Pneumatic and Hydraulic Actuators

Examines cylinders, rotary actuators, and positioners for fluid-power systems. Connects actuator sizing to force, stroke, and response-time specifications.

Lesson 2 • Actuator Accessories and Fail-Safe Design

Covers limit switches, solenoids, handwheels, and fail-safe spring-return mechanisms. Integrates safety requirements from Chapter 1 into actuator design.

Lesson 3 • Control Valves and Valve Sizing

Addresses globe, ball, butterfly, and rotary valves with Cv-based sizing methods. Ensures correct valve selection for flow control applications.

Lesson 1 • PLC I/O Wiring and Configuration

Covers sourcing/sinking wiring, I/O addressing, and module configuration. Connects hardware knowledge to physical installation and commissioning.

Lesson 2 • Ladder Logic Programming

Teaches contacts, coils, timers, counters, and comparison instructions in ladder logic. Builds the primary programming skill used in most industrial PLCs.

Lesson 3 • PLC Diagnostics and Troubleshooting

Applies fault codes, online monitoring, and forced I/O techniques to diagnose faults. Prepares students for real-world maintenance scenarios.

Lesson 4 • PLC Architecture and Hardware

Describes CPU, memory, I/O modules, and power supply components. Establishes hardware knowledge required before programming begins.

Lesson 1 • Advanced Control Strategies

Introduces cascade, ratio, feedforward, and override control configurations. Extends single-loop PID skills to multi-loop and interacting processes.

Lesson 2 • PID Tuning Methods

Applies Ziegler-Nichols, Cohen-Coon, and IMC-based tuning rules to real processes. Develops practical tuning skills using systematic methods.

Lesson 3 • Process Dynamics and Modelling

Explains first-order, second-order, and dead-time process models. Provides the dynamic understanding needed to design effective controllers.

Lesson 4 • PID Controller Principles

Details proportional, integral, and derivative actions and their combined effect. Builds theoretical grounding for practical tuning work.

Lesson 1 • Industrial Communication Protocols

Covers Modbus, PROFIBUS, EtherNet/IP, and OPC standards for device communication. Provides the protocol knowledge needed to integrate field devices.

Lesson 2 • SCADA System Architecture

Describes field devices, RTUs, communication infrastructure, and SCADA servers. Establishes the system-level view before component configuration.

Lesson 3 • Network Design and Cybersecurity Basics

Addresses network segmentation, firewalls, and secure remote access for industrial systems. Introduces cybersecurity practices essential for modern SCADA environments.

Lesson 4 • Tag Configuration and Historian

Explains tag databases, data types, scaling, and historian archiving strategies. Enables structured data management for monitoring and reporting.

Lesson 1 • System Integration and Commissioning

Details FAT, SAT, loop checking, and startup procedures for integrated automation systems. Prepares students for full project delivery and handover.

Lesson 2 • Batch Process Automation

Introduces the ISA-88 batch model, recipes, and procedural control elements. Extends continuous control knowledge to batch manufacturing environments.

Lesson 3 • DCS Architecture and Components

Describes controllers, I/O subsystems, operator stations, and engineering workstations in a DCS. Distinguishes DCS from PLC-based architectures covered earlier.

Lesson 4 • Safety Instrumented Systems

Covers SIL verification, safety function design, and proof-test procedures for SIS. Integrates functional safety concepts introduced in Chapter 1.

Lesson 1 • Alarm Management and Rationalisation

Applies alarm philosophy, rationalisation, and key performance indicators to reduce nuisance alarms. Directly improves operator effectiveness in SCADA and DCS environments.

Lesson 2 • Continuous Improvement in Automation

Applies PDCA, KPI dashboards, and control loop performance monitoring to drive ongoing improvement. Closes the course with a strategic, data-driven improvement mindset.

Lesson 3 • Reliability Engineering Fundamentals

Applies MTBF, MTTR, availability calculations, and failure rate models to automation equipment. Quantifies system reliability for maintenance decision-making.

Lesson 4 • Maintenance Strategies for Automation Systems

Compares corrective, preventive, and predictive maintenance approaches for control assets. Establishes the maintenance framework before reliability analysis tools are introduced.