Instrumentation and Control Course

Lesson 1 • Sensor and Transducer Fundamentals

Explains how physical variables are converted to electrical signals. Connects sensor physics to downstream signal conditioning.

Lesson 2 • Instrument Documentation and Symbols

Introduces P&ID symbols, tag numbering, and instrument data sheets. Enables students to read and interpret plant documentation accurately.

Lesson 3 • Measurement Principles and Units

Covers SI and process units, measurement error types, and accuracy vs. precision. Establishes the quantitative language used throughout the course.

Lesson 1 • Pressure Calibration Techniques

Uses deadweight testers and electronic calibrators to verify pressure instrument accuracy. Students perform multi-point calibration and document results.

Lesson 2 • Temperature Instrument Calibration

Applies dry-block calibrators and reference baths to verify temperature instrument accuracy. Reinforces calibration documentation practices introduced earlier.

Lesson 3 • Pressure Measurement Devices

Covers Bourdon tubes, diaphragm seals, and electronic pressure transmitters. Connects device physics to selection criteria for process conditions.

Lesson 4 • Temperature Sensing Technologies

Compares thermocouples, RTDs, and thermistors across accuracy, range, and cost. Guides instrument selection for diverse thermal applications.

Lesson 1 • Differential Pressure Flow Devices

Covers orifice plates, venturi tubes, and flow nozzles using Bernoulli's principle. Connects DP measurement to volumetric and mass flow calculation.

Lesson 2 • Level Instrument Calibration and Troubleshooting

Applies wet-leg and dry-leg calibration methods and diagnoses common level errors. Builds systematic fault-finding skills for level loops.

Lesson 3 • Velocity and Mass Flow Meters

Examines magnetic, vortex, ultrasonic, and Coriolis meters. Guides selection based on fluid properties and accuracy requirements.

Lesson 4 • Level Measurement Technologies

Surveys float, displacer, hydrostatic, radar, and guided-wave radar level instruments. Matches technology to vessel geometry and fluid characteristics.

Lesson 1 • Loop Wiring and Grounding

Details cable selection, shielding, grounding schemes, and junction box practices. Proper wiring prevents noise, ground loops, and signal degradation.

Lesson 2 • Digital Fieldbus Protocols

Introduces FOUNDATION Fieldbus, PROFIBUS PA, and WirelessHART architectures. Connects digital communication to modern distributed control strategies.

Lesson 3 • Signal Conditioning Circuits

Explains amplification, filtering, isolation, and linearisation of sensor outputs. Prepares students to configure conditioners for accurate data transmission.

Lesson 4 • Loop Testing and Verification

Uses loop calibrators and multimeters to verify signal integrity from field to control room. Confirms correct scaling and alarm setpoints before commissioning.

Lesson 1 • Valve Sizing and Flow Characteristics

Applies Cv calculations and inherent flow characteristic curves to size control valves. Correct sizing ensures stable control across the operating range.

Lesson 2 • Control Valve Types and Construction

Compares globe, ball, butterfly, and rotary plug valves by flow characteristic and application. Provides the selection framework used in subsequent sizing work.

Lesson 3 • Actuators and Positioners

Covers pneumatic, electric, and hydraulic actuators and smart valve positioners. Connects actuator selection to fail-safe requirements and control performance.

Lesson 4 • Control Valve Installation and Maintenance

Specifies installation orientation, bypass piping, and packing maintenance procedures. Proper installation and upkeep extend valve service life and control quality.

Lesson 1 • Control Loop Concepts

Defines open-loop and closed-loop control, process gain, and dead time. Establishes the theoretical basis for all controller tuning work.

Lesson 2 • Loop Performance Assessment

Uses IAE, ISE, and oscillation indices to quantify control loop performance. Systematic assessment identifies loops requiring retuning or hardware attention.

Lesson 3 • Controller Tuning Methods

Applies Ziegler-Nichols, lambda, and IMC tuning rules to real process data. Students select tuning parameters that balance speed and stability.

Lesson 4 • PID Controller Modes

Explains proportional, integral, and derivative actions and their combined effect on loop response. Prepares students for systematic tuning in the next section.

Lesson 1 • SIS Component Specification

Specifies sensors, logic solvers, and final elements for SIS service using SIL-rated equipment. Component selection must satisfy PFD targets and proof-test intervals.

Lesson 2 • Functional Safety Concepts

Defines hazard, risk, safety function, and safety integrity level within a lifecycle framework. Establishes the risk-reduction rationale for SIS design.

Lesson 3 • SIS Management of Change

Establishes procedures for modifying, bypassing, and decommissioning SIS equipment safely. Maintains functional safety integrity throughout the system lifecycle.

Lesson 4 • SIL Verification and Validation

Applies PFD calculation methods and FMEDA data to verify SIL achievement. Validation testing confirms the SIS performs its safety function correctly.

Lesson 1 • Calibration Management and Traceability

Establishes calibration schedules, traceability chains, and records management systems. Traceability to national measurement standards satisfies regulatory audit requirements.

Lesson 2 • Regulatory Inspection and Audit Readiness

Prepares instrument documentation packages for regulatory inspections and third-party audits. Systematic record-keeping demonstrates ongoing compliance and process safety.

Lesson 3 • Hazardous Area Classification

Applies zone and division classification methods to select explosion-protected instruments. Correct classification prevents ignition of flammable atmospheres.

Lesson 4 • Instrument Specification and Procurement

Develops instrument index, data sheets, and requisition packages to procurement standards. Accurate specifications reduce procurement errors and field rework.