Instrument Technician Course

Lesson 1 • Instrument Classification and Terminology

Defines sensors, transmitters, controllers, and final elements within a measurement loop. Provides the vocabulary needed to read datasheets and communicate with engineering teams.

Lesson 2 • Core Process Variables and Units

Introduces pressure, temperature, flow, and level as the four primary process variables. Establishes SI and imperial unit conversions essential for all subsequent instrument work.

Lesson 3 • Signal Standards and Transmission

Explains 4–20 mA, HART, and digital fieldbus signal standards used to transmit measurement data. Connects signal selection to wiring, noise immunity, and system compatibility.

Lesson 4 • Measurement Performance Specifications

Covers accuracy, precision, repeatability, hysteresis, and rangeability as key performance metrics. Students apply these metrics to evaluate instrument suitability for a given process.

Lesson 1 • Differential Pressure Measurement

Explains differential pressure principles and their use in flow, level, and filter monitoring applications. Students connect DP cells and interpret high-side/low-side readings correctly.

Lesson 2 • Pressure Sensing Technologies

Compares Bourdon tube, diaphragm, bellows, and piezoelectric sensing elements by operating range and media compatibility. Guides technology selection based on process conditions.

Lesson 3 • Pressure Instrument Troubleshooting

Diagnoses plugged impulse lines, diaphragm failures, and zero/span drift using systematic fault isolation. Builds a structured troubleshooting mindset applied throughout the course.

Lesson 4 • Pressure Transmitter Installation

Covers impulse line routing, isolation valves, and condensate pots for reliable pressure signal transmission. Proper installation prevents measurement errors caused by liquid heads and blockages.

Lesson 1 • Thermowells and Installation Practices

Addresses thermowell materials, insertion length, wake frequency, and process connection standards for safe installation. Correct thermowell selection prevents mechanical failure and measurement lag.

Lesson 2 • Temperature Calibration and Verification

Uses dry-block calibrators and ice-point references to verify thermocouple and RTD accuracy. Students perform multi-point calibrations and calculate measurement uncertainty.

Lesson 3 • Temperature Transmitter Configuration

Configures smart temperature transmitters for sensor type, range, damping, and failure mode using a handheld communicator. Students verify output signal against a reference standard.

Lesson 4 • Thermocouple Theory and Types

Explains the Seebeck effect, cold junction compensation, and common thermocouple types by temperature range and application. Students match thermocouple type to process requirements.

Lesson 1 • Flow Meter Installation and Straight Run

Specifies upstream and downstream straight-pipe requirements, flow conditioners, and orientation rules for accurate measurement. Incorrect installation is the leading cause of flow meter error.

Lesson 2 • Velocity-Based Flow Meters

Explains electromagnetic, ultrasonic, vortex, and turbine flow meters by operating principle and fluid compatibility. Students match meter type to fluid conductivity, viscosity, and pipe size.

Lesson 3 • Flow Meter Commissioning and Verification

Covers zero-flow verification, wet calibration references, and in-situ diagnostic checks for flow meters. Students document commissioning data and confirm meter factor settings.

Lesson 4 • Differential Pressure Flow Devices

Covers orifice plates, venturi tubes, and flow nozzles using Bernoulli's equation to derive flow from DP. Students calculate flow rates and identify sources of measurement error.

Lesson 1 • Float, Displacer, and Magnetic Level Gauges

Covers mechanical level technologies including float switches, displacer transmitters, and magnetic level gauges. Students identify appropriate applications and common failure modes for each type.

Lesson 2 • Ultrasonic and Capacitance Level Devices

Covers ultrasonic non-contact level measurement and capacitance probes for conductive and non-conductive media. Students select between technologies based on vapour, foam, and dielectric properties.

Lesson 3 • Level Instrument Calibration and Ranging

Performs LRV and URV ranging, wet calibration, and simulation-based verification for level transmitters. Students adjust span and zero to match actual process conditions and vessel geometry.

Lesson 4 • Hydrostatic and DP Level Measurement

Applies hydrostatic pressure principles to calculate liquid level from DP transmitter readings. Students perform wet-leg and dry-leg calculations for pressurised and open vessels.

Lesson 1 • Control Valve Maintenance and Diagnostics

Covers packing replacement, seat and plug inspection, and partial stroke testing for control valve maintenance. Students interpret valve diagnostic signatures to detect stiction, hysteresis, and seat leakage.

Lesson 2 • Valve Sizing and Flow Coefficient

Applies Cv and Kv flow coefficient equations to size control valves for liquid, gas, and steam service. Students calculate required Cv and select the next standard valve size.

Lesson 3 • Control Valve Construction and Types

Describes globe, ball, butterfly, and rotary plug valve bodies, trim materials, and flow characteristics. Students match valve type to process fluid, pressure class, and control requirement.

Lesson 4 • Actuators and Fail-Safe Action

Covers pneumatic diaphragm, piston, and electric actuators with spring-return fail-safe configurations. Students determine fail-open or fail-closed action based on process safety requirements.

Lesson 1 • Controller Tuning Methods

Applies open-loop step test, Ziegler-Nichols, and lambda tuning methods to determine PID parameters. Students tune a simulated loop and evaluate stability using step response criteria.

Lesson 2 • Advanced Control Strategies

Introduces cascade, ratio, feedforward, and split-range control strategies for complex process interactions. Students identify when advanced strategies improve on single-loop PID performance.

Lesson 3 • Feedback Control Loop Fundamentals

Defines the components of a closed-loop control system: process, sensor, controller, and final element. Students trace signal flow and identify the effect of each component on loop behaviour.

Lesson 4 • PID Controller Modes and Equations

Explains proportional, integral, and derivative modes mathematically and in terms of process response. Students predict the effect of each mode on offset, oscillation, and response speed.

Lesson 1 • Pre-Startup and Handover Procedures

Covers instrument pre-startup checklists, punch list clearance, and documentation handover to operations. Students prepare a complete instrument package ready for plant startup and ongoing maintenance.

Lesson 2 • Loop Checking and Functional Testing

Executes end-to-end loop checks by simulating process inputs and verifying correct output at the control system. Students complete loop check sheets and resolve discrepancies before startup.

Lesson 3 • P&ID Reading and Instrument Symbols

Interprets piping and instrumentation diagrams using ISA symbol standards for instruments, lines, and control functions. Students extract instrument specifications and loop configurations from P&IDs.

Lesson 4 • Instrument Data Sheets and Specifications

Reads and completes instrument data sheets for transmitters, control valves, and analyzers to procurement and engineering standards. Accurate data sheets prevent specification errors during procurement.