Industrial Automation Engineering Course

Lesson 1 • Automation System Architectures

Covers hierarchical, distributed, and hybrid control architectures. Connects system structure to project scope and design decisions.

Lesson 2 • Safety and Regulatory Framework

Outlines functional safety standards, risk categories, and compliance obligations. Anchors safety thinking at the start of the learning journey.

Lesson 3 • Automation Concepts and Terminology

Defines automation, control theory basics, and common industry vocabulary. Establishes shared language used throughout the entire course.

Lesson 4 • Core Hardware Components

Identifies sensors, actuators, controllers, and drives used in automation systems. Provides hardware context for later programming and integration topics.

Lesson 1 • Automation Project Phases Overview

Maps the full project lifecycle from feasibility through handover. Gives students a roadmap that frames all subsequent technical content.

Lesson 2 • Scope Definition and Requirements

Teaches how to capture, document, and baseline project scope and requirements. Prevents scope creep and misalignment between stakeholders.

Lesson 3 • Risk Management in Automation Projects

Introduces risk identification, assessment, and mitigation planning. Equips students to proactively manage technical and schedule risks.

Lesson 4 • Resource and Budget Management

Addresses cost estimation, resource allocation, and budget control for automation projects. Builds financial literacy needed for project engineering roles.

Lesson 1 • P&ID Development and Standards

Explains P&ID symbology, drawing conventions, and review processes. P&IDs are the central design document referenced throughout the project.

Lesson 2 • Instrument Selection and Sizing

Teaches criteria for selecting and sizing instruments to match process conditions. Directly supports accurate instrument data sheet preparation.

Lesson 3 • Instrumentation Documentation Package

Assembles the full instrumentation deliverable set including indexes, hook-up drawings, and calibration records. Prepares students for engineering deliverable management.

Lesson 4 • Process Measurement Principles

Covers measurement of pressure, temperature, flow, and level using industrial instruments. Provides the physical basis for instrument selection decisions.

Lesson 1 • DCS Configuration and Control Modules

Explains DCS architecture, control module configuration, and continuous process control strategies. Complements PLC skills for process industry applications.

Lesson 2 • Programme Structure and Modularity

Teaches modular programme design using function blocks, libraries, and naming conventions. Modular code reduces errors and simplifies maintenance.

Lesson 3 • IEC 61131-3 Programming Languages

Introduces all five IEC 61131-3 languages with emphasis on ladder, structured text, and function block diagram. Establishes the programming foundation for all control tasks.

Lesson 4 • Analog and Digital I/O Handling

Covers I/O addressing, scaling, filtering, and fault detection for analog and digital signals. Connects hardware wiring to software signal processing.

Lesson 1 • SCADA and HMI Integration

Covers OPC-UA data exchange, tag configuration, and HMI screen development for operator interfaces. Integrates field data into supervisory visualisation layers.

Lesson 2 • Industrial Network Topologies

Covers star, ring, bus, and mesh topologies and their suitability for automation environments. Topology choice directly affects reliability and maintenance.

Lesson 3 • Fieldbus and Industrial Ethernet Protocols

Compares major fieldbus and industrial Ethernet protocols for device-level communication. Enables informed protocol selection for specific project requirements.

Lesson 4 • MES and ERP Connectivity

Explains data flow between control systems and manufacturing execution and enterprise resource systems. Supports digital transformation and production reporting goals.

Lesson 1 • SIL Determination and Verification

Teaches SIL assignment, PFD calculation, and architectural constraints for safety functions. Ensures designed systems meet required integrity levels.

Lesson 2 • Functional Safety Standards and Lifecycle

Introduces the functional safety lifecycle, key standards for process and machinery sectors, and management responsibilities. Frames all subsequent safety engineering tasks.

Lesson 3 • Safety Instrumented System Design

Covers SIS hardware selection, logic solver configuration, and safety function documentation. Translates risk assessment outputs into engineered safety solutions.

Lesson 4 • Hazard and Risk Assessment

Covers HAZOP, LOPA, and risk graph methods for identifying hazards and determining required risk reduction. Outputs feed directly into SIL determination.

Lesson 1 • Site Acceptance Testing

Defines SAT scope, test case execution, and deficiency management in the field environment. SAT confirms that installed systems match the approved design.

Lesson 2 • Pre-Startup Safety Review

Explains PSSR methodology, checklist development, and action item closure before first startup. PSSR is a critical safety gate in the commissioning process.

Lesson 3 • Startup and Performance Testing

Covers cold and hot startup sequences, performance test protocols, and process optimisation during initial operation. Validates system performance against design specifications.

Lesson 4 • Project Handover and Closeout

Addresses as-built documentation, operator training delivery, and formal handover to operations. Ensures the client receives a complete and operable system.

Lesson 1 • Energy and Asset Optimisation

Addresses energy monitoring, demand management, and asset performance optimisation strategies. Delivers measurable operational cost reductions through control improvements.

Lesson 2 • Continuous Improvement Programmes

Introduces structured improvement methodologies applied to automation systems and control performance. Sustains gains achieved during commissioning and optimisation phases.

Lesson 3 • Model Predictive Control Fundamentals

Introduces MPC principles, process modelling, and constraint handling for multivariable processes. MPC delivers significant performance gains over single-loop strategies.

Lesson 4 • Advanced PID and Cascade Control

Extends basic PID to cascade, ratio, and feedforward configurations for complex process interactions. Builds on foundational control loop skills from earlier chapters.