Industrial Process Control and Automation Course

Lesson 1 • Measurement and Instrumentation Basics

Covers sensor principles, signal types, and measurement accuracy. Provides the instrumentation foundation required for all subsequent control topics.

Lesson 2 • Control System Components Overview

Maps the roles of sensors, transmitters, controllers, and final control elements. Prepares students to trace signal flow in a complete control loop.

Lesson 3 • Core Concepts of Process Control

Introduces process variables, control objectives, and system boundaries. Establishes vocabulary used throughout the course.

Lesson 1 • Transfer Functions and Block Diagrams

Introduces Laplace-domain transfer functions and block diagram algebra. Enables students to analyse closed-loop system structure mathematically.

Lesson 2 • Process Identification Techniques

Covers open-loop and closed-loop methods for identifying process models from plant data. Connects experimental identification to controller design.

Lesson 3 • Higher-Order and Dead-Time Models

Extends modelling to second-order and higher-order systems with transport delay. Prepares students for realistic process identification challenges.

Lesson 4 • Simulation Tools for Process Modelling

Applies simulation software to build and test process models before deployment. Reinforces mathematical concepts through hands-on virtual experimentation.

Lesson 1 • Level and Analytical Measurement

Covers hydrostatic, radar, and guided-wave level technologies plus pH and conductivity analysers. Links analyser selection to process chemistry and safety.

Lesson 2 • Control Valves and Actuators

Details globe, ball, and butterfly valve characteristics and actuator types. Students can size valves and select actuators for given process conditions.

Lesson 3 • Pressure and Flow Measurement

Explains differential pressure, Coriolis, and magnetic flowmeter technologies. Prepares students to match flow measurement technology to fluid properties.

Lesson 4 • Instrument Calibration and Maintenance

Establishes calibration procedures, loop checks, and preventive maintenance schedules. Ensures measurement integrity throughout the instrument lifecycle.

Lesson 1 • Classical PID Tuning Methods

Covers Ziegler-Nichols, Cohen-Coon, and IMC-based tuning rules. Students apply each method and compare resulting performance.

Lesson 2 • PID Controller Structure and Modes

Explains proportional, integral, and derivative actions and their individual effects. Builds intuition for how each mode shapes the closed-loop response.

Lesson 3 • Advanced PID Features and Enhancements

Covers anti-windup, bumpless transfer, and derivative filtering techniques. Prepares students to configure industrial PID controllers for real-world conditions.

Lesson 4 • Stability Analysis for Control Loops

Applies gain and phase margin concepts to assess closed-loop stability. Provides the analytical basis for safe controller tuning.

Lesson 1 • Ladder Logic and Structured Text Programming

Teaches IEC 61131-3 ladder logic and structured text languages with practical examples. Builds programming skills applicable to most industrial PLC platforms.

Lesson 2 • SCADA System Architecture

Explains SCADA components including HMI, historian, and communication servers. Prepares students to design and navigate plant-wide monitoring systems.

Lesson 3 • PLC Architecture and Hardware

Describes CPU, I/O modules, power supplies, and communication backplanes. Provides the hardware knowledge needed before programming begins.

Lesson 4 • PLC and SCADA Commissioning

Covers factory acceptance testing, site acceptance testing, and startup procedures. Ensures students can safely bring automation systems into service.

Lesson 1 • Model Predictive Control Fundamentals

Introduces MPC prediction horizon, control horizon, and constraint handling concepts. Positions MPC as the advanced alternative to classical multivariable strategies.

Lesson 2 • Override and Selective Control

Introduces high-select, low-select, and override schemes for constraint management. Prepares students to protect equipment while maintaining process objectives.

Lesson 3 • Multivariable and Decoupling Control

Analyses interaction in multi-input multi-output processes using the relative gain array. Introduces decoupling strategies to reduce loop interaction.

Lesson 4 • Cascade Control Design

Explains inner and outer loop structure and tuning sequence for cascade control. Demonstrates performance improvement over single-loop control for slow processes.

Lesson 1 • Emergency Shutdown and Interlock Systems

Designs ESD logic, cause-and-effect matrices, and bypass management procedures. Ensures students can implement and test safety interlocks correctly.

Lesson 2 • Functional Safety Principles

Introduces safety lifecycle, safety integrity levels, and risk reduction concepts. Establishes the regulatory and engineering basis for safety system design.

Lesson 3 • Safety Instrumented System Design

Covers SIS architecture, logic solvers, and final elements for safety functions. Students can design and document a basic safety instrumented function.

Lesson 4 • Layer of Protection Analysis

Applies LOPA methodology to quantify risk reduction from independent protection layers. Connects process hazard analysis to SIL determination.

Lesson 1 • Control System Performance Auditing

Applies loop performance monitoring, oscillation detection, and benchmarking methods. Closes the course by connecting all prior topics to continuous improvement practice.

Lesson 2 • Industrial Communication Protocols

Covers HART, FOUNDATION Fieldbus, Profibus, and OPC-UA protocols for field and system integration. Prepares students to select and configure industrial networks.

Lesson 3 • Real-Time Optimisation Techniques

Introduces steady-state and dynamic real-time optimisation above the regulatory control layer. Students can formulate optimisation problems and interpret optimizer outputs.

Lesson 4 • Distributed Control System Architecture

Explains DCS controller redundancy, I/O subsystems, and engineering workstation roles. Connects DCS design to plant-wide control and data management needs.