Instrumentation and Control Course

Lesson 1 • Introduction to Industrial Measurement

Covers the purpose of measurement in process industries and the relationship between variables, sensors, and outputs. Establishes vocabulary used in all subsequent chapters.

Lesson 2 • Safety and Regulatory Fundamentals

Introduces hazardous area classification, functional safety concepts, and industry standards governing instrumentation. Establishes a safety mindset carried through all chapters.

Lesson 3 • Physical Principles of Sensing

Reviews the physics underlying common sensing technologies including thermal, mechanical, and electrical effects. Connects physical phenomena to practical sensor selection.

Lesson 4 • Signal Types and Conditioning

Distinguishes analog, digital, and discrete signals and explains conditioning steps required before transmission. Prepares students for signal-level troubleshooting.

Lesson 1 • Level Measurement Technologies

Surveys float, displacer, differential pressure, radar, ultrasonic, and guided-wave methods for level detection. Students match technology to process conditions.

Lesson 2 • Calibration of Pressure and Level Instruments

Applies zero, span, and linearity adjustments using reference standards and calibration equipment. Students perform and document a full calibration procedure.

Lesson 3 • Pressure Instrument Selection and Installation

Guides selection based on process fluid, range, and environment, then covers correct mounting and impulse line practices. Reduces common installation errors.

Lesson 1 • Calibration and Verification of Flow Instruments

Demonstrates in-situ and bench calibration methods, including wet and dry calibration techniques. Students evaluate meter performance against acceptance criteria.

Lesson 2 • Temperature Instrument Installation

Covers thermowell design, insertion depth, and heat conduction errors that affect measurement accuracy. Connects installation practice to measurement quality.

Lesson 3 • Flow Measurement Principles

Introduces differential pressure, velocity, volumetric, and mass flow measurement methods and their governing equations. Builds the analytical foundation for flow instrument selection.

Lesson 4 • Temperature Sensing Technologies

Compares thermocouples, RTDs, thermistors, and infrared sensors by principle, range, and accuracy. Enables informed selection for specific process requirements.

Lesson 1 • Actuators and Positioners

Covers pneumatic, electric, and hydraulic actuators and the role of valve positioners in achieving precise stem positioning. Students configure positioner split-range and characterization.

Lesson 2 • Valve Sizing and Selection

Applies flow coefficient calculations and process conditions to size control valves correctly. Prevents undersizing, oversizing, and cavitation or flashing issues.

Lesson 3 • Control Valve Testing and Maintenance

Presents partial stroke testing, packing maintenance, and seat leakage classification procedures. Ensures valve reliability and compliance with safety requirements.

Lesson 4 • Control Valve Construction and Types

Describes globe, ball, butterfly, and rotary valve bodies along with trim designs and flow characteristics. Provides the basis for valve selection decisions.

Lesson 1 • Loop Performance Assessment

Uses trend analysis, oscillation detection, and statistical metrics to evaluate and diagnose loop performance. Connects assessment results to corrective tuning or hardware actions.

Lesson 2 • Advanced Control Strategies

Introduces cascade, ratio, feedforward, and override control configurations and their process applications. Students design multi-loop strategies for common industrial scenarios.

Lesson 3 • Control Loop Concepts and Terminology

Defines setpoint, process variable, error, and controller output within a closed-loop framework. Introduces open-loop vs. closed-loop behavior as the foundation for control theory.

Lesson 4 • Controller Tuning Methods

Applies open-loop step testing, Ziegler-Nichols, and lambda tuning methods to determine PID parameters. Students tune a simulated loop and evaluate performance criteria.

Lesson 1 • PLC and DCS Troubleshooting

Applies systematic fault isolation to I/O failures, communication errors, and program logic faults. Students use diagnostic tools to resolve simulated system faults.

Lesson 2 • PLC Architecture and Hardware

Describes CPU, I/O modules, power supplies, and communication backplanes in a PLC system. Students identify hardware components and understand their functional roles.

Lesson 3 • DCS Architecture and Configuration

Explains distributed control system topology, controller redundancy, and engineering workstation configuration. Students configure a basic regulatory control loop in a DCS environment.

Lesson 4 • PLC Programming Languages

Covers ladder diagram, function block diagram, structured text, and sequential function chart languages per IEC standards. Students write and test basic control programs.

Lesson 1 • Functional Safety Concepts

Defines safety functions, safety integrity levels, and the safety lifecycle as required by functional safety standards. Establishes the framework for all SIS design activities.

Lesson 2 • SIS Maintenance and Management of Change

Establishes proof testing schedules, bypass authorization, and management of change procedures for SIS integrity. Students assess the impact of a proposed SIS modification.

Lesson 3 • SIS Architecture and Design

Covers sensor, logic solver, and final element selection for SIS applications, including redundancy architectures. Students design a 1oo2 and 2oo3 voting system.

Lesson 4 • SIL Verification and Calculation

Applies probability of failure on demand calculations using failure rate data and proof test intervals. Students verify that a designed SIS loop meets its target SIL.

Lesson 1 • Common Instrument Faults and Remedies

Catalogs frequent failure modes in transmitters, control valves, and controllers with diagnostic indicators and corrective actions. Builds pattern recognition for rapid fault resolution.

Lesson 2 • Systematic Troubleshooting Methodology

Applies a structured fault isolation process using symptom analysis, hypothesis testing, and root cause identification. Students resolve multi-fault scenarios using the methodology.

Lesson 3 • Calibration Management and Records

Establishes a calibration management system including traceability, uncertainty budgets, and out-of-tolerance reporting. Ensures regulatory compliance and measurement integrity.

Lesson 4 • Preventive Maintenance Programs

Designs maintenance schedules based on manufacturer recommendations, criticality ranking, and regulatory requirements. Reduces unplanned downtime through structured maintenance planning.