Advanced Programming, Control, and Monitoring Systems Course

Lesson 1 • Signal Types and Transmission Standards

Explains analog and digital signal formats used between field devices and controllers. Students interpret signal specifications and identify common transmission standards.

Lesson 2 • Industrial Automation Overview

Introduces the purpose and scope of industrial automation within manufacturing and process environments. Establishes vocabulary and context for all subsequent control system study.

Lesson 3 • Control System Architectures

Examines centralized, distributed, and hybrid control topologies. Students map architecture choices to application requirements and operational constraints.

Lesson 4 • Safety and Regulatory Fundamentals

Introduces functional safety concepts and the regulatory frameworks governing industrial control systems. Students recognize hazard categories and mandatory documentation requirements.

Lesson 1 • Scan Cycle and Execution Model

Analyzes the PLC scan cycle from input scan through output update. Students predict timing behavior and design programs that meet deterministic response requirements.

Lesson 2 • Memory Organization and Data Types

Explains program, data, and system memory regions within a PLC. Students allocate tags and data structures to support efficient program execution.

Lesson 3 • PLC Hardware Architecture

Details CPU modules, I/O racks, power supplies, and backplane communication. Students identify module roles and specify hardware for a given application.

Lesson 4 • Discrete and Analog I/O Configuration

Covers wiring, scaling, and filtering of discrete and analog I/O channels. Students configure modules to match field device specifications and process requirements.

Lesson 1 • Function Block Diagram Programming

Introduces graphical data-flow programming using interconnected function blocks. Students build modular control solutions and reuse certified library blocks.

Lesson 2 • Sequential Function Chart Design

Explains step-transition logic for sequential process control using SFC. Students model multi-step processes and handle divergence, convergence, and exception paths.

Lesson 3 • Instruction List and Language Selection

Introduces IL as a low-level language and establishes criteria for choosing among all five languages. Students select the optimal language for each control task type.

Lesson 4 • Structured Text Programming

Covers high-level text-based programming for complex calculations and algorithms. Students write readable, maintainable ST code following industrial style guidelines.

Lesson 1 • Controller Tuning Methods

Covers empirical and model-based tuning methods including Ziegler-Nichols and IMC approaches. Students apply each method and compare resulting loop performance.

Lesson 2 • PID Algorithm and Modes

Explains proportional, integral, and derivative actions and their combined effect on loop behavior. Students predict how each mode affects setpoint tracking and disturbance rejection.

Lesson 3 • Advanced Loop Strategies

Introduces cascade, feedforward, ratio, and override control to handle complex process interactions. Students design multi-loop schemes that outperform single-loop PID.

Lesson 4 • Loop Performance Validation

Teaches quantitative performance assessment using IAE, ISE, and setpoint step tests. Students identify detuned or oscillating loops and apply corrective retuning.

Lesson 1 • Fieldbus Protocols and Configuration

Covers PROFIBUS, DeviceNet, and FOUNDATION Fieldbus configuration and device commissioning. Students configure master-slave relationships and verify data exchange.

Lesson 2 • Network Troubleshooting and Cybersecurity

Teaches systematic network fault isolation using protocol analyzers and diagnostic tools. Students apply defense-in-depth principles to protect industrial networks from cyber threats.

Lesson 3 • Industrial Ethernet Protocols

Explains PROFINET, EtherNet/IP, and Modbus TCP operation and configuration. Students set up real-time Ethernet networks and verify deterministic data exchange.

Lesson 4 • Industrial Network Fundamentals

Introduces the OSI model adapted for industrial use and the network hierarchy from field to enterprise. Students map device types to appropriate network layers.

Lesson 1 • Alarm Management Systems

Covers alarm philosophy, rationalization, and prioritization aligned with industry alarm management standards. Students configure alarm systems that minimize nuisance alarms and support operator response.

Lesson 2 • SCADA System Architecture

Explains SCADA components including servers, clients, communication drivers, and historians. Students design system architectures that meet availability and scalability requirements.

Lesson 3 • Historian and Data Logging

Teaches process historian configuration for high-speed data collection, compression, and retrieval. Students design tag databases and query historical data for analysis.

Lesson 4 • HMI Screen Design Principles

Applies human factors and situational awareness principles to operator display design. Students create high-performance displays that reduce operator error and response time.

Lesson 1 • Model Predictive Control Fundamentals

Introduces MPC principles including prediction horizons, constraint handling, and optimization objectives. Students build and test linear MPC controllers for multivariable processes.

Lesson 2 • Energy Optimization Techniques

Teaches demand management, load scheduling, and variable-speed drive optimization to reduce energy consumption. Students calculate energy savings and implement control logic for efficiency targets.

Lesson 3 • Batch and Recipe Management

Implements ISA-88 batch control models including recipe, equipment, and procedural elements. Students configure batch servers and execute multi-phase recipes with full audit trails.

Lesson 4 • Statistical Process Control Integration

Applies SPC charts and capability indices to monitor process variation and trigger control actions. Students integrate SPC data with PLC and SCADA systems for real-time quality control.

Lesson 1 • Site Acceptance Testing and Startup

Covers loop checks, interlock verification, and phased startup procedures for live plant commissioning. Students manage startup risks and transition systems from commissioning to operational status.

Lesson 2 • Project Documentation and Handover

Establishes as-built documentation, spare parts lists, and operator training packages for system handover. Students compile complete project records that support long-term system maintainability.

Lesson 3 • System Design and Specification

Covers functional specification, I/O lists, cause-and-effect matrices, and control narrative development. Students produce complete design packages that guide hardware procurement and programming.

Lesson 4 • Factory Acceptance Testing

Teaches FAT planning, test script development, and defect tracking for control system verification. Students execute structured FAT procedures and document results against acceptance criteria.