Industrial Automation and Instrumentation Course

Lesson 1 • Types of Industrial Processes

Distinguishes continuous, batch, and discrete manufacturing processes. Guides selection of appropriate automation strategies for each process type.

Lesson 2 • Introduction to Automation Concepts

Defines automation, its historical evolution, and industrial relevance. Establishes vocabulary and mental models needed for all subsequent technical content.

Lesson 3 • Industrial System Architectures

Examines field, control, and enterprise layers of automation architecture. Connects hardware placement to functional roles within a production environment.

Lesson 1 • Flow Measurement Technologies

Analyses differential pressure, magnetic, vortex, Coriolis, and ultrasonic flow meters. Guides meter selection based on fluid properties, pipe size, and accuracy needs.

Lesson 2 • Sensor Installation and Signal Integrity

Addresses mounting, wiring, grounding, and shielding practices that preserve signal quality. Reinforces measurement accuracy through proper field installation techniques.

Lesson 3 • Measurement Fundamentals

Covers accuracy, precision, resolution, and calibration concepts central to instrumentation. Provides the metrology foundation required to evaluate any sensor technology.

Lesson 4 • Pressure and Level Measurement

Covers gauge, absolute, and differential pressure sensors alongside level measurement technologies. Links sensor physics to process variable monitoring in tanks and pipelines.

Lesson 1 • Valve Actuators and Positioners

Covers pneumatic, electric, and hydraulic actuators paired with smart positioners. Connects actuator selection to response speed, force requirements, and control signal type.

Lesson 2 • Other Final Control Elements

Examines variable-speed drives, dampers, and on-off devices as alternatives to control valves. Broadens the engineer's toolkit for manipulating process variables.

Lesson 3 • Control Valve Fundamentals

Introduces valve body types, trim designs, and flow characteristics. Establishes the link between valve construction and its effect on process control performance.

Lesson 4 • Valve Maintenance and Diagnostics

Presents predictive and preventive maintenance strategies for control valves in service. Applies diagnostic data from smart positioners to reduce unplanned downtime.

Lesson 1 • Ladder Logic Programming

Teaches contacts, coils, timers, counters, and comparison instructions using ladder diagrams. Builds the primary programming skill used in the majority of industrial PLC applications.

Lesson 2 • Advanced PLC Programming Languages

Introduces Function Block Diagram, Structured Text, and Sequential Function Chart per IEC standards. Expands programming capability for complex sequential and continuous control tasks.

Lesson 3 • PLC Troubleshooting and Maintenance

Applies systematic fault-finding methods using online monitoring, force functions, and diagnostic LEDs. Reduces mean time to repair through structured troubleshooting workflows.

Lesson 4 • PLC I/O Wiring and Field Connections

Covers sourcing and sinking wiring, analogue signal connections, and field device interfacing. Ensures safe and reliable electrical connections between PLCs and field instruments.

Lesson 1 • Feedback Control Fundamentals

Introduces open-loop and closed-loop control concepts, block diagrams, and transfer functions. Establishes the theoretical basis for all controller design and tuning work.

Lesson 2 • PID Controller Modes and Actions

Explains proportional, integral, and derivative actions and their individual effects on loop response. Connects each mode to specific process behaviours and control objectives.

Lesson 3 • PID Tuning Methods

Applies Ziegler-Nichols, IMC, and Lambda tuning rules to set PID parameters for various process types. Balances setpoint tracking and disturbance rejection objectives.

Lesson 4 • Process Identification Methods

Covers step test, relay auto-tune, and model-based identification techniques for characterising process dynamics. Accurate process models are prerequisites for systematic tuning.

Lesson 1 • Industrial Network Fundamentals

Introduces OSI model layers, network topologies, and media types relevant to industrial environments. Provides the networking foundation required before protocol-specific configuration.

Lesson 2 • Fieldbus and Serial Protocols

Covers HART, FOUNDATION Fieldbus, Profibus, and Modbus for field device communication. Connects protocol selection to device density, data richness, and installation cost.

Lesson 3 • Wireless Industrial Communication

Introduces WirelessHART, ISA100, and Wi-Fi for industrial monitoring and control applications. Evaluates reliability, latency, and security trade-offs of wireless deployment.

Lesson 4 • Network Troubleshooting and Diagnostics

Applies packet capture, network analysers, and device diagnostics to isolate communication faults. Systematic methods reduce network downtime and restore production quickly.

Lesson 1 • HMI Design and Operator Interface

Applies human factors principles to create effective process graphics, alarms, and navigation. Well-designed HMIs reduce operator error and improve situational awareness.

Lesson 2 • Distributed Control System Architecture

Examines DCS controllers, I/O subsystems, control networks, and engineering workstations. Connects DCS architecture to continuous process control requirements.

Lesson 3 • DCS Configuration and Control Strategies

Configures regulatory, sequential, and batch control modules within a DCS environment. Applies PID and advanced control concepts from Chapter 5 to DCS function blocks.

Lesson 4 • SCADA System Architecture

Describes SCADA components including RTUs, communication networks, and central servers. Positions SCADA within the automation hierarchy established in Chapter 1.

Lesson 1 • Safety Instrumented System Fundamentals

Defines SIS architecture, safety functions, and the relationship between SIS and basic process control. Builds on functional safety concepts introduced in Chapter 1.

Lesson 2 • Industrial Cybersecurity Fundamentals

Introduces OT-specific threat landscape, attack vectors, and the consequences of cyber incidents on safety. Establishes cybersecurity as an integral part of automation system design.

Lesson 3 • Safety Logic Solvers and Field Devices

Examines safety-rated PLCs, voting architectures, and certified sensors and final elements. Connects hardware selection to SIL achievement and proof test intervals.

Lesson 4 • SIL Verification and Lifecycle

Applies quantitative reliability calculations to verify that SIS designs meet target SIL requirements. Covers the full safety lifecycle from concept through decommissioning.