Instrumentation and Control Technician Course

Lesson 1 • Safety and Regulatory Basics

Introduces hazardous area classifications, personal protective equipment, and industry safety standards. Safe work practices are reinforced throughout all practical activities.

Lesson 2 • Signal Types and Transmission

Introduces analog, digital, and pneumatic signal standards used in field devices. Students connect signal types to wiring and communication practices covered later.

Lesson 3 • Introduction to Industrial Instrumentation

Covers the purpose and scope of instrumentation in industrial settings. Establishes vocabulary and context for all subsequent technical content.

Lesson 4 • Process Variables and Their Importance

Defines temperature, pressure, flow, level, and analytical variables. Understanding each variable prepares students for sensor-specific chapters ahead.

Lesson 1 • Wiring Practices and Cable Types

Explains instrument cable types, shielding, grounding, and termination methods. Correct wiring practice prevents signal interference and ensures reliable loop operation.

Lesson 2 • Electrical Safety in the Field

Addresses arc flash hazards, electrical isolation procedures, and permit-to-work systems. Builds on the safety basics introduced in Chapter 1 with electrical-specific protocols.

Lesson 3 • Electrical Measurement Tools

Teaches proper use of multimeters, clamp meters, and oscilloscopes for field measurements. Accurate tool use is critical for loop testing and fault diagnosis.

Lesson 4 • DC Circuit Theory

Covers voltage, current, resistance, and Ohm's law in direct-current circuits. Provides the electrical foundation needed for loop wiring and signal analysis.

Lesson 1 • Installation of Pressure and Temperature Devices

Covers impulse line design, thermowell selection, and mounting best practices. Proper installation prevents measurement errors and protects instruments from process damage.

Lesson 2 • Calibration of Pressure and Temperature Instruments

Teaches zero and span adjustment, deadweight tester use, and calibration documentation. Calibration skills developed here apply to all instrument types in later chapters.

Lesson 3 • Pressure Measurement Principles

Explains gauge, absolute, differential, and vacuum pressure concepts. Establishes the theoretical basis for selecting and applying pressure instruments correctly.

Lesson 4 • Temperature Measurement Principles

Introduces thermocouple, RTD, thermistor, and pyrometer operating principles. Correct sensor selection depends on range, accuracy, and process compatibility.

Lesson 1 • Flow and Level Instrument Calibration

Applies calibration procedures specific to flow and level devices, including wet and dry calibration methods. Builds on calibration fundamentals from Chapter 3.

Lesson 2 • Differential Pressure Flow Devices

Covers orifice plates, venturi tubes, flow nozzles, and pitot tubes. Students calculate flow from differential pressure readings and identify installation requirements.

Lesson 3 • Velocity and Positive Displacement Flow Meters

Introduces turbine, magnetic, vortex, ultrasonic, and positive displacement meters. Each technology's strengths and limitations guide appropriate application choices.

Lesson 4 • Flow Measurement Fundamentals

Explains continuity, Bernoulli's principle, and Reynolds number as they apply to flow measurement. These principles govern the selection and sizing of all flow devices.

Lesson 1 • Valve Actuators and Positioners

Covers pneumatic, electric, and hydraulic actuators and the role of valve positioners. Positioner tuning directly affects control loop response and accuracy.

Lesson 2 • Control Valve Sizing and Selection

Teaches sizing calculations for liquid, gas, and steam service using industry methods. Correct sizing prevents oversizing, hunting, and poor rangeability.

Lesson 3 • Control Valve Maintenance and Troubleshooting

Addresses packing replacement, seat lapping, actuator servicing, and fault diagnosis. Maintenance skills reduce unplanned downtime and extend valve service life.

Lesson 4 • Control Valve Fundamentals

Introduces valve body types, trim characteristics, and flow coefficients. Understanding valve hydraulics is essential for correct sizing and loop performance.

Lesson 1 • PID Controller Modes

Explains proportional, integral, and derivative actions and their individual effects on loop response. Students predict how each mode change affects stability and offset.

Lesson 2 • PID Tuning Methods

Covers open-loop step testing, Ziegler-Nichols, and lambda tuning methods. Selecting the right method depends on process type and acceptable disturbance response.

Lesson 3 • Loop Performance Assessment

Teaches methods for evaluating loop performance using trend analysis, variance, and control indices. Continuous performance monitoring sustains process efficiency and product quality.

Lesson 4 • Feedback Control Concepts

Introduces open-loop and closed-loop control, setpoint, error, and process gain. These concepts form the theoretical core of all control loop work.

Lesson 1 • Ladder Logic Programming Fundamentals

Introduces contacts, coils, timers, counters, and comparison instructions in ladder logic. Students write and simulate programs that replicate real control sequences.

Lesson 2 • PLC Architecture and Hardware

Covers CPU, power supply, I/O modules, and backplane communication in PLC systems. Hardware knowledge is prerequisite to programming and fault diagnosis.

Lesson 3 • Analog I/O and PID in PLCs

Explains analog input scaling, PID function blocks, and output signal conditioning in PLCs. Connects PLC programming to the control theory covered in Chapter 6.

Lesson 4 • SCADA Systems and HMI Design

Covers SCADA architecture, communication protocols, and HMI screen design principles. Effective HMI design improves operator situational awareness and response time.

Lesson 1 • Loop Checking and Commissioning

Teaches systematic loop checking procedures from field device to control system. Loop checks confirm correct wiring, scaling, and signal integrity before startup.

Lesson 2 • Instrument Asset Management

Introduces computerized maintenance management systems, asset registers, and lifecycle tracking. Effective asset management optimizes instrument reliability and total cost of ownership.

Lesson 3 • Preventive Maintenance Planning

Covers maintenance scheduling, criticality ranking, and task development for instrument assets. A structured PM program reduces failures and supports regulatory compliance.

Lesson 4 • Technical Documentation and Drawings

Covers P&IDs, loop diagrams, instrument data sheets, and hook-up drawings. Accurate documentation is essential for safe operation, maintenance, and modifications.