BASICS OF INDUSTRIAL CONTROLS AND AUTOMATION

Objective:

• Interpret and understand Piping and Instrumentation Diagrams (P&ID) and electrical schematics
• Install and wire industrial sensors and actuators to Programmable Logic Controllers (PLCs)
• Develop, simulate, and implement basic PLC programs for industrial applications
• Configure Human Machine Interfaces (HMIs) for monitoring and controlling automated systems
• Understand industrial automation architectures and modern smart factory concepts
• Troubleshoot basic industrial automation circuits and control systems effectively

Content:

Introduction to Industrial Automation

• Understanding automation concepts and definitions
• Types of automation: fixed, programmable, and flexible automation
• Exploring the automation pyramid from field devices to enterprise systems
• Introduction to Industry 4.0 and Industrial Internet of Things (IIoT)
• Understanding industrial safety standards and IEC 60204-1 compliance

Electrical Control Fundamentals

• Understanding electrical control components including relays, contactors, circuit breakers, fuses, and switches
• Developing ladder diagrams for motor control and logic applications
• Understanding power circuits, transformers, and power supply systems
• Reading and interpreting electrical wiring diagrams
• Designing industrial control panels, including component selection, labeling, and layout

Field Instrumentation and Actuators

• Understanding industrial sensors including proximity, capacitive, inductive, optical, photoelectric, and limit switches
• Exploring measurement devices for temperature, pressure, level, and flow applications
• Understanding transmitters including RTDs and thermocouples
• Working with actuators including DC motors, three-phase induction motors, and Servo/VFD systems
• Introduction to hydraulic and pneumatic systems, solenoid valves, and cylinders

Programmable Logic Controllers (PLCs)

• Understanding PLC hardware architecture including CPU, power supply units, and I/O modules
• Introduction to ladder logic programming concepts including NO, NC, OTE, OTL, and OTU instructions
• Applying PLC timers, counters, and comparison instructions
• Developing, simulating, and downloading PLC programs
• Using industrial automation software including Siemens TIA Portal, Rockwell Studio 5000, and Delta ISPSoft
• Performing PLC troubleshooting, debugging, and I/O forcing

SCADA and HMI Systems

• Understanding Human Machine Interface (HMI) design and configuration
• Creating HMI screens, controls, buttons, and visual feedback systems
• Understanding SCADA architecture and supervisory control principles
• Managing alarms, data archiving, historians, and reporting systems
• Understanding industrial communication protocols including RS-232, RS-485, Modbus, and Profinet

Process Control and PID Systems

• Understanding open-loop and closed-loop control systems
• Introduction to feedback control principles
• Understanding Proportional-Integral-Derivative (PID) controllers
• Applying PID tuning techniques for industrial processes
• Implementing control systems for temperature, flow, and process applications

For Whom:

• Automation Engineers and Control Engineers
• Electrical and Instrumentation Engineers
• Maintenance Engineers and Technicians
• Process and Manufacturing Professionals
• Industrial Technicians seeking automation skills development
• Professionals involved in PLC, SCADA, HMI, and industrial control systems