Industrial Electrical and Instrumentation Commissioning & Maintenance Course
Course Overview
This intensive 10-day hands-on training program is designed to provide participants with the practical knowledge and technical skills required to specialize in Industrial Electrical and Instrumentation Troubleshooting, Commissioning & Maintenance.
Target Audience
This training is ideal for:
- Automation & Instrumentation Personnel
- Maintenance Technicians, Supervisors and Engineers
- Electrical Engineers & System Integrators
- Industrial Electricians
- Technical Trainers and Engineering Students
- Beginners with little or no Instrumentation
Prerequisites
- Basic understanding of physics
- Familiarity with Windows-based PC operation
- Prior Instrumentation experience is helpful but not required
Training Objectives
At the end of this course, participants will be able to:
- Understand Instrumentations Fundamentals
- Understand Instrumentation documentation
- Understand Instrumentation Measurement and Calibration
- Understand Instrumentation Maintenance Tasks
Training Structure
- Registration Fee: N50,000
- Advanced Training Fee: N350,000
- Duration: 10 Days
- Mode: Instructor-led 95% Practical & 5% Theory Sessions
Software Tools:
- HART and Foundation Fieldbus Communicator
- PDF and MS Word/Excel
How to apply
- Send email to training@intellectsenergy.com.
- Call or send Whatsapp message to 08051203632
DAY 1 – Fundamentals of Industrial LV Systems & Safety
Morning Session: Electrical & Instrumentation Basics
- Overview of Industrial Power Systems (415V/400V/230V)
- AC/DC fundamentals (Voltage, Current, Power, PF)
- Electrical drawings:
- Single Line Diagrams (SLD)
- Wiring & Loop Diagrams
- Introduction to field instruments:
- Pressure, Flow, Level, Temperature
- Signal types:
- Analog (4–20 mA, 0–10V)
- Digital (DI/DO)
Afternoon Session: Safety & Standards
- Electrical safety practices (LOTO, isolation)
- Hazardous area classification (Zone 0, 1, 2)
- Intrinsic Safety (IS) basics
- PPE requirements
Practical
- Reading electrical & loop diagrams
- Multimeter usage (voltage, current, resistance)
- Identifying field devices
DAY 2 – Electrical Systems Troubleshooting & Maintenance
Morning Session: LV Equipment & Components
- Motors (DOL, Star-Delta, Soft Starters, VFD basics)
- Switchgear & MCC panels
- Relays, Contactors, Circuit breakers
- Cable types & termination practices
Afternoon Session: Troubleshooting Techniques
- Fault finding methodology:
- No power / undervoltage
- Overload / short circuit
- Earth faults
- Insulation testing (Megger)
- Power quality basics
Practical
- Motor fault diagnosis
- MCC panel troubleshooting
- Cable fault simulation
Industry Customization
- Oil & Gas: Explosion-proof motors, EEx equipment
- Manufacturing: Conveyor & machine faults
- Power Plants: Auxiliary systems (pumps, fans)
DAY 3 – Instrumentation Troubleshooting & Calibration
Morning Session: Measurement & Devices
- Transmitters (Pressure, Flow, Level, Temperature)
- Control valves & positioners
- I/P, P/I converters
- Fieldbus basics (HART)
Afternoon Session: Calibration & Troubleshooting
- Calibration procedures:
- 4–20 mA loop calibration
- Zero/span adjustment
- Loop checking & signal tracing
- Common faults:
- Signal drift
- Noise/interference
- Air supply issues (pneumatic)
Practical
- Transmitter calibration using calibrator
- Control valve stroking test
- Loop checking (field → control room)
Industry Customization
- Oil & Gas: Flow metering (DP, Coriolis)
- Manufacturing: Temperature & process control
Power Plants: Boiler instrumentation
DAY 4 – PLC/DCS Interface & SCADA Integration
Morning Session: PLC/DCS Fundamentals
- PLC architecture:
- CPU, I/O modules, power supply
- Input/Output types:
- Digital inputs/outputs
- Analog inputs/outputs
- Signal interfacing:
- Field → PLC → Control System
- DCS overview (distributed control)
Afternoon Session: SCADA & Communication
- SCADA architecture:
- RTU, HMI, Servers
- Communication protocols:
- Modbus (RTU/TCP)
- Profibus / Profinet basics
- Alarm handling & trending
- Interfacing instruments with PLC/DCS
Practical
- Wiring field devices to PLC I/O
- Basic PLC fault diagnosis
- SCADA screen navigation & alarm analysis
Industry Customization
- Oil & Gas: Emergency Shutdown Systems (ESD)
- Manufacturing: Automation lines & batching
- Power Plants: Turbine & boiler control systems
DAY 5 – Commissioning, Advanced Troubleshooting & Case Studies
Morning Session: Commissioning Procedures
- Pre-commissioning checks:
- Cable continuity
- Insulation resistance
- Loop checking procedures
- Functional testing (FAT/SAT concepts)
- Documentation & reporting
Afternoon Session: Advanced Troubleshooting
- Integrated system faults:
- PLC ↔ Instrument mismatch
- Communication failures
- SCADA data errors
- Root Cause Analysis (RCA)
- Preventive vs Predictive Maintenance
Practical / Case Studies
- Full system troubleshooting simulation:
- Field → PLC → SCADA fault tracing
- Real-life scenarios:
- Oil & gas plant shutdown issue
- Manufacturing line failure
- Power plant trip event
Day 6 to Day 10:
- Self practice at our facility with hardware and software
Training Materials & Deliverables
- Comprehensive training manual (soft + hard copy)
- Practical lab exercises and example programs
- Course slides and reference documents
- Certificate of Completion
- Post-training technical support (optional)
Training Methodology
- Instructor-led presentations
- Hands-on programming sessions using actual PLCs or simulators
- Real-world case studies and troubleshooting
- Progressive assessments to reinforce learning outcomes
Duration & Schedule
- Total Duration: 10 Days (Monday–Friday, 2 weeks)
- Daily Schedule: 9:00 AM – 4:00 PM
- Format: Onsite
Certification
Participants who complete both modules and pass the final project assessment will receive a Certificate of Proficiency in Industrial Process Instrumentation issued by Intellects Energy Ltd