Industrial Process Instrumentation Practical Training 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 Process Instrumentation.
The course is ensuring progressive learning from basic logic development to complex control applications, networking, and data handling.
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 Instrumentation (Beginner)
Session 1: Introduction to Instrumentation
- Role of instrumentation in:
- Oil & Gas (upstream, midstream, downstream)
- Manufacturing (process & discrete)
- Power plants (thermal, gas, hydro)
- Process control loop fundamentals
- Open-loop vs closed-loop control
- Field instruments → PLC/DCS → SCADA architecture
- What is instrumentation & control
- Role of instrumentation in industrial plants
- Types of control systems: Manual, Automatic
- Open-loop vs Closed-loop systems
- Basic control loop components
Session 2: Process Variables
- Pressure
- Temperature
- Flow
- Level
- Analytical variables (pH, conductivity, gas analysis)
- Typical industrial applications
Session 3: Measurement Concepts
- Accuracy, precision, repeatability
- Span, range, zero, linearity
- Static vs dynamic characteristics
- Errors and uncertainties
Session 4: Instrument Symbols & Standards
- P&ID basics
- ISA symbols and tag numbering
- Instrument loop drawings
- Hook-up drawings overview
Session 5: Standard & Documentation
- ISA tag numbering
- P&ID interpretation (oil & gas / power plant examples)
- Instrument loop diagrams
- Cause & Effect charts (introduction)
Practical:
- Reading P&IDs
- Identifying instruments on sample drawings
DAY 2 – Pressure, Level & Temperature Instruments (Beginner → Intermediate)
Session 1: Pressure Measurement
- Pressure types: Absolute, Gauge, Differential
- Pressure transmitters
- Bourdon tube, diaphragm, bellows
- DP transmitters (flow & level use)
Session 2: Level Measurement
- Level switches vs level transmitters
- Float, DP level, ultrasonic, radar
- Capacitive level measurement
- Level measurement in tanks & vessels
Session 3: Temperature Measurement
- RTD (Pt100), Thermocouples
- Temperature transmitters
- Thermowells & installation practices
- Common temperature errors
Session 4: Calibration Basics
- Calibration standards
- 2-wire, 3-wire, 4-wire instruments
- Zero & span adjustment
Session 4: PLC/DCS Interface
- 4–20 mA wiring to PLC AI modules
- Scaling raw values in PLC/DCS
- Instrument fault detection
Practical:
- Pressure & temperature transmitter calibration
- Loop simulation using calibrators
DAY 3 – Flow Measurement & Signal Standards (Intermediate)
Session 1: Flow Measurement Principles
- Volumetric vs mass flow
- Flow profile & Reynolds number
- Primary vs secondary elements
Session 2: Flow Meter Types
- Orifice plate, venturi, nozzle
- Magnetic flow meters
- Vortex flow meters
- Turbine & ultrasonic flow meters
- Coriolis mass flow meters
Session 3: Instrument Signals & Communication
- Digital signals overview
- Pneumatic signals (3–15 psi)
- 4–20 mA, 0–10 V
- HART communication
- Modbus RTU/TCP
- Profibus / Foundation Fieldbus (overview)
Session 4: Instrument Installation Practices
- Impulse lines
- Root valves & manifolds
- Cable shielding & grounding
- Hazardous area considerations
Session 5: Hazardous Area Consideration
- ATEX / IECEx basics
- Intrinsic safety barriers
- Ex-proof instrumentation (oil & gas)
Session 6: PLC/DCS & SCADA Integration
- Mapping flow values to SCADA
- Totalizers & trend displays
- Alarm configuration
Practical:
- Flow transmitter setup
- Loop wiring exercises
- Signal troubleshooting
- Modbus data mapping to SCADA tags
DAY 4 – Control Valves, Actuators & Control Concepts (Intermediate → Advanced)
Session 1: Control Valves
- Valve types (globe, ball, butterfly)
- Control valve characteristics
- Valve sizing basics
- Cavitation & flashing
Session 2: Actuators & Positioners
- Pneumatic actuators
- Electric actuators
- Valve positioners
- I/P and P/I converters
Session 3: Control Strategies
- On-Off control
- P, PI, PID control
- Feedback vs feedforward
- Cascade & ratio control
Session 4: Final Control Element Troubleshooting
- Valve hunting
- Stiction problems
- Air supply issues
- Position feedback errors
Session 5: PLC/DCS Control Implementation
- PID blocks in PLC/DCS
- Interlocks & permissives
- Control valve troubleshooting
SCADA Integration
- Control faceplates
- Manual / Auto selection
- Trends & operator graphics
Practical:
- Control valve operation
- Control valve operation & stroking
- PID tuning demonstration
- Common valve faults diagnosis
DAY 5 – Advanced Instrumentation, Safety & Troubleshooting
Session 1: Analytical Instruments
- pH & conductivity analyzers
- Gas analyzers (O₂, H₂S, CO₂)
- Sample conditioning systems
Session 2: Safety Instrumented Systems (SIS)
- Basic safety concepts
- SIL levels overview
- Interlocks & trips
- Emergency shutdown systems
- Interlocks, trips & Cause & Effect
Session 3: Instrument Maintenance & Documentation
- Preventive vs corrective maintenance
- Calibration records
- Instrument datasheets
- Spare parts management
Session 4: Industrial Troubleshooting Workshop
- Signal loop faults
- No output / wrong output
- Process vs instrument faults
- Loop checking procedures
- Instrument failure diagnosis
- PLC/DCS vs field instrument fault isolation
- Real-life case studies
Session 5: SCADA Alarm Management
- Alarm priorities
- Nuisance alarm reduction
- Event logging & reporting
Final Practical & Assessment:
- Complete instrument loop check:
- Field device → PLC/DCS → SCADA
- Fault finding exercises
- Review & certification
- Real industrial fault scenarios
- Final assessment & review
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