Intellects Energy Ltd.

Practical Process Instrumentation and Control Systems Maintenance and Troubleshooting

Course Objective

This 8 days course is developed to provide hand on practical experience on instrumentation commissioning, maintenance and operation. The course is delivered using work place standard instruments, calibration/function testing equipment and control systems (PLCs and HMIs) by certified experienced field instrumentation and controls engineers.


  • Students are supposed to be familiar with basic physic/mathematics and Desktop/Laptop.
  • No other prerequisites for this course, Because instructor will teach everything from scratch

Who Should Attend

This course is opened to electrical and instrument personnel, operations and maintenance personnel and anyone desiring to specialize on instrumentation commissioning, maintenance and operations in live plants

Course Code: ICM004

Duration: 8 days; 9 hours per day

Course Outline

 Day one:

  • Instrumentation documentation
  • Preventive and corrective maintenance
  • To install Pressure and Flow instruments in Gas, Steam and Liquid Process lines
  • To install general field Instruments (Temperature & Level Transmitters/Sensors , Flame /Gas detectors, switches etc)
  • Cable pulling and dressing, signal cable segregation, cable length reading and documentation, cable tags, core markers, sleeves (shrinkable Tube) etc

Day Two:

  • Cable Glanding and Termination
  • Cable trays installation and bends calculations
  • Construction accessories and fittings, terminologies and tips
  • Tubing bending and installation (Practical)
  • Installation of Stanchions and JBs
  • Installation of control system cabinets and internal devices, racks, terminal blocks, I/O Cards, PLCs, current surge protectors, relays , PS, HMI CPUs and Display Screens, etc.

Day Three:

  • Fabrication of instruments supports
  • Test equipment/Tools handling, care and protection (Practical).
  • Commissioning Documentations (eg ICAPS forms, Loop Folders, I/O List, Alarm summary etc)
  • How to operate and use test equipment: Emerson Rosemount 475 Communicator, Loop Calibrator, Multimeter, Temperature bath, RTD and TC simulators, Decade Resistance Box, Vennier calliper, low pressure druck manometer/pump, high pressure pump, dead weight tester etc (Practical)
  • Introduction to control systems (DCS, PLC and SCADA Systems)

Day Four:

  • Instrument calibration
  • Flow Instrument calibration
  • Pressure Instrument calibration
  • Level Instrument calibration
  • Temperature Instrument calibration
  • introduction to analytical instrument calibration

Day Five:

  • Hot Loop Check and Function Test
  • Troubleshooting and maintenance of flow instruments
  • Troubleshooting and maintenance of pressure instruments
  • Troubleshooting and maintenance Temperature instruments
  • Troubleshooting and maintenance Level instruments
  • Well Head WHCP and Instrumentation Maintenance

Day Six:

  • Troubleshooting of loops
  • Fault Root Cause Analysis
  • Continuity tests
  • insulation resistance tests
  • troubleshooting earth fault
  • troubleshooting open loops and closed loops
  • Fault tracing

Day Seven:

  • Troubleshooting and maintenance Analytic instruments
  • Troubleshooting and maintenance of Fire and Gas (F&G) instruments
  • Troubleshooting and maintenance of Control Valves
  • Troubleshooting and maintenance of ON/OFF Control Valves
  • troubleshooting of motor starters and VFDs

Day Eight:

  • PLC hardware troubleshooting
  • Troubleshooting of  loops and control systems I/Os, PLCs and DCS
  • Introduction to analog input, analog output, digital input and digital output of PLCs
  • Simulation of signals, source, sink and contacts.
  • replacement of i/o modules in PLCs
  • Troubleshooting and testing i/o modules
  • Practice and revision
  • Job Search counseling, Curriculum writing tips and restructuring of trainee CV- Bonus topic.
  • Application for online jobs by attendees
  • Copy training videos and materials for employees
  • Final Assessment
  • Issuance of certificate to attendees