Industrial Control System (ICS) Design and Engineering 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 Control Systems.
The course is ensuring progressive learning from basic control system to complex control systems 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 control systems
- Familiarity with Windows-based PC operation
- Prior Instrumentation experience is helpful but not required
Training Objectives
By the end of this course, participants will be able to:
- Understand Industrial Control System (ICS) architecture and design principles.
- Design reliable PLC, DCS, SCADA, and HMI systems.
- Develop instrument loop and control philosophies.
- Design industrial communication networks.
- Produce engineering deliverables used in EPC and brownfield projects.
- Integrate PLCs with DCS and SCADA platforms.
- Apply cybersecurity, redundancy, and reliability concepts for critical facilities.
Training Structure
- Registration Fee: N50,000
- Advanced Training Fee: N750,000
- Duration: 10 Days
- Mode: Instructor-led 95% Practical & 5% Theory Sessions
Software and Engineering Tools
- AutoCAD Electrical
- AutoCAD P&ID
- AVEVA Instrumentation
- EPLAN Electric P8
- Siemens TIA Portal
- Rockwell Studio 5000
- Schneider EcoStruxure Control Expert
- Wonderware InTouch / AVEVA System Platform
- Siemens WinCC
- FactoryTalk View
- OPC UA Servers
- Network diagnostic tools
How to apply
- Send email to training@intellectsenergy.com.
- Call or send Whatsapp message to 08051203632
Day 1 – Fundamentals of Industrial Control System Design
Module 1: Introduction to Industrial Control Systems
- Evolution of industrial automation
- ICS architecture overview
- Components of modern control systems
- Levels of automation (ISA-95)
- Control system lifecycle
Module 2: Process Control Fundamentals
- Open-loop vs Closed-loop control
- PID control concepts
- Analog and digital signals
- Control strategies
- Process variables
- Pressure
- Flow
- Temperature
- Level
- Analytical measurements
Module 3: Oil & Gas and Power Plant Processes
Oil & Gas
- Separation systems
- Compressors
- Pumps
- Pipeline automation
- Tank farms
- Gas metering
- Produced water systems
Power Plants
- Boiler control
- Turbine control
- Generator protection
- Feedwater systems
- Cooling systems
- Switchyard automation
Module 4: Introduction to Control System Design
- Design standards
- Functional Design Specification (FDS)
- User Requirement Specification (URS)
- Design basis
- Design philosophy
Practical
- Review of actual refinery control architecture
- Review of power plant automation architecture
- Process control case studies
Day 2 – Instrumentation and Control System Engineering
Module 1: Instrument Engineering
- Instrument selection
- Instrument sizing basics
- Instrument specifications
- Instrument datasheets
- Control valves
- Final control elements
Module 2: Instrument Loop Design
- Loop drawings
- Hook-up drawings
- Instrument index
- Cable schedules
- Junction box schedules
Module 3: P&ID Interpretation
- ISA symbols
- Instrument tagging
- Control narratives
- Cause & Effect diagrams
Module 4: Control Panel Engineering
- PLC panel design
- DCS cabinet design
- Marshalling panels
- Junction boxes
- Remote I/O panels
- UPS integration
Practical
- Design a complete instrument loop
- Prepare loop drawings
- Prepare cable schedules
- Review engineering packages
Day 3 – PLC, DCS Interface and SCADA Integration
Module 1: PLC System Design
- PLC hardware selection
- CPU sizing
- I/O calculation
- Remote I/O architecture
- Redundancy concepts
Module 2: DCS Engineering
- DCS architecture
- Controller configuration
- Operator stations
- Engineering stations
- Alarm philosophy
- Historian systems
Module 3: PLC–DCS Interface
- Data exchange methods
- Analog mapping
- Digital mapping
- Interlocks
- Shutdown signals
- Redundant communication
Module 4: SCADA Integration
- SCADA architecture
- HMI design principles
- Alarm management
- Historical trending
- Report generation
- Remote monitoring
Module 5: Industrial Communication Networks
- Ethernet/IP
- Modbus RTU
- Modbus TCP
- PROFINET
- PROFIBUS
- Foundation Fieldbus
- HART
- OPC UA
- IEC 61850 (Power Plants)
- DNP3
- IEC 60870-5-104
Practical
- Design a PLC-DCS communication architecture
- Configure SCADA communication
- Build a complete network topology
Day 4 – Control System Engineering, Reliability and Cybersecurity
Module 1: Control Logic Development
- Motor control
- Sequential control
- Batch control
- Process interlocks
- Start-up logic
- Shutdown logic
Module 2: Safety Systems
- Emergency Shutdown (ESD)
- Fire & Gas Systems
- Safety Instrumented Systems (SIS)
- SIL concepts
- Basic safety lifecycle
Module 3: Reliability Engineering
- Redundant PLC systems
- Redundant DCS controllers
- Network redundancy
- Server redundancy
- Hot standby systems
- Fail-safe philosophy
Module 4: Industrial Cybersecurity
- IEC 62443 overview
- Network segmentation
- Firewalls
- VLANs
- User access management
- Patch management
- Backup and disaster recovery
Practical
- Design redundant control architecture
- Configure secure industrial networks
- Develop cybersecurity checklist
Day 5 – Complete Industrial Control System Design Project
Module 1: Engineering Documentation
- Control philosophy
- Functional Design Specification (FDS)
- I/O list
- Instrument index
- Cable schedule
- Network drawings
- System architecture drawings
- FAT/SAT documentation
Module 2: Project Engineering
- Engineering workflow
- Procurement support
- Vendor document review
- Construction support
- Commissioning support
- As-built documentation
Module 3: Integrated Design Project
Participants will design a complete Industrial Control System for either:
Oil & Gas Facility
- Crude oil separation process
- Gas compression station
- Tank farm automation
- Custody metering station
Power Plant
- Boiler automation
- Turbine control
- Generator auxiliary systems
- Electrical switchyard automation
Project Deliverables
- Complete P&ID review
- Instrument index
- I/O schedule
- PLC architecture
- DCS architecture
- SCADA architecture
- Communication network design
- Control philosophy
- Cause & Effect matrix
- Instrument loop drawings
- Control panel layout
- FAT checklist
- SAT checklist
- Commissioning plan
Final Assessment
- Practical engineering design exercise
- Team project presentation
- Written assessment
- Individual competency evaluation
Software and Engineering Tools
- AutoCAD Electrical
- AutoCAD P&ID
- AVEVA Instrumentation
- EPLAN Electric P8
- Siemens TIA Portal
- Rockwell Studio 5000
- Schneider EcoStruxure Control Expert
- Wonderware InTouch / AVEVA System Platform
- Siemens WinCC
- FactoryTalk View
- OPC UA Servers
- Network diagnostic tools
Applicable Standards
- ISA S5.1 (Instrumentation Symbols)
- ISA 18.2 (Alarm Management)
- ISA 84 / IEC 61511 (Safety Instrumented Systems)
- IEC 61131-3 (PLC Programming)
- IEC 62443 (Industrial Cybersecurity)
- IEC 61850 (Power Utility Automation)
- IEEE 802.3 (Industrial Ethernet)
- NFPA 70 (National Electrical Code)
- API RP 551 (Process Measurement)
- API RP 554 (Control Systems)
Expected Learning Outcomes
Participants will be able to:
- Design complete Industrial Control Systems from concept through commissioning.
- Select and specify field instrumentation and control hardware.
- Engineer PLC, DCS, SCADA, and HMI systems for oil & gas and power plant applications.
- Design reliable industrial communication networks using Modbus, PROFINET, EtherNet/IP, OPC UA, IEC 61850, and DNP3.
- Develop engineering documentation including FDS, I/O lists, P&IDs, loop diagrams, Cause & Effect matrices, and network drawings.
- Integrate PLCs with DCS and SCADA platforms while implementing redundancy, alarm management, cybersecurity, and safety system principles aligned with industry best practices.
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 various software 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 Control System (ICS) Design and Engineering issued by Intellects Energy Ltd