Industrial Control Systems 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
At the end of this course, participants will be able to:
- Understand Control Systems Fundamentals
- Understand Control Systems Documentation
- Understand Control Systems Integration
- Understand Control Systems 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 Control Systems
(Beginner Level)
Topics
- Overview of Industrial Control Systems (ICS)
- PLC, DCS, SCADA, SIS – roles & differences
- Typical control system architectures
- Stand-alone PLC
- PLC + SCADA
- DCS-based plant control
- Control loop fundamentals
- Sensors, transmitters, controllers, final elements
- Industrial standards & best practices
- ISA-95, ISA-88, IEC 61131-3
- Electrical & instrumentation basics refresher
- Analog vs Digital signals (4–20 mA, 0–10 V)
- Field wiring fundamentals
Industry Customization
- Oil & Gas: Process plants, compressor stations, metering stations
- Manufacturing: Production lines, packaging systems
- Power Plants: Boiler–turbine–generator control hierarchy
Practical / Workshop
- Identifying ICS components from real P&IDs
- Signal tracing from field device → controller → actuator
DAY 2 – PLC Systems & Field Integration
(Beginner → Intermediate)
Topics
- PLC hardware architecture
- CPU, power supply, I/O modules
- Digital & analog I/O interfacing
- Field instrumentation wiring
- 2-wire / 4-wire transmitters
- Motor starters & VFD interface
- PLC programming concepts
- Ladder Logic, Function Block Diagram
- Basic interlocks & permissives
Industry Customization
- Oil & Gas: Pump start permissives, ESD inputs
- Manufacturing: Conveyor interlocks, machine safety
- Power Plants: Boiler feedwater control signals
Practical / Workshop
- Wiring analog & digital I/O
- Programming start/stop logic
- Simulating field faults and troubleshooting
DAY 3 – DCS Concepts & PLC–DCS Interface
(Intermediate Level)
Topics
- DCS architecture & philosophy
- Controllers, I/O, engineering & operator stations
- PLC vs DCS – integration scenarios
- PLC–DCS communication methods
- Modbus RTU / TCP
- Profibus / Profinet
- Ethernet/IP
- Data mapping & tag management
- Alarm and event handling
Industry Customization
- Oil & Gas: PLC packages (compressors, metering skids) integrated into DCS
- Manufacturing: PLC machines reporting to plant DCS
- Power Plants: Balance-of-Plant (BOP) PLC integration
Practical / Workshop
- Configuring PLC–DCS communication
- Tag mapping and data verification
- Troubleshooting communication loss
DAY 4 – SCADA Systems & HMI Integration
(Intermediate → Advanced)
Topics
- SCADA system architecture
- Servers, clients, RTUs, PLCs
- HMI design principles
- High-performance graphics
- PLC/DCS to SCADA integration
- Communication protocols
- OPC DA / OPC UA
- Modbus TCP
- Alarm management & trends
- Data logging & reporting
Industry Customization
- Oil & Gas: Pipeline & tank farm SCADA
- Manufacturing: Production monitoring & OEE
- Power Plants: Substation & plant SCADA
Practical / Workshop
- Creating SCADA screens
- Real-time trending & alarms
- Linking PLC/DCS tags to SCADA
DAY 5 – Advanced Control, Safety & Troubleshooting
(Advanced Level)
Topics
- Advanced control strategies
- PID tuning (PLC & DCS)
- Cascade & ratio control
- Safety Instrumented Systems (SIS)
- SIL basics & interlocks
- Cybersecurity for ICS
- Network segmentation & best practices
- System troubleshooting methodology
- Field → PLC → DCS → SCADA
- Maintenance & system optimization
Industry Customization
- Oil & Gas: Process upsets, ESD trips
- Manufacturing: Downtime reduction strategies
- Power Plants: Load changes & trip analysis
Practical / Case Studies
- End-to-end fault diagnosis
- Communication failure recovery
- Final integrated project (PLC + DCS + SCADA)
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 Control Systems issued by Intellects Energy Ltd