Industrial Automation: Instrumentation and Control Systems

By the end of this course, you will be able to:

• Apply core instrumentation terminology, measurement principles, and relevant standards in industrial control environments
• Interpret pressure, level, flow, temperature, force, and torque measurements used in process control systems
• Identify the function of control system components, including sensors, transducers, controllers, actuators, and signal-conditioning devices
• Apply basic troubleshooting, calibration, and loop-tuning methods to support reliable system performance
• Explain how PLCs, communication protocols, and SCADA systems support industrial automation and process monitoring

Description

Industrial instrumentation and automation systems are central to safe, reliable, and efficient process operations. When measurements are inaccurate, control loops are poorly tuned, or system components are not properly understood, the result can be reduced performance, unnecessary downtime, and greater operational risk. Engineers, technologists, technicians, and automation professionals need a practical understanding of how instrumentation and control systems work together in real industrial environments.

This course develops that understanding through a structured review of measurement methods, control system fundamentals, signal conditioning, controller modes, troubleshooting principles, PLC standards, communication protocols, and SCADA applications. You will examine how instruments measure key process variables, how control loops respond to changing conditions, and how automation systems collect, process, and present operational data.

Rather than focusing on complex mathematics, this course emphasizes practical application. You will build the knowledge needed to select, interpret, maintain, and troubleshoot instrumentation and automation systems with greater confidence, supporting better decisions in commissioning, operations, maintenance, and process improvement.

Who This Course Is For

This course is designed for:

• Engineers, engineering technologists, and technicians involved in industrial instrumentation, automation, or process control
• Project engineers and project managers responsible for selecting, specifying, or overseeing control system equipment
• Maintenance, operations, and commissioning professionals who troubleshoot instrumentation and automation systems
• Supervisors of process automation systems and industrial control environments
• System integrators and OEM equipment professionals who work with PLCs, communication protocols, or SCADA systems
• Professionals seeking a practical, foundational understanding of instrumentation and automation without advanced mathematical treatment

Day I

Fundamentals of Industrial Instrumentation

• Introduction and evolution
• Systems and controlled systems benefit and historical trends
• Control loops: elements and their role
• Concepts and principles of instrumentation
• Static and dynamic characteristics of instruments
• Measurement units and standards

Methods of Measurement

• Pressure – Basic terms, formulas, measuring instruments, application and installation considerations
• Level – Formulas, devices, application and installation considerations
• Flow - Basic terms, formulas, measuring instruments, application and calibration considerations
• Temperature and Heat – Definitions, formulas, measuring instruments, reaction time and installation considerations
• Force and Torque – Definitions, measuring devices, strain gauges application

Engagement, Working Sessions and Quizzes

Day II

Control Systems Basic Elements

• Analog vs digital world, linearization, calibration
• Transducers
• Current and voltage amplifiers
• Signal Conditioning
• Regulators, valves and actuators

Signal Control and Controller Modes

• Definitions and system terms
• System functions
• Elements of a control system
• Open and closed loops
• Proportional, integral and derivative actions
• Loops tuning methodology
• ON/OFF and continuous control
• The digital world & binary system
• Logic gates

Measurements in Statistics

• Statistics, basic terms
• Measures of central tendency and variation
• Resolution / Accuracy / Precision / Sensitivity
• Basic Troubleshooting Principles

Engagement, Working Sessions and Quizzes

Day III

Industrial automation

• Controller Operation, Input/Output modules, scan modes
• IEC 61131-3 standard for PLCs
• Signal converters: Analog to Digital Conversion, Digital to Analog Conversion
• Communication Error Detection, Handshaking, Multiple Attempts
• Communication interface examples: HART, Modbus and Ethernet protocols

Supervisory control and data acquisition in Process Automation Systems (PAS)

• Engineering model for distributed automation and control
• Data processing and presentation tools
• Examples of Rockwell Automation industrial applications
• SCADA modules: visualization, databases, alarm handling, reports, logging and data archiving
• Diagnostics
• Fail-safe
• Fault tolerance

Engagement, Working Sessions and Quizzes