Advanced Automation training

advanced automation

Automation is one of the fastest growing segments in the field of Process industries like Refinery, Chemical, Oil & Gas, Bottling Plants, Food Processing and many more. Instrumentation & control is the most important development in modern technology. The control system is adaptable, flexible and is universally applied with defined response time, service aids and expandability.

Who need this training

The training is specifically for Engineers, technologist and technicians, plant manager, supervisors as well as those with science background.

Our training is strictly practical hands on and covers the following area

1) Programmable Logic Controllers (PLC)

2) Field Instrumentation

3) Supervisory Control and Data Acquisition (SCADA).

5) Human Machine Interface (HMI)

4) Industrial Networking

6) Distributed Control System (DCS)

7) Electrical motor drive (VFD/DC Drive/Soft Starter)

8) Safety Instrumented System

9) Automation Database administration, Cyber Security & System maintenance

10) Automation Project Management

PLC Course Module

Module I: Introduction to PLC

  • Basic concept of automation
  • PLC definition, evolution, advantage and application
  • PLC system types, brands and product series
  • Overview and physical examination of various PLC brands (eg Siemens, AB, Delta, Omron, etc)
  • Practice and exercise

Module II: PLC Hardware and Software

  • PLC System Hardware Components (PLC system, signal cables, adapters, etc)
  • PLC internal Architecture
  • PLC software overview (Simatic step 7 & TIA Portal, Micrologix 1000, RSlogix 500 & RSlogix/studio 5000, Melsoft, wplsoft, wprolad, CX one, etc)
  • Practice and Exercise

Module III: Input and output Devices

  • Concept of sensors
  • PLC Input devices (Limit Switches, Proximity switches, Photo sensors, encoders, pressure switches, temperature switches, Transmitters, etc)
  • PLC output devices (AC/DC motors, Stepper/Servo Motors, Contactors, Drives, Relays, control valves, solenoid, Lamps, etc)
  • Practice and exercise

Module IV: PLC Input/output processing and wiring

  • PLC Input/output unit data processing (concept of sourcing and sinking, Opto isolator, ADC & DAC, Relays, Transistor, Triac, etc)
  • Signal conditioning (practical consideration of discrete and analog signal conditioning)
  • Interfacing Input/Out devices with PLC input/output unit (load matching calculation and signal isolation with contactors, relays, etc)
  • Wiring Input/Out devices to PLC (discrete wiring of NPN, PNP, two and multi-wire sensors, Analog wiring of two and multi-wire transmitters, current loop design, hardware-software scaling, etc
  • PLC remote connection and networking
  • PLC scan time and addressing
  • Practice and exercise

Module V: PLC programming

  • Relay logic programming and practical relay wiring (programming and wiring up discrete relay, Timer, counter, etc on a control panel)
  • Introduction IEC 61131-3 standard (LD, FBD, IL, SFC and ST)
  • Review and practical programming on the standard IEC 61131-3 programming languages__ Ladder logic (LD), Function Block Diagram(FBD), Sequential Function Chart (SFC), Instruction List(IL), Structured Test (ST)
  • Downloading/uploading PLC programs
  • Practice, Simulation and Exercise

Module VI: Advanced PLC programming

  • Creating of user defined function, function block and program subroutines
  • creation of complex program using two, three, four or all the five IEC 61131-3 programming languages and calling them as subroutines/blocks
  • Analog signal programming(scaling, bit resolution, loss of resolution/signal and hardware-software scaling, floating point IEC 60559 math and its limitation in terms of precision in storing large analog values)
  • programming process control strategies (PID, ratio, cascade, feed forward, multi-loop, etc.)
  • programming for motion control( PWM, VSD, high speed counter, etc)
  • Other advanced concept( interrupt routines, IOT, etc)
  • Practice, simulation and exercise

Module VII: Practical PLC Systems design, Installation and maintenance

  • Program development from control narrative
  • steps in PLC system design
  • PLC system installation steps and commissioning
  • PLC safety (concept of fail-safe, Safety programming, Hardwired programming, SIF SIS, SIL, HAZID, HAZOP, etc)
  • PLC system Documentation
  • PLC fault finding and troubleshooting ( Forcing Input/output, Testing, etc)
  • Practice, simulation and exercise

Module VIII: Practical Industrial Application program

  • Oil and gas (Flow, level, pressure, temperature control, totalizers, phase separators, compressor control, etc)
  • Manufacturing (Batch process, motion control process with servo and stepper motor, Robotic control systems, etc)
  • Power (gas turbine protection control system, transmission/distribution system protection, etc)
  • Facility/building Automation (lighting system control, HVAC, Annuciators, etc)
  • Practice and exercise

Available PLC brand for training:
Siemens PLC
Allen Bradley PLC
Delta PLC
Koyo PLC
Mitsubishi PLC
GE Fanuc PLC
Fuji PLC
Schneider Electric PLC
Omron PLC
Keyence PLC

Supervisory Control And Data Acquisition (SCADA).

Course Modules

Module I : Introduction to SCADA System

  • SCADA System Definition, Evolution and application
  • SCADA System Architecture
  • SCADA System Comparison with other control System
  • SCADA Software Overview
  • Practice and Exercise

Module II: SCADA System Configuration and programming

  • SCADA Software Installation and configuration
  • Creating Application with SCADA
  • Creating Database of Tags
  • Creating & Editing graphic display with animation (filling, sizing, blinking, etc)
  • SCADA scripting
  • SCADA Communication with Hardware/software (concept of OLE, OPC, etc, VB, Excel, etc)
  • Practice and Exercise

Module: III Trends, Alarm, Event and Report

  • Creating Alarm and Event
  • Real Time and Historical Trends
  • Real time project development with PLC interfacing
  • Report generation
  • Fault diagnostic and error handling
  • Practice and Exercise

Module IV : SCADA Communication System

  • SCADA Network Architecture
  • ISO/OSI reference model and network protocol
  • Field buses (Profibus, FF, Modbuses, DeviceNET, etc)
  • Live set up of communication fieldbus network with PLCs, PCs, HMI and field instruments
  • Troubleshooting communication error
  • Sorting communication problems
  • Practice and Exercise

Module V: SCADA System Security

  • Overview of SCADA System vulnerability
  • Access to different security level
  • SCADA System Security control Methods
  • Designing a security proof SCADA system
  • Practice and Exercise

Available Software for SCADA Training

FactoryTalk SE
Wonderware Intouch
winCC Professional

Human Machine Interface (HMI)

Module 1 : HMI Introduction

  • HMI definition, Advantage and Application
  • HMI evolution and brands
  • HMI system overview
  • HMI Architecture
  • Field control Station and Human interface station overview
  • Practice and exercise

Module II: HMI configuration

  • Creating screens/slides
  • Configuring Images and Object
  • Operation of Standard display panel
  • Live Interfacing with PLC
  • Practice and Exercise

Module III : configuring control and monitoring parameters

  • Alarm configuration and process alarm management
  • Historical and System Status Display
  • Tuning parameter display and description
  • Real time graphics display feature
  • Feedback control
  • Practice and exercise

Available HMI Hardware
Allen Bradly

Industrial Networking

Module I:  Introduction to Industrial networking

  • Industrial networking History and advantage
  • Basic networking general overview
  • Industrial network architecture
  • Industrial network hardware and software overview
  • Practice and exercise

Module II: Industrial Network Protocol

  • Digital Data acquisition and transmission media
  • Chanel arbitration (Token passing, Master Slave, CSMA, CSMA/DC, TDMA
  • ISO/OSI reference model
  • Industrial Network standards
  • Field buses (FF, Profibus, profinet, Modbus, CANBUS, EtherNET/TCP, ControNET, etc)
  • HART digital/analogue hybrid communication standard
  • Practice and exercise

Module III:  Practical set up of industrial network

  • Practical session on etherNET, Modbus and Profibus industrial protocol implementation
  • Hardware connection details
  • Network configuration and addressing
  • Communication management
  • Sharing and accessing data on network
  • Practice and exercise

Module IV:  Industrial Network troubleshooting and maintenance

  • Common network issue
  • Steps in diagnosing network problem
  • Preventing network problem
  • Shielding, grounding, and other means of noise reduction
  • Practice and exercise

Distributed Control System (DCS)

Module I:  Introduction to DCS

  • DCS definition, Evolution, advantage and application
  • DCS system overview and Architecture
  • Controllers, I/O cards, control network, power supply, etc.
  • Field control and Human interface stations
  • Practice and exercise

Module II:  Design and configuration of DCS systems

  • DCS hardware set up with PC, Controllers, etc.
  • Peripheral Device connectivity
  • Human Interface Station configuration
  • Field Control Station Configuration
  • Field Wiring Schematics for analogue and digital Signals
  • Practice and Exercise

Module III: DCS Application Development

  • Software Installation and GUI configuration
  • Program development with Sequential Function chart
  • Display Scripting
  • Alarm management and process
  • Process and Trend recording display
  • Practice and exercise

Module IV : DCS Communication System

  • DCS Network Architecture
  • ISO/OSI reference model and network protocol
  • Field buses (Profibus, FF, Modbuses, ProfiNET, ControlNET, DeviceNET, etc)
  • Live set up of fieldbus network
  • Redundancy in DCS systemS
  • Troubleshooting communication error
  • Sorting communication problems
  • Practice and Exercise

The Training will cover the following DCS Systems/Vendors
Yokogawa Centum VP/3000
Emerson Delta V
Honeywell Esperion

Safety Instrumentation System

Module I: Instrumentation Safety Overview

  • Safety Instrumentation standards (IEC 61508 & 61511, ANSI/ISA s48.01, TÜV Rheinland, etc)
  • Safety Protection layers
  • SIL and SIS factor
  • Hazard and risk analysis (PHA, HAZOP, PSA, etc)
  • Safety Life cycle
  • Practice and Exercise

Module II: SIS system overview

  • SIS Architecture
  • Hardware set up and installation
  • Communication and Network design
  • Hardware testing and diagnostics
  • Practice and exercise

Module III: Application Development and programming

  • Application development guideline
  • Programming methods
  • Graphics development
  • Analogue and digital voters
  • Cause and effect matrix
  • Commissioning
  • Practice and exercise

The Industrial Instrumentation Safety Training will cover the following safety Systems/vendors
DeltaV SIS by Emerson
Triconex by Schneider Electric
Honeywell Safety manager
Prosafe by Yokogawa Electric Corporation
Hima Safety PLC

Industrial motor control VFD/DC Drive/Soft starter

Module I: Basic operating principle of Electric motor and control

  • DC and AC motors components and operating principle
  • Type of Motors , construction and their operating principle
  • Basic terminology associated with motors, control and drives
  • Electric symbol, power and control diagrams
  • Practice and exercise

Module II: Methods of starting Industrial Motor

  • Basic principle of starters and variable speed drives.
  • DOL, Star Delta, Auto transformer starters and detailed panel wiring
  • Soft starters
  • Different types of Drives- Variable Frequency, Variable Voltage, and DC drive
  • Drives advantage
  • Practice and exercise

Module III: Variable Frequency Drive (VFD)

  • Different control mode Of VFD
  • Discrete and Continuous control schemes
  • Effect of long distance cables on VFDs
  • Selection of VFDs based on application
  • VFD parameterization/configuration
  • Hands on experience on integrated system
  • Practice and exercise

Field Instrumentation
Course Module

Module I:  Industrial field Instrumentation overview

  • Field Instrumentation definition, Evolution and application
  • Field Instrument overview and type
  • Process control and feedback control system
  • Proportional, Integral and Derivative control (PID control tuning)
  • Reading and interpreting P&ID, PFD, loop sheet, etc.

Module II: pressure Instrument and measurement

  • Pressure measurement Techniques
  • Pressure sensing element and types
  • Pressure, transmitter configuration
  • Pressure Instrument calibration
  • Practice and exercise

Module III: Level Instrument and measurement

  • level measurement Techniques
  • level sensing element and types
  • Level, transmitter configuration
  • Level Instrument calibration
  • Practice and exercise

Module IV: Temperature Instrument and measurement

  • Temperature measurement Techniques
  • Temperature sensing element and types
  • Temperature transmitter configuration
  • Temperature Instrument calibration
  • Practice and exercise

Module V: Flow Instrument and measurement

  • Flow measurement Techniques
  • Flow sensing and types
  • Flow transmitter configuration
  • Flow Instrument calibration
  • Practice and exercise

Module VI: Other Process Instrument and measurement

  • Analytic measurement Techniques (Gas, PH and chemical concentration analyzers)
  • Analyzer sensing types and configuration
  • Vibration measurement Techniques
  • vibration probes and there principle of operation
  • overview of Bentley Nevada for vibration monitoring
  • Practice and exercise

Module VII: Final control Element/actuators

  • Control Valve (Globe, Butterfly, ON/OFF, etc)
  • Actuators (Pneumatic, hydraulic, Electric)
  • Valve characteristics and petitioners
  • Variable speed pump, motor control, etc
  • Practice and exercise

Module VIII: Field instrument integration with control systems

  • Practical session on interfacing field devices with control system
  • 375/475 Filed Communicator set up and configuration
  • Field instrument maintenance
  • Practice and exercise

Automation Database administration, Cyber Security & System maintenance
Course Module:

Module I Introduction

  • Database types, structure & design
  • The general reviews of Ms Utility Application for system administration (Bios, Prompt cmd, User, Task Manager, Registry, and Policies etc.
  • Review of industrial network security issues, network vulnerability and attack technologies
  • The computer system Hardware & software review
  • practice and exercise

Module II Server administration in automation

  • Servers and types of severs
  • Database server client Model
  • Database query language (Ms sql, Mysql, Access, Oracle, etc.)
  • Ms sql server, Opc classic /UA
  • Creation of MS sql database
  •   How to use MS sql Management studio & sql transaction codes to create & maintain database.
  • Practice and exercise

Module III Automation Cybersecurity

  •  Industrial network Vulnerabilities and Hardening Techniques(network separation, segmentation, perimeter protection, etc )
  • practical industrial network cybersecurity architectural setup (DMZ, firewalls, VPN, etc )
  • Configure a managed switch/router/firewall/VPN for the plant floor
  • Building a Secure Plant Floor Web Server:  HTML | XML | Methods to Enhance Security
  • antivirus, firmware updates and access control management techniques for industrial cybersecurity
  • Practice and exercise

Module IV System maintenance

  • System hardware component overview and cloning
  • understanding system hardware/software compatibility
  • System Image backup / clone & Recovery
  • System Virtualization tools/Iso Image creation (Vmware, Vbox, Acromis, etc)
  • Troubleshooting Systems hardware and software issues
  • Practice and exercise 

Automation Project Management
course Module
Module I Introduction

  • Automation project type, advantage and justification
  • project management tools and techniques(PM software, PERT, CPM, Gant etc )
  • Project planning , execution and closeout
  • Practice and exercise 

Module II Project management life cycle

  • Automation Conceptual studies and pre-engineering design/FEED (control philosophy, FDS, etc )
  • Automation detailed engineering design, procurement and project execution (special software design tools: intools smartplant, Aveva Instrumentation, etc)
  • Factory and Site acceptance tests (FAT & SAT)
  • Automation projection commissioning and startup (OTP, documentation, etc )
  • Practice and exercise 

Duration: 240hrs/12weeks

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