Certified Automation Engineer


In recent times automation is increasingly taking over the industrial production systems and processes prompting a high demand for skilled automation engineers and technicians. Many industrial production systems and processes that were once manually run are now mostly automated. There is hardly any well established industry that does not employ automation in one form or the other. For instance, in the oil and gas industry automation is employed to control the flow, level, etc of petroleum product in a process control system. In the bottling industry automation is employed in the filling, cocking and packaging processes. In the power industry automation is normally deployed and utilized in the monitoring and control of power system parameters. The list goes on to include petrochemical, pharmaceutical, Food & beverage, packaging, automobile, chemical, Robotics, Marine, Agricultural, utility, Telecommunication, etc. in fact, it is projected in the business circle that a time will come when industrial production system and processes will be completely automated thus making  automation personnel kings in the industry­­­­­­­­­­­­­­­­­­­­­­­­­­­­­­. This trend no doubt is catching up with the times faster than expected.

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

Programmable Logic Controllers (PLC)

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 (Semantic step 7, RSlogix, 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 etc)
  • PLC output devices (motors, Relays, 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
  • Interfacing Input/Out devices with PLC input/output unit
  • Wiring Input/Out devices to PLC
  • 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, etc on a control panel)
  • Introduction to 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: Practical PLC Systems design

  • Program development from control narrative
  • PLC fault finding and troubleshooting
  • PLC commissioning ( Forcing Input/output, Testing, etc)
  • PLC safety (concept of fail-safe, HAZID, HAZOP, SIS, etc)
  • PLC system Documentation
  • Practice, simulation and exercise

Module VII: Practical Industrial Application program examples

  • Temperature control
  • Automatic Process control
  • Robotic control systems
  • Valve sequencing
  • Practice and exercise

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

Supervisory Control And Data Acquisition (SCADA).

Module I : Introduction to SCADA System

  • SCADA System Definition, Evolution and application
  • SCADA System Architecture
  • SCADA System Comparism 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 and Event

  • 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
win cc

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

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 profinet, 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 Instrumented System

Module I: Instrumentation Safety Overview

  • Safety Instrumentation standards (IEC 61508 & 61511, ANSI/ISA s48.01, 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
Triconex by Schneider Electric
Prosafe by Yokogawa Electric Corporation
DeltaV SIS by Emerson
profisafe by Siemens

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)/converters

  • 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 VI: Flow Instrument and measurement

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

Module VI: 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 VII: 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

Duration: 200hrs/12weeks

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