Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Instrumentation Technicians
• Maintenance Engineers
• Plant Operators,
• Control Systems Personnel

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand the purpose and role of instrumentation in process control
• Learn about basic components, signal types, and system architecture
• Recognize the function of sensors, transmitters, controllers, and actuators
• Master techniques for installing and calibrating instrumentation devices
• Understand the importance of standards and documentation
• Use tools for proper calibration and record-keeping
• Learn how to isolate and resolve instrumentation issues
• Identify common failure causes and symptoms
• Use diagnostic tools effectively
• Understand different maintenance philosophies
• Design and implement preventive maintenance programs
• Analyze and minimize downtime
• Apply relevant industry standards (ISA, IEC)
• Ensure safe work practices during instrumentation tasks
• Collaborate on solving real-world instrumentation problems

DAY 1

Introduction to Instrumentation Systems and Components

• Pre test
• Overview of Industrial Instrumentation

• Role in automation and process control
• Safety and reliability considerations

• Key Components and Signal Types

• Sensors, transducers, transmitters, control valves, actuators
• Analog vs. digital signals, 4–20 mA, HART, FOUNDATION Fieldbus

• Basic Measurement Principles

• Pressure, temperature, flow, level, analytical

• Introduction to Control Systems

• PLC, DCS, SCADA basics

• Case Study

DAY 2

Installation, Calibration, and Documentation

• Instrumentation Installation Best Practices

• Cabling, grounding, shielding, sensor placement

• Calibration Procedures and Tools

• Zero/span, as-found/as-left values
• Calibration equipment and reference standards

• Loop Checking and Commissioning
• Instrument Documentation and Drawings

• Loop diagrams, hook-up diagrams, datasheets

• Case Study

DAY 3

Troubleshooting Techniques and Common Instrumentation Failures

• Systematic Troubleshooting Approach

• Symptoms → Root cause analysis
• 5 Whys, fault tree analysis

• Common Instrumentation Problems

• Signal loss, drift, grounding issues, noise

• Using Multimeters, Calibrators, Loop Testers

Working with Smart Instruments (HART/Fieldbus)

• Using handheld communicators and asset management software

• Case Study

DAY 4

Maintenance Strategies and Preventive Programs

• Types of Maintenance

• Preventive, predictive, corrective, condition-based

• Developing a Preventive Maintenance (PM) Program

• PM checklists, schedules, documentation

• Condition Monitoring Techniques

• Diagnostics, self-checking instruments, signal trend analysis

• Spares Management and CMMS Integration
• Case Study

DAY 5

Safety, Standards, and Case-Based Troubleshooting

• Instrumentation Safety and Best Practices

• Lockout-tagout (LOTO), hazardous areas (Ex-proof), grounding

• Applicable Codes and Standards

• ISA, IEC, ISO for instrumentation and calibration

• Case Studies
• Final Review and Group Exercise
• Post-test