Instrumentation and Control Design – Process Measurement & Automation Engineering

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Introduction

This course offers in-depth training in the design and integration of instrumentation systems used for process measurement and control. It equips learners with essential knowledge in selecting instruments, configuring control loops, interpreting P&IDs, and understanding control system architecture. Ideal for industries such as oil & gas, petrochemicals, power, pharmaceuticals, and water treatment, this course prepares professionals for roles in engineering design, maintenance, and automation.

Modules and Content

Module 1: Fundamentals of Instrumentation
  • Role of instrumentation in process industries
  • Basics of process variables: pressure, temperature, level, flow
  • Units, calibration, and signal types (4-20mA, HART, digital protocols)
  • Selection criteria for pressure, temperature, flow, and level sensors
  • Working principles: RTD, Thermocouples, DP transmitters, Ultrasonic, Radar
  • Mounting, installation, and calibration practices
  • Valve types and characteristics (globe, ball, butterfly, )
  • Actuator types (pneumatic, electric, hydraulic)
  • Control valve sizing and selection
  • Open-loop and closed-loop control
  • PID controllers and tuning basics
  • Distributed Control Systems (DCS) and PLC-based control
  • Process control strategies
  • Single-loop and multi-loop control
  • Loop diagrams and functional logic
  • P&ID (Piping and Instrumentation Diagrams)
  • Loop diagrams, hook-up drawings, instrument index
  • ISA standards and symbology
  • Cable selection, routing, and termination
  • Junction boxes, cable trays, grounding, and shielding
  • Panel layout and wiring practices
  • HART, FOUNDATION Fieldbus, Modbus, Profibus protocols
  • Integration of field instruments with PLC/DCS
  • Addressing, tag allocation, and mapping
  • Instrumentation in safety systems
  • SIS (Safety Instrumented Systems) and SIL (Safety Integrity Level)
  • ESD, fire & gas detection integration
  • Design a complete instrumentation system for a process plant
  • Selection, wiring, loop development, and documentation
  • Preparing bill of materials and cost estimation

Scope & Advantages

Instrumentation and control engineers play a vital role in the safe and efficient operation of any process-driven industry. With increasing automation and digitization, expertise in instrument selection, loop control, and system design is in high demand. This course enhances employability in industries such as oil & gas, petrochemicals, pharmaceuticals, power, and food processing, with strong global career prospects.

Reference

  • “Piping Handbook” by Mohinder L. Nayyar ,
  • “Process Piping: The Complete Guide to ASME B31.3” by Charles Becht IV,
  • “Pipe Stress Engineering” by Liang-Chuan Peng and Tsen-Loong Peng
  • “Piping Design Handbook” by John J. McKetta Jr.
  • “The Planning Guide to Piping Design” by Richard Beale and David R. Sherwood