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The Instrumentation and Control System Design
Introduction
The Instrumentation and Control System Design course is crafted to prepare engineers and technical professionals for the process industry, oil & gas, power plants, and manufacturing sectors. It covers the selection, specification, and layout of instruments used for monitoring, measuring, and controlling industrial processes. The course includes practical exposure to control systems, PLCs, P&IDs, and DCS basics, alongside an understanding of international standards like ISA and IEC. Participants will gain both theoretical and practical knowledge, making them capable of executing and managing instrumentation projects with precision.
Modules and Content
Module 1: Basics of Instrumentation Engineering
- Introduction to instrumentation systems
- Types of process variables: pressure, temperature, flow, and level
- Signal types: analog, digital, pneumatic, and electrica
Module 2: Sensors and Transducers
- Working principles and selection of sensors
- Types of transducers used in industry
- Calibration procedures and accuracy standards
Module 3: Process Control Fundamentals
- Open loop vs closed loop systems
- Control strategies (P, PI, PID)
- Set point, control variables, and feedback mechanisms
Module 4: Control Valves and Actuators
- Types of control valves and their characteristics
- Pneumatic vs electric actuators
- Positioners, converters, and solenoids
Module 5: PLC and DCS Basics
- Introduction to PLC architecture
- Ladder logic and I/O mapping
- Overview of Distributed Control Systems (DCS)
Module 6: Piping and Instrumentation Diagrams (P&ID)
- Reading and preparing P&ID
- Instrument loop diagrams and legends
- Tagging conventions and drawing symbols
Module 7: Instrument Selection and Datasheets
- Criteria for selecting transmitters, gauges, and switches
- Preparation of instrument index and datasheets
- Vendor coordination and spec sheet review
Module 8: Control Panel Design
- Layout of control cabinets and junction boxes
- Wiring diagrams and termination drawings
- Cable schedules and gland plate design
Module 9: Field Instrumentation and Installation
- Hook-up diagrams and impulse tubing
- Mounting, calibration, and testing procedures
- Safety standards and ATEX/IECEx zoning
Module 10: Communication Protocols and SCADA Overview
- HART, MODBUS, PROFIBUS, and FOUNDATION Fieldbus
- Introduction to SCADA systems
- Real-time monitoring and control integration
Module 11: Standards and Compliance
- ISA, IEC, and ANSI instrumentation standards
- Documentation and inspection checklists
- Safety and SIL (Safety Integrity Level) concepts
Module 12: Final Project – Instrumentation Package Design
- Complete instrumentation design for a process plant unit
- Deliverables: P&ID, loop diagrams, control panel layout
- Presentation and report submission
Scope & Advantages
Instrumentation and Control professionals are in high demand across industries that rely on automation, safety, and precise process control. From oil refineries and chemical plants to pharmaceuticals, food processing, and power generation, the ability to design and manage control systems is a critical skill. This course empowers engineers to handle real-world challenges in instrumentation design, selection, installation, and maintenance, making them valuable contributors in any multidisciplinary engineering project.
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