Industrial Automation & Control – IAC

What you will learn

At the end of this program, you will confidently be able to:

• Industrial control panel design and wiring
• Industrial sensors and process instrumentation
• Siemens PLC programming and analog scaling
• HMI and SCADA development
• VFD programming and PLC integration
• Industrial Ethernet, Profinet, and Modbus communication
• System commissioning and fault diagnosis
• Complete industrial automation project development

Course Outline

Module 1: Industrial Safety and Automation Fundamentals

• Electrical safety in automation systems
• Lockout and Tagout procedures
• Emergency stop systems
• Machine safety basics
• Safe use of control voltages
• Industrial automation system overview
• Hazard identification and risk assessment
• Introduction to HAZID
• Introduction to HAZOP
• Introduction to Safety Instrumented Systems (SIS)
• Safety Integrity Level (SIL) awareness

Module 2: Industrial Controls, Circuit Design and Motor Systems

Part A: Electrical Symbols and Standards

• Why diagrams are the language of control
• NEMA and IEC symbols compared
• Push buttons
• The four basic switch symbols (NO, NC, NOHC, NCHO)
• Sensing device symbols
• Selector switch symbols and truth tables
• Coil, contact, timer, and overload symbols
• Contact numbering & identification techniques
• Device letter codes (K, Q, F, S, H, M, B)

Part B: Digital Logic for Control Circuits

• Logic gates and truth tables
• From logic gates to relay contacts (series, parallel, and NC logic)

Part C: Control Components

• Relays and contactors (coil, load, and auxiliary contacts)
• AC and DC control (24VDC and 230VAC)
• On-delay and off-delay timers
• Overload relays, safety relay and solid state relay
• Fuses, MCBs, and MCCBs: short circuit vs overload protection
• Proximity sensors

Part D: Control Systems and Diagram Types

• Manual, semi-automatic, and automatic control
• Types of Control Daigrams
• Power circuit vs control circuit

Part E: Control Diagram Thinking Techniques

• Understand the process before drawing
• Write a simple control narrative
• List all inputs and outputs
• Break the task into steps (sequence table or timing chart)
• Find the start and stop conditions for every output
• Self-holding (latching) circuits
• Electrical and mechanical interlocking
• Stop and safety first: fail-safe design
• Emergency stop circuit design
• Permissives and trips
• Using timers in control logic
• Status lamps and alarm indication
• Building the circuit line by line and testing on paper
• “What if” checks: testing the design against faults

Part F: Diagram Drawing and Referencing

• Line referencing
• Numerical cross referencing
• Wire numbering and wire referencing
• Terminal numbering and terminal schedules
• Device tagging
• Title block and revision control
• Panel layout drawings
• Drawing with design software

Part G: Motor Starting Circuits

• Motor nameplate reading and motor selection
• DOL starter with ON/OFF/TRIP lamps
• Forward and reverse with electrical interlock
• Star delta starter
• Soft starter (introduction)
• Motor insulation testing (megger)

Part H: Control and Automation Tasks (Design and Build)

• Switch on after delay (on-delay and off-delay timers)
• Sequential motor starting (manual and automatic)
• Jogging control with selector switch
• Local and remote control
• Manual/Off/Auto (MOA) control
• Over-travel control with limit switch and proximity sensor
• Pulse counting with proximity sensor
• Water level control with float switch
• Three-pump alternating control
• Automatic reversing conveyor
• Conveyor with timed delay and stop conditions
• Control panel wiring from your own drawings
• Step-by-step troubleshooting with a multimeter and drawings

Module 3: Industrial Instrumentation and Process Signals

• Reading P&IDs and instrument tag numbers (ISA standard)
• Loop diagrams and instrument datasheets
• Pressure, temperature, level, and flow measurement
• Process transmitters wiring
• PT100 sensors and temperature transmitters
• Thermocouples and cold junction compensation
• 4–20mA and 0–10V signals
• HART communication and HART communicator use
• Instrument calibration and calibration records
• Loop checking and signal troubleshooting

Module 4: Process Control and Final Control Elements

• Open loop and closed loop control
• On/off control and hysteresis
• PID control: P, I, and D explained
• PID tuning methods (manual and Ziegler–Nichols)
• Cascade and ratio control basics
• Control valves: types, parts, and selection
• Valve actuators and positioners
• Solenoid valves and pneumatic systems
• Practical: pressure or level control loop

Module 5: Siemens PLC Programming Fundamentals

• PLC hardware: CPU, power supply, and I/O modules
• S7-300 PLC with SIMATIC Manager (STEP 7)
• S7-1200 PLC with TIA Portal
• Project setup and hardware configuration in both software
• Digital input and output wiring to the PLC
• Ladder logic programming
• Function Block Diagram (FBD)
• Timers, counters, and interlocks
• Memory bits, tags, and addressing
• PLCSIM simulation and online monitoring
• Uploading, downloading, and program backup

Module 6: Advanced PLC Programming and Analog Control

• Data Blocks and Function Blocks
• Functions (FC) and reusable code
• Structured Control Language (SCL) basics
• Analog input and output configuration
• Signal scaling and process control logic
• PID control in the PLC
• Sequence control and step logic
• Alarm and fault handling in the PLC
• Diagnostics, error codes, and safe forcing
• Program structure and good coding practice

Module 7: HMI, SCADA and Process Visualization

• HMI screen development
• PLC to HMI communication
• Buttons, indicators, and animations
• Screen navigation and faceplates
• User login and security levels
• Alarms, trends, and recipes
• Alarm management basics
• SCADA system development (WinCC)
• Historical data logging
• Reports and data export to Excel
• Remote access to SCADA

Module 8: VFD and Motor Drives

• How a VFD works
• VFD wiring and parameter configuration
• Motor data setup and auto-tuning
• Speed control by keypad, analog signal, and fieldbus
• PLC and HMI control of VFDs
• Braking resistors and ramp settings
• Harmonics, EMC, and cable practices
• VFD fault codes and troubleshooting

Module 9: Industrial Networking and Communication

• Network basics: IP addressing and subnets
• Ethernet and Profinet communication
• Modbus RTU and Modbus TCP
• Profibus basics
• OPC UA introduction
• PLC to PLC communication
• PLC redundancy setup
• Remote I/O setup
• Industrial switches and router configuration
• Basic OT cybersecurity
• Communication troubleshooting

Module 10: Final Industrial Automation Project and Commissioning

• Automation system design
• Control narrative development
• I/O list and bill of materials
• Field wiring and panel assembly
• PLC, HMI, VFD, and instrument integration
• Factory Acceptance Test (FAT) and Site Acceptance Test (SAT)
• System testing and commissioning
• Fault diagnosis and project documentation
• Final project presentation and assessment

Assessment: Weekly practicals, a written test, and a final project.

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