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MODULE1: PROGRAMMABLE LOGIC CONTROLLER (PLC)

1) Introduction to Industrial Automation System

2) PLC Components & Control Strategy

3) PLC Hardware Configuration & Architecture

4) Types of PLC and Communication Cable

5) Basics of Input /Output Devices & I/O Listing

6) Selection Criteria of PLC System

7) CPU Sizing & I/O Mapping

8) Process condition & Control Philosophy

9) Logic diagram & Control Strategy

10) Scan Cycle & Scan time

11) Relay based logic diagram(Concept of NO-NC)

12) Basics of Programming Software

13) Addressing Concept & Data Files/Function Blocks

14) Programming Languages & Basic Instructions

15) Upload / Download / Monitoring of programs

16) Read / Write Instructions, AND-OR logic & Set Reset function

17) Logic gates & Flipflop Programming

18) Concept of Latching/Holding & Programming

19)Concept of Interlocking & Programming

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20)Compare / Move & Math Computing Blocks instructions

21)Timer & Counter function Programming

22) Digital Signal Interfacing Techniques

23) Analog Signal Interfacing Techniques

24) Concept of Scaling & Calibration.

25)Communication with SCADA Software

26) Control Wiring & Connection diagram

27) Process Simulation & Testing techniques

28) System Installation & Configuration techniques

29)System Integration techniques

30)Fault finding & Troubleshooting techniques

31)Hands on experience on real time applications

31) Standard Practices/Procedure for System Maintenance

NOTE: AB/SIEMENS/MITSHUBISHI
/DELTA/OMRON/MODICON/HOLLYSIS/ABB/GEFANUC/SCHNEIDER/KOYO………………… Etc

MODULE 2: SUPERVISORY CONTROL & DATA ACQUISITION SYSTEM

(SCADA)
Introduction to SCADA Software

Fundamentals of Industrial Monitoring System

Types of Tag & Tag Initialization

Creating & Editing Control Graphic display

Process Alarms & Events

Process Trends (Real & Historical)

Recipe Management System

SCADA Communication with PLC

Data Base (MS EXCEL) Interface

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Net DDE Communication

Remote Monitoring System

Process Simulation & Testing techniques

System Installation & Configuration techniques

System Integration techniques

Hands on experience on real time applications

Fault finding & Trouble shooting techniques

Standard Practices/Procedure for System Maintenance

NOTE: INTOUCH/RSVIEW /FACTORY TALK/FACTORY IOS/ /VIJEO CITECT……………………………….Etc

MODULE 3: HUMEN MACHINE INTERFACE (HMI/MMI)

Introduction to Human Machine Interface

. SCADA Vs HMI/MMI

. System Tags Initialization & Implementation

. Creating & Editing Control Graphic display

. Upload / Download & Process Monitoring

. PLC Interface & Communication

. Process Alarming & Messaging

. Secondary Control & Local Monitoring

. Process Simulation & testing

. System Installation & Configuration

. System Integration techniques

. Hands on experience on real time applications

. Fault finding & Trouble shooting techniques

NOTE: PANEL BUILDER/CCW/TIA/WINCC FLEXIBLE/VIJEO DESIGNER/GT WORKS …………..Etc

MODULE4: FIELD INSTRUMENTATION & CONTROLS

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? Introduction to Instrumentation System

? Basics of Field Instrumentation & Controls

? Sensors Vs Transducers

? Basicsofsensors & measuring instruments

? Process condition & Control Strategy

? Control Philosophy & Logic diagram

? Control loop diagrams

? Analog & Digital Signal Interfaces

? Input & Outputs Device & I/O listing

? Basics of Interfacing/Communication

? Point Scheduling & I/O Summary

? Measurement with Temp/Pressure/Level /Flow/Position/Weight Sensing Elements

? Basics of Transmitters , Switches & Gauges

? General Indications (Ammeters, Voltmeters, GM ,PF & KW meters)

? Instrument transformers (CT, VT)

? Basics of Valves & their types

? Process controllers (On-off, Proportional ,PID)

? System Integration and interfacing techniques

? Wiring of field Instruments & Installation techniques

? Fault finding & Troubleshooting techniques

MODULE 5 :INDUSTRIAL NETWORK & DATA COMMUNICATION

? Introduction to Process Network System & Standards

? Network Topologies & their limitation

? Concept of Nodes, Ports, Drivers, baud rate, Hardware Address

? Communication Protocol with RS232,RS422,RS423,RS485

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? Network Protocol with DF1,DH+,DH485 , PPI /MPI, Ethernet

? Network Configuration and wiring techniques

? Network Communication with Field device

? System Installation & System Integration

? Hands-on practical Exposure in Industrial Networking

? Fault Diagnostics & Network Troubleshooting

MODULE 6: ELECTRICAL MOTION & MOTOR CONTROLS

? Introduction to Electrical motion & Analysis

? Fundamental of Electrical Motors & Controls

? Types of Electrical Motor & Components

? Basics of AC Motors, Operations & Principals

? Operational Criteria of Electrical Motors( Induction/Servo/Stepper)

? Motor Characteristics & Analysis

? Drawbacks of Induction Motor

? Motion Control techniques with hard starters

? Concept of RLC Circuits

? Soft starters & their advantages over conventional starters

? Basics of Motor Starters: DOL, RDOL, Star-Delta, Auto Transformer

? Advantage of Electrical Motor Starters & Operational Limitation

? Power Circuit diagram & Control circuit diagram analysis

? Basics of Electrical Interface & PLC Controls

? Motor control circuits, Interlocking, Inching , forwarding & reversing etc

? System Installation & Integration techniques

? Fault finding & Troubleshooting techniques

? Hands on experience on real time applications

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? Standard Practices/Procedure for System Maintenance

MODULE 7 : VARRIABLE FREQUENCY DRIVE (VFD)

? Introduction to Drives & their types

? Basics of Soft starters & limitation

? VFD advantages over conventional starters

? Selection Criteria of AC Drives

? Basics of AC Drives & Its Applications

? Power Saving technique & PWM Implementation

? V/Hz Control & Analysis

? Basic Programming Parameter

? Main function & parameterization of VFD

? Different control modes of Drives

? VFD Communication with PLC

? Wiring diagram of field devices with Drive

? Basic VFD Programming

? Process Simulation & hardware Integration

? System Installation & Configuration

? Fault finding & Troubleshooting techniques

NOTE: AB/ SIEMENS/MITSHUBISHI /DELTA /OMRON/MODICON/L&T

/ABB/GEFANUC/SCHNEIDER/DANFOSS…………..Etc

MODULE 8: PANEL DESIGN & ELECTRICAL SWITCHGEARS

? Introduction to Industrial Electrical Panel

? Types of Electrical Panel & Accessories

? Fundamental of Electrical Switchgears

? Details of Relay & Contactors

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? Basics of Circuit breakers & Isolators

? Selection Criteria of Electrical Cable

? Basics of Distribution boards (DB’s)

? Selection of Switches and Sockets

? Isolators, Bus ducts ,switch board & socket outlets

? Electrical Earthing /Grounding System

? Power Factor Improvement Techniques

? Load management /load factor(Running & Connected load)

? Basics of Power Supply ,Push Button & Switches

? Basics of Ammeters, Voltmeters, PF & KW meters

? Bus Bar sizing & Line Termination

? Panel Installation Techniques & Operational Guidelines

? Hardware Integration & Connection Diagrams

? Electrical Protections & Safety Consideration

? Hands on experience on Control Panel

? Fault finding & Troubleshooting techniques

MODULE 9: DISTRIBUTED CONTROL SYSTEM (DCS)

? Introduction to Distributed Control System

? DCS Components & Accessories

? DCS Vs PLC & their Advantage

? Basics of Bus Redundant System

? DCS Components & Control Strategy

? DCS Hardware Configuration & Architecture

? DCS Hardware Processor

? Concept of PAC System

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? Addressing Concept & Data Files

? Basics of Input /Output Smart Devices & I/O Listing

? Selection Criteria of DCS

? Basics of DCS Programming Software

? DCS Program Development & Application

? Programming Languages & basic Instructions

? Control Wiring & Troubleshooting Techniques

? Communication with SCADA Software

? Process Simulation & Testing techniques

? System Installation & Integration techniques

? Fault finding & Troubleshooting techniques

? Hands on experience on real time applications

? Standard Practices/Procedure for System Maintenance

NOTE: AB-DCS PLANT PAx -ROCKWELL STUDIO 5000 WITH COMPACTLOGIX

MODULE10: INDUSTRIAL DRAWINGS WITH AUTOCAD

? Introduction to Electrical Drawings & Standards

? Electrical Legends and symbols

? Fundamental of Drafting tools & Applications

? Control Loop Diagram

? Sourcing & Sinking Diagram

? Power & Control Circuit Diagram

? Electrical Panel Drawings & Wiring Diagram

? Panel Drawings & PLC Wiring Diagram

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