Pideya Learning Academy

PLC Applications for Process Automation

Upcoming Schedules

  • Live Online Training
  • Classroom Training

Date Venue Duration Fee (USD)
06 Jan - 10 Jan 2025 Live Online 5 Day 2750
24 Mar - 28 Mar 2025 Live Online 5 Day 2750
26 May - 30 May 2025 Live Online 5 Day 2750
23 Jun - 27 Jun 2025 Live Online 5 Day 2750
11 Aug - 15 Aug 2025 Live Online 5 Day 2750
29 Sep - 03 Oct 2025 Live Online 5 Day 2750
10 Nov - 14 Nov 2025 Live Online 5 Day 2750
01 Dec - 05 Dec 2025 Live Online 5 Day 2750

Course Overview

In today’s competitive industrial environment, automation is no longer an option but a necessity. As businesses strive for efficiency, safety, and reduced operational costs, the role of Programmable Logic Controllers (PLCs) in process automation has grown significantly. The PLC Applications for Process Automation course offered by Pideya Learning Academy is designed to equip professionals with the technical expertise needed to understand, manage, and optimize PLC-based control systems across diverse industrial sectors. From energy and utilities to manufacturing, oil and gas, and chemical processing, the scope of PLC implementation is expansive and continues to evolve.
The global industrial automation market is projected to reach USD 395 billion by 2029, growing at a compound annual growth rate (CAGR) of 9.8%, according to a recent report by Fortune Business Insights. Within this growth, PLCs are recognized as a foundational technology, enabling real-time control, monitoring, and system coordination. Industries are rapidly adopting automation to reduce human error, increase uptime, and achieve compliance with rigorous operational and safety standards. This surge in demand translates into a growing need for skilled professionals who understand both the theoretical and technical aspects of PLCs. The PLC Applications for Process Automation course by Pideya Learning Academy bridges this skill gap by offering participants a structured, comprehensive learning path aligned with current industrial needs.
Throughout the program, participants will gain an in-depth understanding of PLC hardware architecture, digital and analog I/O systems, control logic programming, and the configuration of automation sequences. The course emphasizes integration with Human-Machine Interfaces (HMIs), Supervisory Control and Data Acquisition (SCADA) systems, and other industrial components to ensure seamless automation. By exploring modern PLC platforms and networked control environments, learners will be well-positioned to apply advanced techniques in system design, optimization, and fault detection.
This training is not only a technical deep dive but also a strategic skill development program. For instance, it includes exposure to advanced fault isolation methods and diagnostic techniques that are critical in minimizing system downtime and improving predictive maintenance practices. Additionally, it covers structured programming methodologies, safety protocols, and the principles of scalable system design.
Participants will gain valuable insights into global automation standards, interoperability protocols such as Modbus and Ethernet/IP, and real-time data communication methods. These competencies are essential for developing robust, future-ready automation systems that align with the technological transformation sweeping across industries.
Integrated into this course are several key features that add exceptional value to participants:
Real-world application scenarios of PLCs in complex automation environments
Detailed exploration of modern PLC hardware platforms and configuration workflows
In-depth understanding of control logic development using industry-standard languages
Stepwise instruction on integrating PLCs with SCADA, HMI, and industrial networks
Techniques for predictive diagnostics and systematic fault isolation
Analysis of global trends and compliance with international automation standards
With its industry-relevant curriculum and structured learning methodology, Pideya Learning Academy ensures that participants not only understand how PLCs function but also how to strategically apply them to achieve operational excellence and automation-driven efficiency. Whether upgrading legacy systems or developing new automation strategies, this course provides the confidence and knowledge needed to lead automation initiatives in any process environment.
By enrolling in PLC Applications for Process Automation, professionals will gain more than just a theoretical understanding—they will acquire actionable skills aligned with industry expectations and future innovations in automation and control engineering.

Course Objectives

After completing this Pideya Learning Academy training, the participants will learn:
The essential principles of PLC systems and their application in automated process environments
The interpretation and usage of PLC programming languages such as Ladder Logic and Functional Block Diagrams
How to integrate PLCs with SCADA, HMI, and other control systems for cohesive industrial operations
Methods for identifying and resolving faults in PLC systems using systematic diagnostic approaches
The design of scalable and efficient control logic in line with industry-specific performance requirements
How to apply automation solutions to improve operational efficiency, safety, and regulatory compliance

Personal Benefits

Strengthened expertise in PLC systems relevant to modern industrial settings
Increased confidence in designing and maintaining control architectures
Competitive advantage in automation and control engineering roles
Ability to contribute meaningfully to process optimization and maintenance planning
Recognition as a technically proficient professional within the organization

Organisational Benefits

Improved process reliability through enhanced PLC programming and configuration skills
Reduced system downtime by equipping staff with fault identification and resolution capabilities
Stronger compliance with safety standards and regulatory requirements
Enhanced collaboration between engineering, maintenance, and operations teams
Increased productivity by streamlining automated workflows and control logic

Who Should Attend

Control Engineers
Automation Technicians
Electrical and Instrumentation Engineers
Maintenance Supervisors
Process Engineers
Technicians involved in plant operations
Individuals seeking foundational or advanced knowledge of PLC-based automation systems

Course Outline

Module 1: Foundations of Programmable Control Systems
Evolution of industrial control systems Role of programmable devices in automation Architecture of PLC-based automation systems Core hardware components (CPU, I/O modules, memory) Benefits of PLCs in real-time operations Use cases across manufacturing and processing sectors
Module 2: Hardware Architecture and System Interfaces
Components of modern PLC hardware Digital and analog I/O terminal configurations Power supply units and signal isolation Communication interface modules Environmental and operational design considerations Hardware selection based on application needs
Module 3: PLC Operating Software and Configuration
PLC development environments and tools Ladder Logic editor functionalities Configuration of device settings and memory maps Uploading and downloading firmware/software Simulation and test environments Software version control and backup practices
Module 4: Core Programming Logic and Execution
Ladder Logic syntax and structure Developing logic using timers, counters, comparators Implementing Function Block Diagrams (FBD) Sequential Function Charts (SFC) and control flow Structured Text language elements IEC 61131-3 programming compliance
Module 5: Analog and Digital Signal Processing
Classification of I/O signals and devices Analog signal scaling and linearization Wiring and configuration of digital inputs/outputs Integration with proximity sensors, encoders, and actuators Calibration of analog transducers Diagnosing signal fluctuation and grounding issues
Module 6: Industrial Communication and Data Exchange
Overview of industrial communication buses Ethernet/IP, Profibus, Modbus RTU/TCP, DeviceNet protocols Addressing schemes and node configuration PLC-to-SCADA interfacing and HMI interaction Serial vs. fieldbus communication Securing communication channels in control systems
Module 7: Principles of Closed-Loop Process Control
Basics of control loop dynamics Concepts of process variables, setpoints, and outputs Tuning PID controllers for stability Feedforward and cascade control implementation Real-time control strategies using PLC logic Process feedback analysis and correction
Module 8: Structured Programming and Advanced Logic
Nested loops and subroutines in PLCs Interrupt-driven event handling Development of reusable logic blocks Bit-level manipulation and shift operations Fault-tolerant programming design Memory management and data tracking
Module 9: Human-Machine Interface (HMI) Technologies
HMI and SCADA differentiation Designing intuitive operator panels Live data display and graphical visualization Alarm hierarchy and event response Tag assignment and data binding Touchscreen vs. panel-mounted interfaces
Module 10: Diagnostics, Reliability, and Lifecycle Maintenance
PLC fault detection and troubleshooting workflows Root cause analysis for failure events System logs, diagnostics tools, and event tracing Routine inspection and predictive maintenance Restoring from backups and disaster recovery Industry examples of fault resolution
Module 11: Safety Automation and Functional Integrity
Introduction to machine safety engineering Safety instrumented systems (SIS) design basics Using safety-rated PLCs for critical control Developing safety logic using fail-safe principles SIL (Safety Integrity Level) and HAZOP methodologies Compliance with IEC 61508 and ISO 13849 standards
Module 12: Deployment, Modernization, and Performance Tuning
Commissioning procedures and pre-deployment testing System migration from relay logic to PLCs Load balancing and memory optimization Power usage and energy management in automation Runtime diagnostics and optimization tools Sector-specific automation frameworks (oil & gas, food, pharma)
Module 13: Innovations in Intelligent Automation
Integration of AI in programmable control systems Role of digital twins and simulation environments Predictive analytics and machine learning in PLC data Industry 4.0 and smart factory automation trends Edge computing and real-time analytics Upskilling paths in intelligent automation careers

Have Any Question?

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