Pideya Learning Academy

Instrumentation and Troubleshooting in Process Control

Upcoming Schedules

  • Live Online Training
  • Classroom Training

Date Venue Duration Fee (USD)
20 Jan - 24 Jan 2025 Live Online 5 Day 2750
10 Mar - 14 Mar 2025 Live Online 5 Day 2750
14 Apr - 18 Apr 2025 Live Online 5 Day 2750
19 May - 23 May 2025 Live Online 5 Day 2750
21 Jul - 25 Jul 2025 Live Online 5 Day 2750
15 Sep - 19 Sep 2025 Live Online 5 Day 2750
06 Oct - 10 Oct 2025 Live Online 5 Day 2750
24 Nov - 28 Nov 2025 Live Online 5 Day 2750

Course Overview

In today’s data-driven and efficiency-oriented industrial environment, accurate measurement and effective control of process variables are essential for achieving operational excellence, system stability, and regulatory compliance. From refining hydrocarbons to producing pharmaceuticals, the need for well-functioning instrumentation and robust troubleshooting skills is a cornerstone of every process industry. Pideya Learning Academy introduces its comprehensive training program titled “Instrumentation and Troubleshooting in Process Control”, aimed at empowering technical professionals to build in-depth competence in managing modern instrumentation systems and resolving process anomalies with confidence.
This course is thoughtfully crafted to help participants understand the intricacies of sensors, transducers, signal conditioning, and advanced control systems. The curriculum seamlessly blends foundational theory with applied industry knowledge, enabling learners to interpret data effectively, recognize system inconsistencies, and propose efficient solutions without relying on trial-and-error methods. As industries increasingly turn to automation and intelligent monitoring systems, the relevance of precise instrumentation and timely troubleshooting cannot be overstated.
According to a recent 2023 analysis by MarketsandMarkets, the global market for process automation and instrumentation is projected to reach USD 76.8 billion by 2027, growing at a CAGR of 6.1% from 2022. This growth is driven by increased demand for smart factories, real-time analytics, and integrated control systems across industries such as oil and gas, petrochemicals, manufacturing, energy, water treatment, and food processing. In light of this surge, professionals equipped with cross-functional expertise in process control and instrumentation are among the most sought-after assets within operational and engineering teams.
Through this Pideya Learning Academy training, participants will develop the ability to identify various sensor types, understand process control dynamics, and apply troubleshooting techniques to minimize downtime and enhance productivity. The course covers a broad range of technical domains, including signal transmission, control loop integrity, calibration methodologies, and error diagnostics. Case-based examples are introduced to simulate field conditions and deepen understanding of real-time system behaviors.
Participants will also explore advanced signal processing principles, gain familiarity with non-contact measurement technologies such as ultrasonic and infrared sensors, and learn how to diagnose issues linked to loop instability, sensor drift, and actuator failure. Additionally, attention is paid to safety considerations, instrument integration strategies, and compliance requirements within industrial environments.
Some of the key highlights of the training include:
Comprehensive knowledge of industrial sensors, transducers, and measurement techniques
In-depth exposure to signal conditioning circuits and instrumentation architecture
Application of PID tuning and control loop optimization strategies
Analytical approaches to troubleshooting and resolving process deviations
Exploration of non-contact sensing technologies for modern industrial settings
Case-based learning that bridges technical theory with real-world fault scenarios
Emphasis on system calibration and instrument lifecycle management
By the end of the course, participants will be well-prepared to tackle instrumentation challenges across a wide range of systems and industries. They will be able to evaluate sensor performance, troubleshoot control system inconsistencies, and recommend improvements for greater accuracy, stability, and efficiency. With content designed to reflect the latest industry practices, this training ensures that learners walk away with valuable, immediately applicable expertise.

Key Takeaways:

  • Comprehensive knowledge of industrial sensors, transducers, and measurement techniques
  • In-depth exposure to signal conditioning circuits and instrumentation architecture
  • Application of PID tuning and control loop optimization strategies
  • Analytical approaches to troubleshooting and resolving process deviations
  • Exploration of non-contact sensing technologies for modern industrial settings
  • Case-based learning that bridges technical theory with real-world fault scenarios
  • Emphasis on system calibration and instrument lifecycle management
  • Comprehensive knowledge of industrial sensors, transducers, and measurement techniques
  • In-depth exposure to signal conditioning circuits and instrumentation architecture
  • Application of PID tuning and control loop optimization strategies
  • Analytical approaches to troubleshooting and resolving process deviations
  • Exploration of non-contact sensing technologies for modern industrial settings
  • Case-based learning that bridges technical theory with real-world fault scenarios
  • Emphasis on system calibration and instrument lifecycle management

Course Objectives

After completing this Pideya Learning Academy training, the participants will learn:
The operational principles of diverse industrial sensors and transducers
How to interpret sensor signals and apply signal conditioning techniques for process automation
The characteristics and behavior of process variables such as pressure, temperature, and flow
Methods of evaluating and selecting appropriate instrumentation based on application requirements
PID control fundamentals and techniques for process tuning and system stability
The use of standard measurement units and the ability to perform essential industrial calculations
How to identify suitable instrumentation methods for bespoke measurement challenges in their industry

Personal Benefits

Strengthened foundational and advanced understanding of industrial measurement systems
Increased confidence in interpreting process data and applying control techniques
Expanded knowledge of instrumentation design, calibration, and optimization
Enhanced professional value and credibility in instrumentation and control fields
Exposure to real-world case scenarios and current industry trends

Organisational Benefits

Enhanced operational reliability through improved instrumentation system knowledge
Reduced system downtime and better troubleshooting capabilities
Increased process efficiency via accurate measurement and optimized control
Development of a skilled workforce equipped to manage process instrumentation complexities
Better compliance with safety and operational standards in critical industries

Who Should Attend

This training program is ideally suited for professionals involved in the design, operation, maintenance, or integration of industrial instrumentation and control systems, including:
Instrumentation and Process Control Engineers
Electrical, Mechanical, and Chemical Engineers
Maintenance Engineers and Technicians
Electronic Engineers and Technicians
Design Engineers and Project Engineers
Operations and Production Professionals
System Integrators and Technical Specialists
Instrument Fitters and Plant Technicians
Engineers and Managers transitioning into instrumentation-focused roles
Professionals in the process industry seeking a broader understanding of measurement and control

Course Outline

Module 1: Foundations of Measurement and Instrumentation Systems
Overview of sensor and instrumentation architecture Classification of sensors and transducers Signal conditioning fundamentals Instrumentation system block structures Key definitions: accuracy, repeatability, resolution, span, response time Concepts of hysteresis and sensitivity in measurement Common measurement system errors and uncertainty Introduction to analog and digital signal interpretation Examples of integrated industrial instrumentation systems
Module 2: Measurement of Physical Process Variables
Identification of critical process variables Measurement concepts for: Mass flow Volumetric flow rate Pressure Viscosity Turbidity Data acquisition techniques for process variables Selection criteria for measurement devices
Module 3: Strain Measurement Techniques and Applications
Stress-strain relationships and mechanical properties Young’s modulus and material deformation principles Strain gauge technologies and configurations Wheatstone bridge circuit fundamentals Signal amplification for strain measurement Calibration and error minimization techniques
Module 4: Pressure Measurement Devices and Principles
Working principles of pressure sensing technologies Mechanical pressure sensors: diaphragms, bellows Capacitive pressure sensors and electrical output Overview of fiber-optic pressure sensing systems Installation factors for pressure instruments Application scenarios and industry-specific examples
Module 5: Flow Measurement Fundamentals
Concept of flow dynamics and fluid behavior Reynolds number and laminar/turbulent flow regimes Invasive flow measurement systems: Orifice plates Venturi tubes Flow nozzles Dall tubes Coriolis mass flowmeters Differential pressure devices Non-invasive flow measurement systems: Electromagnetic flowmeters Ultrasonic flowmeters Instrument selection based on process requirements
Module 6: Industrial Temperature Measurement Systems
Overview of temperature scales and conversions Resistance Temperature Detectors (RTDs) Thermistors and their characteristics Thermocouples and voltage-temperature relationships Non-contact temperature sensing with radiation pyrometers Accuracy, stability, and drift considerations in temperature systems
Module 7: Liquid Level Measurement Technologies
Techniques for point-level and continuous-level detection Direct and indirect level sensing methods Technologies for level detection: Ultrasonic level measurement Capacitive level measurement Hydrostatic pressure-based sensing Application integration in storage and process tanks Signal processing in level instrumentation systems
Module 8: Ultrasonic and Non-Intrusive Measurement Approaches
Working principles of ultrasonic sensors Doppler shift technique and transit time method Design considerations for clamp-on ultrasonic sensors Applications of non-contact measurement in hazardous environments Accuracy limitations and environmental sensitivity factors
Module 9: Process Control Concepts and Signal Processing
Process control engineering fundamentals Closed-loop vs open-loop control strategies Functional block diagrams of control systems Roles of controllers, sensors, and actuators Servomechanisms, regulators, and feedback loops System transfer functions: first and second order dynamics
Module 10: Control Modes and PID Control Theory
ON/OFF and two-position control strategies Proportional control and tuning factors Integral and derivative actions in dynamic response Combined PID controller structure Avoiding proportional offset and integral windup Control system stability and transient behavior
Module 11: Frequency Domain Analysis in Control Engineering
Introduction to stability analysis tools Frequency response characteristics of systems Bode plot interpretation Nyquist stability criterion and gain/phase margins Identification and management of load disturbances
Module 12: Controller Tuning Techniques
Tuning objectives: accuracy, speed, stability Empirical controller tuning approaches: Open-loop reaction curve (Ziegler-Nichols) Closed-loop continuous cycling method Default controller parameter configurations Fine-tuning for optimized performance Tuning for disturbance rejection and control loop robustness
Module 13: Advanced Topics in Industrial Measurement and Control
Signal filtering and noise suppression Smart sensors and industrial IoT integration Remote monitoring and SCADA system interfaces Cybersecurity in instrumentation and control systems Maintenance considerations for sensor calibration

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