COURSE OVERVIEW:

Control systems are the intelligent nervous system of industrial plants and power utilities, requiring precise commissioning and expert troubleshooting to ensure operational excellence. This course provides an advanced exploration of the methodologies used to bring complex control architectures—such as Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), and SCADA—from the installation phase to full operational status. Participants will learn how to verify the integrity of the hardware, the accuracy of the software logic, and the reliability of the communication networks that link them.

The scope of this training addresses the entire commissioning lifecycle, including cold and hot loop checks, instrument calibration, and the final functional safety verification. It provides a deep dive into the technical nuances of PID loop tuning, signal conditioning, and the troubleshooting of digital and analog I/O failures. The curriculum focuses on the systematic identification of faults within complex loops, teaching participants how to use diagnostic software and hardware tools to isolate issues in sensors, actuators, or the central processing logic.

Coverage includes the interpretation of complex control diagrams and logic flowcharts, as well as the management of cybersecurity risks during the commissioning phase. Attendees will analyze real-world scenarios involving intermittent control fluctuations and communication latency, learning how to implement corrective actions that stabilize the system. By combining rigorous testing protocols with advanced troubleshooting frameworks, the course ensures that technical personnel can deliver high-performance control systems that maximize plant availability and safety.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the systematic stages of control system commissioning.
• Execute professional loop checks for analog and digital I/O.
• Perform precision calibration of smart instruments using HART and Foundation Fieldbus.
• Troubleshoot PLC and DCS hardware failures at the module level.
• Analyze and tune PID control loops for stability and responsiveness.
• Verify the integrity of industrial communication networks, including Modbus and Ethernet.
• Interpret complex control logic, including Ladder, Function Block, and SCL.
• Identify and mitigate electromagnetic interference (EMI) in signal wiring.
• Conduct Functional Safety (SIS) validation and testing of safety interlocks.
• Manage software versioning and backup procedures during commissioning.
• Execute root cause analysis for intermittent control system resets.
• Develop comprehensive commissioning reports and final handover documentation.

TARGET AUDIENCE:

This course is intended for Control Systems Engineers, Instrumentation Technicians, Commissioning Managers, and Automation Specialists involved in the startup and maintenance of industrial processes.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.