COURSE OVERVIEW:

The Commissioning and Troubleshooting of Control Systems course is a vital program designed to manage the critical phase between the installation of automation hardware and the full-scale operation of an industrial plant. Successful commissioning requires a systematic transition from physical wiring to functional logic, ensuring that every loop, interlock, and safety function performs exactly as designed. This course provides a structured framework for conducting "Cold" and "Hot" commissioning, while providing participants with the diagnostic tools needed to solve the complex problems that inevitably arise during system startup.

The scope of this training encompasses the validation of Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), and Fieldbus networks. Participants will learn how to lead Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT), ensuring that software logic aligns with P&ID requirements and process safety standards. The curriculum covers the systematic checking of I/O points, the verification of communication throughput, and the initial tuning of control loops to handle the dynamic loads of a live process.

This coverage also emphasises advanced troubleshooting methodologies for resolving intermittent faults and system bottlenecks. The course details how to use network sniffers, logic analysers, and trend diagnostics to identify root causes of system failure—whether they are hardware-based, software-based, or result from poor field installation. By focusing on both the project management of the commissioning phase and the technical rigour of deep-system troubleshooting, the program prepares attendees to bring complex industrial assets online safely, on time, and with high operational reliability.

COURSE OBJECTIVES:

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

• Develop and execute a comprehensive commissioning plan for complex control systems.
• Lead Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) effectively.
• Perform systematic I/O loop checking and point-to-point verification.
• Configure and validate industrial communication networks (Ethernet, Fieldbus, Modbus).
• Transition control systems safely from "Cold" to "Hot" commissioning phases.
• Apply systematic troubleshooting models to identify root causes of control failures.
• Utilise advanced diagnostic tools for analysing PLC logic and DCS performance.
• Resolve communication latency and data synchronisation issues in distributed systems.
• Fine-tune control loops during initial plant startup for optimal stability.
• Document commissioning activities and "As-Built" changes for the final handover.
• Ensure safety compliance through the validation of Emergency Shutdown (ESD) systems.
• Manage the hand-over process from the project team to the operations team.

TARGET AUDIENCE:

This course is designed for Commissioning Engineers, Control System Technicians, Project Managers, Automation Specialists, and Maintenance Engineers involved in the startup and support of industrial automation projects.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.