COURSE OVERVIEW:

The purpose of this course is to equip technical personnel with a systematic and logical approach to diagnosing failures in complex, integrated industrial environments. In modern facilities, a process upset can stem from a mechanical valve failure, an electrical power surge, or a corrupted software algorithm, making cross-disciplinary knowledge essential. This program focuses on developing the "detective" mindset required to isolate root causes in interconnected systems efficiently.

The scope of this training encompasses the technical diagnosis of field instruments, electrical motor control circuits, and the digital logic within PLCs and DCS platforms. Participants will explore the interdependencies between physical process variables and the electrical signals that represent them. The curriculum is specifically designed to move beyond simple part replacement, focusing instead on the use of advanced test equipment and analytical techniques to identify intermittent and hidden faults.

Coverage includes the practical aspects of loop checking, electrical insulation testing, and the analysis of control logic execution. Attendees will learn how to interpret circuit diagrams, utilize digital multimeters and oscilloscopes, and perform "half-splitting" techniques to narrow down fault locations. By focusing on a holistic view of the plant, the course ensures that participants can reduce downtime and improve system reliability through precise and rapid troubleshooting.

COURSE OBJECTIVES:

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

• Analyze a systematic five-step approach to industrial troubleshooting.
• Identify the relationship between electrical, mechanical, and control failures.
• Utilize advanced multimeters, process calibrators, and insulation testers.
• Differentiate between "Hard" failures and intermittent signal noise.
• Troubleshoot 4-20mA loops for ground loops and impedance issues.
• Diagnose electrical faults in motor control centers (MCC) and VFDs.
• Interpret PLC status indicators and online logic for fault isolation.
• Execute root cause analysis (RCA) on recurring system trips.
• Identify mechanical issues like valve stiction using signal analysis.
• Troubleshoot industrial communication networks (Modbus, Ethernet).
• Implement temporary bypasses safely during emergency repairs.
• Document troubleshooting steps and findings for maintenance history.

TARGET AUDIENCE:

This course is intended for Instrumentation Technicians, Maintenance Electricians, Automation Engineers, and Multi-skilled Maintenance Staff.

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.