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Manufacturing, Engineering and Technology › Engineering and Related Design

Apply Diagnostic Techniques To A Process Control System Training

SAQA US 119805 | NQF 5 | Credits 8 | Duration 5 Days
From $1,242 per delegate

Description

This course equips learners with the skills to apply diagnostic techniques to process control systems, enabling them to identify, analyse, and resolve faults efficiently. It covers systematic troubleshooting methods, interpretation of system data, and implementation of corrective actions to maintain optimal process performance.

Learning Outcomes

  • Apply systematic diagnostic techniques to identify faults in process control systems.
  • Analyse process control system data to determine root causes of malfunctions.
  • Evaluate diagnostic results to select appropriate corrective actions.
  • Implement corrective measures to restore process control system functionality.
  • Demonstrate adherence to safety and quality standards during diagnostic procedures.
  • Document diagnostic findings and actions taken for reporting and future reference.

Target Audience

This course is designed for process control technicians, instrumentation engineers, and automation specialists who are responsible for maintaining and troubleshooting process control systems in industrial environments.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Foundations of Process Control and Diagnostic Principles

Objectives:
• Understand the fundamental concepts of process control systems and their components.
• Identify common process variables and control loop elements.
• Explain the role of diagnostics in maintaining system reliability.
• Recognise different types of process control strategies (e.g., feedback, feedforward).
• Apply basic diagnostic terminology and principles.

Topics:
• Overview of process control systems: sensors, controllers, actuators.
• Process variables: temperature, pressure, flow, level.
• Control loop types: open-loop vs closed-loop.
• Introduction to system diagnostics: purpose and benefits.
• Common faults in process control systems.
• Safety considerations and standard operating procedures.
• Hands-on: Identifying components in a simulated control loop.

Day 2: Diagnostic Tools and Measurement Techniques

Objectives:
• Describe various diagnostic tools used in process control systems.
• Perform measurements using multimeters, oscilloscopes, and signal generators.
• Interpret instrument readings to detect anomalies.
• Apply calibration techniques to ensure accuracy.
• Document diagnostic findings systematically.

Topics:
• Diagnostic equipment: multimeters, oscilloscopes, signal generators, process calibrators.
• Measurement techniques for voltage, current, resistance, and frequency.
• Signal tracing and loop checking.
• Calibration procedures for transmitters and controllers.
• Troubleshooting common sensor and actuator faults.
• Practical exercise: Diagnosing a simulated 4-20 mA loop fault.
• Reporting and documentation standards.

Day 3: Analysing Control Loop Performance

Objectives:
• Evaluate control loop performance using key metrics (e.g., overshoot, settling time).
• Analyse trends from historical data and real-time monitoring.
• Identify causes of poor loop performance such as tuning issues or valve problems.
• Use software tools for loop analysis (e.g., PID tuning software).
• Implement corrective actions to optimise loop response.

Topics:
• Performance metrics: rise time, overshoot, steady-state error, oscillation.
• Trend analysis: reading charts and data logs.
• Common performance issues: sticking valves, hysteresis, deadband.
• Introduction to PID controller tuning: Ziegler-Nichols methods.
• Using software for loop analysis and tuning.
• Case study: Diagnosing a poorly performing temperature control loop.
• Practical: Tuning a simulated PID controller.

Day 4: Advanced Diagnostics and Fault Finding

Objectives:
• Apply systematic fault-finding methodologies (e.g., half-split, input-to-output).
• Diagnose complex faults involving multiple loop interactions.
• Use advanced diagnostic tools such as spectrum analysers and data loggers.
• Interpret diagnostic codes from programmable logic controllers (PLCs).
• Develop troubleshooting plans and root cause analysis.

Topics:
• Systematic fault-finding methods: half-split, signal injection, substitution.
• Advanced tools: spectrum analysers, data loggers, HART communicators.
• Interpreting PLC diagnostic codes and alarms.
• Dealing with intermittent faults and noise issues.
• Root cause analysis techniques (5 Whys, fishbone diagram).
• Practical: Diagnosing a cascade control loop fault.
• Safety considerations during advanced diagnostics.

Day 5: Integration, Reporting, and Practical Application

Objectives:
• Integrate diagnostic techniques into a comprehensive maintenance strategy.
• Compile detailed diagnostic reports with recommendations.
• Demonstrate competence in a simulated diagnostic scenario.
• Apply knowledge to real-world case studies.
• Review course outcomes and prepare for assessment.

Topics:
• Integrating diagnostics into preventive and predictive maintenance.
• Report writing: structure, findings, corrective actions.
• Communication with stakeholders: operators, engineers, management.
• Simulated practical assessment: diagnose and resolve a multi-fault scenario.
• Review of key concepts and Q&A.
• Final assessment and feedback.
• Course wrap-up and certification information.

Practicals

No practicals for this training.

This course is made up of exercises and case studies delivered alongside the theory — no separate practical sessions are required to complete it.

Summatives

Each delegate is assessed continuously throughout the course and a final summative test at the end.

Daily Exercises — 30%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 30% to the final total.

Final Test — 70%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 70% to the overall mark.

Final Total
Component Out of Weight
Daily Average (multiple choice) 100% 30%
Final Test (multi-answer multiple choice) 100% 70%
Final Total — 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Daily Average 30% + Final Test 70%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
Online training — attend live sessions from anywhere via our virtual classroom.
Start End Delivery Season Price Action
Mon 07 Sep 2026 Fri 11 Sep 2026 Virtual Spring 2026 $1,242 Register
Mon 28 Sep 2026 Fri 02 Oct 2026 Virtual Spring 2026 $1,242 Register
Mon 19 Oct 2026 Fri 23 Oct 2026 Virtual Spring 2026 $1,242 Register
Mon 07 Dec 2026 Fri 11 Dec 2026 Virtual Summer 2026 $1,242 Register
Mon 11 Jan 2027 Fri 15 Jan 2027 Virtual Summer 2026 $1,242 Register
Mon 15 Feb 2027 Fri 19 Feb 2027 Virtual Summer 2026 $1,242 Register
Mon 01 Mar 2027 Fri 05 Mar 2027 Virtual Autumn 2027 $1,242 Register
Mon 08 Mar 2027 Fri 12 Mar 2027 Virtual Autumn 2027 $1,242 Register
Mon 15 Mar 2027 Fri 19 Mar 2027 Virtual Autumn 2027 $1,242 Register
Mon 07 Jun 2027 Fri 11 Jun 2027 Virtual Winter 2027 $1,242 Register
Mon 28 Jun 2027 Fri 02 Jul 2027 Virtual Winter 2027 $1,242 Register
Mon 19 Jul 2027 Fri 23 Jul 2027 Virtual Winter 2027 $1,242 Register
Mon 06 Sep 2027 Fri 10 Sep 2027 Virtual Spring 2027 $1,242 Register
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Mon 18 Oct 2027 Fri 22 Oct 2027 Virtual Spring 2027 $1,242 Register
Mon 06 Dec 2027 Fri 10 Dec 2027 Virtual Summer 2027 $1,242 Register
Mon 27 Dec 2027 Fri 31 Dec 2027 Virtual Summer 2027 $1,242 Register
Mon 17 Jan 2028 Fri 21 Jan 2028 Virtual Summer 2027 $1,242 Register
On-Campus training — face-to-face sessions at our training venues across Africa and beyond.
Showing all 533 sessions across 26 venues
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Mon 22 Jun 2026 Fri 26 Jun 2026 Mombasa, Kenya Winter 2026 $3,834 Register
Mon 22 Jun 2026 Fri 26 Jun 2026 Mbabane, Eswatini Winter 2026 $2,916 Register
Mon 22 Jun 2026 Fri 26 Jun 2026 Nairobi, Kenya Winter 2026 $3,834 Register
Mon 22 Jun 2026 Fri 26 Jun 2026 Maseru, Lesotho Winter 2026 $2,916 Register
Mon 22 Jun 2026 Fri 26 Jun 2026 Windhoek, Namibia Winter 2026 $3,078 Register
In-House training — we bring the trainer to your organisation, tailored to your team.
Start End Delivery Season Price Action
Mon 22 Jun 2026 Fri 26 Jun 2026 Your Premises Winter 2026 $1,615 Register
Mon 14 Sep 2026 Fri 18 Sep 2026 Your Premises Spring 2026 $1,615 Register
Mon 05 Oct 2026 Fri 09 Oct 2026 Your Premises Spring 2026 $1,615 Register
Mon 26 Oct 2026 Fri 30 Oct 2026 Your Premises Spring 2026 $1,615 Register
Mon 14 Dec 2026 Fri 18 Dec 2026 Your Premises Summer 2026 $1,615 Register
Mon 18 Jan 2027 Fri 22 Jan 2027 Your Premises Summer 2026 $1,615 Register
Mon 22 Feb 2027 Fri 26 Feb 2027 Your Premises Summer 2026 $1,615 Register
Mon 08 Mar 2027 Fri 12 Mar 2027 Your Premises Autumn 2027 $1,615 Register
Mon 15 Mar 2027 Fri 19 Mar 2027 Your Premises Autumn 2027 $1,615 Register
Mon 22 Mar 2027 Fri 26 Mar 2027 Your Premises Autumn 2027 $1,615 Register
Mon 14 Jun 2027 Fri 18 Jun 2027 Your Premises Winter 2027 $1,615 Register
Mon 05 Jul 2027 Fri 09 Jul 2027 Your Premises Winter 2027 $1,615 Register
Mon 26 Jul 2027 Fri 30 Jul 2027 Your Premises Winter 2027 $1,615 Register
Mon 13 Sep 2027 Fri 17 Sep 2027 Your Premises Spring 2027 $1,615 Register
Mon 04 Oct 2027 Fri 08 Oct 2027 Your Premises Spring 2027 $1,615 Register
Mon 25 Oct 2027 Fri 29 Oct 2027 Your Premises Spring 2027 $1,615 Register
Mon 13 Dec 2027 Fri 17 Dec 2027 Your Premises Summer 2027 $1,615 Register
Mon 03 Jan 2028 Fri 07 Jan 2028 Your Premises Summer 2027 $1,615 Register
Mon 24 Jan 2028 Fri 28 Jan 2028 Your Premises Summer 2027 $1,615 Register
Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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