Manufacturing, Engineering and Technology Engineering and Related Design

Integrate A Process Control System Training

SAQA US 119803 | NQF 5 | Credits 12 | Duration 9 Days
From $1,798 per delegate

Description

This course equips learners with the skills to integrate a process control system into an industrial environment. It covers planning, configuration, testing, and commissioning of process control systems to ensure seamless operation and compliance with industry standards.

Learning Outcomes

  • Apply relevant standards and procedures to plan the integration of a process control system.
  • Configure hardware and software components of a process control system according to specifications.
  • Implement communication protocols to link field devices with the control system.
  • Test and verify the integrated system to ensure functionality and safety.
  • Analyze system performance and troubleshoot integration issues.
  • Document the integration process and provide handover documentation.

Target Audience

This course is designed for automation engineers, control system technicians, and process engineers who are responsible for integrating or upgrading process control systems in manufacturing, chemical, or utility industries.

Prerequisites

None — open enrollment

Course Outline

Day 1: Introduction to Process Control Systems

Objectives:
• Understand the role of process control systems in industry
• Identify key components of a process control system
• Explain basic control loop concepts
• Describe the importance of process control integration

Topics:
• Overview of process control in manufacturing
• Components: sensors, controllers, actuators, final control elements
• Open vs closed loop control
• Feedback and feedforward control
• Safety and efficiency benefits

Day 2: Sensors and Measurement Devices

Objectives:
• Identify different types of sensors used in process control
• Explain principles of measurement for temperature, pressure, flow, and level
• Understand sensor selection criteria
• Interpret sensor output signals

Topics:
• Temperature sensors: thermocouples, RTDs, thermistors
• Pressure sensors: strain gauge, capacitive
• Flow measurement: differential pressure, magnetic, ultrasonic
• Level measurement: radar, ultrasonic, capacitance
• Signal types: 4-20 mA, digital, fieldbus

Day 3: Controllers and Control Algorithms

Objectives:
• Differentiate between controller types (P, PI, PID)
• Explain how PID control works
• Tune a PID controller using basic methods
• Understand the impact of tuning parameters

Topics:
• On/off control vs proportional control
• Integral and derivative actions
• PID controller tuning: Ziegler-Nichols, trial and error
• Effects of P, I, D on system response
• Limitations and tuning considerations

Day 4: Final Control Elements and Actuators

Objectives:
• Identify common final control elements
• Explain how control valves operate
• Understand actuator types and selection
• Describe the role of variable frequency drives

Topics:
• Control valves: globe, butterfly, ball
• Actuators: pneumatic, electric, hydraulic
• Valve positioners and characteristics
• Variable frequency drives for pumps and fans
• Safety considerations: fail-safe modes

Day 5: Programmable Logic Controllers (PLCs) and Distributed Control Systems (DCS)

Objectives:
• Differentiate between PLC and DCS architectures
• Understand basic PLC programming concepts
• Explain the function of DCS in large-scale processes
• Identify communication protocols used in control systems

Topics:
• PLC components: CPU, I/O modules, power supply
• Ladder logic basics
• DCS architecture: controllers, servers, operator stations
• Communication protocols: Modbus, Profibus, Foundation Fieldbus
• Redundancy and reliability

Day 6: Human-Machine Interface (HMI) and SCADA Systems

Objectives:
• Explain the role of HMI in process control
• Design a basic HMI screen
• Understand SCADA system functions
• Interpret SCADA data for decision-making

Topics:
• HMI design principles: navigation, alarms, trends
• Creating graphic displays
• SCADA architecture: RTUs, MTUs, communication
• Data acquisition and logging
• Alarm management and historian

Day 7: Process Control Integration and Networking

Objectives:
• Describe methods for integrating control system components
• Understand network topologies in industrial control
• Explain the role of OPC (OLE for Process Control)
• Identify integration challenges and solutions

Topics:
• Integration levels: field, control, supervisory, enterprise
• Industrial Ethernet and fieldbus networks
• OPC DA, UA, and HDA
• System interoperability
• Troubleshooting integration issues

Day 8: Safety Instrumented Systems (SIS) and Standards

Objectives:
• Understand safety lifecycle per IEC 61511
• Differentiate between basic process control and safety systems
• Explain SIL (Safety Integrity Level) concepts
• Apply risk assessment methods

Topics:
• Functional safety standards: IEC 61508, IEC 61511
• Safety instrumented functions
• SIL determination: risk graph, LOPA
• Safety system design: redundancy, diagnostics
• Proof testing and maintenance

Day 9: Practical Integration Project and Assessment

Objectives:
• Integrate a small process control system from components
• Configure a PLC, HMI, and sensors
• Tune a control loop and verify performance
• Document the integration process and present results

Topics:
• Hands-on project: temperature control loop
• PLC programming and HMI development
• Loop tuning and optimization
• System testing and troubleshooting
• Final presentation and assessment

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.
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Fri 11 Sep 2026 Wed 23 Sep 2026 Virtual Spring 2026 $1,798 Register
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Tue 28 Dec 2027 Fri 07 Jan 2028 Virtual Summer 2027 $1,798 Register
Mon 17 Jan 2028 Thu 27 Jan 2028 Virtual Summer 2027 $1,798 Register
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Wed 05 Jan 2028 Mon 17 Jan 2028 Your Premises Summer 2027 $2,338 Register
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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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