Instrumentation Component Repair And Maintenance Training

Objectives:
• Understand the scope and importance of instrumentation in industry
• Identify key safety regulations and procedures in instrumentation work
• Recognize common instrumentation components and their functions
• Apply basic safety practices in a workshop environment

Topics:
• Overview of instrumentation in process control
• Safety standards (OHS Act, SANS 10142)
• Personal protective equipment (PPE) requirements
• Introduction to instrument symbols and P&IDs
• Workshop safety and emergency procedures

Objectives:
• Explain fundamental measurement principles (pressure, temperature, flow, level)
• Define calibration and its importance in accuracy
• Identify calibration standards and traceability
• Perform a simple calibration check on a pressure gauge

Topics:
• Measurement units and SI system
• Pressure, temperature, flow, and level measurement basics
• Calibration terminology (accuracy, precision, hysteresis)
• Calibration standards and certificates
• Hands-on: Pressure gauge calibration using a deadweight tester

Objectives:
• Describe different pressure instruments (gauges, transmitters, switches)
• Identify common faults in pressure instruments
• Perform maintenance procedures for pressure devices
• Apply leak testing and pressure testing safely

Topics:
• Bourdon tube, diaphragm, and capacitive pressure sensors
• Pressure transmitters (4-20 mA, HART)
• Troubleshooting pressure gauge drift and zero errors
• Maintenance: cleaning, seal replacement, and recalibration
• Pressure testing procedures and safety

Objectives:
• Differentiate between thermocouples, RTDs, and thermistors
• Understand cold junction compensation and linearization
• Perform maintenance on temperature sensors and transmitters
• Troubleshoot common temperature measurement issues

Topics:
• Thermocouple types (J, K, T) and RTD Pt100
• Thermowells and installation considerations
• Maintenance: sensor replacement, wiring checks
• Calibration of temperature transmitters
• Hands-on: Loop check and sensor simulation

Objectives:
• Classify flow meters (differential pressure, magnetic, ultrasonic, etc.)
• Understand flow measurement principles (Bernoulli, Coriolis)
• Perform maintenance on common flow devices
• Diagnose flow measurement errors

Topics:
• Orifice plates, venturi, and pitot tubes
• Magnetic and ultrasonic flow meters
• Maintenance: cleaning electrodes, checking grounding
• Troubleshooting flow signal fluctuations
• Hands-on: DP flow meter calibration

Objectives:
• Identify level measurement technologies (displacer, radar, capacitance)
• Explain the principles of hydrostatic and non-contact level measurement
• Perform maintenance on level transmitters and switches
• Troubleshoot level measurement problems

Topics:
• Differential pressure level transmitters
• Radar and ultrasonic level sensors
• Maintenance: displacer replacement, stilling well cleaning
• Calibration of level transmitters (wet/dry leg)
• Hands-on: Level switch testing

Objectives:
• Understand principles of pH and conductivity measurement
• Explain gas detection methods (electrochemical, catalytic)
• Perform maintenance on analytical sensors
• Calibrate pH probes and conductivity cells

Topics:
• pH electrodes and buffers
• Conductivity cells and temperature compensation
• Gas detectors (O2, H2S, LEL)
• Maintenance: electrode cleaning, sensor replacement
• Hands-on: pH meter calibration and gas detector bump test

Objectives:
• Identify control valve types (globe, ball, butterfly)
• Understand actuator types (pneumatic, electric, hydraulic)
• Perform maintenance on control valves and actuators
• Troubleshoot valve positioning issues

Topics:
• Valve characteristics (linear, equal percentage)
• Actuator components: diaphragm, spring, positioner
• Maintenance: packing replacement, seat lapping
• Calibration of valve positioners
• Hands-on: Valve stroke check and I/P converter testing

Objectives:
• Explain transmitter operation (smart vs analog)
• Understand signal types (4-20 mA, digital protocols)
• Perform maintenance and configuration of transmitters
• Troubleshoot signal loops

Topics:
• Smart transmitters (HART, Foundation Fieldbus)
• Signal conditioning: isolation, amplification, filtering
• Loop checking and troubleshooting
• Configuration using handheld communicator
• Hands-on: HART communicator use and loop test

Objectives:
• Describe PLC architecture and components
• Understand basic ladder logic programming
• Perform simple PLC troubleshooting
• Interface PLC with instrumentation signals

Topics:
• PLC hardware: CPU, I/O modules, power supply
• Ladder logic fundamentals (contacts, coils)
• Digital and analog I/O wiring
• Troubleshooting PLC faults (LED indicators)
• Hands-on: Simple program download and I/O test

Objectives:
• Differentiate between PLC and DCS
• Understand DCS architecture and components
• Perform basic DCS maintenance tasks
• Navigate a DCS operator interface

Topics:
• DCS vs PLC: application differences
• DCS components: controllers, I/O racks, operator stations
• Communication networks (Ethernet, Profibus)
• Maintenance: card replacement, backup procedures
• Hands-on: DCS screen navigation and alarm acknowledgment

Objectives:
• Explain fieldbus technologies (Profibus, Modbus, HART)
• Understand network topology and termination
• Perform maintenance on fieldbus segments
• Troubleshoot network communication issues

Topics:
• Profibus PA and DP, Modbus RTU/TCP
• Network wiring, termination resistors, and repeaters
• Maintenance: segment check, device replacement
• Troubleshooting using diagnostic tools
• Hands-on: Network scanner and device address assignment

Objectives:
• Read and interpret P&IDs and loop diagrams
• Understand instrument index and datasheets
• Create simple loop diagrams
• Apply documentation for maintenance records

Topics:
• P&ID symbols and tag numbering
• Loop diagrams: wiring, terminals, and power supply
• Instrument index and calibration sheets
• Maintenance logs and work orders
• Hands-on: Drawing a loop diagram from a P&ID

Objectives:
• Develop a preventive maintenance schedule for instruments
• Understand condition-based maintenance
• Perform routine inspections and cleaning
• Document maintenance activities

Topics:
• Preventive maintenance strategies (time-based, condition-based)
• Inspection checklists for field instruments
• Cleaning procedures for sensors and enclosures
• Lubrication and seal replacement
• Hands-on: Creating a PM schedule for a pressure transmitter

Objectives:
• Apply systematic troubleshooting methods
• Use diagnostic tools (multimeter, loop calibrator)
• Identify common instrument faults
• Resolve issues in control loops

Topics:
• Troubleshooting methodology (checklist, half-split)
• Multimeter usage: voltage, current, resistance
• Loop calibrator: sourcing and simulating signals
• Common faults: wiring, power supply, sensor drift
• Hands-on: Troubleshooting a faulty temperature loop

Objectives:
• Understand installation requirements for field instruments
• Perform pre-commissioning checks (loop checks, continuity)
• Commission instruments and verify functionality
• Document commissioning results

Topics:
• Installation standards (SANS, ISA)
• Mounting, piping, and electrical connections
• Pre-commissioning: visual inspection, continuity test
• Commissioning: power-up, configuration, loop check
• Hands-on: Commission a pressure transmitter

Objectives:
• Perform multi-point calibrations with uncertainty analysis
• Understand calibration intervals and drift management
• Use advanced calibration equipment
• Document calibration certificates

Topics:
• Multi-point calibration procedures
• Uncertainty calculation and traceability
• Calibration software and data management
• Hands-on: Calibrate a smart transmitter with documented results

Objectives:
• Identify hazardous area classifications (ATEX, IECEx)
• Understand intrinsic safety and explosion-proof techniques
• Perform maintenance in hazardous areas
• Apply safety precautions when working with Ex equipment

Topics:
• Gas groups, temperature classes, and zones
• Intrinsic safety barriers and isolators
• Explosion-proof enclosures and conduit seals
• Maintenance: hot work permits, Ex d equipment
• Hands-on: Inspect and test an intrinsic safety loop

Objectives:
• Integrate field instruments with control systems
• Understand signal mapping and scaling
• Perform system checks and loop tuning
• Document integration changes

Topics:
• Signal scaling in DCS/PLC (4-20 mA to engineering units)
• Loop tuning basics (PID parameters)
• System integration testing (SIT)
• Change management and revision control
• Hands-on: Configure a loop in a DCS and tune a simple process

Objectives:
• Demonstrate competence in instrument repair and maintenance
• Complete a comprehensive practical assessment
• Apply all safety and quality standards
• Review course learning and identify areas for further development

Topics:
• Practical assessment: troubleshoot and repair a faulty instrument loop
• Written assessment: theory and procedures
• Course review and feedback
• Certification documentation
• Career pathways and continuous learning