Introduction

Industrial automation and control systems (IACS) are at the heart of modern manufacturing, power plants, oil & gas, pharmaceuticals, and smart infrastructure. As industries move towards Industry 4.0, the integration of advanced control systems, AI-driven automation, IoT, and robotics is transforming production processes to be more efficient, reliable, and intelligent.

This training course covers key concepts of industrial automation, including Programmable Logic Controllers (PLCs), Distributed Control Systems (DCS), Supervisory Control and Data Acquisition (SCADA), Industrial IoT (IIoT), and AI-driven predictive maintenance. Participants will gain hands-on experience in automation software, control system programming, and modern industrial communication protocols.

Objectives

By the end of this course, participants will be able to:

1. Understand the fundamentals of industrial automation and control systems.
2. Design and program PLCs, DCS, and SCADA for industrial applications.
3. Implement sensor networks and industrial communication protocols (MODBUS, PROFIBUS, Ethernet/IP).
4. Develop real-time process control strategies for manufacturing and energy systems.
5. Integrate AI and predictive analytics into industrial automation for efficiency and fault detection.
6. Apply robotics and IoT for smart manufacturing and industrial automation.
7. Ensure safety, cybersecurity, and compliance in industrial control systems.

Who Should Attend?

This course is ideal for:

• Automation Engineers & Control System Engineers working in industrial automation.
• Electrical, Mechanical, and Instrumentation Engineers involved in manufacturing and process control.
• Industrial Technicians & Plant Operators responsible for automation systems.
• IT and IoT Professionals integrating smart technologies into industrial environments.
• Manufacturing, Oil & Gas, and Energy Industry Professionals managing large-scale automated processes.
• Researchers & Academics in industrial control and intelligent automation.

Course Outline

Day 1: Fundamentals of Industrial Automation & Control

Session 1: Introduction to Industrial Automation

• Evolution of industrial automation and the transition to Industry 4.0.
• Key components: Sensors, actuators, controllers, and communication networks.
• Industrial automation applications in manufacturing, power, oil & gas, and logistics.

Session 2: Control Systems in Industrial Automation

• Open-loop vs. closed-loop control systems.
• Process control techniques: PID control, feedforward, cascade, and ratio control.
• Real-world examples of industrial control applications.

Session 3: Introduction to Programmable Logic Controllers (PLCs)

• PLC architecture and operation principles.
• Ladder logic programming and structured text.
• Hands-on PLC programming using Siemens, Allen-Bradley, or Schneider Electric software.

Hands-On Workshop: PLC programming basics – writing and simulating ladder logic for an industrial process.

Day 2: Industrial Control Architectures and SCADA Systems

Session 1: Distributed Control Systems (DCS) vs. PLC-based Control

• Key differences between PLC, DCS, and SCADA systems.
• DCS applications in large-scale power plants, chemical plants, and refineries.
• Designing a hybrid PLC-DCS system for industrial automation.

Session 2: Supervisory Control and Data Acquisition (SCADA)

• SCADA architecture and real-time process monitoring.
• Data acquisition, logging, and visualization.
• Web-based SCADA and remote access for industrial automation.

Session 3: Human-Machine Interfaces (HMI) and Industrial Networking

• Designing HMI dashboards for process visualization.
• Industrial communication standards: MODBUS, PROFIBUS, Ethernet/IP, OPC-UA.
• Wireless connectivity and Industrial IoT (IIoT) for automation.

Hands-On Workshop: Configuring a SCADA system to monitor and control a simulated industrial process.

Day 3: Advanced Process Control & Industrial Robotics

Session 1: Process Optimization and PID Tuning

• Tuning Proportional-Integral-Derivative (PID) controllers.
• Model Predictive Control (MPC) and its industrial applications.
• Optimizing chemical, thermal, and mechanical process control.

Session 2: Robotics and Motion Control in Automation

• Industrial robots vs. collaborative robots (Cobots).
• Motion control using servo motors, stepper motors, and drives.
• Integrating robots into automated assembly lines and logistics.

Session 3: Smart Manufacturing and Digital Twins

• Role of digital twins in predictive maintenance.
• AI-based fault detection and anomaly prediction in industrial automation.
• Cyber-physical systems and cloud computing for automation.

Hands-On Workshop: Implementing PID tuning for a process control system and robotic motion programming.

Day 4: AI, IoT, and Cybersecurity in Industrial Automation

Session 1: Artificial Intelligence (AI) and Machine Learning in Automation

• AI for predictive maintenance and anomaly detection.
• Machine learning models for process optimization.
• AI-based computer vision for industrial quality control.

Session 2: Industrial IoT (IIoT) and Edge Computing

• IIoT sensors and data acquisition for real-time monitoring.
• Edge computing vs. cloud computing in industrial applications.
• Case studies on smart factories and intelligent automation.

Session 3: Cybersecurity in Industrial Automation

• Cybersecurity risks in SCADA, PLC, and IIoT systems.
• Best practices for secure industrial network design.
• Industrial standards: IEC 62443, NIST Cybersecurity Framework.

Hands-On Workshop: Implementing AI-based predictive maintenance in an industrial automation system.

Day 5: Industrial Automation Case Studies and Future Trends

Session 1: Case Study – Automation in Smart Grid & Energy Systems

• Power plant automation and smart grid control.
• Integration of renewable energy sources into the power grid.
• AI-driven energy efficiency optimization.

Session 2: Case Study – Automation in Oil & Gas and Manufacturing

• Pipeline automation and remote monitoring.
• Robotic process automation (RPA) in manufacturing.
• Industry case studies on automation-driven productivity improvements.

Session 3: Future of Industrial Automation – Industry 4.0 & Beyond

• AI-driven industrial automation and next-generation robotics.
• Digital transformation with 5G, IIoT, and blockchain in automation.
• The rise of autonomous factories and lights-out manufacturing.

Final Project Presentation: Participants develop and present an automation project solving a real-world industry challenge.

Final Assessment & Certification

• Knowledge Check: Final assessment on industrial automation topics.
• Project Presentation: Participants present their industrial automation solution.
• Certification: Certificate of completion awarded upon successful participation.