Control & Instrumentation
Practical Maintenance Aspects of
Industrial Instrumentation

03 - 07 June 2024
Sandton Centre Johannesburg South Africa.


Register Now! Limited Seats Available!

R17,999.00 Per Delegate

Course Overview

The Control & Instrumentation training course covers the practical maintenance aspects of industrial instrumentation with three modules Measurement, Valves and Controllers and is designed to be progressive with each module building on the previous.

Training consists of three training modules normally delivered over 8 days in two blocks of four days or similar combination to suit shift working patterns. The training delivery can be adapted to suit company’s specific requirements in terms of application, hands on practice or specific customer equipment. The training can be on site our Rochester training centre.

This is a highly practical training course focusing on industrial Instrumentation maintenance practices and fault-finding procedures with a lot of the training being hands-on work directly related to the course content.

Course Objective

This course enables trainees to,

  •  Measure current loop signals
  • Connect additional instruments into current loops
  • Carry out calibrations involving pressure, temperature, level and flow
  • Calibrate delta P and gauge pressure transmitters
  • Zero and span 4 – 20mA current loops
  • Calibrate I to P convertors
  • Understand pneumatic valve positioners
  • Set up valve positioners
  • Stroke check valves
  • Adjust valve actuators
  • Operate single loop controllers in Manual or Auto
  • Change modes using remote Setpoints
  • Set alarms levels and high lo range warnings
  • Adjust PID settings for loop response
  • Understand Controller faceplate indications during problem solving

Course is suitable for and is designed to attract and be of benefit to a range of people who work in the instrumentation and process plant area. Typically, but not exclusively this course will be of benefit to:

  • Electronic Engineers and Technicians
  • Chemical Engineers and Technicians
  • Electrical Engineers and Technicians
  • Electronic Design Engineers
  • Instrumentation Technicians
  • Control & Instrumentation Engineer
  • Electricians
  • Installation and Maintenance Technicians
  • Instrument and Process Control Technicians
  • Instrument Fitters
  • Maintenance Engineers
  • Mechanical Engineers and Technicians
  • Operations Engineers
  • Process Technicians
  • Production Professionals
  • System Integrators
  • Other professions (Engineers, Technicians) involved in the Process Industry who require an appreciation and understanding of the techniques used in Process Measurement and Control  

What you’ll learn

Instrumentation – Measurements (T3) Module 1

Signals and Standards:

  • Pneumatic Signals
  • Voltage Signals
  • Current Loops
  • Loop Connections
  • Power Supplies

Process Measurement

  • Temperature – Resistance, Thermocouple
  • Pressure – DP Cells, Gauge, Differential, Absolute
  •  Level – Head Pressure, Capacitive
  • Flow – Orifice Plate, Magflow, Vortex

Indication and Recording Equipment

  • Digital and Analogue Indicators
  • Installation and Calibration
  • Zero adjustment
  •  Span adjustment
  •  Standard (calibration) equipment
  • Commissioning and bringing on-line

Smart Transmitters

  • Setting up and calibrating using a Smart Transmitter Safety procedure will be covered at each stage and practical exercises will cover the use of isolating/equalising manifolds on flow systems, the use of pockets in conjunction with temperature probes etc. The implications of working on sensors which form part of a control loop will also be covered along with recommended safe working procedures.

Instrumentation – Actuators & Controllers Module 2

Values & Actuators

 Pneumatic Signals:
Pneumatic Instrument – Components:

  • Flapper/Nozzle
  • Air Relays
  • Bellows
  • Booster Relays

Pneumatic Instrument – Equipment

  •  I/P Convertors
  •  P/I Transmitters
  • P/P Transmitters

Control Valves

  • Types, Component Parts

Control Valve Actuators

  • Direct Acting
  • Reverse Acting
  • Double Acting

Control Valve Positioners

  • Types of Positioner
  • Fault-Finding
  • Valve Characterisation

PID Controllers
Basic Principles of Closed Loop Control Systems

  • Feedback in a control system
  • Terminology in control systems – Set point, Process Variable, Output
  • 3-controller operating modes – Automatic, Manual, Remote, Internal
  • Basic closed loop systems and their operation

Types of Control

  • Open loop, Closed loop, Feed-forward control

Controller Actions

  •  Proportional, Integral, Derivative
  • Tuning a PID controller to a process

Control Systems Configuration

  • Cascade Control, Ratio Control
  • Problem Solving
  • Measurement techniques in a control loop
  • Analysis of controller problems and diagnosis of faults

Instrumentation – Advanced Process Controls Module 3

Serial and Highway Communication

  • Wiring and connection requirements
  • Use of spurs and terminators
  • Principle of packet transfers
  • Common Wiring errors


  • RTU and ASCII systems
  • Station numbers and limits
  • Master and slaves
  • Modbus registers


  • DP and AP
  • Speed limitations and settings
  • Master and slaves
  • Common Wiring
  • Interrogating data buffers in the master
  • Commissioning and bringing online
  • PLC and SCADA Programming

Retrieving Modbus and Profibus data from PLCs and displaying on a SCADA system. Common programming techniques to keep this process manageable.

End of the workshop



While both In-House and Online training can present with cost-effectiveness and time-efficacy, there are some very specific differences between in-house courses and those based online.
The demand for additional courses by individuals or groups of people is increasing. Still, it depends entirely on the preferences of a person what type of training he or she wants to receive. Online courses and in-house training carry some similarities but they are considered to exhibit some very pivotal differences too. Despite that, both types of learning can be really beneficial for attendees.

For Registration and other Training arrangements,
contact us on the detail below.

SOUTH AFRICA : +27 11 057 6001
TANZANIA Cell: +255 769 688 544
WhatsApp +27 79 574 0389 /