5035 – Installation and Maintenance of Instrumentation and Control Systems

Modern industrial operations rely heavily on the accuracy, stability, and responsiveness of their instrumentation and control systems. Yet, when reliability issues arise, these systems are often at the root of persistent problems. Studies consistently show that a significant portion of process instability and equipment failure can be traced back to field-installed devices, sensors, transmitters, valves, and positioners, that are improperly configured, poorly maintained, or simply misunderstood. The Installation and Maintenance of Instrumentation and Control Systems course addresses these challenges by providing in-depth, hands-on training focused on ensuring the long-term reliability and performance of these critical components.

This five-day technical training is designed to strengthen both theoretical understanding and practical competency in industrial measurement and control. Participants will engage with real-world simulators and test equipment to reinforce learning outcomes, develop diagnostic skills, and build confidence in their ability to manage the installation, calibration, and maintenance of instrumentation across a wide array of applications.

Reliability Principles and Failure Modes in Instrumentation

The industrial instrumentation training begins with a strong foundation in reliability engineering, highlighting why and how instrumentation fails. Participants explore essential concepts such as the six failure patterns, infant mortality, and the P-F curve (the predictive maintenance framework that links failure progression with detection timeframes). Common mechanical and electronic failure modes are examined to equip learners with the ability to anticipate and prevent common breakdowns in sensors and control devices. This section frames the entire course around the goal of improving equipment performance through informed, proactive practices.

Proficiency with Test and Calibration Equipment

One of the most significant barriers to effective instrumentation maintenance is the lack of familiarity with diagnostic tools. This course places a major emphasis on test equipment proficiency. Participants gain hands-on experience with:

• Multifunction calibrators, used to simulate and measure process variables,
• HART communicators, for digital configuration and diagnostics,
• Oscilloscopes, to assess electrical signals in complex systems,
• Temperature baths and deadweight testers, which provide precise calibration environments,
• Decade boxes, pressure pumps, U-tube manometers, and calibrated test gauges, which all support accurate calibration and troubleshooting.

By learning to use each of these tools correctly, technicians can dramatically reduce uncertainty in device performance and improve the accuracy of field instrumentation.

Pressure and Flow Measurement Systems

A major portion of the course focuses on pressure measurement systems, among the most common yet often problematic in industrial plants. Students review measurement units and learn the differences between direct pressure sensors and pressure transducers, gaining the skills needed for proper installation and preventive maintenance. They also study isolation techniques critical to safe handling and calibration.

Flow measurement is taught in conjunction with pressure systems, since flow calculations often rely on accurate differential pressure data. Participants analyze fluid properties such as viscosity and density and explore a wide variety of primary measuring devices including head-type instruments, variable area meters, magnetic and vortex flowmeters, ultrasonic sensors, and open-channel measurement systems. This is followed by a review of secondary devices like differential pressure cells and flow transmitters. Each method is evaluated for its installation requirements and maintenance needs, ensuring a comprehensive understanding of flow instrumentation.

Temperature and Level Measurement Technologies

The course continues with a full session on temperature measurement, covering both mechanical and electronic approaches. Trainees learn how to work with direct-reading instruments like bimetallic thermometers and gas-filled bulbs, and electrical sensors such as RTDs (resistance temperature detectors), thermocouples, and thermistors. Infrared temperature measurement techniques are also discussed, particularly useful in non-contact and high-temperature environments. Each sensor type is evaluated for accuracy, response time, and suitability in industrial applications, along with proper procedures for installation and upkeep.

Level measurement is explored in depth as well. Participants examine direct methods like sight glasses and float systems, as well as pressure-based hydrostatic measurement and air-bubble systems. Electronic level detection methods, including capacitive, ultrasonic, and radiation-based technologies, are discussed with a focus on real-world application and reliability concerns. Emphasis is placed on matching measurement technology to process needs and environmental conditions.

Analytical Measurement and Output Devices

Day four introduces participants to analytical instrumentation used for monitoring critical process parameters such as pH, conductivity, and emissions. These measurements are essential in industries where chemical composition affects product quality or environmental compliance. The session addresses the specific challenges associated with installing and maintaining analytical sensors, particularly their susceptibility to drift, fouling, and environmental degradation.

The course then shifts to output devices, which play a key role in closing the control loop. A detailed study of valves, actuators, positioners, and solenoids helps participants understand how these elements respond to control signals to regulate flow, pressure, and other process conditions. Actuator types, diaphragm and cylinder-based, are evaluated for their responsiveness and fail-safe configurations. Positioner function and setup is covered extensively, as is solenoid valve troubleshooting. These components are often neglected in training but are vital for maintaining process stability.

Understanding and Reducing Process Variability

The final module addresses process variability, a hidden cause of many quality and efficiency issues. Participants learn to identify sources of variability within input and output devices, process loops, and system design. Tools and techniques for detecting and measuring variability are discussed, along with strategies for its reduction or elimination. This section reinforces the connection between proper instrumentation practice and operational excellence, showing how well-maintained control systems contribute to stable, predictable process outcomes.

Practical Application and Skills Development

Throughout the week, students are immersed in realistic exercises using custom-built simulators and physical models. These hands-on activities replicate the challenges encountered in industrial settings, allowing participants to apply theoretical knowledge in practical scenarios. By the end of the course, learners will have performed installations, calibrations, and diagnostics on a wide range of instruments under instructor guidance.

The course concludes with a comprehensive review, final assessment, and certification of completion. This structure ensures that each participant walks away not only with a deeper understanding of instrumentation and control principles but with measurable skills that can be immediately applied in the field.

Course Audience

While the course is tailored for instrumentation and electrical technicians, it also provides substantial value for production operators, process engineers, and first-line supervisors who need to understand the fundamentals of measurement and control systems. Supervisors, in particular, benefit from enhanced insight into the technical realities faced by their teams, allowing for more effective planning, communication, and reliability advocacy.

By combining robust theory with hands-on training, this course bridges the gap between conceptual knowledge and field execution. It empowers industrial personnel to improve equipment reliability, optimize process control, and ensure compliance with quality and safety standards, objectives that are essential in today’s high-stakes production environments.