Unit 3385: Instrumentation and Control Technician

1. Introduction to Instrumentation and Control Technician

• Overview of the role
• Key responsibilities
• Importance in industries such as manufacturing, oil & gas, pharmaceuticals, and utilities
• Career pathways and professional standards

2. Principles of Instrumentation

• Measurement fundamentals
  • Physical quantities and units
  • Accuracy, precision, and calibration
• Sensors and transducers
  • Types: temperature, pressure, flow, level, etc.
  • Operating principles
• Signal processing
  • Analog vs digital signals
  • Signal conditioning and transmission

3. Control Systems

• Control system basics
  • Open loop vs closed loop
• Feedback loops
  • Concept and examples
• Controllers
  • Types: On/off, proportional, integral, derivative (PID)
• System stability and response
  • Importance and methods to maintain stability

4. Process Instrumentation

• Overview of industrial process variables
• Pressure measurement devices
  • Bourdon tubes, strain gauges, piezoelectric sensors
• Temperature measurement devices
  • Thermocouples, RTDs, thermistors
• Level measurement devices
  • Float, ultrasonic, radar
• Flow measurement devices
  • Orifice plates, magnetic flowmeters, turbine flowmeters

5. Control Valves and Actuators

• Function and application of control valves
• Types of control valves
  • Globe, ball, butterfly valves
• Actuators
  • Pneumatic, electric, hydraulic
• Positioners and their role
• Valve sizing and selection basics

6. Programmable Logic Controllers (PLCs)

• Introduction to PLCs
• PLC architecture and components
• Basic programming concepts
  • Ladder logic and function blocks
• Applications in industrial process control
• Troubleshooting PLC systems

7. Human-Machine Interface (HMI)

• Role of HMI in control systems
• Types of HMIs
• Designing operator interfaces
• Monitoring and control functions
• Alarm management and data logging

8. Calibration and Maintenance

• Importance of calibration
• Calibration procedures for different instruments
• Maintenance schedules and preventive maintenance
• Documentation and record keeping

9. Troubleshooting and Diagnostics

• Common issues in instrumentation and control systems
• Diagnostic tools and techniques
  • Multimeters, loop calibrators, oscilloscopes
• Systematic troubleshooting processes
• Case studies/examples

10. Safety in Instrumentation and Control

• Safety protocols and best practices
• Relevant standards and regulations (e.g., OSHA, IEC)
• Hazard identification and risk assessment
• Safe handling of instruments and tools
• Emergency procedures