🎯 Course Description:
This 5-day focused course provides participants with comprehensive knowledge and practical skills in maintaining and troubleshooting traditional or classic control systems widely used in industrial and oil & gas facilities.
The course covers relay-based control panels, analog instrumentation, timers, counters, and PLC basics, emphasizing diagnostic techniques, fault finding, preventive maintenance, and repair methods. Attendees will gain hands-on experience with real-world troubleshooting scenarios and learn best practices to enhance system reliability.
👥 Who Should Attend:
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Control system technicians and engineers
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Maintenance personnel and electricians
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Instrumentation engineers
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Process control operators
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Technical supervisors and reliability engineers
🗓️ Day 1: Fundamentals of Traditional Control Systems
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Introductions & Course Overview |
| 09:00 – 10:30 | Overview of Classic Control Systems – Relay logic, analog devices |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Control Panel Components – Relays, timers, counters, switches |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Control System Wiring and Schematics – Reading and interpreting diagrams |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Building simple relay logic circuits |
🗓️ Day 2: Maintenance Principles for Control Systems
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Preventive Maintenance Strategies – Inspection and cleaning |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Testing Instruments and Components – Multimeters, oscilloscopes, megger |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Calibration and Adjustment – Analog meters, timers, and controllers |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Performing preventive maintenance on control panels |
🗓️ Day 3: Troubleshooting Techniques
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Systematic Troubleshooting Approach – Step-by-step fault finding |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Common Faults in Classic Control Systems – Relay failure, wiring faults |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Signal Tracing and Diagnosis – Using test equipment effectively |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Troubleshooting real fault scenarios |
🗓️ Day 4: Upgrading and Integration
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Introduction to PLCs and Digital Control – Basics and benefits |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Interfacing Classic Systems with Modern Controls – Hybrid solutions |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Documentation and Record Keeping – Maintenance logs and reporting |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Case Study: Successful upgrades and troubleshooting |
🗓️ Day 5: Safety, Best Practices, and Final Assessment
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Electrical Safety in Control Systems Maintenance |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Best Practices for Reliable Control Systems |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Practical Assessment and Group Troubleshooting Exercise |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Certification Ceremony |
📂 Course Materials Provided:
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Relay logic and analog control manuals
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Maintenance checklists and troubleshooting guides
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Sample wiring diagrams and circuit schematics
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Safety protocols and best practices documents
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Case study reports and workshop exercises
