IDC

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TECHNOLOGIES

TRAINING
DIRECTORY

CONTENTS
Workshop Title

Page

Data Communications & Networking

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Practical Data Communications and Networking for Engineers and Technicians ................................................ 1.1
Practical DNP3, 60870.5 and Modern SCADA Communication Systems .............................................................. 1.3
Practical Troubleshooting and Problem Solving of Ethernet Networks ................................................................ 1.5
Practical Fibre Optics for Engineers and Technicians .............................................................................................. 1.7
Practical Troubleshooting and Problem Solving of Industrial Data Communications ......................................... 1.9
Practical Industrial Networking for Engineers and Technicians ............................................................................1.11
Practical TCP/IP and Ethernet Networking for Industry ......................................................................................... 1.13
Practical Fundamentals of Telecommunications and Wireless Communications ............................................... 1.15
Practical TCP/IP Troubleshooting and Problem Solving for Industry ................................................................... 1.17
Practical Routers and Switches (Including TCP/IPand Ethernet) for Engineers and Technicians .......................1.19
Best Practice in Industrial Data Communications ................................................................................................. 1.21
Practical Fundamentals of Voice over IP (VoIP) for Engineers and Technicians .................................................. 1.23
Practical Troubleshooting, Design and Selection of Industrial Fibre Optic Systems for Industry ..................... 1.25
Troubleshooting Industrial Ethernet and TCP/IP Networks.................................................................................... 1.27
Practical Industrial Wireless for Engineers and Technicians.................................................................................. 1.29
Data Communications, Networking and Protocols for Industry - Back to Basics................................................ 1.31
Practical FieldBus, DeviceNet and Ethernet for Industry ...................................................................................... 1.33
Practical Troubleshooting and Problem Solving of Modbus Protocols ............................................................... 1.35
Practical Radio Telemetry Systems for Industry .................................................................................................... 1.37
Setting Up, Understanding and Troubleshooting of Industrial Ethernet and Automation Networks................ 1.39
Practical Troubleshooting of TCP/IP Networks......................................................................................................... 1.41
Practical Fibre Optics and Interfacing Techniques to Industrial Ethernet and Wireless...................................... 1.43
Hands-On Data Communication, Networking and TCP/IP Troubleshooting......................................................... 1.45
Practical Use and Understanding of Foundation Fieldbus for Engineers and Technicians................................ 1.47
Troubleshooting, Designing and Installing Digital and Analog Closed Circuit TV Systems............................... 1.49
Advanced TCP/IP-based Industrial Networking for Engineers and Technicians................................................... 1.51
Practical Troubleshooting & Problem Solving of Ethernet TCP/IP &Modbus Protocols ..................................... 1.53
Practical Wireless Ethernet and TCP/IP Networking .............................................................................................. 1.55

Electrical Power
Practical Electrical Network Automation and Communication Systems................................................................ 2 . 1
Practical Troubleshooting of Electrical Equipment and Control Circuits................................................................ 2 . 3
High Voltage Safety Operating Procedures for Engineers and Technicians........................................................... 2 . 5
Practical Power Distribution....................................................................................................................................... 2 . 7
Practical Power Quality: Problems and Solutions for Engineers and Technicians................................................ 2 . 9
Practical Power System Protection for Engineers and Technicians...................................................................... 2 . 11
Practical Variable Speed Drives (VSDs) for Instrumentation and Control Systems............................................ 2 . 1 3
Practical Electrical Wiring Standards National Rules for Electrical Installations - ET 101:2008...................... 2.15
Wind & Solar Power Renewable Energy Technologies....................................................................................... 2 . 1 7
Practical Distribution and Substation Automation (incl. Communications)
for Electrical Power Systems.................................................................................................................................... 2.19
Safe Operation and Maintenance of Circuit Breakers and Switchgear................................................................ 2 . 2 1
Troubleshooting, Maintenance and Protection of AC Electrical Motors and Drives........................................... 2 . 2 3
Power Transformers - Operation, Maintenance and Testing.................................................................................. 2 . 2 5
Lightning, Surge Protection and Earthing of Electrical and Electronic Systems in Industrial Networks.......... 2 . 2 7

Continued overleaf

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Maintenance and Troubleshooting of Uninterruptible Power Supply (UPS) Systems and Batteries................ 2 . 2 9
Practical Power System Harmonics, Earthing andPower Quality - Problems and Solutions............................ 2.31
Practical Motor Protection, Control and Maintenance Technologies.................................................................... 2 . 3 3
Practical Medium andHigh Voltage Testing of Electrical Equipment for Engineers and Technicians................ 2 . 3 5

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Practical Earthing of Utility and Industrial Distribution Systems for Engineers and Technicians...................... 2 . 3 7
Practical Electrical Substation Safety for Engineers and Technicians................................................................... 2 . 3 9

Practical HVCable Jointing and Terminations for Engineers and Technicians..................................................... 2 . 4 1

Operation and Maintenance of Diesel Power Generating Plants......................................................................... 2.43
Energy Efficiency, Design, Engineering and Auditing............................................................................................ 2 . 4 5

Critical Power Supply Options and Planning of High Availability Supplies........................................................ 2 . 4 7

Practical Electrical Safety Techniques for Industry................................................................................................. 2 . 4 9

Emergency Power Supplies: Electrical Distribution Design, Installation and Commissioning.......................... 2 . 5 1

Power Cables: Operation, Maintenance, Location and Fault Detection............................................................... 2 . 5 3

Practical Electrical Wiring Standards IEE BS 7671:2008+A1:2011 Edition.......................................................... 2.55

Practical Electrical Wiring Standards AS 3000:2007............................................................................................ 2.57

Electrical Drawings and Schematics........................................................................................................................ 2.59
South African Standard Sans 10142 The Wiring of Premises.............................................................................. 2.61
Electrical Maintenance for Engineers and Technicians.......................................................................................... 2.63
Installing, Programming and Commissioning of Power System Protection Relays and Hardware.................. 2.65

Practical Power Cabling and Earthing..................................................................................................................... 2.67

The Fundamentals of Power Distribution and Power Systems: Hands-on Practical Analysis and Design.......... 2.69
Practical HV and LV Switching Operations and Safety Rules for Engineers and Technicians............................ 2.71
Arc Flash Protection for Electrical Safety Professionals........................................................................................ 2.73
Practical Electrical Metering, Measurement and Instrument Transformers for Engineers and Technicians..... 2.75

Electrical and Instrumentation (E & I) Engineering for Oil and Gas Facilities..................................................... 2.77
Fundamentals of Smart Metering............................................................................................................................ 2.79
Installation, Testing and Troubleshooting of Transformers..................................................................................... 2.81

Medium Voltage AC Motors for the Power Industry Working Principles, Installation,
Maintenance and Troubleshooting........................................................................................................................... 2.83
Switchgear and Distribution Systems..................................................................................................................... 2.85

Electrical Power System Fundamentals for Non-Electrical Engineers ................................................................ 2.87

Inspection, Testing and Commissioning of Electrical Switchboards, Circuit Breakers,
Protective Relays, Cables and PLCs............................................................................................................................... 2.89
High Voltage Electrical Compliance and Safety Operating Procedures.................................................................... 2.91

High Voltage Design and Installations Master Class................................................................................................... 2.93

High Voltage Design and Installations Master Class (UK)........................................................................................... 2.95

Fundamentals of Operation and Troubleshooting of Emergency/Standby Power Generation using

Diesel Generators............................................................................................................................................................ 2.97
Diesel Power Generation plants with Multiple Machines in Parallel and on the Electrical Power Grid................ 2.99
Practical Maintenance & Troubleshooting of Battery Power Supplies.................................................................... 2.101
Standby Power and Energy Efficiency........................................................................................................................ 2.103
Electrical Substation and Switchyard Design ............................................................................................................ 2.105
Understanding Electrical Engineering and Safety for Non-Electricians.................................................................. 2.107
Master Series - Electrical Engineering........................................................................................................................ 2.109
Mechanical, Electrical and Instrumentation Engineering for Non-Engineers.......................................................... 2.111
Practical Earthing, Bonding, Lightning and Surge Protection...................................................................................2.113

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Electronics

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Practical Digital Signal Processing Systems for Engineers and Technicians......................................................... 3.1
Practical Embedded Controllers: Troubleshooting and Design............................................................................... 3.3
Practical EMC and EMI Control for Engineers and Technicians............................................................................... 3.5
Practical Industrial Electronics for Engineers and Technicians................................................................................ 3.7
Practical Shielding, EMC/EMI, Noise Reduction, Earthing and Circuit Board Layout............................................ 3.9
Power Electronics and Switch Mode Power Supply.............................................................................................. 3.11
Practical Troubleshooting of Electronic Circuits for Engineers and Technicians.................................................. 3.13

Information Technology
Industrial Network Security for SCADA, Automation, Process Control and PLCSystems................................... 4.1
Practical Fundamentals of E-Manufacturing, Manufacturing Execution Systems (MES)
and Supply Chain Management................................................................................................................................ 4.3
SNMP Network Management: The Essentials........................................................................................................... 4.5

Practical Android App Development.......................................................................................................................... 4.7

Cybersecurity for Automation, Control, and SCADA Systems (Using the ANSI/ISA-62443 Standards)............. 4.9

Chemical Engineering

Practical Fundamentals of Chemical Engineering ................................................................................................... 5.1

Handling Chemicals and Chemical Processes - Tips, Tricks and Tools ................................................................... 5.3

Instrumentation, Automation & Process Control

Practical Analytical Instrumentation in On-Line Applications................................................................................. 6.1
Practical Alarm Management for Engineers and Technicians................................................................................. 6.3
Practical Programmable Logic Controllers (PLCs) for Automation and Process Control..................................... 6.5
Practical Batch Management & Control (Including S88) for Industry..................................................................... 6.7
Practical Boiler Control and Instrumentation for Engineers and Technicians........................................................ 6.9
Practical Data Acquisition using Personal Computers and Standalone Systems............................................... 6.11
Practical Industrial Flow Measurement for Engineers and Technicians............................................................... 6.13
Practical Hazops, Trips and Alarms.......................................................................................................................... 6.15
Practical Hazardous Areas for Engineers and Technicians..................................................................................... 6.17
Practical Instrumentation for Automation and Process Control........................................................................... 6.19
Practical Intrinsic Safety for Engineers and Technicians........................................................................................ 6.21
Practical Tuning of Industrial Control Loops........................................................................................................... 6.23
Practical Motion Control for Engineers and Technicians........................................................................................ 6.25
Practical Fundamentals of OPC................................................................................................................................ 6.27
Practical Process Control ......................................................................................................................................... 6.29
Practical Process Control and Tuning of Industrial Control Loops 6.31
Practical SCADA and Telemetry Systems for Industry........................................................................................... 6.33
Practical Safety Instrumentation and Emergency Shutdown Systems for Process Industries.......................... 6.35
Practical Industrial Programming using 61131-3 for Programmable Logic Controllers (PLCs).......................... 6.37
Practical Control Valve Sizing, Selection and Maintenance................................................................................... 6.39
Best Practice in Process, Electrical and Instrumentation Drawings and Documentation................................... 6.41
Practical Distributed Control Systems (DCS) for Engineers and Technicians...................................................... 6.43
Fundamentals of Industrial Automation.................................................................................................................. 6.45
Practical Troubleshooting of Data Acquisition and SCADA Systems.................................................................... 6.47

Continued overleaf

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Installation, Calibration and Maintenance of Electronic Instruments.................................................................. 6.49

RFID Tagging: Features and Applications................................................................................................................ 6.51
Practical Industrial Troubleshooting of Instrumentation, Electrical and Process Control
for Engineers and Technicians.................................................................................................................................. 6.53

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Practical Hazops for Engineers and Technicians..................................................................................................... 6.55

Practical SCADA Systems for Industry.................................................................................................................... 6.57
Practical Machine Vision Applications for Industry................................................................................................ 6.59

Practical Advanced Process Control for Engineers and Technicians..................................................................... 6.61

Practical Industrial Safety, Risk Assessment and Shutdown Systems for Industry............................................ 6.63

Introduction to the Selection, Installation, Commissioning and Maintenance of Fiscal Flow

and Metering Equipment.......................................................................................................................................... 6.65
Measurement and Control for Non-Instrument Personnel.................................................................................... 6.67
Programmable Logic Controllers (PLCs) and SCADA Systems............................................................................ 6.69
Practical Drives, Motors and PLCs for Engineers and Technicians....................................................................... 6.71
Practical Troubleshooting and Problem Solving of PLCs and SCADA Systems.................................................. 6.73

Practical Flow Essentials........................................................................................................................................... 6.75

Fundamentals of Instrumentation, Process Control, PLCs and SCADA for Plant Operators
and other Non-Instrument Personnel...................................................................................................................... 6.77
Fundamentals of Practical Building Automation Systems (BAS).......................................................................... 6.79
Design of Industrial Automation Functional Specifications for PLCs, DCSs and SCADA systems................... 6.81

Practical Remote Engineering, Mechatronics and Robotics for Engineers and Technicians ............................. 6.83
Instrumentation Engineering for Oil and Gas Facilities ........................................................................................ 6.85
Practical IEC 61850 for Substation Automation for Engineers and Technicians.................................................. 6.87
Hazardous Areas and ATEX Awareness for Technical and Non-technical Staff.................................................... 6.89

One-day Refresher Training: Electrical Equipment for Practical Hazardous Areas

for Engineers and Technicians (Outside Europe).................................................................................................... 6.91
One-day Refresher Training: Electrical Equipment for Practical Hazardous Areas
for Engineers and Technicians (Within Europe)...................................................................................................... 6.93
Master Series: Instrumentation and Control........................................................................................................... 6.95
Integrated Programming, Maintenance, Troubleshooting and Optimisation of the
Drill Monitor System (DMS)..................................................................................................................................... 6.97

Mechanical Engineering
Practical Fundamentals of Heating, Ventilation and Airconditioning (HVAC) for Engineers and Technicians......7.1
Practical Boiler Plant Operation and Management for Engineers and Technicians...............................................7.3

Practical Cleanroom Technology and Facilities for Engineers and Technicians......................................................7.5

Practical Lubrication Engineering for Engineers and Technicians............................................................................7.7

Practical Safe Lifting Practice and Maintenance........................................................................................................7.9

Practical Pumps - Design, Operation and Maintenance for Centrifugal and Positive Displacement Pumps........ 7.11

Practical Machinery and Automation Safety for Industry.......................................................................................7.13

Practical Machinery Vibration Analysis and Predictive Maintenance....................................................................7.15
Practical Pumps and Compressors: Control, Operation, Maintenance and Troubleshooting.............................7.17
Gas Turbines: Fundamentals, Maintenance, Inspection and Troubleshooting......................................................7.19
Fundamentals of Mechanical Engineering...............................................................................................................7.21
Practical Mechanical Drives (Belts, Chains and Gears) for Engineers and Technicians.......................................7.23
Practical Balancing, Alignment and Condition Monitoring of Rotating Equipment.............................................7.25
Pipeline Systems - Design, Construction, Maintenance and Asset Management................................................7.27

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Fundamentals of Process Plant Layout and Piping Design....................................................................................7.29

Practical Mechanical Sealing with Rotary, Pneumatic and Hydraulic Seal Types plus Gaskets..........................7.31
Best Practice Design, Maintenance and Troubleshooting of Conveyors and Chutes...........................................7.33
Practical Process Compressors.................................................................................................................................7.35
Performance Monitoring of Pumps and Compressors...........................................................................................7.37
Fundamentals of Pipe Stress Analaysis with Introduction to Caesar II..............................................................7.39
Practical Corrosion Management..............................................................................................................................7.41
Reliability Centred Maintenance (RCM)...................................................................................................................7.43
Rigid and Flexible Hose Connections.......................................................................................................................7.45
Safety Relief Valves - Inspection, Operation and Troubleshooting.........................................................................7.47
Mechanical Design Concepts for Non-Mechanical Engineers................................................................................7.49
Practical Hydraulic and Pneumatic Systems: Operations and Troubleshooting...................................................7.51
Practical Conveyor, Chute and Feeder Design.........................................................................................................7.53

Project and Financial Management

Practical Financial Fundamentals and Project Investment Decision Making......................................................... 8.1

How to Manage Consultants...................................................................................................................................... 8.3
Practical Marketing for Technical Professionals........................................................................................................ 8.5
Practical Project Management for Engineers and Technicians................................................................................ 8.7
Practical Specification and Technical Writing for Technical People.......................................................................... 8.9
Train the Trainer - Presentation & Instructing Skills for Engineers and Technical Professionals........................ 8.11
Leading your Engineering Team to Top Performance............................................................................................. 8.13
The Practical Business Engineer.............................................................................................................................. 8.15
People Management Skills for Technical Professionals......................................................................................... 8.17
Engineering Leadership - Making the Transition from Engineer to Leader......................................................... 8.19
Practical Shutdown and Turnaround Management for Engineers and Managers............................................. 6.21

Civil Engineering
Hazardous Waste Management and Pollution Prevention ..................................................................................... 9.1
Structural Design for Non-Structural Engineers ..................................................................................................... 9.3
Best Practice in Sewage and Effluent Treatment Technologies ............................................................................... 9.5
Designing, Specifying and Constructing with Modern Concrete .......................................................................... 9.7
Transportation Planning and Management.............................................................................................................. 9.9

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IDC TECHNOLOGIES
ABOUT IDC
IDC Technologies is internationally
recognised as the premier provider of
practical, technical training for engineers
and technicians. We specialise in the fields
of industrial data communications, telecommunications, automation and control,
and are continually adding to our portfolio
of over 300 different workshops.

COMPANY MISSION

To provide our clients with measurable

and significant productivity gains through
excellence in cutting edge, practical
engineering and technology training.

IDC Technologies is an Internationally

Accredited
Professional
Training
Organisation. IDC has received recognition,
endorsement and/or accreditation (varies
by course and location) from authorising
bodies based around the world. These
organizations include:
IDC Technologies is registered with
Pembangunan Sumber Manusia Berhad
(PSMB) (Human Resources Development
Fund in Malaysia) in Category A.
Institute of Measurement and Control (IMC)
in the United Kingdom is Britains foremost
professional body for the Automation
Industry. IDC Technologies is a recognised
Companion Company of the IMC.
The Institution of Professional Engineers
New Zealand (IPENZ) is the professional
body which represents professional
engineers from all disciplines in New
Zealand. IPENZ members can self assess
for CPD points associated with IDC
Technologies public workshops.
Existing members of Engineers Australia
are entitled to claim CPD hours for private
study, short courses, and learning activities
at the workplace. CPD hours can be claimed
for our courses in most cases, but we
would always advise individual members
to check with the institution if unsure
regarding a specific course.
The South African Institution of Mechanical
Engineers (SAIMechE) covers all fields of
application including automobile, energy
generation, process engineering, heavy
manufacture,
design,
management,
research, mining and education.
It is very important to us, at IDCTechnologies,
to ensure that our clients can confidently
attend our workshops and courses, knowing
that the professional development they are
receiving is of a creditable standard and
will provide them with personal measurable,
productivity gains and the opportunity for
career advancements.

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Our instructors are highly respected in their

fields of expertise and in the last 20 years
have trained over 500,000 engineers,
scientists and technicians worldwide.

With offices conveniently located worldwide,

IDC Technologies has an enthusiastic team
of professional engineers, technicians and
support staff who are committed to providing
the highest quality of training and
consultancy.

ACCREDITATION
AND CONTINUING
EDUCATION

TECHNICAL WORKSHOPS
Training that Works

Expert Instructors

We deliver engineering and technology

training that will maximise your business
goals. In today's competitive environment,
you require training that will help you and
your organisation to achieve its goals and
produce a large return on investment. With
our "Training that Works" objective you and
your organisation will:
Get job-related skills that you need to
achieve your business goals
Improve the operation and design of
your equipment and plant
Improve your troubleshooting abilities
Sharpen your competitive edge
Boost morale and retain valuable staff
Save time and money

We search the world for good quality instructors

who have three imperative attributes:
1. Expert knowledge and experience of
the course topic
2. Superb training abilities to ensure the
know-how is transferred effectively and
quickly to you in a practical hands-on way
3. Listening skills they listen carefully to
the needs of the participants and want to
ensure that you benefit from the
experience
Each and every instructor is evaluated by the
delegates and we assess the presentation after
each class to ensure that the instructor stays on
track in presenting outstanding courses.

Hands-on Approach to Training

Each delegate receives a Certificate of

Attendance documenting their experience.

All IDC Technologies workshops include

practical, hands-on sessions where the
delegates are given the opportunity to apply
in practice the theory they have learnt.

Quality Manuals

A fully illustrated workshop manual with

hundreds of pages of tables, charts, figures
and handy hints, plus considerable
reference material is provided FREE of
charge to each delegate.

Certificate of Attendance

100% MONEY BACK GUARANTEE

IDC Technologies engineers have put

considerable time and experience into
ensuring that you gain maximum value
from each workshop.
If by lunch time of the first day you decide
that the workshop is not appropriate for your
requirements, please let us know so that we
can arrange a 100% refund of your fee.

IDC WORLDWIDE OFFICE LOCATIONS

AUSTRALIA
POBox 1093, West Perth, WA6872
Telephone: 1300 138 522
Facsimile: 1300 138 533
CANADA
402-814 Richards Street
Vancouver, BC V6B 3A7
Telephone: 1-800-324-4244
Facsimile: 1-800-434-4045
INDIA
2nd & 3rd Floor, No.23, Anna Salai,
Saidapet, Chennai 600 015,
Tamilnadu
Tel: +91 44 3061 8525
IRELAND
Caoran, Baile na hAbhann
Co. Galway, Ireland
Telephone: (01) 473 3190
Facsimile: (01) 473 3191

malaysia
26 Jalan Kota Raja E27/E
Hicom Town Center, Seksyen 27,
40400 Shah Alam, Selangor
Telephone: (03) 5192 3800
Facsimile: (03) 5192 3801

UNITEDKINGDOM
Suite 18, Fitzroy House
Lynwood Drive
Worcester Park, Surrey KT4 7AT
Telephone: (020) 8335 4014
Facsimile: (020) 8335 4120

NEWZEALAND
POBox 76142, Manukau City, 2241
Telephone: (09) 263 4759
Facsimile: (09) 262 2304

UNITEDSTATES
67 T.W. Alexander Drive
PO Box 12277
Research Triangle Park, NC 27709
Telephone: 1-800-324-4244
Facsimile: 1-800-434-4045

SINGAPORE
100 Eu Tong Sen Street
#04-11 Pearls Centre, Singapore 059812
Telephone: (65) 6224 6298
Facsimile: (65) 6224 7922
SOUTHAFRICA
POBox 389, Halfway House 1685
Telephone: 011 024 5520/1/2/3/4/5
Facsimile: (086) 692 4368

idc@idc-online .com

vietnam
Suite 501 EPhuong Tower,
31C Ly Tu Trong
Ben Nghe Ward, Dist. 1,
Ho Chi Minh City, S.R. Vietnam
Ph: +84 909 728 048
Fax: +84 838 223 676

www.idc-online .com

A Message from IDC Technologies Technical Director,

Steve Mackay

Dear Colleague

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Welcome to our latest technical training directory. I am proud to present the latest collection of engineering and
technology courses that we present throughout the world.

We have been providing practical training for over 20 years throughout the USA, Canada, United Kingdom, Ireland,
Australia, Singapore and New Zealand. Although we are one of the largest providers of this sort of training and have
trained a remarkable 500,000 engineers and technicians in the past few years alone, we are not content with resting on
our laurels and continue to achieve an amazing 99.8 % satisfaction rating in which delegates indicated the course was
"good", "very good" or "excellent". We want the course that you attend to be an outstanding, motivating experience
where you walk away and say - "that was truly a great course with a brilliant instructor and we will derive enormous
benefit from it".
Our courses are not academic but are rather designed to immediately provide you with the practical skills which will
contribute to your productivity and your company's success. Our courses are vendor independent, free of bias and
targeted solely at improving your productivity.
We have a remarkable group of instructors whom we believe are among the best in the industry. Of greatest benefit is
that they have real and relevant practical experience in both industry and training.

Our policy is to continually re-examine and develop new training programs, update and improve them. Our aim is to
anticipate the shifting and often complex technological changes facing everyone in engineering and business and to
provide courses of the absolutely highest standards - helping you to improve your productivity.

We put tremendous efforts into our documentation with award winning manuals which are well researched, practical
and down to earth in support of the course; so much so that many delegates have remarked that the manual itself
justifies the course fees.
I would urge you to consider our courses and call us if you have any queries about them. We would be glad to explain
in more detail what the courses entail and can even arrange for our instructors to give you a call to talk through the
course contents with you and how it will benefit yourselves.

Finally, thank you for being such tremendously supportive clients. We are blessed with having such brilliant people
attending our courses who are enthusiastic about improving themselves and benefiting their companies with new
insights and methods of improving their productivity. Your continual feedback is invaluable in making our courses even
more appropriate for today's fast moving technology challenges.
We want to be your career partner for life - to ensure that your work is both satisfying and productive and we will do
whatever it takes to achieve this.
Yours sincerely

(C P Eng, BSEE, B.Sc(Hons), MBA)

Technical Director

P.S. Don't forget our no-risk guarantee - we give you a 100% guarantee of satisfaction or your money back.

ON-SITE & CUSTOMISED TRAINING

The objective of training today is to gain knowledge and

experience in the latest developments in technology through
cost effective methods. The investment in training, by companies
and individuals is growing each year as the need is recognised
to keep topical and up to date in the industry in which they are
operating.
In addition to the quality workshops which IDC Technologies
present on a world-wide basis, all IDC courses are also available
for on-site (inhouse) presentation at our client's premises.

ON-SITE TRAINING

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On-site training is a cost-effective method of training for

companies with several employees to train in a particular area.
Organisations can save valuable training dollars by holding
courses on-site, where costs are significantly less. Other benefits
are IDC's ability to focus on particular systems and equipment so
that attendees obtain the greatest benefit from the training.

All on-site workshops are tailored to meet with our client's

training requirements and courses can be presented at beginners,
intermediate or advanced levels based on the knowledge and
experience of the delegates in attendance. Specific areas of
interest to the client can also be covered in more detail.

Very good. The instructor

customised the workshop content
to the ongoing requirements
of our plant.
David Wood

CUSTOMISED TRAINING

In addition to standard on-site training, IDC Technologies

specialises in developing customised courses to meet our
client's training needs. IDC has the engineering and training
expertise and resources to work closely with clients in preparing
and presenting specialised courses.
You may select components of current IDC workshops to be
combined with additional topics or we can design a course
entirely to your specifications. The benefits to companies in
adopting this option is reflected in the increased efficiency of
their operations and equipment.

VER
O
E
V
A
S

Our company has already

been able to measure the
productivity improvements.
Thanks again for an
outstanding job.
Stephan Cocks

50%

For more information or a FREE proposal please contact our Client Services Manager:
Kevin Baker

[email protected]

E-Learning

ENGINEERING INSTITUTE OF TECHNOLOGY

Five years ago IDC Technologies started to offer selected courses via distance education using
the latest e-Learning techniques. Demand for these courses has grown so much that we have
over 1000 students worldwide. Hence we decided to launch a unique new division to focus on
advanced distance learning in engineering and technology.
We are excited to invite you to find out more about the Engineering Institute of Technology (EIT).
The EIT is intended to help you advance your career when you do not have the time for
on-campus study or cannot find courses with practical real world content that you can apply
at work.
The EIT offers engineering certifications, delivered online with practical course content by world
class instructors. This provides you with the benefits of live classroom based study in a more
efficient, flexible and cost effective manner.
The new Institute has been recognised by major international engineering organisations, including IEEE, ECSA
and the Australian Government, building upon the solid foundation started by IDC Technologies.

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COURSES INCLUDE:

Advanced Diploma Programs in:

Industrial Automation
Electrical Engineering
HVAC

Mechanical Engineering

Electrical and Instrumentation Engineering for Mining

Electrical and Instrumentation (E &I) Engineering
for Oil and Gas Facilities
Wireless Technologies
Plant Engineering

Graduate Diploma Programs in:

Engineering (Industrial Automation)

Masters Degree Programs in:

Engineering (Industrial Automation)

And much more

EIT also offers a wide range of short certificate courses

in a variety of engineering topics.

ADVANCE YOUR CAREER WITHOUT LEAVING YOUR DESK

International cutting edge engineering courses, with practical content

Live and interactive on-line distance learning
Flexible and cost effective

Globally accredited and recognised

Industry experienced instructors

For more information please visit the EIT website:

www.eit.edu.au or contact us at [email protected]

ENGINEERING CONSULTING SERVICES

SPECIALIST CONSULTING
IDC Technologies has been providing high quality specialist advice and consulting for more than ten years to
organisations around the world. The technological world today presents tremendous challenges to engineers,
scientists and technicians in keeping up to date and taking advantage of the latest developments in the key technology
areas. We pride ourselves on being the premier provider of practical and cost-effective engineering solutions.

Professionally Staffed
IDC Technologies consists of an enthusiastic and experienced team that is committed to providing the highest quality
in consulting services. The company has thirty-five professional engineers; quality focussed support staff, as well as
a vast resource base of specialists in their relevant fields.

Client Focus

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IDCs independence and impartiality guarantee that clients receive unbiased advice and recommendations, focussed
on providing the best technical and economical solutions to the client's specific and individual requirements.

KEY AREAS OF SERVICE

IDCTechnologies provides specialist advice and services

to organisations around the world. Key areas in which
the company provides consulting and engineering
services include:

Synchronising Systems

Fast Power Transfer Systems

Electrical Network Studies

Power System Investigations & Analysis

Safety Earthing

1. Communications

Industrial Communications and

Telecommunications

Lightning Protection

Fiber Optics

Power Quality

Radio & Satellite Communications

Power Factor Correction & Filter Design

Substation Automation

Wide Area Networks

Local Area Networks

Range of services

Intranets & TCP/IP

IDC Technologies is structured to provide a wide range of

services. These include:

Fieldbus

Pre-investment studies

Project implementation

2. Process Control & Automation

Instrumentation

Environmental management

SCADA & Telemetry Systems

System design

Data Acquisition

Engineering design

PLC & DCS Systems

Feasibility studies

Intrinsic Safety

Cost estimates

DSP Hardware, Firmware & Software

Implementation

Strategic planning

High Quality Earthing

Customised training

Preparation of contracts and specifications

Tender evaluation

3. Electrical Distribution & Protection

Transformers, Cables,
distribution equipment

System audits and evaluation

Switchgear

&

other

Protection Systems (HT & LT) & Protection Grading

Studies

Generator Protection, Excitation & Voltage Control

systems

Project management and execution

On-site measurements and problem solving

Preparation of system documentation
Presentations, seminars and manuals
Additional services on application

For more information on IDC Engineering consulting services, contact our Technical Director:

Steve Mackay

[email protected]

PAST DELEGATES SAY:

Ive gained more useful info
from this seminar than any
Ive previously attended.

Very competent and great

presenter.
David Wolfe, Acromag

Jim Hannen, Wheeling-Misshen Inc.

Excellent instructor with plenty of

practical knowledge.
Ian Kemp, ANSTO

E. Burnie, Sellotape

Excellent,
I have taken a TCP/IPclass
before and didnt understand it.
After this course, I feel
more confident with my
newfound knowledge.
John Armbrust, Phelps Dodge

Filled in many gaps and helped

me to see where I need to
research further and where my
knowledge is sufficient.
David Robertson, NZWorley Ltd

Provided me with a good all round

appreciation, essential for all
mechanical engineers.

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This course offered a layout of

updated systems and modern trends
to keep ahead.

Great refresher on current practice.

Also helped to bring me up to date
on new technology.

Chris Standish, Enterprise

Excellent depth of subject

knowledge displayed.
Hugh Donohue, AMEC

Saved hours of trial

and error.
Mario Messwa, DAPS

This is the 2nd IDC Technologies

class I have taken both have been excellent!

This was one of the best courses

I have ever been on. The instructor
was excellent and kept me fully
interested from start to finish.
Really glad I attended.
Chris Mercer, Air Products

Excellent knowledge of subject

and ability to communicate it.

Well presented,
excellent material

Stephen Baron, Air Products

Written material was about the best

Ive seen for this type of course.
The instructor was able to set an
excellent pace and was very
responsive to the class.

The course went through

a good range of materials,
requirements etc to meet
practical applications.

John McLaren,
Glaxo Smithline

A very worthwhile course.

Excellent presentation!
Well done.

Training is a critical part of our

business and gives us the edge.

Paul Swales,
South Corp Technology Systems

Pat V Hammond, Johnson Matthey PLC

Mike Mazurak, ANSTO

Shane Tucker, Epic Energy

Very good workshop

and instructor.

A most enjoyable and

informative course. Thank you.

Well presented
and the instructor obviously
has the practical knowledge
to back things up.

Mark Moore

John Harms, Avista Corporation

Good presentation and very

knowledgeable.

Clive Waters, Santos Ltd

Brett Muhlhauser, Connell Wagner

Ron Scifleet, Sanitarium

Philip Fraser, NHP

Well compiled
technical material.

Well structured
and very informative.

Robert Higgenbotham, Yallourn Energy

Bruce McLennan, Alcoa

I like the practicality

of the workshop.

The course addresses a very

big need in the industry.

Karl Armfield, Joy Mining

AD Swanepoel, Sasol

Excellent instructor with excellent

depth and spread of knowledge
in this subject.

Was worthwhile, touched on the

subject in areas that I was unsure
about, great workshop.

John Myhill, Automated Control Systems

I would like to arrange this

workshop for my department.
A Mirecki, Sasol

Logan Mudaly, Engen

Dave Thom, Eskom

Companies who have benefitted from IDCTechnologies Training:

AUSTRALIA

SOUTH AFRICA

AIR DUCTER AIR SERVICES ALCOA ALINTA GAS AMPOL REFINERIES

ANSTO AUSTRALIAN COMMUNICATIONS AUTHORITY AUSTRALIAN
GEOLOGICAL SOCIETY AUSTRALIAN RAIL ROAD GROUP BHP BILLITON
BHP BILLITON - PETROLEUM DIVISION BHP IRON ORE BOC GASES BOEING
CONSTRUCTORS INC BRISBANE CITY COUNCIL BRITISH AEROSPACE
AUSTRALIA CAMMS AUSTRALIA PTY LTD CHK WIRELESS TECHNOLOGIES
CI TECHNOLOGIES CITIWATER TOWNSVILLE CITY WEST WATER CIVIL
AVIATION AUTHORITY COMALCO ALUMINIUM CSIRO DELTA ELECTRICITY
DEPT OF DEFENCE DEPT OF TRANSPORT AND WORKS DSTO DUKE
ENERGY INTERNATIONAL EMERSON PROCESS MANAGEMENT ENERGEX
ERG GROUP ERGON ENERGY ETSA FMC FOODTECH PTY LTD FOOD
SCIENCE AUSTRALIA GHD CONSULTING ENGINEERS GIPPSLAND WATER
GLADSTONE TAFE COLLEGE GORDON BROTHERS INDUSTRIES LTD
GOSFORD CITY COUNCIL GREAT SOUTHERN ENERGY HAMERSLEY IRON
HEWLETT PACKARD HOLDEN HOLDEN LTD HONEYWELL I&E SYSTEMS
PTY LTD INTEGRAL ENERGY KALGOORLIE NICKEL SMELTER METRO BRICK
MILLENIUM CHEMICALS MISSION ENERGY MT ISA MINES MURDOCH
UNIVERSITY MURDOCH UNIVERSITY NABALCO NEC NHP ELECTRICAL
NILSON ELECTRIC NORMANDY GOLD NORTH PARKES MINES NU-LEC
INDUSTRIES AUSTRALIA LTD PARKER HANNAFIN PEAK GOLD MINES
PHARMACIA & UPJOHN POWER & WATER AUTHORITY NT (PAWA) POWERCOR
POWERLINK PROSPECT ELECTRICITY QETC QUEENSLAND ALUMINA
RAAF AIRCRAFT RESEARCH AND DEVELOPMENT UNIT RAAF BASE
WILLIAMTOWN RAYTHEON RGC MINERAL SANDS RLM SYSTEMS ROBE
RIVER IRON ASSOCIATES ROYAL DARWIN HOSPITAL SANTOS LTD
SCHNEIDER ELECTRIC SHELL - CLYDE REFINERY SNOWY MOUNTAIN HYDRO
SPC FRUIT STANWELL POWER STATION TELSTRA THOMPSON MARCONI
SONAR TIWEST TRANSEND NETWORKS PTY LTD UNCLE BENS VISION
FIRE & SECURITY WESFARMERS CSBP WESTERN POWER WESTRAIL
WMC - KALGOORLIE NICKEL SMELTER WMC FERTILIZERS WOODSIDE
WORSLEY ALUMINA WYONG SHIRE YOKOGAWA AUSTRALIA

AMATOLA DISTRICT COUNCIL ANGLO AMERICAN BATEMAN METALS

CALTEX REFINERIES CHEVRON ANGOLA COLUMBUS STAINLESS DE BEERS
KIMBERLEY DE BEERS VENETIA MINE DEBEERS DEBTECH DURBAN
METRO EAST DRIEFONTEIN GOLD MINE EASTERN CAPE TECH EMERGENCY
SERVICES, METRORAIL ESKOM GRINTEK EWATION HIGHVELD STEEL
HILLSIDE ILLOVO SUGAR IMPALA PLATINUMS ISCOR IST JOY MINING
KOEBURG POWER STATION LEVER PONDS METSO AUTOMATION
MIDDLEBURG FERROCHROME MINTEK MONDI KRAFT MOSSGAS
NAMAQUA SANDS NESTLE NKOMATI MINE OMNIA FERTILISERS ORBICOM
OTB PALABORA MINING POTGIETERUS MUNICIPALITY PROCONICS PTY
LTD RAND WATER BOARD RDI RICHARDS BAY MINERALS SA NAVY SABC
SALDANHA STEEL SANS FIBRES SAPPI DURBAN SASOL COAL SASOL
MSM ROTATING EQUIPMENT SASOL SYNTHETIC FUELS SATRA SILDANHA
STEEL SKILLTEC SPOORNET STEINMULLER AFRICA TRANSTEL EASTERN
REGION UMGENI WATER WATER UTILISATION CORPORATION WESTERN
PLATINUM WITWATERSRAND TECHNIKON YELLAND CONTROLS

DE BEERS - JWANENG MINE DE BEERS - ORAPA MINE

CANADA

AECL AIRCOM INDUSTRIES (76) LTD ATCO ELECTRIC BC GAS - CANADA

BC HYDRO BOMBARDIER CITY OF LONDON - ONTARIO CITY OF OTTAWA
CITY OF SASKATOON CONOCO CANADA LIMITED DEPT OF NATIONAL
DEFENCE - CANADA ENBRIDGE PIPELINES ENMAX FORD ELECTRONICS
MANUFACTURING PLANT GE ENERGY SERVICES GENERAL MOTORS
GUILLEVIN AUTOMATION HUSKY OIL IMC LTD IMPERIAL OIL INCO LTD
KALPEN VACHHARAJANI KEYANO COLLEGE LABRADOR HYDRO MANITOBA
HYDRO MANITOBA LOTTERIES CORP MEMORIAL UNIVERSITY OF NEW
FOUNDLAND MILLTRONICS NEW BRUNSWICK POWER NOVA CHEMICALS
NXTPHASE CORPORATION - VANCOUVER ONTARIO HYDRO OTTAWA HYDRO
PETRO CANADA POWER MEASUREMENT LTD SASKATCHEWAN POWER
SPARTAN CONTROLS STONE CONSOLIDATED STORA SUNCOR ENERGY
SYNCRUDE TELUS TRANS CANADA PIPELINES TROJAN TECHNOLOGIES
WASCANA ENERGY WEST COAST ENERGY WEYERHAUSER

FRANCE

SCHLUMBERGER

INDIA
MASIBUS

IRELAND

BAYER DIAGNOSTICS ESB DISTRIBUTION INTEL IRISH CEMENT JANNSEN

PHARMACEUTICALS LTD MICROSOL LIMITED PFIZER PILZ IRELAND
PROSCON ENGINEERING

KOREA

US DEPT OF THE ARMY

MALAWI

DWANGA SUGAR CORPORATION

MALAYSIA

GERMAN MALAYSIA INSTITUTE

NAMIBIA

SIMUNYE SUGAR

TANZANIA
GOLDEN PRIDE MINE
UNITED ARAB EMIRATES

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BOTSWANA

SWAZILAND

NAMIBIAN BROADCASTING CORPORATION NAMPOWER NAMWATER

NEW ZEALAND

ACI PACKAGING AJ GREAVES ANCHOR PRODUCTS AUCKLAND REGIONAL

COUNCIL BALLANCE AGRI NUTRIENTS CONTACT ENERGY ENZAFOODS NZ
LTD ERICCSON FISHER & PAYKEL GEC ALSTHOM JAMES HARDIE
METHANEX NZ LTD NATURAL GAS NZ NZ MILK PRODUCTS NZ WATER AND
WASTE ASSOC NORSKE SKOG NZ ALUMINIUM SMELTERS NZ REFINING CO
PAN PAC FOREST PRODUCTS POWERCO ROCKWELL NZ ROTORUA
DISTRICT COUNCIL ROYAL NEW ZEALAND NAVY THE UNIVERSITY OF
AUCKLAND

SAUDI
ARABIA
SAUDI ELECTRIC COMPANY

SINGAPORE
ACTIVEMEDIA INNOVATION PTE LTD FLOTECH CONTROLS LAND
TRANSPORT AUTHORITY NGEE ANN POLYTECHNIC POWER SERAYA LTD
WESTINGHOUSE YOKOGAWA SINGAPORE

EUROMATECH PROMIS GROUP

UNITED KINGDOM

24 SEVEN ABB AUTOMATION LTD AER RIANTA AIR PRODUCTS ALLEN STEAM
TURBINES/ROLLS ROYCE ALLIED COLLOIDS ALLIED DISTILLERS ALSTOM
AMEC DESIGN & MANAGEMENT BAE SYSTEMS BAILEY ICS BBC ENGINEERING
BECHTEL BNFL - MAGNOX GENERATION BP CHEMICALS BRITISH AMERICAN
TOBACCO BRITISH ENERGY BRITISH GAS BRITISH STEEL CEGELEC
CERESTAR COE LTD CONOCO CORBY POWER STATION CORUS GROUP PLC
CRODA LEEK LTD CRUICKSHANKS LTD DARESBURY LABORATORIES DATEL
RAIL SYSTEMS DRAX POWER STATION ELF EXPLORATION UK PLC ENERGY
LOGISTICS EURO TUNNEL EUROTHERM EUROTUNNEL EVESHAM MICROS
EXPRO NORTH SEA LTD EXULT LTD FIRST ENGINEERING LTD FISHER
ROSEMOUNT GEC METERS GENESIS OIL & GAS CONSULTANTS GLAXO
CHEM GLAXO SMITH KLINE GLAXO WELLCOME GRAMPION REGIONAL
COUNCIL GREAT YARMOUTH POWER HALLIBURTON KBR HAMWORHTY
COMBUSTION HONEYWELL - ABERDEEN HONEYWELL BRACKNELL ICI
NOBEL ENTERPRISES ICS TRIPLEX IGGESUND PAPER BOARD INMARSAT LTD
INSTEM LIMITED JOHN BROWN ENGINEERING JOHNSON MATTHEY KODAK
KVAERNER ENERGY LEVER FABRIGE LINDSAY OIL REFINERY LLOYDS
LOGICA LUCAS AEROSPACE MERSEY TUNNELLS METHODE ELECTRONICS
METTLER TOLEDO MILLTRONICS MOBIL OIL MONTELL MWH GLOBAL NDC
INFRARED NEC SEMICONDUCTORS NISSAN UK NORTHERN LIGHTHOUSE
BOARD OKI EUROPE LTD ORGANON LABORATORIES LTD PHARMA SITE
ENGINEERING PHILLIPS PETROLEUM POWERGEN QINETIQ RAIL TRACK
SYSTEMS RIG TECH ROBERTS & PARTNERS ROLLS ROYCE ROVER GROUP
RUGBY CEMENT SCOTTISH COURAGE SCOTTISH HYDRO ELECTRIC PLC
SCOTTISH POWER SHELL CHEMICALS SHELL UK EXPLORATION & PRODUCTION
SHOTTON PAPER PLC SIEMENS - AUTOMATION & DRIVES STRATHCLYDE
WATER SUN VALLEY POULTRY SWALEK TEXACO PEMBROKE THAMES
WATER TMD TECHNOLOGIES LTD TOTAL OIL MARINE TOYOTA UK TRANSCO
TRANSCO LOCKERLEY COMPRESSOR TREND CONTROL SYSTEMS LTD
UKAEA UNITED KINGDOM PAPER VG GAS VICTREX PLC VSEC WATER
SERVICE YARROW SHIPBUILDERS YORKSHIRE ELECTRIC YORKSHIRE
ELECTRIC

USA

ACW INCORPORATED AERO SYSTEMS - NASA AK STEEL CORPORATION

ALCATEL ALLEN BRADLEY AMERICAN ELECTRIC POWER/RADISSON
AIRPORT HOTEL AMGEN INCORPORATED ANDERSEN CORPORATION
ARROW INTERNATIONAL ASTRA ZENECA PHARMACEUTICALS AVISTA
CORPORATION BOEING BOWATER NEWSPRINT CENTRAL MAINE POWER
COMPANY CHEVRON CITY OF DETROIT DAISHOWA PAPER MILL DEGUSSA
CORPORATION DEPT OF ENERGY DEQUESNE LIGHT DETROIT WATER
EXXON MOBIL CHEMICAL COMPANY FMC CORPORATION GENERAL
MONITORS HARNISCHFEGER HOME STAKE MINING CO HONEYWELL
HUGHES AIRCRAFT IDM CONTROLS ISA K-TRON INSTITUTE LCRA
LIFESCAN LONGVIEW FIBER LOOP LLC LUCAS BODY SYSTEMS MCKEE
FOODS MILLTRONICS NASA PARKER COMPUTER PEPPERL FUCHS
PHELPS DODGE PHILIP MORRIS PROCESS EQUIPMENT COMPANY
RALSTON PURINA SAN DIEGO COUNTY WATER AUTHORITY SAN FRANCISCO
WATER DEPARTMENT SANTA CLARA VALLEY WATER SECURITIES INDUSTRY
AUTOMATION CORP SERANO LABORATORIES SIEMENS POWER SIEMENS
WESTINGHOUSE SPAWAR SYSTEMS CENTER SPEEDFAM CORP STILL
WATER MINING CORPORATION TOYOTA MOTOR MANUFACTURING TUCSON
ELECTRIC UNITED TECHNOLOGIES CORP (UTC) UNOCAL ALASKA
RESOURCES UTILITY ENGINEERING VALTEK WASHINGTON WATER POWER
WISCONSIN POWER ZENECA

ZIMBABWE
TRIANGLE LIMITED

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DATA COMMUNICATIONS & NETWORKING

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TRAINING WORKSHOPS
Practical Data Communications and Networking for Engineers and Technicians ................................................1.1
Practical DNP3, 60870.5 and Modern SCADA Communication Systems ...............................................................1.3
Practical Troubleshooting and Problem Solving of Ethernet Networks .................................................................1.5
Practical Fibre Optics for Engineers and Technicians .............................................................................................1.7
Practical Troubleshooting and Problem Solving of Industrial Data Communications ..........................................1.9
Practical Industrial Networking for Engineers and Technicians ...........................................................................1.11
Practical TCP/IP and Ethernet Networking for Industry .........................................................................................1.13
Practical Fundamentals of Telecommunications and Wireless Communications ...............................................1.15
Practical TCP/IP Troubleshooting and Problem Solving for Industry ...................................................................1.17
Practical Routers and Switches (Including TCP/IPand Ethernet) for Engineers and Technicians ....................1.19
Best Practice in Industrial Data Communications ..................................................................................................1.21
Practical Fundamentals of Voice over IP (VoIP) for Engineers and Technicians .................................................1.23
Practical Troubleshooting, Design and Selection of Industrial Fibre Optic Systems for Industry ....................1.25
Troubleshooting Industrial Ethernet and TCP/IP Networks....................................................................................1.27
Practical Industrial Wireless for Engineers and Technicians..................................................................................1.29
Data Communications, Networking and Protocols for Industry - Back to Basics................................................1.31
Practical FieldBus, DeviceNet and Ethernet for Industry ......................................................................................1.33

Practical Troubleshooting and Problem Solving of Modbus Protocols ................................................................1.35

Practical Radio Telemetry Systems for Industry .....................................................................................................1.37
Setting Up, Understanding and Troubleshooting of Industrial Ethernet and Automation Networks..................1.39
Practical Troubleshooting of TCP/IP Networks.........................................................................................................1.41
Practical Fibre Optics and Interfacing Techniques to Industrial Ethernet and Wireless.....................................1.43
Hands-On Data Communication, Networking and TCP/IP Troubleshooting..........................................................1.45
Practical Use and Understanding of Foundation Fieldbus for Engineers and Technicians................................1.47

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Troubleshooting, Designing and Installing Digital and Analog Closed Circuit TV Systems...............................1.49
Advanced TCP/IP-based Industrial Networking for Engineers and Technicians...................................................1.51
Practical Troubleshooting & Problem Solving of Ethernet TCP/IP &Modbus Protocols .....................................1.53
Practical Wireless Ethernet and TCP/IP Networking ...............................................................................................1.55

Practical

DATA COMMUNICATIONS
and NETWORKING

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for Engineers and Technicians

What YOU WILL LEARN:

The fundamentals of data communications

How to troubleshoot RS-232 and RS-485
How to install communications cables

How to set up a simple Ethernet network

How to troubleshoot protocols such as Modbus

The fundamentals of FieldBuses

WHO SHOULD ATTEND:

Anyone with a need to understand the techniques required to use

and apply industrial communications technology as productively and
economically as possible. This includes:
Instrumentation and Control Engineers
Design Engineers

Process Control Engineers

Control Systems Sales Engineers

Electrical Engineers

Maintenance Supervisors
Consulting Engineers

Control Systems Applications Engineers

Process Development Engineers

1.1

The Workshop

The Program

Practical Data Communications and

Networking for engineers and technicians is
a comprehensive 2-day workshop. It covers
RS-232, RS-422, RS-485, industrial protocols,
industrial networks and the communications
requirements for 'Smart' instrumentation. It
will equip you with the tools to analyse,
specify and debug data communications
and
networking
systems
in
the
instrumentation and control environment,
with much of the material presented being
derived from many years of experience
gained by the workshop instructor.

BACKGROUND TO DATA
COMMUNICATIONS

OSI (OPEN SYSTEM

INTERCONNECTION) MODEL

BASIC PRINCIPLES

INDUSTRIAL NETWORKING (LANs)

Topologies and medium access control

Industrial Ethernet
TCP/IP

Workshop Aims

RS-232
RS-422 and RS-485
Troubleshooting techniques

THE DATA COMMUNICATIONS

INTERFACE

Protocol basics
Error detection
Modbus and Allen Bradley Data Highway
Plus

'SMART' INSTRUMENTATION
SYSTEMS

SELECTION AND INSTALLATION

OF CABLES
Copper and fibre optic cable
Interference and noise
Cable selection and installation

PROTOCOLS

AS-i
Seriplex
DeviceNet
Interbus-S
Profibus
Foundation FieldBus

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This workshop is designed to benefit people

who
are
involved
in
specifying,
commissioning and debugging data
communications and networking systems
for instrumentation and control, but who
have little previous experience in this area. It
has been structured to cover the main
concepts of data communications, to clarify
their meaning and to describe their
applications in modern process control and
automation systems.

Analog and digital signals

Parallel and serial communications
Coding of messages e.g. Hex and ASCII
Asynchronous vs. synchronous
transmission
UARTs

MODEMS AND INTERFACE

CONVERTERS
Modem control
Modulation techniques
Data compression techniques

Practical Sessions

There are six practical sessions throughout

the workshop including:

RS-232/485 troubleshooting
Modbus simulation

Protocol analysis on serial links

Protocol analysis on Ethernet networks

Very instructive and

well presented workshop.

Peet du Plessis

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

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DNP3, 60870.5 and Modern SCADA

Communication Systems

YOU WILL LEARN HOW TO:

Explain the fundamentals of DNP3 and associated SCADA

protocols

Apply the best current practice for data communications for

SCADA systems
Specify the most up-to-date hardware and software requirements
of the data communications system for instrumentation and
control
Have a good working knowledge of the DNP3 Protocol
Apply the DNP3 Protocol to your next SCADA project

Troubleshoot simple problems with the DNP3 protocol

Explain how IEC 61850 is structured and works

Provide a working explanation of SCADA Protocols and how they

should be structured and applied
Apply best practice decisions on the most cost effective use of
SCADA open protocols for your company

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand

the techniques required to use and apply SCADA and DNP3 industrial
communications technology as productively and economically as
possible.

1.3

The Workshop

The Program

This is a comprehensive two-day workshop

covering the essentials of SCADA
communication systems focusing on DNP3
and the other new developments in this
area. The workshop commences with a brief
review of the fundamentals of SCADA
systems hardware, software and the
communications systems (such as RS-232
and RS-485 Ethernet andTCP/IP) that connect
the SCADA operator stations together.
A solid review is then done on the DNP3
protocol where its features, message
structure, practical benefits and applications
are discussed. The course is intended to be
product independent but examples will be
taken from existing products to ensure that
all aspects of the DNP3 protocol is covered.

Practical Sessions

There are seven practical sessions.

MODBUS communication

DNP3 Packet Interpretation

RTU Configuration Software

DNP concepts

SCADA systems
OSI reference model
IEC 60870.5 and DNP3.0
Local Area Networks, Ethernet and TCP /
IP
UCA and IEC 61850
protocolsFUNDAMENTALS OF SCADA
COMMUNICATIONS
SCADA systems
Remote Terminal Units (RTU)
The master station
Communication architectures
Communication philosophies
Interface standards: RS- 232 and RS- 485
MODBUS protocolsOPEN SCADA
PROTOCOLS Dnp3 AND IEC 60870
Interoperability and open standards
Development of
standardsFUNDAMENTALS OF DNP3
Fundamental concepts
Understanding DNP3 message structure
Physical layer
Datalink layer
Transport layer (pseudo-transport)
Application layer message handling
Application layer message functions
Data object libraryADVANCED
CONSIDERATIONS OF DNP3
DNP3 subset definitions
Interoperability between DNP3 devices
Implementation rules
Conformance testing
DNP3 polling and communication
options
Time synchronisation
Secure authentication

DNP3 OPERATION OVER LAN AND

WAN NETWORKS

Routers
Types of routers
Routing protocols
Wide area networks
Digital transmission hierarchies
WAN protocol overview
DNP3 over TCP/IP and UDP/IP
Link layer confirmations
Time synchronization over LAN

OVERVIEW OF IEC 60870-5

PROTOCOLS
Introduction
The IEC 60870-5 standards
System topology
Data link layer
Addressing
Message transport
Application layer
Interoperability
IEC 60870-5-104 (T104) architecture

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It provides you with the tools to design your

next SCADA system more effectively using
DNP3 to draw on the latest technologies.

OVERVIEW

Setting up IP Address on Network

Protocol Analysis of DNP3 Protocol

DNP3 over Ethernet

To gain full value from this workshop,

please bring your laptop/notebook
computer.

CONFIGURATION OF DNP3 OVER

SERIAL LINES
General description
Water industry example

REVIEW OF ETHERNET AND TCP/IP

PROTOCOLS

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

IEEE 802.3 CSMA/CD (Ethernet)

Physical layers
Media access control
Ethernet frame format
Fast and Gigabit Ethernet
Switched Ethernet
TCP/IP model overview
Internet protocol
ICMP, TCP and UDP

DIFFERENCES BETWEEN DNP3 &

IEC 60870.5
Differences between DNP3.0 and IEC 870
Which one is better?

INTELLIGENT ELECTRONIC
DEVICES (IEDs)

Definition
Functions
Examples of GE power automation IEDs

IEC 61850 OVERVIEW

Introduction
Basic features of IEC 61850
Data modeling
Abstract communication service interface
Information (data) exchange model
Communication model
Substation configuration language
Conformance testing
Benefits of IEC 61850

FIELDBUS & SCADA

COMMUNICATIONS SYSTEMS

Introduction
Profibus
Foundation Fieldbus

FUTURE DEVELOPMENTS
The future of DNP3

SUMMARY, OPEN FORUM AND

CLOSING

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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Troubleshooting and
Problem Solving of
Ethernet Networks

YOU WILL LEARN HOW TO:

Install and configure a simple Ethernet network

Install cabling, routers, switches and hubs effectively

Troubleshoot Ethernet network problems

Improve the performance of your Ethernet network

Competently use a protocol analyser in fixing networks

WHO SHOULD ATTEND:

Anyone involved in the installation, design and support of

communications systems
Instrumentation and Control System Engineers

Process Control Designers and Systems Engineers

Instrumentation Technologists and Engineers
Systems Engineers

IT Managers working with Networks

Electrical Engineers

Electrical and Instrumentation Technicians

Project Engineers
Maintenance Engineers and Supervisors
Design Engineers

1.5

The Workshop

The Program

Ethernet is fast becoming the obvious choice

for industrial control networking worldwide.
While the basic structure of Ethernet has not
changed much, the faster technologies such
as Fast Ethernet and Gigabit Ethernet have
increased the complexity and choices you
have available in planning and designing
these systems.
As Ethernet has become more complex, a
number of misconceptions have arisen as to
how Ethernet functions and how the system
should be optimally configured. This
workshop addresses these issues in a clear
and practical manner, thus enabling you to
apply the technology quickly and effectively
in your next project.

III. CONSTRUCTION OF THE

ETHERNET SYSTEM CABLING AND
HARDWARE

Background
Network communications
Open systems
Network topologies

OPERATION OF ETHERNET
SYSTEM
Ethernet standards
Logical link control frames
Transmission media and access
techniques
Media access control protocol
Full duplex Ethernet
Auto negotiation

II. ETHERNET CABLING AND

HARDWARE/PROTOCOLS
- DIFFERENT CABLE TYPES

Twisted pair Ethernet

Fibre optic media
Fast Ethernet twisted pair
Fast Ethernet fibre optic cabling
Gigabit Ethernet twisted pair
Gigabit Ethernet fibre optic systems

Structured cabling
Twisted pair cables and connector
Fibre optic cables and connectors
Ethernet repeater hubs
Ethernet switching hubs
Industrial versus commercial networks

NETWORK DESIGN CONCEPTS

System design
Design simplicity
Design documentation

IV. PERFORMANCE AND

TROUBLESHOOTING TYPES OF
PROBLEMS
Hardware
Protocols
Software

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The workshop commences with a brief

outline of the fundamentals of Ethernet and
its operation. The method of access is
discussed in depth and topics such as full
duplex and auto negotiation are explained.
The best methods of designing and installing
the cabling systems are then explored with
the discussion ranging from 10Base-T over
twisted pair to Gigabit Ethernet cabling.
Methods of optimising Ethernet to obtain
best performance are then defined.

I. INTRODUCTION TO ETHERNET
BACKGROUND AND
INTRODUCTION TO ETHERNET

Finally the all important topic of

troubleshooting is examined with a summary
of the typical problems you are likely to
encounter from a two station network all the
way up to a system comprising 30,000 PCs.

Pre-requisites

A fundamental knowledge of basic electrical

concepts is expected with some knowledge
of the basics of the Windows operating
system.

Workshop Objectives

At the end of this workshop you will be able to:

Specify how to install an Ethernet

network
Install and configure a simple Ethernet
network

Compare and know the strengths of the

different types of Ethernet networks

List and explain the main features of high

speed (and Gigabyte) Ethernet

LAN INTERCONNECTION
COMPONENTS

Repeaters
Switches
Bridges
Routers
Gateways
Multi-segment configuration using
repeaters
Redundancy and reliability

PROTOCOLS THAT WORK WITH

ETHERNET

TCP/IP
Modbus and TCP/IP
Ethernet/IP
IPX/SPX and NetBEUI
IP addressing
Routing on the networks
Error and control messages
User Datagram Protocol (UDP)
Utilities with TCP/IP

Know when to use repeaters, bridges,

switches and routers

TOOLS

Basic utilities
Protocol analyser
Ethernet performance
Troubleshooting of Ethernet

There are ten practical

sessions including:

Configuration of an Ethernet network

Configuration of a simple network
protocol
Demonstration of typical failure points
Diagnosis of network hardware problems
Configuration of a network with a switch
and hub
Addition of the TCP/IP protocol
Use of basic utilities for troubleshooting
Troubleshooting with simple protocol
analyser
Identification of problems with utilities
and protocol analyser
Benchmarking performance of Ethernet

Practical Sessions

This is a practical, hands on workshop enabling

participants to work through practical exercises
which reinforce the concepts discussed.
To gain full value from this workshop, please bring
your laptop/notebook computer.

Install the cabling and hardware for a

typical Ethernet network

Learn the truth about deterministic

operation of Ethernet networks

Decide on the best cabling and connectors

for your factory or office environment
Apply the structured cabling system
concepts to your next project

Configure and show how TCP/IP is used

with Ethernet

On-Site Training

Design and build a reliable Ethernet

network

Save over 50% by having an IDCworkshop presented at

Apply the principles of Ethernet security

and redundancy
Perform simple troubleshooting tasks on
a network
Use a protocol analyser to analyse
Ethernet network activity
Assess the performance characteristics of
a typical network

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

Fibre Optics

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for Engineers and Technicians

What YOU WILL GAIN:

Practical hands-on experience in jointing, splicing and testing fibre

optic systems
A solid knowledge of fibre optic communications systems

State of the art fibre optics technology and installation practices

Correct procedures for cable installation and termination

How to design and install your own fully operational fibre optics
system
New approaches to troubleshooting including how to use an OTDR

WHO SHOULD ATTEND:

The workshop will benefit engineers and technicians involved in

specifying, commissioning and maintaining industrial fibre optic
systems, but who have little previous experience in this field,
including:
I & C Engineers and Technicians

Telecommunications Engineers and Technicians

Maintenance Engineers and Technicians
Electrical Engineers and Electricians
Project Engineers and Managers
Process Control Engineers
Consulting Engineers
Systems Engineers

1.7

The Workshop

The Program

This comprehensive two-day workshop will

provide you with the necessary background
to understand the fundamentals of fibre
optic systems and their individual
components including fibres, cable
construction, connectors, splices and optical
sources and detectors. Various pitfalls
associated with the implementation of fibre
optic systems are discussed and workable
solutions to these problems are provided. It
will provide you with the knowledge to
develop the required techniques for design,
installation and maintenance of fibre optic
systems.

OPTICAL DRIVERS AND

DETECTORS

Introduction and overview

Background to fibre optics
Fibre optics vs copper systems

DEFINITIONS AND BASIC

PRINCIPLES
Data communications and
communications channels
Transmission modes
The electromagnetic spectrum
Revisiting copper

THEORY OF FIBRE OPTIC

TRANSMISSION

Fundamental principles of operation

Light transmission nature of glass
Numerical aperture
Modal propagation in fibres
Multimode, single mode, step-index and
graded index
Bandwidth of fibres
Modal and chromatic dispersion
Absorption, scatter, bending, radiation
and mismatches
Other types of fibres

Light emitting diodes and lasers

Transmitter modules
Safety considerations
PIN photodiodes
Receiver modules
Optical amplifiers

INSTALLING FIBRE OPTIC CABLES

Preparation, installation rules and
procedures
Bending radius, cable tension and cable
reels
Cable trays, conduits and lubricants
Indoor cable installation and leaving
extra cable
Outdoor cable installation and
environmental conditions
Splicing trays, organisers, termination
cabinets, breakout boxes, patch and
distribution panels

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The workshop places significant emphasis

on the practical techniques of component
installation and system design. You will have
the opportunity to get hands-on experience
with mechanical and fusion splicing and
with fitting the popular industrial fibre
connectors. A fibre optic link design software
package is provided to allow you to practice
actual link design practicals using various
parameters. Finally, you will have the
opportunity to practice using various fibre
optic test equipment such as optical sources
and power meters.

INTRODUCTION TO FIBRE OPTIC

SYSTEMS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Fibre Optic Link Design - a complete
design of a fibre optic link

Optical Power Measurement - the use of

an optical source and an optical power
meter
Continuity Tester - the principles of
operation of a simple fibre optic continuity
tester

CONSTRUCTION OF FIBRE OPTIC

CABLES

Cable objectives
Tensile ratings and structural elements
Strengthening members
Housings, sheaths and moisture barriers
Classes of cables

CONNECTING FIBRES

Optical connection issues

Fibre end preparation
Splicing fibres
Connectors and optical couplers

Optical Time Domain Reflectometer

(OTDR) - demonstration on the practical
use of ODTR with a video presentation

FIBRE OPTIC SYSTEM DESIGN

Initial design considerations

Future capacity, reliability and operating
wavelength
Repeaters and amplifiers
Design loss calculations and link loss
budgets
Design bandwidth calculations

TESTING OF FIBRE OPTIC

SYSTEMS

Concepts of optical measurement

Continuity and insertion loss testing
Optical Time Domain Reflectometry
(OTDR)
Bit Error Rate (BER) testing
Eye diagrams and laboratory fibre tests

TECHNOLOGIES THAT USE

OPTICAL FIBRES

Low speed modems

10 Base F/FDDI/FIORL
100 Base F
ATM
LANs/MANs/WANs
Analog modulators for video and
microwave links
HDTV

Optical Connectors - gain experience in

the techniques of fitting fibre optic
connectors
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical Troubleshooting
and Problem Solving of

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Industrial Data Communications

YOU WILL LEARN HOW TO:

Identify, prevent and troubleshoot industrial communications

problems
Fix the most common problems that occur in industrial
communications systems
Gain a practical toolkit of skills to troubleshoot industrial
communications systems
Analyse, diagnose and fix problems
We have taken all the key troubleshooting and problem solving skills
from experienced engineers and distilled these into one intensive
course to enable you to solve real industrial communications problems.

WHO SHOULD ATTEND:

Anyone working with or required to trouble shoot industrial

communications systems ranging from RS-232 to Fieldbus and
Ethernet systems, including:

Process Control Engineers

Electronic Technicians

Instrumentation and Control

Engineers/Technicians

Consulting Engineers

Network Planners
Electrical Engineers
Test Engineers
System Integrators

Design Engineers
Plant Managers
Systems Engineers
Shift Electricians

Designers

1.9

The Workshop

The Program

The objective of this workshop is to help

delegates identify, prevent and fix common
industrial data communication problems.
The focus is "outside the box", with the
emphasis on practicals that go beyond the
typical communications issues and theories.
The workshop provides delegates with the
necessary toolkit of skills to solve industrial
data communication problems, whether
they be RS-232/RS-485, Modbus, Fieldbus
and DeviceNet or a Local Area Network,
such as Ethernet.
Industrial communications systems are
installed throughout plants. Communications
problems range from simple wiring
problems to the intermittent transfer of
protocol messages.

HART

Overview of course
List of typical problems

Fundamentals
Problems: cabling, configuration, intrinsic
safety

OVERALL METHODOLOGY
Common symptoms, problems and
solutions
How to quickly identify likely causes
Overall basic steps
Communications issues
Grounding/shielding/noise

BASIC STANDARDS:
RS-232
- Fundamentals
- Problems: cabling, male/female, DTE/
DCE, 9-pin, handshaking, voltages,
noise, isolation
- RS-232 practical troubleshooting
session
RS-485
- Fundamentals
- Problems: cabling, common mode
voltage, converters, isolation, idle
state, terminations, control hardware/
software
- RS-485 practical troubleshooting
session
Current Loop
- Fundamentals
- Problems: cabling, isolation
Fibre Optics
- Fundamentals
- Problems: splicing, interface to cable,
connectors, multimode, monomode,
laser vs LED transmitters, driver
incompatibility, bending radius, shock,
installation issues

ASI Bus
Fundamentals
Problems: cabling, connections, gateways

DeviceNet
Fundamentals
Problems: topology, power and earthing,
signal voltage levels, common mode
voltage, terminations, cabling, noise,
node, communication problems, creeping
errors

PROFIBUS PA/DP/FMS
Fundamentals
Problems: cabling, fibre, shielding,
grounding, segmentation, colour coding,
addressing, token bus, unsolicited
messages, fine tuning of impedance
terminations, drop-line lengths, GSD
files, intrinsic safety

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The communications system on a plant

effects the entire operation. It is critical that
you have the knowledge and tools to quickly
identify and fix problems as they occur, to
ensure you have a secure system. No
compromise is possible here. This workshop
distils all the tips and tricks learnt with the
benefit of many years of experience.

INTRODUCTION

Typical faults are discussed in depth with a

focus on troubleshooting.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
This course includes over 30 practical fixes
for RS-232/RS-485/industrial protocols/ASI
Bus/Devicenet systems methodology given
with real world examples, and over 40
troubleshooting tips for Profibus/foundation
Fieldbus/Ethernet and TCP/IP.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

INDUSTRIAL AUTOMATION
STANDARDS:

Modbus
- Fundamentals
- Problems: no response, exception
reports, noise, radio interfaces,
physical and application layers
- Modbus troubleshooting session
Modbus Plus
- Fundamentals
- Problems: cabling, grounding,
shielding, terminators, token passing
Data Highway Plus/DH485
- Fundamentals
- Problems: cabling, grounding,
shielding, terminators, token passing

FOUNDATION FIELDBUS

Fundamentals
Problems: wiring, grounds, shielding,
wiring polarity, power, terminations,
intrinsic safety, voltage drop, power
conditioning, surge protection,
configuration

INDUSTRIAL ETHERNET

Fundamentals
Protocol analysis
Problems: noise, thin and thick coax and
connectors, UTP cabling, wire types,
components, incorrect media selection,
jabber, too many nodes, excessive
broadcasting, bad frames, faulty autonegotiation, 10/100MBit/s mismatch, full/
half duplex mismatch, faulty hubs,
switched networks, loading
Industrial Ethernet practical
troubleshooting session

TCP/IP

Fundamentals
Software utilities (ping, arp, netstat)
Protocol analysis
Problems: internet layer, IP addresses,
subnet mask, routers, transport layer,
triple handshake, incorrect ports
TCP/IP practical troubleshooting session

RADIO AND WIRELESS

COMMUNICATIONS

Fundamentals
Problems: reliability, noise, interference,
power, distance, licences, frequency, over
and under modulation
Radio and wireless practical
troubleshooting session

Save over 50% by

having an IDCworkshop
presented at your
premises.

SUMMARY, OPEN FORUM

AND CLOSING

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

INDUSTRIAL NETWORKING

for Engineers and Technicians

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The Basics of Industrial Networked Systems including:

Industrial Ethernet
Switches and Routers

TCP/IP
RS-485

Fieldbus & DeviceNet
Cabling rules for Industrial Networks

YOU WILL GAIN:

Practical hands-on experience in setting up a LAN including a

comprehensive overview of current industrial networking
technology
Fundamental rules for cabling of industrial networking

How to install and configure a network under expert guidance

during practical sessions
The most effective approaches to troubleshooting from the experts
The important steps in designing, installing and managing an
industrial network system
How to improve the performance of your system, save your
company money and relieve the frustrations of your
co-workers and management

WHO SHOULD ATTEND:

Instrumentation and Control System Engineers

Electrical Engineers
Project Engineers

Design Engineers
Electrical andInstrumentation Technicians
Process Control Engineers
Maintenance Engineers and Supervisors
Systems Engineers

1.11

The Workshop

The Program

Practical Industrial Networking is a hands-on

basic introduction to the world of industrial
networking. The focus is on the physical
layer and installing and commissioning
simple Industrial Networking systems.
Despite the focus on the basics and
fundamentals you will still leave the
workshop with valuable tools in designing,
installing, commissioning and installing
your own industrial network.
Ethernet is fast becoming the obvious choice
for industrial control networking worldwide
and the course will focus on this. While the
basic structure of Ethernet has not changed
much, the faster technologies such as Fast
Ethernet and Gigabit Ethernet have increased
the complexity and choices you have
available in planning and designing these
systems.

Protocols that work with

Ethernet

Background
Network Communications
LANs/MANs/WANs
The Open Systems Interconnection Model
Interoperability
Network Topologies
Transmission Media and Access
Techniques
Protocols

Fundamentals of Industrial
Networking

Main LAN Types

RS-485
Modbus
Master-slave
Ethernet
Token Passing

Construction of the
Ethernet System Cabling and
Hardware

Fieldbus and DeviceNet as

industrial networks

TCP/IP
Modbus and Ether/IP
IPX/SPX and NetBEUI
IP Addressing
Routing on the networks
Error and Control messages
User Datagram Protocol (UDP)
Utilities with TCP/IP

Structured Cabling
Twisted Pair Cables and Connector
Fibre Optic Cables and Connectors
Ethernet Repeater Hubs
Ethernet Switching Hubs
Industrial versus Commercial Networks

Network Design Concepts

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As Ethernet has become more complex, a

number of misconceptions have arisen as to
how Ethernet functions and how the system
should be optimally configured. This
workshop addresses these issues in a clear
and practical manner, thus enabling you to
apply the technology quickly and effectively
in your next project.

INTRODUCTION TO INDUSTRIAL
NETWORKING

The workshop commences with a brief

outline of the fundamentals of Ethernet and
its operation. The method of access is
discussed in depth and topics such as full
duplex and auto negotiation are explained.
The best methods of designing and installing
the cabling systems are then explored with
the discussion ranging from 10Base-T over
twisted pair to Gigabit Ethernet cabling.
Methods of optimising Ethernet to obtain
best performance are then defined.
Finally the all important topic of
troubleshooting is examined with a summary
of the typical problems you are likely to
encounter from a two station network all the
way up to a system comprising 30,000 PCs.

Pre-requisites

Fundamental knowledge of basic electrical

concepts.

Practical Sessions

ASIbus
DeviceNet
Profibus DP/PA
Foundation Fieldbus

Operation of Ethernet
System

Ethernet Standards
Logical Link Control Frames
Transmission Media and Access Techniques
Media Access Control Protocol
Full Duplex Ethernet
Auto negotiation

Different Cable Types for

Industrial Ethernet

Twisted Pair Ethernet

Fibre Optic Media
Fast Ethernet Twisted Pair
Fast Ethernet Fibre Optic Cabling
Gigabit Ethernet Twisted Pair
Gigabit Ethernet Fibre Optic Systems

System Design
Design Simplicity
Design Documentation

Performance and
Troubleshooting Types of
Problems
Hardware
Protocols
Software

Tools

Basic Utilities
Protocol Analyser
Ethernet Performance
Troubleshooting of Ethernet

Wireless and Industrial

Networks
Fundamentals
Quick overview

Summary, Open Forum

and Closing

LAN Interconnection
Components

Repeaters, Switches, Bridges

Routers
Gateways
Multisegment Configuration using
Repeaters
Redundancy and Reliability

Workshop Objectives

During the 2-days of this workshop there are

ten practical sessions including:

At the end of this workshop participants will be able to:

Configuration of an Ethernet Network

Detail where to apply each type of industrial network

Configuration of a simple Network

Protocol

Specify how to install an Ethernet network

Demonstration of typical failure points

Diagnosis
problems

of

Network

Hardware

Configuration of a network with a switch

Addition of TCP/IP Protocol
Use of basic utilities for troubleshooting
Troubleshooting with simple Protocol
Analyser

Install and configure a simple Ethernet network

List and explain the main features of High speed and Gigabit Ethernet
Know when to use repeaters, bridges, switches, and routers
Install the cabling and hardware for a typical Ethernet Network
Learn the truth about deterministic operation of Ethernet Networks
Decide on the best cabling and connectors for your harsh or office environment
Apply the structured cabling system concepts to your next project
Apply the principles of Ethernet security and redundancy

Identification of Problems with utilities

and Protocol Analyser

Perform simple troubleshooting tasks on a Network

Benchmarking performance of Ethernet

Configure and show how TCP/IP are used in a typical Network

Perform simple troubleshooting tasks on an industrial Network

idc@idc-online .com

www.idc-online .com

Practical

TCP/IP and
Ethernet Networking

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for Industry

What YOU WILL LEARN:

The workshop is designed to give you a superb fundamental

grounding in TCP/IP and the internet, as it is applied to industrial
automation and process control. The objective is
to provide a useful and practical toolbox of skills that can
be applied immediately to your plant or facility.
You will:

Gain a practical understanding of what TCP/IP is and how to apply

it
Learn how to construct a robust Local Area Network (LAN)
Learn the basic skills to effectively troubleshoot TCP/IP and LANs
Be able to improve the performance of a network
Understand how to set up an intranet

Understand how to connect your LAN or intranet to the internet

Be able to apply appropriate network management tools

WHO SHOULD ATTEND:

Anyone designing, installing, commissioning, maintaining or

troubleshooting TCP/IP and intra/internet sites will benefit, including:
Instrumentation engineers
Design engineers
Engineering managers
Network system administrators
Technicians
Network engineers
Electrical engineers

1.13

The Workshop

The Program

The internet has made a substantial impact

on the way we do business, as well as the
plant and factory environment. One of the
great protocols inherited from the internet is
TCP/IP, which is used by most present-day
automation and process control systems.
SCADA systems, Programmable Logic
Controllers (PLCs) and even low level
instruments are using TCP/IP and Ethernet to
transfer information. TCP/IP and Ethernet are
truly open standards, available to competing
manufacturers and providing the user with a
common standard at low cost.

APPLICATION LAYER PROTOCOLS

LANs, WANs, VLANs and VPNs

OSI and ARPA models

BOOTP, DHCP, TELNET, FTP, TFTP, SMTP,

POP3, HTTP, SNMP, and DNS

ETHERNET

TCP/IP utilities

10Mbps (half-duplex) Ethernet

Fast and gigabit Ethernet
Full-duplex, deterministic and dual
redundant Ethernet

CONNECTION DEVICES

INTERNET LAYER PROTOCOLS (IP)

IPV4, addressing, subnetting,
fragmentation and header structure
ARP
ICMP
Routing protocols
IPV6 addressing modes, header structure
and extension headers

Ping, Arp, Tracert, Netstat, Ipconfig,

Wntipcfg and hosts file
Repeaters, hubs, bridges, switches,
routers and gateways

SECURITY CONSIDERATIONS
Authentication, encryption and firewalls

SATELLITE COMMUNICATIONS
(OPTIONAL)
Essentials of satellites
Challenges with TCP/IP

HOST TO HOST LAYER

PROTOCOLS (TCP)

TYING IT ALL TOGETHER

TCP/IP ports, sockets, sequence and

acknowledgement numbers, establishing
and closing connections and sliding
windows
UDP

SUMMARY, OPEN FORUM

AND CLOSING

Current and future trends

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This workshop covers the main aspects of

TCP/IP and Ethernet in detail, including the
practical implementation of TCP/IP in
computer and industrial areas and the
practical use of the internet and intranets.
You will learn to troubleshoot and maintain
TCP/IP networks and communication
systems in an office and industrial
environment.

INTRODUCTION

Pre-requisites

A basic working knowledge of industrial

communications and applications is useful.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:

Construct simple Ethernet LAN

Configure IP addresses and subnet mask

of
ARP/ICMP/IP/UDP/TCP
Analysis
protocols with protocol analyser
Ping, Arp, Netstat, Tracert and route
commands
Set up and analyse FTP/HTTP sessions

Interconnect networks with bridge or

router
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Excellent overview. Giving a good

understanding of ethernet in
general. Detailed course notes for
further reference.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.

Lynne Kelly

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Fundamentals of

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Telecommunications and
Wireless Communications

What YOU WILL LEARN:

Fundamentals of telecommunications

The "jargon" used in telecommunications

The "nuts and bolts" of selecting and installing telecommunications

systems
How to increase the bandwidth by exploiting your existing copper
wire more effectively
How to make "best practice" decisions on the best and most cost
effective access options for your company
How to apply the latest technologies such as wireless
communications

To understand and apply high speed access systems such as ADSL

and beyond

WHO SHOULD ATTEND:

Electrical Engineers

Process Engineers

Technicians

Maintenance Engineers

Managers

Sales Engineers

Instrumentation Engineers and

Technicians

Engineering Managers

Process Control Engineers and

Technicians
Project Engineers

Network Administrators
Software Engineers
Field Technical Support Staff

Systems Engineers

1.15

The Workshop

The Program

The
make-up
and
structure
of
telecommunications networks has changed
dramatically in the past few years. These
changes impact on the equipment you
purchase, the services you use, the providers
you can choose and the means of transporting
the data.
This workshop is of particular benefit to
those who want to apply the latest and most
effective telecommunications technology
immediately. Your company may already be
looking
at
operating
its
own
telecommunications system or may be
looking at using the systems on the market.
With the vast array of equipment and
systems and technology now available to
you, you need the necessary knowledge to
make the best decisions.

Introduction
Standards organisations

TELECOMMUNICATION BASICS
Bandwidth, channel capacity
Full vs. half duplex
Baseband, broadband, narrowband and
wideband
Analogue vs. digital transmission
Multiplexing techniques: FDM, TDM,
PCM, WDM
Connection oriented vs. connectionless
communication
Circuit switching vs. packet switching
Switching vs. routing
Local area vs. wide area networks
The "Communications Cloud"
The PSTN vs. the Internet
The OSI model

TRANSMISSION MEDIA
COMPARISON
Microwave radio
Satellite systems
Infra-red

CUSTOMER ACCESS
TECHNOLOGIES (BROADBAND)
Digital Subscriber Lines (xDSL):
Asymmetric DSL(ADSL); High-data-rate
DSL (HDSL); Symmetric DSL (SDSL); Very
High Speed DSL (VDSL); G.Lite (ITU
G.992.2)
Etherloop (next generation DSL)
Hybrid Fibre Coax (HFC)
Multipoint Microwave Distribution
System (MMDS)
Local Multipoint Distribution Services
(LMDS)
Bluetooth
IEEE 802.16 WirelessHUMAN

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We believe this workshop allows you to

achieve your objectives in learning and then
applying
the
fundamentals
of
telecommunications to your next project.

INTRODUCTION

THE PUBLIC SWITCHED

TELEPHONE NETWORK

Workshop Objectives

This is a cutting-edge practical workshop on

the fundamentals of telecommunications for
anyone looking for a complete understanding
of the essentials of the terms, jargon and
technologies used.This workshop is designed
for those who require a basic but fundamental
grounding in telecommunications and is of
special benefit for those who want to apply
the technology as quickly as possible.

PSTN infrastructure
Local networks
Switching
Line circuit functions
Signaling system #7

TRANSMISSION MEDIA
COMPARISON

Twisted pair
Coaxial cables
Fibre optic
Power system carrier

PBX
Centrex
Key systems

PUBLIC NETWORK TRANSPORT

TECHNOLOGIES

Analogue switched (dial-up)

Public Switched Telephone Network
(PSTN)
Analogue dedicated (leased) alternatives
Digital switched (dial-up) alternatives
Digital dedicated (leased) alternatives

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.
Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

LAN topologies
LAN media access control techniques
LAN standards
LAN extension and interconnection
(bridging, switching, routing)
Metropolitan Area Networks (MANs)
Wide Area Networks (WANs)
Virtual Private Networks (VPNs)

CONVERGED NETWORKS

PRIVATE SWITCHED SYSTEMS

On-Site Training

LOCAL AND WIDE AREA

NETWORKING

Practical Sessions

1. Fibre Optic Design Exercise - design a

fibre optic system and calculate link
power budgets

2. Network Design Exercise - involves

given traffic flows between various
offices and determining the number and
type of communication links needed.

Applications: VoIP, FoIP, etc

Protocols: Packet Transport
WAN transport considerations
Hardware: H.323 terminals; H.323
gateways; gatekeepers; multipoint
control units; audio/video codecs
Implementation considerations

WIRELESS COMMUNICATIONS

Radio/cellular concepts and definitions

Wireless local area networking: IEEE
802.11
Wireless local loop applications
Wireless data networks: Cellular Digital
Packet Data (CDPD); General Packet Radio
Service (GPRS)
Cellular voice systems: Global System for
Mobile Communications (GSM); Code
Division Multiple Access (CDMA); Time
Division Multiple Access (TDMA)
Personal Communications Service (PCS)
Wireless Application Protocol (WAP)
Third Generation (3G) mobile
communications technologies: Universal
Mobile Telecommunications System
(UMTS)

CONCLUSION
Pulling all the strands together

3. Microwave Design Exercise - to

determine required antenna heights and
calculate and select appropriate
components to design the radio system
4. Basic Local Area Network Configurations
5. Overview Design Exercise - conceptual
design of a company-wide
communications network

idc@idc-online .com

www.idc-online .com

Practical

TCP/IP, Troubleshooting
and Problem Solving

for Industry

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A three-day workshop for all those designing, installing, monitoring, maintaining

and troubleshooting Industrial Ethernet, TCP/IP and Intra/Internet sites

What YOU WILL LEARN:

Gain a practical understanding and application of TCP/IP

Learn the basic skills to effectively set up TCP/IP networks

Construct a secure, robust Local Area Network

Diagnose and fix problems with TCP/IP utilities

Plan and design improved networks

Analyse and construct a typical firewall

Understand how to optimise your company's connectivity with

LANs/Intranets and the Internet
How to troubleshoot TCP/IP networks

The essentials of network management

How to track hackers and network problems

To use a protocol analyser to diagnose real TCP/IP problems

How to set up Virtual Private Networks (VPNs)
How to construct Virtual LANs (VLANs)

WHO SHOULD ATTEND:

Network Technicians

Design Engineers

Data Communications
Managers

Network Engineers

Communications Specialists
IT Support Managers and
Personnel
Network Planners
Designers
Programmers

Electrical Engineers
IT and MIS Managers
System Integrators
Network Support Staff
System Analysts
Systems Engineers

Network Administrators
1.17

The Workshop

The Program

This is a truly hands-on workshop in the

sense that you will spend over 70% of the
course time in setting up TCP/IP based
networks and troubleshooting problems. We
have distilled all the practical tips and tricks
in maintaining and troubleshooting TCP/IP
based networks into this hard-hitting threeday workshop. Commencing with a simple
introduction to the hardware level of
Ethernet, you will quickly move onto
coverage of the Internet (IP) layer.

SNMP NETWORK MANAGEMENT

Terms and definitions

LANs, WANs, VLANs and VPNs
Open Systems Interconnection, OSI and
ARPA models

ETHERNET

CONFIGURING AND
TROUBLESHOOTING ETHERNET
AND TCP/IP

Fundamentals
10Mbps Ethernet systems
Fast and Gigabit Ethernet
Collisions and performance
Full duplex, deterministic and
dual-redundant Ethernet
Practical Session

SNMP overview
MIB details
SNMP traps
Network management

To be covered during the practical sessions:

Configuration
Use of TCP/IP and third party utilities
Use of protocol analysers
Practical Session

INTERNET LAYER PROTOCOLS

SATELLITE COMMUNICATIONS

IPV4

Essentials of satellites
Challenges with TCP/IP

Addressing
Subnetting
Supernetting and CIDR
Fragmentation
Header structure

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The host-to-host or TCP layer will then be

covered in considerable practical detail. The
application layer of TCP/IP will be covered by
a detailed examination of protocols such as
Bootp, DHCP, SNMP and DNS. The vital but
simple TCP/IP utilities such as ping, ARP and
tracert will then be tested out on the network.
The SNMP protocol will be looked at with
hands on tests. Finally, you will construct a
Virtual LAN and Virtual Private Network and
configure a simple firewall.

INTRODUCTION

One of the best ways to learn and retain

your knowledge is with hands-on sessions
where you will gain a broad range of skills
that every competent network engineer
needs in his skills toolbox. We believe this
workshop provides this know-how.

VIRTUAL LANS (VLANs)

ARP
ICMP
Routing protocols
IPV6

HOST-TO-HOST LAYER
PROTOCOLS

Introduction to VLANs
VLAN identification
IEEE 802.1p/Q
Configuring a trunk line
VLAN Trunk Protocol (VTP)
VTP pruning
Managing redundant links
Inter VLAN routing
Practical Session

TCP

SECURITY

- Addressing modes
- Header structure
- Extension headers

Practical Sessions

Practical Session

In addition to the 15 practical mini-sessions

that expose you to typical problems that
could occur with TCP/IP networks, there are
at least 10 practical sessions where you will
get hands-on training to take advantage of
the material covered in the class during days
one and two:
Construct simple 100 BaseTX LAN

- Ports and sockets

- Sequence and acknowledgement
numbers
- Establishing and closing connections
- Sliding windows

UDP
Practical Session

Configure network parameters

Communicate over networks

Configure IP addresses and Subnet

Mask

Use Ping utility and observe ARP in

operation
Analysis of ARP/ICMP/IP/UDP/TCP
Router configuration

APPLICATION LAYER PROTOCOLS

BOOTP, DHCP, TELNET, FTP, TFTP, NFS,
SMTP, POP3, HTTP, SNMP and DNS
Practical Session

TCP/IP UTILITIES

Ping, arp, tracert, netstat, ipconfig and

winipcfg
Practical Session

Tracert and Route commands

Use of Hosts file

Set up and analyse FTP sessions

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Day THREE

CONNECTION DEVICES

Repeaters, hubs, bridges, switches,

routers and gateways

Fundamentals
Authentication
Encryption
Layer 2 Tunneling Protocol Concept
IPSec Protocol
Key management for IPSecs
Practical Session

VIRTUAL PRIVATE NETWORKS

(VPNs)
Introduction to VPNs
Layer 2 Tunneling Protocol Concept
IPSec Protocol
Key management for IPSec
Practical Session

FIREWALLS

Fundamentals
Types of firewalls
Tips and tricks
Practical Session

TYING IT ALL TOGETHER

Current and future trends
Critical areas of focus

Very knowledgeable
presented workshop well.
M Torrance

idc@idc-online .com

www.idc-online .com

Practical

ROUTERS and SWITCHES

(Including TCP/IP andEthernet)

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for Engineers and Technicians

YOU WILL LEARN HOWTO:

Configure, maintain and manage your routers

Understand TCP/IP and how to apply it

Design, install and manage routes internetworks

Segment networks with bridges, routers and switches

Analyse internetwork protocols

Troubleshoot and fox router and switch problems

Improve the performance of both networks and internetworks

Construct a secure robust Local Area Network (LAN)
Plan and design your networks more effectively
Analyse and construct a typical firewall

Effectively troubleshoot TCP/IP and LANs

Optimise you company's connectivity with LANs/Intranets and the

Internet
Construct a basic intranet

Apply the appropriate network management tools to routers and

Internetworks

WHO SHOULD ATTEND:

Anyone who will be designing, installing and commissioning,

maintaining or troubleshooting TCP/IP and Intranet/Internet sites
will benefit including:

Instrumentation Engineers

Technicians

Design Engineers

Network Engineers

Electrical Engineers

Engineering Managers

1.19

The Workshop

The Program

Routers and switches are key components

of most networks and internetworks.
Routers are simultaneously the most
complex and the most important component
of networks. This workshop goes through
the basics of routers, routed and routing
protocols and the basic rules to follow in
building internetworks. If you are using any
form of communication system or are
applying modern PLCs/SCADA systems,
this workshop will give you the essential
tools in working with your networks. It is
not an advanced workshop - but a hands on
one.

INTRODUCTION
Basic concepts, access methods and
topologies
LANs, WANs, VLANs and VPNs
Open systems, OSI and ARPA Models
TCP/IP protocol suite architecture

ETHERNET
10MBps Ethernet systems

- Media access control: CSMA/CD

- Layer 1 versions (10Base5/2/T/F)
- Layer 2 addressing (MAC addresses)
Fast Ethernet

- Media access control: Full Duplex

- Layer 1 versions (100BaseTX/FX)

Pre-requisites
A basic working knowledge of industrial
communications and applications is
useful.

Full duplex, deterministic and dual

redundant Ethernet

INTERNET LAYER PROTOCOLS

IPv4

Boot Protocol (BootP)

Dynamic Host Configuration Protocol
(DHCP)
TELNET
File Transfer Protocol (FTP)
Trivial File Transfer Protocol (TFTP)
Network File System (NFS)
Simple Mail Transfer Protocol (SMTP)
Post Office Protocol 3 (POP3)
Hyper Text Transfer Protocol (HTTP)
Simple Network Management Protocol
(SNMP)
Domain Name System (DNS)

TCP/IP UTILITIES

Ping
ARP
Tracert
Netstat
Ipconfig
Winipcfg
Hosts file

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Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:

Connect simple networks together

Construct a simple local area network

using 10/100BaseT
Configure network parameters

Configure IP addresses and subnet

masks
Communicate over network
Use ping
operation

- Address classes
- Subnet masking
- Classless addressing
- Subnetting and VLSM
- Supernetting and CIDR
- Fragmentation
- Header structure
- Deploying IP addresses
- Public and private IP addresses
- Allocating addresses with DHCP
- Multicasting
- Multicast address management: NAT,
PIM
- Network address translation: NAT and
NAPT
- Layer 2 vs Layer 3 address mapping
- Address resolution: ARP
- Reverse address resolution: RARP
- Control messages: ICMP

PROCESS/APPLICATION LAYER
PROTOCOLS

utility

and

observe ARP

Analysis of ARP/ICMP/IP/UDP/TCP

IPv6

Tracert and route commands

Set up and analyse FTP sessions

Quick analysis of packets using protocol

analyser

- Addressing modes
- Header structure
- Extension headers

Web based view of network

Configuration of switches

TCP

Troubleshooting a router and switch

Routers and switches - configuration

issues
Firewall configuration

- Principle of operation
- Header structure
- Ports and sockets
- Sequence and acknowledgement
numbers
- Establishing and closing connections
- Sliding windows

UDP

- Principle of operation
- Header structure

Basic operation of Ethernet repeaters

Hubs

- Hub interconnection
- Dual speed hubs

MECHANICS OF BRIDGING

Basic operation of Ethernet bridges

Transparent, translating and speed
buffering bridges
Application

MECHANICS OF SWITCHING

Basic operation of Ethernet switches

Layer 2 vs Layer 3 switches
Segment, port and IP switching
Applications: VLANs, collapsed
backbones and dual redundant rings
Troubleshooting switches

MECHANICS OF ROUTING

HOST TO HOST PROTOCOLS

Analysis of internetwork protocols

MECHANICS OF REPEATING

Basic operation of routers

Router functions
Static vs dynamic routing
Routing tables, metrics and protocols
Route advertisement
Convergence
Route calculation: distance vector vs link
state
Autonomous systems
Interior vs exterior gateway protocols
Border routers
Applications: WAN routers, collapsed
backbones, parallel backbones

ROUTING INFORMATION
PROTOCOL (RIP)
Origins
Specifications

- Packet format
- Routing tables

idc@idc-online .com

Operation
Vector calculation
Dealing with topology changes
Limitations

www.idc-online .com

BEST PRACTICE in

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INDUSTRIAL DATA COMMUNICATIONS

WHAT YOU WILL LEARN:

Best practice in industrial data communications design, installation

and commissioning
How to design and install your own fully operational industrial
data communications systems
How to integrate different industrial communications protocols and
standards into a complete working system

WHO SHOULD ATTEND:

Anyone working with or required to follow best practice in the

installation of industrial data communications systems ranging from
RS-232 to Fieldbus and Ethernet systems, including:
Instrumentation and Control
Engineers and Technicians
Process Control Engineers
Network Planners

Electrical Engineers

Test Engineers

Electronic Technicians
Consulting Engineers

Design Engineers
Plant Managers

Systems Engineers
Shift Electricians

System Integrators
Designers

1.21

The Workshop

The Program

The objective of this workshop is to outline

the best practice in designing, installing,
commissioning
and
troubleshooting
industrial data communications systems. In
any given plant, factory or installation there
are a myriad of different industrial
communications standards used and the
key to successful implementation is the
degree to which the entire system integrates
and works together. With so many different
standards on the market today, the debate is
not about what is the best - be it Foundation
Fieldbus, Profibus, Devicenet or Industrial
Ethernet but rather about selecting the most
appropriate technologies and standards for
a given application and then ensuring that
best practice is followed in designing,
installing and commissioning the data
communications links to ensure they run
fault-free.

SELECTION METHODOLOGY
Which standards/technologies to use:

Overview of the workshop

OSI model
Systems engineering approach
Attributes of typical communications
systems

- Media
- Physical connections
- Protocols and applications
General issues

- Noise, earthing and shielding

- Protection against dust and moisture

FUNDAMENTALS

- Field management (device) level

- Process management (operator) level
- Business management (enterprise)
level
- Long distance SCADA/telemetry links

INSTALLATION METHODOLOGY
Copper cabling and connectors

- System design and installation

Fibre cabling and connectors

- System design and installation

Wireless

- System design and installation

Copper/fibre

Cable and connector standards

Splicing
Connector attachment
Drivers and detectors
Earthing and termination
Protection against transients

COMMISSIONING, TESTING and

TROUBLESHOOTING

Copper infrastructure
Fibre infrastructure
Wireless infrastructure
Networks

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The industrial data communications systems

in your plant underpin your entire operation.
It is critical that you apply best practice in
designing, installing and fixing any problems
that may occur. This workshop distils all the
tips and tricks learnt with the benefit of
many years of experience and gives the best
proven practices to follow.

INTRODUCTION

The main steps in using today's

communications technologies involve
selecting the correct technology and
standards for your plant based on your
requirements; doing the design of the overall
system, installing the cabling and then
commissioning the system.

Fibre optic cabling is generally accepted as

the
best
approach
for
physical
communications but there are obviously
areas where you will be forced to use copper
wiring and indeed, wireless communications.
This workshop outlines the critical rules
followed
in
installing
the
data
communications physical transport media
and then ensuring that the installation will
be trouble-free for years to come.

The important point to make is that with

today's wide range of protocols available,
you only need to know how to select, install
and maintain them in the most cost effective
manner for your plant or factory - knowledge
of the minute details of the protocols is not
necessary.

Physical layer standards

- RS-232
- RS-485
- 4-20 mA

Industrial networks

Industrial Ethernet
AS-i
DeviceNet
Profibus
Foundation Fieldbus
Modbus Plus
Data Highway Plus
HART
Ethernet/IP
ProfiNet
Foundation Fieldbus HSE

Physical layer issues (OSI Layer 1)

Data link layer issues (OSI Layer 2)
Network layer issues (OSI Layer 3)
Transport layer issues (OSI Layer 4)
Application and "user" layer issues
(OSI Layers 7-8)
- Client/server issues

SUMMARY, OPEN FORUM

AND CLOSING

Industrial protocols

TCP/IP
Modbus and Modbus TCP
DNP3
60870 SCADA

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Practical Sessions
Troubleshooting RS-232
Troubleshooting RS-485

Customise the training to

Troubleshooting Modbus

your workplace.

Troubleshooting Ethernet
Troubleshooting TCP/IP

Have the training

Checking RS-485 behaviour at different

frequencies

delivered when and

where you need it.

Fabricating and testing Cat5 cables

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Fundamentals of

VOICE over IP (VoIP)

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Understand how Voice over IP works and compares to Public

Switched Telephone Network
Understand the basics of VPN and International Telephony
Be able to do a Voice over IP cost-benefit analysis for your
organisation
Understand how VoIP protocols work together
Be able to assess other WAN transport alternatives for VoIP
Understand the fundamentals of H.323 VoIP standard
Know how to implement a simple VoIP system
Be able to deal with packet loss, packet delay, packet jitter, signal
echo and other QOS issues
The "'jargon" used in VoIP and telecommunications
The "nuts and bolts" about selecting and installing VoIP
telecommunications systems
How to make "best practice" decisions on the best and most cost
effective implementation of Voice over IP for your organisation

WHO SHOULD ATTEND:

Electrical Engineers and

Technicians
IT Personnel
Technicians
Managers
Instrumentation Engineers and
Technicians
Process Control Engineers and
Technicians
Project Engineers

Systems Engineers
Process Engineers
Maintenance Engineers
Sales Engineers
Engineering Managers
Network Administrators
Software Engineers
Field Technical Support Staff

1.23

The Workshop

The Program

In the past five years, technologies have

converged to such an extent that one can
transmit voice, fax and video over the same
Internet Protocol Network that one uses for
data. This workshop examines Voice over IP
(VoIP) technologies and provides you with
the skills to competently implement a VoIP
network for your organisation. Numerous
case studies and exercises throughout the
course ensure that you get a good grasp on
the technologies used. Solid practical advice
is given on application, implementation and
most importantly troubleshooting these
systems.

Pre-requisites

Business Case for

Converged Networks

Overview of course
Terms and Definitions

Telecommunications
Fundamentals
Concepts: Signaling, Circuits, Channels,
Lines, Trunks,
Bandwidth, Channel Capacity.
2-Wire vs. 4-wire Circuits
Full vs. Half Duplex
Baseband, Broadband, Narrowband and
Wideband
Analogue vs. Digital transmission
Dial-up vs. Leased Access
Multiplexing techniques: FDM, TDM,
PCM, WDM, DWDM.
Connection Oriented vs. Connectionless
Communication
Circuit Switching vs. Packet Switching
Switching vs. Routing
Local Area vs. Wide Area Networks
The "Communications Cloud"
The PSTN vs. the Internet
The OSI Model

Fundamental Financial Assumptions

Network Traffic Assumptions
Case Studies
Interoffice
In-bound customer call charges
In-bound Call Centre charges

Protocols Used

Ipv4, Ipv6 and ICMP

Packet Addressing
Packet Routing
Host Name-Address Translation
Protocols supporting VoIP

WAN Transport for

Converged Networks

WAN Transport Alternatives

Digital Lines
ISDN/ADSL
IP over Frame Relay
IP over ATM

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A basic knowledge of communications and

applications would be useful.

Introduction

Practical Sessions

Fundamentals of TCP/IP

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Ethernet
Internet Protocol
Transmission Protocol
Application Layer Protocols

Principles of Converged
Networks

Connectionless versus Connection

Oriented Network architecture
Voice and Data Network Characteristics

Applications for the

Converged Network

Telephone to PC communications via the

Internet
IP Voice Virtual Private Network
conversion
Replacing International Leased Lines
Fax over IP Networks
Video over IP

On-Site Training

Hardware Systems for

Converged Networks

Converged Network Environments

H.323 Multimedia Standard
Terminals
Audio and Video Codecs
Client Software
Gateways
Terminal to Gateway Communications
Gatekeepers
Multipoint Control Units

Implementation of
Converged Network

Interoperability Frameworks
Alternatives to H.323
Application Programming Interfaces
Quality of Service (QOS)
Implementation of QOS
Implementation of Converged Network

Conclusion

Revision
Pulling all the strands together

SUMMARY, OPEN FORUM

and CLOSING

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Troubleshooting,
Design and Selection of

Industrial Fibre Optic Systems

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for Industry

YOU WILL LEARN:

Practical hands-on experience in jointing, splicing and testing fibre

optic systems
A solid knowledge of fibre optic communications systems

State of the art fibre optics technology and installation practices

Correct procedures for cable installation and termination

How to design and install your own fully operational fibre optics
system
New approaches to troubleshooting including how to use an
Optical Time Domain Reflectometer (OTDR)

WHO SHOULD ATTEND:

Instrumentation and Control Engineers and Technicians

Telecommunications Engineers and Technicians
Maintenance Engineers and Technicians
Process Control Engineers
Project Engineers

Electrical Engineers
Consulting Engineers
Systems Engineers
Project Managers
Electricians

1.25

The Workshop

The Program

This is a comprehensive two-day workshop

that provides the necessary background to
understand the fundamentals of fibre optic
systems and their individual components
including fibres, cable construction,
connectors, splices and optical sources and
detectors. Attendees will use this knowledge
to develop the required techniques for
design, installation and maintenance of fibre
optic systems.

Optical Drivers and

Detectors

Light emitting diodes

Lasers
Transmitter modules
Safety considerations
PIN photodiodes
Receiver modules
Optical amplifiers

Introduction
Outline of workshop
Historical background to fibre optics
Comparison of fibre optics and copper
systems

Definitions and Basic

Principles

Data communications
Communications channels
Transmission modes
The electromagnetic spectrum
Revisiting copper

Theory of Fibre Optic

Transmission

Fundamental principles of operation

Light transmission nature of glass
Numerical aperture
Modal propagation in fibres
Multimode / singlemode / step-index /
graded index
Bandwidth of fibres
Modal and chromatic dispersion
Absorption / scatter / bending / radiation /
mismatches
Other types of fibres

Installing Fibre Optic Cables

Preparation - site survey and design
Installation rules and procedures
Bending radius / cable tension / cable
reels
Cable trays / conduits / lubricants
Indoor cable installation / leaving extra
cable
Outdoor cable installation /
environmental conditions
Splicing trays / organisers / termination
cabinets / patch panels / distribution
panels / breakout boxes

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The workshop places significant emphasis

on the practical techniques of component
installation and system design. Attendees
will have the opportunity to get hands on
experience with mechanical and fusion
splicing and with fitting the popular industrial
fibre connectors. A fibre optic link design
software package is provided to allow the
attendee to practice actual link design
practicals using various parameters. Finally,
attendees will have the opportunity to
practice using various Fibre Optic test
equipment such as optical sources and
power meters.

Introduction to Fibre Optic

Systems

The material presented in this workshop has

been developed from the many years
experience gained by IDC Technologies
engineers working in consulting and
contracting roles in industry. It is a practical,
hands-on workshop enabling participants to
work through practical exercises which
reinforce the concepts discussed during the
workshop.

Workshop Objectives

This workshop is designed to provide a

thorough background to fibre optic
communications systems and to illustrate
how to design and install these systems.
Various pitfalls associated with the
implementation of fibre optic systems are
discussed and workable solutions to these
problems are provided. It will benefit
engineers and technicians involved in
specifying, commissioning and maintaining
industrial fibre optic systems, but who have
little previous experience in this field.

Construction of Fibre Optic

Cables

Cable objectives
Tensile ratings
Structural elements
Strengthening members
Housings - loose tube / slotted core / tight
buffered
Sheaths and moisture barriers
Classes of cables - aerial / underground /
subaqueous / indoor

Connecting Fibres

Optical connection issues

Fibre end preparation
Splicing fibres - fusion / mechanical
Connectors
Optical couplers

Practical Sessions

Fibre Optic Link Design - a complete

design of a fibre optic link

Fibre Optic System Design

Initial design considerations

Future capacity / reliability / operating
wavelength
Repeaters and amplifiers
Design loss calculations / link loss
budgets
Design bandwidth calculations

Testing of Fibre Optic

Systems

Concepts of optical measurement

Continuity testing
Insertion loss testing
Optical Time Domain Reflectometry
(OTDR)
Bit Error Rate (BER) testing
Eye diagrams
Laboratory fibre tests

Technologies that use

Optical Fibres

Low speed modems

10 Base F / FDDI / FIORL
100 Base F
ATM
LANs / MANs / WANs
Analog modulators for video and
microwave links
HDTV

Bit Error Rate - perform simple tests and

examine the practical implications of the
results

Fusion Splicer - perform a fusion splice

and gain experience in the techniques
Mechanical Splice - perform a simple
mechanical splice
Optical Power Measurement - the use of
an optical source and an optical power
meter
Continuity Tester - the principles of
operation of a simple fibre optic continuity
tester
Optical Time Domain Reflectometer
(OTDR) - demonstration on the practical
use of ODTR with a video presentation

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Troubleshooting

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INDUSTRIAL ETHERNET
and TCP/IP NETWORKS

YOU WILL LEARN HOW TO:

Install and configure a simple industrial Ethernet and TCP/IP

network
Troubleshoot and fix Ethernet network problems

Use a protocol analyser to analyse Ethernet network activity

Use the utilities supplied to fault find TCP/IP and Ethernet networks
Learn how to troubleshoot TCP/IP networks
Identify network problems and fix them

Fault find at the Ethernet/TCP/IP and application levels

Learn the essentials of network management

Learn how to track hackers and network problems

WHO SHOULD ATTEND:

This is not an advanced workshop - but a hands-on one.

Anyone who will be designing, installing and commissioning,

maintaining or troubleshooting TCP/IP and Intra/Internet sites will
benefit including:
Instrumentation Engineers
Technicians
Design Engineers
Network Engineers
Engineering Managers
Electrical Engineers
Network System Administrators

1.27

The Workshop

The Program

This workshop is a practical workshop

devoted to two days of hands-on faultfinding
and troubleshooting.
The workshop has been structured to cover
key issues in troubleshooting TCP/IP and
Ethernet in detail, while going through the
practical implementation of TCP/IP in office
and industrial networks and the practical
use of the Internet and Intranets.
Troubleshooting and maintenance of TCP/IP
networks and communication systems in an
office and industrial environment are also
covered. 15 practical mini-sessions expose
you to typical problems that could occur
with industrial Ethernet and TCP/IP networks
and shows you how to fix them. Most of
each day comprises practical sessions with a
modicum of discussion to explain the key
points. There will be a minimum of two
people to a PC so that the practical
component will be emphasised.

Network communications
Open systems
Network topologies

OPERATION OF ETHERNET
SYSTEMS
Ethernet standards (10Mbits/s to
10Gigabits/s)
Full duplex Ethernet

TROUBLESHOOTING THE
DIFFERENT ETHERNET CABLE
TYPES

Twisted pair
Fibre optic
Fast Ethernet twisted pair
Fast Ethernet fibre optic
Gigabit Ethernet twisted pair
Gigabit Ethernet fibre optic
Structured cabling
Industrial versus commercial networks

TROUBLESHOOTING THE
HOST-TO-HOST CONNECTION
(TCP PROTOCOL)
Using BOOTP with UDP Transport
Clock synchronisation with UDP
Establishing and terminating TCP
connections
TCP data transfers
Repeated Host Acknowledgments
Using the Finger User Information
Protocol
Optimising TCP Window Size
Problems with high delay links (e.g.
satellite)

TROUBLESHOOTING THE
PROCESS/APPLICATION
CONNECTION
Using FTP and TFTP
Hacking passwords and security
problems
Telnet problems
NetBIOS and TCP interactions
Implementing Multi Protocol stacks

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At the end of this workshop you will walk

away with a solid knowledge on
troubleshooting industrial Ethernet and TCP/
IP networks. A comprehensive 400 page
manual will ensure that you have an excellent
reference book for your future work in this
challenging and yet rewarding area of
engineering.

BACKGROUND AND
INTRODUCTION TO ETHERNET

Pre-requisites

A basic working knowledge of industrial

communications and applications is useful.

TCP/IP

Quick review of essentials of TCP/IP

Internet Layer Protocols (IP)
Host-to-Host Layer protocols (incl. TCP/
UDP)
Application Layer protocols (incl. DHCP,
FTP, SNMP, DNS)

TOOLS FOR TROUBLESHOOTING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Basic utilities
Protocol analyser
Ethernet performance
Troubleshooting of Ethernet and TCP/IP
rules

TROUBLESHOOTING ROUTERS
AND SWITCHES
Ethernet repeater hubs
Ethernet switching hubs
Routers

NETWORK MANAGEMENT

Simple Network Management Protocol

(SNMP) client/server session

WRAP UP AND CONCLUSION

Revision of key concepts
Summary of the basic rules

TROUBLESHOOTING THE
NETWORK INTERFACE
CONNECTION

NIC hardware errors

Frame collisions and how they impact on
performance
Incompatibilities with 802.3 and Ethernet
V.2 Frames

TROUBLESHOOTING THE
INTERNETWORK CONNECTION (IP
PROTOCOL)
DNS configuration errors
DHCP configuration problems
Fragmenting and reassembly of long
messages
ARP related problems
Duplicate IP Addresses
Incorrect Sub-Net mask
Using ICMP Echo Messages (Ping)
Misdirected datagrams
Incorrectly configured routers

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

practical

Industrial Wireless

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Understand current wireless networking offerings on the market

Apply today's wireless technology to industrial automation
Implement your own simple wireless LAN (WLAN) for your office
and industrial plant
Implement simple radio telemetry links for SCADA systems
Explain the strengths and weaknesses of the different wireless
technologies
Describe standards such as IEEE 802.15.4 and IEEE 802.11
Implement effective security on your network

Describe how spectrum and frequency allocation is done

Understand the basic terminology and jargon used in this area

WHO SHOULD ATTEND:

This course is designed for personnel with a need to understand the

techniques required for using and applying wireless communications
technology as productively and economically as possible. This includes
engineers and technicians involved with:
Control and instrumentation

Maintenance supervisors

Control systems

Process control

Consulting

Process development

Design

Project management

Electrical installations

Regulatory and legal issues

Equipment manufacturing

SCADA and telemetry systems

IT personnel

1.29

The Workshop

The Program

Wireless communications is being rapidly

implemented in the industrial environment,
with great success, provided certain ground
rules are applied. These include ensuring a
robust wireless link, correct integration with
the wired communications systems, and
proper data security.
The
critical
objective
of
wireless
communications networks must be to
achieve similar capacities, bandwidths,
responsiveness and availability to that of
wire-based communications systems.

WIRELESS MESH NETWORKS

Current trends in industrial wireless

technology
Wireless Industrial Networking Alliance
(WINA) and ISA-SP100
Review of the OSI model
Brief review of Ethernet and the TCP/IP
protocol suite

Mesh basics
Wi-Fi mesh systems
IEEE 802.15.4
- ZigBee
- WirelessHART

WIRELESS FUNDAMENTALS
Radio/microwave spectrum and
frequency allocations
Modulation techniques
Spread spectrum techniques

POINT-TO-POINT TERRRESTRIAL
WIRELESS SYSTEMS
Terrestrial microwave link design
Wireless modems
Point-to-point and point-to-multi-point
configurations

WIRELESS LANs

WIRELESS SENSOR NETWORKS

IEEE 1451.5

OTHER RELEVANT WIRELESS

TECHNOLOGIES

IEEE 802.15.1 (Bluetooth)

Low Power (LP) radio
IEEE 802.16 (WiMax)
Cellular data transmission (GPRS, 1xRTT,
EV-DO, HSPDA)
Satellite systems: VSAT

SECURITY ISSUES
Physical security
Authentication
Encryption

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Apart from covering wireless basics, the

workshop provides an in-depth coverage of
the main industrial wireless technologies in
use today, viz. radio modems, IEEE 802.11
wireless LANs (Wi-Fi) and IEEE 802.15.4
wireless PAN technology as implemented by
a multitude of process control system
vendors. WirelessHART is a specific example
of this.

INTRODUCTION

The workshop also covers some of the secondary

technologies that are not known as industrial
technologies per se, but which still find widespread
application in industrial environments. These
include Bluetooth, LP radio, mobile (cellular) data
systems and VSAT.

WLAN basics
Specifications (IEEE 802.11 a/b/g/n)
Medium access control and frame
structures
Industrial WLAN

summary, open forum

and closing

At the end of the course you should have a

clear understanding of the choices available
to you in designing and implementing your
own industrial wireless network.

Pre-requisites

A
working
knowledge
of
data
communications and applications is useful,
but is not essential.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:

Set up an IEEE 802.11 WLAN and connect

to an Ethernet network
Troubleshoot simple problems
Perform a path loss calculation

Perform a simple analysis of the protocol

packets
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

DATA COMMUNICATIONS,
NETWORKING and PROTOCOLS

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for Industry - Back to Basics

YOU WILL LEARN HOW TO:

Understand the basic concepts of data communications used in

industry
Talk knowledgeably to their peers, clients and suppliers of
equipment on data communications

Have a good understanding of the best current practice for data

communications
Specify simple hardware and software requirements of data
communications systems
Competently explain the RS-232, RS-422 and RS-485 interface
standards;
Provide a working explanation of current industrial protocols such
as Modbus
Troubleshoot simple data communications systems

Understand how to construct simple Ethernet and TCP/IP networks

List and describe simply the most important Fieldbus and
DeviceNet standards

WHO SHOULD ATTEND:

This workshop is designed specifically if you have NO knowledge of
Data Communications, Networking and Protocols for Industry and
wish to acquire a simple understanding of how to apply this to your
work. You will be working in the engineering and industrial
environment.

1.31

The Workshop

The Program

An efficient data communications system

underpins all modern manufacturing
industry, mining plant, water and electrical
utilities and it is critical to have a good
working knowledge of what is being used.
No one and certainly no industrial equipment
is an island any longer but connected
together in some form of network. People
who don't work in the area of data
communications often have a fear of the
unknown and this workshop demystifies the
technology and gives you a solid
understanding of how to apply it effectively
to your job.

BACKGROUND TO DATA
COMMUNICATIONS
What is Data Communications
Brief Overview of the course
Overview of modern industrial systems

DEFINITIONS AND BASIC

PRINCIPLES

Bits , Bytes and Characters

Parallel and Serial Communications
Analog and Digital Signals
The Coding of Messages - The ASCII
Code
Practical Demonstration of Coding
Data Transmission Speeds
The Format of Messages
Introduction to Error Detection and
Correction
The Importance of Standards

Pre-requisites

None whatsoever besides an enthusiasm to

learn.

- ISO , ANSI , CCITT , IEEE , EIA

- EIA , RS-232 Interface Standard

DATA COMMUNICATIONS
STANDARDS BASICS

BACK

MODEMS

Concept of a modem
Various Modulation Techniques
Smart Modems
Radio Modems

OSI-OPEN SYSTEMS
INTERCONNECTION
Modern Factory Automation & Process
Control Systems
OSI Reference Model and Standards

PROTOCOLS FUNDAMENTALS

The Concept of a Protocol

Simple ASCII Based Protocols
Practical Demonstration of ASCII
Industry Standard Protocols eg Modbus
Practical Demonstration of Modbus
Allen Bradley Data Highway Plus Protocol

ETHERNET AND TCP/IP BASICS

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This training workshop assumes you have

no knowledge of the technology and gives
you a thorough review of the basics of
industrial data communications, networking
and protocols so that you can apply this
knowledge to your work immediately on the
completion of the course.

OUTLINE OF COURSE
OBJECTIVES

to

BASICS

Back
to Basics - a
low
level
introductory
workshop for those of you who want to
understand the basics of this exciting and
fast growing technology which is essential
to your plant, factory and business

At least 50% of the course will be practical

with hands on sessions with data
communications equipment, networks and
computers to give you a solid working
knowledge of the basic principles of data
communications without any focus on the
advanced technology concepts.

RS-232
Trouble Shooting of RS-232
RS-422 Interface Standard
RS-485 Interface Standard
Comparison of "RS" standards
RS-232/485 interface Converters

Current Loop Interface

Troubleshooting RS-232 and
RS-485
Testing Equipment (Breakout Box , Line
Analyser)
Protocol Analyser Practical

SELECTION AND INSTALLATION

OF DATA CABLES

How Ethernet Works

The very basics of TCP/IP
How TCP/IP fits onto Ethernet
How to construct a simple Ethernet and
TCP/IP network

SMART INSTRUMENTS CONCEPTS

What is a smart instrument
HART

FIELDBUS and DEVICENET

BASICS

Actuator Sensor Interface (ASI)

DeviceNet
Profibus
Foundation Fieldbus
Where to use each smart instrument
standard

Simple ROADMAP OF DATA

COMMunicationS STANDARDS

Cables with Copper Conductors

Interference and Noise
Optical Fibre cables
Cable Selection and Installation
Recommendations

You do not know anything about this

technology and simply want to understand
the basics which you can apply in to work
with a minimum of fuss.

Good technical information and interchange

of information between attendees.
Neil Miller

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

FIELDBUS, DEVICENET
AND ETHERNET

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for Industry

Covering:

RS-232/RS-485

DeviceNet

ASiBus

Profibus

Foundation Fieldbus

Industrial Ethernet

YOU WILL LEARN How To:

Compare the Ethernet and Fieldbus/Devicenet standards

Troubleshoot and fix simple DeviceNet, Profibus and foundation

Fieldbus problems
Design and install simple Ethernet networks

Know when to use repeaters, bridges, switches, and routers

Apply switched Ethernet systems effectively

Install the cabling and hardware for a typical industrial Ethernet

network
Decide on the best cabling and connectors for your harsh or office
environment
Apply the structured cabling system concepts to your next project
Perform simple troubleshooting tasks on a network

WHO SHOULD ATTEND:

Anyone involved in the

installation, design and
support of industrial
communications systems
IT managers working with
networks
Electrical engineers
Project engineers
Design engineers
Systems engineers

Electrical and instrumentation

technicians
Maintenance engineers and
supervisors
Instrumentation and control
system engineers
Process control designers and
systems engineers
Instrumentation technologists
and engineers
1.33

The Workshop

The Program

The Fieldbus and DeviceNet standards are

becoming a standard at the field and
instrumentation level, and are replacing the
traditional approaches in the plant today.
Ethernet is fast becoming the obvious choice
for industrial control networking at the higher
levels.
While the basic structure of Ethernet has not
changed much, the faster technologies such
as Fast Ethernet and Gigabit Ethernet have
increased the complexity and choices you
have available in planning and designing
these systems. There has also been a
convergence between Fieldbus and DeviceNet
standards in that they are also increasingly
becoming based on industrial Ethernet for the
higher speed data transfer applications.

Quick revision of communications

Interface standards (RS-232/RS-485)
Industrial protocols (Modbus)
Industrial networks
Road map and comparison of Ethernet/
Fieldbus/DeviceNet standards

DeviceNet
Fundamentals
Configuration
Troubleshooting

Fundamentals of Ethernet

ASI Bus

Ethernet standards
Collisions and CSMA/CD
Ethernet frames
MAC addresses hardware/unicast/
multicast and broadcast
Sub Network Access Protocol (SNAP)
frame format
Full duplex Ethernet
Frame related terms (runt/fragment/
jabber/jam, interpacket-gap/slot time)
10Base-5, 10Base-2, 10Base-T
Problems with and upgrade options
Full duplex Ethernet

Construction of the
Ethernet System Cabling
Fibre and Copper

Fundamentals
Configuration
Troubleshooting

Profibus PA and DP
Fundamentals
Configuration
Troubleshooting

Structured cabling
Unshielded twisted pair
(Cat5, Cat5E, Cat6)
Twisted pair cables and connector
Fibre optic cables and connectors
Ethernet repeater hubs
Ethernet switching hubs
Troubleshooting Ethernet

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There is a fair degree of confusion about

where Fieldbus, DeviceNet and Ethernet, are
applied and the workshop commences with a
clear comparison between the different
standards and where they are applied.

Fundamental Principles of
industrial communications

As Ethernet has become more complex, a

number of misconceptions have arisen as to
how Ethernet functions, how the system
should be optimally configured and what
exactly Industrial Ethernet means. This
workshop addresses these issues in a clear
and practical manner enabling you to apply
the technology quickly and effectively in your
next project.

Foundation Fieldbus
Fundamentals
Configuration
Troubleshooting

100Mbit/s Fast Ethernet

Connecting Ethernet,
Fieldbus and DeviceNet

Connecting the different systems

together

Fundamentals of fast Ethernet

Media Independent Interface (MII)
100 Mbit./s physical level encoding
Fast Ethernet 100 Base-TX, 100Base-FX,
100Base-T4, 100Base-T2
Design considerations

1 Gbit/s and 10 Gbit/s Ethernet

Operation
IEEE 802.3z
Gigabit Ethernet repeaters and switches
Backward compatibility

Virtual LANs (VLANs) using

Ethernet

Essentials of VLANs
VLANs based on ports, MAC addresses,
protocols
Frame encapsulation methods
(eg IEEE 802.1Q)
Trunking protocols

Practical Sessions

Ethernet Interconnection
and operation

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

On-Site Training

Configuration of an Ethernet network

Configuration of a simple network
protocol

Demonstration of typical failure points

Diagnosis of network hardware problems

Configuration of a network with a switch
and hub
Addition of TCP/IP protocol
Use of basic utilities for troubleshooting
Set up ASibus, Profibus and DeviceNet
networks
Design calculations of foundation
Fieldbus systems
Connection between Ethernet and
Fieldbus /DeviceNet systems
Design calculations for DeviceNet
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training

to your workplace.

Have the training

Repeaters, switches, bridges

Routers
Gateways
Redundancy and reliability
Switched Ethernet
Spanning tree algorithm

Protocols that work with

Ethernet

TCP/IP
Modbus and Ether/IP
Routing on the network
User Datagram Protocol (UDP)
Utilities with TCP/IP

Summary, Open Forum

and Closing

delivered when and

where you need it.

Contact us for a free

proposal.

idc@idc-online .com

www.idc-online .com

Practical Troubleshooting
and Problem Solving of

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Modbus Protocols

YOU WILL LEARN HOWTO:

Identify, prevent and troubleshoot Modbus protocol

communications problems

Gain a practical toolkit of skills for working with Modbus

Work competently with Modbus and RS-232, RS-485, wireless and

Ethernet
Gain skills to fault find your Modbus based Ethernet, RS-232/485,
wireless, Ethernet and TCP/IP network problems

WHO SHOULD ATTEND:

Anyone working with or required to troubleshoot industrial

communications systems ranging from RS-232 to Fieldbus and
Ethernet systems, including:
Consulting engineers

Designers

Design engineers

Electrical engineers

Electronic technicians

Instrumentation and control engineers/technicians

Network planners
Plant managers
Process control engineers
Shift electricians
Systems engineers
System integrators
Test engineers
1.35

The Workshop

The Program
INTRODUCTION

INDUSTRIAL ETHERNET

Fundamentals
Protocol analysis
Problems: noise, connectors, cabling,
wire types, jabber, excessive
broadcasting, bad frames, faulty autonegotiation, network loading, component
failure
Ethernet practical troubleshooting session

What is Modbus?
Overview of the Modbus standards
Modbus and IDA
How Modbus relates to the RS-232,
RS-485, Ethernet and TCP/IP standards

OVERALL TROUBLESHOOTING
METHODOLOGY
Common symptoms, problems and
solutions
How to quickly identify likely causes
Basic steps
Communications issues
Grounding, shielding and noise

BASIC SERIAL COMMUNICATIONS

STANDARDS
RS-232
- Fundamentals
- Problems: UART settings (baud rate,
parity, etc), cabling, DTE/DCE,
handshaking, voltage levels, noise
RS-232 practical troubleshooting session
RS-485
- Fundamentals
- Problems: cabling, common mode
voltage, voltage levels, transient
protection, biasing, termination,
control (hardware/software), noise
RS-485 practical troubleshooting session

TCP/IP
Fundamentals
Software utilities (ipconfig, ping, arp,
tracert, netstat)
Protocol analysis
Problems: IP addresses, subnet masks,
default gateways, TCP connections
TCP/IP practical troubleshooting session

MODBUS/TCP (MODBUS OVER

TCP/IP)
Fundamentals: overall concept, protocol
stack
Packet structure: PDU, ADU, MBAP
header
TCP connectivity issues
Protocol analysis
Modbus/TCP to Modbus serial gateways
Problems: TCP connection problems,
timing issues
Practical session with Modbus over TCP/IP

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Modbus industrial communications systems

(based on RS-232/RS-485 and Ethernet) are
being installed throughout industry today,
from connecting simple instruments to
Programmable Logic Controllers to PCs
throughout the business part of the
enterprise. Communications problems
range from simple wiring problems to
intermittent transfer of protocol messages.
Whilst the main issues with the Modbus
protocol will be covered in this workshop, a
clear understanding of the protocols and
standards that transport Modbus protocol
data units are required in order to effectively
work with Modbus. This includes such
standards as RS-485/RS-232 and Ethernet
(preferably industrial Ethernet) and TCP/IP.
Modbus, effectively one of the few
(arguably, the only) industrial messaging
protocols recognised by the Internet world
(port 502) has one of the largest installed
bases worldwide with more than 7.2 million
installed nodes. The Modbus TCP/IP profile
has recently been accepted by the
International Electro-technical Commission
(IEC) as a Publicly Available Specification
(IEC PAS 62030) and is now eligible to
become part of future editions of the
International Standards IEC 61158 and IEC
61784-2. So it enjoys the status of a widely
available open standard available to
everyone. And thus the popularity. Whilst
detractors will say the Modbus protocol
lacks some of the refinements of the newer
offerings on the market, there is no doubt
that it is one of the most popular standards
available in the industrial world today.
The communications system on your plant
underpins your entire operation. It is critical
that you have the knowledge and tools to
quickly identify and fix problems as they
occur, to ensure you have a secure system.
No compromise is possible here. This
workshop distils all the tips and tricks learnt
with the benefit of many years of experience.

THE MODBUS SERIAL STANDARD

Fundamentals: overall concept, protocol

stack, client/server interaction, PDU and
ADU
Modbus RTU vs. Modbus ASCII: frame
structures and timing considerations
Problems: timeouts, checksums (CRC/LRC),
incorrect function codes/data parameters,
exception responses
Modbus serial troubleshooting session

MODBUS PLUS

Fundamentals
Problems: cabling, grounding, shielding,
terminators, token passing

RADIO and WIRELESS

COMMUNICATIONS

Fundamentals
Problems: noise, interference, power,
distance, channel separation, encryption
Practical session with Modbus/TCP over
IEEE802.11

TROUBLESHOOTING TIPS
AND TRICKS

Summary of all the problems faced

Further troubleshooting tips

SUMMARY, OPEN FORUM

AND CLOSING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:
RS-232 (COM port) basics

RS-232 point to point communications

RS-485 basics

Logging and protocol analysis on serial

(RS-232/RS-485) communications system
Modbus Serial operation: RTU mode
Modbus Serial operation: ASCII mode
Setting up a basic Ethernet network
IP configuration
Protocol analysis on Ethernet network
Modbus/TCP

Modbus (Serial) over IEEE802.11 wireless

Installation and configuration of Modbus/
TCP to serial communication gateway
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

Radio Telemetry Systems

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for Industry

You will learn how to:

Implement simple radio telemetry links for SCADA systems

Understand the jargon, terminology and latest techniques
Design and install an effective radio telemetry link
Perform simple path loss calculations

Troubleshoot radio telemetry communication problems

Specify the main components of radio, satellite and microwave

telemetry links
Conduct a site survey

Implement effective security on radio, wireless and Ethernet

networks
Explain the infrastructure requirements for effective systems
Outline future trends in SCADA and telemetry systems

WHO SHOULD ATTEND:

Consulting engineers

Control systems applications engineers

Control systems sales engineers
Design engineers
Electrical engineers
Instrumentation and control engineers
Instrumentation technicians
Maintenance supervisors
Network system administrators
Process control engineers
Process development engineers

1.37

The Workshop

The Program

This workshop has been designed in

conjunction with radio telemetry experts
from throughout the world (the SCADA list)
and aims at providing you with all the
critical information that we can effectively
transfer across to you in two hard-hitting
days.

Basics of electromagnetic transmission

Analog and digital modulation techniques
Spread spectrum
Spectrum/frequency allocations

ANTENNAS

Fundamentals
Directionality and gain
Diversity
Specific types (directional and omnidirectional)

FIXED SYSTEMS

Wireless modems (serial)

Wireless modems (Ethernet)
Repeaters
IEEE 802.16 (WiMax)

SATELLITES
Theory of operation
Available satellite services
VSAT

LINE-OF-SIGHT MICROWAVE
Terrain mapping
Fresnel zone and antenna height
calculations
Link budget
Antenna selection

PERFORMANCE ANALYSIS
Availability and reliability
BER testing
Complete system testing

SCADA SYSTEMS

SERIAL DATA COMMUNICATIONS

Terminology and overview

Displays and HMIs
Best practice configuration

RS-232
RS-422/485
Industrial Ethernet

INFRASTRUCTURE
REQUIREMENTS

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The course commences with a discussion of

radio and wireless fundamentals to ensure
everyone is brought up to speed with the
basics. Antennas are then discussed,
followed by fixed systems. The essentials of
data communications (and Ethernet) are
then reviewed as they apply to radio
telemetry systems. A review of Wireless LAN
systems is undertaken and a comparison of
radio modems is given. The fast growing
topic of cellular radio data services is
discussed. Protocols are a key part of all
radio telemetry systems and the important
ones outlined together with the challenges
associated with radio.

RADIO AND WIRELESS

FUNDAMENTALS

A brief overview of satellite and microwave

systems is given for completeness, followed
by performance analysis. A discussion on
radio telemetry systems would not be
complete without sketching out the key
issues of SCADA systems and alarm
management. The
overall
network
architecture of radio telemetry systems is
then detailed. The course is concluded by an
examination of troubleshooting techniques
and the vital topic of security and
encryption.

A thread throughout the workshop reflects

todays emphasis on using open protocols
and networking standards such as DNP3,
TCP/IP and Ethernet, and off-the-shelf
hardware and software to keep the costs
down. A selection of case studies is used to
illustrate the key concepts with examples of
real-world radio telemetry systems in the
water, electrical and processing industries.
This workshop will also be an excellent
opportunity to network with your peers as
well as to gain significant new information
and techniques for your next radio telemetry
project.

WIRELESS LANS

IEEE 802.11a, b, g and n

Medium access control
Components
Topologies
Roaming

CELLULAR (MOBILE) DATA

SERVICES

Cellular basics
2G systems
3G systems
Cellular (mobile) data services

PROTOCOLS

Modbus
TCP/IP
DNP3
IEC 60870-5
IEC 61850
Differences between these alternatives
Potential problems with wireless
networks

Practical sessions throughout the two days

of the course ensure that you can apply the
course materials easily and effectively.

Location
Equipment selection
Infrastructure

NETWORK ARCHITECTURE

Design considerations
Repeater types
Network redundancy

TROUBLESHOOTING AND
MAINTENANCE
Equipment
Procedures

SECURITY

Introduction and terminology

Firewalls
Authentication
Encryption
Remote access to SCADA and telemetry
systems

FUTURE DIRECTIONS AND

REVIEW
SUMMARY, OPEN FORUM
AND CLOSING

Pre-requisites

Knowledge of basic electrical concepts.

Practical Sessions

This is a practical, hands on workshop enabling you to work through practical exercises
which reinforce the concepts discussed.
Practical sessions include:
Construction of Wireless LAN
Site survey
Extension of WLAN with wired distribution system
Microwave point-to-point link design exercise
Implementing encryption and authentication on a WLAN
Protocol analysis of Modbus/TCP over wireless
Design of a wireless telemetry system
To gain full value from this workshop, please bring your
laptop/notebook computer.

idc@idc-online .com

www.idc-online .com

SETTING UP, UNDERSTANDING

AND TROUBLESHOOTING OF

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INDUSTRIAL ETHERNET AND

AUTOMATION NETWORKS

What YOU WILL learn:

A practical toolkit of know-how on latest data communications

technologies
How to grasp the latest updates to OPC

How to understand the operation of industrial wireless systems

Practical experience in troubleshooting cable and wireless systems
Design tips and tricks for your own operational industrial data
communications systems
How to integrate the different industrial communications protocols
and standards
How to skill yourself up as the local guru in industrial data
communications

WHO SHOULD ATTEND:

Anyone who wants to get the latest up to date practical information

on industrial data communications systems and challenges ranging
from fieldbus and Ethernet systems to OPC and security, including:
Instrumentation and control
engineers and technicians

Designers

Process control engineers

Consulting engineers

Network planners

Design engineers

Electrical engineers

Plant managers

Test engineers

Systems engineers

System integrators

Network maintenance staff

Electronic technicians

1.39

The Workshop

The Program

Ethernet is fast becoming the obvious choice

for automation networks worldwide. It is a
rugged, versatile technology, equally at
home in a chemical plant, on an oceangoing vessel and in the cockpit of a fighter
aircraft. While the packet structure of
Ethernet has not changed since its inception,
technologies such as fast and gigabit
Ethernet, industrial Ethernet, VLANs,
redundant rings and real-time (deterministic)
Ethernet for motor control applications have
increased the complexity and choices
available in planning and designing these
systems. As Ethernet has become more
complex, a number of misconceptions have
arisen as to how Ethernet functions and how
the system should be optimally configured.
This workshop addresses these issues in a
clear and practical manner.

OPC

The OSI model and client/server

paradigm
The overall picture: where all these
technologies fit in
Current trends

The OPC concept

OPC specifications and unified
architecture
DCOM and registry issues
OPD DA (Data Access)
Redundancy, tunnelling and bridging
Implementation and troubleshooting
issues (especially Windows XP SP2)

INDUSTRIAL ETHERNET
Background: IEEE 802.3 CSMA/CD
Fast, gigabit and ten gigabit Ethernet
Switched Ethernet networks, redundant
rings and VLANs
Industrial Ethernet components
Real-time (deterministic) Ethernet and
IEEE1588
Implementation and troubleshooting

INDUSTRIAL WIRELESS
Wi-Fi (IEEE802.11a/b/g/n)
Wireless mesh networks (IEEE 802.15.4)
Wireless sensor networks (IEEE 1451)

TCP/IP

AUTOMATION NETWORK
DEVELOPMENTS
Fieldbus definition and standards
HART communication foundation: HART
and WirelessHART
ODVA: DeviceNet, Ethernet/IP and
CIPSync
PNO: PROFIBUS DP/PA, PROFINET v1, v2
(SRT), v3 (IRT)
Fieldbus foundation: FOUNDATION
fieldbus H1 and HSE
Real-time Ethernet fieldbuses:
- EtherCAT
- Ethernet PowerLink (EPL)
- Sercos III

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Ethernet can be easily augmented with

wireless technologies, and the workshop
takes a brief look at the current and emerging
industrial wireless technologies such as
IEEE802.11, wireless mesh and wireless
sensor networks; how they function, and
where they fit into the overall picture.
Ethernet is almost synonymous with the
TCP/IP protocol suite. Because of its rugged
design and the fact that it is Internetcompatible, all major automation system
vendors are adopting TCP/IP (and, of course,
Ethernet). This complex topic will be covered
in an easily-understandable and coherent
manner.

INTRODUCTION

The TCP/IP protocol suite

Network layer protocols (IPv4, ICMP, ARP)
Host-to-host layer protocols (TCP, UDP)
Application layer protocols (FTP, HTTP,
Telnet etc)
Configuration and troubleshooting

Finally we will look at every system

managers nightmare, security, and will
suggest some simple common-sense and
internationally-accepted measures to keep
the hackers at bay.

Authentication
Encryption
Firewalls
Wireless LAN issues
Practical steps to safeguard your
automation network

summary, open forum

and closing

OPC has made vast inroads into the process

automation arena and has been adopted by
every single SCADA system vendor. We will
look at current standards, in particular the
DA standard, and also at new developments
such as the Unified Architecture. We will
also highlight some tricky implementation
issues and ways to avoid the pitfalls.
With regard to the automation arena there is
a strong move to wireless and Ethernet/TCP/
IP. We will look at the offerings of the HART
communication foundation, the open
DeviceNet Vendor Association, The
PROFIBUS/PROFINET user organisations
and the fieldbus foundation, as well as the
latest Ethernet fieldbuses such as EtherCAT,
EPL and SercosIII, to get an overall idea of
the current trends. In particular we will focus
on the real-time issue, a prerequisite for
motor control applications. Real-time
Ethernet can now operate at sub-millisecond
access times and less than one microsecond
jitter. We will look at the various offerings by
the abovementioned vendors and the two
basic methods through which this incredible
performance is being achieved.

SECURITY FOR INDUSTRIAL

NETWORKS

Practical Sessions

This is a practical, hands on workshop enabling you to work through practical exercises
which reinforce the concepts discussed.
Practical sessions include:

Install and configure an industrial wireless access point as part of Ethernet network
Interconnect industrial wireless and
Ethernet networks

Control access with MAC address filtering

Perform path loss calculations on radio link

Use protocol analyser to solve Ethernet problems

Connect up simple analog and digital I/O system to network
Troubleshoot a HART instrument
Analyse protocols for ProfiNet and
Ethernet/IP
Configure IP addresses and subnet masks
Analyse ARP/ICMP/IP/UDP/TCP using protocol analyser
Connect up different packages using OPC
Troubleshoot a simple OPC problem
Set up a simple firewall
Demonstrate network security using encryption and authentication
To gain full value from this workshop, please bring your laptop/notebook computer.

idc@idc-online .com

www.idc-online .com

Practical

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Troubleshooting of
TCP/IPNetworks

you will learn how to:

Troubleshoot TCP/IP networks

Find faults at the network interface, internet, Host-Host and

application levels
Learn the essentials of network management
Learn how to detect hackers

WHO SHOULD ATTEND:

Communications specialists

Data communications managers

Designers

Design engineers

Electrical engineers

IT and MIS managers

IT support managers and personnel

Network administrators

Network engineers
Network planners

Network technicians
Network support staff
Programmers
System analysts
Systems engineers
System integrators

1.41

The Workshop

The Program

This is a hands-on workshop in the true

sense of the word, where you will spend
over 70% of the course time in setting up
and troubleshooting TCP/IP-based networks.
We have distilled all the practical tips and
tricks in maintaining and troubleshooting
TCP/IP networks into this intensive two-day
workshop.
Commencing with a simple introduction to
the hardware level of Ethernet, you will
quickly move onto coverage of the Internet
(IP) layer. The Host-to-Host (TCP) layer also
be covered in considerable practical detail.
The application layer of the TCP/IP protocol
suite will be covered by a detailed
examination of protocols such as BOOTP,
DHCP and SNMP. The simple but vital TCP/IP
utilities such as Ping, Arp and Tracert will
then be tested out on the network.

OSI model
Ethernet
TCP/IP protocol suite
Internet layer (OSI layer 3) protocols: IP,
ARP, ICMP
Host-Host layer (OSI layer 4) protocols:
TCP, UDP
Application layer (OSI layer 5/6/7)
protocols: FTP, HTTP, Telnet
Network components

TOOLS
DOS utilities
Windows utilities (IP scanners, port
scanners, route tracers)
Protocol analysers

NETWORK CONSTRUCTION

TROUBLESHOOTING AT LAYER 3
Checking stack operation (loop-back test)
Connectivity checking (ping, trace)
between subnets
Pinging and tracing via router (Telnet)
Packet debugging via router (Telnet)
Tracing Ethernet packet contents between
subnets
Detecting duplicate IP addresses
Effect of incorrect subnet masks
Effect of incorrect routing tables
Automatic IP address allocation (DHCP
server down)
Faulty WINS resolution
Inability of application programs to
resolve NetBIOS names
Checking router CPU resources and ACLs

TROUBLESHOOTING AT LAYER 4
Checking TCP connections
Observing TCP sequence numbers and
acknowledgements
Checking open connections on hosts
Scanning ports on network
Checking TCP/UDP delay and data rate
between hosts on WAN

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Finally, you will construct a virtual LAN and

virtual private network, and configure a
simple firewall. One of the best ways to
learn and retain your knowledge is with
hands-on sessions where you will gain a
broad range of skills that every competent
network engineer needs in his skills toolbox.
We believe this workshop provides the
required know-how.

NETWORKING BASICS
(OVERVIEW)

Pre-requisites:

A basic working knowledge of industrial

communications and applications is useful.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Constructing a simulated wide area

network simulation with hubs, switches
and routers
Setting up cisco routers
Setting up managed switch
Setting up DHCP and BOOTP servers
Configuring IP

BASIC SYSTEM CHECKS

Host configuration (ipconfig, wntipcfg)

Router configuration
Switch configuration
Connectivity (ping, arp, tracert)
Name resolution (hosts file, NetBIOS
name resolution)

TROUBLESHOOTING THE MEDIUM

Fiber connectivity
Cat5 connectivity (damaged and miswired cabling)

INTERNET CONNECTION

Setting up NAT router

Testing internet uplink/downlink
performance
Ping and tracing across the internet (DOS
and Windows utilities)

HACKING TOOLS

Cain and Abel (packet diversion and

analysis, password cracking)

SUMMARY, OPEN FORUM

AND CLOSING

TROUBLESHOOTING AT LAYER 2

Ethernet packet analysis

Checking Ethernet NIC driver
configuration
Detecting duplicate MAC addresses

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

Fibre Optics And

Interfacing Techniques

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to Industrial Ethernet and Wireless

YOU WILL Learn How to:

Practical hands-on experience in jointing, splicing and testing fibre

optic systems
A solid knowledge of fibre optic communications systems

State of the art fibre optics technology and installation practices

Correct procedures for cable installation and termination

How to design and install your own fully operational fibre optics
system
New approaches to troubleshooting including how to use an OTDR
Know-how on interfacing fibre/wireless and industrial Ethernet
Ability to apply design rules for fibre/wireless and Ethernet

WHO SHOULD ATTEND:

The workshop will benefit engineers and technicians involved in

specifying, commissioning and maintaining industrial fibre optic
systems, but who have little previous experience in this field, including:
Consulting engineers

Electrical engineers and electricians

I&C engineers and technicians
Maintenance engineers and technicians
Process control engineers
Project engineers and managers
Systems engineer
Telecommunications engineers and technicians

1.43

The Workshop

The Program

This comprehensive two-day workshop will

provide you with the necessary background
to understand the fundamentals of fibre optic
systems and their individual components
including fibres, cable construction,
connectors, splices and optical sources and
detectors. Various pitfalls associated with the
implementation of fibre optic systems are
discussed and workable solutions to these
problems are provided. It will provide you
with the knowledge to develop the required
techniques for design, installation and
maintenance of fibre optic systems.

Introduction and overview

Background to fibre optics
Fibre optics versus copper systems

DEFINITIONS AND BASIC

PRINCIPLES
Data communications and
communications channels
Transmission modes
The electromagnetic spectrum
Revisiting copper

THEORY OF FIBRE OPTIC

TRANSMISSION

Fundamental principles of operation

Light transmission nature of glass
Numerical aperture
Modal propagation in fibres
Multimode, single mode, step-index and
graded index
Bandwidth of fibres
Modal and chromatic dispersion
Absorption, scatter, bending, radiation
and mismatches
Other types of fibres

INSTALLING FIBRE OPTIC CABLES

Preparation, installation rules and
procedures
Bending radius, cable tension and cable
reels
Cable trays, conduits and lubricants
Indoor cable installation and leaving
extra cable
Outdoor cable installation and
environmental conditions
Splicing trays, organisers, termination
cabinets, breakout boxes, patch and
distribution panels

FIBRE OPTIC SYSTEM DESIGN

Initial design considerations
Future capacity, reliability and operating
wavelength
Repeaters and amplifiers
Design loss calculations and link loss
budgets
Design bandwidth calculations

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The workshop places significant emphasis on

the practical techniques of component
installation and system design. You will have
the opportunity to get hands on experience
with mechanical and fusion splicing and with
fitting the popular industrial fibre connectors.
A fibre optic link design software package is
provided to allow you to practice actual link
design practicals using various parameters.
Finally, you will have the opportunity to
practice using various fibre optic test
equipment such as optical sources and power
meters. At the conclusion of the workshop
you will gain know-how in interfacing,
integrating and troubleshooting fibre with
industrial wireless and Ethernet systems.

INTRODUCTION TO FIBRE OPTIC

SYSTEMS

CONSTRUCTION OF FIBRE OPTIC

CABLES

Practical Sessions

This is a practical, hands-on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:

Fibre optic link design - a complete

design of a fibre optic link

Optical power measurement - the use of

an optical source and an optical power
meter
Continuity tester - the principles of
operation of a simple fibre optic continuity
tester

Cable objectives
Tensile ratings and structural elements
Strengthening members
Housings, sheaths and moisture barriers
Classes of cables

CONNECTING FIBRES

Optical connection issues

Fibre end preparation
Splicing fibres
Connectors and optical couplers

OPTICAL DRIVERS AND

DETECTORS

Light emitting diodes and lasers

Transmitter modules
Safety considerations
PIN photodiodes
Receiver modules
Optical amplifiers

Optical Time Domain Reflectometer

(OTDR) - demonstration on the practical
use of ODTR with a video presentation

TESTING OF FIBRE OPTIC

SYSTEMS

Concepts of optical measurement

Continuity and insertion loss testing
Optical Time Domain Reflectometry
(OTDR)
Bit Error Rate (BER) testing
Eye diagrams and laboratory fibre tests

COPPER TO FIBRE

Industrial Ethernet
EMI/crosstalk/distance
Where to switch out
Interface devices - media converters/
Gigabit interface converter modules/SFPs
(Small Form Pluggable)
Devices with multiple media connectors
Multiplexers
Design considerations
Compromises

COPPER TO WIRELESS

Industrial wireless
Wireless to fibre and copper
Interface units

TROUBLESHOOTING FIBRE/
WIRELESS AND COPPER
Hardware troubleshooting
Ping/arp/wireshark/tracert

SUMMARY, OPEN FORUM

and CLOSING

Optical connectors - gain experience in

the techniques of fitting fibre optic
connectors

Use the patch cords constructed by

participants to link 2 media converters to
simulate (and test) a small backbone
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

hands-on

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data communication,
networking and
tcp/ip troubleshooting

you will learn how to:

Set up, configure and troubleshoot RS-232 and 2-wire as well as

4-wire RS-485 links
Set up and configure basic Ethernet networks containing hubs,
switches and routers, and troubleshoot these networks down to
the packet level
Configure IP parameters, and do basic TCP/IP troubleshooting
down to the packet level by means of DOS and Windows utilities
such as IP address and port scanners as well as protocol analysers
Troubleshoot Modbus serial and Modbus TCP systems down to
byte level
Set up IEEE802.11 access points in infrastructure and point-to-point
mode, do site surveys and sniff packets
Implement authentication and encryption on IEEE 802.11 wireless
LANs

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand the

techniques required to use and apply industrial communications
technology as productively and economically as possible. This includes
engineers and technicians involved with:

Consulting
Control and instrumentation
Control systems
Design
Electrical installations
Instrumentation

Maintenance supervisors
Process control
Process development
Project management
SCADA and telemetry systems

1.45

The Workshop

The Program

Data communication is given high priority in

todays industrial environment.This workshop
is designed to be hands-on, providing the
participants with essential knowledge and
helping them to understand and troubleshoot
systems.
This is a comprehensive two-day hands-on
workshop that covers practical aspects of
data communication such as serial
communications, Ethernet networking, TCP/
IP, Modbus, wireless communications and
security.

Asynchronous serial communication

basics
PRACTICAL EXERCISES
RS-232, RS-485 basics
- Setting up the software
- RS-232 basics
- RS-232 point-to-point communication
- RS-232 via virtual null modem
- RS-485 basics (2W and 4W) using
Listen 32 software, voltmeter and
oscilloscope (if available)

ETHERNET AND TCP/IP

NETWORKING
NETWORKING BASICS (BRIEF REVIEW)
Ethernet
TCP/IP protocol suite
Internet layer (OSI layer 3) protocols: IP,
ARP, ICMP
Host-host layer (OSI layer 4) protocols:
TCP, UDP
Application layer (OSI layer 5/6/7)
protocols: FTP, HTTP, Telnet
Utilities
Network components

ETHERNET AND TCP/IP

NETWORKING (cont.)
TROUBLESHOOTING AT LAYER 4
PRACTICAL EXERCISES
Checking TCP connections, observing TCP
sequence numbers and
acknowledgements with Wireshark
Scanning ports on hosts with advanced
ports scanner
Scanning ports on hosts with NMap
Checking TCP/UDP delay and data rate
between hosts on WAN with IXIA
QuickCheck

INDUSTRIAL PROTOCOLS:
MODBUS
MODBUS SERIAL
Basic client/server concept
Addressing scheme
Message structure
PRACTICAL EXERCISES
Master/slave simulation over null modem

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This workshop is for enthusiastic engineers

and technicians who wish to develop and
enhance their practical knowledge in the field
of data communications and networking. It
will help them to understand the concepts
behind data transmission, the various
protocols involved, and the topologies that
govern data exchange among various
systems in industry. It will also equip them
with the skills and tools to design and/or
maintain these systems on an ongoing basis.

SERIAL DATA COMMUNICATIONS

Pre-requisites:

A basic working knowledge of industrial

communications and applications will be
useful.
Real-life experience with equipment and
hands-on testing will enable the workshop
to be placed in context.

NETWORK CONSTRUCTION
PRACTICAL EXERCISES
Constructing a simulated Wide Area
Network simulation with hubs/switches
and pre-configured Cisco 2500 routers
IP configuration (IP addresses, subnet
masks, default gateways) of hosts

BASIC SYSTEM CHECKS

PRACTICAL EXERCISES
IP configuration checks (ipconfig,
wntipcfg)
Router configuration checks using IOS
commands via Telnet
Switch configuration checks using
browser
Connectivity checks (ping, arp, tracert)
Name resolution (hosts file, Lmhosts file)
TROUBLESHOOTING THE MEDIUM
PRACTICAL EXERCISES
Fiber connectivity basic checks
Cat5 connectivity (damaged and miswired cabling, with cable tester)

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

TROUBLESHOOTING AT LAYER 2
PRACTICAL EXERCISES
Ethernet packet analysis with Wireshark
Checking Ethernet NIC driver
configuration

TROUBLESHOOTING AT LAYER 3
PRACTICAL EXERCISES
Checking stack operation with loop-back
test
Tracing Ethernet packet contents between
subnets with Wireshark
Detecting duplicate IP addresses
Automatic IP address allocation (DHCP
server down)

MODBUS TCP
Basic concept
Message structure
PRACTICAL EXERCISES
Master/slave simulation over Ethernet
and TCP/IP
Modbus Serial/TCP gateway (Moxa Nport
6110)

WIRELESS

IEEE802.11 wireless LAN overview

PRACTICAL EXERCISES
Setting up Cisco Aeronet access point
Configuring an access point as
workgroup bridge to establish a point-topoint link (wireless bridge) with two
Cisco Aeronet access points
Sniffing wireless packets with Wireshark
Quick site survey
Measuring signal-to-noise ratio with
Netstumbler

SECURITY

Basic security issues

WPA2 encryption (AES)
WPA2 authentication
- Personal mode
- Enterprise mode
PRACTICAL EXERCISES
Enabling encryption (AES) on a wireless
LAN
Authentication via RADIUS server

SUMMARY, OPEN FORUM

AND CLOSING

Customise the training

to your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

Practical Sessions
This is a practical, hands on workshop enabling you to work through practical exercises
which reinforce the concepts discussed.
To gain full value from this workshop, please bring your
laptop/notebook computer.

idc@idc-online .com

www.idc-online .com

PRACTICAL USE AND UNDERSTANDING OF

FOUNDATION FIELDBUS

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for ENGINEERS AND TECHNICIANS

you will learn how to:

List the differences between a Fieldbus system and the traditional

4-20 mA approach
Describe the fundamental operation of Foundation Fieldbus
Describe the main wiring rules of Foundation Fieldbus

List the main considerations in configuring and installing a

Foundation Fieldbus System
Perform a simple configuration of a Foundation Fieldbus system
using Function Blocks
Perform basic troubleshooting of a Foundation Fieldbus system
Design fieldbus segments

Select the proper components to build the segments

Configure and connect FF field devices to the network.

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand

the techniques required to use and apply Foundation Fieldbus
technology as productively and economically as possible. This
includes engineers and technicians involved with:

Control and Instrumentation

SCADA and telemetry systems
Process Control
Electrical Installations
Consulting
Design

Process Development
Control Systems
Maintenance Supervisors
Project management
Instrumentation

1.47

The Workshop

The Program

Foundation Fieldbus (FF) is one of the leading

fieldbuses in Process Automation. Its
sophisticated architecture is tailor-made for
today's automation systems. Its unique set of
features allows for the implementation of
true distributed control. The Foundation
Fieldbus includes an H1 protocol based on
IEC 61158-2 physical layer specification as
well as an HSE standard for communication
over Ethernet/IP. These features and the
possibility for distributed control make the
Foundation Fieldbus unique for process
control application.

Theory of FF technology
Key features and benefits of FF
Topologies, cable types, and constraints
Components required for building FF
segments

HANDS-ON FOUNDATION
FIELDBUS
Design of FF segments - power, voltage,
device load constraints
Wire and configure devices to a process
control system
Installation in hazardous areas

ECONOMICS OF FOUNDATION
FIELDBUS
Quantifying potential savings
Justifying a FF project

FOUNDATION FIELDBUS
CHARACTERISTICS

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The main aim of this workshop is to give

you a clear understanding of Foundation
Fieldbus and to enable you to specify and
design systems using this technology. In the
past year there has been a surge of interest
in Foundation Fieldbus due to the
tremendous benefits it provides. This
workshop aims to break down the
terminology and jargon barriers and to
explain Foundation Fieldbus in a simple and
understandable way; thus enabling you to
apply the technology effectively.

INTRODUCTION AND OVERVIEW

OF FOUNDATION FIELDBUS

Delegates will gain a solid understanding of

proper wiring practices when applying FF in
non-incendive,
explosion-proof,
and
intrinsically safe hazardous areas.
The course includes an introductory overview
of the technology of Foundation Fieldbus and
its specifications. During the course you will
gain knowledge about the architecture of
Foundation Fieldbus and its relation to other
communication systems.
Benefits and limitations will be discussed, so
that you are in the position to evaluate the
benefit of the Foundation Fieldbus for your
individual application. The information will be
demonstrated on a multi-vendor application.

Pre-requisites:

A basic working knowledge of industrial

communications and applications is useful.

On-Site Training

ROOTS OF FOUNDATION
FIELDBUS (IN ISP, PROFIBUS)

Explanation of basic elements (OSI

model etc.)
IEC 61158 transmission technology
"Data Link Layer"
- device types and services
("Link Master", "Field Device")
- address formats
- connection types
- DLL schedule
Basics FMS object dictionary,
communication relations, services
"Network Management"
"System Management"
"Function Blocks" (concept, types,
elements)
Linking of "Function Blocks" to
communication interfaces

Paul Swales, South Corp Technology Systems

summary, open forum

and closing

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training

to your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.
idc@idc-online .com

Good presentation and very

knowledgeable.

Delegates will gain a solid understanding of

proper wiring practices when applying FF in
non-incendive,
explosion-proof,
and
intrinsically safe hazardous areas.

Connection types (cyclic/acyclic, one-toone, one-to-many)

Fieldbus Message Specification
- coding of information
- accessing data (process data/
configuration data)
Function Block Application
High Speed Ethernet

www.idc-online .com

Troubleshooting, Designing and Installing

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Digital and Analog

Closed Circuit TV Systems

you will learn how to:

Understand the essentials of CCTV systems

Install and commission simple CCTV systems

Design a CCTV system

Maintain CCTV cameras

Define the differences between analogue and digital CCTV

Apply the CCTV lab test charts

Compare the standards used in CCTV

Networking simple digital CCTV systems

List the differences between wire and wireless video transmission

Identify the security issues in CCTV

Outline the main steps in maintenance and commissioning of

CCTV

WHO SHOULD ATTEND:

Building management technicians and engineers

Consulting engineers
Design engineers
Electrical engineers and technicians
Electronic engineers and technicians
Plant engineers
Security managers and consultants
Security system designers, installers and vendors

1.49

The Workshop
The objective of this workshop is to provide a practical know-how in designing, installing, commissioning, maintaining and troubleshooting
analog and digital CCTV systems.
The poor quality of CCTV images often seen doesn't inspire much confidence in the technology. However the purpose of this workshop is to
ensure you apply best practice in all your work with CCTV systems. With the recent terrorist outrages in London and other cities, CCTV systems
have been essential as a key tool in fighting crime, and have perhaps shifted from being part of "Big Brother" to a useful tool.
CCTV systems have undergone a remarkable technology transformation in the past decade, transitioning from analog to digital, operating on
a wireless or cabled network, with a host of additional features. This has made the design and maintenance considerably more complex. This
workshop thus provides useful expertise in building and maintaining high quality CCTV systems.
The workshop commences with a detailed review of the fundamentals; progressing to optics and TV systems. Modern CCTV cameras and
monitors are then examined followed by a review of video processing equipment and analog video recording. The vital changes from the
analog to digital world are then examined in considerable depth. The essentials of networking as applied to CCTV systems are then discussed
with practical examples. The workshop is concluded with best practice in CCTV system design and commissioning and maintenance.

Pre-requisites:

Fundamental knowledge of television and its parts and the very basics of CCTV.

The Program
INTRODUCTION TO LIGHT

General
Light basics and human eye
Light units
Artificial lighting
Colours in television
Colour temperatures and light sources
Eye persistence - motion pictures
Comparison between eye and camera

OPTICS IN CCTV

Refraction
Lenses as optical elements
Aspherical lenses
CTF (Contrast Transfer Function) and MTF
(Modulation Transfer Function)
F (Focal) and T (Transmission) numbers
Depth of field
Neutral Density (ND) filters
Manual, auto and motorised iris lenses
Video - and DC - driven auto iris lenses
Image and lens formats in CCTV
Angles of view and determining them
Fixed focal length lenses
Zoom lenses
C - and CS - mount and back-focus
Optical accessories in CCTV

GENERAL CHARACTERISTICS OF
TELEVISION SYSTEMS

Basics of television
Working of television
The video signal and its spectrum
Colour video signals
Picture resolution
Television synchronisation
Television signals
Instruments commonly used in CCTV
HDTV (High Definition Television)

CCD (Charge Coupled Device) camera

Sensitivity and resolution of the CCD
Types of charge transfer in CCDs
Camera specifications and their
meanings
Colour CCD cameras
CMOS (Complementary Metal Oxide
Semiconductor) technology
Camera power supplies and copper
Synchronisation
V-phase adjustment
Camera check list

CCTV MONITORS

VIDEO PROCESSING EQUIPMENT

Analogue switching equipment
Switching and processing equipment

ANALOGUE VIDEO RECORDING

Early concept of VCR (Video Cassette
Recording)
Video recording principle
VHS (Video Home System)
Super VHS
Time lapse recording
Time lapse VCR features
VCR maintenance
Video head cleaning

DIGITAL VIDEO

Digital video recorders

Various standards
Need for compression
Types of compression
DCT (Discrete Cosine Transformation) as a
basis
Compression standards in CCTV
About pixel and resolution
Dots Per Inch (DPI)
Psychophysiology of viewing details
Recognising faces and licence plates in CCTV
Operating systems and hard disks
Hard disk drives
The different file systems
MTBF (Mean Time Between Failure)
Digital video tape
Disk-based video recording
Recording capacity
Security of digital information

TRANSMISSION MEDIA

CCTV CAMERAS

Projectors and projection monitors

Plasma display monitors
Field emission technology displays

The OSI seven-layer model of networking

IP addresses
Domain Name Systems (DNS)
Networking hardware
Wireless LAN
Bluetooth
Putting a network system together

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General about CRT (Cathode Ray Tube)

monitors
Block diagram
Monitor sizes, safety and adjustments
Impedance switch
Viewing conditions
Gamma
LCD (Liquid Crystal Display) monitors

Coaxial cables
Twisted pair video transmission
Microwave links
RF wireless (open air) video transmission
Infrared wireless (open air) video
transmission
Fibre optics
Fibre optic cables
Installation techniques
Fibre optic link analysis

NETWORKING IN CCTV

Computers and networks

LAN and WAN
Ethernet
The main Ethernet categories
Data speed and types of networking
cabling
Ethernet over coax and UTP (Unshielded
Twisted Pair) cables
Network concepts and components
Network software

idc@idc-online .com

TELEMETRY CONTROL

Hard wired control

Control data transmission
Pan/Tilt (P/T) control
Receiver unit
Dome systems
Data communications

ANCILLARY EQUIPMENT

Camera mounting
Towers and columns
P/T units
Preset position P/T heads
Lighting in CCTV
Infrared lights
Ground loop correctors
Lighting protection
Monitor brackets
Power supplies

VIDEO TESTING

The CCTV labs test chart

Setup procedure
What you can test
The CCTV labs test pattern generator
TPG-8

CCTV SYSTEM DESIGN

Understanding the customer requirements

Site inspection
Selecting equipment according to the
requirements
Sensor selection
Designing and quoting a CCTV system
Installation considerations
Drawings - CCTV symbols

COMMISSIONING AND
MAINTENANCE

Commissioning
Measuring resolution
Training and manuals
System handover
Preventative maintenance
Corrective maintenance
Fault location
Oscilloscope default settings

SUMMARY, OPEN FORUM

AND CLOSING

www.idc-online .com

Advanced

TCP/IP-based Industrial
Networking

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for ENGINEERS AND TECHNICIANS

you will learn how to:

Design redundant Industrial Ethernet networks

Select appropriate Industrial Ethernet components

Configure and troubleshoot TCP/IP

Set up Industrial Ethernet switches and routers

Address security issues on Industrial Ethernet networks

Extend Industrial Ethernet networks with wireless technologies

Select appropriate Ethernet-based technologies for real-time
applications

WHO SHOULD ATTEND:

The workshop is designed for personnel with a need to understand

the techniques required to use and apply Ethernet and TCP/IP-based
industrial communications technology as productively and
economically as possible. Anyone involved in the installation, design
and support of Ethernet and TCP/IP-based networks:

Control system engineers

Design engineers
Electrical engineers
Electrical technicians

IT managers working with

networks
Maintenance engineers and
supervisors

Instrumentation engineers

Process control designers and

engineers

Instrumentation technicians

Project engineers

Instrumentation technologists

Systems engineers

1.51

The Workshop

The Program

This workshop is for engineers and

technicians who need a practical and
extensive knowledge of the design and
troubleshooting of Industrial Ethernet
networks, as well as the selection, installation,
and configuration of components such as
routers and switches.
It deals in-depth with the underlying TCP/IP
protocols, and specifically addresses both
design and configuration issues related to
IPv4 and the more recent IPv6.

ROUTING

OSI and TCP reference models

Topologies
Medium Access Control

ETHERNET
Frame structure and MAC addresses
Variants (10 Mbps Ethernet, fast Ethernet,
GbE, 10GbE, 100GbE)
Industrial Ethernet
Intrinsically safe (Ex) Ethernet
Power over Ethernet (IEEE 802.3af, IEEE
802.11at)
Point-to-Point Protocol over Ethernet
(PPPoE)

INTERNET LAYER PROTOCOLS

IPv4

-
-
-
-

Address structure and classes

Subnet masks and default gateways
Private addressing schemes
ARP and ICMP

Mechanics of routing
VLSM and CIDR
Subnetting
Virtual mapping (NAT) and masquerading
Port forwarding
Routing metrics
Interior Gateway Protocols (RIPv2, EIGRP,
IS-IS, OSPF)
Exterior Gateway Protocols (BGPv4)
Multi-Protocol Label Switching (MPLS)

CCTV OVER IP
Analog vs. IP cameras
Compression (JPEG, MPEG4, H.264)
Bandwidth requirements

ETHERNET AND TCP/IP IN

INDUSTRIAL APPLICATIONS
Modbus/TCP
OPC
Ethernet-based field buses

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It also covers the more advanced aspects and

applications of Ethernet such as advanced
switching and routing, CCTV over IP, OPC and
Modbus/TCP over Ethernet, industrial
security, intrinsically safe applications,
switched rings (included the latest IEC 624393 redundant ring standard), and highlydeterministic Ethernet-based field buses (e.g.
for servo control) capable of 1 millisecond
repetition rates and jitter of less than 1
microsecond.

OVERVIEW

A strong practical hands-on focus with real

equipment as detailed in the list of practical
sessions ensures you apply and test out your
knowledge and skills.

Pre-requisites:

A basic working knowledge of Ethernet

networks and IPv4 addressing will be useful.
Real-life experience with equipment and
hands-on testing will enable the workshop
to be placed in context.

IPv6

- Address structure: multicast, unicast

and anycast addresses
- Address scope
- ICMPv6

HOST-TO-HOST LAYER
PROTOCOLS

Ports and sockets

TCP operation, connections, header
structure
UDP operation, header structure

APPLICATION LAYER PROTOCOLS

HTTP, HTTPS, FTP

DNS and DynDNS
SNMP
DHCP, BootP and APIPA

SWITCHING

On-Site Training

Mechanics of switching
Spanning Tree Protocols (STP, RSTP,
MSTP, SPB)
VLANs and port prioritisation (IEEE
802.1p/Q)
QoS and DiffServ
Redundant switch rings
Parallel Redundancy Protocol (IEC 624393)
Port-based authentication (IEEE 802.1X)
Link aggregation/trunking (Etherchannel,
IEEE 802.3ad, IEEE802.1ax)

SECURITY

Access Control Lists (ACLs)

MAC address, port, and protocol filtering
Stateful Packet Inspection (SPI)
VPNs (IPSec and VTUN)
Authentication: IEEE 802.1x/EAP, LEPS
Security Data Sheets (SDSs)
Encryption: AES, TKIP
Secure Shell (SSH) tunnelling
DoS (Denial of Service) protection

WIRELESS

Wireless Ethernet backhauls

Ethernet modems for PtP and PtMP
applications
IEEE 802.11: Industrial WLANs
Authentication: IEEE 802.11i (WEP, WPA,
WPA2)

SUMMARY, OPEN FORUM

AND CLOSING

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training

to your workplace.

Have the training

delivered when and
where you need it.
Contact us for a
free proposal.

Practical Sessions

This is a practical, hands on workshop enabling you to work through practical exercises
which reinforce the concepts discussed.
Practical sessions include:
IP configuration
Protocol analysis: IPv4, IPv6, ARP, ICMP, TCP, UDP
Setting up an Industrial Ethernet managed switch
Setting up an Industrial Ethernet router
Analysing CCTV over IP traffic
Simulating Modbus/TCP over Ethernet
Setting up a Tofino firewall
To gain full value from this workshop, please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Practical Troubleshooting
and Problem Solving of

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Ethernet TCP/IP and

Modbus Protocols

you will learn how to:

Gain a practical understanding of what TCP/IP is and how to

apply it
Identify, prevent and troubleshoot Modbus protocol
communications problems

Gain a practical toolkit of skills for working with Modbus

Work competently with Modbus and RS-232, RS-485, wireless and

Ethernet
Gain skills to fault find your Modbus based Ethernet, RS-232/485,
wireless, Ethernet and TCP/IP network problems

WHO SHOULD ATTEND:

Anyone working with or required to troubleshoot Modbus systems;

or anyone designing, installing, commissioning, maintaining or
troubleshootingTCP/IP and intra/internet sites will benefit, including:

Consulting engineers

Network planners

Design engineers

Network system administrators

Designers

Plant managers

Electrical engineers

Process control engineers

Electronic technicians

Shift electricians

Engineering managers

System integrators

Instrumentation and control

engineers/technicians

Systems engineers

Instrumentation engineers

Technicians
Test engineers

Network engineers

1.53

The Workshop

The Program

One of the great protocols inherited from the

internet is TCP/IP, which is used by most
present-day automation and process control
systems. SCADA systems, Programmable
Logic Controllers and even low level
instruments are using TCP/IP and Ethernet to
transfer information. TCP/IP and Ethernet are
truly open standards.

MODBUS PLUS
Fundamentals
Problems: cabling, grounding, shielding,
terminators, token passing

What is Modbus?
Overview of the Modbus standards
Modbus and IDA
How Modbus relates to the RS-232,
RS-485, Ethernet and TCP/IP standards

OVERALL TROUBLESHOOTING
METHODOLOGY
Common symptoms, problems and
solutions
How to quickly identify likely causes
Basic steps
Communications issues
Grounding, shielding and noise

BASIC SERIAL COMMUNICATIONS

STANDARDS
RS-232
- Fundamentals
- Problems: UART settings (Baud rate,
parity, etc.), cabling, DTE/DCE,
handshaking, voltage levels, noise
RS-232 practical troubleshooting session
RS-485
- Fundamentals
- Problems: cabling, common mode
voltage, voltage levels, transient
protection, biasing, termination,
control (hardware/software), noise
RS-485 practical troubleshooting session

Whilst detractors will say the Modbus

protocol lacks some of the refinements of
the newer offerings on the market, there
is no doubt that it is one of the most
popular standards available in the industrial
world today.
This two-day workshop focuses on the main
issues of troubleshooting Modbus serial (i.e.
Modbus over RS-232, RS-485) and Modbus/
TCP (i.e. Modbus over TCP/IP and Ethernet)
installations.

INTRODUCTION

LANs, WANs, VLANs and VPNs

OSI and ARPA models

ETHERNET

10Mbps (half-duplex) Ethernet

Fast and gigabit Ethernet
Full-duplex, deterministic and dual
redundant Ethernet

Practical Sessions

This is a practical, hands-on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:
RS-485 basics

INDUSTRIAL ETHERNET
Fundamentals
Protocol analysis
Problems: noise, connectors, cabling,
wire types, jabber, excessive
broadcasting, bad frames, faulty autonegotiation, network loading, component
failure
Ethernet practical troubleshooting session

TCP/IP
Fundamentals
Software utilities (ipconfig, ping, arp,
tracert, netstat)
Protocol analysis
Problems: IP addresses, subnet masks,
default gateways, TCP connections
TCP/IP practical troubleshooting session

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Modbus is one of the few (if not the only)

industrial messaging protocols recognised
by the internet world, using port number
502. It has one of the largest installed bases
world-wide with more than 7.2 million
installed nodes. The Modbus TCP/IP profile
has recently been accepted by the
International Electro-technical Commission
(IEC) as a Publicly Available Specification
(IEC PAS 62030) and is now eligible to
become part of future editions of the
International Standards IEC 61158 and IEC
61784-2. So it enjoys the status of a widely
available open standard available to
everyone, hence its popularity.

INTRODUCTION

Logging and protocol analysis on serial

(RS-232/RS-485) communications system
Modbus serial operation: RTU mode

THE MODBUS SERIAL STANDARD

Fundamentals: overall concept, protocol
stack, client/server interaction, PDU and
ADU
Modbus RTU vs. Modbus ASCII: frame
structures and timing considerations
Problems: timeouts, checksums (CRC/
LRC), incorrect function codes/data
parameters, exception responses
Modbus serial troubleshooting session

MODBUS/TCP (MODBUS OVER

TCP/IP)

Fundamentals: overall concept, protocol

stack
Packet structure: PDU, ADU, MBAP
header
TCP connectivity issues
Protocol analysis
Modbus/TCP to Modbus serial gateways
Problems: TCP connection problems,
timing issues
Practical session with Modbus over TCP/IP

RADIO AND WIRELESS

COMMUNICATIONS

Fundamentals
Problems: noise, interference, power,
distance, channel separation, encryption
Practical session with Modbus/TCP over
IEEE802.11

TROUBLESHOOTING TIPS AND

TRICKS
Summary of all the problems faced
Further troubleshooting tips

SUMMARY, OPEN FORUM

and CLOSING

Modbus serial operation: ASCII mode

Setting up a basic Ethernet network
IP configuration

Protocol analysis on Ethernet network

Modbus/TCP

Construct simple Ethernet LAN

Configure IP addresses and subnet ,ask

Analysis
of
ARP/ICMP/IP/UDP/TCP
protocols with protocol analyser
Ping, Arp, Netstat, Tracert and route
commands
Set up and analyse FTP/HTTP sessions
Interconnect networks with bridge or
router
Modbus (serial) over IEEE802.11 wireless
Installation and configuration of Modbus/
TCP to serial communication gateway
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training
Save over 50% by having an IDCworkshop presented at
your premises.
Customise the training to your workplace.
Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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WIRELESS ETHERNET
AND TCP/IP NETWORKING

what you will learn:

Understand current Wireless LAN (WLAN) technologies

How to apply WLANs to industrial automation

Implement a simple WLAN for your office and industrial plant and
interface it to Ethernet
Understand the strengths and weaknesses of the different WLAN
technologies
Understand the operation of IEEE 802.11 WLANs

Implement effective security on Wireless and Ethernet LANs

How to conduct a site survey in preparation for WLAN
Implementation

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand

the techniques required for using and applying WLAN technology
as productively and economically as possible.

1.55

The Workshop

The Program

The use of Wireless and Ethernet in industrial

and plant floor environments has grown
dramatically in the last few years. Industrial
users face a wide range of options when
designing and implementing plant-level
Wireless and Ethernet networks. Great
success is being achieved using Wireless,
provided certain ground rules are applied.
This two-day workshop covers IEEE 802.3
Ethernet LANs and IEEE 802.11 WLANs, as
well as all the supporting technologies. It
addresses these issues in a clear and practical
manner, thus enabling you to apply the
technology quickly and effectively in your
next project. By the end of the workshop you
will have a clear understanding of the choices
available to you in designing and
implementing your own Wireless and
associated Ethernet LANs.

WIRELESS FUNDAMENTALS

ETHERNET

Frame structure
VLANs
Half-duplex operation (CSMA/CD)
Full-duplex operation
Auto-negotiation
Deterministic Ethernet

PROTOCOLS USED OVER

ETHERNET

Modbus/TCP and Ethernet/IP

IP addressing
Routing
ICMP
TCP and UDP
TCP/IP utilities

Basics of electromagnetic transmission

Frequency allocations
Gain and loss (dB)
WLAN modulation techniques (BPSK,
QPSK, 16-QAM and 64-QAM)
Spread spectrum techniques (FHSS and
DSSS)
OFDM and CCK

ANTENNAS
Basics
Dipole, Yagi and parabolic reflector
antennas
Diversity
VSWR WLANs IEEE 802.11
Architecture (Ad-hoc vs infrastructure)
Bridging and roaming
Specifications (IEEE 802b, a g, n)
Medium access control
Frame structure

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Pre-requisites

INTRODUCTION
LANs and WLANs vs the OSI model
Brief overview of Wi-Fi, TCP/IP and
Ethernet

A basic working knowledge of data

communications and applications is useful,
but is not essential. This workshop starts at a
very basic level and advances to a solid
practical implementation level. However with
the outstanding IDC documentation;
everything is detailed in a simple-tounderstand manner for future reference.

WIRELESS PANS:
BLUETOOTH/IEEE 802.15.1

LAN COMPONENTS

Repeaters and hubs

Bridges and switches
Routers
Gateways

Overall concept
Practical implementation

INSTALLING AND CONFIGURING

APS

Site survey
Component selection
AP configuration

SECURITY

Practical Sessions

LAN and WLAN vulnerabilities

Authentication and encryption
WPA2/IEEE 802.11i
Firewalls

SUMMARY, OPEN FORUM

and CLOSING

There are various practical sessions ranging

in difficulty from very simple to more
challenging. Full support will be provided by
the instructor to ensure that all participants
will derive maximum benefit from these
sessions.
Install and configure Access Points (APs)

Interconnect Wireless and Ethernet LANs

Configure IP addresses and subnet masks

Analyse ARP/ICMP/IP/UDP/TCP
protocol analyser

using

Perform path loss calculations

Demonstrate the use of encryption and

authentication
Control access with MAC filtering

Measure wireless signal to noise ratio

On-Site Training
Save over 50% by having an IDCworkshop presented at
your premises.
Customise the training to your workplace.
Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

ELECTRICAL POWER

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TRAINING WORKSHOPS
Practical Electrical Network Automation and Communication Systems................................................................. 2.1
Practical Troubleshooting of Electrical Equipment and Control Circuits................................................................ 2.3
High Voltage Safety Operating Procedures for Engineers and Technicians........................................................... 2.5
Practical Power Distribution......................................................................................................................................... 2.7
Practical Power Quality: Problems and Solutions for Engineers and Technicians................................................ 2.9
Practical Power System Protection for Engineers and Technicians...................................................................... 2.11
Practical Variable Speed Drives (VSDs) for Instrumentation and Control Systems............................................. 2.13
Practical Electrical Wiring Standards National Rules for Electrical Installations - ET 101:2008..................... 2.15
Wind & Solar Power Renewable Energy Technologies......................................................................................... 2.17
Practical Distribution and Substation Automation (incl. Communications)
for Electrical Power Systems................................................................................................................................. 2.19
Safe Operation and Maintenance of Circuit Breakers and Switchgear................................................................. 2.21
Troubleshooting, Maintenance and Protection of AC Electrical Motors and Drives............................................ 2.23
Power Transformers - Operation, Maintenance and Testing................................................................................... 2.25
Lightning, Surge Protection and Earthing of Electrical and Electronic Systems in Industrial Networks.......... 2.27
Maintenance and Troubleshooting of Uninterruptible Power Supply (UPS) Systems and Batteries.................. 2.29
Practical Power System Harmonics, Earthing andPower Quality - Problems and Solutions............................. 2.31
Practical Motor Protection, Control and Maintenance Technologies..................................................................... 2.33
Practical Medium andHigh Voltage Testing of Electrical Equipment for Engineers and Technicians................. 2.35
Practical Earthing of Utility and Industrial Distribution Systems for Engineers and Technicians....................... 2.37
Practical Electrical Substation Safety for Engineers and Technicians.................................................................... 2.39
Practical HVCable Jointing and Terminations for Engineers and Technicians...................................................... 2.41
Operation and Maintenance of Diesel Power Generating Plants........................................................................... 2.43

Energy Efficiency, Design, Engineering and Auditing.............................................................................................. 2.45

Critical Power Supply Options and Planning of High Availability Supplies.......................................................... 2.47
Practical Electrical Safety Techniques for Industry................................................................................................... 2.49
Emergency Power Supplies: Electrical Distribution Design, Installation and Commissioning............................ 2.51
Power Cables: Operation, Maintenance, Location and Fault Detection................................................................. 2.53
Practical Electrical Wiring Standards IEE BS 7671:2008+A1:2011 Edition........................................................... 2.55
Practical Electrical Wiring Standards AS 3000:2007.............................................................................................. 2.57
Electrical Drawings and Schematics......................................................................................................................... 2.59

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South African Standard Sans 10142 The Wiring of Premises............................................................................... 2.61

Electrical Maintenance for Engineers and Technicians............................................................................................ 2.63
Installing, Programming and Commissioning of Power System Protection Relays and Hardware.................... 2.65
Practical Power Cabling and Earthing....................................................................................................................... 2.67
The Fundamentals of Power Distribution and Power Systems: Hands-on Practical Analysis and Design............ 2.69
Practical HV and LV Switching Operations and Safety Rules for Engineers and Technicians............................. 2.71
Arc Flash Protection for Electrical Safety Professionals.......................................................................................... 2.73
Practical Electrical Metering, Measurement and Instrument Transformers for Engineers and Technicians........ 2.75
Electrical and Instrumentation (E & I) Engineering for Oil and Gas Facilities....................................................... 2.77
Fundamentals of Smart Metering.............................................................................................................................. 2.79
Installation, Testing and Troubleshooting of Transformers....................................................................................... 2.81
Medium Voltage AC Motors for the Power Industry Working Principles, Installation,
Maintenance and Troubleshooting......................................................................................................................... 2.83
Switchgear and Distribution Systems....................................................................................................................... 2.85
Electrical Power System Fundamentals for Non-Electrical Engineers .................................................................. 2.87
Inspection, Testing and Commissioning of Electrical Switchboards, Circuit Breakers,
Protective Relays, Cables and PLCs............................................................................................................................. 2.89
High Voltage Electrical Compliance and Safety Operating Procedures...................................................................... 2.91
High Voltage Design and Installations Master Class..................................................................................................... 2.93
High Voltage Design and Installations Master Class (UK)............................................................................................ 2.95
Fundamentals of Operation and Troubleshooting of Emergency/Standby Power Generation using
Diesel Generators.......................................................................................................................................................... 2.97
Diesel Power Generation plants with Multiple Machines in Parallel and on the Electrical Power Grid................. 2.99
Practical Maintenance & Troubleshooting of Battery Power Supplies.......................................................................2.101
Standby Power and Energy Efficiency.......................................................................................................................... 2.103
Electrical Substation and Switchyard Design ............................................................................................................. 2.105
Understanding Electrical Engineering and Safety for Non-Electricians.................................................................... 2.107
Master Series - Electrical Engineering........................................................................................................................... 2.109
Mechanical, Electrical and Instrumentation Engineering for Non-Engineers............................................................2.111
Practical Earthing, Bonding, Lightning and Surge Protection.................................................................................... 2.113

idc@idc-online .com

www.idc-online .com

Practical

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Electrical
Network Automation
and Communication Systems

YOU WILL LEARN:

The requirements for data communications in an electrical

environment
The suitability of different communication protocols for
automation of power distribution and transmission networks
New techniques in electrical protection, leading to increased
reliability, performance and safety to personnel
How to obtain extensive real-time information of your power
network via SCADA, leading to informed decisions and
productive use of manpower
How to implement local and remote control of switchgear,
including interlocking and intelligent load shedding
How to effectively compare and critically analyse different
products and systems available for protection, control and
automation of electrical power networks

WHO SHOULD ATTEND:

Electrical Engineers
Control Engineers

Project Engineers

Design Engineers
Consulting Engineers
Power System Engineers
Protection Engineers
Technicians
Maintenance Supervisors

2.1

The Workshop

The Program

Power System Automation is the cuttingedge technology in electrical engineering. It

means having an intelligent, inter-active
power distribution and transmission network
including:

Introduction

increased performance and reliability of

electrical protection

Historical Development

advanced disturbance and event

recording capabilities, aiding in detailed
electrical fault analyses
display of real-time substation
information in a central control centre
remote switching and advanced
supervisory control over the power
network
increased integrity and safety of the
electrical power network, including
advanced interlocking functions

Requirements of SCADA for electrical

networks
Hardware and support requirements
Software and configuration

Short overview of technical

developments in related industries

Comparison of Power System

Automation Systems

Electrical Protection

Types of power system automation

systems
Discussion of leading manufacturers
systems
Advantages and disadvantages of
various systems

Short overview of the fundamentals of

electrical protection
New techniques in protection using
intelligent relays
Designing more advanced and
economical protection schemes

Practical Considerations

Control, Monitoring and

Metering
Local intelligence and Intelligent
Electronic Devices (IEDs)
Limitations of conventional RTU systems
and PLCs
Modern trends

Benefits of power system automation

systems
Capital expenditure and maintenance
issues
Cost savings
Evaluating your requirements
Choosing a system and supplier

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advanced automation functions e.g.

intelligent load-shedding

SCADA for Electrical

Monitoring and Control

Discussion of concepts involved in

automating power distribution and
transmission networks

Workshop Objectives

This practical 2-day workshop will enable you

to:
identify the suitability of different
communication protocols for the
electrical environment
evaluate the communication
requirements for your specific
circumstances

apply new protection techniques to

increase reliability and performance
while reducing costs

Data Communications in an
Electrical Environment

Practical Demonstration

Basics of Data Communications

Different communication protocols used
for power networks
Communication requirements for
substations
Suitability of different protocols for
substation communications
Standardisation of communication in
substations: goals and status
Radio and satellite communication
Trends in technology

implement advanced real-time

monitoring and metering techniques of
your electrical network by implementing
local and remote control

Demonstration of a power system

automation system at work
Configuration of IEDs

specify the requirements for SCADA

regarding your electrical network and
substations

recognise and evaluate the practical and

economic benefits automating your
power network can bring to your
workplace

The workshop was excellent and

valuable to my line of work.

David Selems

Practical Sessions

Participants will be given the vital hands-on

experience needed to confidently work with
this cutting-edge technology. On the second
day of the workshop, there will be a
demonstration of a Substation Automation
System at work and the opportunity to
configure
a
multi-function
relay,
communication link and SCADA system.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
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Practical

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Troubleshooting of
Electrical Equipment and
Control Circuits

YOU WILL LEARN HOW TO:

Diagnose problems "right-first-time"

Eliminate expensive trial and error approach

Reduce unexpected downtime on electrical motors and other

equipment
Improve plant safety

Learn specific techniques to troubleshoot equipment and

control circuits
Analyse equipment problems

Determine causes of equipment failure

2.3

The Workshop

The Program

There is a chasm between the theory of

electron flow, magnetic fields and
troubleshooting electrical equipment and
control circuits in the plant. This workshop
shows delegates how to troubleshoot
electrical equipment and control circuits.
The course helps individuals and employers.
It does this by increasing all delegates
knowledge and skills in improving equipment
productivity whilst reducing maintenance
costs.

COURSE DESCRIPTION
BASIC PRINCIPLES

Industrial electricity
Single and three phase power systems
Meters used in troubleshooting
Clamp on ammeter/megohmmeter

DEVICES, SYMBOLS AND

CIRCUITS
Devices and symbols
Language of control circuits
Reading and understanding electrical
drawings
Reading and understanding ladderlogic
Wire and terminal numbering

BASIC PRINCIPLES IN
TROUBLESHOOTING

MOTOR CIRCUIT BREAKERS AND

SWITCHBOARDS
Purpose and duty
Clearance times
Types

TROUBLESHOOTING VARIABLE
SPEED DRIVES
Fundamentals of variable speed drives
Problems associated with variable speed
drives
Terminology used
Manufacturer's literature - what they
don't tell you
Minimisation of equipment failure
Troubleshooting Tricks

TROUBLESHOOTING CONTROL
CIRCUITS

Basic control circuits

Ladderlogic circuits
Troubleshooting strategies
Two-wire control and hands-off/auto
Overload protection
Three-wire control - start/stop
Jog/inch circuits
Sequence start and stop
Automatic sequence starting
Reversing circuits
Plug stop and anti-plug circuits
Two speed motor control
Reduced voltage Starting circuits

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Attendance on this course will help all

delegates identify, prevent and fix common
electrical equipment and control circuits. The
focus is "outside the box". The emphasis is
on practical issues that go beyond typical
electrical theory and focus on providing
those that attend with the necessary tool-kit
of skills in solving electrical problems,
ranging from control circuits to motors and
variable speed drives.

INTRODUCTION

This workshop focuses on the main issues

of troubleshooting electrical equipment and
control circuits of today to enable you to
walk onto your plant or facility to troubleshoot
and fix problems as quickly as possible.

This is not an advanced workshop but one

aimed at the fundamentals of troubleshooting
systems. The workshop is very practical in
its approach to troubleshooting and the
examples you will be shown are applicable
to any facility.

Practical Sessions

You will work in teams on simulation

software running on PC's on electrical
equipment to simulate real problems for at
least 40% of the course proceeding through
ten practical sessions ranging from the
elementary to the more advanced. These will
be very close in structure to the motor
control circuits in your plant. In addition we
will give three case study wiring diagrams
with potential problems and expect you to
uncover faults when given the symptoms.

BASIC PRINCIPLES IN USING A

DRAWING AND METER IN
TROUBLESHOOTING CIRCUITS
Circuits
Equipment

TROUBLESHOOTING AC MOTORS
AND MOTOR STARTERS

Fundamentals of AC motors
Types of AC and DC motors used
Motor terminal identification and
connection diagrams
Identification and construction
Connecting up a multiple speed motor
Connection of dual voltage motor
Motor name plate information
Operating a motor for forward and
reverse operation
Motor braking methods
Test equipment to check motor operation
Why motors fail and how to extend life
Troubleshooting of motors

TROUBLESHOOTING MORE
COMPLEX CONTROL CIRCUITS
Tank fill control
Duplex Pump control

SUMMARY & OPEN FORUM

COMPLETE FEEDBACK SHEETS

CLOSING

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Very good.

I will recommend this course

to my technicians and
other plant engineers.
A.F. Barnard

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

HIGH VOLTAGE SAFETY

OPERATING PROCEDURES

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for Engineers and Technicians

yOU WILL LEARN HOW TO:

Demonstrate approved ways of operating and earthing high

voltage equipment to ensure safety of personnel at all times.
Identify safe and unsafe working conditions

Identify requirements for a responsible person or appointed

operator
Demonstrate a fundamental knowledge of the documentation
required for Occupational Safety Acts
Perform live chamber and limited access procedures

WHO SHOULD ATTEND:

Electrical engineers
Project engineers

Design engineers

Instrumentation and design engineers

Electrical tradespeople

Electrical technicians
Field technicians

Electricians
Plant operators
Staff visiting or working in hazardous areas

2.5

The Workshop

The Program

Safety should be the first consideration for

anyone working with electricity, especially
high voltage. This course introduces
participants to all aspects of the procedures
required for ensuring safe work in any job
involving high voltage.

INTRODUCTION

Pre-requisites

Fundamental knowledge of electrical

engineering and some experience with high
voltage systems.

The requirements of a typical Safety Act

with reference to employer and
employee

PLANT SAFETY REGULATIONS IN

PERSPECTIVE
Identify industrial hazards
Understand dangers and precautions
Regulations awareness
Identify basic duties/responsibilities of
employers and employees
Offences and penalties policy
Protection against electrical hazards

DEFINITIONS AND BASIC SAFETY

PRINCIPLES

Practical Sessions

Official terminology
Operating terms and their meanings
Electric shock hazards
Electrical arcing hazards
Electrical insulation and its maintenance

The meaning of live chambers and

prohibited areas
The locking of doors and gate
Entry to live chambers and prohibited
areas
The security of keys
State the conditions under which skilled
and unskilled persons may enter live
chambers and prohibited areas
List the responsibilities of persons to
whom keys have been issued

ABNORMAL CONDITIONS

What is emergency switching?

Testing high voltage equipment
Managing the testing
The precautions taken for high voltage
testing

APPOINTED OPERATOR AND THE

RESPONSIBLE PERSON

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This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

LIVE CHAMBERS AND

PROHIBITED AREAS

To gain full value from this workshop,

please bring your laptop/notebook
computer.

FUNDAMENTAL PRINCIPLES

Regulations and their purpose

Operating regulations
Fundamental principles that regulations
are based upon
Study the various dangers of electricity
and the precautions to be taken to avoid
these dangers
High voltage operations and safety
precautions

ISOLATION

The meaning of isolation

List the terms related to isolation
Procedures of isolating a device
Study breakers, links and switches and
their uses

REASONS FOR EARTHING

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

What is earthing?
Earthing arrangement families
The unearthed system
The properties of safe earth connections
The dangers of inadequate earth
connections
The concepts of dead and alive
Understand how the apparatus can be
accidentally alive
Study the meanings of static charge and
residual voltage
List the reasons for earthing isolated
apparatus

MAKING FEEDERS AND

APPARATUS SAFE TO WORK ON

Minimum earthing requirements

Additional earths
The procedure of work on a cable feeder
The special provision for double circuit
structures

Operative procedures
Appointed operators and their duties and
responsibilities
The responsible person and his duties
and responsibilities
Supervision of work
The reasons, prevention and
investigation of accidents/incidents

LOCKOUT AND TAGOUT

PROCEDURES

Hazardous energy control

The lockout method and lockout/tagout
program
The Lockout/tagout procedures and
policies
Common lockout devices
LOTO implementation steps

TYPICAL ELECTRICAL
MACHINERY REGULATIONS

List the safety appliances

Safety in switch gear and transformer
premises
Electrical control gear and switch board
Electrical machinery in hazardous
locations
Study proper use and precautions while
handling portable tools
Portable electric lights and electric fences
The clearance of power lines

FIRST AID AND ARTIFICIAL

RESUSCITATION

Electric shock
The types of contacts
The parameters which lead to shock
The precautions to avoid shock
First aid facilities within the work place
Resuscitation and emergency procedures

THE WORK PERMIT SYSTEM

Explain the purpose of the work
permit system
State the conditions under which a
permit is not required
List, in the correct order, the steps in
issuing and clearing of a permit
Explain the duties of a responsible
person and the appointed operator, re
the Workman's declaration
Explain what the workman declares when
he signs the workman's declaration

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Practical

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Power Distribution

objectives:

Correctly implement the right type of switchgear for the

appropriate application
Economically select and install the best-suited power cable for
a specific application
Evaluate the need for power factor correction and successfully
implement correction strategies
Implement successful maintenance strategies and procedures
Effectively use software techniques to solve problem areas in
your power network

WHO SHOULD ATTEND:

Electrical engineers
Project engineers

Design engineers

Instrumentation and design engineers

Electrical technicians
Field technicians
Electricians
Plant operators

2.7

The Program

The Workshop
A practical two-day workshop in power
distribution, focusing on medium voltage
(1kV-36kV) power considerations, switchgear,
power cables, transformers, power factor
correction, earthing, lightning protection
and network studies.
You will gain technical know-how in these
areas which are not covered by university
or college programs.

Objectives
At the end of this workshop participants will be
able to:
Understand practical power distribution
fundamentals
Determine short-circuit ratings quickly
and effectively
Assess the influence of fault levers on
switchgear ratings

POWER CABLES

History and growth of power distribution

Typical characteristics of a distribution
system
Main components of a distribution system
Main equipment types in a distribution
system
Electrical safety and power security

OVERVIEW OF POWER
DISTRIBUTION
Voltage classification
Multiple voltage levels in power
distribution
Types of distribution arrangements and
redundancy
Expandability

SHORT-CIRCUIT CURRENT
CALCULATIONS

What is a fault?
Effects of a fault
Types of faults
Limiting the damaging effects of a fault
Need to know the magnitude of fault
current
Fault current calculations

Types and construction of cables

Basic design and selection
Insulating materials for LV and HV cables
Accessories for cable installation
High voltage power transmission using
cables
Failure of cables
Fault detection
New technologies superconductivity for
high capacity cables

PRACTICAL WORK
Sizing and installation of power cables
using cable datasheets - typical problems

ELECTRICAL SAFETY AND ROLE OF

EARTHING

Overview of system earthing

Hazards posed by electrical equipment
Electrical shock hazard
Direct and indirect contact
Role of protective earthing
Indirect contact hazard importance of
protection
Sensing of earth faults
Equipotential bonding
Use of Personal Protective Equipment
(PPE)
Arc flash danger in electrical equipment

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Select the correct type of switchgear for

the right application

INTRODUCTION

Evaluate the advantages of modern

state-or-the-art switchgear protection for
your applications, including preventative
maintenance information

Recognise the different applications for

various cable insulation types

PRACTICAL WORK

Calculation examples

Know when and how to use single core

cables vs three core cables

TRANSFORMERS

POWER QUALITY AND

PF COMPENSATION

Specify correct power cable installation

methods

Correctly utilise and protect power

transformers
Assess and specify correct grounding
throughout your electrical network

Determine the need for Power Factor

Correction (PFC) for your environment

Assess the economic justification for

installing PFC equipment
Correctly specify PFC equipment and be
aware of practical consequences

Confidently use computer simulation

software to solve and predict power
network

Pre-requisites

A fundamental knowledge
engineering is very useful.

of

electrical

Excellent experience, imports

information freely.
Gavin Bloch

Introduction
Transformer theory

Transformer construction
Transformer cooling
Transformer voltage control
Power transformers and distribution
transformers
Installation of transformers
Special aspects in installation of large
power transformers
Fire protection measures for large
transformer installations
Transformer troubleshooting

MEDIUM VOLTAGE (MV) CIRCUIT

BREAKERS

Role of a circuit breaker in a distribution

system
Distinction between circuit breaker and
disconnector/isolator
Different types of circuit breakers and their
operating principle
Comparison of relative features and
applications
Circuit breaker operating mechanisms
Circuit breaker ratings

Limits on electrical parameters

What is power quality?
Power quality indicators
Power quality improvement measures
Causes and effects of low power factor
Power factor compensation
Methods to improve power factor and
benefits
Economic justification for power factor
correction - worked out examples
Caution: capacitors with induction motors

POWER SYSTEM AUTOMATION

Definition of the term

What is power system automation?
Power system automation architecture
Use of DCS

summary, open forum and

closing

MV SWITCHGEAR

Switchgear options
Outdoor MV switchgear
Indoor MV switchgear
MV switchgear panel configurations
MV switchgear auxiliary devices
MV switchgear ratings

Practical Sessions
This is a practical, hands on workshop
enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

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Practical

POWER QUALITY:
PROBLEMS & SOLUTIONS

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for engineers and technicians

YOU WILL Learn How to:

Develop a sound working knowledge of earthing and harmonics

Gain practical knowledge of surge and transient protection
Design electrical and electronic systems correctly by applying
knowledge of harmonics and earthing principles
Describe applications for the latest technologies in correcting
earthing, harmonics, surge, and transient problems
Troubleshoot electrical and electronic systems
Isolate and rectify power quality problems

WHO SHOULD ATTEND:

Instrumentation and Control Engineers

Consulting Engineers
Electrical Engineers
Project Engineers

Maintenance Engineers
Building Service Designers
Power System Protection and Control Engineers
Data Systems Planners and Managers
Electrical and Instrumentation Technicians

2.9

The Workshop

The Program

Monitoring power quality in industrial

environments is essential to the health and
stability of your plant and equipment.
This hands-on workshop examines the
procedures for design and installation for
earthing and neutral systems, while reviewing
the fundamentals of power quality and EMC.
Common misconceptions about noise are
discussed and reviewed along with surge and
transient protection, you will walk away with
practical steps outlined to minimise or even
eliminate these problems. The two days are
rounded off with realistic case studies covering
a wide variety of industries ranging from
manufacturing and process control to
telecommunications. The material is covered
by means of an interactive learning style, with
plenty of practical examples and realistic case
studies.

Pre-requisites

HARMONIC SOURCES AND THEIR

EFFECTS

What is Power Quality and EMC?

The IEC/IEEE and FIPS standards
Interfacing with electrical utilities

Principles of harmonic analysis

Variable speed drives
Power conversion equipment and
apparatus deterioration
Controllers, power supplies, PCs and
lighting equipment

RECOMMENDED DESIGN AND

INSTALLATION PRACTICE
Wiring and earthing for safety and
performance
Wiring and distribution systems
Dedicated and derived neutral systems
Earthing and bonding equipment

EARTHING AND NOISE CONTROL

Site Auditing for noise control
Misconceptions in performance
grounding
Single Point versus Multi Point
techniques
Noise and the zero signal reference grid
Avoiding non-recommended practices

POWER SYSTEM CAPACITIVE/

INDUCTIVE RELATIONSHIPS
Displacement and distortion power factor
Reactive power relationships
Power factor efficiencies

HARMONIC SITE ANALYSIS

PROCEDURES
Measurement fundamentals and true
RMS/predictive analysis
Instrumentation and procedures
Harmonic order and sequences and
resonances
Voltage and current waveforms
(signatures)
Harmonic interaction auditing

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Some working knowledge of basic electrical

engineering principles is required, although
this will be revised at the beginning of the
course. Real-life experience with earthing
and harmonics problems will enable the
workshop to be placed in context.

INTRODUCTION TO POWER
QUALITY AND EMC

SURGE AND TRANSIENT

PROTECTION

Basics of lightning phenomena

Power system faults and switching
surges
Mitigation techniques and case study
review

POWER CONDITIONING

CONDUCTING A SITE ANALYSIS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Overview of sources of power quality

problems
Site survey procedures
Monitoring and analysis instrumentation

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Power conditioners
Uninterruptible power systems
Power quality source alternatives
Power disturbance cost comparisons

CASE STUDIES

Checklist for powering, earthing and

communications
Commercial buildings
Manufacturing and process control
Medical facilities
Computers and data processing
environments
Telecommunications

summary, open forum and

closing

Very good course. Learned a lot on causes and

remedies for Power Quality. Very good presenter,
knows the subject well.

A. Bloem

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

POWER SYSTEMS
PROTECTION

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for Engineers and Technicians

You will learn how to:

Describe the fundamentals of electrical power protection

Identify and rectify the different fault types

Perform simple fault and design calculations

Work with protection system components (including fuses/

transformers/circuit breakers)
Complete relay settings and check a current transformer
Demonstrate a fundamental knowledge of applications in
protection

WHO SHOULD ATTEND:

Design engineers

Electrical engineers

Electrical technicians
Electricians

Field technicians

Instrumentation and design engineers

Plant operators

Project engineers

2.11

The Workshop

The Program

This workshop has been designed to give

plant operators, electricians, field technicians
and engineers a better appreciation of the
role played by power system protection
systems. An understanding of power
systems along with correct management
will increase your plant efficiency and
performance as well as increasing safety for
all concerned.

Objectives

FAULT TYPES AND THEIR EFFECTS

Active, incipient, passive, transient,
asymmetrical etc
Phase and earth faults

SIMPLE CALCULATION OF SHORT

CIRCUIT CURRENTS
Revision of simple formulae
Calculation of short circuit MVA and fault
currents
Worked examples

SYSTEM EARTHING
Solid, impedance, touch potentials etc
Effect of electric shock on human beings
Earth leakage protection

PROTECTION SYSTEM
COMPONENTS INCLUDING FUSES
History, construction, characteristics
Energy, let-through, application

This is an intermediate level workshop, by

the end of which you will have an excellent
knowledge of the principles of protection.
You will also have a better understanding of
the possible problems likely to arise and
know where to look for answers. In addition
you are introduced to the most interesting
and "fun" part of electrical engineering to
make your job more rewarding. Even those
who claim to be protection experts have
admitted to improving their knowledge after
attending this workshop.

Pre-requisites
Fundamental
engineering.

Selectivity, stability, sensitivity, speed

Reliability, dependability, security

APPLICATIONS CO-ORDINATED
BY TIME GRADING
Problems in applying IDMT relays

UNDERGROUND MINE
DISTRIBUTION PROTECTION
Earth leakage protection, pilot wire
monitor, earth fault lockout, neutral earth
resistor monitor

PRINCIPLES OF UNIT
PROTECTION
Differential protection basic principles

FEEDER PROTECTION

Cables
Pilot wire differential
Overhead lines
Distance protection (basic principles,
characteristics, various schemes)

TRANSFORMER PROTECTION
Phase shift, magnetising in-rush, interturn, core and tank faults
Differential and restricted earth fault
schemes
Buchholz relay, oil and winding
temperature
Oil testing and gas analysis

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The workshop is designed to provide

excellent understanding on both a
theoretical and practical level. Starting at a
basic
level
and
then
moving
onto more detailed applications, it features
an introduction covering the need for
protection, fault types and their effects,
simple calculations of short circuit currents
and
system
earthing. This
work-
shop includes some practical work, simple
fault calculations, relay settings and the
checking of a current transformer
magnetisation curve.

NEED FOR PROTECTION

knowledge

of

electrical

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

INSTRUMENT TRANSFORMERS

Current transformers: construction,

performance, specification,
magnetisation, curves etc
Voltage transformers: types, accuracy,
connections

CIRCUIT BREAKERS

Purpose and duty, clearance times, types

etc

TRIPPING BATTERIES

Battery types, chargers, maintenance,

D.C. circuitry

RELAYS

Inverse Definite Minimum Time (IDMT)

relay construction principles and setting
Calculation of settings practical
examples
New era modern numerical relays and
future trends

PRACTICAL DEMONSTRATION
SESSION

Including simple fault calculations, relay

settings and checking a current
transformer, magnetising curve etc

SWITCHGEAR (BUSBAR)
PROTECTION

Requirements, zones, types

Frame leakage, high, medium and low
impedance schemes, reverse blocking

MOTOR PROTECTION

Thermal overload, time constants, early

relays
Starting and stalling conditions
Unbalanced supply voltages, negative
sequence currents, de-rating factors
Phase-phase faults
Earth faults core balance, residual
stabilising resistors

GENERATOR PROTECTION

Stator and rotor faults

Overload and over-voltage
Reverse power/unbalanced loading
Loss of excitation and synchronism
Typical protection scheme for industrial
generators

OVERHEAD LINE PROTECTION

On-Site Training

Basic principles of the distance relay

Tripping characteristics
Application onto power lines
Effect of load current and arc resistance
Various schemes using power line carrier

Save over 50% by

MANAGEMENT OF PROTECTION

Customise the training to

SUMMARY, OPEN FORUM

AND CLOSING

Routine testing, annual testing,

investigation and performance
assessment, up-grading
Organisation, training, records, access
planning

having an IDCworkshop
presented at your
premises.

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

Practical

VARIABLE SPEED DRIVES (VSDs)

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for Instrumentation and Control Systems

YOU WILL LEARN how to:

Demonstrate a sound understanding of how AC Variable Speed

Drives (VSDs) work
Install VSDs properly
Select the right VSD for a given application
Troubleshoot VSDs competently
Competently explain how flux-vector control works for drive
applications
Understand squirrel cage induction motors
Identify the protection and control system requirements for
VSDs
Interface VSDs with PLCs
Understand the causes of motor burnout
Deal effectively with VSD harmonics and EMC/EMI problems

WHO SHOULD ATTEND:

Anyone associated with the use of Variable Speed Drive techniques in

the industrial or automation environment. The workshop will also
benefit those working in system design as well as site commissioning,
maintenance and troubleshooting. Typical personnel who would
benefit are:
Plant engineers
Instrument technicians
Operations personnel
Electrical maintenance technicians and supervisors
Instrument and control engineers
Process control engineers
Mechanical engineers
Service technicians
Maintenance personnel
2.13

The Workshop

The Program

This course gives you a fundamental

understanding of the installation, operation
and troubleshooting of variable speed
drives. Typical practical applications of VSDs
in process control and materials handling,
such as those for pumping, ventilation,
conveyers, compressors and hoists are
covered in detail. You will learn the basic
setup of parameters, control wiring and
safety precautions in installing a VSD. The
various drive features such as operating
modes, braking types, automatic restart and
many others will be discussed in detail. You
will learn the four basic requirements for a
VSD to function properly with emphasis on
typical controller faults, their causes and
how they can be repaired.
The concluding section of the course gives
you the fundamental tools in troubleshooting
VSDs confidently and effectively.

PROTECTION OF MOTORS AND

CONVERTERS

The need for variable speed drives

Fundamental principles of speed control
Efficiency, torque, inertia, horsepower/
power factor
Torque-speed curves
How the motor produces torque
Types of variable speed drives

3 PHASE AC INDUCTION
MOTORS

CONTROL SYSTEM FOR AC

VARIABLE SPEED DRIVES

Basic construction and physical

configuration
Principles of operation and performance
Equivalent circuit and fundamental
equations
Starting, acceleration, running and
stopping
Power, torque and thermal rating

POWER ELECTRONIC
CONVERTERS

AC frequency converter protection

Fault diagnostics
Electric motor protection
Thermal overload protection current
sensors
Thermal overload protection direct
temperature

The overall control system

Power supply to the control system
DC bus charging system
VSD control loops
Vector control and its applications
Current feedback in AC VSDs
Speed feedback from the motor

THE SELECTION OF AC
CONVERTERS FOR VARIABLE
SPEED DRIVE APPLICATIONS

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Even though the focus of the course is on

the direct application of this technology, you
will also gain a thorough understanding of
the problems that can be introduced by
VSDs such as harmonics, electrostatic
discharge and EMC/EMI problems.

INTRODUCTION TO VARIABLE
SPEED DRIVES

Pre-requisites

A fundamental knowledge of basic electrical

concepts would be useful.

Definitions and basic principles

Power diodes and thyristors
Principles of communication
Power electronic rectifiers
Power electronic inverters
Gate commutated converters
Gate controlled devices GTO, FCT, GTR,
FET, IGBT

ELECTROMAGNETIC
COMPATIBILITY (EMC)

Sources of electromagnetic interference

Harmonics on the power supply side of
AC converters
The effect of harmonic distortion on
other connected equipment
Methods of reducing the effect of supply
side harmonics
Electric motor protection
Thermal overload protection current
sensing
Thermal overload protection direct
temperature sensing

The basic selection procedure

Loadability of converter fed induction
motors
Operation in the constant power region
The nature of the machine load
Starting and stopping VSDs
How to calculate acceleration torques and
times
How to select the correct motor and
converter for pump and fan loads
How to select the correct motor and
converter for constant torque loads
Summary of the selection procedure

INSTALLATION AND FAULT

FINDING TECHNIQUES

General installation and environmental

requirements
Power supply connections and earthing
Where to install the contactors in the
power circuit
Installing AC converters into metal
enclosures

SPECIAL TOPICS

PWM rectifier for AC converters

Soft switching
The matrix converter

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by having an IDCworkshop presented at

Practical Sessions

your premises.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

Electrical Wiring Standards:

National Rules for Electrical
Installations - ET 101:2008

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(including Amendments 1 and 2)

YOU WILL LEARN:

The essentials of the ET 101 Standard

How to find your way around ET 101

Harmonisation issues with European standards

Principles and practice of shock protection
Calculation of circuit impedances
Discrimination between devices
Cable sizing

Earthing and bonding

Inspection and testing requirements

Certification requirements

WHO SHOULD ATTEND:

Building services engineers

Electrical apprentices

Electrical design staff

Electrical engineers

Electrical trades persons

Engineering managers
Graduate electrical engineer trainees
Maintenance and shutdown planning staff
Maintenance managers
Private electrical contractors

2.15

The Workshop

The Program

Internationally there has been steady

progress towards the harmonisation of
electrical wiring standards. European
standards are based on the international IEC
364 under the umbrella of Harmonisation
Document HD 384. The format of these is
reflected in the ETCI national rules ET 101:
2008 and the UK IEE wiring regulations BS
7671:2008.

SELECTION AND ERECTION OF

EQUIPMENT

Structure of international and Irish

national rules
Foundation electrical principles terminology and definitions
Scope of national rules
Growth of electrical distribution systems
and polyphase circuits
Types of earthing systems
Requirements for safety and planning of
electrical installations
Definitions

Common rules and wiring systems

Isolation, switching, control and
monitoring
Earthing arrangement and protective
conductors
Luminaries and lighting installations
Safety services

EARTHING ARRANGEMENTS
Need for earthing in electrical systems
Supply system earthing
Protective earthing of consumer
installations
TN-C-S systems
Earth faults
Earth electrodes
Equipotential bonding

INSPECTION AND TESTING

Initial verification
Testing
Periodic inspection and reporting
Certification and reporting

SPECIAL INSTALLATIONS OR
LOCATIONS
Locations of increased shock risk such as
bath or shower, swimming pools, hot air
saunas
Construction installations, agricultural
and horticultural premises
Installations in restrictive conductive
locations
Caravans and marinas
Medical locations
Exhibitions
Solar photovoltaic power supply systems
Outdoor lighting, mobile units, temporary
installations such as fairgrounds and
amusement parks
Floor and ceiling systems
Maintenance gangways

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This workshop is designed to provide up to

date information and training on the current
edition of National Rules ET 101: 2008. It will
consist of in-depth teaching on all aspects of
the national rules and their application with
many practical examples and sample design
calculations. The workshop includes
references to safety, maintenance, inspection
and testing. In addition, it provides a
summary of some of the basic principles
necessary for a good understanding of
electrical installation technology.

INTRODUCTION TO IRISH
NATIONAL RULES

Pre-requisites

You will need a fundamental understanding

of electrical systems. We will provide this
material to you if you feel you would like
some further pre-course reading.
Please bring a calculator (or computer) and
pen along to the course to assist with the
calculations.

PLANNING OF ELECTRICAL
INSTALLATIONS

Purpose, supplies and structure

External influences
Compatibility and maintainability
Safety services
Continuity of service
Voltage band

ELECTRICAL HAZARDS AND

PROTECTION

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. There will be at least 8 exercises
to illustrate some of the calculations that are
required during installation design, to
reinforce the knowledge gained on the
course.

Electrical hazards
Codes for degree of protection by
enclosures
Principles of basic and fault shock
protection
Calculation of disconnection times
Thermal effects
Protection against voltage disturbances
Isolation and switching

To gain full value from this workshop,

please bring your calculator and if
possible your laptop/notebook
computer.

MAINTENANCE CONSIDERATIONS

SAMPLE DESIGN CALCULATIONS

SUMMARY, OPEN FORUM

AND CLOSING

Enlightening - dealing with

daily problems which we
find unexplainable.

Richard Collinette

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
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WIND & SOLAR POWER RENEWABLE ENERGY TECHNOLOGIES

What YOU WILL LEARN:

The fundamentals of Photovoltaic technology

The Essentials of wind power technology

The vital practical issues of wind and solar power technology

The practical steps in installing photovoltaic systems and
windpower systems
How to design and install simple photovoltaic and windpower
systems
How to deal competently with contractors and consultants
installing these systems
How to assist your company in complying with the ever
growing "Greenhouse Gas" Laws
To use the 32 Point checklist before commencing any work on
Wind and Solar Power Systems

WHO SHOULD ATTEND:

Mechanical, Electrical, Electronic Engineers

Technicians
Electricians

Control and Instrumentation Engineers

Facility Managers
Energy Specialists
And those who are keen to improve the environment and take
advantage of cheap and clean power

2.17

The Workshop

The Program

In the past ten years there has been a significant

increase in applying wind and solar power
technologies from the domestic user to the
corporate market. There has been a dramatic
improvement in the efficiencies in these
technologies and this has helped make the
applications economical. Specific energy
yields from wind turbines have increased by
60% and installation costs have dropped
significantly (up to 50% in many cases). Global
wind generating capacity has reached 100,000
MW capacity in March 2008 with almost
20,000 MW installed during 2007 alone.
Applications of photovoltaic (PV) systems are
growing rapidly worldwide with worldwide
installation of PV modules skyrocketing to
2,826 MW in 2007 (= 62% growth from 2006).
Many countries are passing legislation to
enforce greater use of PV systems and this is
helping to drive up the production of these
systems.

WIND ENERGY

Course Overview
Energy
Renewable and Sustainable Energy
Applications of the technology
Sustainable Energy
Economics of Renewable Energy
Forces Driving the technologies today
Fundamentals of Electricity (dc and ac)
Basics of Electronics for Renewable
Energy
Fundamentals of Mechanical Engineering

PHOTOVOLTAIC ENERGY
SYSTEMS
FUNDAMENTALS OF
PHOTOVOLTAIC TECHNOLOGY

Applications
Photovoltaic System components
Typical System configurations
Photovoltaic cells
Modules and Arrays

FUNDAMENTALS OF WIND
ENERGY

The wind Resource

Mechanics of Wind
Local Effects on Wind Flow
Wind Assessment at a Potential Site

DEVELOPMENT

Finance
Site Design
Planning
Contracts

TURBINE TECHNOLOGY

System Design
Aerodynamics and Power Control
Dynamics and Fatigue
Electricity Generation
Integration

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All of these technologies are interdisciplinary

requiring a knowledge of topics as varied as
aerodynamics, electricity and wind statistics
for wind power and mechanical engineering,
electronic and electrical engineering for solar
power.

INTRODUCTION

This workshop will outline the step by step

process of designing, installing and
commissioning photovoltaic and wind
powered systems. It should be emphasised
that this is not an advanced in-depth workshop
but one covering the important issues
enabling you to do simple designs and then
to investigate the design and installation
issues in more detail after the workshop
either by further study or in conjunction with
experts in the field.
In recent years the annual growth rate of the
solar and wind energy industry has consistently
exceeded 30% with 3 digit growth figures in
many regional markets. So in these rather
challenging economic times; this is a good
industry in which to focus one's career on.

Pre-requisites

You will need a fundamental understanding

of electrical systems and an understanding of
the fundamental issues driving renewable
energy development. We will provide this
material to you if you feel you would like
some further pre-course reading.

MECHANICAL DESIGN AND

INSTALLATION

Mechanical Design
Panel Assembly and Roof Attachment
methods
Mechanical Design Problems

ELECTRICAL DESIGN AND

INSTALLATION

Electrical System overview

Inverters
System Electrical Design
Grid Connection
Design Problems
Storage of energy
Load Profiles

BRIEF OVERVIEW OF
MISCELLANEOUS SYSTEMS
Solar Water Heating Systems
Energy Efficient Building Design
Hybrid Energy Systems

OPERATION AND MANAGEMENT

Management
Site Commissioning
Monitoring and Maintenance
Safety

TROUBLESHOOTING OF SYSTEMS

Typical Problems
Tips & Tricks

SUMMARY, OPEN FORUM

and CLOSING

SYSTEM INSTALLATION AND

COMMISSIONING
Check List of Items

Please bring a calculator (or computer) and

pen along to the course to assist with the
calculations.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

DISTRIBUTION and
SUBSTATION AUTOMATION

ID CO
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(incl. COMMUNICATIONS)
for Electrical Power Systems
YOU WILL LEARN:

Fundamental principles of distribution and substation

automation, specifically on protection, control and
communication issues
Important steps in designing, installing and managing a
substation automation project
The nuts and bolts of IEC 61850* standard
Typical techniques in troubleshooting distribution and
substation automation systems
How to avoid pitfalls and costly mistakes when implementing a
substation automation system
How to critically appraise the different products and systems
available for distribution and substation automation
* The IEC 61850 standard is being rapidly implemented throughout the world
for substations and many other areas such as power quality, substation
control centres, condition monitoring and power generation

WHO SHOULD ATTEND:

Engineers and Managers responsible for planning and

justifying substation automation
Project Engineers responsible for implementing a substation
automation project
Communications Engineers working in the power industry
Technicians and Operators installing and working with
substation automation systems
and generally
Electrical Engineers
Power System Engineers
Protection Engineers Design Engineers
Electrical Technicians Control and Instrumentation
Engineers
2.19

The Workshop

The Program

Distribution and substation automation

offers you a multitude of benefits including:
Increased function and reliability of
electrical protection
Advanced disturbance and event
recording capabilities aiding in detailed
electrical fault analyses
Display of real-time substation
information in a central control centre
Remote switching and advanced
supervisory control over the power
network
Increased integrity and safety of the
electrical power network, including
advanced interlocking functions
Advanced automation functions
* The IEC 61850 standard is being rapidly implemented

DATA COMMUNICATIONS FOR THE

ELECTRICAL POWER SYSTEMS
(cont)

Role of substation as a node in power

system
Main functions and equipment
Controls in conventional non-automated
substations

Discussion of most important protocols

used in the electrical industry (DNP3,
IEC60870.5 and UCA)
Communication requirements for
substations
Wireless communications
Suitability of different protocols for
substation communications
OPC for SCADA and substation
automation

SUBSTATION AUTOMATIONOBJECTIVES AND HISTORICAL

PERSPECTIVE
Automation functions at different levels
Objectives of an integrated automation of
the power network
SCADA in electrical systems
Key differences in the objectives of SCADA
and substation automation

FUNCTIONS OF MODERN
SUBSTATION AUTOMATION AND
ITS BENEFITS

THE IEC 61850 STANDARD

Need for a common standard and
development phases of IEC
Scope and outline of IEC 61850
Use of IEC 61850 in SCADA applications
Typical structure
Use of SCL

Inputs and outputs (HMI)

Controls and interlocking
Alarms
Protection and safety of individual
equipment and feeders
Remote protection setting and appropriate
control
Condition monitoring systems for
substation equipment - integration with
automation system

INFORMATION MODELS (IEC 61850

PART 7-4 AND 7-3)

SUBSTATION AUTOMATION
ARCHITECTURE

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throughout the world for substations and many other areas

such as power quality, substation control centres, condition
monitoring and power generation

THE SUBSTATION AND ITS

PRINCIPAL COMPONENTS AND
FUNCTIONS

This workshop is designed to familiarise you

with all aspects of distribution and substation
automation.The different levels of substation
integration and automation are outlined and
discussed while the components and
architecture of the typical distribution and
substation automation system are detailed.
The different approaches promoted by the
different substation automation vendors are
identified and the advantages of each are
outlined. The characteristics and operation
of the Intelligent Electronic Devices (IEDs)
are examined. A practical checklist is then
provided of the optimum way to implement
this technology to your next project.

Practical Sessions

This is a practical, hands on workshop

enabling participants to work through
practical exercises which reinforce the
concepts discussed.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

Typical automation architecture of MV and

HV substations
Bay controller for HV and intelligent relays
on a bus for MV
RTU as a means of interfacing an MV
panel
Auxiliary equipment automation
functionality through PLC/RTU
Process level interconnection by a
communication bus - future outlook

MODERN TRENDS IN CURRENT

AND VOLTAGE MEASUREMENTS

Current and voltage - the only parameters

that be sensed
Conventional equipment for measurement
Problems inherent in these designs
Modern measurement principles
Conventional instrument transformer but
with digital output
Pure optical sensors using Faraday
principle
Optical interconnection to field bus of IED
Typical utility experience from network

WIDE AREA FUNCTIONS

INCLUDING PROTECTION

Examples of functions that involve

multiple stations
Existing trends of dealing with such
functions
Limitation of communication
Response based and event based systems

DATA COMMUNICATIONS FOR THE

ELECTRICAL POWER SYSTEMS

delivered when and

where you need it.
Contact us for a
free proposal.

Basics of data communications, incl.

different techniques and media access
methods
Physical media, including radio and
satellite communication
Different communication protocols used
for substations

idc@idc-online .com

Physical and logical devices

Logical nodes
Common Data Classes (CDC)
Attributes and addressing
IEC 61850 object model
IEC 61850 data exchange model

COMMUNICATION MAPPINGS

Interoperability
ACSI models
Protocols and mapping
Sampled values and GOOSE applications
SCL and XML

ENGINEERING AND
CONFIGURATION OF SYSTEMS

System configuration tool

SCL applications
Peer to peer, one to many messaging
SCL, MMS and MICS data supports
Time synchronisation
Gateway engineering

CONFORMANCE TESTING

Data structure
System performance tests and FAT
Tests during life cycle

SECURITY ISSUES IN SUBSTATION

AUTOMATION
Common vulnerabilities of automation
systems
Inappropriate use of wireless
communication
Inadequate authentication of control
systems communications
Lack of detection and logging of intrusion
Dual use of control systems networks
Lack of security checking of control
systems software/applications
Potential mitigation strategies based on
multiple levels of implementation

IMPLEMENTATION ISSUES IN
SUBSTATION AUTOMATION
Planning automation in new substations
Planning a retrofit
Forward and backward compatibility
issues

www.idc-online .com

SAFE OPERATION and MAINTENANCE OF

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CIRCUIT BREAKERS AND SWITCHGEAR

WHATYOU WILL LEARN:

Selection of appropriate type and rating of circuit breakers and

switchgear
Fundamentals of operating switchgear

Switchgear components (CTs, VTs, relays and cable

terminations)

Safe operational policies including safety rules and safety

documents
Diagnostic tools and test equipment

Safe maintenance policies including safe working in switch

rooms, indoor and outdoor substations

WHO SHOULD ATTEND:

Managers, engineers and technicians who work with switchgear

and circuit breakers and who need to update their skills and
knowledge in this critical area of electrical power systems
protection.

2.21

The Workshop

The Program

Switchgear (and circuit breakers) are critical

components in electrical distribution
systems and their operation significantly
affects the overall operation of the system.
This two-day workshop will discuss
application, installation, maintenance and
testing issues relating to medium and high
voltage switchgear and circuit breakers. Low
voltage switchgear will be covered in detail.
You will gain a solid understanding of the
issues associated with the proper application,
installation and maintenance of these critical
items of equipment with an overriding
emphasis on safety.

Single line diagrams

Active and passive network components
Circuit breaker utilisation
Alternative forms of MV switchgear- ring
main units and load breaking/fault
making switches
Fuse switches
HV fuses in combination with, and as
alternatives to circuit breakers
Auto-reclosers and auto-reclose
operations

APPLICATION OF SWITCHGEAR
Principles of current interruption
Plain break circuit breakers
Bulk and small oil volume circuit
breakers
Turbulator (explosion pot)
Operating mechanisms
Transfer earth circuit breakers
Air break and air blast switchgear
SF6 and vacuum
Switchgear in association with
disconnectors
Fixed and withdraw-able designs
Switchgear standards
Factors affecting switchgear selection

SAFETY POLICIES
General safety precautions and the use of
personal protective equipment
Principles of safety rules
Principles of personal authorisation
Operative training for safe operation of
switchgear
Isolation in a circuit breaker context
Safety documentation
Operational and safety locking, caution
and danger notices
Work safety in a substation environment
Safety interlocks
Substation alarms
Individual study tasks and presentationsafety policies in my company and how
they might be improved

OPERATION OF MODERN
SWITCHGEAR

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This comprehensive and practical two-day

workshop emphasises medium voltage
switchgear which represents most of the
switchgear installed on electrical distribution
systems. The focus is on air blast, oil, SF6
and vacuum circuit breakers. Case studies
covering the main manufacturer's equipment
will illustrate the important practical
principles. Other power system protection
components will be discussed as well to
ensure that switchgear is understood in the
correct context.

SWITCHGEAR- ORIGINS AND

TYPES

Practical Sessions

This is a practical, hands on workshop

enabling participants to work through
practical exercises which reinforce the
concepts discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

SPECIFICATION OF SWITCHGEAR

Switchgear ratings- highest system and

impulse withstand voltages, load and
short circuit currents
Simple and complex protection systems
Switchgear ancillaries, measurement CTs,
VTs and relays
Cable terminations
Indoor and outdoor operations
Substation and switch room layouts and
design

SHORT CIRCUIT TESTING

On-Site Training

Symmetrical and asymmetrical breaking

Make and break operations
Understanding test oscillograms
Case study- Specification for a 132 Kv
Switchboard

Save over 50% by

Case studies
Sprencher and Schuh
Schneider
ABB
Siemens

ASSETS MANAGEMENT IN A
SWITCHGEAR CONTEXT

Principles of time and condition based

asset management
Asset registers
Asset management systems

DIAGNOSTICS, TESTING AND

MAINTENANCE

Switchgear inspection methodologies

Partial discharge measurement and
survey
Timing tests
Thermovision
Mechanisms of deterioration
Principles of circuit breaker maintenance
Maintaining oil circuit breakers
Contact maintenance and contact wipe
Oil testing
Maintaining vacuum circuit breakers
Maintaining SF6 circuit breakers
SOPs and DINs
Switchgear defects and defect control
systems

SUMMARY, OPEN FORUM

AND CLOSING

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

TROUBLESHOOTING,
MAINTENANCE and PROTECTION OF

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AC ELECTRICAL MOTORS andDRIVES

YOU WILL LEARN HOW TO:

Understand AC motor operation and construction

Specify, select and install motors

Specify protection requirements for motors

Specify speed control requirements for motors

Install and commission motors
Fix faults on motors

Interpret motor performance curves

Interface control circuits of motors with PLCs/DCSs

Reduce downtime on electrical motors
Improve plant safety

Improve plant throughput

Reduce your spares usage and requirements

WHO SHOULD ATTEND:

Anyone associated with the use of electrical motors in the industrial

or automation environment. The workshop will also benefit those
working in system design as well as site commissioning, maintenance
and troubleshooting. Typical personnel who would benefit are:
Electrical maintenance supervisors
Electrical maintenance technicians
Instrument and control engineers
Instrument technicians
Maintenance personnel
Mechanical engineers
Operations personnel
Plant engineers
Process control engineers
Service technicians
2.23

The Workshop

The Program

It is estimated that electrical drives and other

rotating equipment consume about 50% of
the total electrical energy consumed in the
world today. The cost of maintaining electrical
motors can be a significant amount in the
budget item of manufacturing and mining
industries. This workshop gives you a
thorough understanding of electrical motors
working, maintenance and failure modes and
gives you the tools to maintain and
troubleshoot electrical motors.

PROTECTION OF AC MOTORS

FUNDAMENTALS OF MOTOR
TECHNOLOGY
Basic principles of rotating electric
machines
Fundamental principles of speed control
Efficiency, torque, inertia, horsepower/
power factor
Torque-speed curves
How the motor produces torque
Types of motors

AC MOTOR THEORY,
CONSTRUCTION AND
MAINTENANCE

Protective devices
Thermal overload
Over current / overload
Under-voltage / over-voltage
Under frequency
Current unbalance or negative phase
sequence
Earth fault protection
Pole slip / out of step
Loss of excitation
Inadvertent energisation
Over fluxing
Stall protection / acceleration time / start
up supervision (time between starts /
starts per hour)
Voltage controlled or restrained over
current
Protection settings

Basic construction and physical

configuration, windings
Principles of operation and performance

THREE PHASE AC INDUCTION

MOTORS

SPEED CONTROL OF AC MOTORS

PROTECTION OF AC CONVERTORS
AND MOTORS

Components
Theory of operation
Induction motor design
Duty cycles
Insulation and cooling requirements
Starting methods
Selecting motors
Maintenance of AC machines
Types of faults, fault finding and testing
of AC machines
Testing instrumentation

Introduction to variable speed drives or

power electronic converters
Types, and designs of variable speed
drives

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You will gain a fundamental understanding of

the installation, operation and troubleshooting
of electric motors. Typical applications of
electric motors in mining, manufacturing,
materials handling, process control are
covered in detail. You will learn the basic steps
in specifying, installing, wiring and
commissioning motors. The concluding
section of the workshop gives you the
fundamental tools in troubleshooting motors
confidently and effectively.

INTRODUCTION

Pre-requisites

A fundamental knowledge of basic electrical

concepts would be useful.

Practical Sessions

Frequency converter protection circuits

Protection settings

CONTROL SYSTEMS FOR AC

VARIABLE SPEED DRIVES
Control theory of VSDs explained

THE SELECTION OF AC
CONVERTORS FOR VARIABLE
SPEED DRIVE APPLICATIONS

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Selection procedure
Nature of the load
Selection of correct size motor and
converter

To gain full value from this workshop,

please bring your laptop/notebook
computer.

INSTALLATION AND
COMMISSIONING OF AC
VARIABLE SPEED DRIVES

General installation and environmental

requirements
Electrical connections and earthing
requirements
Control wiring and pre-commissioning
Commissioning tests

NEW TECHNOLOGIES AND

DEVELOPMENTS

On-Site Training

summary, open forum

AND closing

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

POWER TRANSFORMERS -

ID CO
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OPERATION, MAINTENANCE and TESTING

What YOU WILL LEARN:

Fundamental theory and principles of the operation of power

transformers
Insight into the identification and application of transformers
types
Understand the power transformer components and their
construction
Power transformer protection

Power transformers' oil, oil tests and interpretation of results

The most effective power transformer electrical tests
How to manage power transformer breakdowns to
ensure a minimum disruption

WHO SHOULD ATTEND:

Power System Engineers

Electrical Engineers

Consulting Engineers

Project Engineers

Power System Technicians

Electrical Contractors and Technicians
Tradesman Electricians
Electrical Inspectors
Utility Engineers

2.25

The Workshop

The Program
STATION TRANSFORMERS

Installation of high voltage distribution and

transmission equipment has increased
significantly over the years due to ongoing
global demand for power. As a result, the
need to ensure reliability of operation of
power systems is paramount. Power
transformers are among the most important
and most expensive components of power
systems. Their failure can impose
extraordinarily high costs on plants, factories
and utilities of all descriptions. It is critical
that all personnel operating and working
with such equipment have a sound
knowledge of their operational requirements
and maintenance. This practical workshop
provides knowledge on both the theory and
operation of power transformers. The course
will develop and enhance an understanding
of what is involved in the maintenance of
these essential components of the power
systems, through the tips and tricks learnt
and developed by some of the world's
preeminent electrical engineers.

TRANSFORMERS' MAIN
FUNCTIONS AND CLASSIFICATION

Pre-requisites

Thermal performance, loading,

paralleling, tap-changing, connections
and vector groups

AC Tests:
- Power factor tests (insulation, oil, and
bushings)
- Single phase excitation current test
- Transformer turns ratio test
DC Tests:
- Insulation resistance test
- Dielectric absorption test
- Polarisation index test
- Step voltage test
- Hi-pot test

POWER TRANSFORMER
PROTECTION

PREVENTATIVE MAINTENANCE
ON POWER TRANSFORMERS

Construction (shell type and core type)

Classification and type in relation to
insulation, windings, core, cooling
systems, voltage level, sizing, tank and
breathing action
Transformer parts

POWER TRANSFORMERS AND

SAFETY
How to install, operate and work with
high voltage power transformers safely
Earthing of HV transformers

TRANSFORMER THEORY
Electrical values and their definition in a
power transformer - voltage, current,
umber of turns, impedance and their
interrelation

POWER TRANSFORMER OIL AND

OIL QUALITY
Oil contents: water, acidity and dissolved
gas
Oil tests: dielectric breakdown, moisture,
resistivity, interfacial tension, specific
gravity, power factor and furan analysis.
Recovery voltage measurement test

POWER TRANSFORMER
ELECTRICAL TESTS

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OPERATION OF POWER
TRANSFORMERS IN A POWER
SYSTEM

Design criteria
Specifications

Some basic knowledge of electrical

engineering and general knowledge of
nature and operation of transformers is
required. However participants do not need
specific knowledge on transformers as the
course will start from the basic theory.

Practical Sessions

Surge protection
Protective relaying (differential, overcurrent and earth fault)
Buchholz relay and pressure relief relay
Thermal devices and instruments (oil
temperature alarm and trip, winding
temperature alarm and trip)

Techniques to improve life expectancy

SUMMARY, OPEN FORUM

AND CLOSING

AUTO-TRANSFORMERS

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Design criteria
Specifications

GENERATOR TRANSFORMERS
Design criteria
Specifications

UNIT TRANSFORMERS
Design criteria
Specifications

On-Site Training

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having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

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LIGHTNING, SURGE PROTECTION and

EARTHING of Electrical and Electronic

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Systems in Industrial Networks

You will learn How To:

Select and apply an appropriate lightning dissipation system

Understand how earth electrodes work and their role in
preventing lightning and surges from damaging equipment
List the types of systems that cannot be earthed

Describe what systems can be operated unearthed

Correctly select and apply surge protection appropriate to the

type of equipment being protected
Apply practical knowledge of surge and transient protection
Troubleshoot and fix earthing and surge problems

Design, install and test an effective earthing system for

electronic equipment

Understand lightning and how to minimise its impact on your

facility
Protect sensitive equipment from lightning

WHO SHOULD ATTEND:

Instrumentation and control engineers

Consulting engineers and safety professionals

Electrical engineers and contractors
Project engineers
Power system protection and control engineers
Maintenance engineers
Building service designers
Data systems planners and managers
Electrical and instrumentation technicians
Electricians and electrical inspectors
2.27

The Workshop

The Program

Few topics generate as much controversy

and argument as that of lightning and surge
protection of electrical and electronic
systems. Poor practices in earthing, and
incorrect application and selection of
lightning and surge protection devices can
be the cause of continual and intermittent
problems in a facility, often resulting in lost
production and equipment failure.

INTRODUCTION AND BASICS

ELECTRICAL FAULTS

Earth fault circuit interrupters

Equipment earth fault protection systems

Fundamentals of earthing
Bonding
Lightning
Surge protection
Dissipation arrays

RECOMMENDED DESIGN AND

INSTALLATION PRACTICES

This workshop looks at these issues from a

fresh yet practical perspective and enables
you to reduce expensive down time on your
plant and equipment by the correct
application of these principles. Essentially
the workshop is broken down into the
methods used to prevent lightning entering
a facility such as dissipation arrays and
those that divert surge energy away from
sensitive equipment.

Wiring and earthing for safety and

performance
Wiring and distribution systems
Dedicated and derived neutral systems
Earthing and bonding equipment
Earth electrodes and earth mats
Supplementary earthing systems
(chemical earths)

Dissipation systems are discussed with

associated earthing systems. The unique
properties of various surge protection
devices are reviewed, enabling you to select
the correct device suited to the application
required. Earthing and surge protection for
telecommunications and IT systems are
examined in detail as well as the impact of
lightning and simple techniques for
minimising its impact.

Earthing of building systems

Which electrical systems can be operated
unearthed?
Proper methods of earthing building
electrical systems
Location of the service earthing
connection
Proper sizing of earthed (neutral)
conductors

Earthing and bonding in hazardous

(classified) locations
Earthing and bonding for health care
Earthing and bonding for swimming
pools, hot tubs and spas
Static and electricity: earthing and
bonding requirements
Common violations
Building electrical inspection procedures
How to recognise hazards

LIGHTNING
Need for a lightning protection system
Which protection systems work and
which don't
Best location for IT equipment
Optimum earthing for building
Pitfalls of isolated earthing
Shielding and bonding of electronics and
communications
Optimum location of surge protection
devices

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FUNDAMENTALS FOR BUILDING

ELECTRICAL SYSTEMS

APPLICATIONS OF EARTHING
AND BONDING

Pre-requisites

Some working knowledge of basic electrical

engineering principles is required, although
there will be a revision at the beginning of
the workshop. Experience with earthing
problems will enable the workshop to be
placed in context.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

TYPICAL RULES TO BE APPLIED

Rules for multiple services to one

building
Rules for low impedance and high
impedance systems
Rules for bonding requirements at
building service equipment
Earthing electrodes, systems and
conductors
Bonding enclosures and equipment
Equipment earthing conductor types
Enclosure and equipment earthing
Earthing of separately derived systems
Earthing at more than one building
Disconnecting means for separate
buildings

EARTHING AND NOISE CONTROL

SURGE AND TRANSIENT

PROTECTION

Lightning phenomena
Protection of power supply
Protection of electric communications
circuits
Power system faults and switching
surges
Mitigation techniques
Case studies

POWER CONDITIONING

Power conditioners
Uninterruptible power systems
Power quality alternative sources

SUMMARY, OPEN FORUM

AND CLOSING

Misconceptions of performance earthing

Single point versus multi point
techniques
Noise and zero signal reference grid
Shielding

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Maintenance and Troubleshooting of

UNINTERRUPTIBLE POWER SUPPLY

(UPS) SYSTEMS and BATTERIES

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Also including high reliability power supplies

YOU WILL LEARN HOW TO:

Describe the basic building blocks of UPS and high reliability

power supply systems
Understand the construction and operation of the major
commercial UPS systems
Detail the operation of the popular UPS systems

Maintain and test lead acid and nickel cadmium batteries

Understand how to performance test lead acid and nickel
cadmium batteries
Identify the relevant hazards and apply safe working practice
for UPS systems and batteries

WHO SHOULD ATTEND:

Electrical Technicians and Engineers

Instrumentation and Control Engineers

Consulting Engineers
Project Engineers

Maintenance Engineers
Power System Protection and Control Engineers
Building Service Designers
Data Systems Planners and Managers
Maintenance Tradespeople and Technicians
Electrical and Instrumentation Technicians

2.29

The Workshop

The Program

This practical workshop will provide you

with a basic understanding of the application,
installation, operation and troubleshooting
of UPS systems and batteries. It covers
theory of operation and standard testing as
well as troubleshooting and maintenance of
typical single and three phase uninterruptible
power supplies and batteries.

BASICS OF BATTERIES

Maintaining continuity of power and the

role of the UPS in ensuring reliable
power

Types of batteries: primary and

secondary
General features of lead-acid and nickel
-cadmium batteries
Comparison of the chemistry involved
Lead acid batteries - subtypes,
construction and relative features
Manufacture of batteries

POWER QUALITY-BASIC FACTS

What constitutes power quality?

Sags and swells
Voltage fluctuations and mitigation
Interruptions
Surges - their causes, effects and
remedies
Noise and harmonics
Frequency disturbances and mitigation

RELIABILITY AND CONTINUITY OF

POWER SUPPLY
Interruptions and their impact
Deciding the requirements of your plant
and equipment
Uninterrupted power - how much and
where?
Improving reliability by redundancy and
automation
Uninterrupted power options available?
Rotary UPS systems

CHARGING AND DISCHARGING

OF BATTERIES
Float charging and boost (equalizing)
charging
Facts about charging of lead acid
batteries
Internal loss and the factors that affect it
Current during charging cycle - variants
Overcharging and undercharging
Sulphation and hydration
The discharge process
Specifics about charging of UPS batteries
Nickel cadmium batteries
Charging strategy for nickel cadmium
batteries

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Day one commences with the fundamentals

of UPS's and a comparison between the
various topologies and how they operate.
Typical issues with troubleshooting and
maintenance of UPS's are also covered. The
fundamentals
of
typical
electrical
components within a UPS are detailed as
well as the operation of the conversion
process from AC to DC and then back to AC.
The second day focuses on how to work
competently and safely with lead acid and
nickel cadmium batteries. The initial
discussions centre around battery theory,
types of batteries, installation, testing and
maintenance. The workshop is concluded by
examining case studies of various
configurations of batteries and UPS
systems.

INTRODUCTION

Pre-requisites

Some working knowledge of basic electrical

engineering principles is required, although
this will be revised at the beginning of the
course. Real-life experience in working with
batteries and UPS systems will enable the
workshop to be placed in context.

Practical Sessions

Their are eight practical exercises and

demonstrations throughout the workshop.

BASICS OF RECTIFIERS AND

INVERTERS

Solid state devices - diodes, transistors,

thyristors and IGBTs
Basic configurations of rectifiers and
their output waveforms
Ripples and control
Rectifiers in static UPS systems
Controlled rectifiers and their impact on
power factor
Why are rectifiers treated as sources of
harmonics?
Basic principles of an inverter
Synthesizing the AC wave
Pulse width modulation technique of
synthesis

STATIC UPS SYSTEMS

On-Site Training

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having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

Static UPS
Basic components of the general UPS
configuration
Passive standby, line interactive and
double-conversion type of UPS
Preferred metering, indication and alarms
in a UPS
Power quality and UPS
Need for isolation transformer
Computer power supplies and
comparison of UPS configurations
Rating of UPS systems - pitfalls
Redundant UPS systems
Earthing of UPS systems recommendations from the IEEE Green
Book

UPS SYSTEM TROUBLESHOOTING

AND MAINTENANCE

delivered when and

where you need it.
Contact us for a
free proposal.

SELECTION, CONFIGURATION
AND SIZING OF BATTERIES

Matching the battery type to the

application
Life cycle cost of battery
Battery configuration - selecting the
voltage
Use of parallel battery strings
Alternative approaches to sizing of
battery for DC supply systems
Battery sizing for UPS systems

INSTALLATION OF BATTERIES
Receiving, checking and storage
Pre-installation planning and rack
installation
Installation of cells and inter cell
connections
Safety precautions

BATTERY UPKEEP, FAILURES

AND DISPOSAL

Need for upkeep and monitoring

Causes of failures and failure modes
Periodic inspection and residual life
assessment
Test equipment and safety of personnel
Predictive monitoring by conductance
testing
Disposal and recycling

CASE STUDIES

Selection and sizing

UPS systems
Batteries
Combination of batteries and UPS
systems

Critically apply the manufacturer's

recommendations
Basic use of test equipment and tools
Rectifier and Inverter troubleshooting

idc@idc-online .com

www.idc-online .com

Practical

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POWER SYSTEM harmonics,

earthing and power quality
- Problems and Solutions

YOU WILL LEARN HOW TO:

Develop a sound working knowledge of power quality problems

and solutions
Do a step-by-step site analysis on various aspects of power
quality such as power interruptions, voltages variations,
harmonics, surges and electrical noise
Deal with power interruptions
Gain practical knowledge on surge and transient protection
Design electrical and electronic systems correctly by applying
knowledge of harmonics and earthing principles
Troubleshoot electrical and electronic systems for power quality
and harmonic problems
Isolate and rectify power quality, harmonic problems and
electrical noise
Network with your peers on solving these problems

WHO SHOULD ATTEND:

This course is designed for personnel who want to understand

the issues related to power quality in plants. Those who will
benefit the most from this workshop include the following:
Electrical designers and engineers
Electrical maintenance engineers
Personnel from EPC (Engineering, Procurement and
Construction) companies
Project engineers
Consulting engineers
Plant maintenance personnel
Electrical and electronics technicians
2.31

The Workshop

The Outline

The practical quality and harmonics

problems and solutions course is a
comprehensive, highly practical and
interactive two-day course dealing with the
various types of power quality problems
that have a wide ranging effect on the power
systems equipments and apparatus in any
plant.

The second day moves onto conducting a site analysis with a step-by-step set of instructions
on harmonic site analysis procedures. A practical discussion on power conditioning is also
discussed and the two days are rounded off with realistic case studies covering a wide
variety of industries ranging from manufacturing and process control to telecommunications.
You will also be provided with a high quality course manual that IDC is known for. This
course manual will be useful for many years after the course.

The Program
POWER QUALITY OVERVIEW
What is power quality?
Power quality indicators
Need for improving power quality

HARMONICS IN POWER SYSTEMS

Principles of harmonic analysis

Problems due to harmonics
Limits of harmonic presence
Analysis of harmonic components
Control of harmonics

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You will have an opportunity to learn and

discuss the fundamentals of power quality
problems such as surges and voltage sags.
Other problems having wide ranging effects
on power system equipments such as
voltage swells, voltage fluctuations, supply
interruptions,
frequency
variations,
harmonics and noise shall also be discussed
in details. Issues related to control of the
occurrence of these problems by appropriate
system design and mitigation of the effects
of these by adoption of appropriate
protective measures and by the addition of
power conditioning equipment shall be
discussed.

The workshop commences with a review of the fundamentals of power quality issues and
the need to improve and maintain the quality of power in any installation. The ways to deal
with power interruptions and voltage variations are explained in details. Surge and transient
protection is then reviewed with practical steps outlined to minimise or even eliminate this
problem. Hereafter the workshop focuses on what harmonics in power systems are and how
to minimise them. The common problem of noise is reviewed and some misconceptions in
this area are discussed.

Also, aspects related to designing of the

systems, proper installation practices
analysis of the probable reasons and
corrective measures will be discussed in
detail. Practical examples from actual
projects will be used extensively to illustrate
the principles and drive home the point.
The material is covered by means of an
interactive lecturing style, with plenty of
practical examples and realistic case
studies derived from real work performed
in this area.

Practical Sessions

DEALING WITH POWER

INTERRUPTION

Failures and power interruptions

Redundancy and automation
Types of UPS systems
UPS configuration for computer
application

VOLTAGE VARIATIONS

Reasons for voltage variations

Sags and swells
Handling voltage fluctuations
Control measures for mitigation
Recommended system changes

SURGE AND TRANSIENT

PROTECTION

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Basics of lightning phenomena

Power system faults and switching
surges
Mitigation techniques and case study
review

VOLTAGE ASYMMETRY

Reasons and analysis of voltage

asymmetry
Effects of asymmetry
Permissible limits of asymmetry
Dealing with assymetrical loads

ELECTRICAL NOISE AND

MITIGATION

How are sensitive circuits affected by

noise?
Time and frequency domain
representation of noise
Categories and sources of noise
Importance of grounding in noise control
Zero signal reference grid and signal
transport ground plane

SYSTEM INSTALLATION GUIDES

Commercial power, power interruptions
and issues of location
Evaluation of power conditioning options
Noise suppression sensitive loads by
proper grounding
Checking for redundancy requirement
Signal/data cabling susceptibility
Radio Frequency Interference (RFI)
protection
Static electricity related problems
Surge and lightning protection
Documentation
Planned maintenance

CONDUCTING SITE ANALYSIS

AND SURVEY

Overview of sources of power quality

problems
Site survey procedures
Solutions generated

Save over 50% by

SUMMARY, OPEN FORUM

AND CLOSING

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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Motor Protection, Control

and Maintenance Technologies

YOU WILL LEARN HOW TO:

Specify protection requirements for motors

Maintain electrical motors
Specify speed control requirements for motors
Understand essentials of motors and drives
Detail the main issues with testing of motors
Prevent or at least minimise motor bearing failure
Troubleshoot and fix faults on motors and drives
Interface control circuits of motors with PLCs/DCSs
Reduce downtime on electrical motors
Improve plant safety
Improve plant throughput
Reduce your spares usage and requirements

WHO SHOULD ATTEND:

Anyone associated with the use of electrical motors in the industrial

or automation environment. The workshop will also benefit those
working in system design as well as site commissioning,
maintenance and troubleshooting. Typical personnel who would
benefit are:
Electrical consulting
engineers
Electrical contractors
Electrical maintenance
supervisors
Electrical maintenance
technicians
Engineering and design
personnel

Instrument and control

engineers
Instrument technicians
Maintenance personnel
Mechanical engineers
Operations personnel
Plant engineers
Process control engineers
Service technicians

2.33

The Workshop

The Program

It is estimated that electrical drives and other

rotating equipment consume about 50% of
the total electrical energy consumed in the
world today (and this figure increases to 70%
if you only consider industry). The cost of
maintaining electrical motors can be a
significant amount in the budget item of
manu-facturing and mining industries. This
workshop
gives
you
a
thorough
understanding of electrical motors
protection, control and maintenance and
gives you the tools to maintain and
troubleshoot electrical motors.

Basic principles of rotating electric

machines
Fundamental principles of speed control
Efficiency, torque, inertia, horsepower/
power factor
Torque-speed curves
Induction/synchronous/wound rotor types
Basic construction and physical
configuration, windings
Principles of operation and performance

THREE PHASE AC INDUCTION

MOTORS

Components
Theory of operation
Induction motor design
Duty cycles
Insulation and cooling requirements
Starting methods
Selecting motors
Types of faults, fault finding and testing of
AC machines
Testing instrumentation

BEARING FAILURE ANALYSIS

Bearing failures
Grease and greasing
Belt drive aspects
Balance
Storage issues
Service factor loading

PROTECTION OF MOTORS

Thermal overload
Time constraints
Early relays and new digital relays
Starting and stalling conditions
Over current/overload
Under-voltage/over-voltage
Under frequency
Pole slip/out of step
Loss of excitation
Inadvertent energisation
Over fluxing
Stall protection/acceleration time/start up
supervision (time between starts)
Unbalanced supply voltages
Negative sequence currents
De-rating factors
Earth faults core balance, residual
stabilising resistors
Calculation of protective relay settings

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You will gain a fundamental understanding of

the protection, control and maintenance of
electric motors and drives.Typical applications
of electric motors in mining, manufacturing,
materials handling, process control are
covered in detail. The concluding section of
the workshop gives you the fundamental
tools in troubleshooting motors confidently
and effectively.

FUNDAMENTALS OF MOTOR
TECHNOLOGY AND
CONSTRUCTION

Pre-requisites

A fundamental knowledge of basic electrical

concepts would be useful.

ENERGY LOSSES AND EFFICIENCY

OF THREE PHASE AC INDUCTION
MOTORS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Congestion on fan cover

Improper spacing at end of motor
Incorrect belt alignment
Solid belt guards
Excessive loading causing bearing
clearance problems
Insulation failures
Bearing current problems

TESTING

Save over 50% by

having an IDCworkshop
presented at your
premises.

MOTOR CONTROL

Standards
Power circuit
Types of losses
Control circuit
Tests for measurement and computation of Full online voltage starting
losses and efficiency
Reduced voltage starting
Dynamometers
- Delta-star
Principles of load application by braking
- Resistance
Torque measurement basics
- Reactor
Types of practical dynamometers
- Autotransformer
- Soft start
MOTOR FAILURE ANALYSIS

Braking
Frequent starts
Speed control
High inertia
Reversing
Inadequate cooling

On-Site Training

Insulation life and resistance

Polarisation index
DC hipot
DC ramp test
AC hipot
Capacitance test
Dissipation factor
Partial discharge
Surge test
Mechanical testing
Online testing

Customise the training to

CONTROL SYSTEM FOR AC

VARIABLE SPEED DRIVES

Overall control system

Power supply for the control system
DC bus charging system
VSD control loops (open loop/closed loop)
Vector control
Current feedback in AC variable speed
drives
Speed feedback from motor

INSTALLATION AND FAULT

FINDING

General installation and environmental

requirements
Power supply connections and earthing
Where to install contactors in power circuit
Installation of AC converters into metal
enclosures

NEW TECHNOLOGIES AND

DEVELOPMENTS

summary, open forum and

closing

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

Practical

Medium & High Voltage Testing

of Electrical Equipment

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for Engineers and Technicians

WHAT YOU WILL LEARN:

Types of HV and MV test performed

Good industry practice

The need for testing of MV and HV electrical equipment

Various types HV equipment encountered in the industry
Testing equipment

The need for good record keeping on tests conducted

The role of standards on testing, test basis and interpretation of

results
National test labs and their importance in quality assurance

WHO SHOULD ATTEND:

Instrumentation and Control Engineers

Consulting Engineers
Electrical Engineers
Project Engineers

Maintenance Engineers
Power Systems Protection and Control Engineers
Building Service Designers
Data Systems Planners and Managers

2.35

The Workshop

The Program

Testing is an essential activity in any

engineer's career. Whatever your role in the
industry - electrical designer, purchase
engineer,
manufacturer,
installation
contractor or maintenance engineer, solid
knowledge of electrical tests is a necessity.
This workshop is designed to familiarise you
with various aspects of testing general
electrical equipment and high voltage testing
in particular.

Practical Sessions

A mixture of videos, equipment and

exercises will be used to illustrate key
principles with seven sessions:
Practical sessions include:

High voltage test equipment

Oil dielectric testing
Transformer testing
CT testing
Ductor testing

Induced over voltage tests

Winding resistance measurement
Ratio testing
Vector group verification
Tests for transformer losses
Partial discharge testing
Tan Delta testing
Test Instruments
Practical Session: Transformer Testing

INSULATION TESTING

Purpose of insulation testing

Equipment
Insulation
Construction of a tester
Connections of tester to test equipment
Safety precautions
Discharging
Noting of readings and interpretation
Determining dryness of insulation using
absorption ratio
Practical Session: Insulation Testing

HIGH POTENTIAL TESTS

Purpose of testing
AC and DC Hipot tests
Test equipment/block diagram and
construction details
Connections of tester to test equipment
Safety precautions
Discharging after test
Noting of readings and interpretation
Standards and precautions
Practical Session: High Voltage Test
Equipment

OIL TESTING

Insulation testing

PT testing

TRANSFORMER TESTING

HV AND MV equipment
Need and purpose of testing
Categories of testing

CT TESTING

Ratio test of Current Transformers (CTs)

Test with rated burden
Polarity testing
Magnetising current and knee point
voltage measurement
Insulation test and high voltage test
Test instruments
Practical Session: CT Testing

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Examples are used from various international

standards regarding the procedures for
conducting tests and interpreting the results.
The need for keeping proper records of tests
conducted both in the initial stages and later
during routine maintenance is discussed.
Some of the tests are too complex to be
performed on a routine basis or may require
specialised equipment which may not be
normally available to user industries or even
manufacturers. This is where the services of
an independent and accredited test lab are
useful. The roles of such labs are briefly
discussed.

INTRODUCTION

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Dielectric test using high voltage

testing kit
Electrodes and test voltage
Test voltages as per applicable standards
Tests of acidity
Effect of additives
Other possible uses of oil testing
(dissolved gas analysis)
Improvement of dielectric strength by
filtration
Practical Session: Oil Dielectric Testing

PT TESTING

Ratio test of Potential Transformers (PTs)

Test with rated burden
Polarity testing
Magnetising current measurement
Insulation and HV tests
Test instruments
Practical Session: PT Testing

DUCTOR TESTING

Working principle
Use of doctor for verifying contact
resistance of circuit breakers
Precautions and analysis
Practical Session: Ductor testing

OTHER MISCELLANEOUS TEST

EQUIPMENT SUMMARY

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

Earthing of Utility and

Industrial Distribution Systems

ID CO
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Te YR
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for Engineers and Technicians

WHAT YOU WILL LEARN:

The basic principles of grounding of electrical systems

The function of power system grounding and the various
options available
Role of protective grounding in ensuring safety; sizing of
grounding conductors
Importance of equipotential bonding in ensuring safety
Design of ground electrodes, measurement of soil resistivity
and ground electrode resistance
Fundamental principles in the design of grounding systems in
substations
Solving static electricity-related hazards by grounding and
bonding
Role of grounding in protecting substation structures from
lightning hazard
Role of grounding in surge protection of power distribution
equipment and sensitive systems
Noise in electrical systems and the role of grounding in noise
mitigation

WHO SHOULD ATTEND:

Instrumentation and control engineers

Consulting engineers
Electrical engineers
Project engineers
Maintenance engineers
Power system protection and control engineers
Building service designers
Data systems planners and managers
Electrical and instrumentation technicians

2.37

The Workshop

The Program

Few topics generate as much controversy

and argument as that of grounding (or
earthing as it is called in some countries)
and the associated topics of lightning and
surge protection of electrical and electronic
systems. Any engineer dealing with power
supply networks needs to understand the
basic principles of grounding system design
and its role in ensuring safety of equipment
and personnel. A correct understanding of
the basic principles involved will help him/
her to avoid mistakes in grounding system
design, mistakes that could lead to expensive
failures and long downtime.

Basics of grounding
Bonding
Role of grounding in lightning protection
Ground electrodes and factors affecting
their efficacy
Grounding issues in outdoor substations
Grounding for static charges
Surge protection
Importance of grounding in mitigation of
noise in sensitive circuits
Importance of local codes

POWER SUPPLY SYSTEM

GROUNDING
Types of system grounding
- Ungrounded systems
- Solidly grounded systems
- Impedance grounding using neutral
reactor
- Resonant grounding using neutral
reactor
- Impedance grounding through neutral
resistance
Classification of supply systems based
on grounding
Point of grounding
Other challenges

SUBSTATION GROUNDING
DESIGN cont.
Transferred potential and ways of
avoiding
Points needing special attention in
substation grounding design and for GIS
equipment
Design of substations containing
converter equipment feeding to HVDC
transmission systems
Ensuring effective substation grounding important aspects

STATIC ELECTRICITY AND

PROTECTION
What is static electricity and how is it
generated?
Examples of static charge build up and
its dangers
Energy of spark due to static electricity
Ways of controlling static build up
Risk assessment and preventive
measures

ID CO
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In this workshop, we will try to demystify the

concepts of grounding as applicable to utility
networks and industrial plant distribution
systems as well as their associated control
equipment. In fact, a lot of myths have been
built around this subject, although it is quite
a simple one when approached from basic
principles. Our endeavour will therefore be
to explain the fundamentals of grounding,
which we hope will enable the readers to
gain a correct perspective of the subject and
give them the knowledge needed to solve
real life grounding problems.

OVERVIEW

Essentially this workshop is broken down

into system grounding, protective grounding
and surge/noise protection of power and
electronics systems normally found in
distribution networks. A brief introduction
to the design of substation grounding has
been included. Detailed information on
ground electrodes and measurement of
ground resistance is also available.

Pre-requisites

Some working knowledge of basic electrical

equipment is required, although this will be
covered at the beginning of the course.
Real-life experience with such equipment
and hands-on testing will enable the
workshop to be placed in context.

PROTECTIVE GROUNDING

Electric shock, its cause and effects

Direct and indirect contact
Touch and step potential
Role of protective grounding in
minimising the shock hazards
Equipotential bonding
Protective grounding conductors and
installation
Ground fault protection
System classification based on system/
protective grounding

GROUND ELECTRODE SYSTEMS

Soil resistance and factors affecting soil

resistivity
Measurement of soil resistivity
Resistance of ground electrode and
distribution of resistance in surrounding
soil layers
Electrode current capacity
Ground electrode configurations
Parallel electrodes
Ground electrode resistance
measurement
Chemical electrodes
Concrete encased electrodes and splicing
methods
Corrosion of buried electrodes
Grounding system maintenance

SUBSTATION GROUNDING
DESIGN

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

The physics of lightning

Lightning incidence in different land
masses
Lightning strike probability
Lightning protection
Planning for protection and decision
factors
Improved approach to lightning
protection and non-conventional systems
Effect of lightning strikes on electrical
installations

SURGES AND SURGE

PROTECTION

Surges, their causes and mitigation

The ways by which surges couple into
electrical circuits
Bonding of grounding systems
Basic principle of surge protection and
commonly used surge protection devices
Graded surge protection
Selecting appropriate surge protective
devices and their positioning in a system
Importance of correct grounding
practices for sensitive equipment
Other ways and devices for mitigating
surge problems
Comparative merits of different types of
SPDs for sensitive equipment
Hybrid surge protective devices
Surge protection of telemetry and data
communication systems

ELECTRICAL NOISE AND

MITIGATION

SUMMARY, OPEN FORUM

AND CLOSING

Grounding practices
Basic design approach
Calculating the ground fault current
Ground potential rise in HV systems
Grounding design in LV and MV
substations/installations
Grounding grid design for HV/EHV
substations - a step-by-step approach
Introduction to two-layer soil model

Practical Sessions

GROUNDING FOR LIGHTNING

PROTECTION OF BUILDINGS AND
STRUCTURES

Definition of electrical noise

How are sensitive circuits affected?
Noise categories
Noise from power electrical equipment
Noise coupling into signal circuits
Noise mitigation measures
Role of proper grounding in reducing
noise
Noise control by proper grounding of
UPS derived supplies

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Practical

Electrical Substation Safety

ID CO
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Te YR
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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Identify the hazards in operation and maintenance work in

different parts of electrical installations
Identify the various statutory and legal regulations/acts
dealing with electrical safety at work
Appreciate the basic theoretical aspects involved in electrical
safety
Understand the importance of proper design of electrical
equipment in ensuring safety
Gain a clear understanding of the procedures/practices
adopted for safe working
Appreciate the role of regular inspection and condition-based
maintenance in ensuring safe operation
Gain an insight into the organisational aspects of safety
Become familiar with the organisations electrical safety rules
(applicable to on-site training)

WHO SHOULD ATTEND:

Instrumentation and control engineers

Consulting engineers

Electrical engineers
Project engineers

Maintenance engineers
Power system protection and control engineers
Building service designers
Data systems planners and managers
Electrical and instrumentation technicians

2.39

The Workshop

The Program

Electrical substation safety is an important

issue in utility networks as well as large
industrial installations and requires adequate
attention in the stages of system planning,
design,
installation,
operation
and
maintenance.
A number of serious accidents including
fatalities occur every year in industrial
establishments due to accidents involving
electricity, resulting in huge financial losses
and wasted man-hours.
Electrical safety is a well-legislated subject
and the various Acts and Regulations lay a
lot of stress on the responsibility of both
employers and employees in ensuring safe
working conditions.

Hazards of general nature in industrial

installations
Electrical hazards
Direct and indirect electric shock
The deadly combination of heights and
electric shock
Hazards due to arcing/flashover
Hazards from use of electrical equipment
in explosive environment
Hazards due to high temperature in
electrical equipment
Need for periodic inspection and
maintenance for safe operation of
electrical equipment

BASIC THEORY OF ELECTRICAL

SAFETY

Electrical shock - why does it happen?

Touch and step potential (voltage)
Direct and indirect contact
Role of electrical insulation in safety
Avoiding electric shock-different
approaches
Earth leakage circuit breakers
Earthing of power supply systems and its
safety implications
Role of earthing of equipment enclosures
(protective earthing) in human safety
Earthing in outdoor installations
Earthing of buildings and structures for
safety during a lightning strike
Dangers due to arc flash in electrical
equipment

INSPECTION OF ELECTRICAL
SYSTEMS FOR SAFETY

Objectives of inspection
Stipulations of IEE Regulations
Inspection of new installations
Checklists of items/aspects to be
inspected
Periodic inspection
Documentation of inspection
Planned and condition-based preventive
maintenance

SAFETY IN BATTERY
INSTALLATIONS
Hazards involved in lead-acid battery
installations
Premises used for housing lead acid
batteries
Transportation and storage
Installation and commissioning
Charging and storage
Dismantling and disposal
Protective clothing
First-aid measures

ID CO
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In this course, we will take a look at the

theoretical aspects of safety as well as the
practical and statutory issues. Safety is not
simply a matter of taking precautions in the
workplace. It has to start at the stage of
equipment design. Safety should be built
into the design of electrical equipment and it
is the responsibility of every manufacturer
of electrical equipment to remove every
possible hazard that can arise from its
normal use.

OVERVIEW

Correct selection and application of electrical

machinery is also important for ensuring
safety. A thorough inspection during initial
erection and commissioning as well as on a
periodic basis thereafter is also very essential
to ensure safety. Batteries used in substations
need particular attention since they contain
toxic materials such as lead, corrosive
chemicals such as acid or alkali.

Electrical safety is not just a technical issue.

Accidents can only be prevented if
appropriate safety procedures are evolved
and enforced. This includes appropriate
knowledge of equipment and systems
imparted through systematic training to
each and every person who operates or
maintains the equipment. We will cover all
these aspects in detail.

Pre-requisites

Some working knowledge of basic electrical

equipment is required, although this will be
covered at the beginning of the course.
Real-life experience with such equipment
and hands-on testing will enable the
workshop to be placed in context.

SAFETY ASPECTS IN ELECTRICAL

EQUIPMENT DESIGN

Objectives of safe design

Insulation and its role in safety
Enclosures for safety
IP classification
Adverse thermal effects and prevention
Isolation and blocking of switching to
prevent hazards
Role of standards in safety

ORGANISATIONAL ASPECTS OF
SAFETY
Legislative aspects of safety
Role of an organisation in ensuring/
improving work safety
Functional requirements
Intra-organisational safety
implementation
External interfacing and compliance

DISCUSSION ON ELECTRICAL
NETWORKS, SPECIFIC HAZARDS
AND SAFETY RULES APPLICABLE

SUMMARY, OPEN FORUM

AND CLOSING

SAFE OPERATION AND

MAINTENANCE OF ELECTRICAL
EQUIPMENT

Key safety issues in O&M of electrical

installations
Isolation and earthing of equipment
Use of warning signs for operation and
maintenance
Safety while working in outdoor
switchyards and overhead lines
Work on underground cable systems
Use and upkeep of safety appliances in
substations and other electrical premises
Gas safety and ventilation
First-aid for burns and electric shock

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Practical Sessions

Have the training

delivered when and

where you need it.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Contact us for a
free proposal.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Practical

HV Cable Jointing and Terminations

ID CO
C P
Te YR
ch IG
no H
lo T
gi
es

for Engineers and Technicians

WHAT YOU WILL LEARN:

Basic principles of cable jointing and terminations

Construction of electrical power cables, different types of cables

for various voltage ratings and manufacturing aspects
Different types of connectors and connection methods

Methods of cable terminations and jointing and choosing an

appropriate type for every application
Importance of stress control and methods of stress
redistribution in joints and terminations

Important installation aspects in cable joints and terminations

International and national standards applicable
Type testing and routine testing

Failures, failure analysis and failure prediction

Future trends in cable technology and cable accessories

WHO SHOULD ATTEND:

Consulting Engineers
Electrical Engineers
Project Engineers

Maintenance Engineers
Power System Protection and Control Engineers
Building Service Designers
Data Systems Planners and Managers
Electrical and Instrumentation Technicians
Master Electricians

2.41

The Workshop

The Program

The range of voltage and capacity of power

transmitted through cables has shown a
steady increase over the years. Environmental
concerns, aesthetic issues, lack of
transmission corridors and difficulty in
routing overhead lines in crowded human
habitats are some of the reasons for the
explosive growth of cable technology well
into the extra high voltage range.

STRESS CONTROL

Need for cable joints and terminations

Cables - types and historic perspective
Types of insulation materials
Basic types of terminations and joints
Installation aspects - reducing the
number of joints by proper planning
Standards and testing
Failures

Effect of joints and terminations on stress

gradients
Areas requiring stress control:
terminations and joints
Basics of stress control approach:
geometric solutions, use of stress control
tubes, cones, high permittivity solutions,
use of stress control tapes

CABLES

JOINTING AND TERMINATION

PRACTICE

Basic construction
Conductor materials and configurations
Insulation materials for different
applications and voltages: PVC, paper
and XLPE
Use of screen in HV cables
Use of armour for earth continuity and
mechanical protection
Special aspects of single core cables
Voltage rating of cables and impact of
system earthing method on voltage
rating
Stress distribution in single core and
multicore power cables
Electrical breakdown of insulating
materials
HV cables using XLPE insulation
Treeing in XLPE and need for end sealing
of cables in storage
Basic manufacturing process

Kits for joints and terminations

Shelf life issues
Importance of matching diameter of
insulated conductor with kit
specifications in pre-fabricated kits
Preparation of cable for termination and
jointing
Connection
Reconstitution of cable properties
Continuity and earthing aspects
Sealing
Healthiness of joint/termination
Installation aspects for joints: buried
joints and markers for identification,
joints placed on cable structures with
other cables-safety issues, access for
repairs

ID CO
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Due to physical limits on cable lengths for

manufacturing and packaging, joints in cable
become inevitable, particularly in the context
of the utility sector. The cables also need to
be terminated at sending and receiving end
equipment, a very wide variety of them, in
utility as well as industry applications and
this calls for appropriate cable termination
accessories. Cable terminations and joints
form the weakest link in any distribution
system. Also, a failed joint in an underground
distribution system is much more difficult to
locate and repair compared to any similar
problem in overhead distribution systems.
This means that we should do our utmost to
achieve a good joint or termination, which
can give years of trouble-free service.

INTRODUCTION

The quality of a joint or termination depends

to a large extent on the skill of cable jointer.
The aim of a cable jointer must therefore
obtain a joint whose electrical properties are
as good as the original cable both in electrical
and mechanical terms. The design of cable
jointing and termination accessories is
based on this perception. Dependence on
operator-skill is sought to be reduced by
good choice and quality of jointing materials,
though such dependence cannot be totally
eliminated.
We will discuss these issues in this course
by looking at the fundamental aspects
involved so that the importance of the correct
execution of a termination or joint will be
brought home to those who attend the
workshop.

Pre-requisites

Some working knowledge of basic electrical

equipment is required, although this will be
covered at the beginning of the course. Reallife experience with such equipment and
hands-on testing will enable the workshop to
be placed in context.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

CABLE CONNECTORS

Materials
Types of connectors for cable
terminations and joints
Current path
Method of connections: soldering,
brazing, welding, crimping (compression)
and bolting
Comparison
Contact resistance
Preferred methods in practice for
different cable ratings
Contact of dissimilar materials and
galvanic effects, use of bi-metal
accessories

JOINTS AND TERMINATIONS THEORY

Basic approaches
Broad classification of joints/terminations
approach: prefabricated and site
fabricated from kits
Comparative merits
Prefabricated: pre-moulded (slip-on) and
cold shrink
Site fabricated: taped and compound
sealed, taped and cast resin sealed and
heat shrinkable
Additional requirements of outdoor
terminations
Reconstitution of cable properties:
insulating tape, semi conducting tape,
high permittivity stress control tape and
sealing against moisture
Connectivity for cable screen and armour
Mechanical protection of joints and
terminations

idc@idc-online .com

STANDARDS AND TESTING

International/national standards
Type tests
Limitations
Routine tests
Training and certification of personnel

TERMINATIONS TO EQUIPMENT
Terminations to indoor switchgear: need
for coordination with manufacturer of
switchgear, issues arising from multiple
terminations, design of switchgear
terminals
Terminations to electrical machines
Terminations of outdoor HV installations
Terminations to GIS installations
Importance of correct orientation of
terminations

FAILURES AND ANALYSIS

Reasons for failures

Documentation of work
Documentation of failures
Analysis of failures
Predictive approach: use of partial
discharge detection

NEW TRENDS

Reasons for increasing preference to

underground cables
New technologies for very high capacities
and voltages
EHV XLPE
High temperature superconductivity in
cables and likely impact on current
practices

SUMMARY, OPEN FORUM

and closing

www.idc-online .com

Operation and Maintenance of

ID CO
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Diesel Power Generating Plants

WHAT YOU WILL LEARN:

You will gain valuable know-how related to diesel generating plants

on:
Combustion processes and engine operation principles
Types and applications

Fuel and lube oil requirements

ISO ratings and terminologies

Engine components and their functions

Generator principles and construction

Plant layout requirements for single and multiple units

Associated control panels and operation
Testing and commissioning procedures

Plant performance troubleshooting techniques

Good maintenance practices

WHO SHOULD ATTEND:

Mechanical Engineers

Instrumentation and Control Engineers

Electrical Engineers
Project Engineers
Maintenance Engineers

Power System Protection and Control Engineers

Building Service Designers
Systems Planners and Managers
Electrical and Instrumentation Technicians

2.43

The Workshop

The Program

Diesel generating plants have an important

role in power plants as well as in industries
and commercial installations to meet
continuous and emergency standby power
requirements
for
d a y
to day use. Good knowledge of basic
operation principles, layout requirements,
associated components and maintenance
practices for diesel power plants help the
career development of many engineers and
technicians in today's demanding world.
Whatever your role in industry - designer,
purchase engineer, installation contractor or
maintenance engineer, a solid understanding
of diesel power plants is always useful.

DIESEL GENERATING SETS

Power generation methods

AC power vs DC power
Single phase and three phase AC power
Prime movers
Power plant types
Diesel power plants
Advantages of diesel power generation
Engine types

DIESEL TECHNOLOGY AND

CLASSIFICATIONS

Basic engine processes

Reciprocating and spark ignition engines
Diesel and dual fuel engines
Speed and service classifications

BASIC ENGINE DESIGN AND

RATINGS

Design characteristics and formulas

Turbo charger
Ambient conditions
ISO ratings
Performance, efficiency and engine speed
Fuel combustion methods

Coupling requirements
Skid mounting
Layout requirements
Paralleling of multiple DG sets
Standard control panels
Interconnections

OTHER COMPONENTS

Starting methods and characteristics

Battery sizing
Step load requirements
Standby requirements
Auto start and auto transfer schemes
Auto transfer switches

DG PLANT LAYOUTS

Industrial applications
Power generation plant applications
Single and multiple sets
Fuel storage requirements
Air intake system
Exhaust system
Auxiliary power requirements
Typical power schemes

ID CO
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This workshop is designed to familiarize you

with various aspects of diesel generating
power plants for practical application.
Examples are taken from various industrial
standard practices regarding the construction,
layouts, application and maintenance
procedures followed for reliable and trouble
free operation of diesel power plants. The
various tests conducted during commissioning
and maintenance checks to ensure proper
and long term operation of diesel power
plants are covered along with some essential
systems such as fuel oil layouts, lube oil
requirements and control circuitry.

INTRODUCTION

Pre-requisites

Some working knowledge of diesel power

plant and testing on electrical items may be
of use, although this will be covered in the
workshop. Real-life experience with diesel
generating units and use of such equipment
and hands-on testing will enable the
workshop to be placed in context.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

FUEL OIL SYSTEMS AND LAYOUTS

Crude oil, HSD, LDO and heavy fuels

Economics of fuel selection
Pressure and temperature characteristics
Viscosity
Specific heat and temperature
Specific fuel consumption
Filters, heaters, nozzles and igniters
Emission control and storage
requirements
Fuel system layouts and components

LUBE OIL SYSTEMS

Lube oil specification

Lube oil consumption in diesel engines
Typical lube oil system layouts
Viscosity and temperature
Lube oil filters and heaters

TESTING AND COMMISSIONING

Factory tests
Pre-commissioning checks and tests
Performance monitoring
Fuel and lube oil consumption checks

OPERATION AND MAINTENANCE

Safety requirements
Operation monitoring based on
applications
Maintenance techniques
Spares and inventory management
Inspection
Engine overhaul and repair
Troubleshooting

SUMMARY AND CLOSING

GENERATORS

Principle of operation
Major components
Generator types
Low voltage and medium voltage
generators
Typical circuitry
Load types and generator sizing
System earthing methods
Faults and protection
Performance evaluation and testing

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
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Te YR
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energy efficiency, design,

engineering and auditing

YOU WILL LEARN HOW TO:

Establish an energy savings strategy for your organisation

Put together practical energy efficiency plans
Use the energy savings toolkit and checklist
Conduct a simple energy audit

Read and interpret data from measurement equipment

Interpret and analyse case study data

Improve employee working conditions and productivity

Assist in the reduction of greenhouse gases

Set demand-side energy management strategies

Decide the importance of choices with energy suppliers

WHO SHOULD ATTEND:

Energy managers

Project and consulting engineers

Electrical contractors and engineers

Electrical inspectors and maintenance engineers

Building service designers
Electrical and instrumentation technicians

2.47

The Workshop

The Program
Management Overview of
Energy Efficiency
What is energy efficiency?

Energy and environment

Energy forms and conversion
Energy sources and sinks
Channelling waste energy into useful
output
Energy audit and principles

Case Studies
Schools, mines and factories
Practical Exercises
Simple checklist on doing an energy
audit

Alternative energy sources

Fossil fuels, green energy and fuel cells
Alternatives - renewable energy and
hydrogen

Main forms of energy

Energy efficient practices in

electricity use

High efficiency motors

Better T&D practices
Role of power factor
Motor rating and efficiency correlation
Variable speed drives as energy-savers
Lighting efficiency
Efficient luminaires
Use of daylight and intelligent buildings

Energy efficiency in climate

control applications

Need for climate control

Efficiency in heating and cooling
Reducing heat loss
Building design features to improve
cooling
The paradox of cooling
Temperature reduction but no energy
recovery
Use of waste heat for cooling
Comparison between compression
refrigeration and absorption chillers

ID CO
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Reducing the energy costs at your facility

must be one of the most effective and
achievable strategies for lowering the
operating costs. This workshop gives you the
practical tools to identify and implement
programs and projects to reduce energy
consumption in the most effective and
practical ways. You will be provided with the
skills and latest knowledge on proven methods
of making real savings in your energy bills.
You will be greatly surprised at the levels of
energy loss and the poor efficiency of some of
the devices in your facility - some that
consume power even when the facility is not
operational. These factors are costing your
organisation money. Energy bills are generally
at least 20% of the running costs of a business,
so reductions in these bills are directly
responsible for better profits. This workshop
teaches you the fundamental principles of
energy efficiency by assessing wastage, cost
of energy and looking at the benefits you will
accrue from improving your facilities
efficiency.

Pre-requisites

A working knowledge of basic engineering

principles is required. Adequate industrial
experience in operating and maintaining
energy intensive equipment and processes
will enable better appreciation of the topics
discussed.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
You will perform calculations and examine
case studies to practice many of the
principles covered and have the opportunity
to use software for some energy saving
solutions.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Energy converted to electricity for direct

use
Electricity in metal smelting
Use of fuels for motive power
Direct use of fuels for heating
applications
Use of fuels as part of a process
Conversion equipment and challenges

Electrical energy
generation

Electricity as the preferred energy carrier

Conversion systems for electrical energy
Commonly used fuels
Improving conversion efficiencies
Better equipment
Waste energy recovery and process
improvements
Cogeneration for better efficiency
Combined cycle process for gas turbines

ELECTRICAL ENERGY USAGE

Sectors using the major portion of

electricity
Better efficiencies in electricity usage
Uses of electricity
Motive power
Lighting, space heating and cooling

INTRODUCTION TO ENERGY
AUDITS

Know your process, fuels and major

systems
Compare energy usage
Energy use and cost index
Lighting and HVAC energy use
Data forms and collection
Walk-through inspections

AUDIT AREAS AND ESSENTIAL

INSTRUMENTS AND SOFTWARE

Building and HVAC systems

Motor and boiler systems
Water systems and lighting
Heat recovery areas

FINANCIALS AND COSTINGS

Energy audit reports and economic

measures
The time value of money
Cost and benefit analysis
Rate of return and life-cycle costing
After tax cash flows

summary, open forum

and closing

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
C P
Te YR
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Critical Power Supply Options

and Planning of High
Availability Supplies

You Will learn How To:

Critically assess the different uninterruptible power supply

options
System design for high reliability power

Deal with harmonics generated by loads

Perform best practice design on critical power distribution

systems
Identify the level of failure-proofing for specific equipment

WHO SHOULD ATTEND:

Automation engineers

Control engineers

Distribution planning engineers

Electrical and instrumentation engineers

Engineering managers
Facilities managers
Operators and technicians
Plant engineers

Anyone actively involved with implementing or optimising a

critical power supply system

2.47

The Workshop

The Program

Our dependence on electricity is growing

and even a few seconds or minutes of power
disruption has become unthinkable. An
unscheduled interruption can cause
immense damage and loss of life. While it is
impossible to guarantee 100% availability of
power at all points in any system, vulnerable
sections can be provided with alternative
critical power supply equipment to ensure
reliable power availability, thereby avoiding
the problems of power interruption.

Problems arising from power failure in

industries
Tolerance for interruptions and voltage/
frequency excursions
- CBEMA, ITIC and ANSI voltage
sensitivity curves
Distinguishing between standby power,
emergency power and critical power
Different solutions for critical power
needs
- Sag support systems for transient
disturbances-Electrical and
electromechanical
- Critical power supply systems to cater
to outages
Reliability assessment
- What is MTBF?
- What is MTTR?
- Arriving at overall reliability
expectation from a critical power
supply system

CONFIGURING A POWER
DISTRIBUTION SYSTEM FOR
CRITICAL LOADS
Integrating normal and critical power
needs in the distribution network
Multiple units nearer the consumer vs.
larger centralised units
Capacity and voltage planning for critical
power in large industries
Sizing of critical power supply
Paying attention to motor starting
requirements and accompanying voltage
sag
Beware of harmonic producing loads and
their effect on rated capacity of power
supply
Tackling harmonics produced by static
UPS
Typical distribution scenarios in large
industrial systems for integration of
critical power
- Ensuring that process does not
abnormally terminate due to noncritical load interruption
- Safe shutdown requirements
- Control room power and escape route
lighting
High reliability systems- 4-tier model
Use of redundant modules and impact on
availability

ID CO
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This workshop shows you how to ensure

reliable power supply to critical systems
using various available options. The
solutions can vary from the simple diesel
generating set as standby sources to
superconducting sag support systems.
Nascent technologies like fuel cells have
matured and are fast becoming mainstream
solutions. Of course, all this comes at a
price, which means that the solution must
match the actual needs without excessive
insurance and thereby optimise investments.
This workshop will discuss how to save
dollars by finding the right solution to your
needs so that you invest just what is needed
and where it is needed.

CRITICAL POWER NEEDS AND

SOLUTIONS

Another major aspect is to ensure that the

critical power supply is itself very reliable.
This will need suitable redundancies and a
well-engineered distribution system so that
when the need arises they cut-in and take
over the load without any hitches. This
workshop will also briefly look at the design
issues involved in planning the distribution
of critical power by deploying state-of-the
art control devices such as static transfer
equipment.
If you are responsible for maintaining power
availability in your facility, this workshop is
something, which you simply cannot afford
to miss. And all you need is to just invest
half-a-day of your time to gain state of the
art know-how from our expert instructor.

Pre-requisites

Working knowledge of electrical engineering

and hands-on work with power distribution
systems in a plant environment with critical
processes is desirable. Real-life experience
with critical power supply sources such as
Uninterrupted Power Supply (UPS) systems
will further enable the workshop to be
placed in context.

Critical power supply

equipment

Critical power supply

- Stored energy systems using flywheel/
compressed air
- Rotary power supply systems
- Battery-backed static UPS
- Fuel cells as source of power
Stored energy system
Rotary UP system for critical supply
Battery-backed UPS system
Fuel cells basics
Fuel cell applications for critical power
Choosing the right option
- What is the quantum of load that is
considered critical?
- What are the characteristics of this load
(technical criteria)?
- Power system reliability and cost of
outage
- Comparing the costs (upfront,
operating both in short term and long
term)

Static Transfer systems for

critical power supplies
UPS as a separately derived source
Need for neutral isolation between input
and Output
Multiple sources with independent
neutral connections
Basics of static transfer
Static transfer applications in practical
critical power systems
Neutral management
Comparing 3-pole and 4-pole static
transfer equipment
Standards governing static transfer
systems
EMC and performance compliance
aspects

SUMMARY, OPEN FORUM

AND CLOSING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

Electrical Safety Techniques

ID CO
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for Industry

you will Learn how to:

Identify the hazards in operating and carrying out maintenance

work in different substations (including batteries)
Identify the various statutory or legal regulations/acts

Appreciate the basic theoretical aspects involved in electrical

safety
Understand the importance of proper design and selection of
electrical equipment
Gain a clear understanding of the procedures/practices adopted
for safe working
Appreciate the role of regular periodic inspection and planned/
condition based maintenance
Draw up procedures for reporting accidents and carrying out
investigations

WHO SHOULD ATTEND:

Instrumentation and control engineers

Mechanical engineers
Consulting engineers

Electrical engineers
Project engineers

Maintenance technicians and engineers

Power system protection and control engineers
Building service designers
Data systems planners and managers
Electrical, mechanical and instrumentation technicians
Any staff working within an industrial environment will benefit from
this training, all staff that may enter, pass by or have any direct or
indirect contact with electrical infrastructure should attend.
2.49

The Workshop

The Program

A number of serious accidents and fatalities

occur every year in industry due to accidents
involving electricity, taking a huge financial
and human toll. The dangers and risks from
electrocution, shock, explosions and arc blast
can never be eliminated but you can take
definite steps to protect yourself and your
co-workers.

Electrical hazards
Requirements for safety
Operative training
Personnel levels of competency
Safety documentation
Work on live Systems, close to live systems

ELECTRICAL SHOCK AND METHODS

OF SHOCK PREVENTION

Shock - direct and indirect contact

Touch and step potential
Effects of shock on the human body
The deadly combination of heights and
electric shock
Locations of increased shock risk
Principles of shock protection
First-aid for burns and electric shock
Earth leakage circuit breakers
Role of electrical insulation in safety

HAZARDS DUE TO ELECTRICAL

ARCING AND HEATING

SAFE OPERATION AND

MAINTENANCE OF ELECTRICAL
EQUIPMENT
Key safety issues in O&M of electrical
installations
Policies of operational and safety locking,
safety notices and remote operation
Use of warning signs for operation and
maintenance
Personnel protective equipment
Work on underground cable systems
Use and upkeep of safety appliances in
substations and other electrical premises
Gas safety and ventilation
Switching schedules
Electrical testing procedures
Need for periodic inspection and
maintenance for safe operation of electrical
equipment

EARTHING AND BONDING

Objectives of earthing
Earthing of power supply systems and its
safety implications
Role of earthing of equipment enclosures
(protective earthing) in human safety
Neutral earthing of electrical supply systems
Thermal capability
Use of protective metallic conduits for
earthing conductors
Objectives of bonding
Equipotential bonding

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Safety should be built into the design of

electrical equipment and followed up with
proper installation, operation, maintenance
and periodic inspection. Electrical safety is
not just a technical issue. Accidents can only
be prevented if appropriate safety procedures
are developed and enforced. This includes
complete familiarity with equipment and
systems often imparted through structured
training to each and every person who
operates or maintains the equipment. In this
workshop, we will take a look at the theoretical
aspects of safety as well as the practical
issues including the statutory and safetytraining related aspects. This know-how will
certainly enable participants to deploy
appropriate safety procedures in their
workplace and improve their safety record.

PRINCIPLES OF SAFETY RULES

Practical Sessions

Throughout the workshop, participants will

work through a number of practical exercises
and case studies to support the theory
presented during the workshop.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Thoroughly enjoyed the

workshop and was impressed
with the instructor's knowledge
and experience.

Stephen Miller, Energy Australia

Arc flash definition

Arc blast
Hazards due to arcing/flashover
Effects of arc flash on humans - physiological
effects, tissue damage, internal organ damage,
burns, fibrillation, curable 2nd degree burn,
arc blast pressure, sound pressure
Reducing arc-flash hazards - minimise risk
with good safety practical, consideration for
new equipment, reduce the available fault
current, increasing worker distance, faster
tripping time
Hazards from use of electrical equipment in
explosive environment
Hazards due to high temperature in
electrical equipment

STATIC ELECTRICITY AND

PROTECTION

What is static electricity?

Generation of charge
Common examples of static build up
Energy of spark and its ignition capability
Dangers of static electricity buildup
Control of static electricity
Static electricity danger in un-energised
overhead lines
Assessment of static risks and planning
prevention

SAFETY ASPECTS IN ELECTRICAL

EQUIPMENT DESIGN AND
SELECTION

Design of equipment for ensuring safety

Equipment ratings and fault withstand
capability
Containing and deflecting arcs during
equipment faults
Role of equipment enclosures in ensuring
safety-discussion on motor terminal boxes
as an example
Degree of protection and its significance in
safety
Damage due to overload or excessive fault
current in electrical conductors
Types of insulation and their temperature
limits
Protecting electrical systems by over current
protective devices (relays, releases, fuses,
circuit breakers)
Detection of hot spots by infrared sensors
or viewing devices
Equipment selection-its contribution to safe
operations
In-built earthing devices and interlocks
Special requirements to be observed in
restrictive conductive locations (IEE Wiring
Regulations)

idc@idc-online .com

SUBSTATION SAFETY

Safety while working in outdoor switchyards

and overhead lines
Special precautions when working on
switch gear
Substation check list
Fire protection in substations

SAFETY IN BATTERY INSTALLATIONS

Hazards involved in lead-acid battery
installations
Premises used for housing lead acid
batteries
Transportation and storage
Installation and commissioning
Charging and storage
Dismantling and disposal
Protective clothing

REGULATIONS GOVERNING
WORKPLACE SAFETY (COUNTRYSPECIFIC)

Evolution of safety-related legislation

Safety at work act
Electricity at work regulations
Electricity supply regulations
Electricity usage regulations
Special regulations for hazardous areas
(ATEX or other applicable rules)
Codes of practice (non-mandatory
guidelines)

ORGANISATIONAL REQUIREMENTS
OF SAFETY
Statutory requirements for working in
electrical installations
Competency and authorisation
Responsibility of employer and employee in
regard to electrical safety at work
Safety organisation within the company
Accident reporting, investigation, analysis
and prevention
Safety awareness promotion among
workforce and importance of appropriate
training

www.idc-online .com

Emergency POWER SUPPLIES:

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Electrical Distribution Design,

Installation and Commissioning

What you will learn:

Understand the level of failure-proofing that specific equipment

may require
Know the various available options of critical power supply
systems
Evaluate options objectively

Specify the solution that is the best and most economical for
your needs
Design a suitable power distribution system for emergency
power
Manage the installation, commissioning and maintenance of
the distribution system

WHO SHOULD ATTEND:

Power System Protection and Control Engineers

Electrical Engineers

Maintenance Engineers

Building Service Designers

Project Engineers

Systems Planners and Managers

2.51

The Workshop

The Program

Power is becoming a commodity that cannot

be taken for granted. Our dependence on
electricity is growing and even a few hours
of power disruption has become unthinkable.
While it is impossible to guarantee 100%
availability of power at all points in any
system, vulnerable sections can be provided
with alternative emergency power supply to
ensure more reliable power availability,
thereby avoiding the problems of
interruption. This workshop has the objective
of teaching the basic facts about ensuring
reliable power supply to critical systems
using various available options.

STATIC UPS SYSTEMS

Configuration
Types of static UPS systems
UPS metering, indications, alarms and
protection
Power quality and UPS
UPS configurations
Redundant UPS configuration and
building high reliability power supplies

Electrical parameters
What is power quality?
Problems - effects and mitigation
Reliability
Available solutions and making the right
choices

VOLTAGE VARIATIONS

Voltage amplitude
Voltage sag and its effects
Equipment sensitivity
Control measures
Voltage improvements, fluctuations and
flicker

CONTINUITY OF POWER

Power failure
Needs of equipment
Understanding failures
Interruptions and voltage/frequency
excursions
Uninterrupted, emergency and standby
power
Redundancy and automation

NEW TECHNOLOGIES
Problems in existing technologies
Maintenance issues on prolonged
operation
Environmental problems
Fuel cell
Micro turbine

FUEL CELL

Historical perspective
Operating principle
Types of cells available and comparison
Fuel cell system for backup poweroverview
Comparison with battery powered UPS
Case study

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The solutions can vary from the simple

diesel generating set as standby sources to
super-conducting energy sag support
systems. Newer technologies like fuel cells
are now available and are fast becoming
mainstream solutions. This workshop will
discuss how to save costs by finding the
right solution to your needs so that you
invest just what is needed and where it is
needed. This workshop will also briefly look
at the design issues involved in planning the
distribution of emergency power.

POWER QUALITY

Pre-requisites

Working knowledge of electrical engineering

and hands-on work with power distribution
systems in a plant environment with critical
processes is desirable.
Real-life experience with diesel generating
units and other critical power supply sources
such as Uninterrupted Power Supply (UPS)
systems will further enable the workshop to
be placed in context.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

DIESEL TECHNOLOGY AND

CLASSIFICATIONS

Basic engine processes

Reciprocating engines
Spark ignition engines
Diesel and dual fuel engines
Speed and service classifications

BASIC ENGINE DESIGN AND

RATINGS

Design characteristics and formulas

Turbo charger
Ambient conditions
ISO ratings
Performance and efficiency
Engine speed
Fuel combustion methods

CONVENTIONAL UNINTERRUPTED
POWER SUPPLY
Main classification

On-Site Training

- Rotary and static

Rotary, advanced and hybrid UPS

systems

Save over 50% by

having an IDCworkshop
presented at your
premises.

Conventional gas turbine power plant

Efficiency issues and combined cycle
power generation
Comparison of micro turbines with
conventional turbines
Typical micro turbine based standby
power unit
Case study involving critical process
application

CONFIGURING POWER
DISTRIBUTION SYSTEM FOR
EMERGENCY LOADS

Integrating emergency and critical power

needs in the distribution network
Multiple units nearer the consumer vs.
larger centralised units
Paying attention to motor starting
requirements and accompanying
voltage sag
Typical distribution scenarios in large
industrial systems for integration of
emergency power
Automation of starting, load changeover
and shutdown

PARALLEL OPERATION AND TIE

PROTECTION
Parallel operation between emergency
sources
Load sharing between sources
Parallel operation of emergency source
with normal source
Utility stipulations and local codes
Issue of tie-line separation
Static transfer switch and its application
in critical power installations

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.

SUMMARY, OPEN FORUM

AND CLOSING

Contact us for a
free proposal.

idc@idc-online .com

MICRO TURBINE

www.idc-online .com

Power Cables:

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OPERATION, Maintenance,
Location and Fault Detection

what you will learn:

Participants can use the skills and knowledge gained in this course
to select and operate Power Cables and to perform testing and
preventative maintenance on power cable to ensure safety and
longer equipment life.

WHO SHOULD ATTEND:

Anyone associated with power cable operation, maintenance,

location and fault detection techniques. The workshop will also
benefit those working in system design as well as site
commissioning, maintenance and troubleshooting.
Typical personnel who would benefit are:
Operations Personnel

Electrical Maintenance Technicians and Supervisors

Process Control Engineers
Service Technicians

Maintenance Personnel

2.53

The Workshop

The Program

Faults in underground cable may cause loss

of supply to customers and loss of revenue
for suppliers so it is imperative that the fault
location process is efficient and accurate to
minimise excavation time, which results in
reducing inconvenience to all concerned.
For fault locating to be efficient and accurate
technical staff need to have expert knowledge
accompanied with experience in order to
attain service reliability.
This course is designed to ensure that those
responsible for the selection, laying,
operation, maintenance and monitoring of
power cables understands the technical
issues involved and comply with relevant
specifications and requirements.

Pre-requisites

Historical perspective
Development of cables for LV and HV
systems
Role of cables in modern power
distribution systems
Cable accessories and their role
Cable failures and installation practices
Detection of faults

BASIC THEORY

Construction
Conductor materials and configurations
Insulation materials
Use of screen in HV cables
Use of armor for earth continuity and
mechanical protection
Special and single core cables
Voltage rating
Stress distribution in single core and
multicore power cables
Electrical breakdown of insulating
materials
HV cables using XLPE insulation
Treeing in XLPE and need for end sealing
of cables
Manufacturing process
Standards for cables

JOINTING AND TERMINATIONS

PRACTICE
Kits for joints and terminations
Shelf life issues
Matching diameter of insulated
conductor with kit specifications in prefabricated kits
Preparation of cable
Connection
Reconstitution of cable properties
Continuity and earthing aspects
Sealing
Healthiness
Installation aspects for joints

COMMISSIONING AND PERIODIC

TESTING

Review of codes for testing requirements

Drum length checks
Post installation checking
Pre-commissioning and periodic tests
Tests as tools for condition monitoring
and early failure alarm
HV tests using DC and very low
frequency AC
Partial discharge tests and mapping of
results
Dielectric dissipation factor
measurements
Micro destructive and non-destructive
tests for life assessment
Operation and maintenance of cables

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A fundamental knowledge of basic electrical

concepts would be useful.

INTRODUCTION

Practical Sessions

Study of manufacturer's specifications

and data of typical cable types
Examples of selection and sizing of
cables in actual applications

Study of manufacturer's information for

different types of MV cable accessories
Case studies of investigations of cable
systems for residual life assessment
Study of manufacturer's application
notes of typical test instruments

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Practical Session

SELECTION OF CABLES AND

INSTALLATION

Criteria for selection

Cable sizing
Installation - directly buried
Installation - conduits
Installation on structures
Special needs Eg. bending radii

Practical Session

JOINTS AND TERMINATIONS

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Basic approach
Broad classification
Comparative merits
Pre-fabricated
Site fabricated
Additional requirements of outdoor
terminations
Reconstitution of cable properties
Special joints
Mechanical protection
Stress control

Practical Session

Practical Session

FAILURE MODES AND FAULT

DETECTION

Types of failures
Reasons for failures
Fault location
Electrical tests for detection of cable
faults
Safety issues in fault location
Analysis of failures

Practical Session

NEW TRENDS IN CABLE

TECHNOLOGY

Increasing preference to underground

cables
New technologies for very high capacities
and voltages
EHV XLPE in sub transmission systems
High temperature superconductivity in
cables

SUMMARY, open forum

and CLOSING

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

ELECTRICAL WIRING STANDARDS -

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- IEE BS 7671:2008+A1:2011 Edition

WHAT YOU WILL LEARN:

Up to date information and training on the current edition of

BS7671:2008+A1:2011, requirements for electrical installations
In depth teaching on all aspects of the regulations and their
application with many practical examples and sample design
calculations
References to safety, maintenance, inspection and testing
The course also provides a summary of some of the basic
principles necessary for a good understanding of electrical
installation technology

WHO SHOULD ATTEND:

Building services engineers

Electrical apprentices

Electrical design staff

Electrical engineers

Electrical trades persons

Engineering managers
Graduate electrical engineer trainees
Maintenance and shutdown planning staff
Maintenance managers
Private electrical contractors

2.55

The Workshop

The Program

Internationally there is steady progress

towards alignment of the electrical wiring
standards for low voltage installations. This
is reflected in the IEC standard 60364, the
European Harmonisation Document HD
60364 and the UK IET Wiring Regulations
17th edition, now also known as British
Standard BS7671:2008+A1:2011, all of which
share a common format.
Each day will be divided into sessions with
practical examples of each of the concepts
discussed. Delegates will have the
opportunity to raise relevant issues and
debate these in the sessions.

EARTHING ARRANGEMENTS

Structure of international and UK wiring

regulations
Foundation electrical principles and
terminology
Scope of regulations
Requirements for safety

Calculation of protective conductor sizes

Bonding requirements
Supplies for safety services

PROTECTION FOR SAFETY

Shock
Basic and fault protection
Effects of shock on the human body and
livestock (IEC 60479)
Electrical hazards
Calculation of disconnection times
Voltage disturbances and protection
against overvoltage
Operating gangways
Measures against electromagnetic
disturbances

CABLE PROTECTION
Over-current
- Cable sizing
- Neutral conductors
Selecting protective devices
Calculation of adiabatic heating effect
Effect of harmonic currents thermal
effects
Parallel cables

SPECIAL INSTALLATIONS OR
LOCATIONS
Locations of increased shock risk,
including:
- Medical locations
- Bathrooms
- Swimming pools and fountains
- Saunas
- Confined spaces

INSPECTION AND TESTING

Test Instruments
Certification including reference to new
documentation

MAINTENANCE CONSIDERATIONS
SAMPLE DESIGN CALCULATIONS

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The programme below sets out the various

sessions and the content of the sessions.
Delegates should note that the order of the
sessions and content will be varied according
to the needs of the delegates. Practical
worked examples will be interspersed with
the slides used. There is always time during
coffee, lunch and tea breaks for further
discussion.

INTRODUCTION TO REGULATIONS

Pre-requisites

You will need a fundamental understanding

of electrical systems. We will provide this
material to you if you feel you would like
some further pre-course reading.
Please bring a calculator (or computer) and
pen along to the course to assist with the
calculations.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. There will be at least eleven
exercises (with many sample calculations
and designs to be undertaken) to re-inforce
the knowledge gained including an in-depth
study on the second day.

summary, open forum

and closing

SELECTION AND ERECTION OF

EQUIPMENT

Wiring systems
Switchgear
Characteristics and limitations of fuses
and circuit breakers
Breaking capacity
Co-ordination and discrimination
between devices
Calculation of fault levels

To gain full value from this workshop,

please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

ID CO
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Electrical Wiring Standards

- AS/NZS 3000:2007

YOU WILL LEARN how to:

Identify the various sections and requirements of the standards

Understand these requirements and apply them in your day-today functioning
Appreciate the importance of fulfilling the requirements for safe
use of electrical equipment and systems
Have a clear knowledge of earthing and its importance in safety
Make simple calculations to check the adequacy of conductors
and protective earthing components to ensure safe operation
List the periodic checks and verification measures to be carried
out in an electrical installation as mandated by the standard

WHO SHOULD ATTEND:

Building service designers

Electricians

Consulting engineers

Instrumentation and control

engineers

Data systems planners and

managers

Maintenance engineers

Electrical and
instrumentation technicians

Power system protection and

control engineers

Electrical contractors

Project engineers

Electrical engineers

Safety professionals

Electrical inspectors

2.57

The Workshop

The Program

This workshop aims to familiarise the

participants with the requirements laid
down in the standard AS/NZS 3000:2007,
commonly known as Australia-New Zealand
Wiring Rules. For those installations covered
in the scope of this standard, its provisions
are mandatory and must be followed. Any
engineer involved in planning and design of
electrical systems, their installation or
maintenance must have a clear idea about
the various requirements contained in the
standard.

INTRODUCTION

The primary purpose of this standard, like

many of its various other equivalent national
standards, is to ensure the safety of
personnel against the dangers arising from
the use and handling of electrical equipment
and appliances. The introductory modules of
this workshop outline the basic principles
that should be understood for a better
appreciation of the standard. These include
modules, which illustrate the calculation for
the power demand of a system and the
computation of earth fault current as
discussed in the appendices of the standard,
which are informative in nature but yet are
very important in making an electrical
system safe for operation. The actual
provisions of the standard are then discussed
in detail in the subsequent modules.

AS/NZS 3000 STANDARD-SCOPE

AND DEFINITIONS

Evolution of electrical distribution systems

Electrical insulation
Current limits of conductors based on
insulation
Current ratings based on installation
methods
Earthing and its importance in safety
Methods adopted for system earthing
Earth fault sensing methods
Other hazards
AS/NZS 3000:2007 preface and contents

SELECTION AND INSTALLATION

OF APPLIANCES AND
ACCESSORIES

Protection against thermal effects

Socket outlets
Lighting equipment and accessories
Cooking appliances
Heaters
Motors
Capacitors
Transformers
Batteries

REQUIREMENTS FOR EARTHING

IN ELECTRICAL INSTALLATIONS

Earthing arrangements
Multiple Earthed Neutral (MEN) system
Earthing conductors
Earthing system components
Equipment earthing and equipotential
bonding
Earth fault loop impedance
Earthing requirements for other (nonelectrical) systems

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Application areas
Learning a few terms
Alterations, additions and repairs
alternative arrangements
Protection for safety
Design of an electrical installation
Selection and installation of electrical
equipment
Inspection and testing

PRACTICAL WORK
CALCULATIONS

Pre-requisites

A working knowledge of basic electrical

engineering
principles
is
required.
Experience in planning, installation and
maintenance of electrical equipment and
systems will enable the workshop to be
placed in context.

SELECTION AND INSTALLATION OF

SWITCHGEAR AND CONTROLGEAR
Arrangement and control of electrical
installation
Devices for isolation and switching
Fault protection
Devices for protection against overcurrent
and short circuit
Coordination and discrimination
Protection against earth leakage current,
overvoltage and undervoltage
Switchboards
Circuit arrangements, protection
coordination, limits of LV feeder lengths
for proper earth fault detection (as per AS/
NZS 3000:2007)
Calculating the demand of electrical
systems for proper conductor sizing (as
per AS/NZS 3000:2007)
The degree of protection of an item of
enclosed equipment (as per AS/NZS
3000:2007

PRACTICAL WORK
CALCULATIONS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Please bring your copy of the AS/
NZS3000:2007 Wiring Rules to the
workshop.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

SELECTION AND INSTALLATION

OF WIRING SYSTEMS

Types of wiring systems

External influences
Current-carrying capacity
Sizing of conductors
Voltage drop considerations in sizing
Electrical connections
Identification of wires and cables
Installation
Enclosure of cables
Underground wiring systems
Aerial wiring systems
Cables supported by a catenary
Emergency systems
Busbar trunking systems and rising mains
Earth sheath return system
Sinking depth and sizes of support
structures for private aerial lines (as per
appendix D of AS/NZS 3000:2007)
Application of the WS classification of
wiring systems in accordance with AS/
NZS 3013 (as per appendix H of AS/NZS
3000:2007)

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REQUIREMENTS FOR SPECIAL

ELECTRICAL INSTALLATIONS/
LOCATIONS
Locations containing baths, showers or
other fixed water containers
Swimming pools, paddling pools and
spa pools or tubs
Locations containing sauna heaters
Refrigeration rooms
Locations where general hosing down
operations are carried out
Fountains and water features
Extra-low voltage electrical installations
High voltage electrical installations
Hazardous areas
Emergency systems
Requirements for electrical installations
operating at high voltage as per
appendix K

TESTING AND VERIFICATION

REQUIREMENTS OF THE
STANDARD

Visual inspection
Testing
Common inspection and test methods
for low voltage, Multiple Earthed
Neutral (MEN) electrical installation as
per AS/NZS 3017
Periodic verification of existing
electrical installations of low voltage AC
supply system as per AS/NZS 3019

summary, open forum

and closing

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Electrical Drawings
and Schematics

What you will learn:

Various types of electrical drawings and their applications

Planning electrical drawings, selecting a proper (paper) size for
each type of drawing and the most appropriate scale to be used
Use of industry-standard symbols/representation approach
Formulation of company standards for drawing naming and
preparation
Drawing office organisation and workflow procedures

Use of CAD tools and linkage to CAM for manufacturing

Challenges in the management of CAD drawings and future
possibilities

WHO SHOULD ATTEND:

Design engineers

Design technicians

Drawing office managers

Facility managers and technicians

Installation engineers
Maintenance engineers
Maintenance technicians
Manufacturing engineers
Project engineers
Testing engineers

2.59

The Workshop

The Program
ENGINEERING DRAWINGS - AN
INTRODUCTION
Drawings their relevance to engineering
Origin of worldwide standards in electrotechnology
Purposes served by different types of
drawings
Standards in a drawing office
Organisation of a typical drawing office
Printing and distribution different
options for making multiple copies

COMPONENTS OF A DRAWING,
DRAWING SIZES AND SCALES
What is a typical engineering drawing
made up of?
Various categories of electrical drawings
Planning a drawing
Sizes/arrangement
Single and multi-sheet drawings
Use of drawing scales
Multi-scale drawings
Title block in a drawing and what should
a title block contain?
Legend block
Bill of materials block
Drawing notes block
Revision history, revision numbering and
use of revision marks

LOGIC DIAGRAMS

Purpose
Typical examples
Use of symbols
Applications
Logic diagrams spread over a number of
sheets
Cross-referencing
Practical exercises involving reading and
interpretation of logic diagrams

CABLING AND WIRING DRAWINGS

Purpose
Typical examples
Sub types of cabling drawings
Cable layouts
Cable schedules
Tray/conduit schedules
Control cable interconnections
Panel internal wiring
Applications
Conventions used
Practical exercises involving reading and
interpretation of cabling drawings

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It is often said that drawing is engineers

language.
Drawings
are
used
to
communicate and share information
between different teams of engineers; the
design engineer who conceptualises an
equipment or system, the production
engineer who plans the steps in
manufacturing the required components
and subsystems, the assembly engineer
who puts the components together, the
testing engineer who tests the complete
system, the installation engineer who
installs the system or equipment and the
maintenance engineer who is responsible
for its upkeep. To all these engineers with
diverse backgrounds and expertise, a
drawing should convey precise and identical
information. This calls for standardised
methodologies, conventions and approach
in preparing drawings. This workshop will
cover all these aspects with respect to
engineering drawings in general and
electrical drawings in particular. Various
types of electrical drawings and their
application, the steps in planning a drawing,
selection of drawing size and scale, use of
standardised symbols etc will be described
in detail with commonly used examples
from industry practice.
Computer Aided Drafting (CAD) has brought
about a major change in the way drawings
are prepared and has caused a phenomenal
improvement in drawing office productivity.
No organisation can afford to use the older
manual methods of preparing drawings
today. Apart from reuse and easy
modification of existing drawings to create
new ones, complete or partial automated
drawing preparation has also become a
possibility. The workshop discusses the
advances made in this field and the links
between drawings and manufacturing using
3D visualisation tools and Computer Aided
Manufacturing (CAM) approach.

Use of CAD-CAM tools presents its own

challenges in the way drawings are stored,
shared between different groups of users
and revised for reuse. The workshop also
covers these aspects and takes a look at
future possibilities in the way drawings will
be used to disseminate information.

Pre-requisites

A basic knowledge of electrical engineering

is expected. It will be assumed that the
participants use some types of electrical
drawings in their day-to-day work but no
previous exposure to drawing preparation
is essential, as the course starts right from
the basics.

SYMBOLS USED IN ELECTRO

TECHNOLOGY AND GOVERNING
STANDARDS

Which are the drawings that need

symbols?
Symbols as per electro-technology
standards particularly IEC
Non-standard symbols when and why?
Use of colours and line types in
representing various services
Company standards for drawings why?

SINGLE LINE AND 3-LINE

DIAGRAMS

Purpose
Typical examples
Use of symbols
The differences between single-line and
3-line diagrams
Applications
Conventions used
Practical exercises involving reading and
interpretation of single line diagrams

SCHEMATIC DIAGRAMS

Purpose
Typical examples
Use of symbols
Applications
Schematics spread over a number of
sheets
Cross-referencing between coils and
contacts
Practical exercises involving reading and
interpretation of schematic drawings

LAYOUT DRAWINGS

Purpose
Typical examples
Sub types of layout drawings
Electrical room layouts
Lighting and lightning conductors layouts
Earthing layouts
Cabling layouts
Applications
Conventions used
Practical exercises involving reading and
interpretation of layout drawings

ADVANCES ARISING FROM

COMPUTER AIDED DRAFTING
(CAD)

Drawing office revolution by CAD and the

role of PC based CAD applications
2-D and 3-D CAD applications and links
to CAM
Drawing to true dimensions in CAD
applications
Use of symbols, attributes and symbol
libraries
Automated bill of material generation
from a CAD drawing
Information sharing on multi-disciplinary
drawings
Concept of layers and their use in
sharing information
Automation of drawing through
programming
Linking imagery with drawings GIS
related applications

MANAGEMENT OF DRAWINGS

Practical Sessions

This is a practical hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

SUMMARY, OPEN FORUM

and closing

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

Planning and assigning of drawings

Need for drawing numbering standards
Drawing process flow
Revision control and ownership of
drawing
Comments and their marking
Drawing management system for work
flow control
On-line distribution of drawings - the end
of the era of paper drawings?
Drawing as a database for engineering
and construction the future

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South African Standard Sans 10142

- The Wiring of Premises

What YOU WILL LEARN:

The role of the Occupational Safety and Health (OSHA)

standards

The necessity of international and national standards and their

hierarchical relationships
An introduction and elucidation of the SANS 10142:1 standards
Basics of electrical power distribution systems

Role and functioning of the different components of power

distribution systems
Simple calculations of equipment and rating requirements
Safety requirements in power distribution systems

Electrical system protection, bonding and earthing practices

Electrical system and equipment operational and safety
installation practices

The nature, identification and mitigation of electric shock

hazards in electrical distribution systems
Verification and certification requirements for installations

WHO SHOULD ATTEND:

A workshop designed to teach electrical and instrumentation

personnel, who have prior knowledge of electrical engineering.
This workshop is a "must have" for those working in the residential,
commercial, or industrial electrical industry. Each article of the code
is thoroughly discussed and reviewed in easy-to-understand
language.

2.61

The Workshop

The Program

Electricity has long been recognised as a

serious workplace hazard. SANS electrical
standards are designed to protect employees
exposed to dangers such as electric shock,
electrocution, fires, and explosions. This unit
standard is intended for use in the training
of electricians and covers a basic
understanding of the framework of
standards, which govern their work in South
Africa.

INSTALLATION REQUIREMENTS
(PARTS 1 AND 2)

Historical perspective of growth of 3

phase AC electrical systems
Generation, transmission and distribution
Transformers
Switching equipment
Circuit breakers LV and HV
Dangers of electricity
Need for safety in operation and
maintenance

General circuit arrangements

Current-carrying capacity of conductors
and cables
Installation of conductors and cables
Positioning and fixing of cables
Rigid and flexible wire ways
Distribution boards
Protections against excessive currents
and earth leakage
Circuit breakers and their use as
disconnector
Main switch disconnector
Disconnection of neutral
Fuses
Earthing and consumer's earth terminal
Bonding
Requirements for lightning circuits
Socket outlets
Requirements for wiring of fixed
appliances

SAFETY REQUIREMENTS OF
ELECTRICAL INSTALLATIONS BASICS (PARTS 1 AND 2)

Electric shock
Earthing and bonding for safety
System classification based on earthing
Safe clearances
Arc danger in electrical installations
Protection against arc faults
Importance of isolation
Insulation
Enclosures of electrical equipment (IP
ratings)
Role of electrical protection
Protection against surge voltages
Harmonics fundamentals and need for
harmonic control
Designing for safety
Role of periodic maintenance and safety
procedures and safety education
Certification and authorisation

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This workshop is designed to provide up to

date information and training on the latest
edition of South African Standard SANS
10142 The Wiring of Premises. With
references
to
safety,
maintenance,
inspections, testing, and wiring of premises,
it provides a summary of some of the basic
principles
necessary
for
a
good
understanding of electrical installation
technology. It is compulsory for each user to
follow the instructions given by authorised
person to obtain the necessary certificate of
compliance.

DISTRIBUTION SYSTEM
OVERVIEW

Pre-requisites:

Fundamental knowledge of basic electrical

engineering.

Practical Sessions

Study of surge protection requirements

Harmonic correction

Earthing of information technology

equipment

Assessment of load in domestic

installations

INTRODUCTION TO SANS 10142

STANDARD

Cable sizing considering correction

factors for installation
Voltage drop calculation
Conduit selection

Testing documentation

Compliance documentation

To gain full value from this workshop,

please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

Need for standards in industry

Objectives of SANS 10142
Overview of the standard
Scope and exclusions
Applicability of amendments to the
standard in contracts
Compliance with acts for occupation
health and safety and mine health and
safety
Future development part 2 for HV
installations
Mandatory and informative requirements
of the standard
Information given under annexure to the
standard
Comparison with IEC and UK codes of
wiring

FUNDAMENTAL REQUIREMENTS

Safety stipulations
Basic requirements of electrical systems
and wiring
System characteristics
Harmful effect of equipment on electrical
systems
Derating for altitudes exceeding 2000m
Special requirements for medical location
Safety by extra low voltage systems and
special requirements

idc@idc-online .com

SPECIAL LOCATIONS AND

INSTALLATION (PARTS 1 AND 2)
Bathrooms, showers and spas
Swimming pools, paddling pools and
ornamental pools
Saunas
Construction and demolition sites
Agricultural and horticultural locations
Caravan parks, mobile homes and
marinas
Medical locations
Temporary installations
Extra low voltage lighting installations
Stage and theatre equipment
Safety and emergency lighting
Alternative supplies
High-voltage (HV) apparatus
Hazardous locations
DC system earthing

VERIFICATION AND
CERTIFICATION OF
INSTALLATIONS

Responsibility
Installation characteristics
Electricity supply system
Prospective short-circuit current
Inspection
Testing
Certificate of compliance

SUMMARY, OPEN FORUM

AND CLOSING

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Electrical Maintenance

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for Engineers and Technicians

WHAT YOU WILL learn:

A practical toolkit of know-how on latest testing and

maintenance requirements

Grasp the latest updates in cable testing and technical skills in

EPM programming
Understand the operation of electrical motors, transformers,
switchgears, UPS, SCADA and circuit breakers
Practical experience in MV and HV testing, transformer
troubleshooting and fire protection measures for large
transformer installations

Design tips and tricks in motor and circuit breaker cleaning,

testing and installations
How to detect faults in cables and motors

Skill yourself up as the local guru in electrical maintenance and

testing

WHO SHOULD ATTEND:

Consulting engineers

Design engineers
Designers

Electrical engineers
Electronic technicians
Instrumentation and control engineers/technicians
Plant managers
Process control engineers
System engineers
System integrators
Test engineers
2.63

The Workshop

The Program

We have taken all the latest techniques and

know-how relating to electrical maintenance
and distilled this hard-hitting workshop so
that you can update yourself in this fastmoving and powerful area. This workshop
will also update you with the latest
information on the maintenance and
installation aspects of cables, substations
and switchgear, transformers, circuit breakers
and motors. You will become familiar with
the latest techniques in safety operations of
the above-mentioned electrical equipment.
The section on Electrical Preventive
Maintenance (EPM) within the program cover
the key aspects of EPM and its benefits. The
electrical drawing and schematics area
discusses the various types of drawings logic
diagrams, ladder diagrams, cabling and
wiring diagrams etc.

ELECTRICAL PREVENTIVE
MAINTENANCE (EPM) PROGRAM

EPM and its benefits

Energy conservation
Planning an EPM program
Personal safety
Equipment loss
Production economics
Main parts of an EPM program
Programmed inspections
Recordkeeping
Training for safety and technical skills

ELECTRICAL DRAWINGS AND

SCHEMATICS

Single line and 3 line diagrams

Schematic diagrams
Logic diagrams
Ladder diagrams
Cabling and wiring diagrams

MOTOR PROTECTION, CONTROL

AND MAINTENANCE

Protection of motors
Installation and fault finding
Motor failure analysis
Testing
Maintenance and cleaning

CABLES

Cable installation
Failure of cables and fault detection
Visual inspection
Cable testing

POWER QUALITY
Introduction to power quality
Installation guidelines

UNINTERRUPTED POWER SUPPLY

(UPS)

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Safety is a very important aspect of electrical

maintenance and equipment needs to be
inspected and maintained according to the
relevant international regulations. In this
workshop the basic concepts related to safety
rules and hazards are covered in detail with a
separate section on inspection procedures.

INTRODUCTION

ELECTRICAL SAFETY TECHNIQUES

Special focus has been given to the

maintenance and asset management of
switchgear.We also look at the testing
procedures for major electrical equipment. A
separate section is dedicated to covering
special aspects of the installation of large
power transformers and fire protection
measures taken while installing them. A
section on troubleshooting of transformers is
also included.

This course also covers the new approaches

of fault finding, maintenance, testing and
troubleshooting of electric motors. As well
as a section on installation and fault detection
for cables.

Grounding techniques, types of faults and

their effects, effects of inadequate grounding
and inspection, concepts of SCADA, testing
and maintenance of SCADA are covered in
detail. We have also focused on issues with
power quality, the role of the UPS in
maintaining power quality, installation and
maintenance of UPS, types of relays and
relay maintenance.

Pre-requisites:

Delegates will need a general understanding

of electrical systems.
Please bring a calculator (or computer),
pens and notepaper along to the course to
assist with the calculations and practical
exercises.

Principles of safety rules

Basic theory of electrical safety
Static electricity and protection
Hazards due to electrical arcing and
heating
Inspection of electrical systems for safety

SUBSTATION COMPONENTS,
MAINTENANCE AND ASSET
MANAGEMENT OF SWITCHGEAR

Substation types
Substation components
Switchgear diagnostic techniques
Substation battery conditioning and
monitoring
Circuit breaker measurement
Maintenance and asset management of
switchgear

PRACTICAL MV AND HV TESTING

OF ELECTRICAL EQUIPMENT

Introduction
Insulation testing
High potential tests
Oil testing
Testing of transformers
CT testing
VT testing
Ducter testing
Tests on other major equipment
Field tests

TRANSFORMERS

Installation of transformers
Special aspects of installation of large
power transformers
Fire protection measures for large
transformer installations
Transformer troubleshooting

Practical Sessions
This is a practical hands on workshop
enabling you to work through practical
exercises which reinforce the concepts
discussed.

Static UPS systems

Testing
Periodic inspection and maintenance of
UPS batteries

SAFE OPERATION AND

MAINTENANCE OF ELECTRICAL
EQUIPMENT
Introduction
Key safety factors in operations and
maintenance of electrical installations
Isolation during maintenance of electrical
installations
Visual checks for safety
Monitoring hot spot to improve safety
Earthing for safety during maintenance
Need for periodic inspection and
maintenance
Emergency first aid training

GROUNDING AND GROUND FAULT

PROTECTION

Need for protection

Basic requirements of protection
Types of protection
Faults, types and effects
Causes of inadequate grounding
Grounding system inspection
Testing and monitoring
Maintenance of grounding system
Grounding for safety during maintenance
Use of personal protective equipment
Fault finding and troubleshooting

SUPERVISORY CONTROL AND

DATA ACQUISITION (SCADA)

Introduction
SCADA components
Monitoring
Testing and maintenance

OTHER TOPICS
Relay types and maintenance
Portable electric tools
Maintenance reports

SUMMARY, OPEN FORUM

and CLOSING

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Installing, Programming and

commissioning of

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Power System Protection

Relays and Hardware

what you will learn:

Fundamentals of power system protection

Key electrical system protection techniques including fault

analysis
How to calculate basic fault currents flowing in any part of your
electrical system
Key technologies and principles behind protective devices
Architecture of the modern numerical (or microprocessor
based) relay
How to configure the various relays

How to apply the modern relays to your distribution network

How to assess and manage relay settings

Typical problems and solutions with modern power system

relays
How to improve your electrical system protection against faults
and other disturbances

who should attend:

Electrical engineers
Project engineers
Design engineers
Instrumentation and design
engineers
Electrical technicians

Field technicians
Electricians
Plant operators

2.65

The Workshop

The Program

The continuity of the electrical power supply

is very important to consumers especially in
the industrial sector. Protection relays are
used in power systems to maximise
continuity of supply and are found in both
small and large power systems from
generation,
through
transmission,
distribution and utilisation of the power. A
good understanding of their application,
operation and maintenance is critical for
operating and maintenance personnel.

TYPICAL BLOCK DIAGRAM OF

NUMERICAL PROTECTION Cont.

Requirements of protection in an
electrical system
- Reliability, dependability, security
Types of faults
Evaluation of short circuit currents in a
power system
Exercises in fault calculations in simple
circuits
Earth faults and role of system earthing
Characteristics of protective relaying
- Sensitivity
- Selectivity
- Stability
- Speed
Protection using fuses
The protective relay/release and circuit
breaker combination
Instrument transformers and their
application in protection systems
Practical session 1: Fault level calculations
of typical power distribution networks

From individual protection relays to a

complete protection management system
Structure of the Intelligent Electronic
Device (IED)
Typical examples of the use of IEDs in
functions other than protection
Configuring substation automation using
IEDs
Practical session 5: Designing a substation
automation system architecture using IEDs

DIFFERENT TYPES OF NUMERICAL

PROTECTION SYSTEMS AND
PRINCIPLES
Functional protection relays
Equipment protection systems with
multiple functions
Practical session 6: Designing the protection
system of a typical HV/MV step-down substation with outgoing feeds to MV motors
and MV switchboards and incoming
transformer feeders and standby generator
source

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In this workshop, you will gain a thorough

understanding of the capabilities of power
system protection relays and how they fit
into the overall distribution network. The
practical sessions covering the calculation of
fault currents, selection of appropriate relays
and relay coordination as well as hands-on
practice in configuring and setting of
some of the commonly used types of
protection relays used in industry will give
you an excellent understanding. Simulation
software and real relays (but at safe voltages)
will be used to give the participants practical
experience in setting up and configuring the
various power parameters. Both electromechanical and microprocessor relays will
be used to demonstrate the key configuration
settings required and the major differences
in the approach adopted between these two
classes of relays.

BASICS OF POWER SYSTEM

PROTECTION

The strengths and weaknesses of the latest

microprocessor (or numerical) relays as
compared to the older electromechanical
relays will be outlined. You will also gain a
solid appreciation of how the modern relay
communicates not only to the central SCADA
system but also between themselves
resulting in a truly multifunctional system
which includes protection, control and
monitoring. Finally, you will gain a solid
understanding of issues of reliability and
security for the modern relay.

RELAYS AND THEIR

DEVELOPMENT

Types of protective relays (DMT and

IDMT)
Electromechanical static relays
Microprocessor relays and numerical
relays
IDMT characteristics expressed as a
mathematical function
Comparison of electromechanical/static
and numerical relays
- Key features: flexibility/reliability/
communications/SCADA interface
- Cost
- Integrated protection and control
Practical session 2: Reconstructing different
IDMTL characteristics using a spreadsheet
graphical display

PROTECTION COORDINATION

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
There will be at least nine practical sessions
interspersed within the different theory
sessions. These will enable participants to
gain a practical feel of actual power systems
and their protection system designs, as well
as the flexibility afforded by numerical
protection systems. Participants will also be
exposed to substation automation and wide
area protection architecture using the
communication facilities of numerical
protection systems.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Need for coordination

Time grading
Current grading
Application of time and current grading
in power systems
Grading using IDMTL characteristics
Better grading through numerical relays
Practical session 3: Grading between IDMT/
DMT characteristics of current relays by
using Excel spreadsheet
Practical session 4: Coordination between
directing trip devices used in LV circuit
breakers using typical software package

TYPICAL BLOCK DIAGRAM OF

NUMERICAL PROTECTION

Basic approach used in numerical

protective relays
Typical block diagram
Hardware and software architecture of a
numerical relay
Importance of sampling interval in the
operation of relay
Examples of how waveform asymmetry
and harmonic components are handled
in numerical relays
Extension of capabilities of relays in
numerical design

idc@idc-online .com

CONFIGURATION OF NUMERICAL
RELAYS
(Examples using industry standard
protective relays)
Setting approach in conventional relays
Configuring numerical relays
Configuration security through
passwords
Protection settings as a part of
configuration
Methods adopted for setting numerical
relays
Configuration exercises for typical relays/
simulation software
Practical session 7: Hands on configuration
using the front keyboard of a typical single
function numerical current relay
Practical session 8: Hands on configuration
using a PC and configuration software with
actual relays

COMMUNICATION ASPECTS OF
NUMERICAL PROTECTION
DEVICES
Setting up a substation automation
system using the communication
capability of numerical relays
Problems of compatibility between
vendors
DNP3 communication standard
The new substation standard IEC 61850
Logical grouping of functions
Intercommunication using GOOSE
Using IEC with Unified Modeling
Language (UML)
Example of substation automation
system with IEDs compatible with IEC
61850
Practical session 9: Designing a wide area
network protection system architecture by
connecting the substation automation
systems of different substations all using
IEC 61850 compatible devices

summary, open forum

and closing

www.idc-online .com

Practical

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Power Cabling and Earthing

YOU WILL LEARN HOW TO:

Select appropriate power cables

Perform testing and preventative maintenance on power cables

Design and install appropriate earthing systems
Size earthing conductors

Apply equipotential bonding in ensuring safety

Protect structures from lightning hazard

Protect power distribution equipment and sensitive systems

from surges

WHO SHOULD ATTEND:

Anyone associated with design, operation, installation,

commissioning and maintenance of electrical systems can
benefit from this workshop. Typical personnel who would
benefit are:
Building service designers

Electrical engineers and technicians

Electrical maintenance technicians
Electrical supervisors
Maintenance personnel
Operations personnel
Process control engineers
Service technicians
2.67

The Workshop

The Program

In any distribution system, cabling and

earthing are critical components in ensuring
continuity, reliability and safety of operation
and maintenance. The entire flow of power
in a system (or at least a major part of it)
goes through cables and thus any failures
would result in major disruption of power
flow. Correctly selected, sized and installed
cables can give trouble-free operation for
several decades. Not only cables, but also
accessories used for jointing and terminating
cables play an important role in reliability.
As the voltage rating of cables goes up,
installation, termination and jointing require
greater care since failures could be
expensive to repair and can cause
widespread disturbances in the power
system. And when failures do occur, they
need to be pinpointed accurately using
modern test methods so that repairs can be
undertaken promptly and service restored
with minimum delay.

INTRODUCTION

NEW TRENDS

Role of power cables in electrical systems

Main issues in ensuring trouble free
operation of cabling in power distribution
Earthing and its importance
Various functions of earthing in electrical
installations
System and protective earthing

Increasing use of underground cables

New technologies for very high capacities
and voltages
EHV XLPE cable systems
High temperature superconductivity in
cables

On the other hand, the earthing system does

not play a direct part in the normal power
flow but is very important in ensuring that
insulation failures can be promptly detected
and isolated by proper selection of system
earthing. The other major function is to
ensure that no unsafe voltages appear in
any external or extraneous conducting parts
of an electrical system. A good knowledge of
earthing system is necessary to design a
safe system and ensuring continued safe
operation.

CONSTRUCTION OF CABLES

Section I: CABLES
CABLES AND ACCESSORIES

EARTHING OF POWER SUPPLY

SYSTEMS
Types of system earthing and
comparison
Ungrounded systems
Solidly grounded systems
Impedance and resonant earthing using
neutral reactor
Impedance earthing through neutral
resistance
Point of earthing in power supply
systems without a neutral point

ID CO
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Low and high voltage cables

Advantages over overhead transmission
lines
Disadvantages of cables in power
transmission
Various types of cables
Cable jointing (splicing) accessories
Need for termination kits
Installation of cables

Section II: EARTHING

This course is designed to ensure that those

responsible for the selection, installation,
and maintenance of power cabling and
earthing systems understand the technical
issues involved and comply with relevant
specifications and requirements in a
practical and effective manner.

SELECTION AND INSTALLATION

OF CABLES

Pre-requisites

A fundamental knowledge of basic electrical

concepts would be useful.

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

Selection criteria
Sizing
Installation
Special locations
Fire prevention and fire protection for
cable installations

PRACTICAL ASPECTS OF CABLE

JOINTING AND TERMINATION

On-Site Training

Basic constructional aspects

Insulation
Application areas
Cable standards

Kits for joints and terminations

Shelf life
Issues with prefabricated kits
Preparation of cable for termination and
jointing
Connection and reconstitution of cable
properties
Continuity and grounding aspects
Sealing, healthiness of joint/termination
and repairs
Safety issues and access for repairs
Termination to electrical machines
Termination of outdoor HV installation
Terminations to GIS installation
Importance of correct orientation of
terminations
Installation aspects for cable joints and
terminations
Safety issues and access for repairs

CABLE FAILURES

Types of failures
Reasons for failures
Fault location
Electrical tests for detection of cable
faults
Safety issues in fault location
Analysis of failures
Documentation of work and failures

delivered when and

where you need it.

EQUIPMENT (PROTECTIVE)
EARTHING

Shock hazard
Earthing of equipment
Operation of protective devices
Thermal capability
Touch potential during ground faults
Induced voltage problem
Mitigation by multiple ground connection
Mitigation by reduction of conductor
spacing
EMI suppression
Metal enclosures for earthing conductors
Earthing connections for surge protection
equipment
Sensing of ground faults
Equipotential bonding

GROUND ELECTRODE SYSTEMS

Earthing electrodes
Soil resistance
Measurement of soil resistivity
Resistance of a single rod electrode
Current carrying capacity of an electrode
Use of multiple ground rods in parallel
Measurement of ground resistance of an
electrode
Concrete encased electrodes
Corrosion problems in electrical earthing
systems
Maintenance of earthing system
Chemical electrodes

CABLING AND EARTHING:

CONVERGENCE

Inter-relation between cabling and

earthing
Need to earth insulation screens of
cables
Earth continuity in cable joints
Use of armour in providing earth
continuity
Earthing of cable screen/armour in cable
terminations when using core balance CT

summary, open forum

and closing

Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

The Fundamentals of

Power Distribution
and Power Systems:

ID CO
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Hands-on Practical Analysis and Design

what YOU WILL LEARN:

You will have a deeper understanding of the fundamentals of

power distribution systems
Carry out advanced calculations in power distribution systems
with greater confidence
Master difficult concepts like three-phase power system
network analysis, active, reactive and apparent power
calculations, power factor correction and much more
Extend your learning experience by problem solving; use
specific solution formulations on your own applications

WHO SHOULD ATTEND:

This course is designed for practical engineers and technicians

interested in maintaining power quality and minimising outages
in power distribution networks:
Design engineers

Electrical engineers

Electrical technicians
Electricians
Field technicians

Instrumentation engineers
Plant operators
Project engineers

2.69

The Workshop

The Program

Practical Engineers and Technicians are

always under pressure to meet the day-today challenges of maintaining power quality
and minimising outages in power
distribution networks. As a result of this
challenge they tend to sharpen their skills
only with regard to the most obvious
practical and theoretical tools and to allow
other insights that are as necessary to power
systems as vitamins are to biological
systems, to be relegated to the archives or to
the "experts". It is often possible to apply
quick-remedies or to use trial and error to
obtain "cures" to correct difficult to diagnose
faults in power distribution systems. By
gaining a deeper and more fundamental
understanding of the basics, the traditional
trial-and-error approach makes way for
deterministic solutions with surer cures.

Pre-requisites

Introduction to study of
three phase systems

Definitions of AC voltages, currents and

power based on concepts of time
dependent voltage, current and power
Review of DC circuit principles and
extending those to AC circuits with
sinusoidal waveforms
Review of complex algebra, important
trigonometric relations, polar and
rectangular coordinate systems
RMS and average values of periodic
waveforms

Introduction to balanced three phase

power systems: voltage, current and
power relationships between phases
Comparison of single and three phase
power systems and the advantages of
three phase systems over single phase
systems
Per phase calculation method and single
line diagram representation of balanced
three phase power distribution systems
Analysis and definitions of voltages,
current and impedance in three phase
networks with star and delta configured
sources and loads
Calculation of power in three phase
power distribution systems
Time domain simulations of examples to
complement analytical calculations of
three phase power systems

Practical Exercises

Introduction to vectors and

phasors
Introduction to voltage and current
rotating vectors and phasors and their
use in AC circuit calculations
Multiplication and division of complex
quantities
Fundamental physical meanings of
resistance, inductance and capacitance
and their influence on power distribution
systems
Impedance of resistance, inductance and
capacitance in AC circuits
Impedance networks and their use in AC
circuit calculations

Practical Exercises

ID CO
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A fundamental knowledge of electrical

engineering is very useful.

REVIEW OF AC CIRCUIT
FUNDAMENTALS

Workshop Objectives

At the end of this workshop delegates will

understand:
Fundamentals of power distribution
systems

Master difficult concepts that relate to

power distribution

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Practical Exercises

Introduction to Electrical
system studies

Time domain simulations of different

types of single phase AC circuits
Transient and steady state behaviour of
AC circuits
Admittance, conductance and
susceptance and their usage in power
distribution system calculations
Principles of AC network reductions and
its use in power distribution circuits
Definitions of power in AC circuits, time
dependent power, active, reactive and
apparent power
Power dissipation and storage in AC
circuits involving resistance, inductance
and capacitance

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

Transformers and their use in AC power

transmission and distribution systems
Transformer design principles; flux
density, number of turns, voltage
transformation, current ratio, core size,
core material implications
Development of the equivalent circuit of
a power transformer through addition of
winding resistance, leakage inductance,
magnetising inductance, core losses
Three phase power transformers and
their use in power distribution systems
Extending single phase concepts for
transformers to balanced three phases
The per unit system for multi-voltage
level power distribution system
calculations
Calculations and simulations showing
phase shift and the effects of different
vector groupings

Practical Exercises

Fundamentals of Harmonics

Usage of software for calculating RMS

and average values of periodic nonsinusoidal waveforms
Use of real, imaginary and complex
power to streamline power calculations
in AC circuits
Phasor diagrams and their use in AC
circuit analysis
Meaning, consequences and correction
of displacement power factors in AC
circuits

Introduction to steady state harmonics

Fundamental definitions under sinusoidal
conditions
The concept of othogonality
What is meant by power system
harmonics
Harmonic problems in practice
Limits of harmonic presence in power
system
Quality factor
Bandwidth
Series and parallel resonance in power
systems
Neutral overloading
Other harmonic problems in brief

Practical Exercises

Practical Exercises

Practical Exercises

Introduction to Electrical
system calculations

On-Site Training

Introduction to analysis of
transformers

Introduction to harmonic
studies

your workplace.

The one sided exponential fourier series

Power system definitions based on a
time domain model
Modelling of power systems with
harmonics

Have the training

delivered when and

where you need it.

Practical Exercises

SUMMARY, OPEN FORUM

and CLOSING

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

ID CO
C P
Te YR
ch IG
no H
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gi
es

HV and LV switching operations

and safety rules

YOU WILL LEARN HOW TO:

Appreciate the basic theoretical aspects involved in electrical

safety
Understand the importance of proper isolation procedures for
HV and LV equipment
Understand the coordinating permit access authority
procedures

Gain a clear understanding of the procedures/practices adopted

for safe working
Identify the various statutory and legal regulations/acts dealing
with electrical safety at work
Gain an insight into the organisational aspects of safety
Become familiar with the organisations electrical safety rules
(applicable to on-site training)

WHO SHOULD ATTEND:

Building service designers

Consulting engineers

Data systems planners and managers

Electrical and instrumentation technicians
Electrical engineers
Instrumentation and control engineers
Maintenance engineers
Power system protection and control engineers
Project engineers
2.71

The Workshop

The Program

In this workshop, we will take a look at the

theoretical aspects of safety as well as the
practical and statutory issues. One of the
main causes of electrical accidents is said to
be incorrect isolation of the circuits where
work is to be done. To ensure safety of
operators and maintenance personnel,
proper switching procedures are necessary
and more so when the circuits have multiple
feeds and are complex. The possibility of
voltage being fed back from secondary
circuits needs to be considered as well. This
workshop emphasises on the isolation
procedures to ensure proper and safe
isolation of HV, LV and secondary circuits.

OVERVIEW OF HV SWITCHING
OPERATIONS

Electrical shock - why does it happen?

Touch and step potential (voltage)
Direct and indirect contact
Role of electrical insulation in safety
Avoiding electric shock different
approaches
Earthing of power supply systems and its
safety implications
Role of earthing of equipment enclosures
(protective earthing) in human safety
Earthing in outdoor installations

HV equipments - components and

apparatus
Fundamentals of HV switching
operations
HV switching operations safety
Restriction pertaining to HV switching
equipment
Isolation of HV transmission and
distribution systems
Commissioning and maintenance of HV
equipments

ARC FLASH HAZARD AND

SAFETY MEASURES

OVERVIEW OF LV SWITCHING
OPERATIONS

Arc flash definitions

Hazards presented by arc flash
Causes of arc flash
Arc blast and its consequences
Concept of incident thermal energy
Arc flash protection program

LV equipments - components and

apparatus
Fundamentals of LV switching operations
LV switching operations safety
Commissioning and maintenance of LV
equipment

ID CO
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Te YR
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no H
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gi
es

Electrical safety is not just a technical issue.

Accidents can only be prevented if
appropriate safety procedures are evolved
and enforced. This includes appropriate
knowledge of equipment and systems
imparted through systematic training to each
and every person who operates or maintains
the equipment. We will cover all these
aspects in detail.

BASIC THEORY OF ELECTRICAL

SAFETY

Pre-requisites

Some working knowledge of basic electrical

equipment is required, although this will be
covered at the beginning of the workshop.
Real-life experience with such equipment
and hands-on testing will enable the
workshop to be placed in context.

SAFE OPERATION AND

MAINTENANCE OF ELECTRICAL
EQUIPMENT

Key safety issues in O&M of electrical

installations
Isolation and earthing of equipment
Use of warning signs for operation and
maintenance
Safety while working in outdoor
switchyards and overhead lines
Work on underground cable systems
Use and upkeep of safety appliances in
substations and other electrical premises
First-aid for burns and electric shock

COORDINATING PERMIT ACCESS

AUTHORITY PROCEDURES

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Requirements for access to electrical

equipment
Planning for switching and isolation
Document management
Communication in switching and
isolation
Auditing of switching and isolation
procedures

SECONDARY ISOLATION
PROCEDURES

Fundamentals of secondary isolations

Communications for secondary
isolations
Procedural and technical aspects

APPLICABLE REGULATIONS AND

STANDARDS ON SAFETY
Necessity of safety rules and standards
on safety
Acts and regulations dealing with safety
at the work place
Regulations related to usage of
electricity
Regulations related to supply of
electricity
Standards for wiring, design and
selection of LV installations

ORGANISATIONAL ASPECTS OF
SAFETY
Environment, health and safety policy of
the organisation
Mandatory compliance to statutory
requirements
Monitoring safety compliances
Safety training
Role of an organisation in ensuring/
improving work safety

DISCUSSION

On-Site Training

HV and LV switching operations, specific

hazards and safety rules applicable
(these can be organisation-specific for
on-site courses)

Save over 50% by

summary, open forum and

closing

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

practical

Arc Flash Protection

ID CO
C P
Te YR
ch IG
no H
lo T
gi
es

for electrical Safety Professionals

YOU WILL LEARN how to:

Identify the important hazards in O&M work in different parts of

electrical installations
Recognise the dangers of arc flash events to working personnel
and their impact on equipment
Know the codes and standards dealing with arc flash danger
Acquire the necessary theoretical knowledge to carry out arc
flash impact studies by collecting system data and computing
the arc flash incident energy and flash protection boundary
Understand the importance of proper design of electrical
equipment in avoiding arc flash incidents and ensuring safety
in the event of an arc flash.
Select appropriate Personal Protective Equipment (PPE) and
Flame Resistant (FR) clothing required for avoiding serious or
lethal injuries

WHO SHOULD ATTEND:

Consulting engineers
Electrical and instrumentation technicians
Electrical design engineers
Electrical maintenance engineers
Power system protection and control engineers
Project engineers
Purchasing engineers
Safety engineers

2.73

The Workshop

The Program

Electrical safety is an important issue for

those working on electrical facilities in utility
networks and large industrial installations. A
number of serious accidents including
fatalities occur every year due to accidents
involving electricity resulting in huge
financial losses and wasted man-hours. Arc
flashes in electrical equipment are now
considered one of the major causes of
electrical accidents even surpassing the well
known hazards of electric shock. Avoiding
arc flash incidents and the resulting injuries
is one of major challenges today facing
electrical workers and requires adequate
attention in the stages of system planning,
design,
installation,
operation
and
maintenance.

Hazards with examples

- Electric shock, arc flash events
- Working at heights
- Working in confined spaces
- Fire and explosion
- Mechanical hazards
Common electrical equipment and
hazards posed

ARC FLASH AND ITS EFFECTS

Definitions
Reasons for arc flash events
What really happens in an arc flash
event?
- Insulation failure/violation of
clearances
- Arc flash mechanism
Impact on equipment
Hazards to personnel in the vicinity
- Burns
- Organ damage due to pressure wave
- Hearing damage
- Shrapnel effects
Videos of arc flash events

ARC FLASH STUDY DETAILED

PROCEDURE
Flash protection approach boundary
- 1.2 calories per square centimeter
- 4 foot boundary
- Calculated boundaries based on
transformer size and bolted short
circuit MVA
Detailed arc flash study
- Calculation of incident energy and
flash boundaries
- Warning labels
- Personal protective equipment
requirements
Calculation of working distance and flash
boundary as per IEEE Standard 1584

DATA COLLECTION AND SYSTEM

MODELING
Data for calculation of fault currents
Modes of operation
Lower short circuit conditions with long
tripping times

ID CO
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Injuries due to arc flash can depend on

many factors, one of which is the incident
thermal energy on a worker exposed to a
flash. Today, a considerable body of
knowledge exists as a result of research
efforts and is available to designers and
maintenance engineers in the form of
standards such as IEEE 1584 and NFPA 70E.
This workshop will detail the basis of this
approach and also about the major advances
have been made in the area of PPE made of
HR fabrics and rated for different levels of
thermal exposure.

ELECTRICAL HAZARDS

Prevention however still remains the best

form of protection and switchgear
manufacturers have made considerable
design advances to ensure that the effect of
arc flash incidents is contained within the
enclosure of switchgear (often called arc
flash resistant switchgear) and methods of
testing such switchgear have also evolved
simultaneously. Another important factor is
the approach to avoid arc incidents within
the switchgear by proper design and
maintenance and techniques to reduce the
severity of the flash should such incidents
occur.
These would form the key focus areas of this
workshop.
This is a practical, hands on workshop
enabling you to work through practical
exercises which reinforce the
concepts discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

FUNDAMENTALS OF POWER
SYSTEMS

Configurations
Equipment used
System earthing and its role
Protective earthing and its role
Faults and types of faults
Bolted faults and arc faults

CALCULATION OF FAULT
CURRENTS

Fundamentals of short circuit calculations

Simplifying assumptions
Ohmic impedance and per unit
impedance
Infinite bus
Base KVA of a system and its use in
calculations
Network theorems commonly used
Equivalent diagrams
Fault calculation approach for a simple
system
Earth faults and the importance of
system earthing
Mitigation of fault levels in a system
Practical work: sample problems

PROTECTION IN POWER SYSTEMS

DETERMINING ARC FLASH

HAZARD RISK CATEGORY

Detailed examples and exercises

simplified tables approach
Matrix table
Single line diagram approach
Short circuit study report coordination
Hazard risk category for metal clad
switchgear 1kv and above
NFPA 70E table 130
Practical work: arc flash study calculations

REDUCING ARC-FLASH HAZARD

Mitigation of energy by reduced short
circuit current and faster protection
Overvoltage protection to reduce
insulation failure risk
Reducing the risk of arc flash by better
equipment design (clearances, creepage,
insulation)
Providing arc vents to direct arc away
from operator
Containing internal arc flash by
switchgear that is arc resistance
Avoid local operations and live work
Better maintenance practices
- Insulation status and PD monitoring
- Contacts and joint status-monitoring
through thermography

PERSONAL PROTECTIVE
EQUIPMENT MADE OF FR
CLOTHING

Save over 50% by

Fundamentals of power system protection

Protection attributes
Protective devices (fuses, built-in release
and relays)
Time-current characteristics
Impact of bolted faults on tripping time
I2t: the important factor in deciding the
hazards of faults
Commonly used protection approaches

The evolution of Flame Resistant (FR)

fabrics
The various types of FR fabrics that are
available in the marketplace
FR fabrics and the effects of
undergarments
Limitations of FR fabrics
Test method ASTM F 1959
Garment construction standard ASTM F
1506-02a

Customise the training to

ARC FLASH STUDIES - CODES

AND STANDARDS

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

having an IDCworkshop
presented at your
premises.

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

OSHA 29 CFR - part 1910

National Electrical Code NFPA 70Estandard for electrical safety in the
workplace
- Safety related work practices
- Installation safety requirements
- Table 130.2(C
IEEE Standard 1584
- Guide for arc flash hazard analysis
Definitions used in arc flash study

idc@idc-online .com

www.idc-online .com

Practical

ELECTRICAL METERING,
MEASUREMENT AND
INSTRUMENT TRANSFORMERS

ID CO
C P
Te YR
ch IG
no H
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es

for Engineers and Technicians

YOU WILL LEARN HOW TO:

Understand the importance of proper measurement

Identify different types of measuring instruments

Appreciate the role of instrument transformers in measurement

Use and apply metering devices and principles of operation
Maintain, commission and test measuring equipment

Understand future technologies in measuring instruments

WHO SHOULD ATTEND:

Instrumentation and Control Engineers

Consulting Engineers
Electrical Engineers

Project Engineers

Maintenance Engineers
Power System Protection Engineers
Building Service Designers
Data Systems Planners and Managers
Electrical and Instrumentation Technicians

2.75

The Workshop

The Program

Measurement of electrical parameters is

necessary to know the status of a power
system and for protection against abnormal
incidents such as short circuits and earth
faults. Accurate measurements are also
important for tariff metering since large
sums of money can be involved in these
transactions and is therefore in the interest
of both suppliers and consumers of electrical
energy. This course discusses the details of
instrument transformers including their
construction, ratings and specifications.
Various measuring devices such as
instruments and transducers, their operating
principles and applications will be covered
as well.

Pre-requisites

Introduction to electrical measurement

Need of measurement in electrical
installations
Why accuracy is important in
measurement
Different types of measuring devices
used for measuring
Transducers and their principle of
operation
Instrument transformers and principles
Purpose of instrument transformers

VOLTAGE TRANSFORMERS
(PT OR VT)
Basic electrical theory of voltage
transformers
Types and categories of voltage
transformers
How voltage transformers are used for
measurement
Characteristics and classes of voltage
transformers
Standards for voltage transformers
Hazards with voltage transformers
Accuracy checks on voltage transformers
Applications of voltage transformers

TRANSDUCERS
Types of transducers depending on
principle, active and passive
How measurement is carried out with
transducers
Power transducers and their use
Average responding transducers
RMS responding transducers
Use of interposing transformers
Applications of transducers

APPLICATIONS IN PRACTICAL
SYSTEMS (CIRCUIT
CONNECTIONS)
Traffic metering and control and
indication metering
Metering code
Parameters monitored and purpose
Tariff metering arrangements
Importance of accurate and reliable
metering
Standards applicable with stress on
accuracy

ID CO
C P
Te YR
ch IG
no H
lo T
gi
es

Some working knowledge of basic electrical

equipment is required, although this will be
covered at the beginning of the course.
Real-life experience with such equipment
and hands-on testing will enable the
workshop to be placed in context.

INTRODUCTION TO ELECTRICAL
MEASUREMENT

CURRENT TRANSFORMER (CT)

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Basic electrical theory of current

transformers
How current transformers are used for
measurement
Characteristics and classes of current
transformers
Comparison of a metering CT and a
protection CT
Standards for current transformers
Hazards with current transformers
Accuracy of current transformers
Applications of current transformers

METERING DEVICES AND

PRINCIPLES

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.

COMMISSIONING, TESTING AND

MAINTENANCE OF MEASURING
SYSTEMS

Testing of a voltage transformer

Testing of current transformers
Testing of transducers
Commissioning of voltage transformers
Commissioning of current transformers
Commissioning of transducers
Maintenance of current transformers,
voltage transformers and transducers
Special emphasis on accuracy checks

THE FUTURE OF MEASURING

TECHNOLOGY

Smart metering
Technology behind smart metering
Benefits of smart metering
AMR and metering for smart grids

Different types of meters

Classification of meters
Measurement principles
Alternating current system and peak
value, RMS value
Active and reactive power
Circuit configurations (direct and through
instrument transformers)
Ammeters and voltmeters
Frequency meter
Power factor meters
Power and energy meters
Measurement of current, power and
frequency
Integrating instruments
Registering instruments
Recording instruments
Digital instruments
Instrument mounting and wiring

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Electrical and Instrumentation

(E & I) Engineering

ID CO
C P
Te YR
ch IG
no H
lo T
gi
es

for Oil and Gas Facilities

what YOU WILL gain:

Skills and competencies in E&I oil and gas engineering

Knowledge of the latest technologies in E&I oil and gas engineering
Key techniques in operating your facility to the highest level of safety
and in protecting the environment
Decades of real experience distilled into the course presentations and
materials
Guidance from real E&I oil and gas experts in the field
Hands-on, practical knowledge from the extensive experience of
instructors, rather than the theoretical information from books and
colleges
Networking contacts in the oil and gas industry

WHO SHOULD ATTEND:

This workshop is ideal for you if you are seeking expertise in the oil and
gas business, including:
Recent graduate electrical, instrumentation or mechanical engineers
Chemical engineers
Electrical engineers
Experienced electricians
Fire and gas engineers
Instrument and control systems engineers
Instrument and process control technicians or technologists
Instrument fitters
Mechanical engineers
Even if you are highly experienced you will find this a great way to become
familiar with the oil and gas technology as quickly as possible.

2.77

The Workshop

The Program

There is a growing shortage, and hence

opportunity, for Electrical and Instrumentation
(E&I) technicians, technologists and engineers
in the oil and gas industry. This is due to an
increasing need for higher technology
methods of obtaining and processing oil and
gas as it is a finite declining resource. The
price of oil is heading upwards steadily, thus
making personnel and their associated oil
and gas expertise in these industries even
more valuable. The technical challenges of
extracting oil and gas are becoming ever
more demanding, with increasing emphasis
on more marginal fields and previously
inaccessible zones such as deep oceans,
Polar regions, Falkland Islands and Greenland.
The aim program is to provide you with core
E&I engineering skills to enhance your career,
and to benefit your firm.

Fundamentals of electrical engineering

Fundamentals of instrumentation,
measurement and process control
engineering

INSTRUMENTATION AND
CONTROL
General instrumentation standards in oil
and gas
Best practice in process, electrical and
instrumentation drawings and
documentation
Process instrumentation
Calibration, installation and maintenance
of instruments
Process control basics
Control valves sizing, selection and
maintenance (including pressure relief
valves)
Programmable Logic Controllers
SCADA systems
Distributed control systems
Industrial data communications
(including Fieldbus and industrial
Ethernet)
Safety instrumentation and emergency
shutdown systems for oil and gas (IEC
61511 and IEC 61508) basic introduction
Wellhead and flowline control control
systems
Emergency wellhead blowout controls

SPECIALISED APPLICATIONS IN
OIL AND GAS
Power generation
Cathodic protection
Compressor control (including surge
control)
Drilling control systems and
instrumentation
Subsea instrumentation and control
systems
Pig launcher/receiver systems
Critical flare knock out drum controls and
instrumentation
Flare flame front generator and ignition
monitoring system
Distributed control systems

ELECTRICAL ENGINEERING IN OIL

AND GAS
Electrical drawings, documentation and
schematics
Transformers
Troubleshooting, maintenance and
protection of AC electrical motors
Power distribution
Power system protection and
co-ordination (including fault
calculations/stability and protective
relays)
Switchgear and distribution systems
Cables and wires maintenance and
installation practice
Variable (or adjustable) Speed Drives
(VSDs) for instrumentation and control
systems
Electrical safety
Earthing/grounding, power system
harmonics and power quality onshore/
offshore
Lightning and surge protection
Uninterruptible Power Supplies (UPSs),
batteries and battery chargers
Emergency power supplies
Electrical equipment in hazardous areas
Electrical applications to an oil and gas
platform and site

ID CO
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This course provides a whole spectrum of

activities ranging from basic electrical and
instrumentation engineering to advanced
practice including hazardous areas, data
communications along with a vast array of
E&I equipment utilised in an oil and gas
environment as well as practical treatment of
electrical power systems and instrumentation
within the oil, gas, petrochemical and
offshore industries. Whilst there is some
theory this is used in a practical context
giving you the necessary tools to ensure that
the E&I hardware is delivering the results
intended. No matter whether you are a new
electrical, instrumentation or control
technician/technologist/graduate engineer or
indeed, even a practising facilities engineer,
you will find this course beneficial in
improving your understanding, skills and
knowledge. This is a 5-day intensive
workshop, covering considerable material, if
you are looking for a far higher level of
knowledge and competencies, you can
undertake our 18 month in-depth Advanced
Diploma of E&I Engineering for Oil and Gas
Facilities through the EIT.

Introduction Setting the

scene in oil and gas E & I
engineering

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

Practical Sessions
This is a practical, hands on workshop
enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

fundamentals of

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Smart Metering

what YOU WILL learn:

Need for smart metering

What smart metering means
How to implement a smart metering system
Technologies used in smart metering
Components in a smart metering system
What smart meter data management means

WHO SHOULD ATTEND:

This workshop is designed for personnel who want to understand the design
and engineering principles involved in smart metering. Those who will benefit
the most from this workshop include the following:
Billing managers
Business development managers
Commercial people within utilities
Customer service directors/managers/supervisors
Data and MDM directors/managers/supervisors
Distribution managers
Energy managers
Energy marketers
Energy service providers
Facilities managers
Heads of electricity, water, gas unit
IT professionals within utilities (senior and middle-management)
Marketing managers
Metering project directors/managers/supervisors
Tariff managers
Technical managers
Regulators/commissioners
Regulatory affairs directors managers/supervisors
2.79

The Workshop

The Program

Smart metering is a technique used to meter

the energy consumption in more detail than
a conventional meter. The increasing cost of
energy has put power consumption firmly
on the political radar. It is one of the factors
driving the adoption of smart metering
technology.
The objective of this workshop is to learn
the implementation of smart metering for
domestic and business places and to learn
to design smart homes and smart premises
using this technique. The workshop also
introduces the participants to the new
methods adopted and the implementations
of smart metering done across the globe by
different countries.

kWh meters
After Diversity Maximum Demand
(ADMD)
Principle of operation of various kWh
meters
kVArh meters
Various connections of kWh and kVArh
meters
Calculation of multiplier factor
Apparent, active and reactive power
calculation
kWh and kVArh meters: testing and
calibration

Introduction to smart
metering

Energy measurement
Gas/water/heat metering
Conventional meters
Metering approaches
Need of smart metering
Features of smart metering

Advanced Metering
Infrastructure (AMI)
Definition of AMI
Advanced Meter Reading (AMR)
solutions
Implementing AMI
Benefits of AMI
AMI communication strategy
Security aspects for AMI
AMR vs AMI capability

Introduction of Smart Grid

Need for smart grid

Characteristics of smart grid
Future of smart grid
Features and implementation of smart
grid
Technologies for smart grids
Smart grid milestones

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This workshop will cover the methods and

concepts used in smart metering. The
technologies used to handle data from smart
meters and the new software utilities to
handle the reading. The technologies used in
the billing and handling of customers. Upon
completion of this course the attendees will
have a clear understanding of the design
and engineering principles used in smart
metering. This workshop will increase
understanding of energy utilisation and
energy efficiency.

kWh and kVArh meters

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Basics of smart meters

Definition of a smart meter

Functions and features of smart meters
Block diagram and design of smart
meters
Introduction of prepayment meters
Tampering and security of meters
Introduction to M-bus(EN13757) and
wireless M-bus

Metering Technologies

Metering technologies for smart metering

Technologies used for communication
Technologies for data storage
Meter Data Management (MDM)
Methods used for billing (tariff structure)
Load control technology
System architecture and implementation

Applications of smart
metering

Implementation of smart metering for

water utilities
Implementation of smart metering for
gas utilities
Study reports of smart metering for
energy savings
Designing of smart homes using smart
metering
Designing of smart premises using smart
metering
AMR used in submetering

Implementation of Smart
Metering in Different
Countries

Smart metered countries

Smart metering initiatives around the
world
Cost benefit analysis for AMI
Case study and roll out of AMI trials for
Australia

summary, open forum

and closing

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

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Installation, Testing and

Troubleshooting of Transformers

what YOU WILL Learn:

Gain the valuable know-how used by electrical engineers in operation

and maintenance of power transformers
Understand different kinds of testing of transformers and their
purposes
Understand the basis of acceptance and rejection of a test result
based on standards
Be aware of important points to be considered between the
manufacturer and the requestor to avoid dispute at a later stage

WHO SHOULD ATTEND:

This workshop will be appropriate for the following professionals:

Electrical engineers
Maintenance engineers
Maintenance supervisors
Power electricians
Power engineers

2.81

The Workshop

The Program

This will provide you with practical

knowledge (including tips, tricks and tools)
covering the fundamentals of power
transformers and their testing. It will greatly
assist you in communicating more effectively
with your electrical engineering colleagues.
At the end of this workshop, participants will
be familiar with the importance of
transformer testing and their purpose, the
different kinds of transformer tests and their
procedures and the practical applications of
principals applied in transformer operation
and maintenance.

Pre-requisites
An elementary understanding power
transformers and their purpose in an
industry will be undertaken at the
commencement of the course.

Kinds of Tests
Routine test
Type test
Special test

General Requirements of
Tests
Transformer Tests
Measurement of winding resistance
Measurement of voltage ratio and check
of voltage vector relationship
Measurement of impedance voltage/
short-circuit impedance (principal
tapping) and load loss
Measurement of no load loss and current
Measurement of insulation resistance
Dielectric tests
Temperature rise
Test on on-load tap changers
Short-circuit test
Measurement of acoustic noise level
Measurement of the harmonics of the
NLC
Measurement of power taken by fans/oilpumps
Magnetising current test
Magnetic balance test

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Please bring a pocket calculator for solving

problems during the practical sessions.

Introduction: Transformer
and their Testing

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Insulating Oil

Characteristic of insulating oil

Causes of deterioration of insulating oil
Testing of insulating oil
Inhibitors an introduction

Introduction to Dissolved
Gas Analysis
Tolerance Table

summary, open forum

and closing

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Medium Voltage ac Motors

for the Power Industry

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Working Principles, Installation,

Maintenance and Troubleshooting

YOU WILL Learn how to:

Understand ac motor operation and construction

Specify, select and install motors
Specify protection requirements for motors
Specify speed control requirements for motors
Install and commission motors
Fix faults on motors
Interpret motor performance curves
Interface control circuits of motors with PLCs/DCSs
Reduce downtime on electrical motors
Improve plant safety
Improve plant throughput
Reduce your spares usage and requirements

WHO SHOULD ATTEND:

Anyone associated with the use of electrical motors in the industrial or

automation environment. The workshop will also benefit those working in
system design as well as site commissioning, maintenance and
troubleshooting. Typical personnel who would benefit are:
Electrical maintenance supervisors
Electrical maintenance technicians
Instrument and control engineers
Instrument technicians
Maintenance personnel
Mechanical engineers
Operations personnel
Plant engineers
Process control engineers
Service technicians

2.83

The Workshop

The Program

It is estimated that electrical drives and

other rotating equipment consume about
50% of the total electrical energy consumed
in the world today. The cost of maintaining
electrical motors can be a significant amount
in the budget item of manufacturing and
mining industries. This course gives you a
thorough understanding of electrical motors
working, maintenance and failure modes
and gives you the tools to maintain and
troubleshoot electrical motors.

Basic principles of rotating electric

machines
Fundamental principles of speed control
Efficiency, torque, inertia, horsepower/
power factor
Torque-speed curves
How the motor produces torque
Standardisation and the meaning of
frame size
Types of motors and their characteristics
- Cage motors
- Slip ring motors
- Synchronous motors
Relative merits of the above types and
reasons for preferring cage type motors
Relationship between output of motor
and the voltage of operation-some
pointers
Medium voltage motors (3.3kv, 6.6 kv
and 11 kv) and features

PROTECTION OF AC MOTORS
Protective devices
- Thermal overload
- Over current / overload
- Under-voltage / over-voltage
- Under frequency
- Current unbalance or negative phase
sequence
- Earth fault protection
- Pole slip / out of step
- Loss of excitation
- Inadvertent energisation
- Over fluxing
- Stall protection / acceleration time /
Start up supervision (time between
starts / starts per hour)
- Voltage controlled or restrained over
current
- Protection settings

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You will gain a fundamental understanding

of the installation, operation and
troubleshooting of electric motors. Typical
applications of electric motors in mining,
manufacturing, materials handling, process
control are covered in detail. You will learn
the basic steps in specifying, installing,
wiring and commissioning motors. The
concluding section of the course gives you
the fundamental tools in troubleshooting
motors confidently and effectively.

FUNDAMENTALS OF MOTOR
TECHNOLOGY

Pre-requisites

A fundamental knowledge of basic electrical

concepts would be useful.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.

THREE PHASE AC INDUCTION

MOTORS

Components
Theory of operation
Induction motor design
Duty cycles
Insulation and Cooling requirements
Starting methods
Selecting motors

AC MOTOR CONSTRUCTION AND

MAINTENANCE

Basic construction and physical

configuration, windings
Mechanical components and their role
Bearings and lubrication system
Types of enclosure, cooling arrangements
and temperature supervision
Embedded temperature sensors for
winding and bearings
Special constructional features of
medium voltage motors

DETERMINATION OF LOSSES AND

EFFICIENCY OF THREE PHASE AC
INDUCTION MOTORS
Standards
Types of losses
Tests for measurement and computation
of losses and efficiency
Dynamometers
Principles of load application by braking
Torque measurement basics
Types of practical dynamometers
Eddy current dynamometer and its
characteristics
dc and ac dynamometers and their
working principles
Testing of larger motors - back-to-back
test approach

Contact us for a
free proposal.

MEDIUM VOLTAGE MOTORS IN

POWER INDUSTRY
Overview of a typical power generation
plant using steam turbines
Important drives and their requirements
Considerations for selection and deployment
of electric motors for these applications
- High inertia fan drives
- Pump drives
- Mill drives
- Need for immunity from electrical
voltage disturbances
- Critical auxiliary systems
Selection of motors for these applications

SPEED CONTROL OF AC MOTORS

Introduction to variable speed drives or
power electronic converters
Types, and designs of variable speed drives
Control theory of VSDs explained

INSTALLATION, COMMISSIONING,
PERIODIC MAINTENANCE AND
TROUBLESHOOTING OF MEDIUM
VOLTAGE MOTORS
General Installation and environmental
requirements
Electrical connections and earthing
requirements
Commissioning tests
Maintenance of AC machines and
periodic checks/tests
Condition monitoring and record keeping
for optimum maintenance
Bearing and lubrication system and their
monitoring
Types of faults, fault finding and testing
of AC machines
Failure mechanism in AC motors
Identifying the underlying causes
- Extended starting
- Harmonic related failures
- Single-phasing and consequential
failures
- Insulation overheating and accelerated
aging
Testing instrumentation
New technologies and developments

summary, open forum

and closing

idc@idc-online .com

www.idc-online .com

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Switchgear and
Distribution Systems

what YOU WILL Learn:

How to identify typical characteristics of an industrial distribution

system
Become familiar with the main components of an industrial
distribution system
Learn about the different types of distribution system equipment
Cover aspects of electrical safety and power security

WHO SHOULD ATTEND:

This workshop is designed for personnel who want to understand the

design and engineering principles involved in industrial distribution
systems. Those who will benefit the most from this workshop include the
following:
Design engineers
Electrical engineers
Electrical technicians
Electricians
Field technicians
Instrumentation and design engineers
Plant operators
Project engineers

2.85

The Workshop
Electrical supply is important in any industry.
It is necessary to protect power distribution
systems, equipment, motors, generators,
etc. from dangerous fault conditions in an
electrical supply. Hence, it is necessary to
arrange the equipment so it can be switched
ON or OFF under different conditions such
as, no load or load conditions, or even under
fault conditions. The collection of equipment
used for switching and protecting purposes

in a power system is called switchgear. The

most important element of good power
system design is the proper selection of the
distribution equipment.
The purpose of this workshop is to familiarise
students with the basic concepts of a power
distribution system, switchgear design and
the principles of operation and applications
of protection systems for the industrial
electrical distribution systems.

The workshop provides an overview of the

basics of industrial power distribution
systems, the various components in the
distribution systems, components of power
system protection schemes and concludes
with safety and maintenance aspects.
This workshop should be helpful for
engineers and technicians in the field of
electrical design or maintenance.

The Program
Overview

Circuit breaker basics

Typical characteristics of an industrial

distribution system
Main components of an industrial
distribution system
Distribution system equipment
Electrical safety and power security

Common distribution system

alternatives

MV distribution switchgear

Voltage classification
Voltage levels in a distribution system
Types of distribution - simple radial
distribution, radial with redundant sources,
radial with redundant feeds, primary loop
type distribution
Typical industrial distribution configuration
Single and multiple incoming feeders
Isolation arrangements
Need for a transformer
Imperatives of distribution without a
transformer
Voltage control in installations fed from
transmission/sub-transmission circuits
Outdoor vs indoor arrangement

Planning of power
distribution systems

System planning - why is it needed?

Approach
Data needed for planning and collection of
data
Studies needed - load estimation, load
flow (active and reactive), fault level,
voltage profile, motor starting, harmonic
power flow, relay coordination

Indoor and outdoor construction

Comparison
Metal clad switchgear basics
Major components
Safety features
Protection

Selection of circuit
breakers and switchgear
and their ratings and
specifications

Standards
Factors affecting circuit breaker selection
Rated voltage
Rated insulation level
Rated short time withstand current
Rated peak withstand current
Symmetrical and asymmetrical rating
Rated supply voltage of closing or
opening devices
Stored energy operation
Locking and interlocking devices
Enclosure degrees of protection

Protection, protective
relays and coordination of
protection

Need for protective apparatus

In-plant generation
requirements and alternatives Basic requirements of protection

Why in-plant generation?

Engine generators as source of power
Emergency power, standby power
Integrating emergency sources with plant
distribution
Parallel operation of generator with
external supply
Points to note in parallel operation

Transformers

DC supply equipment for

electrical switchgear

Need for DC supply

Possible alternatives to DC control
Power source for DC supply
Batteries - basic principles and common
types
Battery sizing
Battery charging
Battery chargers - principle and basic
schemes
Trip circuit supervision for circuit
breakers
Substation battery condition and
monitoring
Overcharging
Measurement of contact resistance

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Function
Historical development
Principle of operation
Major components
Typical construction - HV circuits, MV
circuits, LV circuits

Basic theory
Constructional features
Cooling methods
Voltage control
Power vs distribution transformers
Installation features
Transformer protection
Fire safety
Troubleshooting

Basic components of protection

Protection in distribution systems
Protective relays for circuit breaker
application
Role of fuses in LV and MV distribution
Protection integrated in LV devices
Importance of settings and coordination
of protective relays
Time and current grading

Power delivery systems Cables for power distribution

Types and construction of cables

Basic design and selection
Insulating materials for LV and HV cables
Accessories for cable installation
Buried installation vs open installation
Fault detection of underground cable
installations

idc@idc-online .com

Safety in operation and

maintenance of circuit
breakers and switchgear

Basics of electrical safety

Electrical shock
Touch and step potential (voltage)
Direct and indirect contact
Role of electrical insulation in safety
Avoiding electric shock different
approaches
Earth leakage circuit breakers
Earthing of power supply systems and its
safety implications
Role of earthing of equipment enclosures
(protective earthing) in human safety
Safety regulations and procedures

Maintenance and Asset

management of circuit
breakers and switchgear

Asset records
Condition Based Maintenance (CBM)
Reliability Centered Maintenance (RCM)
Insulation deterioration
Diagnostic techniques
- Partial discharge
- Partial discharge - Transient Earth
Voltage (TEV) monitoring
- Partial discharge testing by acoustic
methods
- Tan delta testing
- Thermal imaging
Problems that may be found during
switchgear maintenance
Defect management
Examples of switchgear defects

summary, open forum

and closing

www.idc-online .com

ELECTRICAL POWER SYSTEM

FUNDAMENTALS

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FOR NON-ELECTRICAL ENGINEERS

what YOU WILL Learn:

The basics of electrical power engineering

Basic electrical design rules
Practical steps in selection, installation and commissioning
of electrical systems
How to work more effectively with electrical engineering
professionals
How to apply the local electrical codes effectively
The role that electrical power plays within your organisation

WHO SHOULD ATTEND:

Administration staff
Civil, mechanical, chemical, mining engineers, technologists
and technicians
Electrical contractors
Finance, IT and accounting managers
Human resources managers
Managers who are involved with or work with staff and projects
in electrical engineering
Non-electrical engineers and technicians
Non-electrical personnel who want to understand the broader
picture
Plant and facility engineers
Project managers
Procurement and buying staff
Sales engineers

Comprehensive Course Documentation

In addition to the course materials, we will also include comprehensive reference
manuals comprising Practical Power Distribution and Safe Operation and Maintenance
of Circuit Breakers and Switchgear.

2.87

The Workshop

The Program

The focus is on the building blocks of electrical

engineering, the fundamentals of electrical
design and integrating electrical engineering
know-how into the other disciplines within an
organisation. Unnecessary theory will be
minimised and you will focus on best practice
over the two days of the course.
The course will commence by reviewing
basic electrical circuits and electrical laws.
You will then be exposed to the basic
principles
of
electrical
generation,
transmission and distribution. Electrical
distribution will then be covered in
considerably more detail. The interesting area
of electrical measurements as applied to
single phase and three phase systems will
then be reviewed. You will then be exposed to
earthing, transformers, isolators, fuses and
circuit breakers.

ELECTRICAL ROTATING
MACHINES AC AND DC

A brief historical perspective, overview of

course

Basic principles, machines, DC motor operation,

speed, flux and armature voltage, speed control,
single phase AC motors, 3-phase induction
motor, synchronous machines, torque versus
speed, efficiency and power factor

BASIC CONCEPTS
Units and electrical quantities, voltage, current,
resistance, power, energy, frequency,
inductance and capacitance, Ohms law, rms
and average values, single and three phase
systems, power factor
Practical session

ELECTRICAL GENERATION,
TRANSMISSION AND
DISTRIBUTION

Practical session

ELECTRICAL LIGHTING AND

ILLUMINATION
Incandescent lamps, high intensity discharge
lamps, mercury vapour, metal halide lamps,
fluorescent lamps, compact fluorescent lamps,
LEDs, luminaire concepts, energy efficiency
Practical session

Various forms of energy, energy conversion,

modern power station, coal-fired power plant,
hydro and nuclear, impact on environment,
solar, wind, geothermal, transmission of
electricity, distribution, power demand and
tariffs, power factor, HVDC

ELECTRICAL HEATING IN
INDUSTRY

Practical session

Practical session

ELECTRICAL DISTRIBUTION

POWER ELECTRONICS AND

APPLICATIONS

Principles of heating, electrical heating,

resistance heating, welding, electric arc
furnaces, induction heating

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The second day will commence with an

examination of AC and DC motors, followed by
a review of electrical lighting and illumination
concepts. You will then cover electrical heating,
power electronics, power quality and power
systems protection in some detail.

OVERVIEW OF THE ELECTRIC

POWER SYSTEMS

The workshop is concluded with modern

developments such as substation automation,
the smart grid, industrial data communications
and the still controversial topic of carbon
trading. In two action packed and enjoyable
days, you will leave with a valuable toolbox of
skills in electrical engineering, thus becoming
far more productive and safer in your career
and in working with electrical engineers,
technicians and managers.

Power source, typical electrical power system,

electrical distribution systems, substations, step
down transmission, distribution substation,
distribution feeder circuits, switches and circuit
breakers, industrial and residential customers,
types radial, loop, network, network reliability
(outages/power interruptions), power
transformers and distribution boards
Practical session

ELECTRICAL MEASUREMENTS
AND APPLICATIONS

Electrical parameters W/VA/VAr, measuring,

power and energy measurement, smart
metering, measuring voltages, currents and
resistance

Pre-requisites

Practical session

No formal electrical education is required as

everything is examined from a fundamentals
and practical point of view.

EARTHING

Need for earthing, direct and indirect shocks,

touch and step potential, types of earthing,
system and protective earthing, isolation, earth
conductors and electrodes, measurement of
earth resistance, lightning protection, bonding
connection
Practical session

TRANSFORMERS

Practical Sessions and

Activities

We firmly believe that no one learns by

simply listening to an instructor. So we have
added in numerous activities to liven the
show up and to make it a truly memorable
and enjoyable course. You will thus engage
in: eight hands-on practical electrical labs
with real equipment to demonstrate the
basics, twelve simple electrical design
exercises using software and calculators,
five case studies undertaken in groups of
your colleagues in assessing real situations,
a case study in a group of your colleagues
where you go through an entire project for
design,
specification,
procurement,
installation and commissioning to sign off
and handover.

Magnetic fields, electromagnetic fields,

transformer operation, step down and step up,
construction, single and polyphase
transformers, cooling, oils and coolants,
efficiency, tap changers, voltage regulation,
earthing of transformers
Practical session

ISOLATORS, FUSES AND CIRCUIT

BREAKERS
Isolation, electrical faults, fuses, isolation,
switching, tripping, circuit breakers,
components of circuit breakers, medium
voltage circuit breakers
Practical session

Semi conductor devices, motor controllers,

rectifiers, AC motors and soft starting, variable
speed drives
Practical session

POWER QUALITY

Power quality problems, voltage variations,

overvoltage and undervoltages, voltage
imbalances, voltage and frequency variations,
interruptions and surges, lightning and
harmonics, harmonic compensation
Practical session

POWER SYSTEMS PROTECTION

Incipient and solid faults, need for protection,
overloads, overvoltage and overcurrent, fuses,
circuit breakers, relays, protection of equipment
Practical session

ELECTRICAL SAFETY AND

NATIONAL ELECTRICAL CODES
Key elements of National Electrical Codes
(AS3000/NEC/CEC/SANS), electrical hazards,
electrical shock, arc flash and burns, personal
protective equipment, safety through better
design and installation, work permits,
authorisation personnel, training and first aid,
legislation
Practical session

CUSTOMER INSTALLATIONS

Metering and billing, tariff structures, connections

THE ENTIRE ELECTRICAL

PROJECT

Design rules, specification, procurement,

installation, commissioning, punchlist of
defects, contractual disputes, certificate of
compliance
Case study

THE ELECTRICAL ENGINEER/

TECHNOLOGIST/TECHNICIAN

The engineering team, roles of the team, management of the engineering team, leading the team

LOAD FORECASTING, PLANNING

AND PROJECT EVALUATION
Load forecasting principles, forward planning,
supply and demand side management,
evaluation of electrical projects

MODERN DEVELOPMENTS
The smart grid, substation automation and
industrial IT, data communications (including
wireless), cost of carbon/emissions trading

We will also make extensive use of video

clips, visual effects and simulation software
to help you with the understanding of these
concepts.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

INSPECTION, TESTING AND COMMISSIONING OF

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ELECTRICAL SWITCHBOARDS, CIRCUIT

BREAKERS, PROTECTIVE RELAYS,
CABLES AND PLCs

what YOU WILL Learn:

Nuts and bolts of electrical inspection, testing and

commissioning

Detailed principles and rules for inspection, testing and

commissioning of switchboards, switchgear, cabling and
protection relays
Selection of appropriate type and rating of switchgear and
circuit breakers
The different standards and specifications used for switchgear
and circuit breakers
Asset management of switchgear and protective relays

Safe maintenance policies including safe working in switch

rooms, indoor and outdoor substations

WHO SHOULD ATTEND:

Design engineers

Electrical engineers and technicians

Electrical maintenance engineers, technicians and supervisors

Electricians

Field and service technicians

Instrumentation engineers and technicians
Plant operators
Project engineers
And Managers, engineers, technicians and electricians who
work with switchgear, circuit breakers, switchboards and cabling
who need to update their skills and knowledge in this critical area
of inspection, testing and commissioning.
2.89

The Workshop

The Program

The overall focus of this workshop is on

electrical
inspection,
testing
and
commissioning and will commence with a
detailed examination of switchgear (and
circuit breakers). Circuit breakers are critical
components in electrical distribution
systems and their operation significantly
affects the overall operation of the system.
Protection relays are then discussed. These
are used in power systems to maximise
continuity of supply and are found in both
small and large power systems from
generation,
through
transmission,
distribution and utilisation of power in plant,
industrial and commercial equipment.

Single line diagrams

Typical construction LV/MV and HV
Active and passive network components
Circuit breaker utilisation
Fuse switches
HV fuses in combination with and as
alternatives to circuit breakers
Auto-reclosers and auto-reclose
operations
Practical Session

SPECIFICATION OF SWITCHGEAR
Switchgear ratings highest system and
impulse withstand voltages, load and
short circuit currents
Simple and complex protection schemes
Switchgear ancillaries, measurement CTs,
VTs and relays
Cable terminations
Indoor and outdoor operation
Practical Session

CONFIGURATION OF NUMERICAL
RELAYS
Setting approach in conventional relays
Configuration of relays
Troubleshooting typical problems

CABLING COMMISSIONING AND

PERIODIC TESTING

Review of codes for testing

Drum length checks
Post installation checking
Pre-commissioning and periodic tests
Tests as tools for condition monitoring
and early failure alarm
HV tests using DC and very low
frequency AC
Partial discharge tests and mapping
of results
Dielectric dissipation factor
measurements
Micro destructive and non-destructive
tests for life assessment
Operation and maintenance of cables
Practical Session

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Day two will cover commissioning and

periodic inspection of cables and their
various failure modes and how to detect
these faults. The often neglected topic of
switchboards will be detailed next, followed
by the interesting topic of interfacing to the
control system (either PLCs or other control
devices).

FUNDAMENTALS OF SWITCHGEAR

The course will be concluded with a number

of practical case studies which will pull
together the materials examined over the
past two days.

SHORT CIRCUIT TESTING

Symmetrical and asymmetrical breaking

Make and break operations
Understanding test oscillograms
Case study specification for a 132kV
switchboard
Practical Session

SWITCHGEAR DIAGNOSTICS,
TESTING AND MAINTENANCE

Asset records
Condition Based Maintenance (CBM)
Reliability Centred Maintenance (RBM)
Switchgear inspection methodologies
Insulation deterioration
Diagnostic techniques:
- Partial discharge measurement and
survey
- Partial discharge Transient Earth
Voltage (TEV) monitoring
- Partial discharge by acoustic methods
- Timing tests
- Thermovision
- Tan delta testing
Principles of circuit breaker maintenance
Contact maintenance and contact wipe
Oil testing
Maintenance of vacuum circuit breakers
and SF6
Switchgear defects and defect control
Switchgear installations
Practical Session

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:

31 short, punchy videos on switchgear,

circuit breakers, protective relays and
cables

32 short, practical design exercises on

each topic using simulation software and
calculators

POWER SYSTEM PROTECTION

PRINCIPLES AND RELAYS
Principles of protection
Types of faults
Types of protection systems
Types of protective relays
Electromechanical and static relays
Numerical relays
Practical Session

CABLE FAILURE MODES AND

FAULT DETECTION

Types of failure
Reasons for failure
Fault location
Electrical tests for detection of cable
faults
Safety issues in fault detection
Analysis of failures
Practical Session

SWITCHBOARD INSTALLATION,
INSPECTION AND
COMMISSIONING
Inspection
Routine, type, acceptance and precommissioning tests
High voltage equipment test techniques
Commissioning procedures
Practical Session

INTERFACE TO CONTROL
EQUIPMENT (PLCS)
Overview of PLC
PLC I/O modules
Pre-commissioning tests
Commissioning procedures
Typical faults
Practical Session

CASE STUDIES OF TYPICAL

PROBLEMS

Improper circuit breaker trip unit and

relay settings
Motor overload protection
Medium voltage distribution system
installation problems
Switchboard metering problems
Emergency distribution problems
Noisy transformers
Incorrect earthing and neutrals
And many others

4 case studies on switchgear, circuit

breakers, protective relays and cables
where you will work in small groups to
solve real electrical engineering
problems
Please bring a calculator to get
maximum benefit.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

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High Voltage Electrical

Compliance and Safety
Operating Procedures

what YOU WILL Learn:

Knowledge of safety rules/regulations applicable in your

workplace
How to identify the electrical hazards and take steps to achieve
zero risk
Evolve enterprise safety policies and implement them by taking
appropriate safety management steps
Plan electrical installations with in-built safety measures
Ensure safety through proper safety procedures in operation
and maintenance
Conduct safety audits in the workplace to detect systemic
issues

WHO SHOULD ATTEND:

Design engineers
Electrical operators
Maintenance technicians
Plant electrical engineers
Project engineers
Testing and commissioning engineers and technicians

2.91

The Workshop

The Program

Employees performing operations and

maintenance work on high voltage electrical
transmission and distribution systems are
exposed to a greater hazard than most other
employees. In industry the majority of safety
rules and regulations originated from the
painful experience of workers who suffered
serious injuries or even death. Therefore,
rules should not be seen as a means of
limiting our freedom, but should rather be
looked upon as valuable advice to ensure
safe working conditions. This training
workshop covers the basic procedures in
working safely on high voltage systems
including the aspects of safety management
and safety auditing.

Objectives

Health and Safety at Work Act

PUWER regulations
Electricity at Work Regulations
Enforcement Management Model (EMM)
Protocol on work related deaths
Risk gap

OVERVIEW OF BASIC SAFETY

REQUIREMENTS

Risk, danger, shock and burn

HV consequences
Zero risk approach
Elimination, substitution, control, PPE

MANAGEMENT ASPECTS

Safety policy, objectives

Risk assessments and method statements
Competence
Training and retraining
Authorisation including levels of
authorisation
Authorising engineer
Competent persons
Authorised persons
Senior authorised persons
Communication
Audit and review

OPERATIONAL ASPECTS
Rules, procedures and instructions
Method statements, risk assessments etc
Switching plan and possibility of back
feeding etc
Safety documents: permits to work,
sanctions for test, limitation of access
Duties of permit issuer and recipient
Working party control
Isolation, lockout / tagout
Caution and danger notices
Proof of dead
Safety earthing

MAINTENANCE, INSPECTION AND

TEST
Specification for maintenance and
inspection routines and frequencies

AUDIT AND REVIEW

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The workshop aims to impart a thorough

overall knowledge of working safely on high
voltage installations and the various related
topics including:

UK LEGISLATION, INCLUDING ON
SHORE AND OFF SHORE
REQUIREMENTS

Safety legislation

Electrical hazards and safety management

Technical aspects of electrical safety

Safety in operation and maintenance

Importance of periodic inspection of

electrical installations for ensuring safety
Safety audits to detect shortcomings

The workshop will include hands-on practice

in
safety
documentation
such
as
development of switching plans and
electrical access permits of different types.

Pre-requisites

A fundamental knowledge of electrical

engineering

Some experience in operation and

maintenance of electrical equipment and/
or electrical networks

Internal or external audit of procedures,

rules etc to ensure they are fit for
purpose
Safety document audit
Inspection of equipment, locks, notices
etc.
Audit of persons, training records,
authorisations etc.

summary, open forum

and closing

EQUIPMENT ASPECTS

Power system fundamentals

Circuit breakers and switches
Operating mechanisms
Instrumentation, test equipment and
testing points
Standard rating factors, plain break / arc
suppression systems
Insulation types, vacuum, air, SF6
Protection systems
System earthing
Commissioning procedures
Test equipment

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Customise the training

to your workplace.

Development of switching plans

Have the training

delivered when and
where you need it.

Operating mechanisms
Permits to work
Sanctions for test
Working party control
Abnormal event scenarios and how to
remedy

Contact us for a
free proposal.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

ID CO
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High Voltage Design and

Installations Master Class

WHAT YOU WILL GAIN:

Update your knowledge on best practice and find practical

solutions to your HV design and installations issues
Network with experienced experts and your peers
How to design to the AS 2067-2008 standard

Learn how to plan a HV substation to meet the load demand,

customers expectations, and site conditions
Learn how to design a HV substation based on current
engineering practices

Team work to solve worked HV examples and case studies

WHO SHOULD ATTEND:

Design engineers

Electrical engineers

Instrumentation engineers
Electrical technicians

Project engineers
Plant operators

2.93

The Workshop

The Program

This intensive two-day master class

addresses the AS 2067-2008 standard
(substations and high voltage installations
exceeding 1kV a.c.) in a practical applied
manner.
This standard applies to all customer and
utility high voltage installations and
compliance is mandatory.
This course will extract the key elements of
the standard and apply it via a series of case
studies in the following structure:

Standard AS2067 2008

(substations and HV
installations)

Planning
Design
Installation

Scope and definitions

Exclusions
Status
Contents
Fundamental requirements
Safety measures
- Earthing systems
- Insulation coordination
- Basic insulation level (BIL)
- Electric shock
- Power frequency test

Power system planning

Relay types
Fault types
Protection functions
Protection criteria
- Speed
- Stability
- Sensitivity
- Simplicity
- Selectivity
Current transformers
- CT ratio
- Burden
- CT error
- CT accuracy class
Voltage transformers
- VT ratio
- VT error
- VT accuracy class
Protection techniques
- IDMT
- DT
- High-set instantaneous
- Directional protection
- Differential protection
- Distance protection
Protection schemes
- Feeder protection
- Transformer protection
- Line protection
- Motor protection

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Case Study Based

The case studies will cover different stages

of planning and design of a large HV
installation such as a transmission
substation. You will need to have your
calculator. You will cover the following key
areas:

Planning criteria
- Safety
- Reliability
- Flexibility
Load forecasting
Voltage selection
Site conditions
- IP class
- Soil resistivity
Security of supply
Busbar configurations
System studies
- Load flow analysis
- Fault calculations

Power system protection

Planning feasibility studies

Load studies
Fault studies
Incoming HV supply
Operational flexibility
Busbar configurations
Supply redundancy
Cable sizing
Overhead conductor sizing
Earthing system

Earthing system design

Power system protection

To gain full value from this workshop,

please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Need for earthing

Earthing electrodes
Earthing mesh
Equipotential bonding
Static charges
Lightning and its effects
Earthing methods
- Ungrounded
- Solidly earthed
- Resistance earthed (NER)
- Impedance earthed
- Resonant earthing (tuned reactor)
Soil resistivity
Touch potential
Step potential
Earthing of MV/LV installations
Lightning protection

Customise the training

to your workplace.

Overhead system design

Line design criteria

Line definitions
- Sag
- Span
- Slack
- Swing of conductor
- Conductor tension
Overhead line design
- Line conductor codes
- Line conductor ampacity
- Line conductor sizing
Line conductor fault capacity
Line capacity voltage drop

Underground cable design

Cable system criteria
- Cable codes
- Cable ampacity
- Cable sizing
Derating factors
Cable fault capacity
Cable voltage drop

SUMMARY, OPEN FORUM

AND CLOSING

Have the training

delivered when and
where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

ID CO
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High Voltage Design and

Installations Master Class (UK)

WHAT YOU WILL GAIN:

Update your knowledge on best practice and find practical

solutions to your HV design and installations issues
Network with experienced experts and your peers

How to design to the BS EN 61936-1:2010 standard

Learn how to plan a HV substation to meet the load demand,

customers expectations, and site conditions
Learn how to design a HV substation based on current
engineering practices

Team work to solve worked HV examples and case studies

WHO SHOULD ATTEND:

This is a master class for electrical engineers and technologists and

associated disciplines involved in high voltage design, installation,
inspection, testing and commissioning, e.g.:
Design engineers

Electrical engineers

Instrumentation engineers
Electrical technicians
Project engineers
Plant operators

2.95

The Workshop

The Program

This intensive two-day master class

addresses the BS EN 61936-1:2010 standard
(substations and high voltage installations
exceeding 1kV a.c.) in a practical applied
manner.
This standard applies to all customer and
utility high voltage installations and
compliance is mandatory.

Scope & definitions

Exclusions
Status
Contents
Fundamental requirements
Safety measures
- Earthing systems
- Insulation coordination
- Basic insulation level (BIL)
- Electric shock
- Power frequency test

Power system protection

Power system planning

Planning criteria
- Safety
- Reliability
- Flexibility
Load forecasting
Voltage selection
Site conditions
- IP class
- Soil resistivity
Security of supply
- Busbar configurations
System studies
- Load flow analysis
- Fault calculations

Relay types
Fault types
Protection functions
Protection criteria
- Speed
- Stability
- Sensitivity
- Simplicity
- Selectivity
Current transformers
- CT ratio
- Burden
- CT error
- CT accuracy class
Voltage transformers
- VT ratio
- VT error
- VT accuracy class
Protection techniques
- IDMT
- DT
- High-set instantaneous
- Directional protection
- Differential protection
- Distance protection
Protection schemes
- Feeder protection
- Transformer protection
- Line protection
- Motor protection

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This course will extract the key elements of

the standard and apply it via a series of case
studies in the following structure:
Planning
Design
Installation
Commissioning, Testing and Validation
As per the Scope Statement in Section 1 of
the Standard documents: This standard
provides minimum requirements for the
design and erection of high voltage
installations in systems with nominal
voltages above 1 kV a.c. and nominal
frequency up to and including 60Hz, so as
to provide safety and proper functioning for
the use intended.

STANDARD BS EN 61936-1:2010
(SUBSTATIONS & HV INSTALLATIONS)

Case Study Based

Earthing system design

The case study will cover all the typical

design phases for a large industrial
installation. The design phases could
typically be described as: the conceptual
design of the incoming HV supply and
internal HV distribution (taking into account
the plants requirements and need for
operational flexibility and redundancy etc),
the design of any aerial HV lines required,
the design of any major underground cable
circuits required, the design of substations
including earthing systems required,
selection of type of HV switchgear required,
selection and design of the protection
systems typically required.

This course is aimed at the private electrical

installation designer. However, the topic HV
design and installation could also be
interpreted as possibly covering the
electricity
utility
transmission
and
distribution sector (HV transmission and
distribution network design) for which the
HV design approach would be quite different,
even though the technical fundamentals
(and some of the technical standards such as
BS EN 61936-1:2010) are the same. This will
not be the focus of this presentation.

Need for earthing

Earthing electrodes
Earthing mesh
Equipotential bonding
Static charges
Lightning and its effects
Earthing methods
- Ungrounded
- Solidly earthed
- Resistance earthed (NER)
- Impedance earthed
- Resonant earthing (tuned reactor)
Soil resistivity
Touch potential
Step potential
Earthing of MV/LV installations
Lightning protection

Overhead system design

Line design criteria

Line definitions
- Sag
- Span
- Slack
- Swing of conductor
- Conductor tension
Overhead line design
- Line conductor codes
- Line conductor ampacity
- Line conductor sizing
Line conductor fault capacity
Line capacity voltage drop

Underground cable design

Cable system criteria
- Cable codes
- Cable ampacity
- Cable sizing
Derating factors
Cable fault capacity
Cable voltage drop

SUMMARY, OPEN FORUM

AND CLOSING

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Fundamentals of Operation and Troubleshooting of

Emergency/Standby Power Generation

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using Diesel Generators

WHAT YOU WILL Learn:

To select and apply Diesel engines for emergency power

requirements in your work place
To choose appropriate ratings and fuel options

To select and apply alternators, their excitation and protection

systems
To plan for auxiliary systems of the engine as a part of the
package
To formulate procedures for testing and commissioning of
Diesel engine generators
To be able to guide your team to operate and maintain Diesel
engine generators

WHO SHOULD ATTEND:

Plant electrical/mechanical engineers

Design engineers
Project engineers
Testing and commissioning engineers and technicians
Maintenance technicians (engine/electrical)

2.97

The Workshop

The Program

Industries require stable, reliable power

supply. Sometimes this becomes difficult
due to remote location of the industry or
weak grid supply. Essential loads need to
be provided with power supply from
in-plant generators either to supplement
the grid supply or as an emergency source
for critical loads which can tolerate very
little or no interruptions. Diesel engine
generators are useful in these circumstances
because of their simplicity, ease of
maintenance and ability to run with
different types of fuels. They can be started
easily without external supply assistance,
available in a variety of ratings and can be
operated in parallel with other generators
or with the supply grid if needed.

A brief history of electricity

The static and dynamic forms of
electricity-the difference
Electrical circuits
Voltage, current, resistance and Ohms law
Dc and ac circuits-how they differ
Ac amplitude-time curve-Why is it called
a sine wave?
Phasors -Introduction
Reactance and impedance and Ohms law
for ac circuits: Calculation examples
Concept of power factor (displacement
power factor)
Circuit theory and applicable laws for
solving problems of power flow in ac
and dc circuits
DC and ac sources

FORMS OF ENERGY AND

CONVERSION-WHY ELECTRICITY IS
A CONVENIENT ENERGY CARRIER

LUBE OIL SYSTEM

Lube oil specification

Lube oil consumption in diesel engines
Typical Lube oil system layouts
Viscosity and temperature
Lube oil filters and heaters

BASICS OF AC SYNCHRONOUS
GENERATORS AND ESSENTIAL
COMPONENTS

The basic electrical generator

Components of the alternator
Stator winding in alternators
Rotor (field) windings
Damper windings
Slip rings
Sources for supplying field current to
rotor
- Rotary exciters
- Static exciters
- Brushless excitation
Cooling components and methods of
cooling

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This training describes the principles of

engines and generators starting with the
fundamentals, discusses the options
available and the constructional details of
engines, the electrical alternators and
auxiliary equipment in an easy to
understand manner. The testing and
commissioning of Diesel engine generators
and their operation and maintenance
aspects are also discussed.

REFRESHER ON THE BASIC

ELECTRICAL THEORY

An optional third day is also offered (refer

to the separate outline given in this
document) for those who wish to achieve a
more in-depth knowledge of the enginebased power plants, operation of more
than one engine generator in parallel and
also synchronised to the utility grid.

Pre-requisites

A fundamental knowledge of mechanical

or electrical engineering
Some experience in operation
maintenance of general machinery

and

Planning plant installations

Potential and kinetic energy as the main

classification of energy forms
Energy types based on the source such
as fuel, chemical, nuclear and mechanical
What is meant by energy carrier?
Why is electricity the most preferred
energy carrier?
Points of comparison
Law of energy conservation and laws of
thermodynamics-Applications to power
generation

ENGINES FOR POWER

GENERATION-LIQUID AND
GASEOUS FUELS

A brief historical perspective

External combustion cycles (Otto, Diesel)
External combustion engines-Spark and
compression ignition types
Industrial generating sets based on
compression ignition cycle
Fuels used: liquid and gas engines

DIESEL TECHNOLOGY AND

CLASSIFICATIONS

Basic Engine processes

Dual Fuel Engines
Speed Classifications
Service Classifications

BASIC ENGINE DESIGN AND

RATINGS

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

Design characteristics and formulas

Turbo charger
Ambient conditions
ISO ratings
Performance and Efficiency
Efficiency enhancements
Engine speed
Fuel combustion methods

FUEL OILS USED AND FUEL

HANDLING SYSTEM

Crude oil
HSD, LDO and Heavy fuels
Economics of fuel selection
Pressure and temperature characteristics
Viscosity characteristics
Specific heat and temperature
Viscosity conversion
Specific fuel consumption
Fuel filters and heaters
Fuel nozzles and igniters
Emission control
Storage requirements
Typical fuel system layouts and
components

idc@idc-online .com

PROTECTION OF AC
SYNCHRONOUS GENERATORS

Failure modes of ac generator

Stator winding protection-short circuits
Stator winding protection-earth faults
Differential (circulating current type)
protection for windings
Rotor winding protection-Single and
double earth fault
Negative sequence current protection
Excitation failure and pole slip/out-of-step
protection
Over voltage protection of generators

DIESEL GENERATING SETS

Coupling Requirements
Skid mounting
Layout requirements
Standard Control panels
Interconnections

OTHER COMPONENTS

Starting methods
Starting characteristics
Battery sizing
Step load requirements
Standby requirements
Auto start and auto transfer schemes
Auto Transfer switches

TESTING AND COMMISSIONING

Factory tests
Pre-commissioning checks
Pre-commissioning tests
Performance monitoring
Fuel and lube oil consumption checks
Electrical system tests

OPERATION AND MAINTENANCE

OF DIESEL GENERATING PLANTS

Safety requirements
Operation monitoring based on
applications
Philosophy of maintenance
Maintenance techniques
Maintenance planning and scheduling
Spares and inventory management
Maintenance tools
Inspection
Engine overhaul and repair
Training
Health monitoring
Troubleshooting

SUMMARY, OPEN FORUM

AND CLOSING

www.idc-online .com

Diesel Power Generation plants

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with Multiple Machines in Parallel and on the

Electrical Power Grid

WHAT YOU WILL Learn:

To plan a power generation facility for your industry using

diesel engine generators
To plan telecontrol and protection equipment for the generation
facility
To achieve successful operation of multiple engine generators
in parallel
To configure a multi-engine generation system for operating in
parallel with an external power network
To apply engine based electromechanical UPS systems in large
process industries

WHO SHOULD ATTEND:

Plant electrical/mechanical engineers

Design engineers
Project engineers
Testing and commissioning engineers and technicians
Maintenance technicians (engine/electrical)

2.99

The Workshop

The Program

The earlier part of the course covered the

fundamental principles of the diesel enginegenerator set. This part will discuss the need
for standby/emergency power generation in
industries and the details of engine-based
power stations. Achieving large standby
capacities would call for multiple generating
sets to be operated in parallel and at times
synchronised with an external power source.
The factors to be considered to achieve
proper load sharing and also to safeguard
against power grid abnormalities are
discussed. A brief description of the enginebased uninterrupted power source is also
included.

DIESEL POWER GENERATING

STATIONS

OPERATION WITH EXTERNAL

POWER GRID

Industrial applications
Power generation plant applications
Essential subsystems in a Engine based
power plant
Single and multiple sets
Fuel storage requirements
Air Intake system
Exhaust system
Auxiliary power requirements
Typical power schemes
Typical power plant layout

Important aspects of operating

generators in parallel with external
sources
Active power and power factor control
Precautions against asynchronous
closing
Protection aspects against external earth
faults
Protection of tie line
Directional protection requirements
Protecting against external system
problems
Reverse power, frequency based and
vector surge protection systems
Islanding and load management after
islanding
Re-synchronisation with grid

DIESEL GENERATOR
MEASUREMENT AND CONTROLS
Measurements and alarms
Engine and generator control
Auto operation modes
Auxiliary system measurement and
alarms
Battery charger and alternator controls
Telecontrol-Local and remote control
Communication by RS232, Modbus,
ModbusIP and Ethernet

ENGINE BASED UNINTERRUPTED

POWER SUPPLY (UPS)
Need for uninterrupted power in
industries
Static UPS as an option-its limitations
Parallel operation as an alternative
means of uninterrupted power
Engine-based no-break power option and
applications in industry
Special features of engine-based (Rotary)
UPS
Advanced features of rotary UPS
Configuration of a power distribution
system with rotary UPS

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Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

POWER GENERATION
APPLICATIONS IN INDUSTRY

Need for in-plant generation

Difference between standby, emergency
and base load generation
Black start capability in industrial
generators
Stand alone operation of a generator
Alternator capability curves
Speed governor as frequency controller
Voltage regulation through excitation
control
Why multiple generators are often used?
Multiple generators-Load sharing and
voltage regulation

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical Maintenance & Troubleshooting of

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Battery Power Supplies

the workshop:

This workshop provides you and your personnel with the

knowledge and information required to perform their duties
competently and safely in working with lead acid batteries. This
workshop will encompass basic battery theory, types of batteries,
installation, testing and maintenance.

WHO SHOULD ATTEND:

Maintenance Personnel
Supervisors
Electrical and Instrumentation Technicians
Health and safety personnel
Purchasing personnel
Maintenance and Plant engineers

2.101

Practical Sessions

The Program

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

INTRODUCTION

ROUTINE TESTING PROCEDURES

Objectives of the course

Basic Technical Concepts

External Load Banks

Other specialised test equipment

HEALTH AND SAFETY ISSUES

GENERAL MAINTENANCE AND

REPORT DATA

National and International Standards (eg

BS 6133:1995)
Regulations and Law

BASIC BATTERY THEORY

How a battery works

Battery Construction
Manufacturing processes
Failure Modes
Terminology and design

TYPES OF BATTERIES

Regulated Lead Acid

Vented Lead Acid
Nickel Cadmium
Battery Ratings

Maintenance to ensure long life and

reliability
Instruments: What is available and how
to use them
Routine care, maintenance and servicing
Changing procedures
Handling equipment
Safety
Inspection
Data Interpretation
Causes of Battery Failure
Storage of batteries

DIAGNOSIS OF BATTERY
CONDITION
Recognising problems at an early stage
Rectifying problems to ensure long life

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BATTERY INSTALLATION

New battery installation

Receiving new battery shipments
Working practices in compliance with BS
6133 and AS/NZ standards

INITIAL AND FLOAT CHARGING

Different charging methods

Correct Methods
Importance of correct Float Voltages

BATTERY MONITORING SYSTEMS

Float Voltage, charge and discharge
currents
Temperatures

DATA LOGGING AND

INTERPRETATION
Recording
Interpreting test data

BATTERY PERFORMANCE
PREDICTION

Estimation and prediction of battery and

life expectancy
Time to run

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

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your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

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Standby Power and

Energy Efficiency

YOU WILL Learn how to:

Understand the level of failure-proofing that specific equipment

may require
Know the various available options of critical power supply
systems
Assess the various power supply options objectively

Design a suitable power distribution system for critical power

Specify the solution that is the best and most economical for
your needs
Establish an energy savings strategy for your installation

WHO SHOULD ATTEND:

Distribution planning engineers

Electrical and instrumentation engineers
Plant engineers
Automation engineers
Control engineers
Mechanical engineers
Engineering managers
Operators and technicians
Anyone actively involved with implementing or optimising a
critical power supply system

2.103

The Workshop

The Program

Ensuring a reliable power supply for your

installation is probably one of your key tasks
as an engineer, technician or manager
especially with the current challenges of
rolling black outs in South Africa. An
unscheduled interruption can cause loss of
production, , immense damage and possibly
accidents and loss of life. While it is
impossible to guarantee 100% availability of
power at all points in any system, vulnerable
sections can be provided with alternative
critical power supply equipment to ensure
reliable power availability, thereby avoiding
the problems of power interruption.

ELECTRICAL ENERGY USAGE

ELECTRICAL POWER SCENARIO
TODAY
CRITICAL POWER NEEDS AND
SOLUTIONS
OVERVIEW OF CRITICAL POWER
SUPPLY EQUIPMENT
DIESEL GENERATING SET
(PART 1: ENGINES)
DIESEL GENERATING SET
(PART 2: GENERATORS)
STATIC UPS BASICS

SELECTION AND SIZING OF

BATTERIES
INSTALLATION OF BATTERIES
STATIC TRANSFER SYSTEMS FOR
CRITICAL POWER SUPPLIES
EMERGING TECHNOLOGY FOR
CRITICAL POWER APPLICATIONS:
FUEL CELLS
WHAT IS ENERGY EFFICIENCY?
ENERGY EFFICIENT PRACTICES IN
ELECTRICITY USE
ENERGY EFFICIENCY IN CLIMATE
CONTROL (HVAC) APPLICATIONS

BASICS OF BATTERIES

INTRODUCTION TO ENERGY
AUDITS

CHARGING AND DISCHARGING

OF BATTERIES

SUMMARY, OPEN FORUM

AND CLOSING

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The key initial objective of the workshop is

to go through the key steps in ensuring a
reliable power supply to critical systems
using various available options. The
solutions can vary from the simple diesel
generating set as standby sources to highcapacity UPS systems for large business
premises. New technologies such as fuel
cells have matured and are fast becoming
mainstream solutions. Of course, all this
comes at a price, which means that the
solution must match the actual needs at a
reasonable cost. We will discuss how to save
dollars by finding the right solution to your
needs so that you invest just what is needed
and where it is needed.

MAIN FORMS OF ENERGY

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Another major aspect is to ensure that

critical power supply is itself very reliable.
This will need suitable redundancies and a
well-engineered multi-module system so
that when the need arises the redundant
modules cut-in and take over the load
without any hitches. This workshop will also
briefly look at the design issues involved in
planning the distribution of critical power by
deploying state-of-the art control devices
such as static transfer equipment.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Finally, strategies you can implement to

optimise energy efficiencies at your facility
will be examined. Reducing electric power
usage results in reduced expenditure to the
consumer. On a macro-level, it reduces
power demand and avoids the need for
power cuts and load shedding by the power
supply agencies. It also reduces the capacity
requirement and capital expenditure on
standby power equipment. The workshop is
concluded with the steps to take to optimise
the energy efficiency of your installation.
If you are responsible for maintaining power
availability in your facility, this workshop is
something which you simply cannot afford
to miss. And all you need is to just invest
three days of your time and listen to what
our expert instructors have to say!

Pre-requisites

Working knowledge of electrical engineering

and hands-on work with power distribution
systems in a plant environment with critical
processes is desirable. Real-life experience
with critical power supply sources such as
uninterrupted power supply (UPS) systems
will further enable the workshop to be
placed in context.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

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Electrical Substation and

Switchyard Design

YOU WILL Learn how to:

Select an optimised location for a substation being set up to fulfil a

given set of needs
Choose the most appropriate configuration and type of substation
for this requirement
Design a detailed layout taking into account all essential aspects
Develop a set of conditions for which detailed system studies need
to be carried out
Specify the equipment required based on the studies
Design the individual subsystems for control and protection of the
power system which the substation serves
Design earthing and lightning protection systems to ensure safety
of equipment and personnel in the event of abnormal system
conditions such as faults and lightning events
Design the required electrical interconnections to ensure correct
functioning of the substation equipment
Draw up a list of design inputs for building and structural design
engineers
Plan the support facilities required for the substation

WHO SHOULD ATTEND:

This course is aimed at engineers are already working as electrical

system designers as well as those who belong to any of the fields
listed below and wish to prepare themselves for moving into the role
of a substation designer.
Utility engineers dealing with power transmission and distribution
systems
Electrical engineers involved in power generating plants with
utility scale generators
Electrical engineers in large industries who are associated with
power distribution
Consulting engineers involved in design of substations
Contractors executing projects involving electrical HV substations
Electrical commissioning engineers
2.105

The Workshop

The Program
ROLE OF SUBSTATIONS IN AN
ELECTRICAL NETWORK, TYPES
AND CONFIGURATIONS OF
SUBSTATIONS

Networks-an introduction
Different voltages in a network
Substations as network nodes
Substation types based on their position
in the network
Optimising the location of a substation
Substation options: Outdoor air
insulated, GIS, Indoor air insulated
Configurations of HV substations based
on their bus arrangement (typical SLD)
Data on the industrial loads required for
the design of the electrical supply
substation
Load assumptions for residential and
commercial consumers
Environmental issues in the location of a
switchyard and mitigation measures

SYSTEM STUDIES REQUIRED FOR

FINALISING EQUIPMENT RATINGS

EARTHING SYSTEM AND

LIGHTNING PROTECTION OF
SWITCHYARDS

Basics of functional and protective

earthing
Touch and step voltages in substations
Earth grid and its role in safety
Switchyard fence-why it should be a part
of the earth grid
Design of earth grid-basic considerations
in conductor sizing and mesh spacing
Pros and cons of including the control
building within the switchyard earth grid
Earth mat laying and welding
Safety mesh at operating points
Role of gravel layer in safety
Transferred voltage hazards
Planning isolation of outgoing services to
avoid transfer voltage
Basics of lightning and hazards
Role of shield wire and lightning masts
Typical configurations of lightning
protection of switchyards
Analysis of hazard using cone of
protection and rolling sphere methods
Selection of lightning arrestors-Types,
class and ratings

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Electrical substations form important nodal

points in all power networks. Substations
can be of various capacities, voltages,
configurations and types depending on
what is the application for which the
substation is being designed. Location and
layout of a substation present a number of
challenges to the designer due to a large
variety of options available to a designer.
There are ever so many constraints too that
need to be kept in mind; technical,
environmental and naturally financial.
Arriving at an optimum design within these
constraints is as much an art as it is a
science. Designing a substation which will
operate with utmost reliability for at the
least three or four decades involves a
thorough knowledge of the current state-ofthe art equipment, emerging technologies,
the tools for presenting and evaluating all
available options and a good appreciation
of
power
system
operation
and
maintenance. This course will present a
comprehensive capsule of all the knowledge
essential for a substation designer and walk
the participants through the substation
design process using a set of interlinked
case studies.

Pre-requisites

A good basic knowledge of electrical

transmission and distribution equipment

Experience in operating, maintaining and

troubleshooting of substation equipment
Some exposure to design will be an
advantage but not essential

A good theoretical background of electrical

engineering and willingness to use and
upgrade their numerical and computer
skills
A basic appreciation of the related
engineering disciplines such as civil,
structural and data communications

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

Load flow study (active/reactive loads)

Short circuit study
Harmonic flow
Voltage profile and reactive power
compensation
Stability study

SWITCHYARD CONTROL AND

INTERLOCKING

OVERVIEW OF SWITCHYARD
EQUIPMENT AND THEIR
ORDERING SPECIFICATIONS

Dc power requirements for switchyard

equipment
Dc equipment configuration and
specifications
Dc distribution for switchyard equipment
Battery calculations basis
Space planning and related facilities for a
battery installation
Ac auxiliary power for switchyard
systems-loads which require ac power
Possible source options
Ac auxiliary distribution for switchyard
equipment and support systems
Control scheme of disconnectors and
circuit breakers
Control interconnection approach
Use of optical fibre-based control scheme
Role and location of marshalling kiosks in
different bays

SUBSTATION EQUIPMENT FOR

FAULT LIMITING, PFC AND
HARMONIC CONTROL

SWITCHYARD-FACILITY
PLANNING

Main (primary) equipment

- Busbars
- Disconnectors
- Circuit breakers
- Instrument transformers
- Lightning arrestors
- Power transformers
- Structures
Layout options
Sectional and Safety clearances and their
influence on the layout
Design of busbars (strung/tubular) and
interconnections between equipment
Interconnecting cables and use of
marshalling kiosks

Need for and application of:

- Fault limiting reactors
- Power factor compensation equipment
- Static VAR compensators
- Harmonic filters
Equipment design and selection of
ratings
Layout of these equipment in a
switchyard

PROTECTION DESIGN FOR

SUBSTATION

Brief overview of protection

Over current protection
Protection coordination
Protection of transformers
Busbar protection
Feeder protection
Current transformers requirements for
protection
Equipment requirements for substation
automation
PLCC applications in protection and
communication
PLCC hardware and integrating them
with the switchyard equipment

Site preparation, levelling

Earth resistivity measurement and its role
in design verification
Civil works such as equipment
foundations, cable trenches, control
building, storm drains, transformer oil
collection pit
Structures and their design requirements
Substation fence and physical security
Surveillance
Planning water requirements and supply
arrangement
Fire protection, lighting and ventilation of
control room and other equipment

GAS INSULATED SWITCHGEAR

(GIS) AS AN ALTERNATIVE TO
OUTDOOR SWITCHYARD

Why gas insulated substation?

SF6 properties, advantages and
environmental impact
Typical substation configurations in SF6
Indoor/outdoor options
Gas safety considerations
Equipment for handling SF6
SF6 substation layout planning
Cable terminations to SF6 equipment

SUMMARY, OPEN FORUM

AND CLOSING

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Understanding Electrical
Engineering and Safety

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for Non-Electricians

WHAT YOU WILL Learn:

Basic facts about electricity and its uses

Operating principles of common appliances

Protection of electrical circuits against faults

Working on electrical circuits and troubleshooting

What makes electricity unsafe and how to work safely

WHO SHOULD ATTEND:

Civil, mechanical, chemical, mining engineers, technologists

and technicians
Managers who are involved with or work with staff and projects
in electrical engineering
Non-electrical engineers and technicians
Non-electrical personnel who want to understand the broader
picture
Plant and facility engineers
Procurement and buying staff
Project managers
Sales engineers

2.107

The Workshop

The Program

Electrical engineering is often considered

to be a mysterious science, because
electricity cannot be seen. However, we are
all aware of its existence and usefulness in
our daily lives. This workshop aims to take
the mystery out of electrical engineering
and give a good understanding of the
fundamental principles of electricity. While
many of us work on electrical systems, we
do not fully appreciate the dangers, which
we get exposed to when doing so. All it
takes is a few simple precautions to avoid
getting hurt. This workshop teaches you all
about the dangers of careless handling of
electrical appliances and prevention of
electrical accidents.

Electricity is a form of energy

Static electricity
Electrical cells and DC
Voltage and current relationship - ohms
law
Power and energy relationship
A simple circuit using DC (battery) source
Electromagnetic generators (AC) relation between magnetism and
electricity
Speed of rotation and frequency
Single phase and 3-phase AC systems basic facts
Phase sequence

HOW IS ELECTRICITY
DISTRIBUTED?

A modern electrical power system

Multiple voltage levels and transformers
Substations
Your local power utility
Measurement of energy usage and tariff
Conductors for carrying current
(insulated versus bare)
Receiving power from the utility
Distribution within a facility
Distribution boards
Circuit breakers (ACB, MCCB, MCB,
ELCB)
Isolators and fuses

ELECTRICAL FAULTS

Basic faults in electrical circuits an open

connection or an unwanted connection
Insulation and its importance
Reasons for failure
Preventing overloads
- Overload protection by thermal relay,
temperature protection etc.
Faults due to insulation failure
- Short circuits
- Earth faults
Short circuit protection
- Fuses
- Circuit breakers with magnetic releases
Earth fault protection
- Earth leakage relay
- Fuses and breakers can protect too
Open circuits and reasons
- Importance of proper terminations
Danger of open circuit causing single
phase operation of 3-phase motors
- Why is single-phasing dangerous to
motors?
- Detection by single-phasing relays

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This workshop is not meant for electrical

engineers and other qualified technicians. It
is for those who are not formally trained as
electricians but often have to handle and
maintain electrical appliances in the course
of their work. The participants will have an
opportunity to understand how the
appliances they see everyday actually
function. This workshop will deal with the
subject with a minimum of theory while
emphasising on the practical, hands-on
approach.

ELECTRICITY

HOW IS ELECTRICITY USED?

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. Some of these sessions will be in
the nature of discussion groups and will take
a specific topic related to the module for
discussion.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.

Electricity as an energy carrier

Electricity is clean, easily controlled and
instantaneous in action
Lighting
Heating
Mechanical drive/motion and
transportation
Common examples of appliances

BASIC FACTS ABOUT ELECTRICAL

APPLIANCES
Lighting
Light sources and their relative merits
- Filament lamps
- Metal halide lamps
- Fluorescent lamps and CFL
- Mercury and sodium vapor lamps
- Starters and their function
Electric heaters
- Resistance heaters
- Heaters using high frequency methods
(example: microwave)
Electrical motors
- Pumps and compressors
- Cooling and refrigeration
- Transportation and lifting
Control of electrical motors
- Difference between single phase and
3-phase motors
- Starting methods
- Speed-frequency relationship
- Speed control methods in AC motors
- Phase reversal and its effect on
direction of rotation in 3-phase motors

Have the training

delivered when and
where you need it.

WORKING ON ELECTRICAL
CIRCUITS

Why is work needed on electrical

circuits?
For maintenance
For fault finding (troubleshooting)
For testing
Working with circuit energised (refer to
relevant codes)
Lamp changing
Troubleshooting (measuring current flow
or checking for voltage at specific points)
Working with circuit switched off
Procedures lock-out/tag-out
Earthing a circuit for safety
Checking that a circuit is dead
Voltage tester (neon stick, single and twolamp testers)
Instruments used for troubleshooting
Multimeters - what do they measure?
Clip-on ammeter
Continuity tester
Insulation tester

ELECTRICAL SAFETY

Dangers of electricity
- Electric shock (direct and indirect)
- Fall caused by electric shock
- Arc flash and burns
Role of PPE in safety
- Examples of PPEs
Avoiding shock danger
- Safety while doing permitted live work
- Safety while working on dead circuits
- Role of protective earthing for safety
during normal operation
Arc flash dangers
- Severe burns
- Avoid live work except as permitted
under codes
- Use insulated tools
- PPE for live work and for operations
such as switching
Codes and the need to follow them
strictly
- Australian Wiring Regulations; locally
applicable code
Electrical accidents and first-aid

SUMMARY, OPEN FORUM

AND CLOSING

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Master Series

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Electrical Engineering

WHAT YOU WILL Learn:

Gain skills and know-how in the latest technologies in electrical

engineering
Gain a clear picture of the latest developments and future
directions in electrical engineering from experts in the field
Learn how to make reliable, well grounded and commercially
viable technical, financial and management decisions in
electrical engineering.
Learn how successful electrical engineers communicate their
vision and values to build up a super effective team.

WHO SHOULD ATTEND:

This Master Series course is designed for people from an electrical

background. It has been developed for those whose time is limited
and who work in a critical role or situations where a lengthy time
away for study is impossible.
Automation and process engineers
Chemical and mechanical engineers
Consulting engineers
Electrical engineers and technicians
Electrical technicians
Energy management consultants
Field technicians
Graduate engineers
Instrumentation and design engineers
Maintenance engineers and supervisors
Project and production managers
Project engineers

2.109

Practical Sessions

The Workshop
The Electrical Engineering Master Series delivers a critical blend of knowledge and skills,
covering technology in electrical engineering, industry analysis and forecasts, leadership,
management and everything that is relevant to a modern electrical engineer. You will be
exposed to four high impact days where you will not only hear from outstanding experts
in each of the key areas but undertake practical hands-on sessions and exercises.
This course is not intended as a substitute for a 4 or 5 year engineering degree or diploma,
or for an accomplished and experienced professional electrical engineer who is working at
the leading edge of electrical practice in these varied fields. It is however, intended to be
the distillation of the key skills and know-how in practical, state-of-the-art electrical
engineering.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. Some of these sessions will be in
the nature of discussion groups and will take
a specific topic related to the module for
discussion.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

The Program
SETTING THE SCENE

Issues, timing, instructors and protocols

to be followed during the exercises.
Participants will be introduced to each
other and their assigned team.

Electrical system earthing

Earth electrode systems
Earthing design of substations
Lightning and protection against
lightning
Lightning protection of structures,
electrical lines and substations
Lightning protection of marine electrical
systems
Surge protection
Electrical noise and mitigation-role of
earthing

Oil testing
TAN Delta testing
Partial Discharge (PD) testing
Impulse testing
Transformer testing
Cable testing

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UNDERSTANDING ELECTRICAL
DRAWINGS

EARTHING AND LIGHTING SURGE

PROTECTION

Engineering drawing for electrical

engineers
Symbols used in electro technology and
governing standards
Single line and 3-line diagrams
Cabling and wiring drawings
Layout drawings
Advances arising from computer aided
drafting (cad)

ELECTRICAL POWER
DISTRIBUTION FUNDAMENTALS

Common distribution system alternatives

Planning of power distribution system
Fault level in electrical systems and their
role in the choice of equipment
Fault current evaluation of simple power
distribution systems
In-plant generation requirements and
alternatives
Distribution equipment sizing
Power distribution system automation
Maintenance and asset management in
distribution systems

CIRCUIT BREAKERS AND

SWITCHGEAR

Circuit breaker basics

Difference between isolator and circuit
breaker
Principle of arc quenching
Major components
Enclosures for indoor use and IP ratings
HV Circuit breakers
Common types of HV circuit breakers
(BOCB, MOCB, ABCB and SF6 CB)
Outdoor construction examples
Operating principles of different type of
CBs
Maintenance aspects of HV circuit
breakers
LV Circuit breakers
Common types of LV circuit breakers
(ACB, MCCB, Motor CB and Miniature
CB)
Selection of circuit breakers and
switchgear, their ratings and
specifications

POWER CABLES

Introduction
Basic theory
Selection of cables and installation
Joints and termination
Jointing and termination practice
Commissioning and periodic testing
Failure modes and fault detection
New trends in cable technology

POWER SYSTEM PROTECTION

Need for protection

Fuses
Instrument transformers
Tripping power source
Relays and relay coordination
Principles of unit protection
Switchgear (busbar) protection
Transformer protection
Motor protection relays
Generator protection

BUDGETING, ROI AND FINANCE

OF ELECTRICAL PROJECTS

Introduction
Basic accounting concepts
Budget preparation and control
Understanding cash flow
Estimation and costing
Time value of money and discount rates
Investment appraisal methods: DCF,
Payback, NPV, IRR
Capital budgeting
Decision making
Tax
Risk and uncertainty

ELECTRICAL SAFETY AND WIRING

REGULATIONS
An Introduction to Electrical Safety
Role of protective earthing in electrical
safety
Hazards due to electrical arcing and
heating - 1
Hazards due to electrical arcing and
heating - 2
Safety aspect in electrical design and
selection
Safe operation and maintenance
Substation safety
Safety in battery installations
Organizational aspects of safety
Australian regulations on safety

TESTING, TROUBLE SHOOTING

AND MAINTENANCE OF
ELECTRICAL ENGINEERING

PROJECT MANAGEMENT OF
ELECTRICAL PROJECTS

Fundamentals of project management

Time management
Cost management
Integrated cost and time management
Construction contracts
Management of the project team
Risk management
Contract law
Project planning
Application to instrumentation and control

PREPARATION FOR
PRESENTATIONS

Each team will prepare for the

presentations on the next day. The
instructors will spend time with each group
to ensure that their materials are presented
as effectively and practically as possible

ENERGY USE AND EFFICIENCY

What is energy efficiency?

Alternative energy sources
Electrical energy generation/usage
Energy efficient practices in electricity
use
Energy cost structures
Introduction to Energy Audits

DELEGATE PRESENTATIONS

Throughout the technical modules,

participants operating in small teams,
complete a series of exercises based on
constructing a new plant. Time will be set
aside to collate the exercises into a
presentation
During this session, each team will
present its plans to the other teams

REVIEW OF EXERCISES AND CASE

STUDY
A review will be made on the exercises and
submissions and builds on previous
sessions. The instructor will participate here

FORECASTS AND PREDICTIONS

Main technology trends

Conflicting data
How to resolve
Technical skills squeeze
Outsourcing
The China challenge
Market predictions

SUMMARY, OPEN FORUM

AND CLOSING

Fundamentals of testing
Insulation testing
High potential tests

idc@idc-online .com

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Mechanical, Electrical and

Instrumentation Engineering

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for Non-Engineers

WHAT YOU WILL Learn:

Basic mechanical engineering concepts such as force, work,

power, moments and torques
The importance of common engineering material properties in
relation to component life and failure
The basics of electrical power engineering

Practical steps in selection, installation and commissioning of

electrical systems
How to protect yourself and others from electrical hazards
The fundamentals of instrumentation and process control
The basics of Programmable Logic Controllers (PLCs) and
SCADA systems

WHO SHOULD ATTEND:

Administration staff

Civil, mechanical, chemical,

mining engineers,
technologists and technicians
Electrical contractors

Finance, IT and accounting

managers

Human resources managers

IT personnel
Legal personnel
Managers who are involved
with or work with staff and
projects in electrical
engineering

Non-electrical and
mechanical engineers and
technicians
Non-electrical and
mechanical personnel who
want to understand the
broader picture
Non-engineering personnel
Operators
Plant and facility engineers
Procurement and buying staff
Project managers
Sales engineers
Senior managers

2.111

The Workshop

The Program

In two fascinating and intensive but easy-tounderstand days you will learn the basic
applied concepts of mechanical, electrical
and instrumentation engineering. This will
enable you to work more effectively with
your engineering colleagues no matter
whether they are operators, tradespersons,
technicians or engineers.
There are three main threads running
through this course initially mechanical
engineering, then electrical engineering best
practice and concluded with instrumentation
(or industrial automation).

INSTRUMENTATION

Mechanical Engineering Basics

Engineering Materials
Gears and Bearings
Mechanical Drives
Fluid Engineering
Heat Transfer
Maintenance

Practical demonstration

Introduction to Process Measurement

Pressure Measurement
Level Measurement
Temperature Measurement
Flow Measurement
Fundamentals of Programmable Logic
Controllers (PLCs)
Introduction to SCADA Systems

Practical demonstration

ELECTRICAL
Overview of the Electric Power Systems
Basic Concepts
Electrical Generation, Transmission and
Distribution
Electrical Measurements and Applications
Earthing
Transformers
Power Quality
Power Systems Protection
Electrical Shock and Methods of Shock
Prevention
Hazards Due to Electrical Arcing and
Heating

SUMMARY, OPEN FORUM

AND CLOSING

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Mechanical engineering in simple terms

deals with any equipment that moves; this is
what makes it perhaps the most broad and
diverse of engineering disciplines. The
mechanical discipline essentially derives its
breadth from the need to design and
manufacture everything from small, even
nano, individual devices, such as measuring
instruments, to large systems such as
machine tools and power plants.

MECHANICAL

The focus in electrical engineering is on the

building blocks of electrical engineering, the
fundamentals of electrical design and
integrating electrical engineering know-how
into the other disciplines within an
organisation. Unnecessary theory will be
minimised.

Practical demonstration

The dangers and risks from electrocution,

shock, explosions and arc blast can never be
eliminated but you can take definite steps to
protect yourself and your co-workers.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

The topics in instrumentation engineering

commence with an introduction to
instrumentation and measurement ranging
from pressure, level, temperature and flow
devices followed by a review of process
control including the all important topic of
PID loop tuning.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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Earthing, Bonding,
Lightning and Surge Protection

YOU WILL Learn how to:

Apply good earthing practice to your next installation

Detail the applicable national standards

Describe the purposes of earthing and bonding

Apply the various methods of earthing electrical systems

List the types of systems that cannot be earthed

Describe what systems can be operated unearthed

Correctly shield sensitive communications cables from noise

and interference
Apply practical knowledge of surge and transient protection
Troubleshoot and fix earthing and surge problems

Design, install and test an effective earthing system for

electronic equipment

Understand lightning and surges and how to minimise its

impact on your facility
Protect sensitive electronic equipment from surges and
lightning

WHO SHOULD ATTEND:

Building service designers

Consulting engineers
Data systems planners and
managers
Electrical and
instrumentation technicians
Electrical contractors
Electrical engineers
Electrical inspectors

Electricians
Instrumentation and control
engineers
Maintenance engineers
Power system protection and
control engineers
Project engineers
Safety professionals

2.113

The Workshop

The Program

Few topics generate as much controversy

and argument as that of earthing and the
associated topics of surge protection,
shielding and lightning of electrical and
electronic systems. Poor earthing practice
can be the cause of continual and intermittent
difficult-to-diagnose problems in a facility.
This workshop looks at these issues from a
fresh yet practical perspective and enables
you to reduce expensive down time on your
plant and equipment to a minimum by
correct application of these principles.

EARTH ELECTRODE SYSTEMS

Basics of earthing
Bonding
Lightning and surge protection
Static charges
Shielding
UPS systems and their earthing practice

EARTHING OF POWER SYSTEM

NEUTRAL
Unearthed and solidly earthed systems
Impedance earther systems
Resonant impedance earth systems

Practical session: problem solving on

calculation of charging current and
neutral impedances

EQUIPMENT EARTHING

Shock hazards to the human body

Earthing of equipment
Operation of protective devices
Thermal capacity of earthing wires
Touch potential
Induced voltages
Multiple earthing connections
Surge protection earthing

Earthing electrodes
Soil resistance
Measuring soil resistivity
Resistance of single rod electrodes
Current carrying capacity of an electrode
Measurement electrode resistance single
and multiple rods
Concrete encased electrodes
Corrosion of electrode systems
Maintenance of electrode systems
Chemical electrodes

Practical session: problem solving on

earth resistivity, electrode resistance and
current carrying capacity

SURGE PROTECTION OF
ELECTRONIC EQUIPMENT

What is a surge?
Bonding of different earthing systems
Surges and surge protection
Principles of surge protection
Achieving graded surge protection
Positioning and selecting surge
protection

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This workshop is designed to demystify the

subject of earthing and presents the subject
in a clear, straightforward manner.
Installation,
testing
and
inspection
procedures for industrial and commercial
power systems will be examined in detail.
Essentially this workshop is broken down
into earthing, shielding and surge protection
for both power and electronics systems.
Earthing and surge protection for
telecommunications and IT systems are
examined in detail. Finally, the impact of
lightning is examined and simple techniques
for minimising its impact described.

EARTHING BASICS

Practical session: problem solving on

safe touch voltage and sizing of earthing
conductors

LIGHTNING AND ITS EFFECT ON

BUILDINGS AND ELECTRICAL
SYSTEMS

The incidence and probability of lightning

strike
Methods of lightning protection
Planning for lightning protection
Improvements to lightning protection
Effects of lightning strike on overhead
lines
To protect or not to protect

Practical session: problem solving on

protection zones using attraction radii
principle

STATIC ELECTRICITY AND

PROTECTION

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

What is static?
Generation of charge
Common examples
Energy of a spark
Ignition capability of a spark
Dangers of static buildup
Control of static
Assessment of risks and planning

Practical session: problem solving on

ignition due to spark energy

ELECTRICAL NOISE AND

MITIGATION

Definitions of electric noise

Analysis and categories of noise
Electrostatic coupling
Electromagnetic coupling
Shielded isolation transformer
Insulated earth receptacle
Zero signal reference grid
Harmonics

UPS SYSTEMS AND THEIR

EARTHING PRACTICES

Power quality issues

Abnormal voltage conditions
Susceptibility and measures to handle
voltage abnormalities
Regulating transformers
Standby sources
Electro-mechanical UPSs
Solid state UPSs
Multiple redundant systems
Selection of a UPS
Earthing practices

Practical session: case studies involving

real life problems

CASE STUDIES

SUMMARY, OPEN FORUM

AND CLOSING

Customise the training

to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

ELECTRONICS

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TRAINING WORKSHOPS
Practical Digital Signal Processing Systems for Engineers and Technicians........................................................ 3.1
Practical Embedded Controllers: Troubleshooting and Design................................................................................ 3.3
Practical EMC and EMI Control for Engineers and Technicians............................................................................... 3.5
Practical Industrial Electronics for Engineers and Technicians............................................................................... 3.7
Practical Shielding, EMC/EMI, Noise Reduction, Earthing and Circuit Board Layout............................................. 3.9
Power Electronics and Switch Mode Power Supply................................................................................................ 3.11
Practical Troubleshooting of Electronic Circuits for Engineers and Technicians................................................ 3.13

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Practical

DIGITAL SIGNAL PROCESSING

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for Engineers and Technicians

THIS WORKSHOP WILL OFFER YOU:

A clear understanding of Digital Signal Processing (DSP)

Benefits and application of DSP technology to improve efficiency
Frequency analysis of signals and the application of this
knowledge
Information about and actual design of digital filters
Analysis of the performance of DSP systems
Identification of the key issues in designing a DSP system
An understanding of the features and capabilities of commercial
DSP applications
Current DSP technology

WHO SHOULD ATTEND:

Communication System Engineers

Electrical and Electronic Engineers
Control System Engineers
Instrumentation Engineers
Electrical and Electronic Technicians
Design Engineers
Condition Monitoring Engineers and Technicians

3.1

The Workshop

The Program

Digital Signal Processing (DSP) is the

capture, analysis and manipulation of an
analogue signal by a digital computer. The
integration of DSP software and hardware
into products across a wide range of
industries has necessitated the understanding
and application of DSP by engineers and
technicians.

Workshop Objectives

IIR DIGITAL FILTER DESIGN

Review of classical filter approximation

techniques
Characteristics of IIRfilters
Design methods
Design examples

Terminology and motivation

Why process digitally?
A typical DSP system
Some current application areas

DIGITAL-TO-ANALOG AND
ANALOG-TO-DIGITAL
CONVERSION

Periodic sampling and aliasing

Digital to analog converters
Analog reconstruction
Analog to digital converters

DISCRETE SIGNALS AND

SYSTEMS
Discrete-time signals: notation and
representation
Classification of discrete systems
The concept of impulse response
The concept of convolution
Autocorrelation and cross-correlation of
signals

Practical Session

FIRDIGITAL FILTER DESIGN

Characteristics of FIRfilters
Design methods
Design examples

Practical Session

DIGITAL FILTER REALISATIONS

Direct form
Hardware realisations
Quantisation effects

Practical Session

COMMERCIAL DSP HARDWARE

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The introduction of DSP from a practical

point of view using a minimum of
mathematics. The emphasis is on the
practical aspects of DSP, implementation
issues, tips, tricks and pitfalls, and practical
applications. Intuitive explanations and
appropriate examples are used to develop a
fundamental understanding of DSP theory.
The workshop participants will gain a clear
understanding of DSP technology in a variety
of fields from process control to
communications.

INTRODUCTION

Digital filtering for cleaning a signal from

noise

Discrete Fourier Transforms for finding a

particular frequency component
Correlation techniques to find a signal
buried in noise
Industrial control with digital controllers

Instrumentation and test for better

accuracy
Vibration analysis
frequency signatures

for

identifying

Image and video processing for enhancing

images
Communications especially for filtering
out noise

FREQUENCY ANALYSIS OF
DISCRETE SIGNALS

Fourier series for periodic signals

Discrete Fourier Transform (DFT) for nonperiodic signals
Understanding the DFT equation
DFTproperties
The Inverse DFT
The Fast Fourier Transform (FFT)
Frequency analysis of discrete signals:
use of windows and DFT results
interpretation
Fast computation of convolution using
DFT
Other related transforms

PRACTICAL TOOLS FOR DSP

SYSTEM DEVELOPMENT
Simulation tools for algorithm
development
Software development tools
Hardware development tools

Practical Session

Practical Session

DSP APPLICATION EXAMPLES

Practical Sessions

Practical Session

Digital waveform generators

Speech modelling and synthesis
Noise reduction and signal enhancement
Image restoration
Communications system

Practical Session

A. J. Pretorius

There are eight practical sessions designed

to enhance the delegates understanding of
the workshop. Most are software-based and
make use of the widely used MATLAB
software from Mathworks, Inc. Other
sessions use the Texas Instrument DSP
boards for experimentation.
Introduction to MATLAB/SIMULINK and
Signal Processing Toolbox
Introduction to SIMULINK
FIR Filter Design
IIRFilter Design
Filter Realisation
Image Processing
Sampling and Quantisation
DSP Implementation

Instructor has excellent

knowledge on the subject.

Some of the DSP techniques included in the

workshop:

Practical Session

Architectural difference between

DSPchips and general purpose
microprocessors
Texas Instrument TMS320 family
Motorola DSP56000 family
Analog Devices ADSP-2100 family
Choosing a DSP architecture
DSP trends

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

EMBEDDED CONTROLLERS:
TROUBLESHOOTING and DESIGN

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for Engineers and Technicians

YOU WILL LEARN:

How to design, set up and program a complete embedded

controller development system
How to apply the latest techniques in programming these
versatile devices
Troubleshooting tips, tricks and traps for microcontrollers
Installation techniques for microcontrollers
How to fix problems due to electrical noise and interference
How to design correctly the first time to avoid earthing and EMC
problems.
How to avoid the five most common problems in the design of
Microcontrollers
How to choose and configure the correct software

WHO SHOULD ATTEND:

This is not an advanced course but one aimed at engineers and

technicians who want a solid grounding in the fundamentals from
an expert in the area. You may already have been working in this
area but want to get more out of your designs with some useful
practical information which you can apply immediately when
troubleshooting or performing your next design.
Electronic Technicians & Engineers
Instrumentation & Control System Engineers and Technicians
Electrical Engineers & Technicians
Project Engineers
Design Engineers
Technicians
Process Control Engineers
Systems Engineers
3.3

The Workshop

The Program

From microwave ovens to alarm systems to

industrial PLC and DCS control systems,
embedded controllers are controlling our
world. The microcontrollers that are at the
heart of these and many more devices are
becoming easier and simpler to use. But
when these devices fail the solution to the
problem needs to be found and the repairs
done quickly.
The Embedded Controllers: Troubleshooting
and Design workshop will help the technician,
engineer and even the most casual user
understand
the
inter-workings
of
microcontrollers along with the most
common problems and their solutions.

Data Communications

Introduction
Microcontroller Introduction
Microcontroller Design & Functions
Assembly Language Programming
Inputs & Outputs
Data Communications
Noise Reduction
Grounding Solutions
Installation Techniques

Microcontroller Basics
Introduction
Number Systems - Binary, Hex, &
Decimal
Gates - AND, OR, XOR & NOT gates
Accumulators, A, B & D
Registers - X, Y, D & Stack
Communications - Synchronous &
Asynchronous
Power Systems - Resetting & Brownouts
Crystals & Oscillators

Introduction to Data Communication

Basics of Serial Data Communication
Open System Interconnection Model
Modes of Communications
RS 232
RS 485
Fibre Optic Cables
Fieldbus Protocols used in Controllers

Electronic Noise Reduction

in Controllers and PCBs

Introduction to Noise Reduction

Conductive Coupled Noise
Capacitive Coupled Noise
Magnetic Coupled Noise
EMC & Noise Reduction in PCB Design

EMC Grounding Solutions

Introduction to EMC Grounding Solutions

EMC Grounding
EMC Grounding on a PCB
Protecting Controllers from Lightning
Microcontroller Equipment Ground
Enclosure or Safety Ground

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Embedded controllers are used in most

electronic equipment today. Embedded
controllers are intelligent electronic devices
used to control and monitor devices
connected to the real world. This can be a
Programmable Logic Controller (PLC),
Distributed Control System (DCS) or a Smart
Sensor. These devices are used in almost
every walk of life today. Most automobiles,
factories and even kitchen appliances have
embedded controllers in them.

Introduction

This two-day workshop covers all aspects of

embedded controllers but focussing
specifically on troubleshooting and design.
The workshop covers design, specification,
programming, installation, configuration
and of course troubleshooting.

This hands-on workshop gives both the

novice and experienced user a solid grasp of
the basic principles enabling you to go away
and apply the material learnt immediately to
your application.

Introduction to
Programming the
Microcontroller

Programming Structure & Specifications

Addressing Modes
Load, Stores & Transfers
Arithmetic Operations
Logical Operations
Shifts & Rotates
Index Registers & The Stack
Condition Code Register
Branches, Jumps, Interrupts & Calls
Assembly Programming

Introduction to Memory

Workshop Objectives

The objectives are simply to give you a

thorough grounding in the use of
microcontrollers; thus enabling you to
design your own system hardware and then
to program it. Further to this it will also help
you to troubleshoot, diagnose and fix faults
on your microcontroller systems.

User Ram
Buffalo Routines, Memory Map & Vectors
Interrupts, Vectors & Pseudo-Vectors
Control Registers
EEPROM

Introduction to Inputs and

Outputs

Single Ended vs. Differential Inputs

Digital Inputs
Digital Outputs
Analog Inputs
Digital Control of Analog Devices
Keypad Interfacing
LCD Interfacing

Installation and
Troubleshooting

Introduction to Installation &

Troubleshooting
Connections - Screw, Crimp & Solder
Cable Runs & Trays
Cable Ties & Mounting
Cooling, Heating & Air Conditioning
Cable Run Wire Management
Conduit Installation
Troubleshooting Specifics
Safety Considerations

Conclusion

CPU Design & Functions

Assembly Language Programming
Memory
Inputs & Outputs
Data Communication
Noise Reduction
Grounding Solutions
Installation Techniques

Practical Sessions

Groups of two attendees will be allocated a

PC and microcontroller development board
to develop complete projects. You will use
internationally known software packages,
chosen for their high profile and popularity
in the industrial environment. You will
develop your ability in working with
Embedded Controller systems and reinforce
the information learned in the workshop.
You will learn first-hand how to set up and
use the development system to build a
complete working prototype project.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

EMC and EMI CONTROL

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Apply the relevant IEC Standards and relate to the European

Directive which is now widely applicable worldwide
Understand the issues surrounding EMC and the CE mark
Determine the testing procedures and equipment used for
measuring conformance to the standards
Design for minimum emission and susceptibility
Configure systems made up of a number of component subassemblies, for conformance
Render older equipment conformant to new standards
Maintain equipment in a compliant state after repair or servicing

WHO SHOULD ATTEND:

Engineers and technicians involved in the design and

manufacture of electrical and electronic equipment that produce
electromagnetic disturbances and may be susceptible to
electromagnetic interference
Engineers and technicians involved with the maintenance and
service of electrical and electronic equipment
Those that need to ensure that goods conform to the required
standards
Those involved with the marketing and sale of goods that need to
comply with the required standards

3.5

The Workshop

The Program

This
Practical
EMC/EMI
Control
(Electromagnetic
Compatibility/
Electromagnetic Interference) two-day
workshop is a 'hands-on', 'how-to' course. It
will show you in a practical and straight
forward way how to understand and
implement the relevant standards required
to reduce and control electromagnetic
disturbances and interference.
This workshop will enable you to measure
equipment for conformity to standards and
equip you to design and configure goods
and systems for minimum emission and
susceptibility. It will also equip you to render
older equipment standard compliant and
allow you to maintain compliancy levels
when repairing and servicing equipment.

DAY ONE REVIEW & QUESTIONS

Introduction of day two material

EMISSION TYPES

Harmonic minimisation
Preventing transient interference/damage

RF Emissions
Harmonic injection into the mains
Transients
Standards
Testing procedures
Test equipment

DESIGNING FOR COMPLIANCE

RF radiation principles
PCB design for reduced radiation
Digital circuits
Analog circuits

Practical: Demonstration

POWER SUPPLIES

Practical: Demonstration of effects of

design practices

SYSTEM CONSIDERATIONS:
INTERFACING TO OTHER
EQUIPMENT

Practical: RF Emission measurement

Practical: Harmonic emission
measurement

Filtering
Shielding
Interconnecting

INTERFERENCE COUPLING
MECHANISMS

MANAGING THE EMC PROCESS

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Save on down-time and manufacturing

delays with this practical EMC/EMI Control
workshop.

INTRODUCTION TO EMC
Electromagnetic disturbances and their
sources
Electromagnetic susceptibility/immunity
Coupling between source and victim
Electromagnetic compatibility
The need for harmonisation
The European Directive
Current standards
Routes to compliance

Pre-requisites

Fundamental knowledge of basic mechanical

plant and operation thereof.

ELECTROMAGNETIC
SUSCEPTIBILITY/IMMUNITY

Workshop Objectives

Interfacing with management

Interfacing with management and Quality
Assurance

Relevant standards
Testing procedures

Practical: Susceptibility testing

This practical workshop will offer you the

most up-to-date knowledge to:

understand the importance of EMC/EMI

control
relate to
standards

the

relevant

compliancy

determine testing procedures and

equipment for measuring conformance
design equipment and goods for
minimum emission and susceptibility
configure systems for conformity

render older equipment compliant

maintain compliancy in equipment after

repair and service

This has been a great eye

opener and I wish I had done
this sooner in my career.

know the routes to compliance

Richard Paveley

Practical Sessions

To ensure practical knowledge and

experience, this workshop offers 5 practical
sessions:
RF emission measurement

Harmonic emission measurement

Susceptibility testing

On-Site Training

Designing for compliance

Demonstration of effects of design
practices

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

INDUSTRIAL ELECTRONICS

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Work effectively with common electric components and systems

Troubleshoot problems (save on downtime)
Multi-skill into electronics; to improve your employability
Confidently carry out simple repair procedures for faults on
printed circuit boards

WHO SHOULD ATTEND:

Maintenance technicians, electricians, foremen and engineers

Mechanical and chemical engineers, operators and personnel
who need electronics knowledge
All engineering, operations and management personnel who are
directly or indirectly involved with electronic controls
Those involved with the installing, programming, maintaining and
purchasing of electronic control equipment
Those involved with sales and installation of electronic products
Anyone whose work requires the use of electronic equipment

3.7

The Workshop

The Program

Industrial electronics has become an integral

part of our businesses. A working knowledge
of electronics has now become a prerequisite
for efficiency in the work place.
This two-day workshop will 'demystify' the
world of electronics to you and equip you to
understand, identify and confidently
troubleshoot electronic problems. You will
gain the vital knowledge that you need to:
multi-skill, reduce down-time, save your
company money, and secure your value in
the workplace. You will learn the latest
trends and techniques in the fast-moving
field of industrial electronics.

Pre-requisites

Operational amplifiers

Workshop Objectives

This practical, hands-on workshop will

introduce industrial electronics to anyone
who needs to understand electronics and
confidently troubleshoot electronic problems
in their work place.
You will gain the most up-to-date knowledge
to:

Atomic structure
Insulators, conductors and
semiconductors
Current, voltage, resistance, power
Direct and alternating current
Units and abbreviations

common

Practical session: Using test equipment

Practical session: Discrete components

Circuit laws
Ohm's Law
Kirchhoff's Voltage Law
Kirchhoff's Current Law

Practical session: Circuit laws

Amplifiers

Small signal amplifiers

Power amplifiers
Amplifier frequency response
Amplifier applications

Industrial practices

Soldering aids
Printed circuit boards preparation
Component preparation
Constructing a soldered joint
Common defects in soldered joints
Desoldering
Safety in the work area

implement procedures for the testing of

electronic components

confidently carry out simple repair

procedures for the correction of faults on
printed circuit boards
in

Enjoyable and will be of value

in the workplace.

colleagues

your

Barry Byrne

Practical Sessions

There are a total of 5 practical hands-on sessions,

which aim to give you the confidence and experience
you need to work with and troubleshoot electronic
equipment.
Discrete components
Circuit laws
Use of test equipment
Industrial practices

Open circuits
Short circuits
Testing diodes, DIACS and TRIACS
Testing BJTS, JFETS and MOSFETS
Testing digital and linear components
Components out of tolerance
Troubleshooting, using circuit laws

identify components and read their

values

These practical sessions are:

Troubleshooting

Practical session: Troubleshooting

identify electronic component symbols

with

Practical session: Industrial practices

electronic

effectively apply the principles of analog

meters, digital meters and oscilloscopes

Troubleshooting

Current measurement
Voltage measurement
Analogue meters
Digital meters
Oscilloscopes

Resistors, inductors and capacitors

Transformers and bridge rectifiers
JFETS and MOSFETS
SCRS, DIACS and TRIACS
LEDS

understand the construction and

operation of common electronic
components

multi-skill
industry

Using test equipment

Discrete components

recognise and efficiently troubleshoot

common electronic component and
circuit problems

understand
terminology

Op-amp parameters
Negative and positive feedback
Op-amp frequency response, stability
and compensation
Basic op-amp circuits
Power supplies

Basic concepts

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This workshop is not designed for

experienced electronic engineers and
technicians.

Introduction

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

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SHIELDING, EMC/EMI, NOISE REDUCTION,

EARTHING and CIRCUIT BOARD LAYOUT

You Will Learn How to:

Know why and how to earth a circuit effectively

Efficiently diagnose noise problems
Identify, design, manufacture and fix EMI/EMC problems
Effectively design to filter at MHz frequencies
Understand the four noise coupling mechanisms and minimise them
Understand the function of the signal earth versus the signal return
Earth a cable shield correctly
Reduce DC power bus noise
Select cables appropriately
Know when to shield and when to filter
Effectively earth mixed analog and digital signals
Minimise pulse ringing and rounding problems
Reduce earth loop noise
Reduce emission and susceptibility problems
Create a check list of items to ensure CE approval

WHO SHOULD ATTEND:

Instrumentation and control

engineers
Electronics and systems
engineers and technicians
Consulting engineers
Electrical engineers
Project engineers
Maintenance engineers
Electrical contractors
Safety professionals
Consulting engineers
Electricians
Electrical inspectors
Power system protection and
control engineers

Building service designers

Data systems planners and
managers
Electrical and instrumentation
technicians
Mechanical engineers
Printed circuit board designers
Logic designers
Signal integrity specialists
CAD managers
EMC specialists
Design engineers
Test engineers
Technical managers
3.9

The Workshop

The Program

Any training class is a considerable investment

in terms of cost and your time. You cant
afford to waste any of your precious time and
you need to attend something that is useful
and improves your productivity. After five
years of presentation throughout the world,
this workshop is well polished, practical and
relevant.
The aim of this workshop is to help you
identify, design, prevent and fix common EMI/
EMC problems with a focus on earthing and
shielding techniques. Learning how to fix
earthing and shielding problems on the job
can be very expensive and frustrating.
Although it must be noted that most of the
principles involved are simple, this course will
give you the tools to approach earthing and
shielding issues in a logical and systematic
way.

SELECTION OF THE RIGHT CABLE

AND CONNECTOR

Fundamentals
Interference sources
EMI/EMC regulations

BASIC PRINCIPLES OF NOISE

REDUCTION

Importance of wiring inductance

Bandwidth of pulse waveforms
Noise coupling examples
Common and differential modes
Balanced circuits and common mode
rejection

PRINCIPLES OF EARTHING

What is electrical earthing?

Function of an earth
Safety and EMI
Analog/digital earthing
Single point, multipoint, and hybrid earths
Earth grid technique
Isolated earthing technique
Earth loops
Earth loop noise reduction

Cable earthing
Cable crosstalk
Cable shielding and connectors

SIGNAL ROUTING AND LEAST

IMPEDANCE
Controlling layout inductance
Signal integrity and EMC at the PCB level
Hidden transmitters and receivers and
antennae
Trace routing
Transmission line effects
Termination

NOISE COUPLING MECHANISMS

Magnetic causes of common mode current

Capacitive causes of common mode current
Identification of unintentional antennas
Controlling of kHz current paths

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This course focuses on the issues of interest

to you if you are working in design, operation
or maintenance of analog or digital systems
involving sensors, data acquisition, process
control,
cables, signal processing,
programmable logic controllers, power
distribution, high speed logic etc.

INTRODUCTION

The circuit board layout section concentrates

on design and layout of circuits and
components on a printed circuit board. The
overall focus is on useful design and systems
issues; not about regulations and standards.
The idea is that you will take this material
back with you to your work and apply the key
principles immediately to your design and
troubleshooting challenges.

Pre-requisites

Some working knowledge of basic electrical

engineering principles is required, although
there will be a revision at the beginning of the
workshop. No prior EMC or electrical noise
knowledge is necessary.

DIAGNOSIS OF NOISE PROBLEMS

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presented at your
premises.

Identification of critical circuits

Clock and reset circuits
Embedded controllers and EMC
On board power regulators
Component placement
I/O treatments
Clock dithering

NOISE REDUCTION TECHNIQUES

FILTERING CONDUCTED NOISE

Minimisation of bandwidth
Best place to earth cable shield
Reducing mutual inductance

POWER CIRCUITS AND POWER

SUPPLIES
Power quality and EMI
Filters and transient protection
Switch mode power supply design

INDUCTIVE AND CAPACTIVE

SHIELDING

On-Site Training

Relating symptoms to causes

Ringing, rounding and reflections
Practical methods of diagnosis
Noise coupling examples

CIRCUIT BOARD EARTHING ISSUES

Materials and limitations

Openings and penetrations
Enclosure design techniques
Shielded racks and shielded rooms
Magnetic fields
Shielding design guidelines

Series blocking and shunt diverting

Filtering clock harmonics
Reduction of filter mutual inductance
Ferrite bead applications

DC POWER DISTRIBUTION AND

DECOUPLING

Ideal DC power bus

Plane resonances and field containment
Reduction of capacitor inductance
Isolation of split power planes

COMPONENT PLACEMENT AND

LAYER STACKUP
Optimal connector location and pin
assignments
Lateral segregation by DC voltage
Layer stack up alternatives

REDUCTION OF ELECTROMAGNETIC CHASSIS, CABLE AND SYSTEM

ISSUES
COUPLING

Requirements of EM containment
EM shielding of cables
Seams and apertures
Shielding for ESD and RF
To shield or to filter?

HF design at connection/chassis interface

Reduction of chassis and cable resonances

SUMMARY, OPEN FORUM

and CLOSING

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your workplace.

Have the training

delivered when and

where you need it.
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free proposal.

idc@idc-online .com

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Power Electronics and

Switch Mode Power Supply

YOU WILL LEARN HOW TO:

Demonstrate a sound understanding of how switcH mode power

supplies (SMPS) operate
Correctly select components for a switch mode power supply
design
Select the right switch mode topology for a given application
Understand PWM and what controller to select for a given
application
Design an input stage for a switch mode power supply and
correctly evaluate EMI/RFI
Apply power transistors correctly to SMPS design
Correctly apply high frequency transformers and select the
appropriate design (including an example push - pull design
application)
Design an output section of a SMPS
Evaluate the performance and stability of a SMPS design
Perform a complete analysis of the noise generated by the
design (EMI/RFI)
Make an accurate assessment of the heat-sink requirements to
ensure reliable operation
Design a SMPS that complies with safety standards

WHO SHOULD ATTEND:

Application Engineers
Product Designers
Component Suppliers
Instrument for Control Engineers
Electrical and Electronic Maintenance
Technicians and Supervisors

Sales Engineers
Product Managers
Technicians
Service Technicians

3.11

The Workshop

The Program

Power electronic circuits have revolutionised

almost every device that we use today from
PC's to TV's, microwave ovens and heavy
industrial drives.
Switch mode power supplies (SMPS) have
thus become an important part of equipment
design in all types of industrial equipment
and an understanding of the different types
and designs has become essential for
reliable operation of complex equipment.
This workshop gives you a fundamental
understanding of the basic components that
form a SMPS design. You will understand
how the selection of components affects the
different performance parameters and
operation of the SMPS. Typical practical
applications of the SMPSs in industry will be
discussed.

BASIC CONCEPTS

Introduction to Power Electronics Circuits

Basic principles of PSU circuits
Power Supply specifications
Linear and SMPS comparison
SMPS block diagram

Topologies

Non-isolated topologies
Isolated topologies
Comparison of topologies
Choice of topology based on power
supply specifications

Output rectification and filtering

Power Rectifier Characteristics
Output Power Inductor design
Output Filter Capacitor Design

Stability in SMPS

Transfer functions
Criteria for stability
Control to output gain
Design compensation network
Loop stability measurements

EMI-RFI considerations
Noise specifications
RFI sources in SMPS
Filters for RFI suppression

IC PWM Controllers

PWM controller review

UC3825 block diagram
The speed critical path
High speed complementary blocks
Glue or remaining blocks

Power supply electrical

safety standards

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The concluding section of the workshop

gives you the fundamental tools in
troubleshooting SMPS designs confidently
and effectively.

The Output Section

INTRODUCTION

Even though the focus of the workshop is on

the direct application of this technology, you
will also gain a thorough understanding of
the problems that can be introduced by
SMPSs such as harmonics, electrostatic
discharge and EMC/EMI problems.

Pre-requisites

A fundamental knowledge of basic electrical

concepts would be useful.

Construction requirements

The Input section

Component selection and design criteria

- Input rectifiers
- Input filter capacitors
- AC or DC Input line filters for RFI
suppression
- Input filter interaction with SMPS

Heat-sinking

Input protective devices

The thermal equation

Selecting a heat-sink
Custom heat-sink

Power Transistors

Transistor selection
Gate/base drive considerations and
circuits
Design considerations for safe operating
of transistor

- Transistor losses
- Ripple current
- Derating factors

Switch Protection circuits

High-frequency
transformers

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Customise the training to

your workplace.

Basic transformer theory

Core material and geometry selection
Design of a power transformer for a
converter
Losses and temperature rise
Winding techniques

Transformer construction

a. Insulation
b. Dielectric strength
c. Insulation resistance
d. Temperature rating

- Inrush current
- Input transient voltage protection

On-Site Training

a. Spacing requirements
b. Dielectric test
c. Insulation resistance

SMPS troubleshooting

Safety guidelines
Test equipment
Safe discharge of capacitors in SMPS
SMPS failure modes
General SMPS troubleshooting approach
Initial post-repair testing
Some general SMPS repair comments
Periodic or pulsing outputs

SUMMARY, OPEN FORUM &

CLOSING

The presentation was excellent and of great value.

Julian Dalesio

Have the training

delivered when and
where you need it.

Very good summary. Should have done it years ago!

D. Lane

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Troubleshooting of

Electronic Circuits

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for Engineers and Technicians

You will learn how to:

Recognise and efficiently troubleshoot common electronic

component and circuit problems
Demonstrate the construction and operation of common
electronic components
Utilise common electronic terminology
Effectively apply the principles of analog meters, digital meters
and oscilloscopes
Identify electronic component symbols
Identify components and read their values
Implement procedures for the testing of electronic components
Confidently carry out simple repair procedures for the correction
of faults on printed circuit boards

WHO SHOULD ATTEND:

All those who wish to be able to multi-skill into electronics

Maintenance technicians, electricians, foremen and engineers
All engineering, operations or management personnel who are
directly or indirectly involved with electronics controls
Those involved with the installing, programming, maintaining and
purchasing of electronic control equipment
Those who want to improve their understanding and capabilities
in electronic technology
All those involved with sales and installation of electronic
products into industry

3.13

The Workshop

The Program

This workshop will teach you how to

recognise and efficiently troubleshoot
common electronic component and circuit
problems. The workshop will give you a
solid understanding in common electronic
terminology and symbols, as well as the
construction and operation of common
electronic components.
The general
troubleshooting process is explained,
followed by a brief study of various hand
tools and electronic test and measuring
instruments. You will learn to implement
procedures for the testing of electronic
components as well as carry out simple
repair procedures for the correction of faults
on printed circuit boards with confidence.

Practical Sessions

INTRODUCTION
BASIC CONCEPTS
Current, voltage, resistance, power
Units and abbreviations
Direct and alternating current

DISCRETE COMPONENTS, PART 1

Resistors, inductors and capacitors

Transformers and bridge rectifiers
Diodes and bipolar junction transistors
JFETS and MOSFETS
SCRS, DIACS and TRIACS
LEDS

FAILURE ANALYSIS AND

PREVENTION IN ELECTRONIC
CIRCUITS

Failure symptoms
Failure causes
Failure types
General preventive measures

TESTING IN ELECTRONIC
CIRCUITS
Equipments / devices used in testing
(ex. logic analyser, spectrum analyser,
multimeter, oscilloscope, lCR meter,
DVM, MDA, AWG etc.)

CIRCUIT LAWS

DEVICE TROUBLESHOOTING

Ohms law
Kirchhoffs voltage law
Kirchhoffs current law

Diode, transistor, resistor, capacitor,

op-amp, thermocouple, microprocessors,
multivibrator, thermister, switch, PLD,
FLASH, RS-232, PCI bus, transmission
lines etc

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AMPLIFIERS

This is a practical, hands on workshop

enabling participants to work through
practical exercises which reinforce the
concepts discussed.

Small signal amplifiers

Power amplifiers
Amplifier frequency response
Amplifier applications

USING TEST EQUIPMENT, PART 1

Current measurement
Voltage measurement
Resistance measurement
Analogue meters
Digital meters
Oscilloscopes

INDUSTRIAL PRACTICES

Soldering aids
Printed circuit boards preparation
Component preparation
Constructing a soldered joint
Common defects in soldered joints
Desoldering
Safety in the work area

INTRODUCTION TO
TROUBLESHOOTING

On-Site Training

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presented at your
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Open circuits
Short circuits
Testing diodes, DIACS and TRIACS
Testing BJTS, JFETS and MOSFETS
Testing digital and linear ICS
Testing other electronic components
Components out of tolerance
Troubleshooting, using circuit laws
Gaining circuit familiarity
Troubleshooting basics
Common troubleshooting techniques

DESIGN TROUBLESHOOTING FOR

DIGITAL AND ANALOG SYSTEMS

Moving from analog to digital

Measuring signal and noise in high speed digital and analog circuits
Design troubleshooting

LOGICAL TROUBLESHOOTING

Component level troubleshooting

Board level troubleshooting
System level troubleshooting

POWER SUPPLY

Introduction
Power delivery input impedence
Linear power supply

PCB TESTING

PCB design techniques

SMT technology
Soldering and desoldering techniques
Practical tips and tricks for PCB design
Solder flux and heat sink
Troubleshooting strategies
Special tools, clips, cleaners, sprays,
extension, scope probes

SAFETY ASPECTS

Generic precautions
Specific precautions
Safety steps at installation time

SUMMARY, OPEN FORUM

and CLOSING

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

INFORMATION TECHNOLOGY

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TRAINING WORKSHOPS
Industrial Network Security for SCADA, Automation, Process Control and PLCSystems...................................4.1
Practical Fundamentals of E-Manufacturing, Manufacturing Execution Systems (MES)
and Supply Chain Management............................................................................................................................... 4.3
SNMP Network Management: The Essentials............................................................................................................. 4.5
Practical Android App Development........................................................................................................................... 4.7
Cybersecurity for Automation, Control, and SCADA Systems (Using the ANSI/ISA-62443 Standards)............... 4.9

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INDUSTRIALNetwork Security

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for SCADA, Automation,

Process Control and PLC Systems

YOU WILL LEARN HOW TO:

Apply the fundamental concepts of industrial network security to

your SCADA and automation systems
Conduct a preliminary analysis of your industrial networks and
prepare to withstand and anticipate attacks and apply defences
Discuss the issues of industrial network security competently
with your associates in IT and vendors
Understand and be able to construct a secure robust Local Area
Network
Learn how to plan and design your networks better
Analyse and construct a typical firewall

WHO SHOULD ATTEND:

If you are using any form of communication system this workshop will
give you the essential tools in securing and protecting your industrial
networks whether they be automation, process control, PLC or
SCADA based. It is not an advanced workshop but a hands-on one.
Anyone who will be designing, installing and commissioning,
maintaining, securing and troubleshooting TCP/IP and intra/internet
sites will benefit including:
Design engineers
Electrical engineers
Engineering managers
Instrumentation engineers
Network engineers
Network system administrators
Technicians

4.1

The Workshop

The Program

This workshop will give you a fundamental

understanding of security in effective
industrial
networking
and
data
communications technology. It will also
present you with the key issues associated
with security in industrial communications
networks and will assist managers, system
operators
and
industrial
data
communications specialists in setting up
secure systems.
One completion of the workshop you will
have developed a practical insight into how
to achieve optimum industrial network
security for your organisation.

ENCRYPTION

Background to workshop
Overview of basic concepts

Symmetrical encryption schemes (DES,

RC4)
Public-key encryption schemes (RSA)
Certificate Authorities (CAs)

DANGERS

Hackers
Viruses
Denial-of-service
Information leakage
File manipulation
Database access
Elevation of privileges
Spoofing
SYN flooding
Router attacks
Sniffing

PROXIES/FIREWALLS
Basic firewall operation
Natural Address Translation (NAT)
Firewall types (IP filtering, stateful
inspection, proxy, DMZ)

INTRUSION DETECTION SYSTEMS

(IDSS)
Types
Deployment

SECURITY POLICIES AND

ADVISORY SERVICES

Corporate policies
CERT
Audits
Threats
Vulnerabilities
Countermeasures
Disaster recovery

ROUTER SECURITY

Administrator access
Firmware upgrades
Logging
Access Control Lists (ACLs)

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Topics covered include: introduction and

terminology; firewalls; authentication,
authorisation and anonymity; remote access
to corporate networks; cryptography; VPNs;
data security; desktop and network security;
security precautions in a connected world;
and internet security.

INTRODUCTION

Pre-requisites

A basic working knowledge of industrial

communications and applications is useful.

SWITCH SECURITY

PHYSICAL SECURITY

Physical and logical access to networked

equipment
Network segmentation

AUTHENTICATION

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Authentication basics
Client-side certificates
Passwords
Smart cards
Tokens
Biometrics
PAP
CHAP
RADIUS
TACACS/TACACS+

Administrator access
Port based MAC address management
ACL filtering
Virtual LAN (VLAN) implementation

VPNS

Virtual Private Network (VPN) concept

Tunnelling
L2TP
IPSec
SOCKS 5

WIRELESS LANS

Encryption and authentication - current

problems and developments
IEEE 802.1x
WEP
WZC
WPA
AES
LEAP
EAP-TLS
EAP-TTLS

Summary, Open Forum

and Closing

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Fundamentals of

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E-Manufacturing, Manufacturing
Execution Systems (MES) and
Supply Chain Management

YOU WILL LEARN HOW TO:

Identify and model enterprise and business automation system

hierarchies
Use internationally recognised process and system design concepts
Identify and design E-Manufacturing and Supply Chain components
Financially motivate projects and measure improvement after
installation
Determine the best integration model to use for your company
Manage software projects, system integrators and software vendors
Manage behavioural change during system implementations to
reduce disruption
Choose objectively between different software and technology
providers
Make sense of vendor marketing techniques and ploys
Differentiate between data summation/transformation/communication
tools and tools driving business processes within the plant

WHO SHOULD ATTEND:

CEOs and CFOs

Finance Managers
E-Commerce Managers
IT Managers
Business Managers
Strategy Managers
Operations Managers and Engineers
Production Managers and Engineers
Senior Process Engineers
Network and Telecommunications Managers

4.3

The Workshop

The Program

WHAT IS E-MANUFACTURING, MES AND

SUPPLY CHAIN MANAGEMENT?

Introduction to automation
systems

System integration models

and concepts

Supply Chain Management involves the

optimisation of the way in which a company
plans the production of goods or services,
procures raw materials from various
suppliers, manufactures the goods or
services, delivers it to customers and
handles returns.

History of process control and accounting

systems
Development of manufacturing execution
systems
Systems architecture

Introduction to the S95 integration

standard
Integration vs. interfacing
The 8 types of systems integration

E-Manufacturing starts with an order for a

product and then encompasses the entire
manufacturing cycle of the product.
Manufacturers need a highly responsive
supply chain and manufacturing system to
ensure that they meet the high expectations
of their customers who, in today's economy,
demand absolutely the best service, price,
delivery time and product quality.

Introduction to Eli Goldratt's Theory of

Constraints and the impact on business
automation
Introduction to the Supply Chain
Council's SCOR model
Understanding the AMR Research's
REPAC model (Ready, Execute, Process
control, Analyse, Co-ordinate) and its
application during business process
mapping and system design
Introduction to S88 Batch Control
standard and potential impact on
business management and process
control systems

Managing software
projects
Determining the scope
Maintaining the project scope and
managing changes/additions
Project life-cycle
Ensuring milestone delivery
Testing cycle
Implementation considerations

System implementation and

change management
considerations
Industry misconceptions for system
implementation effort
Resistance to change, culture change and
training
Human behavior vs. performance
measurement
Behavioral change process and why it is
essential
Making behavioral change measures and
audits part of performance measurement
systems

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Manufacturing Execution Systems (MES)

provide up-to-the-minute mission-critical
information about production activities
across the factory and supply chain via
communications networks (e.g. Local Area
Networks), resulting in the optimisation of
activities throughout all aspects of the
manufacturing process. MES accomplish
this task by guiding, initiating, responding
to, and reporting on plant activities in real
time, by using current and accurate data.
This rapid response to changing conditions,
together with a focus on reducing nonprofitable activities, lead to more efficient
plant operations and processes.

Business process design

concepts and
considerations

MES reduces cycle times, levels of Work in

Progress (WIP), data entry time, paperwork
and scrap. It also improves utilisation of
plant capacity, process control quality,
arrangement of plant activities, tracking of
orders and customer service.
Research figures show that manufacturers
have been able to achieve the following
improvements through MES:
an average reduction of manufacturing
cycle time by 45%
an average reduction of data entry time
by 75%
an average reduction of WIP by 24%

an average reduction of paperwork

between shifts by 61%

an average reduction of lead time by

27%

an average reduction of paperwork and

blueprint losses by 56%
an average reduction of product defects
by 18%

Implementation of MES invariably results in

improved returns on production assets,
on-time delivery, faster inventory turnover,
larger net profits (through increased cost
reduction) and improved cash flow.

Pre-requisites:

Definition and practical

application of
e-Manufacturing and Supply
Chain processes

Customer relations management

Procurement management
Logistics planning and optimisation
Material returns management
Resource allocation and status
Operations/detail scheduling
Dispatching production units
Document control
Data collection/acquisition
Labor management
Quality management
Process management
Maintenance management
Product and material storage
Product tracking and genealogy
Performance analysis

Project motivation and

benefit quantification, the
why's
and how's

Project portfolio management

Business case tools
Benefit base-line design
Post-implementation benefit evaluation/
review

Business and process

modeling tools analysis

Examples of modeling tools available

Concepts and assumptions used by the
tools
Advantages and disadvantages
of the various tools

Product and vendor

evaluation methodology

Identifying the requirements

Developing the measurement methods
and selection criteria
Preparing the vendors
Facilitating the demonstration
Reporting the results

MES and Supply Chain

products overview

Examples of packaged products

available:

-
-
-
-
-
-
-
-

i2
Aspentech
Wonderware
Simatic IT
ABB
OSI
Honeywell
Intellution, etc.

Concepts and assumptions used by the

various products
Advantages and disadvantages of the
various products

Summary, Open Forum

and Closing

An elementary understanding of business

and manufacturing operations processes.
No specific knowledge of software is
required.

idc@idc-online .com

www.idc-online .com

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SNMP NETWORK MANAGEMENT:

The Essentials

What YOU WILL LEARN:

You will understand the structure and operation of SNMP

You will use SNMP to identify faulty devices
You will use RMON to analyse remote network information
You will interpret and explain MIB I and MIB II (Public/Private/
Proprietary)
You will track the important variables on your network
You will install and configure a typical Network Management
Package

WHO SHOULD ATTEND:

CEOs and CFOs

Finance Managers
E-Commerce Managers
IT Managers
Business Managers
Strategy Managers
Operations Managers and Engineers
Production Managers and Engineers
Senior Process Engineers
Network and Telecommunications Managers

4.5

The Workshop

The Program

This workshop will give you a fundamental

understanding of security in effective
industrial
networking
and
data
communications technology. It will also
present you with the key issues associated
with security in industrial communications
networks and will assist managers, system
operators
and
industrial
data
communications specialists in setting up
secure systems.
One completion of the workshop you will
have developed a practical insight into how
to achieve optimum industrial network
security for your organisation.

Using SNMP

What is Distributed Network

Management?
The Need for Network Management
Proprietary vs. Open Approach to
Network Management
Elements of A Network Management
Architecture
The OSI Model Revisited
What is SNMP?
SNMP Functions and Components
The SNMP Model
SNMP History

Network Management System

Implementations (OpenView, Solstice,
etc)
Remote Monitoring
- What is RMON?
- RMON MIB Extensions
- RMON2
Web-Based Network Management
(X.700)
- Configuration Management
- Accounting Management
- Performance Management
- Security Management
- Fault Management

Revision of Supporting
Network Technology
TCP Stack Overview and Layer
Responsibilities
- Process/Application Layer
- Host-to-Host Layer
- Internet Layer
- Network Interface Layer
Transmission Control Protocol (TCP)
User Datagram Protocol (UDP)
Internet Protocol (IP)
Ethernet

Practicals
Set up Ethernet + TCP/IP network with
SNMP clients installed on Windows
platforms.
Quick revision of using a protocol
analyser to capture packets on network.
View MIBS on a router (e.g. Cisco).
Use the Protocol Analyser to capture the
various SNMP commands (Set Request/
Get Response/Get Next Request/Get
response)
Install and set up a typical Network
Management Package (CastleRock).
Simulate various scenarios and use the
Network Management Software to
diagnose what is happening.

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Topics covered include: introduction and

terminology; firewalls; authentication,
authorisation and anonymity; remote access
to corporate networks; cryptography; VPNs;
data security; desktop and network security;
security precautions in a connected world;
and internet security.

INTRODUCTION

Pre-requisites

A basic working knowledge of industrial

communications and applications is useful.

SNMP Overview

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

What is Simple Network Management

Protocol?
The SNMP Model
Manageable Objects
Management Information Base (MIB)
Object Identifier
The SNMP Protocol
SNMP Agents
Abstract Syntax Notation.1 (ASN.1)
Basic Encoding rules (BER)

Save over 50% by

having an IDCworkshop
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SNMP v1 Details

On-Site Training

SNMP v2

Module, Object and Type Definitions

Object Names
Network Management Relationships
Accessing (Identifying and
Communicating) Object Instances
SNMP Protocol Data Units (PDUs)
- Get Request
- Get Next Request
- Set Response
- Set Request
- Trap Response
MIB Structure
MIB Tables
MIB Groups
MIB Definitions
MIB Examples
Private MIBs

Background
Structure
Textual Conventions
Changes from SNMPv1
PDUs
- GetRequest
- GetNextRequest
- Response
- SetRequest
- GetBulkRequest
- InformRequest
- SNMPv2-Trap
- Report
Transport Mappings
SNMPv2 over UDP
The SNMPv2 MIB (MIB-II)
MIB-II Extensions
SNMPv2 Security
SNMPv1 and SNMPv2 Co-existence

SNMP v3

Customise the training to

Have the training

Summary, Open Forum

and Closing

your workplace.

delivered when and

where you need it.

Background
Changes from SNMPv2
Documentation
Architecture
Message Formats
SNMPv3 MIB Modules
SNMPv1, SNMPv2 and SNMPv3
Co-existence

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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Android App Development

What YOU WILL LEARN:

Ability to create your own Android Apps

Industrial app development focus: Monitor and control equipment!
Learn easy to understand basic and advanced concepts
Step-by-step practical app development
Tips and tricks for publishing and distributing your app
Being current with innovative trends in technology
Skill in using existing app open source code (Dont re-invent the
wheel)
Tuition from an expert
Dos and donts of app development

WHO SHOULD ATTEND:

This course is designed for individuals who want to understand and build
techniques required to develop and apply Android applications to
industrial and other environments as productively and economically as
possible. No previous programming skills or development know-how
required. Individuals with a drive for innovation and interest in staying
ahead of the curve with modern resources would also benefit, including
those involved in:

Automation
Consulting
Control and instrumentation
Control systems
Design
Electrical installations
Instrumentation

IT
Maintenance
Process control
Process development
Project management
Sales and marketing
SCADA and telemetry systems

4.7

The Workshop

The Program

Ever thought, There should be an app for

this!? Have you ever wanted to create an app
for reading and controlling your equipment?
Especially for those in the hard to reach
remote areas? With the free and open Android
development tools, and the right know-how,
you can do it! This course will empower you
with the skills and know-how.

INTRODUCTION

Apps, mobile phones and tablets have

become extensions of the standard human
machine interfaces and have become tools
for everyday use. The market is flooded with
new and advancing technology, aiming to
release more and more capable and smarter
devices. The Android operating system has
become one of the worlds largest and most
widely used mobile touchscreen operating
system. It is popular for its ease of use,
open-source nature, Google backing and
support. However, the operating system
only serves as the foundation; the true
power and functionality sits with the
applications (apps) running on the system.
Hence, these apps enable most high-tech
devices to interface with the real world, the
internet, and ultimately, the end user.

STARTING OUT

Background on Android: history of app

development
Why? Features, framework

ENVIRONMENT SETUP
Basic setup of the Android SDK (ADK)
and Eclipse

List-based menu structures

Context menu
ListFragment,
User actions

Practical session: List design

MULTI-PANE UI
Multi-screens
Layout and navigation
Pass data and CRUD

New project template

Basic layout
AVD (virtual device)

Practical session: Hello world

USER INTERFACE DESIGN

MENU DESIGN, LISTS AND

ADAPTERS

Basic user interface layout

String resource
Text field
Buttons and images

PUBLISHING TO PLAY STORE

Android Package file (APK)

Digital signatures
Google Play developer profile
Pricing (paid and free)
Screenshots

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Practical session: User input, button

and image

Practical session: Multi-pane UI

development (Control / Display panes)

Apps now feature across most technical and

engineering fields, especially since the ever
developing general connectivity within
industrial systems. The convergence of
Ethernet into control, monitoring, I/O,
motion, safety and security type systems
has brought about unlimited information
access. Industry is moving to advanced
automation and human-machine-interfaces
in environments such as: oil and gas, water/
waste water management, factories and
production lines, fire detection control
systems, power stations, home automation,
building management, health care,
transportation and mining.
Companies use apps for an infinite range of
scenarios; from improvement in embedded
systems,
communication
access,
visualisation methods, Manufacturing
Execution Systems (MES), general SCADA
or simply marketing product ranges using
catalogues. Skills and understanding in app
development have become crucial for future
career development.

CODING AND BEHAVIOUR

Attributes and methods

Stacks and states
Action response, intent, activity
Event handler

Practical session: Text-type-send-display;

switching between two images
representing open/close control action

ANDROID RESOURCES AND

FEEDS

Framework classes
Errors and debugging
Permissions, strings, values and layout
Image, dimension, style, theme, menu,
and colour

Practical session: Toggle silent mode

using AudioManager; data feeds from
web or external devices

CREATING HOME SCREEN

WIDGETS

Intent, IntentService and pending intents

BroadcastReceiver and AppWidgetProvider
Widget layout, Metadata and Manifest

Practical session: App created previously

turned into home screen widget

MULTI-DEVICE SUPPORT AND

TABLET DEVELOPMENT

Practical Sessions

You will undertake practical sessions using

the Android Development Kit software
provided for a thorough step-by-step tutorial
on app development. You will also have
access to remote labs, with the software
installed, for further development after the
course.

The practical app developed throughout will

focus
on
reading
and
displaying
measurements and sending control signals
using buttons and menus. It will have
various entry fields, drop down lists and On/
Off Control states. These values and states
will be called from local SQLite database
within the app. It will connect with a realworld I/O interface, for receiving
measurements, and sending control signals.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Languages, screen size and screen density

Landscape design
Tablet layouts and fragments
Platform versions and localisation

Practical session: App layout improved

LONG-RUNNING PROCESSES

Lifecycle call-backs, active status, and

passive status
UI threads and update
Handler/Bundle and Adapters
Start, pause, resume

Practical session: Add progress

dialogues, refresh buttons, spawn
threads, feed handlers

PERSISTENT DATA STORAGE

Data storage media and user permissions
SQLite database, create, manage and
queries
Loaders and implementation
Save files

Practical session: Create device/

component DB for list selection

idc@idc-online .com

REAL-WORLD INPUT / OUTPUT

PRACTICAL

Connecting and setup of Android

supported hardware
Reading inputs displayed using text
Transmitting outputs sent using on/off
buttons

USER INPUT

EditText views
Date and time pickers
Alert dialog
Validation

Remote practical session: Modify and

improve user input text in App

RELATIVE LAYOUT; CONTACTS

LIST; ALARM MANAGER
Replacing linear with relative
Contact selection, update and action
Alarm manager schedule, permissions
and alarms

Remote practical session: Making app

relative

STATUS-BAR UPDATES;
PREFERENCE FRAMEWORK;
ADVANCED GRAPHICS

Status bar, actions and notifications

Preference screens and preference activity
Image buttons and 9-patch image
stretching

Remote practical session: Notifications,

preferences and images

LEVERAGING GEOLOCATION AND

MAPPING CAPABILITIES
Plotting positions on Google Maps
Establishing location through GPS, CellID and WiFi

FURTHER POSSIBLE ADVANCED

TOPICS

Content sharing, connectivity and cloud

Multimedia
Graphics and animation
User info and location
Interaction and engagement
Security and privacy
Sample applications and development
tools
Publishing, distribution and Marketing

Summary, Open Forum

and Closing

www.idc-online .com

Cybersecurity for Automation,

Control, and SCADA Systems

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(Using the ANSI/ISA-62443 Standards)

YOU WILL LEARN HOW TO:

Discuss the principles behind creating an effective long term

program security
Interpret the ANSI/ISA99 industrial security guidelines and apply
them to your operation
Define the basics of risk and vulnerability analysis methodologies
Describe the principles of security policy development
Explain the concepts of defence in depth and zone/conduit
models of security
Analyse the current trends in industrial security incidents and
methods hackers use to attack a system
Define the principles behind the key risk mitigation techniques,
including anti-virus and patch management, firewalls, and virtual
private networks

WHO SHOULD ATTEND:

If you are using any form of communication system this workshop will
give you the essential tools in securing and protecting your industrial
networks whether they be automation, process control, PLC or
SCADA based.
This course is required for the ISA99/IEC 62443 Cybersecurity
Fundamentals Specialist Certificate Program.
Anyone who will be designing, installing and commissioning,
maintaining, securing and troubleshooting industrial networked sites
will benefit including:

Design engineers
Electrical engineers
Engineering managers
Instrumentation engineers

Network engineers
Network system
administrators
Technicians

4.9

The Workshop

The Program

The move to using open standards such as

Ethernet, TCP/IP, and web technologies in
supervisory control and data acquisition
(SCADA) and process control networks has
begun to expose these systems to the same
cyberattacks that have wreaked so much
havoc on corporate information systems.
This course provides a detailed look at how
the ANSI/ISA99 standards can be used to
protect your critical control systems. It also
explores the procedural and technical
differences between the security for
traditional IT environments and those
solutions appropriate for SCADA or plant
floor environments. This workshop will
assist managers, system operators and
industrial data communications specialists
in setting up secure systems.

Background to workshop
Overview of basic concepts
Concepts of physical, operational, and
electronic security;
Defining Cyber Security relating to
industrial automation and control
systems

TERMINOLOGY, CONCEPTS,
MODELS AND METRICS

Discuss IEC/TS 62443-1-1

Terminology,
Concepts and models
Understanding the Current Industrial
Security Environment

SECURITY BASICS

Networking Basics Part 1

Networking Basics Part 2
Industrial Networking
Network Security Basics
Network types
ISO/OSI reference models
IP addressing
IT vs. Industrial Control System
differences.
Address security
Firewalls
Segmentation
Encryption
Secure protocols
Intrusion detection.

SECURITY MANAGEMENT
PROGRAM
Creating an ICS Security Management
Program
ISA-62443-2-1
How to create a security program for
control systems
Cyber Security Management System
(CSMS)
Elements and requirements:
- Risk Analysis
- Addressing the Risk with CSMS
- Monitoring and Improving the CSMS

DESIGNING / VALIDATING SECURE

SYSTEMS

Understand how to apply security levels

Security Lifecycle
Identify risks and significance
Study Qualitative/Quantitative risks
Risk assessments
Identifying threats
Security level (SL) definitions

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Topics covered include: introduction and

terminology; electronic security; threat
sources; understanding the current industrial
security environment; how cyberattacks
happen; creating a security program; risk
analysis; addressing risk with security
policy, organization, and awareness;
addressing risk with selected security
counter measures; addressing risk with
implementation measures; monitoring and
improving the CSMS.

INTRODUCTION

Pre-requisites

A basic working knowledge of industrial

communications and applications is useful.

Classroom/Laboratory
Exercises:

DEVELOPING SECURE PRODUCTS

AND SYSTEMS
Software Security Assurance (SSA)
Control System Security Layers of
Responsibility
Incorporating security
Integration of security at the various
phases of the development lifecycle
ISA Security Compliance Institute (ICSI)
ISASecure Certification

Summary, Open Forum

and Closing

Develop a business case for industrial

security
Conduct security threat analysis
Investigate scanning
analysis tools

and

protocol

Apply basic security analysis tools

software

Includes ISA Standards:

ANSI/ISA-62443-1-1 (ANSI/ISA-99.00.012007) - Security for Industrial Automation

and Control Systems Part 1: Terminology,
Concepts & Models (A $155 Value!)

Practical Sessions

ANSI/ISA-62443-2-1 (ANSI/ISA-99.02.012009) - Security for Industrial Automation

and Control Systems: Establishing an
Industrial Automation and Control
Systems Security Program (A $215
Value!)

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

ANSI/ISA-62443-3-3 - Security for

industrial automation and control
systems: System security requirements
and security levels (A $260 Value!)

Recommended Resource:
ISA Text: Industrial Network Security by
David J. Teumin

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

CHEMICAL ENGINEERING

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TRAINING WORKSHOPS
Practical Fundamentals of Chemical Engineering ...................................................................................................5.1
Handling Chemicals and Chemical Processes - Tips, Tricks and Tools .................................................................5.3

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Practical FUNDAMENTALS OF

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CHEMICAL ENGINEERING

You will learn how to:

Understand the fundamentals of chemical engineering

Do simple specifications of pumps and heat exchangers
Understand mass transfer phenomena including agitation scale-up
Perform simple process calculations
Troubleshoot process equipment and provide fixes
Contribute to process design activities
Understand process drawings and link them to plant operation
Apply safety guidelines to a process or chemical plant
Understand basic chemical engineering jargon and terminology

WHO SHOULD ATTEND:

This workshop will be appropriate for the following professionals:

Process development engineers
Industrial engineers
Electrical engineers
Mechanical engineers
Civil engineers
Control and instrumentation engineers
Plastics and material engineers
Maintenance engineers
Food scientists
Environmental engineers
Environmental technicians
Chemists
Chemical plant operators
Maintenance supervisors
Laboratory technicians
Shift tradespeople
5.1

The Workshop

The Program

This workshop aims to cover the fundamental

concepts of chemical engineering and
provide you with a solid working knowledge
associated with it. If you are a non-chemical
engineer this course will enable you to
confidently talk to and work effectively with
chemical engineers and process equipment.
Many technical professionals today find
themselves working with large-scale
chemical processes even-though they do
not have formal training in chemical
engineering. This workshop intends to fill
this gap and provide you with this knowledge
in the chemical engineering fundamentals
and the ability to apply this knowledge to
specify, design, operate, maintain and
trouble-shoot chemical processes.

Pre-requisites

Day TWO

INTRODUCTION: THE CHEMICAL

PROCESS UNDERSTANDING A
PROCESS FLOW SHEET

CHEMICAL ENGINEERING
THERMODYNAMICS

Process Flow Diagrams (PFDs)

Piping and Instrumentation Diagrams (P&
IDs)
Process legends used in flow sheets

STOICHIOMETRY

Dimensions and units

Processes and process variable
Process data representation and analysis
Basic chemical calculations
Material and energy balance
Combustion

FLUID MECHANICS

Fluid statics and its applications

Fluid-flow phenomena
Basic equations and fluid flow
Flow of incompressible fluids in conduits
and thin layers
Flow of compressible fluids
Flow past immersed bodies
Transportation and metering of fluids
Agitation and mixing

Fundamental quantities
First law of thermodynamics
Volumetric properties of pure fluids
Heat effects
Second law of thermodynamics
Thermodynamic properties of fluids
Thermodynamic properties of
homogenous mixtures
Phase equilibria
Chemical reaction equilibrium
Thermodynamics of flow processes
Conversion of heat into work by power
cycles
Refrigeration and liquefaction
Thermodynamic analysis of processes

CHEMICAL KINETICS

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An elementary understanding of engineering

concepts such as fluid flow, heat and mass
transfer is useful; however a revision will be
undertaken at the commencement of the
course. Please bring your scientific calculator
for solving problems during the practical
sessions.

Day ONE

HEAT TRANSFER AND ITS

APPLICATIONS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. There are twelve practical design
sessions throughout the workshop.
Practical sessions include:
Simple physical reaction

Simple chemical reaction

Ideal gas law: how temperature changes

in gases can cause pressure changes in
gases
Simple heat transfer: how heat flows
from high temperature to low
temperature

Change in density of boiling fluids:

boiling fluid has a lower density than a
non-boiling fluid

Heat transfer by conduction in solids

Principles of heat flow in fluids
Heat transfer to fluids with and without
phase change
Radiation heat transfer
Heat-exchange applications
Evaporation

MASS TRANSFER AND ITS

APPLICATIONS

Equilibrium-stage operation
Distillation
Leaching and extraction
Introduction to multi component
distillation
Principles of diffusion and mass transfer
between phases
Gas absorption
Humidification operations
Adsorption
Drying of solids

Basic definitions
Kinetics of homogenous reactions
Interpretation of batch reactor data
Introduction to reactor design
Single ideal reactors
Design for single reactions
Design for multiple reactions
Temperature and pressure effects
Non ideal flow
Mixing of fluids
Introduction to design for heterogeneous
reacting systems
Fluid - particle reactions
Fluid - fluid reactions
Solid - catalyst reactions
Reactivating catalysts

PROCESS EQUIPMENT DESIGN

Design considerations
Storage vessels
Pressure vessels
Reactors
Heat exchangers
Evaporators and crystallisers
Distillation and fractionation equipments
Agitators
Filters
Dryers
Process hazards and safety measures
Fundamentals of computer aided design

PROCESS CONTROL AND

INSTRUMENTATION

Pressure of two different density liquids:

lower density fluid needs a greater
height to create the same pressure
gradient as a higher density fluid

Quantities of measurement
Process instrumentation
- Temperature
- Pressure
- Level
- Flow

Natural convection evaporation: how

evaporation of a fluid below its boiling
point can occur, and how it cools

Sublimation: how some components can

go from vapour to solid without making
a liquid

PROCESS ECONOMICS

Simple mass transfer: how a

concentration driving force works, and
to see the effect of temperature

Investment and profitability

Accounting and cost control
Manufacturing - cost estimation
Fixed and capital cost estimation

SUMMARY, OPEN FORUM

AND CLOSING

Density: how a density can change

buoyancy
Endothermic reaction: how a chemical
reaction can lower temperature
Exothermic reaction: how a chemical
reaction can raise temperature
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Handling Chemicals
and Chemical Processes

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- Tips, Tricks and Tools

YOU WILL LEARN HOW TO:

Gain the valuable know-how used by chemical engineers to

troubleshoot chemical processes and process equipment
Understand process design activities

Design a simple plant from the ground upwards

Understand the role of safety in a Process or Chemical Plant

Understand the fundamentals of Chemistry, Chemical
Processing and Chemical Engineering

Understand chemical formulae, equations and process

calculations

Get an overview of Thermodynamics, Fluid mechanics and Heat

transfer applications
Understand mass transfer phenomena
Perform simple process calculations

Get a first hand look at a chemical disaster and learn how to

avoid this

WHO SHOULD ATTEND:

Process Development
Engineers
Industrial Engineers
Electrical Engineers

Mechanical Engineers
Civil Engineers
Control and Instrumentation
Engineers
Plastics & Material Engineers

Food Scientists

Environmental Engineers
Environmental Technicians
Chemists
Chemical Plant Operators
Maintenance Supervisors
Laboratory Technicians
Shift Tradespeople

Maintenance Engineers
5.3

The Workshop

The Program

This will provide you with practical

knowledge (including tips, tricks and tools)
covering the fundamentals of Chemistry,
Chemical and Process engineering. It will
greatly assist you in communicating more
effectively with your chemical engineering
colleagues. In industry, handling chemicals
is considered a hazardous occupation.
Chemical engineers are a trained set of
specialists who have spent years in
understanding the nature and behavior of
chemicals and chemical process systems. If
you are a non-chemical engineer we aim at
bringing this knowledge to you in a two-day
interactive workshop.

Pre-requisites

Please bring a pocket calculator for solving

problems during the practical sessions.

Workshop Objectives

At the end of this workshop, participants will

be familiar with the following aspects:
1. The fundamentals of Chemistry and
Chemical Engineering (using practical
tips and tools) with regards to:
Stoichiometry & Reaction Kinetics
Thermodynamics
Heat Transfer

Mass Transfer & Fluid Flow

Process Control

2. Quick tips in understanding Process

Design considerations for:
Heat Exchangers
Reactors
Agitators

INTRODUCTION: Chemistry,
Chemical Processing and
Chemical Engineering

Chemical Engineering
Thermodynamics

Stoichiometry
Dimensions and Units
Processes and Process Variable
Process Data Representation and
Analysis
Basic Chemical Calculations
Material Balance without chemical
reactions
Material Balance with chemical reactions
Energy Balance
Combustion

Chemical Kinetics

Basic definitions
Kinetics of homogenous reactions
Interpretation of batch reactor data
Introduction to reactor design
Single ideal reactors
Design for single reactions
Design for multiple reactions
Temperature and Pressure effects
Non ideal flow
Mixing of fluids
Solid-catalyst reactions
Reactivating catalysts

Fluid Mechanics

Fluid statics and its applications

Fluid-flow phenomena
Basic equations and fluid flow
Transportation & Metering of fluids
Agitation & Mixing

Heat transfer & Its

Applications

Unit Operations

Pumps

DAY TWO

Fundamental quantities
First Law of Thermodynamics
Volumetric properties of pure fluids
Heat Effects
Second law of Thermodynamics
Thermodynamic properties of fluids
Thermodynamic properties of
homogenous mixtures
Phase Equilibria
Chemical reaction equilibrium
Thermodynamics of flow processes
Conversion of heat into work by power
cycles
Refrigeration & Liquefication
Thermodynamic analysis of processes

Understanding a Process
Flow Sheet

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An elementary understanding of engineering

concepts such as fluid flow, heat and mass
transfer is useful; however a revision will be
undertaken at the commencement of the
course.

Day One

Filtration Equipment

3. Practical application of the Principles

involved in Design and Process revamp
4. Troubleshooting various Processes and
Process Equipment

5. Understanding why safety is of

paramount importance - troubleshooting
a real-life disaster

Practical Sessions

Chemical formulae and equations

Designing a chemical processing unit
Troubleshooting a chemical disaster

Heat transfer by Conduction in solids

Principles of heat flow in fluids
Heat transfer to fluids without phase
change
Heat transfer to fluids with phase change
Radiation heat transfer
Heat-exchange applications
Evaporation

Mass Transfer And Its

Applications

Equilibrium-stage operation
Distillation, Leaching & Extraction
Introduction to Multi component
distillation
Principles of diffusion and Mass transfer
between phases
Gas absorption
Humidification operations
Adsorption
Drying of solids

Process Flow Diagrams (PFD's)

Piping and Instrumentation Diagrams
(P&ID's)
Process Legends used in flow sheets

Process Equipment Design

Design considerations
Storage vessels
Pressure vessels
Reactors
Heat Exchangers
Evaporators and Crystallisers
Distillation and Fractionation Equipments
Agitators
Filters
Dryers

Process Control and

Instrumentation
Quantities of Measurement
Process Instrumentation

- Temperature
- Pressure
- Level
- Flow

Safety, the environment and

the chemical industry
The Bhopal Chemical Disaster
Long term effects of chemical pollution

Practical Sessions

Summary, Open Forum and

Closing

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

INSTRUMENTATION, AUTOMATION
and PROCESS CONTROL

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TRAINING WORKSHOPS
Practical Analytical Instrumentation in On-Line Applications.......................................................................... 6.1
Practical Alarm Management for Engineers and Technicians........................................................................... 6.3
Practical Programmable Logic Controllers (PLCs) for Automation and Process Control.............................. 6.5
Practical Batch Management & Control (Including S88) for Industry.............................................................. 6.7
Practical Boiler Control and Instrumentation for Engineers and Technicians................................................. 6.9
Practical Data Acquisition using Personal Computers and Standalone Systems.........................................6.11
Practical Industrial Flow Measurement for Engineers and Technicians......................................................... 6.13
Practical Hazops, Trips and Alarms................................................................................................................... 6.15
Practical Hazardous Areas for Engineers and Technicians.............................................................................. 6.17
Practical Instrumentation for Automation and Process Control..................................................................... 6.19
Practical Intrinsic Safety for Engineers and Technicians................................................................................. 6.21
Practical Tuning of Industrial Control Loops.................................................................................................... 6.23
Practical Motion Control for Engineers and Technicians................................................................................. 6.25
Practical Fundamentals of OPC......................................................................................................................... 6.27
Practical Process Control .................................................................................................................................. 6.29
Practical Process Control and Tuning of Industrial Control Loops 6.31
Practical SCADA and Telemetry Systems for Industry.................................................................................... 6.33
Practical Safety Instrumentation and Emergency Shutdown Systems for Process Industries................... 6.35
Practical Industrial Programming using 61131-3 for Programmable Logic Controllers (PLCs)................... 6.37
Practical Control Valve Sizing, Selection and Maintenance............................................................................ 6.39
Best Practice in Process, Electrical and Instrumentation Drawings and Documentation............................ 6.41
Practical Distributed Control Systems (DCS) for Engineers and Technicians............................................... 6.43

Fundamentals of Industrial Automation........................................................................................................... 6.45

Practical Troubleshooting of Data Acquisition and SCADA Systems............................................................. 6.47
Installation, Calibration and Maintenance of Electronic Instruments............................................................ 6.49
RFID Tagging: Features and Applications......................................................................................................... 6.51
Practical Industrial Troubleshooting of Instrumentation, Electrical and Process Control
for Engineers and Technicians....................................................................................................................... 6.53
Practical Hazops for Engineers and Technicians.............................................................................................. 6.55

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Practical SCADA Systems for Industry............................................................................................................. 6.57

Practical Machine Vision Applications for Industry......................................................................................... 6.59
Practical Advanced Process Control for Engineers and Technicians.............................................................. 6.61
Practical Industrial Safety, Risk Assessment and Shutdown Systems for Industry..................................... 6.63
Introduction to the Selection, Installation, Commissioning and Maintenance of Fiscal Flow
and Metering Equipment............................................................................................................................... 6.65
Measurement and Control for Non-Instrument Personnel............................................................................. 6.67
Programmable Logic Controllers (PLCs) and SCADA Systems..................................................................... 6.69
Practical Drives, Motors and PLCs for Engineers and Technicians................................................................ 6.71
Practical Troubleshooting and Problem Solving of PLCs and SCADA Systems........................................... 6.73
Practical Flow Essentials.................................................................................................................................... 6.75
Fundamentals of Instrumentation, Process Control, PLCs and SCADA for Plant Operators
and other Non-Instrument Personnel........................................................................................................... 6.77
Fundamentals of Practical Building Automation Systems (BAS)................................................................... 6.79
Design of Industrial Automation Functional Specifications for PLCs, DCSs and SCADA systems............ 6.81
Practical Remote Engineering, Mechatronics and Robotics for Engineers and Technicians ...................... 6.83
Instrumentation Engineering for Oil and Gas Facilities ................................................................................. 6.85
Practical IEC 61850 for Substation Automation for Engineers and Technicians........................................... 6.87
Hazardous Areas and ATEX Awareness for Technical and Non-technical Staff............................................. 6.89
One-day Refresher Training: Electrical Equipment for Practical Hazardous Areas
for Engineers and Technicians (Outside Europe)......................................................................................... 6.91
One-day Refresher Training: Electrical Equipment for Practical Hazardous Areas
for Engineers and Technicians (Within Europe)........................................................................................... 6.93
Master Series: Instrumentation and Control.................................................................................................... 6.95
Integrated Programming, Maintenance, Troubleshooting and Optimisation of the
Drill Monitor System (DMS).......................................................................................................................... 6.97

Practical

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ANALYTICAL INSTRUMENTATION
IN ON-LINE APPLICATIONS

Specifically tailored for those without a chemical background, this

workshop has been designed to take the mystery out of on-line
analytical measurement and explain it in terms that are easily
applied in the workplace.

WHATYOU WILL LEARN:

The basics of chemistry and how to read chemical formulae

How analytical chemistry is applied in industrial control

To improve your understanding and capabilities in on-line

analytical chemistry
How to troubleshoot problems in the measurement of pH,
conductivity, turbidity, hygrometry, DO and chlorine

WHO SHOULD ATTEND:

For many years, chemical measurement has remained the preserve

of the analytical chemist. Increasingly, on-line analytical
measurement is being applied in on-line process control and is
therefore rapidly becoming the responsibility of the instrumentation
and control technologist.

Electricians

Consulting Engineers

Technicians

Maintenance Engineers

Senior Operators

Process Control Engineers

Project Engineers

Instrumentation Sales
Engineers

Design Engineers
Systems Engineers
Electrical Engineers

Instrumentation and Control

Engineers

6.1

The Workshop

The Program

On-line analytical measurement has become

an integral part of process control
measurement. As a result, a working
knowledge of analytical measurement is
now a prerequisite for anyone working with
process instrumentation and control.
The two-day workshop will 'demystify' the
world of analytical measurement and equip
you with the knowledge required to
understand, identify and confidently
troubleshoot
On-Line
Analytical
Measurement Instrumentation in Process
Control.
This workshop will offer you the vital
knowledge that you need to multi-skill,
reduce downtime, save your company
money and secure your value in the
workplace.

Basic chemistry

Turbidity measurement

Elements, compounds and mixtures

Properties of elements
Formation of ions
Bonding
Chemical formulae and equations
Atomic weight
Molar concentrations
Acids and bases

Electrochemical cells

Electrode potentials
Simple voltaic cell
Polarisation
Daniell cell
Electrolytic bridges
Electrochemical series

Hygrometry

Vapour pressure and humidity

Partial vapour pressure
Relative humidity
Hygrometric instruments
Hygrometric calculations

Dissolved oxygen measurement

pH measurement
Definition of pH
Measurement of pH
The measuring electrode
The reference electrode
Nernst equation
Temperature effect
Antimony electrode
Sources of errors
Calibration

Measuring cells
Calibration
Installation and troubleshooting
Electrode maintenance and storage

Total free chlorine

measurement

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Interaction between light and matter

Absorptiometers
Nephelometers
Practical on-line systems
Calibration
Applications

This
practical,
hands-on
workshop
introduces on-line analytical measurement
to anyone who needs to understand
industrial and chemical analysis techniques
used in process control.
This workshop offers you the most up-todate knowledge to allow you to:
recognise and efficiently troubleshoot a
wide variety of industrial analytical
measuring instruments

understand the construction and

operation of the most important analytical
instruments
understand chemical technology

effectively apply the principles of

chemical
analysis
to
industrial
instrumentation
identify chemical formulae and symbols

implement procedures for testing and

calibration of analytical instruments

Measurement of Redox

Applications
Calibration/checking procedure

Basic chlorine chemistry

Measuring principle and systems
Calibration
Applications

On-line colorimetry and

titration

On-line gas chromatography

Conductivity measurement

Ionic mobility
Cell construction and constant
Temperature compensation
Conductivity measurement of high
purity water
4-electrode sensor
Installation
Sensor maintenance
Preventative maintenance
Troubleshooting
Applications

Workshop Objectives

multi-skill with colleagues within your

industry

Enlightening
Trevor Jones

Practical Sessions

There are a total of five practical, hands-on

sessions that aim to give you the confidence
and experience you need to work with and
troubleshoot analytical instruments.
These practical sessions are:
Basic chemistry

pH measurement

Conductivity measurement
Dissolved oxygen
Colorimetry

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

ALARM MANAGEMENT

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Design and create a consistent and effective alarm philosophy

for your installation
Recognise and deal with human problems in interfacing to
alarm systems
Apply the ergonomic design factors to a good alarm system
Analyse alarm data for root causes of problems and to improve
your operation
Benchmark your alarm system performance

Develop and apply a consistent alarm philosophy across your

installation
Improve your plant reliability and operator effectiveness with a
top notch alarm philosophy

WHO SHOULD ATTEND:

Anyone involved in the

installation, design and
support of alarm systems
Design engineers

Electrical and
instrumentation technicians

Electrical engineers
Instrumentation and control
system engineers
Instrumentation technologists
and engineers
IT managers working with
networks

Maintenance engineers and

supervisors
Operations managers

Plant engineers

Process control designers

and systems engineers
Process control engineers
and technicians
Process engineers
Production engineers
Project engineers
Systems engineers

6.3

The Workshop

The Program
Introduction

Design of Alarm System

SAFETY EXAMPLES OF SYSTEMS

Why alarm systems need to be
managed?
Practical Exercise

Fundamental Principles of
Alarm System Management
Philosophies of alarm management
Practical Exercise

Design Overview
Human and ergonomic factors
Structure of good alarm system
Safety Integrity Level (SIL)
Practical Exercise

Definition of Strategy

Practical Exercise

Measurement of Performance
Practical Exercise

Management of Improvement
Program
Alarm review
Elimination of spurious alarms
Process alarms
Intermittent and fleeting alarms
Control of modifications
Practical Exercise

HAZOPs and Alarms

Establish a strategy
Practical Exercise

Practical Exercise

Tie it all together

Measurement of the Alarms

The way forward

Summary of key concepts

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It is 6.00 in the evening after a hot summers

afternoon and the shift has just changed
over. The control room has been rather quiet
through the day with the odd alarm
punctuating the serene silence. In fact this
plant has been a truly contented baby with
no major problems for over 18 months since
it was commissioned. Apart from the
inevitable mechanical wear and tear
associated with a new plant. Suddenly there
is an explosive roar outside and the control
room door bursts open with the shift
foreman dripping with sweat shouting:
Weve just lost Unit 3, Im not sure what is
happeningcan you tell me what is going
on. Within seconds the alarms start pouring
in. The operator starts to systematically work
his way through the overview displays
trying to identify what is going on. But he is
slowly overwhelmed by the sheer number of
alarms which are flitting across the screen
so fast that he cannot even read them. And
Unit 3 is now starting to lurch into a
dangerous state with pressures, flows and
temperatures well outside acceptable
operating ranges. So it looks like an
immediate shutdown of the plant is going to
be required with some very unhappy
customers over the next few weeks.

Audit the current alarm status

Practical Exercise

Analyse the Alarms

SUMMARY, OPEN FORUM

AND CLOSING

Practical Exercise

Was there any other approach possible?

It is important that throughout the plant that

a consistent philosophy is adopted for
alarms and that your operators are not
distracted from the main ball game of
operating the plant.
This workshop will give you the necessary
information to ensure that your alarm
system is well designed and provides your
operators with the best picture of the
operations of the plant. The workshop
focuses on simple and practical information
for personnel ranging from operators all the
way up to supervisors, engineers and
managers.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Nine Practical Sessions focussing on the

design of Alarm Systems throughout the
two days will ensure that you can apply the
information from the course to your system.

The course was well presented.

Excellent Instructor.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

There are nine practical sessions in the

design of alarm systems throughout the
workshop, these ensure that you can apply
the information gained in the training to
your own plant and systems.

Hopefully this is not the scenario on your

plant; but could this just perhaps happen?
Does your alarm system ensure the operator
stays unerringly focussed on the source of
the problem or is there a possibility that he
could get overwhelmed and distracted by
the number of alarms where many of them
may not be relevant to the immediate
problem?

J. Pollock

Pre-requisites

Some background in working with SCADA

and process control systems would be
useful to maximise your benefit from this
workshop

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

PROGRAMMABLE LOGIC
CONTROLLERS (PLCs)

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for Automation and Process Control

YOU WILL LEARN how to:

Specify PLC hardware and installation criteria

Describe PLC software structure

Write medium level PLC programs (using ladderlogic)

Troubleshoot a typical PLC system
Specify PLC systems

WHO SHOULD ATTEND:

Process control operators

Shift electricians

Trades staff working with or near PLCs

Instrumentation and control engineers
Electrical engineers
Design engineers

Consulting engineers

Instrumentation technicians
Process control engineers
Engineering managers
DCS personnel

6.5

The Workshop

The Program

This workshop is designed to benefit you

with practical up-to-date information on the
application of PLCs for the automation and
process control of plants and factories. It is
suitable for people who have little or no
exposure to PLCs, but expect to become
involved in some or all aspects of PLC
installation. It aims to give practical advice
from experts in the field, to assist you to
correctly plan, program and install a PLC
with a shorter learning curve and more
confidence.

ADVANCED CONTROL WITH PLCS

Introduction to PLCs
A brief history of PLCs
Alternative control systems where do
PLCs fit in?
Why PLCs have become so widely
accepted
Lingering concerns about PLCs

The concept of reusable logic - examples:

drive logic, alarm handling
Use of advanced programming functions
Matrix logic
Table functions and indirect addressing
Examples: simple display driver

FUNDAMENTALS OF PLC HARDWARE

Block diagram of typical PLC
PLC processor module memory
organisation
Input / output section module types
Power supplies

FUNDAMENTALS OF PLC SOFTWARE

Methods of representing logic
- Boolean algebra
- Instruction code
- Graphical presentation: functional logic
diagrams, ladder logic
Fundamental ladder logic instruction set
Comparison of different manufacturers
- Memory and data representation
- Instruction code

BATCH PROCESSES AND

SEQUENTIAL CONTROL

Remembering the program state

Creating a stepper
Step advance
Fault detection and recovery
Operator intervention
Multiple recipes or alternate paths
Sequential function charts

PID CONTROL
The importance of timing and scan time
When PID is not always appropriate:
- Intermittent measurements
- Long transport delays

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While the workshop is ideal for electricians,

technicians and engineers who are new to
PLCs, much of the workshop and additional
material in the extensive manual will be of
value to those who already have some basic
skills, but need a wider perspective for larger
and more challenging tasks ahead. The
accompanying manual includes contributions
from a number of experts and will become a
valuable reference in your work. The
information contained in this workshop
advances from the basics to challenge even
the most experienced engineer in the industry
today.

INTRODUCTION

Pre-requisites

A basic electrical knowledge would be useful

but is not essential.

Practical Sessions

USING LADDERLOGIC FOR SIMPLE

DIGITAL FUNCTIONS

The basic rules

Comparison with relay ladder diagrams
The concept of the scan and how to
apply it
Infinite fan-out
Contact normal states
Positive and negative logic
Basic boolean functions
The usefulness of De Morgans Law

USING REGISTERS (WORDS)

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Number systems
Types of register data
Timers
Counters
Bit shift / rotate
Table functions
Register (matrix) logic functions
Practical Session

GOOD PROGRAMMING HABITS

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.

Keeping track of addresses and data used

Looking ahead how will programs be
maintained
Practical methods to improve program
quality
- Organisation of code
- Through documentation
- Simplifying changes
Practical Session

GOOD INSTALLATION PRACTICE

Location of hardware
Good wiring practice
- Cable spacing
- Power distribution
- Wire numbering
Reducing noise and interference
Screening and shielding
Earthing and grounding
Practical Session

SAFETY PROGRAMMABLE SYSTEMS

Why regular PLCs should not be used for
safety functions
Programmable electronic logic solvers
Safety certification
Certified programming systems
Application examples
Growth of networked safety devices and
certified networks
Integrated safety systems

DATA COMMUNICATIONS

Interface standards, RS-232, RS-422/423,

RS-485
Protocols, Modbus and DH+
Local area networks, Ethernet and token
bus
Monitoring communication links and
simple watchdog timers

INTRODUCTION TO IEC 61131-3

Concepts
Common elements
Programming languages: structured text
Function block diagrams
Ladder diagrams
Instruction list
Sequential function chart

OPC

Introduction to OPC
What is OPC?
Architecture

SYSTEM CHECKOUT AND TESTING

Development and verification of code

Factory acceptance testing
Testing procedures
Emulating missing hardware
Emulating process responses

SUMMARY, OPEN FORUM

AND CLOSING

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

BATCH MANAGEMENT and CONTROL

(INCLUDING S88)

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for Industry

YOU WILL LEARN HOW TO:

Automate batch processes using the appropriate standards and

techniques
Design a batch manufacturing control system for new or
upgrade projects using principles supported by the ISA S88
standard
Obtain guidance in the integration of batch control systems
with manufacturing information systems
Design and specify instrumentation and batch controls in
modules leading to complete unit operations
Carry out the detailed design of batch control operations
including the sequencing and interlocking functions
Develop batch operations into complete recipe based
production systems
Evaluate the choices in the range of batch control system
products.
Avoid the pitfalls of not having the batch control system
package match your requirements

WHO SHOULD ATTEND:

Engineers and technicians in process or control/instrument

fields who are involved in batch process control projects
Production Supervisors or Managers interested in developing
improved batch management techniques through the use of
automation systems
System Integrators seeking to provide a design service to clients
Those in businesses that have automated batch manufacturing
as a part of their production activity
Instrumentation and Design Engineers
Chemical Engineers
Process Engineers

Electrical Engineers
Project Engineers

Design Engineers
Field Technicians

Electrical Technicians
Electricians


Plant Operators
6.7

The Workshop

The Program

This workshop shows you how to:

structure the activities of batch control into
easy to understand tasks
choose, design and manage an automated
batch management control system
save your business time and money by
choosing and designing the correct, and
therefore efficient batch process control
system

Workshop Outline and

Objectives

Batch & Sequence Programming

Fundamentals

Identification of batch processes,

characteristics and examples
Background to the demand for integrated
batch systems
Overview of batch systems engineering
Introduction to Standards: ISA S88 and
IEC 849/BS 7716

Practical techniques for batch control

elements
Implementation of valve elements, motor
controls, interlocks and permits etc.
Interactions with continuous process
sections

The workshop is presented in learning

modules. At the end of each module we will
examine the way in which the particular
feature we have built contributes to the
overall scheme. The scheme can be simple or
it may be a complete manufacturing scheme
integrated to a sales operation.

Identify and Define Physical

Models

How to capture the need, design the

operation and document it for
programming into PLC/DCS
Practical methods for functional
specifications; flowcharts and structured
text
Defining equipment and process states
using transition diagrams
Dealing with sequencing problems such
as alarms, holds, aborts and restarts

Interfacing to the Operator and

the Supervisor

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For example we will examine situations

such as:
businesses where the weekly tally of sales
is collected into a shopping list for the
factory production campaign
how the plant responds quickly to the
shopping list
how we report back on what was actually
produced
how we report on batch numbers
tracing which batch tanks were used
identifying if a tank was contaminated
how do we know which products to recall?

We begin with a hypothetical but typical

process in batch manufacturing
Presentation of a typical P&ID with
several units linked to supply systems
Show how this is structured into
elements, equipment modules, units,
cells and trains using the physical models
technique in S88
Show how well structured batch plants
can save on equipment costs

Practical Techniques in
Sequence Control Design

Identify and Define Process

Models, Actions, Operations and
Stages
Relationship between physical and
process models
A unit operation example based on the
typical P&ID shown in the first practical
session

Historically batch control systems were

designed in individual ways to match the
basic arrangement of plant equipment. They
lacked the ability to convert to new products
without having to modify the control systems.
These schemes did not lend themselves to
recipe based operations or to integration
with manufacturing management systems.

Identify and Define Procedural

Models

This workshop concentrates on getting the

building bricks right and arranging the
structures into flexible schemes suitable for
automated batch management, e.g being
able to work in response to new recipes that
use the same plant equipment in different
combinations.

The relationship between procedural

control, physical model and procedural
model
Explanation of basic control, procedural
control and co-ordination control
This concept illustrated by using the
example process
Show how batch control is built up
around the common, functional entities
of control modules, equipment modules
and units

The material in this workshop aligns with

current practices in the automation of batch
processes, including the drive for integration
with MES and ERP products from major IT
product companies. References and
examples will be drawn from DCS/PLC batch
control products in the market place.

Sequence steps, phases, operations and

unit procedures
Introduction to co-ordination control

The Concepts of Equipment

Entities

Introduction to Recipes

This workshop is designed for you to:

The use of recipes to define all

requirements for batch manufacture of a
given product
The concepts of master and control
recipes
Using and creating recipes
How to hide the complexities of unit
operations and create flexibility for the
production team

be able to plan, structure and manage a

batch manufacturing project

Batch Manufacturing Basics

Workshop Objectives

gain a basic knowledge of the S88

standard and be aware of critical design
issues in batch control systems

Display screens for recipes, monitoring

of sequence operations, trouble shooting
and maintenance
Illustrations using currently available
software packages

Batch Management Issues

Introduction to batch control activities

and activity models as described in ISA
S88
Practical problems in batch management
Ownership issues and conflict
Using command structures to resolve
problems

Practical Batch Control

Technologies

Overview of DCS/PLC architectures

Examples of current products
Integration of batch control systems to
production management and ERP
systems
ERP requirements as inputs to batch
production
Sending process quality and production
reports back to ERP

Practical Software Project

Planning and Implementation
What to look for in batch software
packages
Batch control software products
Overview of S88 compliant packages
Examples and demonstrations of key
features from existing vendor packages

Batch numbering, tracking and reporting

Batch planning and scheduling

have a basic knowledge of current

technologies in batch control and how to
utilise them in the implementation stages
of a project
be able to plan for growth into a production
management facility with ERPintegration
potential

Pre-requisites

Your knowledge of batch control system

fundamentals, will assist you to avoid the
expensive mistake of choosing the incorrect
package for your business requirements.

idc@idc-online .com

A basic knowledge of electrical engineering

principles and concepts will be an advantage.

www.idc-online .com

Practical

Boiler Control and

Instrumentation

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Understand the objectives of the principal boiler control

functions
Recognise and understand typical boiler control diagrams and
their design intentions
Contribute to the setting up and tuning of boiler control loops
Identify principles and design concepts governing:
- Boiler feed water control

- Furnace draft measurement and control

- Steam demand and firing rate control

- Main steam and reheat steam temperature control

- Flue gas analysis and fuel combustion trimming controls

Importance of boiler safety control and start-up interlocks
Explore advanced control strategies for improved boiler plant
efficiency

WHO SHOULD ATTEND:

Senior boiler plant operators, repairers and installers

Control system engineers

Instrumentation engineers and technicians

Boiler plant commissioning engineers
Mechanical engineers and technicians
Operation, maintenance, inspection and repair specialists
Design engineers
Consulting engineers

6.9

The Workshop

The Program

This 2-day workshop introduces the basic

practices of controls systems and safety
controls for industrial steam generating
boilers. It focuses on the control and safety
requirements applicable to most types of
boilers from small gas-fired units to large
multi-fuel installations. The workshop will
provide training in how control and
instrumentation is designed to manage the
main variables such as drum water level,
furnace draft, combustion fuel and air
conditions. Burner management systems
are introduced with their principal features
including flame safety systems. The essential
safety requirements for boilers and burners
are identified and the corresponding safety
interlocks are explained as practical
solutions in accordance with the latest safety
standards.

Pre-requisites

COMBUSTION CONTROLS

Objective of boiler controls

Overview of boiler types
Boiler processes in block diagrams to
show keys inputs and output variables
Hazards of boiler operations
The main control functions in boiler
furnaces

The combustion process and its

requirements for efficiency and safety
Coal, oil and gas firing types
Stoichiometric air and excess air
requirements
Fuel-air ratio control and its
measurements
Firing rate controls and cross limiters for
improving dynamic response
Methods for measurements of boiler
efficiency using analysers
Application of optimising controllers

REVIEW OF PROCESS CONTROL AND

INSTRUMENTATION RELEVANT TO
BOILERS
Principles of sensors and transmitters
with examples of boilers
Closed loop control principles including
feedback, feedforward, ratio and limiting.
Control system hardware and software
tools.
Safety instrumented controls and the
impact of IEC 61511
Instrumentation diagrams and symbols
per ISA and SAMA
Distributed control systems and the
separation of safety systems

BURNER MANAGEMENT SYSTEMS

Safety and performance requirements of
pulverisers, burners and igniters
Furnace safety standards and regulations
Flame monitors and flame failure
detection
Start up protection and sequencing
Furnace supervisory controls and
shutdown systems

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Fundamental knowledge of basic boiler

plant and operation thereof and some
understanding of control systems.

ESSENTIALS OF BOILER PROCESSES

FEEDWATER AND DRUM LEVEL

CONTROL

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Performance requirements: Level, quality,

stability
Characteristic responses of drum level
Level control solutions, 1,2 and 3 element
types
Level measurement problems and
practices
Drum level safety systems

FURNACE AIR AND DRAFT CONTROLS

Performances requirements; pressures
and temperatures
Characteristic responses and means of
control
Pressure measurement methods and the
pressure profile
Temperature control and the impact of
dew point
Protection against implosion

STEAM TEMPERATURE CONTROL

Superheater and attemperator

arrangements
Essential control requirements
De-superheater controls

STEAM PRESSURE AND BOILER LOAD

CONTROLS
Pressure and flow response
characteristics
Single boiler load control
Multiple boiler installations and load
sharing controls

SUMMARY, OPEN FORUM

and closing

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

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DATA ACQUISITION using Personal

Computers and Standalone
Systems

YOU WILL LEARN how to:

Install and configure a data acquisition system

Choose and configure the correct software

Apply state of the art approaches in design of data acquisition

systems
Configure data communications systems

Avoid the common pitfalls of designing a data acquisition

system

WHO SHOULD ATTEND:

Instrumentation and control system engineers

Electrical engineers

Project engineers

Design engineers
Technicians

Process control engineers

Maintenance engineers
Systems engineers
DCS Personnel

6.11

The Workshop

The Program

Pre-requisites

INTRODUCTION

Basic electrical knowledge would be useful.

What is data acquisition and control

Fundamental principles of data
acquisition and control systems
Typical PC based applications

ANALOG AND DIGITAL SIGNALS

Practical Sessions
This is a practical, hands on workshop
enabling you to work through practical
exercises which reinforce the concepts
discussed.

RS-232 Hardware Interface

RS-485 Hardware Interface
Multipoint Systems
Serial Interface Converters
Communication Protocols
Error Detection
Trouble shooting Serial Data
CommunicationsDISTRIBUTED AND
STANDALONE CONTROLLERS / DATA
LOGGERS
Choice between External and Internal
Systems
Hardware Structure of Standalone
Devices
Software and Firmware Design
Practical applications of Data Loggers
How to minimise communication
Bottlenecks
Practical applications of Data Loggers
How to minimise communication
Bottlenecks

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To gain full value from this workshop,

please bring your laptop/notebook
computer.

Classifications of signals
Sensors and Transducers
Temperature Transducers (RTD /
Thermocouples / Silicon IC'S)
Strain Gauges
Single Ended and Differential Systems
Noise and Interference
Sources and Types of Noise
Field Wiring and Noise Considerations
Ground Loops
Common Mode Voltages and CMRR
Earthing and Isolation Techniques to
Reduce Noise
Cable Shielding and Earthing

RS-232 / RS-485 SERIAL DATA

COMMUNICATIONS STANDARDS

SIGNAL CONDITIONING

Classification of signal Conditioning

Hardware
Distributed I/O (Two wire Transmitters /
Digital Transmitters)
Signal Conditioning Functions
Instrumentation Amplifiers
Filters for Signals (Low Pass / Band Pass /
High Pass / Butterworth)
Isolation and Overvoltage Protection

LAB VIEW SOFTWARE PRACTICAL

PLUG IN DATA ACQUISITION BOARDS

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Advantages of plug in systems

Typical Analog to Digital (A /D) boards
Analog Input Circuitry (Multiplexers /
Amplifiers / Sample and Hold)
Analog to Digital Board specifications
Single Ended vs Differential Signals
Resolution / Dynamic range / Accuracy of
A/D boards
Sampling Rate and Nyquist Theorem
Preventing Aliasing
Sampling Techniques ( Channel Scanning
/ Simultaneous Sampling / Block Mode
Operations)
Speed versus Throughput
Typical Digital to Analog (D/A) boards
Digital I/O boards
Interfacing Digital I/O
Electromechanical vs Solid State Relays
Practical considerations in the use of
digital I/O boards
Counter Timer I/O boards

CITECT PRACTICAL

IEEE-488 SYSTEMS

IEEE-488.1 / IEEE-488.2 and SCPI

Specifications
Hardware Configuration
Device Types (Controllers / Listeners/
Talkers)
Basic Communications
Advanced Communications
Multiple Device Communications
Problem Diagnosis
System Specification

SUMMARY, OPEN FORUM

AND CLOSING

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

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www.idc-online .com

Practical

INDUSTRIAL FLOW MEASUREMENT

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Describe and compare important existing technologies in flow

measurement
Explain the critical fundamentals of flow measurement
Specify and design flow measurement systems

Troubleshoot and install flow instrumentation systems

Avoid common errors in the installation of flow meters

Describe and specify emerging technologies

WHO SHOULD ATTEND:

Those in the design, implementation and upgrading of industrial

control systems and:
Instrumentation and control engineers
Control technicians

Data systems planners and managers

Electrical engineers

Building service designers

Electricians

Automation engineers
Electrical and instrumentation technicians
Maintenance engineers
Energy management consultants
Process engineers
Power system protection and control engineers

6.13

The Workshop

The Program

Practical Industrial Flow Measurement is

suitable for the engineer, electrician,
technician, raftsperson, operator and others
who require practical, specialist knowledge
for selecting and implementing flow
measurement systems.
This workshop is ideal for cross-skill training.
The two-day course focuses on typical realworld applications. Close attention is given to
special installation considerations and
application limitations when selecting and
installing different flow instruments.

Practical Sessions

VARIABLE AREA METERS

Operating principle
Floats
Metering tube

Basic fluid properties

Non-Newtonian fluids
Velocity profiles
Reynolds number
Flow measurement
Mass flow rate
Multi-phase flows

ELECTROMAGNETIC FLOWMETERS

POSITIVE DISPLACEMENT METERS

Introduction
Sliding vane
Oval gear meters
Lobed impeller
Oscillating piston
Nutating disc

Measuring principle
Construction
Conductivity
Field characterisation
Measurement in partially
Empty pipe detection
Field excitation
The pulsed D.C. field
Bipolar pulse operation
Meter sizing

filled pipes

INFERENTIAL METERS

ULTRASONIC FLOWMETERS

Turbine meter

Woltman meter
Propeller type

Impeller meters
Installation recommendations

Doppler method
Transit time meter

Flow profile

Frequency difference
Clamp on instruments
Velocity of sound measurement
Factors influencing the velocity of sound
Beam scattering

Summary


Advantages
Disadvantages
Application limitations

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This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

BASIC PROPERTIES OF FLUIDS

To gain full value from this workshop,

please bring your laptop/notebook
computer.

OSCILLATORY FLOW METERS

Primary devices
Sensors
Application guidelines for vortex flow
metering
Avoiding problems

DIFFERENTIAL PRESSURE METERS

Basic theory
Orifice plate
Tapping points
Venturi tube meter
Venturi and flow nozzles
The Dall tube
Target meter
Pitot tube
Point averaging
Elbow
Troubleshooting

MASS FLOW MEASUREMENT

The Coriolis force

A practical system


Multiple phase flow
Density measurement

Loop arrangements

Straight through tube

Application in the food industry
Applications in the chemical industry
Summary of Coriolis mass measurement
Thermal mass meters

OPEN CHANNEL FLOW

MEASUREMENT

The Weir

The flume

Level measurement
Linearisation

summary, open forum

and closing

Good structure, touches on

all the relevant issues.

Roel Stausebach

On-Site Training

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your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

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HAZOPS, TRIPS and ALARMS

YOU WILL LEARN:

The hazard study life cycle and safety life cycle models
Principles and procedures of Hazop studies

Hazard analysis methods and application of fault tree analysis

Protection system principles based on alarms and trips

Introduction to functional safety standards IEC 61508 and

IEC 61511
The concept of safety integrity levels and methods for
determination of SIL targets

How to convert Hazop outputs into safety requirements

specifications
To use the latest software tools for Hazops

WHO SHOULD ATTEND:

Process plant engineers, technicians and supervisors involved

in new plant projects or in the modification or upgrading of
existing plants
Loss prevention officers, trainee Hazop team leaders

Plant managers, project managers and planners seeking an

awareness of the role of Hazops in overall safety management
Instrument and electrical engineers, process control engineers
and system integrators who are likely to be participants in
Hazops or who will be asked to engineer safety control systems
Commissioning engineers and plant supervisors, process
maintenance technicians

6.15

The Workshop

The Program

Do you have trips and safety interlocks in

your plant? Are they good enough or are
they perhaps over-designed and much
more expensive than necessary? Are you
or your company aware of how Hazard
Studies should define risk reduction
requirements? Are you actually using
hazard studies at all?
Are you aware that safety systems are
rated according to need using a scale of
SILs? What does this mean and what are
the cost implications? How do these
things relate to regulatory requirements?
How will this workshop help?
If you work with hazard studies it helps to
know how trips and alarms are supposed
to be built
If you work with trips and alarms it helps
to know how hazard studies are supposed
to be performed

Introduction to hazards and risks

Safety management principles; risk
assessment and risk reduction
Concepts of ALARP and Tolerable Risk
Regulatory frameworks and examples
from EU, USA, Australia, RSA
Methods of identifying hazards
Methods of assessing hazards

Planning and Leadership of

HAZOP Studies
Relationship to project phases
Preparatory work
Roles and responsibilities of the hazop
team
Duties of the study leader
Practical exercise: Hazop team trial study
and report

Hazard Studies at Level 1 and

Level 2

Safety Instrumented Systems

(SIS)

Life cycle model for hazard study levels

Hazard study1: Concept and definition
phase: methods
Hazard study 2: Design and development
phase. Tools and checklists
Practical exercise: Level 2 hazard study
example.

Principles of risk reduction by

instrumented protection systems
Introduction to standards IEC 61508 and
IEC 61511
The safety life cycle model and the role
of hazard studies
Specifying SIS requirements from the
hazard studies
Meaning of safety integrity and the SIL
ratings
Practical exercise: Determine the SIL
requirements of an SIS application

Risk Reduction Measures

The concept of "Equipment under
Control"
Failures of operators and control systems
as contributors to hazards
Layers of protection
Process and operational safety measures
The role of alarms in safety, principles of
alarm management
Safety instrumented protection systems,
principles of separation.
The role of hazops in defining alarms and
trips

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The link between the two is critical: It is not

unusual for the plant safety systems to be
out of touch with the original problem
analysis. This is one of main causes of
accidents on process plants.

Introduction to Hazard Studies

How can you deal with this problem?

The answer is the integrated approach to

safety management.

New international standards combined with

well-proven hazard study methods can
improve safety management in your
company.

Scope of the Workshop

The workshop describes the role of hazard

studies in risk management and then
proceeds with basic training in Hazop
techniques. The concepts of risk reduction
and some techniques of hazard analysis are
introduced at this stage. Training in alarm
and trip systems concentrates on features
that are relevant to project teams at the
Hazop study stages. These include the
practical implications and costs of calling for
trips and the often-confusing subject of
safety integrity levels (SILs) and how they
are determined.

Hazard Studies at Level 3: HAZOP

Method
Introduction to IEC 61822: Application
guide for hazops
Hazop study procedure for the design &
development phase
Purpose, context and outcomes of the
hazop
Principles of guide word examination
procedure
Design representation and selection of
elements for study
Study procedure and examples
Practical Exercise: Trial hazop study and
recording of results

A number of practical exercises support the

training information and allow participants
test their understanding of the material
provided in the training manual.

Hazard Analysis Methods

Principles of FEMA
Principles of Fault Tree Analysis (FTA)
Practical exercise: Fault tree analysis for
process control problem

Key factors in the choice of

protection systems

Technology choices and their implications

for cost
Programmable safety systems and
certification of equipment
Issues of reliability and redundancy
SIL ratings versus cost
Nuisance trips versus safety availability

Exercise in converting Hazop

output to alarm and trip
requirements
Examples of requirements specifications
Examine and use the latest software tools
available for:

- Hazard study worksheets and

lifecycle records
- Determination of SIL ratings
- Calculation of trip system reliabilities

Practical exercise: Hazop report and

specification outputs

Practical Sessions

There are six practical exercises which you

will undertake over the two days.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

HAZARDOUS areas

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for Engineers and Technicians

you will learn how to:

Demonstrate a good understanding of the terminology used

with hazardous areas
Design and install safe working systems in hazardous areas
Assist in hazardous area classification

Detail the types of apparatus that can be used in a given

hazardous area
Demonstrate a good understanding of the basic hazards
associated with electricity near flammable gases and vapours
Explain the types of equipment that can be used

Understand safety and operational aspects of hazardous areas

Understand system limitations in using hazardous areas
protection
Detail the key areas of the national codes of practice

Understand the basics of explosion protection to IEC standards

WHO SHOULD ATTEND:

Anyone involved in design, specification, installation,

commissioning, maintenance or documentation of industrial
instrumentation, control and electrical systems, including:

Tradespersons working in Potentially Explosive Atmospheres

(PEAs)
Electrical and instrument tradespersons
Instrumentation and control engineers
Electrical engineers
Instrumentation technicians
Design engineers

6.17

The Workshop

The Program

This workshop provides you with an

understanding of the hazards involved in
using electrical equipment in potentially
explosive atmospheres. It is based on the
international IEC79 series of standards that
are now replacing the older national
standards. Installation utilising ExplosionProtected (Ex) equipment can be expensive
to design, install and operate. The wider
approaches described in these standards
can significantly reduce costs whilst
maintaining plant safety.

BACKGROUND TO HAZARDOUS
AREAS

The associated terminology and its correct

use are explained throughout the workshop.
It covers area classification, selection of
explosion protected electrical apparatus as
well as describing how protection is achieved
and maintained in line with these international
requirements. Standards require that
engineering staff and their management are
trained effectively and safely in hazardous
areas and this workshop is designed to help
fulfil that need.

EARTHING AND BONDING

Basic principles
Earthing requirements
Static protection
Lightning protection
Noise and interference control
Requirements for IS systems
System earthing approach

CLASSIFICATION SYSTEMS

CODE OF PRACTICE FOR SELECTION

AND INSTALLATION
OF Ex EQUIPMENT

Explosion consequences
Nature of hazards
Definition of hazardous area
Flammability concepts
Ignition sources
Properties of gases, vapours, mists and
dusts
Introduction to types of protection
Source of release
Area classification into zones
Equipment (apparatus) grouping
Temperature classification and ambient
rating
Summary of principles of Ex protection
Equipment protection levels

INSPECTION AND MAINTENANCE

REQUIREMENTS

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TYPES OF PROTECTION

Application of code of practice

General requirements for all types of
protection
Documentation requirements and the
verification dossier
Cabling
Overview of requirements for individual
Ex protection types
Dust installations overview

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Definitions
Principles
Application of:
- Flameproof: Ex d
- Increased safety: Ex e
- Pressurisation: Ex p
- Intrinsic safety: Ex i
- Non-incendive: Ex n
- Oil filling: Ex o
- Powder filling: Ex q
- Encapsulation: Ex m
- Special: Ex s

Inspection and maintenance definitions

Types of inspection
Initial detailed pre-commissioning
Inspection regimes and documentation
Record keeping

FAULT FINDING AND REPAIRS OF Ex

EQUIPMENT

Planned maintenance
Use of tools
Procedures
Safe methods
Test equipment suitability

STANDARDS, CERTIFICATION,
CERTIFICATES, MARKING AND
APPROVALS

Authorities
Marking and identification
Component certification
Equipment certification
Systems certification
Systems descriptive documentation (for Ex
i)

ATEX DIRECTIVES

Introduction and explanation (European

requirements)
Non-electrical ignition-capable equipment
protection
ATEX marking
DSEAR (UK) requirement summary

On-Site Training

summary, open forum

and closing

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

INSTRUMENTATION

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FOR AUTOMATION AND PROCESS CONTROL

YOU WILL LEARN how to:

Specify and design instrumentation systems for pressure, level,

temperature and flow
Correctly select and size control valves for industrial use
Predict and avoid the problems with installing measurement
equipment
Troubleshoot instrumentation systems and control valves
Isolate and rectify instrumentation faults

Describe most of the major technologies used for

instrumentation and control valves

WHO SHOULD ATTEND:

Design engineers

Electrical engineers

Electrical technicians and technologists

Electricians

Experienced fixed plant operators

Graduate engineers

Instrumentation engineers
Project engineers

6.19

The Workshop

The Program

This workshop is for engineers and

technicians who need to have a practical
knowledge of selection, installation and
commissioning of industrial instrumentation
and control valves.
In many respects a clear understanding and
application of these principles is the most
important factor in an efficient process
control system. You can only achieve
excellent control of your processes when
your instrumentation provides the correct
information. This would involve the design,
specification and implementation of control
and measurement equipment.
The workshop focuses on real applications,
with attention to special installation
considerations and application limitations
when selecting or installing different
measurement or control equipment.

INTRODUCTION TO PROCESS
MEASUREMENT
Basic measurement concepts
Definition of terminology
Measuring instruments and control
valves as part of the overall control
system
Pressure, level, temperature and flow
overview
Overview of control valves

PRESSURE MEASUREMENT

Principle of pressure measurement

Pressure sources
Pressure transducers and elements
Specifications
Installation considerations
Impact on the overall control loop
Future technologies

LEVEL MEASUREMENT
Principles of level measurement
Simple sight glasses
Buoyancy tape systems
Hydrostatic pressure
Ultrasonic measurement
Radiation measurement
Electrical measurement
Density measurement
Installation considerations
Impact on the overall control loop
Future technologies

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:
PRESSURE

Principles
Thermocouples
Resistance Temperature Detectors (RTDs)
Thermistors
Liquid in glass, filled, bimetallic
Pyrometers
Installation considerations
Impact on the overall control loop
Future technologies

FLOW MEASUREMENT

Principles of flow measurement

Open channel flow measurement
Oscillatory flow measurement
Magnetic flow measurement
Positive displacement
Ultrasonic flow measurement
Mass flow measurement
Installation considerations
Impact on the overall control loop
Future technologies

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TEMPERATURE MEASUREMENT

Hydrostatic pressure

Pressure sensors in pipe with isolation

valve, check response and accuracy

CONTROL VALVES

Principles of control valves

Control valve types
- Globe valves, cage valves, butterfly
valves, ball valves
Control valves selection
Control valve bodies
Control valves characteristics/trim
Control valve noise and cavitation
Actuators and positioners operation
Valve calibration and stroking
Installation considerations
Impact on the overall control loop
Future technologies

PROCESS CONSIDERATIONS

Compare gauge, absolute and differential

pressures
Pressure calibration

Transmitters
Noise
Materials of construction

LEVEL

INTEGRATION OF THE SYSTEM

Point detection with level probes, vibrating

and conductive

TEMPERATURE

configure,

test

and

Temperature response and accuracy

RTD, 2/3/4 wire comparison

T/C, ref. junction, grounded, sheathed

T/C, extension leads compared with

compensation leads
SIMULATION

The basis of signal simulation

Transmitter simulation
Transducer simulation
CALIBRATION

The basis of transmitter calibration

accuracy

and

Updates you with the

latest technology.

SUMMARY, OPEN FORUM

AND CLOSING

K. Chetty

On-Site Training

Zero and span adjustment

Performance
calculations

Level measurement with capacitive probe

Ultrasonics,
commission

Calculation of individual instrument error

and total error for the system
Integration of the pressure, level,
temperature and flow systems
Integration of new smart subsystems
with data communication links
Testing and commissioning of the
subsystems

error

Save over 50% by having an IDCworkshop presented at

your premises.

VALVE SIZING (SOFTWARE)

Valve selection and sizing
Inherent characteristics
Process, material or other considerations
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

INTRINSIC SAFETY

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for Engineers and Technicians

Gain a solid understanding of Intrinsic Safety techniques

supported by hands-on practical exercises

YOU WILL LEARN how to:

Design and install safe working systems using

Intrinsic Safety (IS)
Explain the fundamentals of IS

Apply the national and international standards

Identify the vital issues of grounding and bonding IS systems

Fault find IS problems

Obtain hands-on practical experience with the IS systems

WHO SHOULD ATTEND:

Instrumentation and control technicians and engineers

Design engineers

Electrical technicians and engineers

Instrument technicians

Engineering managers and supervisors

6.21

The Workshop

The Program

This practical, intensive, two-day workshop

explains the application concepts of
explosion protection using Intrinsic Safety
(IS or Ex 'I'). This is with reference to British,
European and International Standards for
the certification and use of electrical
'apparatus'. Where electrical equipment is
used
in
'Potentially
Flammable
Atmospheres', the IEC79 Series of
International Standards are now emerging
and gaining acceptance in order to develop
a global approach to hazardous area plant
safety. The workshop covers IS as the
preferred technique for instrumentation
applied to industrial plant Inputs/Outputs in
hazardous areas. The principles of IS do not
change since these are based on the laws of
physics, however, the implementation of IS
is open to interpretation and causes some
conflict as the subject is still seen as a 'black
art'.

Explosion consequences
Definition of hazardous area

REVIEW OF PLANT AREA AND

APPARATUS CLASSIFICATION
SYSTEMS

Properties of gasses
Protection requirements
Zones and definitions
Apparatus grouping definitions

PRINCIPLES OF INTRINSIC SAFETY

Background and history

Energy limiting concept
Gas ignition curves
Hazardous area apparatus
Simple apparatus
Safe area associated apparatus and
interfaces
Barriers and isolators
Systems concepts

APPLICATIONS

Low level measurements

Temperature
Strain gauge bridge
Techniques for solving application
problems
Practical session

STANDARDS AND CERTIFICATION/

APPROVAL

Authorities
Marking
Apparatus and systems certification
Systems descriptive documentation

INSTALLATION

Relevance of codes of practice

Interpretation of IEC79-14
Safe area requirements
Safe area apparatus
Interconnecting cabling and junction
boxes
Hazardous area apparatus
Practical session

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The workshop aims to widen the

understanding of this technique by
explaining the basic rules within the context
of their application. Engineers and
technicians working in hazardous process
control and instrumentation areas must
have an understanding of the close
integration between the safety and
operational aspects of Intrinsic Safety (IS) as
a protection technique in order to specify,
design and maintain systems. The workshop
is designed to explain the theory of IS and
its close integration with operational signal
transfer.You will gain a greater understanding
of IS loop concepts as a basis for working
with measurement and control loops using
standard and custom IS solutions. Defining
and applying the correct terminology will
assist you in communicating and
documenting important safety details.

BACKGROUND TO HAZARDOUS
AREAS

Pre-requisites: Fundamental grounding in

basic electrical concepts.

Practical Sessions

APPLICATIONS

Introduction to applications
Status inputs
Practical session

OTHER METHODS OF PROTECTION

Separation: Ex p, o, q, m
Construction: Ex n, e
Containment: Ex d
Special: Ex s
Design: Ex i (ia and ib)

APPLICATIONS

Analogue inputs
High level
Systems
Practical session

EARTHING AND BONDING

INSPECTION AND MAINTENANCE

Interpretation of IEC79-17
Grades of inspection
Requirements for IS
Use of tools
Procedures
Test equipment suitability

FAULTFINDING AND COMMISSIONING

Safe methods
Earthing requirements
Common problems
Loop testing
Repairs

SUMMARY, OPEN FORUM

AND CLOSING

Basic principles
Requirement for IS systems
Noise and interference control
System earthing approach

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Excellent Instructor
A. van den Berg

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical Tuning of

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INDUSTRIAL CONTROL LOOPS

WHAT YOU WILL LEARN:

Fundamentals of tuning loops - both open and closed loop

How to recognise the key characteristics of process plant from a

control perspective
Significance of dead time and transfer lags
PID controller behaviours

How to troubleshoot and identify problems

Differences between ideal/real/interacting/non-interacting controllers

Combination of control modes to use

How to tune more control loops in less time with effective results
Practical rules of thumb for tuning systems
Ziegler Nichols and Lambda Tuning

How to recognise configuration deficiencies

Optimum amount of filtering or dampening to apply to the

measurement
How control valves impact on control loop performance

How to solve problems such as valve hysteresis, stiction and non

linearities
How to tune complex loops ranging from cascade to feedforward
When to use derivative control for the best tuned loop

WHO SHOULD ATTEND:

Automation engineers
Consultants
Control and instrumentation
engineers
Electrical engineers
Electricians
Electronic engineers

Energy management
consultants
Facility managers
Mechanical engineers
Installation and maintenance
technicians
Technicians
6.23

The Workshop

The Program

This workshop is designed to train you and/

or your staff, in the configuration and tuning
of industrial control loops using a minimum
of mathematics and formulas. Controllers
need to be carefully matched to the process
to work optimally; this matching procedure
is called tuning. Controllers that are not
correctly configured and tuned will not
perform optimally and will not reduce
variability in the process as they should.

TUNING OF VALVES

Processes, controllers and tuning

PID controllers - P, I and D modes of
operation
Load disturbances and offset
Speed, stability and robustness
Gain, dead time and time constants
Process noise
Feedback controllers
How to select feedback controller modes
Practical Session

Hysteresis
Stiction
Characteristic selection and correction
Positioner configuration and tuning
Practical Session

FUNDAMENTALS OF TUNING
Open loop characterisation of process
dynamics
Default and typical settings
General purpose closed loop tuning
method
Quick and easy open loop method
Fine tuning for different process types
Simplified lambda tuning
Practical Session

TUNING OF MORE COMPLEX

SYSTEMS
Cascade systems - tuning of them
Feedforward, ratio, multivariable systems
Interactive loops tuning
Dead time compensation
Practical limitations
Practical Session

GOOD PRACTICE
Good practice for common loop
problems
Flow control loop characteristics
Level control loop characteristics
Temperature control loop characteristics
Pressure control loop characteristics
Other less common loops
Practical Session

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The aim of this workshop is to provide and/

or enhance the skills required to configure
and tune a controller for optimum operation.
An optimally tuned processed loop is critical
for a wide variety of industries ranging from
food processing, chemical manufacturing,
oil refineries, pulp and paper mills, mines
and steel mills. Although tuning rules are
designed to give reasonably tight control,
this may not always be the objective. Some
thought needs to be given when retuning a
loop as to whether the additional effort is
justified as there may be other issues which
are the cause of the poor control. These
issues will be discussed in some detail in the
workshop. At the end of this workshop you
will have the skills to troubleshoot and tune
a wide variety of process loops.

FUNDAMENTALS OF LOOP TUNING

Pre-requisites

THE DIFFERENT TUNING RULES

Different rules compared

Typical tuning settings
When to use them/when not to use them
Rules of thumb in tuning
Practical Session

SUMMARY, OPEN FORUM

AND CLOSING

Basic knowledge of instrumentation and

process plant would be useful.
Please bring a calculator (or computer) and
pen along to the course to assist with the
calculations.

Simulation Exercises

Throughout the workshop, simulation

software is used to simulate real loops and
to give you real hands-on exercises in a safe
practice environment. You will see the
simulated process output respond to your
input and configuration changes on the loop
controller. You will reinforce and apply the
concepts learnt using real field test data in
simulation.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Instructor extremely well

presented, professional and
well versed on the subject.
Excellent.

Glen Saunders

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

MOTION CONTROL

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Design and troubleshoot a complete motion control system

Apply new knowledge of servos to motion control applications
Troubleshoot servo systems

Size and select the appropriate drives/amplifiers/servos/

steppers for your application
Apply the concepts of load, inertia, force and real time to
motion control problems
Understand concepts such as backlash, static/running friction,
resolution, stiffness, speed and torque
Design and troubleshoot six basic motor types for motion
control

WHO SHOULD ATTEND:

Control and instrumentation engineers and technicians

Instrumentation and control engineers/technicians
Electrical engineers

Process control engineers

Electronic engineers
System integrators
Designers
Design engineers
Systems engineers
Test engineers

6.25

The Workshop

The Program

This workshop is designed for personnel

who need to apply motion control technology
as productively and economically as
possible.
This practical course initially examines the
basic building blocks and design tools to
implement motion control systems.
Fundamental concepts of load, inertia, force
and real time will be discussed.
The various factors such as performance
limitations and costs that impact the
selection of electro hydraulic, pneumatic,
electromechanical
technologies
are
discussed.
Servo basics are then examined in
considerable detail giving you the practical
tools in which to work with these systems.

Definition of motion control

Fundamental concepts
Engineering practices and techniques

MOTION CONTROL TECHNOLOGIES

Hydraulics
Pneumatics
Electromechanical
Mechanical

MOTION CONTROL SYSTEM LOOPS

Open and closed systems

Block diagrams
Implementation of a control system
Event controlled systems
PID controls

SELECTION OF THE FEEDBACK

Analog vs digital and incremental vs
absolute feedback
Resolution and bandwidth considerations

SERVO RESPONSES

Sinusoidal inputs
Step inputs
Performance prediction
Importance of gain setting
Feedforward
Type 2 systems
PID in a servo
Stability criteria in a servo
Load effects on stability
S curves and their application

INTRODUCTION TO BASICS OF DRIVES

DC/AC - analog/digital
Drive classifications
Drive motor characteristics
Drive motor equations
Amplifiers and types
Compensating techniques
Drive speed and acceleration
Drive thrust and torque
Drive inertia considerations
Drive ratios

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The electrical and mechanical characteristics

important in tying together the drive and
motor to the mechanical device are then
reviewed from a practical perspective.

FUNDAMENTALS OF MOTION
CONTROL

The basic motors used in motion control

such as DC and AC motors, stepper and
servo motors and their applications, are also
examined. These motors range from small
instrumentation motors to robust AC
induction motors and to the stepper motors
used in open loop control.

Pre-requisites

A basic working knowledge of electrical

engineering concepts is useful but not
essential as there will be brief revision at the
commencement of the class. Please don't
forget to bring a scientific calculator!

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

PHYSICS OF MECHANICAL LOADS

Brief overview of concepts

MECHANICAL TRANSFORMATION
DEVICES

Reflecting loads through the transformer

Other transforming devices
Gears
Conveyers - elevators
Inertia at the shaft
Belts and pulleys

NON LINEAR LOAD TRANSFORMATION

Equivalent mass
Mass polar moment of inertia
Parallel axis theorem
Spring-inertia resonance method of
determining inertia empirically
In position holding force load resonance

LOAD/SYSTEM ANALYSIS

Motor/load considerations
Stability/bandwidth considerations
Inertia calculations
Estimating design alternatives
PWM vs analog vs linear

SERVO BASICS

Basic gain equations

Selecting system components of a servo
system
Criteria for motor
Criteria for amplifier
Criteria for encoder
Criteria for coupling
Criteria for controller
Command generation
Feedback
Type 0,1, 2 servos
Bode diagrams made easy
Predicting servo response
Characteristics of a motor for servos

ADVANCED CONSIDERATIONS OF
DRIVES

Performance, stiffness, resolution, friction

Duty cycle
Drive sizing

OPERATION OF ELECTRIC MOTORS

Types of motors
DC motors (permanent/armature/field/
commutation/brush vs brushless)
AC motors (induction/synchronous/
universal)
Stepper motors (indexers/sequencers/
microstepping)
Miscellaneous types
Characterising motors (torque-speed/data
sheets)

MOTORS

Brush AC motors
AC induction motors
Brushless DC motors
Stepper motors
Linear motors: commutation, performance,
figures of merit, data sheets, motor
drivers, applications

MULTI AXIS CONTROL

Splines, circles and linear motion

co-ordination
Multi axis data handling - software

LATEST DESIGN APPLICATIONS AND

TECHNIQUES
Solving your real time systems motion
control problem
Position control
Linear motion and circular motion
Master/slave control
Electronic gearing
Dual loops to eliminate backlash
Tension control systems

SUMMARY, OPEN FORUM

AND CLOSING

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

Practical

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FUNDAMENTALS OF OPC

YOU WILL LEARN HOW TO:

Describe what OPC is and how to apply it to your applications

Understand why OPC is such a robust solution
Understand OPC Data Access 3.0
Describe the key components of OPC
Understand DCOM
Describe the key features of OPC
Configure a simple application to display data from the plant
floor
Build a simple SCADA system and supporting components
using OPC
Enhance your existing legacy control system networks to use
OPC
Learn why you need to demand OPC in your products
Migrate your process data seamlessly into your MS Office
applications

WHO SHOULD ATTEND:

If you are using any form of automation or communication

system or are applying PCs/PLCs/SCADA systems, this workshop
will give you essential tools in working with OPC. This is not an
advanced workshop but a hands-on practical experience. Among
those that will benefit by attending are:
Process Control and Instrumentation Engineers
Process Control and Instrumentation Technicians
Design Engineers
Network Engineers
Electrical Engineers
Engineering Managers
Network System Administrators
6.27

The Workshop

The Program

OPC has come a long way in making the

engineers dream of plug and play
compatibility in automation engineering
achievable. OPC is an industry-wide standard
that breaks this proprietary lock by allowing
open connectivity based on the principles
adapted from widely accepted and applied
Microsoft Windows integration standards.
OPC capabilities have been demonstrated in
many practical applications and it is now a
well-established approach for different
competing manufacturers. It is now easily
considered to be the standard interface in the
windows environment. If you are serious
about reducing your costs of installing and
maintaining your automation systems you
need to use OPC.

OTHER OPC SPECIFICATIONS

Classes and objects

Clients, servers and client/server
interaction
OLE
DDE and NetDDE
ActiveX
.NET

OPC OVERVIEW

COMMUNICATIONS ISSUES

What is OPC?
Problems addressed by OPC
The OPC logical object model
OPC data (sources, formats, etc)
OPC client/server relationships
Current OPC specifications

COM AND DCOM

What is COM?
COM basics
- Classes
- Interfaces
- Components (proxy/stub files,
wrappers)
- Globally Unique IDs (GUIDs)
- OPC registry entries (ProgID, ClassID,
AppID, CatID)
- OPC client/server interaction
(in-process, local, remote)
Setting up DCOM (programmatically or
declaratively)

OPC
OPC
OPC
OPC
OPC
OPC
OPC

common information
alarms and events
batch
data exchange (DX)
historical data access
security
XML-DA

Networking protocols
LANs, WANs
OSI Model
Network infrastructure (Ethernet)
Transports (TCP/IP)

TROUBLESHOOTING

DCOM protocol stack

Physical and data link layer problems
Network and transport layer problems
COM/DCOM-related problems
Client/server-related problems
Simulation and conformance testing
Error codes

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If you have only briefly heard about OPC and

want to get to grips with its tremendous
power and apply this to your plant and
application, then this workshop will give you
the necessary tools.You will receive a valuable
overview of OPC and understand why it is the
standard of choice for data access in
automation systems. You will be exposed to
and understand the essential components of
OPC based on typical applications. You will
understand how OPC servers are installed
and how they are then accessed by OPC
clients (which could be SCADA systems). The
exercises that you will work through in the
class will allow you to apply the theory you
gain in the class in a practical manner.

CONCEPTS AND DEFINITIONS

The OPC specification will be discussed in

great detail and you will be exposed to the
development of OPC servers and clients. The
interaction between OPC and DCOM will be
discussed in practical detail.

The latest trends and future developments

with OPC in the USA and Europe will be
detailed.

OPC DA SPECIFICATION (3.0)

Functional description
Logical object model (OPCServer,
OPCGroup, OPCItem)
Typical server and client structures
Read/write methods (synchronous,
asynchronous, refresh, subscription)
Data source (cache, device)
OPCServer interfaces and methods
OPCGroup interfaces and methods
Group and item properties
Server configuration procedure

PRACTICAL EXERCISES

Setting up network (IP addresses, subnet

masks, default gateways)
Connecting simple clients to a SCADA
system
Setting up an OPC server
Data export to Excel
Generating and importing tag lists in
CSV format
Graphical (drag and drop) clients
AE client/server interaction
Validating servers
Setting up DCOM to enable OPC clients
and servers to interact across a network
Tunnelling (across local network and the
Internet)

summary, open forum

and closing

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

To gain full value from this workshop, please

bring your laptop/notebook computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

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PROCESS CONTROL

YOU WILL LEARN How to:

Understand the fundamentals of process control and new

techniques
Tune PID control loops

Correct stability problems

Understand cascade loops and feed-forward control

Identify and correct problems with dead time in the process

WHO SHOULD ATTEND:

Instrumentation and control engineers

Building service designers
Automation engineers

Control technicians

Electrical technicians

Instrumentation technicians
Process operators

Electrical engineers

Electricians

Maintenance engineers
Process engineers
Consulting engineers
DCS personnel
Energy management consultants
Those involved in the design, implementation and upgrading of
industrial control systems.

6.29

The Workshop

The Program

This practical two-day workshop covers all

the essentials of process control and tools to
optimise the operation of your plant and
process, including the ability to perform
effective loop tuning.
Practical process control is aimed at
engineers and technicians who wish to have
a clear, practical understanding of the
essentials of process control and loop
tuning, as well as how to optimise the
operation of their particular plant or process.
These persons would typically be primarily
involved in the design, implementation and
upgrading of industrial control systems.
Mathematical theory has been kept to a
minimum with the emphasis throughout on
practical applications and useful information.

Pre-requisites

TUNING OF CLOSED LOOP CONTROL

Typical manual control

Feedback and feed-forward control
Block diagrams

Tuning constants calculation according to

Ziegler and Nichols
Open loop tuning procedure
Closed loop tuning procedure
Damped oscillation tuning method
Fine tuning of practical control loops
Tuning considerations for controllers
with saturation and non-saturation
output limits
Practical Session

INTRODUCTION TO SENSORS AND

TRANSMITTERS

Selection and specification of devices

Pressure transmitters
Flow meters
Level transmitters
Temperature sensors

INTRODUCTION TO CONTROL VALVES

Basic principles
Rotary control valves
Ball valves
Control valve characteristics and
specifications

BASIC PRINCIPLES OF CONTROL

SYSTEMS

CASCADE CONTROL
Equation types for cascade control
Initialisation and PV tracking
Use of multiple outputs in cascade
control
Tuning procedure for cascade control
Practical Session

FEED-FORWARD CONTROL
Feed-forward balance a control concept
Tuning procedure for feed-forward
control
Practical Session

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Knowledge of basic electrical concepts

would be useful.

BASIC CONTROL CONCEPTS

On/off control
Modulation control
Principle of closed loop control
PID control modes
Practical Session

Practical Sessions

STABILITY AND CONTROL MODES OF

CLOSED LOOPS

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Cause of instability in control loops

Change of stability through PID control
modes
Methods to improve stability
Principles of closed loop control tuning
Practical Session

DIGITAL CONTROL PRINCIPLES

Principle of incremental control

algorithms
Identifying control blocks in the time and
frequency domain
Multiple outputs through digital
algorithms
Practical Session

IDEAL PID VS REAL PID

Non-field-interactive or ideal PID

Field-interactive or real PID
Distinguish between process noise and
instability
Selection of ideal or real PID
Practical Session

On-Site Training

COMBINED FEEDBACK AND FEEDFORWARD CONTROL

Concept of combined control with
incremental algorithms
Tuning procedure for combined control
Practical Session

LONG DEAD-TIME IN CLOSED LOOP

CONTROL
The problem of long dead-time in closed
loops
Use of process simulation for process
variable prediction
Tuning procedure for control loops with
long dead-time
Practical Session

ALARM HANDLING AND PROCESS

SECURITY

RANGE OF CONTROL AND

INSTRUMENTATION IN INDUSTRIAL
PROCESS CONTROL
INTRODUCTION TO STATISTICAL
PROCESS CONTROL

Introduction in the use of statistics in

process control
Standard deviation: static value alarm
Practical Session

PRACTICAL APPLICATIONS

Tools of statistical process control

PLC systems
Stand alone loop controllers
Practical Session

Save over 50% by

having an IDCworkshop
presented at your
premises.

EXPERT SYSTEM AND MODEL BASED

SELF TUNING CONTROLLERS

Customise the training to

Basis auto tuning

Expert system control
Model based adaptive control

Have the training

SUMMARY, OPEN FORUM

AND CLOSING

your workplace.

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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PROCESS CONTROL AND TUNING OF

INDUSTRIAL CONTROL LOOPS

What YOU WILL LEARN:

Understand the fundamentals of process control

Fundamentals of tuning loops - both open and closed
Get the best PID settings
Troubleshoot to achieve optimally tuned control loops
Apply step-by-step descriptions of the best field-proven tuning
procedures
Typical procedures for troubleshooting tuning problems
Tune more control loops in less time with consistently excellent
results
Apply the practical rules of thumb for tuning systems
Determine the minimum settling time for a control loop
Know the optimum amount of filtering or dampening to apply
to the measurement
Know why and how to size valves for best control loop
performance
Handle problems such as valve hysteresis, stiction and non
linearities
Tune complex loops ranging from cascade to feedforward
When to use derivative control for the best tuned loop
Understand cascade loops and feedforward control
Identify and correct problems with dead time in the process

WHO SHOULD ATTEND:

Instrumentation and Control

Engineers
Process Control Engineers
Mechanical Engineers and
Technicians
System Integrators
Consultants
Operators Monitoring and
Controlling Processes

Installation and Maintenance

Technicians
Energy Management
Consultants
Electrical Engineers
Electricians
Automation Engineers

6.31

The Workshop

The Program

This workshop is designed to give you a

solid understanding of the essentials of
process control and skill you and/or your
staff, in the latest procedures for the tuning
of industrial control loops using a minimum
of mathematics and formulas. A clear review
of the principles and essentials of process
control is given thus allowing you to gain
the skills to tune a wide variety of controllers.
Tuning controllers is an exact science that
requires precise configuring of the process
controller using the correct procedures.

AUTOMATED TUNING

Typical manual control

Feedback and feedforward control
Block diagrams

Self tuning loops

Adaptive control
Practical Session

INTRODUCTION TO
INSTRUMENTATION

TUNING OF MORE COMPLEX

SYSTEMS

Cascade systems - tuning of them

Feedforward, ratio and multivariable
systems
Interactive loop tuning
Dead time compensation
Practical limitations
Practical Session

Selection and specification of devices

Pressure measurement
Flow measurement
Level measurement
Temperature measurement

INTRODUCTION TO CONTROL VALVES

Basic principles
Rotary control valves
Ball valves
Characteristics and specifications

FUNDAMENTALS OF PROCESS
CONTROL
Processes, controllers and tuning
PID controllers - P, I and D modes of
operation
Load disturbances and offset
Speed, stability and robustness
Gain, dead time and time constants
Process noise
Feedback controllers
How to select feedback controller modes
Practical Session

GOOD PRACTICE
Good practice for common loop
problems
Flow control loop characteristics
Level control loop characteristics
Temperature control loop characteristics
Pressure control loop characteristics
Other less common loops
Practical Session

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The aim of this workshop is to provide and/

or enhance the skills required to tune a
controller for optimum operation. An
optimally tuned processed loop is critical for
a wide variety of industries ranging from
food processing, chemical manufacturing,
oil refineries, pulp and paper mills, mines
and steel mills. Although tuning rules are
designed to give reasonably tight control,
this may not always be the objective. Some
thought needs to be given when retuning a
loop as to whether the additional effort is
justified as there may be other issues which
are the cause of the poor control. By the end
of this workshop you will have the skills to
troubleshoot and tune a wide variety of
process loops.

BASIC CONTROL CONCEPTS

Pre-requisites

This is not an advanced course, but one

aimed at the fundamentals. Basic electrical
concepts and some knowledge of
instrumentation would be useful.

Simulation Exercises

Throughout the workshop, simulation

software is used to simulate real loops and
to give you a minimum of twelve real handson exercises in a safe practice environment.

You will see the simulated process output

respond to your input and configuration
changes on the loop controller. You will
reinforce and apply the concepts learnt
using real field test data in simulation.

FUNDAMENTALS OF TUNING

Open loop characterisation of process

dynamics
Default and typical settings
General purpose closed loop tuning
method
Quick and easy open loop method
Fine tuning for different process types
Simplified lambda tuning
Practical Session

THE DIFFERENT TUNING RULES

Ten different rules compared

Tables of typical tuning settings
When to use them/when not to use them
Rules of thumb in tuning
Practical Session

TUNING OF VALVES

On-Site Training

Hysteresis
Stiction
Practical Session

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

SCADA and TELEMETRY SYSTEMS

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for Industry

FOCUSSING ON:

Fundamentals of SCADA Systems

Communication Protocols & Standards

Essentials of OPC applied to SCADA

Wireless and Radio Standards for Telemetry

SCADA System Security

WHAT YOU WILL GAIN:

A fundamental understanding of SCADA systems

A knowledge of the key industrial communication protocols

How to set up industrial data communications networks
The different industrial communications networks used

How to troubleshoot typical SCADA and telemetry systems

The essentials of OPC as applied to SCADA systems

How to design and install radio & wireless links for SCADA
systems
How to effectively apply SCADA system security

WHO SHOULD ATTEND:

Instrumentation and
Control Engineers

Maintenance Supervisors

Process Control Engineers

Control System Application

Engineers

Electrical Engineers

Project Engineers

Consulting Engineers

Technicians

Design Engineers

Plant Engineers

Control Systems Sales

Engineers

IT Personnel
6.33

The Workshop

The Program

SCADA has traditionally meant a window

into the process of a plant or gathering of
data from devices in the field, but now the
focus is on integrating this process data into
the actual business and using it in real time.
The emphasis today, is on using Open
Standards such as communication protocols
(eg IEC 60870, DNP3 and TCP/IP) and off-theshelf hardware and software to keep the
costs down. This comprehensive two day
workshop covers the essentials of SCADA
systems and telemetry and radio/wireless
communications.
A selection of case studies is used to
illustrate the key concepts with examples of
real world working SCADA systems in the
water, electrical and processing industries.
This workshop will be an excellent
opportunity to network with your peers as
well as gain significant new information and
techniques for your next SCADA project.

Radio and Wireless Basics

Terminology and overview

SCADA system hardware
Communication architecture

SCADA Software

Industry standard protocols

Displays and MMI's
Configuration of SCADA systems
Best practice configuration of alarms
Rules for SCADA design

SCADA Communication
Protocols and standards

RS-232/RS-485
Industrial Ethernet
Industrial protocols such as Modbus
TCP/IP
IEC 60870 and DNP3 SCADA protocols
Substation automation protocols

OPC and SCADA Systems

Fundamentals of propagation
Selection of frequency bands
Equipment - transmitters
Cabling - coaxial/audio/signal
Implementation and design
Spread spectrum
Duplication and diversity
Path loss calculations and multipathing

Review of Wireless LAN Systems:

IEEE 802.11

Specifications
System components
Antennas
Topologies
Modes: infrastructure, ad hoc
IP roaming
Security issues

Satellite Systems

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Although the emphasis of the workshop will

be on practical industry topics highlighting
recent developments using case studies and
the latest application of SCADA technologies
the fundamentals of SCADA systems will be
covered. The workshop is aimed at those
who want to be updated on the latest
developments in SCADA systems and want
to get a solid appreciation of the
fundamentals of SCADA and Telemetry
design, installation and troubleshooting.

Fundamentals of SCADA

Essentials of OPC
Implementation of an OPC server and
client
Practical demonstration

Security and Risk Management

Introduction and terminology
Firewalls
Authentication, authorisations and
anonymity
Remote access to SCADA systems
Security precautions

Line of Site Microwave

Point to point and multipoint

Equipment/dishes and antennas

Performance Analysis

Availability and reliability/BER testing

Complete systems testing

SCADA and Telemetry

Infrastructure

Practical sessions include:

constructing a simple SCADA system

Excellent.

operating the SCADA system

Andre van Zyl

radio telemetry path loss design exercise

performing an intermodulation products
calculation
Bit Error Rate analysis

Base stations and repeaters

Location and mast selection
Cabling/power distribution
IP and temperature rating of equipment
Lightning and surge protection

Future trends

Practical Sessions

Basic technology
Analog and digital types
Operation/downlinks and uplinks
Practical implementation

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

SHUTDOWN and TURNAROUND

MANAGEMENT

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for Engineers and Managers

WHAT YOU WILL GAIN:

Describe typical turnaround management techniques

Co-ordinate a simple turnaround project from planning to

execution and handover
Co-ordinate the personnel in a shutdown and turnaround
project
Apply shutdown best practices and planning

Build an effective maintenance project plan for shutdowns

Use critical paths to identify risks and manage these risks
effectively
Plan to meet deadlines and complete turnaround projects
within budget and on time
Manage resources effectively on a turnaround project

Develop the personal skills critical to effective turnaround

project management
Organise and improve performance to create a productive and
competent team

WHO SHOULD ATTEND:

Project Engineers

Engineering Professionals
Shutdown Managers and Co-ordinators
Maintenance Planning Managers
Cost Control Staff
Construction Superintendents
Technical Personnel
Maintenance/Supervisory Managers
Project Team Members in: manufacturing, process industries,
research & development, utilities, local authorities
6.35

The Workshop

The Program

The engineering world is littered with

examples of poor shutdowns with massive
overruns in costs and problems in resource
planning. Performing an effective shutdown
is an example of applying many of the
principles of good Project Management with
some important exceptions which are
outlined in the workshop. This workshop
gives you an excellent review of shutdown
management from the perspective of
someone who has done it from the trenches.
There are many case studies of successful
shutdown projects to ensure that you get
the latest and most up to date information to
successfully apply to your next project no
matter what position you hold.

Pre-requisites

Overview & Introduction

Structure of Shutdown Plan
Critical Ingredients of Good Shutdown
Management
Typical Problems
Co-ordination Issues
Success Stories
Not So Successful Stories

Planning and Scheduling

Management Plan & Procedures

Scheduling Maintenance Activities
Monitoring & Control Techniques
Backlog Management Techniques
Planning for the Shutdown

- People
- Materials
- Work Permits & Isolation
The Actual Shutdown

Time Management of Shutdowns

Critical Path Method of Schedule Analysis

Precedence Method of Schedule Analysis
Presentation of the Schedules
Resource Analysis
Monitoring & Reporting Achieved Progress
Selection of Software
Case Study - Application of the Precedence
Method Analysis Technique

Cost Management of Shutdowns

Cost Estimation
Budget Preparation
Financial Control
Change Control
Cost Reporting
Value Management
Case Study - Preparation of a Project Cost
Report

Risk Management of Shutdowns

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A basic knowledge of maintenance

management on a Plant would be useful but
is not essential.

Fundamentals of Shutdowns
and Turnarounds

Implementation
Test & Acceptance
Variations to Contract
Progress Reviews & Deadlines
Tracking of Work
Controlling Time and Costs

Post Shutdown

This course offers a layout of

updated systems and modern
trends to keep ahead.

Chris Standish

Reporting Systems
Review of Reports
Audit of Work Done
Punchlists

Maintenance Concepts

Measurement & Improvement of

Maintenance Performance
Maintenance Audits

Human Resources

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.

Management of Contractors & Incentives

Management of Claims
Variations to Claims
Liaison Between Teams
Organisational Charts
Motivation & Team Building
Training of Contractors
Quality Control of Human Resources

Materials & Equipment

Planning

Definition of Equipment & Materials

Interfaces Between Different Equipment
Packages
Long Lead Times
Off Site Construction & Suppliers
Variations to Scope

Principles of Engineering
Project Management for
Shutdowns

Overview of the Project Environment

Project Life Cycle & Phases
Project Organisations
Project Definitions
Case Study: An Exercise in Developing a
Work Breakdown Structure

Risk Management Defined

Risk Identification
Risk Analysis
Risk Management Responses

Quality in Shutdown
Management

Definition of Quality & Management

Quality Program
Project Quality Assurance
Quality Procedures
ISO 9000

Introduction to Contract Law

on Shutdowns
Legal System
Essential Elements of Contracts
Factors Destroying the Legal Force of
Contracts
Termination of Contracts
Breach of Contracts
Liquidated Damages
Techniques to Ensure Completion of
Shutdown Contracts Without "Going
Legal"

Project Planning Session

Work in teams to develop and document

an outline Project Plan for a defined
Shutdown Project

Case Studies

Manufacturing Plant
Offshore Platform
Oil Refinery
Power Plant

Conclusion

After the Shutdown - Continuous

Improvement
Elimination of Problems and Bottlenecks
Planning the Next Shutdown - Retaining
Data

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

INDUSTRIAL PROGRAMMING

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using 61131-3 for

Programmable Logic Controllers (PLCs)

WHAT YOU WILL LEARN:

To confidently work with the generic standard IEC 61131-3 for

industrial programming
To effectively utilize IsaGraf programming software to program
PLCs
To understand the concepts and common elements concerning
the IEC 61131-3 programming model
To program using languages such as: structured text, function
blocks, ladder diagrams, instruction lists and sequential
function charts
To troubleshoot sequencing problems

To boost productivity and enhance software quality

WHO SHOULD ATTEND:

For anyone who needs to program Programmable Logic Controllers

(PLCs) using the standard developed by the International Electrotechnical Commission (IEC) which is now being used worldwide by
most major PLC manufacturers.

6.37

The Workshop

The Program

PLCs have become part of the backbone of

industrial automation. The International
Electro-technical Commission (IEC) has
developed a standard set of programming
languages for industrial PLCs. The success
of these languages can be measured by the
large number of major PLC manufacturers
who are developing products that are 611313 compliant. IEC 61131-3 is becoming the
standard of choice in many industries, and
will boost productivity and enhance software
quality. If you master the subject today,
your programming knowledge will be
applicable across brands well into the future.
This knowledge is vital for personal career
development.

What is IEC 61131-3?

Why the need for IEC 61131-3?
Deficiencies of current ladder logic
IEC 61131-3 main features
IEC 61131-3 major benefits
Other components of IEC 61131-3

IEC 61131-3 Concepts

I/O interfaces
Communication interfaces
System interfaces
IEC 61131-3 PLC software model main
elements:

- Configuration
- Resource
- Programs
- Tasks
Mapping software model to real systems

Common Elements

Programming Language:
Ladder Diagrams
Concepts
Symbols
Methodology
Connecting FBs
Execution control: jumps and labels
Network evaluation rules
Practical Session: Programming using
ladder diagrams

Programming language:
Instruction list
Language structure
Instruction semantics: modifiers
Comparison and jump operators
Calling FBs
Practical Session: Programming using
instruction list

Programming language:
sequential function chart

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The aim of this intensive two-day course is

to go beyond the basic concepts and
introduce you to the practical techniques
and applications of 61131-3. We cut across
apparent differences wherever PLCs are
used and introduce standards that are
widely applicable.

Introduction

If you ever need to program PLCs or just

understand more about their capabilities,
then this course is for you. The course is
pitched at an intermediate level suitable for
anyone with some experience with PLCs. If
you are a trainee engineer, graduate, control
systems engineer, technician, or senior
operator you will gain essential knowledge
that will significantly enhance existing
knowledge of PLCs.

Workshop Objectives

Character set
Identifiers
Data types elementary: integer, floating
point, date and time, strings, boolean
and generic
Data types derived: structured,
enumerated and array
Variables: input, output, input/output,
global, external, directly represented and
access
Functions: numerical, bit string, boolean,
comparison and bit string
Program: usage and instances
Resources and tasks: usage, scheduling non pre-emptive and pre-emptive
Configuration

Effectively utilize typical industrial

programming software to program PLCs
Explain important concepts and common
elements concerning the IEC 61131-3
programming model

Programming language:
Function Block (FB) diagrams

Confidently work with this emerging

generic
standard
for
industrial
programming

Program in the following languages:

-

Structured text

Function blocks

Ladder diagrams

Instruction lists

Sequential function charts

Tying it all together Project

Complete programming project

Conclusion

Workshop review and discussion

Programming language:
Structured text

Language
Assignment statements
Expressions
Operators
Statements: calling FBs, conditional and
iteration
Practical Session: Programming using
structured text

At the completion of this course participants

will be able to:

Chart structure
Main features
Steps
Transitions
Actions
Rules of evaluation
Practical Session: Programming using
Sequential function chart

Methodology
Signal flow
Feedback paths
Execution control: jumps and labels
Network evaluation rules
Practical Session: Programming using
Function Block Diagrams

Troubleshoot sequencing problems by

differentiating application issues from
sequencing issues

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

Practical Sessions

delivered when and

where you need it.

PLCs have become an integral part of

industrial automation and it is for this reason
that there are 5 practical exercise sessions in
this workshop. This is to give you the vital
hands-on experience you need to confidently
work with 61131-3 and OPC in your
workplace.

idc@idc-online .com

Contact us for a
free proposal.

www.idc-online .com

Practical

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CONTROL VALVE SIZING,

SELECTION AND MAINTENANCE

YOU WILL LEARN:

What happens inside a control valve

The difference between cavitation and flashing
Choked flow
Simple calculations to determine CV values
How to recognise severe service applications
The types of control valves and relative advantages
The different characteristics and specifying seat leakage rates
Size actuators for linear and rotary applications
The advantages of pneumatic, hydraulic and electric types
How to select materials for bodies, trims, packing boxes, and
gaskets
Computer sizing programs
Failure modes for control valves
New approaches to troubleshooting

WHO SHOULD ATTEND:

Consulting engineers
Control valve specialists
Electrical engineers
Instrumentation and control engineers and technicians
Maintenance engineers, technicians and planners
Plant safety specialists
Process control engineers
Project engineers
Systems engineers

6.39

The Workshop

The Program

It is claimed that the majority of control

valves throughout the world have not been
correctly sized and that large numbers
operate on manual mode. Whether this is
true or not is difficult to establish but we do
know that the method of sizing and selecting
a control valve for a specific application is
generally not well understood. Although
there are many factors that need to be taken
into account the subject is not difficult to
understand if dealt with in a logical manner.

Introduction and definitions

Energy types
What happens inside a control valve
Cavitations and flashing
Choked flow
Valve co-efficient CV

DIFFERENT TYPES OF CONTROL

VALVES

Globe valves
Butterfly
Eccentric disk
Ball
Rotary plug
Diaphragm and pinch

Pneumatic
Hydraulic
Electric
Sizing on rotary valves and linear valves
Mounting considerations
Manual over-rides
Accessories

POSITIONERS

Basic principles
Conventional pneumatic
Conventional electro-pneumatic
Smart positioners
Feedback options

PNEUMATIC CIRCUITS
Volume tank fail system
Fail fix
Volume boosters

CHARACTERISTICS

ACTUATORS

Equal percent
Linear
Quick opening
Selection method

MATERIALS

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Many maintenance problems result from

people treating the symptoms of a problem
rather than tackling the true cause - a basic
understanding of the principles is all that is
usually needed to solve the problem for good.
This practical, hands-on workshop is designed
to maximise knowledge retention and
understanding. It provides an opportunity for
participants to discuss with the presenter and
others, specific problems and appropriate
solutions. All delegates take away a detailed
and comprehensive copy of the material
presented; therefore minimal note taking is
encouraged to ensure maximum delegate
participation and attention.

INTRODUCTION TO CONTROL VALVE

THEORY

Pre-requisites

No specialist knowledge or skills are

required only a technical background so
that there is an understanding for such
factors as the difference between pressure
and force. In fact this workshop is a good
introduction to someone who has had no
dealings with control valves in the past as
well as an important refresher workshop for
control valve specialists who benefit from
the backto-basics approach.

HIGH PRESSURE DROP APPLICATIONS

Cavitations control and elimination

Low noise
Diffuser plates
Chokes
Disk stack technology
Pressure balanced trim

VALVE SIZING EXAMPLES OF HIGH

PRESSURE DROP APPLICATIONS
USING COMPUTER PROGRAMS

Water pump bypass

Steam turbine bypass
Gas pressure reducing
Oil choke valve

Body materials and pressure ratings

Trim and packaging
Guides and gaskets

QUALITY STANDARDS

ASME
NACE
ISO 9000/2000
PED
NAMUR

INSTALLATION AND MAINTENANCE

Installation, commissioning and routine
maintenance
Fault finding
Modes of failure

SUMMARY, OPEN FORUM

AND CLOSING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Best Practice in

PROCESS, ELECTRICAL and

INSTRUMENTATION DRAWINGS
and DOCUMENTATION

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Includes: Standards, Masters, Specifications,

Templates, Drawings, Schedules & Diagrams

YOU WILL LEARN HOW TO:

Define and use process flow diagrams, P&IDs, instrument lists,

specification forms, logic diagrams, location plans, installation
details and loop diagrams
Understand process control devices and the symbols used to
define them
Define and specify vendor criteria for the production of plant
documentation to the order of the company
Use specifications to control the design scope of the project
Understand the purpose of a HAZOP in the development of a
plant
Implement and manage drawing plant modifications from
conception to completion
Be aware of the ISA standards available to assist you in
developing and understanding instrument and control
documents

Understand the scope, responsibility and interaction of each

discipline in the completion of a project or plant modification

WHO SHOULD ATTEND:

Instrumentation and Control Engineers & Technicians

Electrical Engineers and Electricians
Project Engineers
Telecommunications Engineers & Technicians
Process Control Engineers
Consulting Engineers
Maintenance Engineers & Technicians
Production Controllers
Project Managers
Drawing Office Staff

6.41

The Workshop

The Program

This two day hands-on workshop concentrates

on demonstrating how a thorough knowledge
and understanding of how the plant works
from a drawing and documentation perspective
will greatly enhance your ability to maintain
and enhance the operation of the plant. You
will learn to diagnose problems and suggest
solutions on a plant you have never seen. Too
often plant modifications that are instituted fix
the symptom instead of the underlying
problem, this workshop will show you why it is
so important to keep looking at the plant
documentation as a whole in order to solve the
problem.

Introduction
Standards - a history and overview
Drawing office and company standards

BASIC CIRCUITS AND COMPONENTS

Power supply and protection

Relays and contacts
Switches
Ladder logic
Fail safe design

PROCESS DIAGRAMS

Process block diagram

Process flow diagram
Process description including scheduling
Utility flow diagram and developing from
flow diagrams
Piping and instrumentation diagrams
P&ID standards, definition and use
P&ID symbols
P&ID layout, design and construction
Cooling water plant study
Hazardous area considerations
Practical Session

ELECTRICAL DOCUMENTATION
Load lists
Single line diagrams
Schematic and control diagrams
Cable schedules and routing drawings
Point to point schedules
Lighting layouts
Installation details
Electrical specifications
Practical Session

VENDOR PACKAGES
Panel wiring diagram
Combined E&I disciplines
Panel schematics
Panel layout
Document supply specification
Maintenance specification
Practical Session

CHANGE CONTROL
Request for change
HAZOP, RCM analysis and configuration
management
ISO 9002
Practical Session

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You will also learn how to create documentation

using simple standards and specifications as
well as custom design a solution for your own
plant. Disciplines covered include process,
electrical and instrumentation and numerous
practical exercise sessions allow the application
of knowledge gained to reinforce the principles.
This is not an advanced course but focusing on
the basic practical principles.

INTRODUCTION TO PLANT DESIGN,

OPERATIONS AND MAINTENANCE
DOCUMENTATION

INSTRUMENTATION
DOCUMENTATION

Practical Sessions

Practical Session 1 - Mechanical Drawings

Mechanical projections and sections

drawing to get a feel for the main issues
with drawing
Practical Session 2 - Ladder Logic and
Control

Ladder logic development and tying this

into the control circuits and hard wiring
Practical Session 3 - Process and P&IDs

SUMMARY, OPEN FORUM

AND CLOSING

Overview of instrument schedules,

drawings and diagrams
Purpose and target audience of each
document
Defining loop masters - loop layout
Reading instrumentation documentation
Wire numbering
Logic diagrams - definition, use and
interpretation
Instrument specifications
Practical Session

Process flow diagram, process

description and P&ID execution

Practical Session 4 - Instrumentation

Drawings

Production of instrument index, loop list,

loop drawings, I/O lists and Trip/Alarm
schedule
Practical Session 5 - Electrical Drawings

Take the ladder logic drawings earlier and

draw the electrical schematic for a typical
main and control circuits of a cooling fan

On-Site Training

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

DISTRIBUTED CONTROL
SYSTEMS (DCS)

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for Engineers and Technicians

WHAT YOU WILL LEARN:

Fundamentals of the architecture and operation of Distributed

Control Systems (DCSs)
How to design the overall DCS and process control system
Techniques to specify DCSs
Methods to optimise the performance of your plant
Understanding of the key ergonomic issues in design of
operator displays
How to apply advanced control strategies to your plant control
system
More effective use of your existing DCS process control
capabilities
How to design and create a consistent and effective alarm
philosophy for your installation
How to recognise and deal with human problems in interfacing
to alarm systems

WHO SHOULD ATTEND:

Process Control Engineers and Technicians

Automation Engineers
Operations Managers
Operators and Control Room Personnel
Metallurgists
Production Engineers
Process Engineers
Plant Engineers
IT Managers working with Networks
Electrical Engineers
Project Engineers
Electrical and Instrumentation Technicians
Maintenance Engineers and Supervisors

6.43

The Workshop

The Program

This workshop will cover the practical

applications of the modern distributed
control system (DCS). Whilst all control
systems are distributed to a certain extent,
there is a definite merging of the concepts of
DCS, Programmable Logic Controller (PLC)
and SCADA and despite the rapid growth in
the use of PLCs and SCADA systems, some
of the advantages of a DCS can still be said
to be:
Integrity: The expected process down-time
caused by a conventional DCS is significantly
less than with using a SCADA/PLC. One
incident in a refinery can cost more than the
difference in price between a DCS and
SCADA/PLC. Reasons for this would include
redundancy, fault tolerance, diagnostic
alarming on I/O errors, system design, and
others.

INTRODUCTION
SUMMARY OF TYPICAL DISTRIBUTED
CONTROL SYSTEMS
DCS VERSUS SCADA VERSUS PLCs
Comparison
The smart instrument as the key
component in a DCS system

DCS SYSTEM ELEMENTS

Main differences between a distributed
control system and PLC/SCADA systems
Requirements of the operator interface
within the DCS
Layout of a DCS system with data
highway communications paths
Redundancy in the DCS

DATA COMMUNICATIONS IN A DCS

Overview of DCS and SCADA
Communications (field/operator/long
distance)
Network topologies
Foundation Fieldbus
Profibus
Devicenet
Industrial Ethernet
Routers, switches, hubs
TCP/IP
Industrial Network security
Links to MES and ERP

Abnormal Situation Management and

Intelligent Alarm Management is a very
important DCS issue that provides significant
advantages over PLC and SCADA systems.
Few DCSs do justice to the process; in terms
of controlling for superior performance most of them merely do the basics and leave
the rest to the operators. Operators tend to
operate within their comfort zone; they don't
drive the process "like Schumacher drives
his Ferrari". If more than one adverse
condition developed at the same time and
the system is too basic to act protectively,
the operator would probably not be able to
react adequately and risk a major deviation.

THE BASIC CONTROLLER

Philosophies of alarm management

Human and ergonomic factors
Structure of good alarm system
Safety Integrity Level (SIL)
Design of alarm system
Measurement of performance

DISTRIBUTED CONTROL SYSTEM

REPORTING
Alarm reporting, types of alarms
generated and acceptance of alarms
The different types of logs and reports
which can be configured on a DCS
system
Data history use in logs, reports and
trend displays

DISTRIBUTED CONTROL SYSTEM

CONFIGURATION
The organisation of system data files
Data configuration procedures necessary
for setting up the DCS area database
The need for different security levels
attached to various operating parameters
Configuration control procedures
adopted to ensure data integrity

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Engineering time: A small SCADA/PLC

system is easy to design and configure. As
the system grows bigger, the effort involved
to properly design and configure the system
grows exponentially, and also the risks that
things can go wrong. To design and
implement a single loop PID controller in a
SCADA/PLC system is easy and quick. To
design and implement the base layer control
on a refinery using a SCADA/PLC system
can be challenging without a highly skilled
team of industrial automation engineer and
technicians.

ALARM SYSTEM MANAGEMENT FOR

DCSs

Operators have little feedback on their own

performance and exceptional adverse
conditions are often not handled as well as
they should be. Why are DCSs generally so
under utilised? Often because the vendor
minimises the applications software
development costs to be sure of winning the
job, or because he does not know enough
about the process or if it is a green-field
situation, enough could not be known at
commissioning time but no allowance was
made to add the missing functionality during
the ramp-up phase.
This workshop examines all these issues
and gives suggestions in dealing with them
and whilst by no means exhaustive, provides
an excellent starting point for you in working
with DCSs.

Identification of the PCBs, which make up

the controller
Function of the central processing unit
(CPU)
The types of memory
Discrete and logic control
Sequential and batch control

BASIC DCS CONTROLLER

CONFIGURATION

ADVANCED CONTROL STRATEGIES

MAINTENANCE CONSIDERATIONS
Maintenance requirements of system and
system elements
The requirements for in-built diagnostics
and for maintenance diagnostic routines
The requirements for installation of UPS
system
Recovery of a DCS following a power
outage

THREE TYPICAL APPLICATIONS

SUMMARY AND CLOSURE

Control modes available within each

controller slot
Tracking and initialisation in control slots
used for cascade control
Control algorithms
The use of diagnostics

PROGRAMMING OF DCS SYSTEMS

Block configuration
IEC 61131-3 "open" programming
languages (structured text, function
block, ladder, sequential)
Tips and tricks in programming

THE OPERATOR INTERFACE

The operators process 'window'

The various operator display
configurations
The requirement for keyboard entry of
data
Ergonomic requirements in the operator
environment

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Practical Sessions

Have the training

delivered when and

where you need it.

Specification of a DCS
Configuration of a typical DCS control loop
using a typical plant problem

Contact us for a
free proposal.

Design of an alarm system

Advanced process control - configuration and
testing

idc@idc-online .com

www.idc-online .com

Fundamentals of

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INDUSTRIAL AUTOMATION

What you will learn:

An appreciation of the latest developments in industrial

automation

Cutting edge best practice in instrumentation, PLCs, PACs

Update on fieldbus, industrial ethernet and industrial wireless
Review of current SCADA practice

Best practice in industrial automation

A clear understanding of the acronyms and terminology used

WHO SHOULD ATTEND:

This course is aimed at you if you are interested in gaining an

overall appreciation and general understanding of industrial
automation and control technology.
Engineering managers

Mechanical and electrical engineers

Instrumentation engineers

Maintenance engineers, supervisors

and technicians
Sales engineers
Programmers
Project leaders and managers
IT managers
Process engineers

Production managers and engineers

Business managers

6.45

The Workshop

The Program

The elements of an industrial control system

form part of an interconnected web using
Ethernet, Fieldbus and wireless. Information
is effortlessly transferred from an instrument
to the SCADA terminal on a boardroom
table. In this workshop real life examples
from current control system technologies
are used to give you the latest background
in current vendor solutions. The material is
presented in an easy to understand practical
way enabling you to apply the concepts
quickly and effectively to your next
automation project.

Objectives of course
Road map for the course
History and background
Building blocks of industrial automation
Digital control
Hierarchy and pyramid of control (sensor
to boardroom)

INSTRUMENTATION

Sensors
Instrumentation
Actuators and valves
Fieldbus
Impact of Fieldbus and wireless PLCs,
PACs, DCSs AND SCADA SYSTEMS
Programmable Logic Controllers (PLCs)
Programmable Automation
Controllers(PACs)
Operator panels
Distributed Control Systems (DCSs)
Supervisory and Control and Data
Acquisition Systems (SCADA)
Soft PLCs
Standard programming languages
(IEC 61131-3)

INDUSTRIAL DATA
COMMUNICATIONS
Essentials of data communications (OSI
layers)
Essentials of RS-232/RS-485
Fieldbus and DeviceNet systems
ASi-bus
Profibus
Foundation fieldbus
Industrial ethernet and TCP/IP
Industrial versus commercial ethernet
Industrial wireless
Battle of the application layers
Industrial network security
OPC

PROCESS CONTROL

PID control
Cascade control
Advanced process control
Implementation of control

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Once you have completed the course you

should have a good overall understanding
of how to harness the power of industrial
automation and to deal with contractors and
experts working in the area. This will result
in quicker ability to make decisions on the
best way forward resulting in a quicker time
to design, install and commission industrial
automation equipment and, naturally,
reduced costs.

INTRODUCTION

Practical Sessions

The course is made highly interactive with

short clips of videos, practical design
exercises, and practical hands-on sessions
with simulation software to demonstrate the
key concepts.

FROM SCADA TO BUSINESS

SYSTEMS

Manufacturing Execution Systems (MES)

S88 batch language
System integration models and concepts
- S95 standard

SUMMARY

Tying all the components together

A view of the future

To gain full value from this workshop,

please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Troubleshooting of

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Data Acquisition and SCADA

Systems

YOU WILL LEARN HOW TO:

Install and configure a data acquisition system

Choose and configure the correct software

Apply state of the art approaches in design of data acquisition

systems
Configure data communications systems

Avoid the common pitfalls in designing a data acquisition

system

WHO SHOULD ATTEND:

Electronic Engineers

Instrumentation and Control System Engineers

Electrical Engineers

Project Engineers

Design Engineers
Technicians

Process Control Engineers

Systems Engineers

6.47

The Workshop

The Program

This two-day workshop covers all aspects of

data acquisition and control using a PC and
data loggers, including design, specification,
programming, installation and configuration.
Both the novice and experienced user will
gain a solid grasp of the principles and
practical implementation of interfacing the
PC and standalone instruments to real world
signals. Upon completion of the workshop
you will have a thorough understanding of
PC based data acquisition systems and will
be able to design, specify, install, configure
and program data acquisition systems
quickly and effectively. In addition, the
workshop aims to cover the industrial
communications standards that are used
with instruments today.

Aims

ANALOG AND DIGITAL SIGNALS

Sensors, transducers and temperature
transducers
Strain gauges
The difference between single ended and
differential systems
Earthing and isolation techniques to
reduce noise
Cable shielding and earthing

SIGNAL CONDITIONING
The different types of signal conditioners
Signal conditioning functions and signal
filtering
Isolation and over voltage protection

RS-232/RS-485 SERIAL DATA

COMMUNICATIONS STANDARDS

RS-232 hardware interface

Principles of RS-232 handshaking
RS-485 hardware interface
Communication protocols (e.g. Modbus)
Error detection
Troubleshooting serial data
communications systems

CONTROLLERS AND DATA LOGGERS

Hardware structure of standalone devices
Practical applications of data loggers
How to improve communication
bottlenecks IEEE-488 SYSTEMS
IEEE-488.1/IEEE-488.2 and SCPI
specifications
Hardware configuration
Device types (controllers/listeners/talkers)
Basic communications
Advanced communications

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Personal computers have become a popular

and affordable platform from which to
perform data acquisition and control for a
variety of industrial and scientific
applications. Data acquisition with the PC
enables one to log and control a variety of
real world signals such as pressure, flow
and temperature and to interface to various
standalone instruments.

INTRODUCTION
Data acquisition and control
Fundamental principles of data
acquisition and control systems
Typical PC based applications

This practical workshop will equip you with

the knowledge and expertise to configure an
efficient and effective data acquisition and
control system using a PC and standalone
instruments. You will learn various simple
approaches to the design of data acquisition
systems and choice of software, hardware
and analysis tools.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

THE PC FOR REAL TIME WORK

The different data transfer methods

Streaming of data to hard disk

PLUG IN DATA ACQUISITION BOARDS

Typical analogue to digital (A/D) boards
Single ended vs differential signals
Analogue to digital (A/D) board
specifications
Capturing high speed transient data
Principles of data sampling
Speed vs throughput of data
Typical digital to analogue (D/A) boards
Input/Output (I/O) boards
Counter/timer I/O boards
Practical considerations with use of
digital I/O boards

INDUSTRIAL ETHERNET
and TCP/IP

Configuring an Ethernet system

Troubleshooting TCP/IP and Ethernet
Connecting Ethernet based instruments
and data loggers to a PC
Tips and tricks with Ethernet

UNIVERSAL SERIAL BUS (USB)

Concept and practice

USB explained
Benefits for data acquisition and
communications

REVIEW OF THE COURSE AND

QUESTIONS

Practical Sessions

Groups of attendees will be allocated a PC to develop simulated Data Acquisition and SCADA
software projects. You will use internationally known software packages, chosen for their
high profile and popularity in the industrial environment. You will put these software
programs to the test, developing your ability to understand DAQ systems and reinforcing the
information learnt in the workshop.
Learn how to use real SCADA software

The SCADA software used is industry standard DAQ software preferred by factories and
plants around the world and is designed for large-scale sites. You will design a simulated
project and learn first-hand how to set up and use the software to build a complete factory
SCADA system.
Learn how to use real Data Acquisition software
The Labview data acquisition software is an industry standard package used for small to
medium scale industrial systems. You will develop a simulated tank to pump data acquisition
system on the PC. Through designing this simple virtual system, you will receive an
understanding of the use and limitations of data acquisition software packages like Labview.

Have the training

delivered when and

where you need it.

Learn how to set up and acquire data using real hardware

Contact us for a
free proposal.

As a bonus you will have the opportunity to see how a data acquisition device is set up and
used. You will configure the data logger, read real inputs and analyse the information.
Learn the basic tips in troubleshooting RS-485, Ethernet and TCP/IP
Connect up an Ethernet based instrument/logger and troubleshooting typical problems
To gain full value from this workshop, please bring your laptop/notebook computer.

idc@idc-online .com

www.idc-online .com

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Installation, Calibration
and Maintenance of
Electronic Instruments

YOU WILL LEARN HOW TO:

Apply correct practice to installation, calibration and

maintenance of instruments
Calibrate electronic transmitters and controllers
Configure instruments correctly to vendor instruction sheets
Apply intrinsic safety techniques to instrumentation installation
Maintain instruments correctly
Connect instrument wiring correctly
Predict and avoid the problems with installing measurement
equipment
Troubleshoot, isolate and fix electronic instrumentation
problems
Specify instrument and loop documentation requirements and
standards to vendors
Fault find with drawings
Design and install safe working systems in hazardous areas
Apply ISO 9000 to maintenance practices
Effectively apply the principles of analog meters, digital meters
and oscilloscopes
Carry out simple repair procedures for the correction of faults
on instrument systems where possible

WHO SHOULD ATTEND:

Design engineers
Electrical engineers
Electrical technicians and technologists
Electricians
Experienced electrical tradespersons and artisans
Experienced fixed plant operators
Graduate engineers
Instrumentation engineers
Project engineers
6.49

The Workshop

The Program

This workshop is designed for engineers

and technicians from a wide range of
abilities and backgrounds and will provide
an excellent introduction and hands-on
experience in installation, calibration,
commissioning and maintenance of
electronic instrumentation. The workshop is
initiated with coverage of the basics on
electrical measurements and some tips and
tricks. Instrument performance and
calibration principles are then covered with
rules for calibrating transmitters. Hereafter
the procedures for calibrating and installing
smart transmitters are covered. Typical
documentation requirements for instruments
are examined with a focus on instrument
data sheets, P&IDs and wiring diagrams.
During the life span of any plant, a multitude
of different vendors will supply plant
modifications and equipment as the plant is
continuously enhanced. The quality of the
documentation
produced
will
vary
enormously with each new supplier.
Instruments in hazardous areas are then
detailed. The course is then finalised with a
discussion on integration of the entire
system and testing and commissioning
procedures for instruments detailed.

MAINTENANCE

Pre-requisites

CALIBRATION PRINCIPLES

Practical Sessions
Measure and troubleshoot
current, resistance problems

voltage,

Open and short circuit tips and tricks

The basis of signal simulation
Transmitter simulation

Zero and span adjustment

accuracy

and

error

Block diagrams
Standards for calibration
Five point calibration
Charts

Basic measurement concepts

Definition of terminology
Measuring instruments and control
valves as part of the overall control
system
Pressure, level, temperature and flow
overview
Overview of control valves

Perform digital trim

Shop calibration
Electro pneumatic calibrators
In-shop or field
Temperature calibration (RTD/
thermocouples)

PID CONTROLLERS

Fieldbus and Digital Transmitter

Rerange

Basic measurement and control concepts

Accuracy/range/hysteresis/linearity/
repeatability/response/dead time
Zero/span
Process dynamics
Specifications

The basis of transmitter calibration

Configure

INSTRUMENT PERFORMANCE

CALIBRATION OF TRANSMITTERS

Transducer simulation

Performance
calculations

Use of multimeter
Voltage/current and resistance
measurement
Analog and digital meters
Oscilloscopes
Current to voltage conversion
Multiple loop devices
Diodes and resistors
Soldering and component preparation
Open and short circuits
Testing of diodes/DIACS/TRIACS
Components out of tolerance
Isolation and earthing

FUNDAMENTALS OF PROCESS
MEASUREMENT

Basic Measurements

Calibration

ELECTRICAL MEASUREMENTS

SMART AND FIELDBUS

TRANSMITTERS

Operation
Configuration
Reranging
Characteristics
Trimming

TRANSDUCERS AND TRANSMITTERS

Fundamentals
Calibration
Interfacing to instrument

INSTRUMENT DOCUMENTATION AND

P&ID's

Control loops on the P&ID

Instrument lists
Wiring diagrams
Schedules and lists
Data sheets
Loop diagrams
Standards and symbols

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A knowledge of fundamental electrical

concepts would be useful.

Simulation

Corrective/preventative/predictive
Troubleshooting
Meaning of ISO 9000 and 9001

Direct/reverse acting
P, I and D control
Spanning and range
Instrument/controller and process gains

PID Feedback Loops

HAZARDOUS AREAS

Explosion consequences
Definition of hazardous area
Classification of apparatus
Apparatus grouping and temperature
Principles of Ex protection
Requirements for IS systems
Noise and interference control
Earthing requirements
Static protection
Lightning protection

Maintenance, Fault Finding and

repairs of Ex Equipment

Planned maintenance
Use of tools
Procedures
Safe methods
Test equipment suitability

STANDARDS, CERTIFICATION,
MARKING AND APPROVAL

Authorities
Marking and identification
Apparatus certification

INTEGRATION OF THE SYSTEM

Calculation of individual instrument error

and total error for the system
Integration of the pressure, level,
temperature and flow systems
Integration of new smart subsystems
with data communication links
Procedures
Testing and commissioning
Start up

SUMMARY, OPEN FORUM & CLOSING

Wire up and install a PID feedback loop

Check the loop out
Tune the loop

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

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RFID* Tagging Features and Applications

* Radio Frequency Identification

YOU WILL LEARN HOW TO:

Apply RFID technology to your next project

Understand the strengths and weaknesses of the technology

Detail the physics and electronics behind RFID

Specify RFID system components and types of tags

List types of RFID communication system and frequency ranges

Design and install a simple RFID system

Understand transmission and collision avoidance techniques

employed in RFID
Describe a typical transmitting sequence

Distinguish between the various types and workings of

transponders and antenna
Explain RFID standards and current regulations

Appreciate the middleware requirements and their integration

with varied business applications
Detail the cost involved to set up a RFID system

Undertake a RFID implementation study from case study

examples
Gain hands-on experience in setting up, testing and running a
RFID system using notebook computers and RFID demo-kits

6.51

The Workshop

The Program

RFID is one of the fastest growing

technologies in the automatic data collection
industry. The widespread use of RFID in
such varied applications as electronic article
surveillance, animal tagging and high
volume logistics supply has resulted in low
prices of the tags. It is conceivable with the
affordability of tags that they can be
permanently used to identify foodstuffs and
clothing items. There are still a number of
questions raised about issues such as cost
and in particular privacy. This 2-day
workshop will cover all the essential aspects
of RFID systems to not only provide you
with a broad understanding of its technology
but also the various types of applications
and uses where it can be applied to.

RFID APPLICATIONS
Current market opportunities &
application areas
Specific examples of RFID applications

RFID - an overview
Genesis of an idea - history of RFID
RFID in 1990s
RFID promises: stepping into 21st century
RFID limitations
Patents
What's happening today?

- Transportation/distribution
- Retailing
- Industrial security and access control
- Animal identification
- Automated library systems
- Check point systems
- Toll road control
- Healthcare
- Digital card mail
- Toy industry
- Banking

NUTS & BOLTS: PART 1

Revisit physics and electronic fundamentals

Antenna Maps
RFID - system components
RFID - types of communication: radio
frequency and range
System handshake - a typical
transmitting sequence
Data modulation
Data encoding
Transmission & collision
Evolving RFID standards
Definitions & acronyms
Case study

MARKET OPPORTUNITIES &

PRODUCTS
Market analysis & survey: case study and
costs
Major players/products

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The workshop will provide an overview of

RFID technology, explain the physics and
electronics driving this technology whilst
also focusing on communication protocols,
industry standards and security issues. It
also covers software requirements,
middleware and integration with various
business applications and practices.
Implementation strategies and challenges,
cost analysis, market opportunities and the
road-ahead will be discussed throughout the
2 days.

INTRODUCTION

The workshop provides hands-on training in

setting up, testing and running a RFID
system using notebook computers and RFID
demo-kits. These sessions will explore
identifying components, studying the
characteristics of RFID transponders,
antenna,
their
limitations
and
troubleshooting.
Case studies are shown throughout the 2
days to give you a practical understanding
of its application to industry.

Pre-requisites

Basic knowledge of electrical and electronics

concepts useful. Knowledge of data
communications and applications are
desirable, but not essential.

NUTS & BOLTS: PART 2

Transponder apparatus and system

Remotely powered transponder
Remotely powered transponder having
a dipole antenna array
Passive encoding microwave transponder
Identification system using coded passive
transponders
Passive transponder apparatus for use in
an interrogator - responder system
Electronic detection and identification
system
Essentials of troubleshooting exercise

TYPICAL BUSINESS CASE STUDY/

SUCCESS STORIES: PART 1

INSTALLATION/TROUBLESHOOTING
SAMPLE RFID SYSTEM
Installation of a RFID system: Practical
sessions in setting up, testing and
running a RFID system using notebook
computers and RFID demo-kits
Troubleshooting of a RFID system

TYPICAL BUSINESS CASE STUDY :

PART 2
ROAD AHEAD

Research projects
Innovative products for the home
Future vision
Ethics & privacy issues

SUMMARY, OPEN FORUM and

CLOSING

Case studies

Who Should Attend

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

Engineers and Technicians working with or required to implement a RFID system, including:
Test Engineers
System Engineers
Software Engineers
Instrumentation and Control Engineers/
Technicians
System Integrators
Process Control Engineers
Designers
Network Planners
Electronic Technicians
Electrical Engineers
Consulting Engineers
Packaging Engineers
Design Engineers
System Integrators
Plant Managers
Application Engineers
Systems Engineers
Solution Providers
Electricians
Electronic Engineers
This workshop will also be of interest to:
All those who wish to be able to multi-skill into RFID systems
Maintenance technicians, electricians, foremen and engineers
All engineering, operations or management personnel who are directly or indirectly
involved with electronics controls
Those involved with the installing, programming, maintaining and purchasing of
electronic control equipment
Those who want to improve their understanding and capabilities in electronic technology
All those involved with sales and installation of electronic products into industry

idc@idc-online .com

www.idc-online .com

Practical industrial Troubleshooting of

Instrumentation, Electrical
and Process Control

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Evaluate industrial processes

Competently diagnose fault conditions

Accurately interpret drawings and documentation

Reliably explain the nature of faults, how they should be

repaired and how the system should be tested on completion
Troubleshoot communication links using test equipment and
available software packages - IDCs Protocol Analysis Tool (PAT).
Free copy of this tool for all delegates
Demonstrate a working knowledge of how instrumentation and
control systems are interfaced
Compile concise fault analysis reports and make
recommendations to prevent recurrence

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand

the techniques required to use and apply industrial fault finding,
troubleshooting and repair technology as productively and
economically as possible. This includes technicians and artisans
involved with:

Consulting and design

Control and instrumentation
Control systems
Electrical and instrumentation installations
Maintenance supervisors
Maintenance technicians
Process control
Process development
Project management
SCADA and telemetry system

6.53

The Workshop
This interactive workshop uses a systems
approach to troubleshooting and is designed
to encourage delegates to take a new look at
the methodology of faultfinding and
rectification on their plant. Having covered
the types of equipment, we look at first line
troubleshooting, then the advanced level
and finally work through some typical
examples.
The first step is to get to grips with the
processes and relevant process variables,
then to look at their measurements and the
basics of the systems that control them.
Before embarking on the look-feel-listendecide sequence, we pause for a while to
consider aspects of safety; at the plant,
equipment, component and personal levels.

Taking the case of an apparent PLC fault, the

first level trouble-shooting can eliminate the
PLC from the actual fault condition and
pin-point the section of plant where the real
fault may be located; typically a range of
5 to 10 components. The advanced section
will focus more on tracing faults to the final
component and might require using more
sophisticated equipment, and/or debugging.
The point is that if the PLC programming
was correctly commissioned, it will not be
the cause of the problem.
Similarly, first line motor faults can be
related to individual motors, drive circuitry,
relays, switches, etc. The advanced troubleshooting will cover tracing the fault to the
specific IC or other drive component, such
as a thyristor or fuse. In some cases, a
re-calibration of the drive might also be
required.

loose connections, etc wrong. This can be

addressed by first line troubleshooting. If
the fault goes beyond this and is caused by
a faulty component, it needs to be verified
by a person with more expertise. Rarely is
incorrect configuration or malfunctional
coding the actual problem.
Emphasis is placed on the diagnosticians
dependence on accurate drawings and
documentation and the need to be able to
correctly interpret the facts contained in
drawings and documentation.
Clients often feel the same way about these
problems; where components are being
replaced more on an ad-hoc basis, so
causing unnecessary wastage and plant
down-time.
Delegates will be encouraged to bring
typical troubleshooting problems to the
workshop and to discover a more costeffective way of resolving their problems,
thereby saving them time, whilst saving
their plant from unnecessary wastage and
down-time.

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Troubleshooting
basics
covers
the
systematic approach to information
gathering, fault diagnosis and decisionmaking. Emphasis is placed on gathering
relevant information and using it to prove
where the fault isnt; thereby eliminating
false decisions and red herrings.

components. The 'advanced' chapters will

cover more details/expert level investigation
and will address the component level and,
more importantly, a validation of the
decision taken at the first level troubleshooting; verifying if it requires a component
change - incorrect decisions at this stage
having significant cost implications.

Having implemented the right solution, we

then look at how to learn from the experience
and prevent a recurrence.

First level troubleshooting will help in

localising the faulty module or sub-system
and narrow it down to a set of possible

The assumption here is that most faults can

be traced to fuses, misaligned components,

Pre-requisites

A basic working knowledge of industrial

electrical,
instrumentation
and
communications applications is useful.

The Program

Practical Sessions

This is a practical, hands on workshop

enabling participants to work through
practical exercises which reinforce the
concepts discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

BASICS

ACTUATORS AND DRIVES

Processes
Process variables
Measurement
Control systems basics
Matters of safety
Decision making
Troubleshooting basics
Feedback to prevent a recurrence
Examples of personal experience

PLC TROUBLESHOOTING

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

Types of PLCs in use

System architecture
Communication strategies
Strategic use of documentation to aid
fault location and diagnosis
Actual PLC fault identification
Examples of typical fault conditions,
diagnosis and repair

SENSORS AND MEASURING DEVICES

Overview of sensor types
Voltage, current and frequency/pulse
interfacing
Using the P&I Diagram and loop
schematics to aid fault location
Testing, repair, replacement ant
recommissioning of devices
Examples of typical fault conditions,
diagnosis and repair

delivered when and

where you need it.

ELECTRICAL SYSTEMS

Overview of MV power systems, cabling,

transformers and switching, shielding
and grounding
Motors and Motor Control Centres
(MCCs)
Variable Speed Drive (VSD) suites
Lighting and small power systems
Examples of typical fault conditions,
diagnosis and repair

COMMUNICATIONS AND NETWORK

TROUBLESHOOTING
Overview of process plant
communications and network strategies
Interfacing problems and system fault
location
Examples of typical fault conditions,
diagnosis and repair

TROUBLESHOOTING TOOLS AND

INSTRUMENTS

Overview of appropriate tools and test

equipment
Safe and effective use
Calibration of test equipment
Examples of how fault conditions can be
incorrectly diagnosed

SUMMARY, OPEN FORUM

and CLOSING

Contact us for a
free proposal.

idc@idc-online .com

Overview of actuators and drive types

Control strategies
Communication and power interfacing
Examples of typical fault conditions,
diagnosis and repair

www.idc-online .com

Practical

HAZOPS*

for Engineers and Technicians

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*Hazard and Operability Studies

what YOU WILL LEARN:

The principles of hazard and operability studies

Planning and timing of HAZOP studies as part of safety

management

How to structure your plant operations into parts for study

How to generate and test deviations from design intent
Strengths and weaknesses of the HAZOP approach

Optimum team selection and information gathering

Format of workshop records, recommendations and

risk ranking
Tips on leadership styles

Follow-up reporting and closeout of actions

Safety instrumented systems and how they relate to HAZOP

Hazard analysis methods of FMEA and fault trees

WHO SHOULD ATTEND:

Process engineers, plant engineers, technicians and supervisors

involved in new projects or in the modification or upgrading of
existing plants
Trainee HAZOP team leaders
Loss prevention officers
Plant managers, project managers and planners seeking an
awareness of the role of HAZOP in overall safety management
Instrument and electrical engineers, process control engineers
and system integrators who are likely to be participants in
HAZOP or who will be asked to engineer safety control systems
Commissioning engineers, plant supervisors and process
maintenance technicians
6.55

The Workshop

The Program

This two-day workshop concentrates on

awareness level training for managers,
engineers and technicians in the practical
application of hazard and operability studies
(known as HAZOP). HAZOP is widely used
for identifying hazards in an industrial
process and for assessing the potential
consequences where there are risks of harm
to persons, the environment or to assets.
The HAZOP technique is recommended by
professional engineering institutions,
government regulators and insurance
companies and is one of the principle risk
management tools. HAZOP is applied at
both the design stage and throughout the
life of a process plant, where it supports the
safety management and (where applicable)
the validation of the plant safety case.
HAZOP is also an essential technique when
reviewing modifications and upgrades to
existing plant.

Workshop outline and objectives

References to guides and standards
Glossary of terms

INTRODUCTION TO HAZOP
Outline of HAZOP method
Scope of study
Timing and purposes

HAZARD STUDIES AND RISK

MANAGEMENT
The need for quality assurance in hazard
studies
The process hazard study lifecycle and
the six levels of studies
Principles of risk management
Legal requirements for hazard studies,
US and EU regulatory frameworks

TYPICAL HAZOP WORKSHOP

Step by step introduction to the activities
of a HAZOP workshop
Timing and duration of the study
Documents required
Team membership and duties
Outline of the examination phase
Recording, reporting and follow up

PLANNING AND LEADERSHIP OF

HAZOPS
Organising the study, planning, scoping
and objectives
The team leaders skills and duties
Essential members of the team and their
roles
Conducting the study sessions, dealing
with problems
Using additional checklists for operability
Contents of the HAZOP study report
Tips for the facilitator

FROM HAZOPS TO SIL

The relationship between hazard studies
and safety instrumented systems
Risk reduction concepts and the risk
matrix
Concepts of tolerable risk and the ALARP
principle
Layers of protection
The role of safety instrumented systems
in risk reduction
The meaning of SIL and how it relates to
safety and cost
SIL determination methods and the input
from HAZOPS

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This workshop introduces the basics of the

HAZOP technique and discusses its
relationship with other safety (risk)
management tools. HAZOP can be applied
to any process industry, onshore or offshore,
including oil and gas, mining, chemical or
other processing industries. The relationship
between HAZOP and other risk management
techniques such as HAZID, hazard analysis,
FMEA, fault tree analysis and the Safety
Integrity Levels (SIL) of instrumented
systems will also be demonstrated. This
workshop will be of interest to a variety of
managers and to most engineering
disciplines.

INTRODUCTION

Workshop examples include the design of

new process plant and modifications to
existing process plant. It involves the study
of process flow-sheets and Process and
Instrumentation Diagrams (P&IDs). Hazard
studies interact closely with process design
and safety engineering solutions in the
critical stages of engineering projects.
Understanding these interactions assists
engineers and technicians to plan their work
efficiently and to contribute effectively to the
reduction of risks in the workplace.

EXAMINATION PHASE METHODS

Defining the system and selecting the

parts for study
Elements and parameters
Generating deviations with guidewords
and a matrix
Guideword examination procedures and
responses
Worked examples of continuous and
batch process studies
Control HAZOPS
Software tools for the examination and
reporting phases

HAZARD ANALYSIS METHODS

The reasons for hazard analysis

Failure modes and effect analysis method
Fault tree and event tree analysis
methods
Adding risk reduction measures to the
fault tree

summary, open forum and

closing

Practical Sessions

The HAZOP techniques and

safety system practices
described in this workshop are
based on the latest
international practices
including the guidelines in
IEC 61822 for
HAZOP studies.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
There are six practical exercises, which you
will undertake, some of them in groups, all
intended to provide experience in hazard
studies and hazard analysis.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

SCADA SYSTEMS

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for Industry

What YOU WILL LEARN:

The fundamentals of SCADA systems

The essentials of SCADA software configuration

Tricks and tips in installation of SCADA systems
The essentials of telecommunications links

The use of industrial Ethernet in SCADA systems

SCADA network security issues

How to troubleshoot SCADA systems

WHO SHOULD ATTEND:

This workshop is designed to benefit engineers and technicians

who are involved in specifying, commissioning and debugging
industrial SCADA systems but who have little previous experience
in this field.
It is also of particular benefit to personnel involved in areas of
design, specification, installation, commissioning, maintenance
and documentation of industrial control and instrumentation
systems where used, this includes:

Instrumentation and Control

Engineers

Maintenance Supervisors

Process Control Engineers

Control System Application

Engineers

Electrical Engineers

Project Engineers

Consulting Engineers

Technicians

Design Engineers

Plant Engineers

Control Systems Sales

Engineers

IT Personnel

6.57

The Workshop

The Program

SCADA has traditionally meant a window

into the process of a plant or gathering of
data from devices in the field, but now the
focus is on integrating this process data into
the actual business and using it in real time.
The emphasis today, is on using open
standards such as communication protocols
(eg DNP3, MODBUS, and TCP/IP) and off-theshelf hardware, such as industrial Ethernet
to keep the costs down. This comprehensive
two day workshop covers the essentials of
SCADA systems. The topics covered on the
two days are as follows:
Day One gives an introduction to SCADA
systems then focuses on the SCADA system
hardware and software, including alarm
management and Human Management
Interface (HMI) issues. This is followed by a
review of the RS-232/RS-485 interface
standards and the MODBUS and DNP3
protocols.

This workshop will be an excellent

opportunity to network with your peers as
well as gain significant new information and
techniques for your next SCADA project.

Although the emphasis of the workshop will

be on practical industry topics highlighting
recent developments using case studies and
the latest application of SCADA technologies
the fundamentals of SCADA systems will be
covered. The workshop is aimed at those
who want to be updated on the latest
developments in SCADA systems and want
to get a solid appreciation of the fundamentals
of SCADA design, installation and
troubleshooting. The
comprehensive
workshop manual covers other topics for
your reference, including Fieldbus systems,
maintenance,
system
specification,
installation and commissioning issues. It
also includes various case studies and
design exercises.
Pre-requisites

Industrial Ethernet

Communication architectures
Communication philosophies

Fundamentals
Redundancy

Overview of SCADA Systems

TCP/IP

Hardware alternatives (RTU/PLC etc)

Communication concentrators
Communication alternatives

Configuration
Troubleshooting utilities

SCADA System Hardware

Overview

Hardware components
Operation and selection issues

SCADA System Software

SCADA software functions

Response times
Redundancy issues
Specification and configuration Issues

SCADA Alarm Management

Alarm layout and organisation
Alarm priorities
Alarm processing and reporting

Modbus TCP
Open Process Control (OPC)
Overview

SCADA Network Security

Security issues
SCADA firewall configuration

SCADA Historian
Archiving plant data
Data access

Troubleshooting Issues

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Day Two gives a review of Industrial Ethernet

, TCP/IP and MODBUS/TCP. The role of Open
Process Control (OPC) in plant SCADA
systems is also discussed. This is followed by
discussion of network security, SCADA
historians and troubleshooting issues.

Introduction

Human Management Interface

(HMI)
Ergonomic factors
HMI organisation
HMI screen design

Problem isolation
Testing methodology
Noise issues
Communications testing

Review and Questions

Communication Protocols

RS-232/RS-485 interface standards

MODBUS protocol
DNP 3.0 protocol

Fundamental knowledge of SCADA.

On-Site Training

Practical Sessions

This is a practical, hands on workshop enabling you to work through practical exercises
which reinforce the concepts discussed.

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Each day has many practical sessions designed to apply and reinforce the theory concepts.
Day One

1. Configure alarms on Citect SCADA system

2. HMI screen design using Citect SCADA package

3. MODBUS RTU communication
4. Configure SCADA master communications using Citect
Day Two
1. Setup Ethernet network and configure TCP/IP

Have the training

2. Ethernet troubleshooting utilities and protocol analysis

delivered when and

where you need it.

3. Setup and monitor MODBUS/ TCP communication

4. Use OPC client to access data

Contact us for a
free proposal.

5. Troubleshooting exercise
To gain full value from this workshop, please bring your
laptop/notebook computer.

idc@idc-online .com

www.idc-online .com

Practical

Machine Vision Applications

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in Industry

WHAT YOU WILL LEARN:

The fundamentals of image processing and machine vision

How to develop a simple machine vision system

How to select cameras, lighting, frame grabbers and software

How to assess resolution requirements

Best practice in alignment and calibration procedures

Identification and correction for sources of error
Designing for harsh industrial applications
Configuring of a machine vision system

Selection of optimal lighting to achieve best contrast

How to apply the best optics to achieve optimal resolution

How to do a simple design for high-speed real time
performance
Troubleshooting simple machine vision problems

6.59

The Workshop

The Program

Machine vision has progressed in leaps and

bounds since the disappointments in the
eighties with tremendous results achievable
today. Nowadays, machine vision systems are
highly effective and a key part of many
industrial systems ranging from mineral
processing to manufacturing.The fundamentals
of image processing and machine vision are
covered in the beginning to give everyone a
solid foundation to work from. The workshop
commences with an examination of optics and
lighting - as the experts say - machine vision is
easy if you can get a good image into the
system.
You will be shown how to select and design
lighting to achieve the best contrast. The
selection of cameras, frame grabbers and
vision appliances are next covered in practical
detail. Finally, you will be shown how to select
and integrate all the varying components into
a professional and working system.

Image Processing

Real time processing

Precision and accuracy
Selection of frame grabber and vision
appliance
Frame grabbing
Use of multiplexing
IEEE 1394 'FireWire' serial bus standard
interface
Image processing for dummies
Image analysis

However, despite the advances in technology

don't expect your machine vision to have the
versatility and brilliance of a humanyet. But
if you apply the key concepts in this workshop
to your machine vision application, you should
have a reliable and effective solution.

Fast Fourier Transform

Digital Fast Fourier Transform
Sampling theory
Aliasing
Bits and pixels
Trade-offs
Demonstrations

Common algorithms
Enhancing the image
Blob analysis
Pattern matching
Optical character recognition
Read bar codes and data matrix
Perform measurements
Overlay graphics

Machine Vision System

components

Basic approach of image representation

and processing software applications
Interactive image processing for system
prototyping
High speed vs real time approaches
Selection of software packages

Lighting, filters and optics

External Interface

Image sensor (camera)

Image processor and analysis (frame
grabber, vision processor/computer,
image analysis software and
interpretation)
Mechanical interface
(part conveyor/feeder)
An example of a machine vision system

Lighting

Practical Sessions
Fundamentals of
(five exercises)

image

processing

Lighting optimisation (one exercise)

Configuration of software program

Troubleshooting
system

of

machine

vision

Integration into complete system

Why is lighting critical?

Lighting techniques
Light sources
Beyond visible spectrum-IR and UV
radiation
Laser light in machine vision
Use of strobe lighting in machine vision
Placement of sources
Effect of stray and ambient light
Enclosing the object to eliminate stray
light
Filters and their use
Optical devices for image enhancement

Cameras and Sensors

Frame grabber set up

Calibration

Digital Image Processing basics

Camera set up

Overview of workshop
Systems approach to machine vision
Machine vision vs image processing
Human and computer vision
Basics of image processing
Pattern recognition
Practical Fast Fourier Transforms
Filtering
Inverse filtering
Seeing problem
Colour properties and the eye
Colour properties of image input and
output devices

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The workshop will be presented with minimal

use of mathematics and extensive use of
practical concepts and applications. There will
be extensive use of practical hands-on
exercises ranging initially from illustrating the
key concepts of image processing to setting up
a complete working machine vision system.
This experiential hands-on approach will
ensure that you maximise your learning
experience on this workshop.

INTRODUCTION

CMOS and CCD sensors

CCPD arrays
Color vs monochrome applications
Charge transfer device and charge
injection device
3D sensing applications
Sensor positioning
Sensors for difficult environment
Speed vs resolution
Types of cameras
Camera viewpoint
Field of view
Resolution evaluation
Selection of a lens

idc@idc-online .com

Function of external interface

- Input and output
Object presentation
Physical tolerances
Handling special objects
- Flexible, articulated and semi-fluid
Actions after image processing
Interfacing through Programmable Logic
Interface
Interfacing machine vision with industrial
robots
Industrial challenges - heat, cold,
vibration and EMI/EMC issues

Constructing a machine vision

system
Selecting an application for machine
vision implementation

- Perceived value addition

- Cost justification
- Alteration in process line

Building a system with off-the-shelf

components
Integration requirements
Buying turn-key solutions
Obsolescence and expandability issues
Budgeting

Typical Applications

Application profiles
Component inspection
Pharma applications
Packaging applications
Road inspection using vehicle mounted
sensors
3D application examples

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Practical

Advanced Process Control

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for Engineers and Technicians

YOU WILL LEARN How To:

Understand the essentials of Advanced Process Control (APC)

Grasp the key differences between the various technologies
Perform simple APC design strategies and implementations
Be able to perform PID control

Troubleshoot simple APC problems

Identify processes suited to APC

WHO SHOULD ATTEND:

Instrumentation and control engineers

Process control engineers
Senior technicians

Automation engineers

System integrators

Electrical engineers

Chemical engineers

Chemical plant technologists

Process engineers

6.61

The Workshop

The Program

In today's environment, the processing,

refining and petrochemical business is
becoming more and more competitive and
every plant manager is looking for the best
quality products at minimum operating and
investment costs. The traditional PID loop is
used frequently for much of the process
control requirements of a typical plant.
However there are many drawbacks in using
these, including excessive dead time which
can make the PID loop very difficult (or indeed
impossible) to apply.

Advanced versus classical control

Advanced on-line control versus
statistical process control
Comparison of pay back time on various
examples of applications in real plants
Practical exercise 1: Model representation

FUNDAMENTALS OF PROCESS
CONTROL
Processes, controllers and tuning
PID controllers P, I and D modes off
operation
Load disturbances and offset
Speed, stability and robustness
Gain, dead time and time constants
Process noise
Feedback controllers
Practical exercise 2: PID loop tuning
parameters refresher

FUNDAMENTALS OF TUNING PID

LOOPS

MPC: MODEL IDENTIFICATION

Identification requires a good knowledge
of the unit
Black box models / grey box models
Causality graph of the unit
What to identify?
How? Step responses - pseudo random
binary signals
Exercises of identification on various
types of petrochemical units
Practical exercise 7: MPC controller
calculation programming and setup

MPC: OBSERVERS
Overall formulation
Purpose of observers in control algorithm
based on state / space representation
Innovation on measured output estimation of the state
Study of Kalman algorithm
Practical exercise 8: Gain scheduling

MPC: CONTROL

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Advanced Process Control (APC) is thus

essential today in the modern plant. Small
differences in process parameters can have
large effects on profitability; get it right and
profits continue to grow; get it wrong and
there are major losses. Many applications of
APC have pay back times well below one year.
APC does require a detailed knowledge of the
plant to design a working system and continual
follow up along the life of the plant to ensure it
is working optimally. Considerable attention
also needs to be given to the interface to the
operators to ensure that they can apply these
new technologies effectively as well.

JUSTIFICATION OF ADVANCED
CONTROL

Pre-requisites

Basic electrical concepts are necessary and it

is strongly advised that students attend the
IDC Practical Process Control class before
attending this advanced course.

Open and closed loop tuning

Ziegler Nichols
Fine tuning for different process types
Lambda tuning
Ten different rules compared
Cascade systems
Feedforward control
Deadtime
Models and disturbances.
Practical exercise 3: Loop tuning refresher
(both open-loop and closed-loop)

INTERNAL MODEL CONTROL (IMC)

Practical Sessions

This is a practical, hands-on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.
Have the training

Open loop model of the process in

parallel with the process
Control system in two blocks
Equivalence with a classical controller
Disturbances rejection and control
IMC and delays
IMC and feed forward (measured
disturbances rejection)
Practical exercise 4: IMC controller

MODEL PREDICTIVE CONTROL (MPC)

Single input / output versus multivariable

control
Example on a binary column causality
graph
Constraints and planning ahead before
acting
Different notions of models
Action model - measured disturbances
model
Unmeasured disturbance models
Reference trajectories
Example of a quality blender control
system
Practical exercise 5: MPC controller
representation

MPC: MODEL REPRESENTATIONS

State space representation
Transfer function representation
Impulse response representation
Various mathematical formulations
Practical exercise 6: MPC controller
interaction calculation

delivered when and

where you need it.

REFERENCE MODELS

Handling setpoints on controlled

variables
Measured disturbances rejection
Unmeasured disturbances rejection
Handling soft constraints on controlled
variables
Rejection of disturbances
Practical exercise 10: Ratio control

CONTROL FORMULATION PROBLEM

Quadratic criterion versus geometric

control
Importance of the horizon length
Use of the weight matrix
Handling output constraints along the
horizon
Projection of measured and unmeasured
disturbances along the horizon
Final quadratic problem formulation and
resolution
Off-line pre-processing
On-line calculations
Practical exercise 11: Decoupling circuits
(both feed forward as well as inverting)

MPC STEADY STATE OPTIMISATION

Degrees of freedom and rationale for

optimisation
Economic output submitted to setpoint
Slogans to maximise or minimise
Bridge from optimisation to control
Reachable targets for economic variables
Interpretation of the horizon for
economic variables
Change of the control formulation
problem
Practical exercise 12: Dead time
compensation (using formulae as well as a
Smith Predictor)

APPLICATION OF THE THEORY TO THE

CONTROL OF TWO DIFFERENT UNITS
ON A PROCESS SIMULATOR
Complete application (identification,
controller design, control and
optimisation)
Practical exercise 13: Cascade control,
using PV tracking and initialisation

Contact us for a
free proposal.

idc@idc-online .com

Overall formulation
Hard constraints on manipulated
variables
Set values and soft constraints on control
variables
The notion of horizon
Practical exercise 9: Feed forward

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Practical

industrial SAFETY, risk assessment

and SHUTDOWN SYSTEMS for industry

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The design, installation and application of reliable safety

instrumentation and shut-down systems, incorporating new
standards, current practices and practical solutions
What YOU WILL LEARN:

Practical know-how and real-world applications

Detailed, up-to-date, functional safety instrumentation practices

The knowledge to plan and participate in hazard and risk
assessment studies
The knowledge to implement and operate safety systems
Design and implementation skills for quality assurance in safety
systems
The knowledge to specify and critically evaluate safety systems
Techniques to help ensure high reliability and maintenance of
safety systems

WHO SHOULD ATTEND:

Design, installation and maintenance engineers and technicians

in the process industries
Engineering firms

Instrumentation and control engineers and technicians

Managers and sales professionals employed by end users

System consultants
System integrators

6.63

The Program
INTRODUCTION TO SAFETY
INSTRUMENTATION

SAFETY REQUIREMENTS
SPECIFICATION (SLC phase 4)

How to define functional requirements

for the safety instrumented system
- Input requirements from the Hazop
- Safety functional requirements
- Safety integrity requirements
Deciding the required Safety Integrity
Levels (SILs): revision of quantitative
method, introduction to qualitative
methods, risk graphs and severity matrix
for processes, risk graph methods for
machinery safety categories
Practical exercise: exercise in SIL
determination
Practical exercise: exercise in defining
safety requirements

Course outline and objectives

Introduction to hazards and risks
Overview of safety systems engineering
Introduction to standards: IEC 61508, IEC
61511 and ISA S84
Some implications of IEC 61508 for
control systems
The safety lifecycle model and its phases
(SLC phases)
Management of functional safety

HAZARD AND RISK ANALYSIS (IEC

phases 1 and 2)

TECHNOLOGY CHOICES AND THE

CONCEPTUAL DESIGN STAGE
Finding the right equipment for the job
(IEC phase 9)
The safety instrumented system model
and its components: sensors, logic
solver, final elements, interfaces, power
supplies
Types of equipment and choices for the
logic solver: simple interlocks,
E/E/
PES terminology, relay based systems,
hard wired electronic systems, PES/PLC
based systems, redundant PES
configurations: 1oo2D, 2oo3, 2oo4D,
developments in networking of SIS
components

Software components of a PES

Safety critical systems: concerns about
software
Software safety lifecycle as per IEC 61508
part 3
Safety lifecycle for application software
as per IEC 61511
Application software activity steps
Application tools and documentation
packages
Certification of software

OVERALL PLANNING (IEC phases 6,

7, and 8)
The IEC requirements and the benefits
arising
Operation and maintenance
Safety validation
Installation and commissioning

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Identification of hazards, typical sources

and examples
Principles of risk reduction and layers of
protection
Process control versus safety control
Simple and complex shut-down
sequences, examples
Risk classification and risk reduction
terms: hazard demand rate, consequences
of an incident, risk reduction factor,
probability of failure on demand
The concept of Safety Integrity Level (SIL)
Quantitative method for determining SIL
requirements
Practical exercise: determination of SILs
for process examples

ENGINEERING THE SAFETY SYSTEM:

APPLICATION SOFTWARE (IEC phase
9 software safety lifecycle)

HAZARD STUDIES (SLC phase 3)

Hazard and operability study (Hazop)

methods
- Hazard study levels 1, 2 and 3
Hazops for control systems
Practical exercise: trial hazard study and
extraction of results for safety functions
Translating hazard study outputs into
safety functions. (SLC phases 4 and 5):
process and operational safety measures,
the role of alarms functions in safety,
safety instrumented functions
Fault tree analysis techniques
Practical exercise: using fault trees to
predict hazard rates and risk reductions,
modelling of the SIS function

ENGINEERING THE SAFETY SYSTEM:

HARDWARE (IEC phase 9 E/E/PES
safety lifecycle)

Project engineering responsibilities

Realisation phase of IEC 61508
Project activities and key design
requirements
Practical design features for safety
systems including: energised versus
de-energised trip systems, steps to
minimise common cause faults, power
sources, diagnostics and testing facilities,
overrides and bypasses
A review of the ISA S84.01 standard
requirements for SIS design
Information flow and documents for the
engineering stage

INSTALLATION AND COMMISSIONING

(IEC phase 12)
Factory Acceptance Tests (FAT): benefits
of FATs, using simulators for testing,
essential documents
Site installation practices: segregation
principles, physical checkout forms,
device functional checkouts
Training functions
Pre-commissioning acceptance tests
Handover to operations

VALIDATION, OPERATIONS AND

MANAGEMENT OF CHANGE (IEC
phases 13, 14 and 15)

Validation: documented evidence that the

overall safety requirements have been
met
Operations: standard operating procedures, IEC 61508 maintenance activities
model, functional testing and safety
audits, practical online test methods,
on-line testing of ESD valves, test
procedure documentation and records
Managing changes: the need to manage
changes, IEC Management Of Change
(MOC) procedures

JUSTIFICATION FOR A SAFETY

INSTRUMENTED SYSTEM

Review of failure modes and their impact

on plant safety
The impact of nuisance trips
How to calculate life cycle costs

SUMMARY, OPEN FORUM

AND CLOSING

The Workshop

Many of todays computer controlled industrial processes involve large amounts of energy and
have the potential for devastating accidents. Reliable, well-engineered safety systems are
essential for protection against destruction and loss of life.

The safety instrumentation and shut-down systems workshop is an intensive, practical and
valuable two-day course. We offer you the most vital, up-to-date information and practical
know-how to enable you to participate in hazard studies and specify, design, install and
operate the safety and emergency shut-down systems in your plant using international
safety practices.
This workshop will provide you with a broad understanding of the latest safety instrumentation
practices and their applications to functional safety in manufacturing and process industries.
This workshop is not to be missed and could save your business a fortune in possible
downtime and financial loss.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Pre-requisites
Fundamental knowledge of electrical engineering is required.

idc@idc-online .com

Practical Sessions

www.idc-online .com

Introduction to the Selection, Installation,

Commissioning and Maintenance of

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Flow and Fiscal Metering

equipment

What YOU WILL LEARN:

Fundamentals and concepts of fiscal metering

Custody transfer metering in practice and commercial

implications
Operating procedures
Field instruments

Properties of fluids

Different types of flow meters

How to select, install, maintain and operate fiscal meters

correctly
How to troubleshoot, repair fiscal metering devices

Practical knowledge about fiscal metering in practice

WHO SHOULD ATTEND:

Automation engineers

Chemical engineers

Consulting engineers
Control engineers
Design engineers
Electrical engineers
Instrument fitters

Maintenance engineers
Mechanical engineers
Operations and production engineers
Process control technicians
Project engineers and managers
6.65

The Workshop

The Program

The workshop on fiscal metering is for

engineers and technicians who require a
practical knowledge of selection, installation
and commissioning of fiscal metering.
A clear understanding of fundamentals and
concepts of fiscal metering and its
commercial implications is an important
factor in an efficient implementation of fiscal
metering system. You can only achieve
excellent and reliable fiscal metering when
your field instrumentation provides the
correct information.

FLOW METERS

Introduction
Concepts and practice of custody transfer
metering
Fundamentals of fiscal metering
Commercial implications of fiscal
metering

FIELD INSTRUMENTS
Theory of functionality of field
instruments
Processing of data received from field
instruments
Calculation methods used for fiscal
quantities
Metering algorithms
Processing of fiscal data
Calibration
Application of standards and
re-certification of systems and
instruments

Positive displacement meters

Inferential meters
Oscillatory flow meters
Differential pressure meters
Variable area meters
Electromagnetic flowmeters
Ultrasonic flowmeters
Mass flow measurement
Open channel flow measurement

INSTALLATION MAINTENANCE AND

REPAIRS

Installation
Commissioning
Maintenance
Fault diagnostics and troubleshooting

DOCUMENTATION
Documentation procedure
Documentation control

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It is for those primarily involved in achieving

effective results for the industrial processes
they are responsible for. This would involve
the design, specification and implementation
of control and measurement equipment. The
workshop focuses on practical applications,
with special attention to installation
considerations and application limitations
when selecting or installing different
measurement or control instruments for
fiscal metering.

INTRODUCTION TO FISCAL METERING

Training Methodology

The latest educational methods and

strategies will be employed. The workshop
is designed to maximise delegate benefit
from the outset. Questions are encouraged
throughout. This provides opportunities for
participants to discuss with the presenter
and others, specific problems and
appropriate solutions. All delegates take
away a detailed and comprehensive copy of
the material presented, therefore minimal
note taking is encouraged to ensure
maximum delegate participation and
attention. Practical hands-on training
ensures knowledge retention.

OPERATING PROCEDURES

Fiscal metering in practice

Startup
Shutdown
Operating conditions
Fault conditions and mismeasurements
Limitations

BASIC PROPERTIES OF FLUIDS

Basic fluid properties

Non-newtonian fluids
Velocity profiles
Reynolds number
Flow measurement
Mass flow rate
Multi-phase flows

Pre-requisites

No specialist knowledge or skills are

required only a technical background so
that there is an understanding for such
factors as the difference between pressure
and force. In fact this workshop is a good
introduction to someone who has had no
dealings with relief valves in the past as well
as an important refresher course for control
valve specialists who benefit from the back
to-basics approach.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop, please
bring your laptop/notebook computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Measurement and Control

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for Non-Instrument Personnel

What you will gain:

A fundamental understanding of industrial automation

An introduction to instrumentation and measurement

The key know-how to converse regarding your plants key

functions
An ability to configure/understand simple PLC and SCADA
systems
An ability to work with and comprehend plant documentation
such as P&IDs

WHO SHOULD ATTEND:

Anybody with an interest in gaining know-how in the full range of

fundamentals of instrumentation, measurement, process control,
PLCs, SCADA and P&ID documentation. This can range from the
plant secretary, to operators, trades personnel (artisans),
procurement staff, technicians, engineers from other backgrounds/
disciplines, such as mechanical, electrical and civil. Managers who
are keen to understand the key workings and the future of their
plants.

6.67

The Workshop

The Program

Have you ever wondered about getting a

thorough introduction to the fundamentals
of instrumentation, automation and control;
thus allowing you to do work and perform
simple tasks in the area? The current
challenges presented by the world economy
mean that automation is more critical than
ever before.

SCADA AND PLCs

Introduction to process measurement

Pressure measurement
Level measurement
Temperature measurement
Flow measurement
Process considerations
Integration of the system

PROCESS CONTROL

Fundamentals of loop tuning

Fundamentals of tuning
The different tuning rules
Tuning of valves
Automated tuning
Simple tuning of more complex systems
Good practice

CONTROL VALVES

Introduction to control valve theory

Different types of control valves
Characteristics
High pressure drop applications
Use of computer program for valve sizing
Examples of high pressure drop
applications
Actuators
Positionser
Pneumatic circuits
Materials
Quality standards
Installation/maintenance

Background to SCADA
SCADA systems hardware
SCADA systems software
Human Machine Interfaces (HMIs)
Introduction to PLCs
Fundamentals of PLC hardware
Fundamentals of PLC software
Using Ladderlogic for simple digital
functions
Good installation practice
Landline media
Wide Area Network (WAN) technologies
Local Area Networks (LANs)
Industrial communications protocols
SCADA network security
Troubleshooting and maintenance
Project management of SCADA systems

THE ROLE OF PLANT

DOCUMENTATION, STANDARDS AND
SPECIFICATIONS

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This workshop represents a tremendous

opportunity to grab expertise in all the key
areas of the fast growing area of industrial
automation. Presented by an expert in the
area but who is obsessed with getting the
key chunks of know-how and expertise
across to you in simple understandable bits
which you can immediately apply to your
job. This is most definitely not a boring
lecture style presentation but an intensive
learning experience where you will walk
away with real skills as a result of the handson practical exercises, calculations, case
studies and group sessions to ensure across
the board take up and understanding of the
theoretical concepts and ideas discussed.
Delegates are provided with these practical
sessions at approximately 20 to 30 minute
intervals to maximise the absorption rate.

INSTRUMENTATION

The topics covered commence with a solid

introduction to instrumentation and
measurement ranging from pressure, level,
temperature and flow devices. There is a
formal review of process control including
the all important topic of PID loop tuning
and good practice in setting up your own
system. There is also focus on valves with a
review of the different valves and operating
characteristics. SCADA and PLC systems are
covered with an examination of both
hardware and software, supplemented by
writing your own PLC program. The all
important topic of industrial data
communication networks are also examined.
Finally, the course is rounded off with a
hands-on review of reading and interpreting
simple plant documentation such as P&IDs
so that you can see and understand the
operation of the plant in your mind through
the documentation.

The workshop is all presented in easy to

understand practical English. All you need to
benefit from this workshop is a basic
understanding of mathematics and electrical
theory. Contact us for comprehensive precourse reading and preparation if you are
unsure about your level of understanding.
It is not an in-depth workshop but one
covering a wide range of topics in industrial
automation to give you an overview and
practical understanding of the key concepts.
Nevertheless, a lot of material is covered,
with the intent to give you an overview and
practical understanding of the concepts and
equipment, and how they all come together
to create an efficient and safe control
environment in instrumentation, process
control, SCADA, PLCs and control valves.

Drawing types and standards

Piping and Instrument Diagrams (P&ID)
Instrumentation
Electrical
Pneumatics and hydraulics
Ladderlogic
Electro pneumatic circuits
Explanation of acronyms

SUMMARY, OPEN FORUM

AND CLOSING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. Practical sessions include:
Develop basic hydraulic, electrical and
pneumatic drawings
Develop P&ID drawings for pressure,
temperature, flow and level loops
Detail the documentation for typical
instruments
Proceed through development of a full
plant set of drawings from flow diagrams
and process description to P&ID,
electrical, hydraulic and pneumatic
symbols
Use software to undertake these typical
tasks

To gain full value from this workshop, please

bring your laptop/notebook computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

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Programmable Logic
Controllers (PLCs)
and SCADA Systems

what YOU WILL LEARN:

Fundamentals of SCADA systems

Essentials of SCADA software configuration

Tricks and tips in installation of SCADA systems

Essentials of data communications

Use of Industrial Ethernet in SCADA systems

OPC and SCADA systems

SCADA network security issues

How to troubleshoot SCADA systems

Specifying PLC hardware and installation criteria

Describe PLC software structure

How to write medium level PLC programs (using ladder logic)

Troubleshooting a typical PLC system
Specifying PLC systems

WHO SHOULD ATTEND:

Instrumentation and Control Engineers

Electrical Engineers
Design Engineers
Consulting Engineers
Instrumentation Technicians
Process Control Engineers
Engineering Managers

6.69

The Workshop

The Program
INTRODUCTION

GOOD PROGRAMMING HABITS

Introduction and brief history of PLCs

Alternative control systems - where do
PLCs fit in?
Why PLCs have become so widely
accepted
Lingering concerns about PLCs

Keeping track of addresses and data used

Looking ahead - how will programs be
maintained?
Practical methods to improve quality,
organisation of code, documentation and
simplifying changes

FUNDAMENTALS OF PLC HARDWARE

GOOD INSTALLATION PRACTICE

Block diagram of a typical PLC

PLC processor module - memory
organisation
Input and output section - module types
Power supplies

BACKGROUND TO SCADA
Fundamentals and definition of terms
Comparison of SCADA, DCS, PLC and
smart instruments
Typical SCADA installations

SCADA SYSTEM HARDWARE

Comparison of SCADA, DCS, PLC and
smart instruments
Remote Terminal Unit (RTU) structure
Analog and digital input/output modules
Application programs
PLCs used as RTUs
Master site structure
Communications architectures
Point-to-point and point-to-multipoint
systems
System reliability and availability
Configuration of a master station

Location of hardware
Good wiring practice
Cable spacing, power distribution and
wire numbering
Reducing noise and interference
Screening and shielding

ADVANCED CONTROL WITH PLCs

The concept of reusable logic

Examples: drive logic and alarm handling
Use of advanced programming functions
Matrix logic
Table functions and indirect addressing
Example: simple display driver

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SCADA has traditionally meant a window into

the process of a plant and / or a method of
gathering of data from devices in the field.
Today, the focus is on integrating this process
data into the actual business, and using it in
real time. In addition to this, today's emphasis
is on using Open Standards, such as
communication protocols (eg. IEC 60870,
DNP3 and TCP/IP) and 'off-the-shelf' hardware
and software, as well as focusing on keeping
the costs down. PLCs continue to gain in
popularity. This comprehensive workshop
covers the essentials of SCADA and PLC
systems, which are often used in close
association with each other. A selection of
case studies are used to illustrate the key
concepts with examples of real world working
SCADA and PLC systems in the water,
electrical and processing industries. This
workshop will be an excellent opportunity to
network with your peers, as well as to gain
significant new information and techniques
for your next SCADA / PLC project.

Although the emphasis of the workshop will

be on practical industry topics highlighting
recent developments, using case studies, the
latest application of SCADA, PLC technologies
and fundamentals will be covered. The
workshop is aimed at those who want to be
updated on the latest developments in SCADA
and PLC systems and want to get a solid
appreciation of the fundamentals of their
design, installation and troubleshooting. You
will benefit by gaining practical up-to-date
information on the application of PLC and
SCADA systems to the automation and
process control industries. It is suitable for
people who have little or no exposure to
PLCs, but expect to become involved in some
or all aspects of PLC and SCADA installation.

FUNDAMENTALS OF PLC SOFTWARE

Methods of representing logic - boolean,

algebra, instruction code and graphical
presentation
Fundamental ladder logic instruction set
Comparison of different manufacturers,
memory and data representation and
instruction code

USING LADDER LOGIC FOR

SIMPLE DIGITAL FUNCTIONS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

To gain full value from this workshop, please

bring your laptop/notebook computer.

The basic rules

Comparison of relay ladder diagrams
The concept of the 'scan' and how to
apply it
Infinite fan-out
Contact 'normal' states
Positive and negative logic
Basic Boolean functions
The usefulness of DeMorgan's Law

USING REGISTERS (WORDS)

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.

Number systems, timers , types of register

data, counters, bit shift and rotate, table
functions and register (matrix) logic
functions

SCADA SYSTEMS SOFTWARE

Components of a SCADA system

Software - design of SCADA packages
Configuration of SCADA systems
Building the user interface
Connecting to PLCs and other hardware
SCADA system design
The twelve golden rules

Have the training

delivered when and
where you need it.

PID CONTROL

The importance of timing and scan time

When PID is not always appropriate:
- Intermittent measurements
- Long transport delays

SAFETY PROGRAMMABLE SYSTEMS

Why regular PLCs should not be used for
safety functions
Programmable electronic logic solvers
Safety certification
Certified programming systems
Application examples
Growth of networked safety devices and
certified networks
Integrated safety systems

DATA COMMUNICATIONS AND

NETWORKING

Background to cables
Noise and interference on cables
Twisted pair cables and fibre optic cables
Public network provided services

INDUSTRIAL COMMUNICATIONS
PROTOCOLS
RS-232 interface standard
RS-485 interface standard
Fieldbus; Modbus; DNP3.0

INTRODUCTION TO IEC 61131-3

Concepts
Common elements
Programming languages: structured text
Function block diagrams

SCADA NETWORK SECURITY

Introduction
Authentication and encryption
SCADA firewalls
Firewall architectures and guidelines

LOCAL AREA NETWORKS (LANs)

Ethernet networks: industrial Ethernet

TCP/IP
LAN connectivity: bridges, routers and
switches
Redundancy options
Web based Industrial SCADA
Wireless: OPC

Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

Practical

dRIVES, mOTORS AND plcs

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for engineers and technicians

YOU WILL LEARN HOW TO:

Demonstrate a sound understanding of how motors work,

specifically the induction motors
Demonstrate a sound understanding of how AC Variable Speed
Drives (VSD's) work
Install VSDs properly
Select the right VSD for a given application
Troubleshoot VSDs competently
Competently explain how flux-vector control works for drive
applications
Identify the protection and control system requirements for
VSD's
Understand architecture of PLC and its associated components
and systems
Interface VSDs with PLCs
Understand the causes of motor burnout
Deal effectively with VSD harmonics and EMC/EMI problems

WHO SHOULD ATTEND:

This workshop is designed for personnel who want to understand

the utilise variable speed drives and PLCs for energy efficient
application comprising of motor driven systems. The workshop will
also benefit those working in system design as well as site
commissioning, maintenance and troubleshooting.Typical personnel
who would benefit are:
Electrical maintenance
technicians and supervisors
Instrument and control
engineers
Instrument technicians
Maintenance personnel

Mechanical engineers
Plant engineers
Process control engineers
Operations personnel
Service technicians
6.71

The Workshop

The Program

This workshop gives you a fundamental

understanding of all the three components of
a complete drive system, the VSD, motor and
the PLC. There is a good coverage as well on
installation and commissioning, operation
and maintenance and troubleshooting of
these devices.
Besides, the criteria behind selection of
components of a drive system for optimum
operation are also covered in details. Typical
practical applications of VSDs in process
control and materials handling, such as those
for pumping, ventilation, conveyers,
compressors and hoists are covered as
examples.

Electromagnetic Compatibility

Variable Speed Drives (VSD) their

utilities in industry
Commonly used parameters associated
with drives
VSD for speed control and energy saving
Basics of electrical machines
AC power system
PLC basics
PLC and process interaction

The electromagnetic interference

Sources of electromagnetic interference
Harmonics on the supply side of AC
converter
Power factor and displacement factor
Voltages and current on the motor side of
the PWM

Mechanical, Hydraulic and

Electrical type of VSDs

Types of variable speed drives

Mechanical variable speed drives
Hydraulic variable speed drives
Electrical variable speed drives

3-Phase AC Motors; Theory,

Construction and Maintenance

Fundamentals of 3-phase AC motors

Operating principles; 3-phase AC motors
3-phase wound rotor motors
3-phase synchronous motors
3-phase induction motors
Induction motor equivalent circuit
Selection of motor

Selection of AC Converters
Important parameters considered for
selection
The basic selection procedure
The loadability factor
The characteristics of machine load
The requirements for starting and
stopping motor of VSD
Selecting motor and converter of correct
specification
Summary of selection
Retrofitting electronic VSD

Installation and Commissioning

of VSD Components

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On completion of the workshop the

participants would get significant insight and
understanding on the working of these
essential components of the drive mechanism.
They would be able to better utilise the
existing system or introduce the new and
more efficient ones working on the discussed
technologies at their work places. The
accompanying manual includes simple but
appropriate and highly effective technical
content along with suitable examples on wide
areas of topics relevant to variable speed
drives, motors and Programmable Logic
Controllers.

The Basic Concepts

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Power Electronic Converters

Terminology and definitions; power

electronics
Components of power electronic
converters
Power diodes
Power thyristors
Commutation in electronic device
switching
Power electronic rectifiers (AC/DC
converters)
Gate commutated inverters (DC/AC
converters)
Gate controlled power electronic devices

Electrical Protection of VSD

Components

AC converter protection circuit

Operator information and fault
diagnostics
Protection of electric motors
Temperature; the critical parameter to
monitor
Current sensor for thermal overload
protection
Thermal overload protection direct
temperature sensing

VSD Control Systems

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

The overall control system

Control system power supply
The DC bus charging control system
The PWM rectifier for AC converter
VSD control loops
Vector control of AC drives
Closed-loop field oriented vector drives
Speed feedback from motor

Installation and environment

requirements
Power supply connections and earthing
requirements
Installing controls of AC drives
Control wiring of VSDs
Commissioning of VSDs

PLC Architecture

The processor unit

The PLC power supply
The PLC programming device
The memory system
Digital input output interaction
Analog I/O interaction
Digital input output modules
Connecting analog input output systems
to PLC

Basics of PLC Programming

Introduction to PLC programming

PLC programming steps
PLC programming languages
Commonly used logical instructions in
PLC programming
Timers and counters
Program flow control instructions
Data load/transfer instructions
Arithmetical (math) instructions
Working example of PLC programming;
drive application

summary, open forum and

closing

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical Troubleshooting
and Problem Solving of

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PLCs and SCADA systems

You will learn how to:

Quickly interpret, isolate and fix common hardware problems

related to PLC input/outputs
Troubleshoot PLC software (especially ladderlogic)
Identify typical SCADA problems and fix them

Safely make changes to a system without overriding machine

safety or personnel safety programming
Make temporary fixes to a program to test out new components
or ideas

Identify and fix electrical noise, earthing and power problems

Identify and fix PLC/SCADA data communications problems
Network with your peers on their automation troubleshooting

WHO SHOULD ATTEND:

Operators

Electricians

Design engineers
Project engineers

Instrumentation technicians
Trades staff working with PLCs
Electrical, control and instrumentation engineers
IT technicians and IT staff
Plant engineers
And those who want to achieve a good proficiency in
troubleshooting their PLC and SCADA systems.

6.73

On-Site Training

The Workshop
The objective of this workshop is to help you troubleshoot, and identify, prevent and fix
common PLC and SCADA problems. The emphasis is on practical hard hitting information
that goes beyond typical theory, focusing unerringly on providing you with the necessary
skills to solve your problems whether it is a PLC, SCADA system, or indeed communications
system linking the two together. The automation system on your plant underpins your entire
operation. It is thus critical that you have the knowledge and tools to quickly identify and fix
problems as they occur to ensure you have a safe, secure and productive system. No
compromise is obviously possible here. This workshop distils all the tips and tricks learnt
over many years.
The first step in PLC troubleshooting is to decide if the problem is internal to the processor or
in the I/O system. Experience shows that more than 80% of all PLC malfunctions come back to
problems with I/O modules or field equipment (or indeed wiring). Problems that can be traced
back to an I/O module (and specific input) or usually external field components; whilst internal
PLC problems often result in large scale failure or erratic behaviour on the part of the PLC.

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.

The content of the workshop brings everyone up to date by briefly reviewing PLC and
SCADA systems and then examining in a logical step-by-step fashion with hands-on
exercises (both PLCs and simulation software to get to the problems quickly) PLCs and
SCADA systems. The key industrial communications problems are briefly covered.

Contact us for a
free proposal.

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The Program

Introduction to PLCs and SCADA

Systems
PLC block diagram of components
PLC processor module and memory
organisation
PLC input/output modules
SCADA hardware
Power supplies
Good installation practice
Practical Session

Fundamentals of PLC Software

Methods of representing logic

Boolean algebra
Instruction code
Graphical representation: functional logic
diagrams and ladderlogic
Ladderlogic instruction set (coils and
contacts/timers/counters)
Advanced instructions (program flow/
arithmetic/data transfer and PID)
Start-up/shutdown and fault routines
Good programming habits
Comparison of different manufacturers
Practical Session

SCADA Software

Communication architectures
HMI interface
SCADA software blocks
SCADA alarm management
Practical Session

PLC Troubleshooting Road Map

Review of the key PLC troubleshooting
issues
Practical Session

PLCs Power and Earth

Visual inspection
Measuring voltages
Power supply test
AC ripple on DC power supplies
Batteries testing
EMI/RFI impacts
Earthing and screening/shielding
Practical Session

Troubleshooting PLC Inputs/

Outputs

Internal memory status against the field

activity
Digital input status
Output modules and power supply
Fuses
Forcing outputs ON and OFF
Leaky inputs and outputs
Isolation problems
You have located the problem - what to
do now?
Tracking down intermittent problems
Practical Session

Troubleshooting PLC Analog

Input/Outputs
Isolated and non-isolated inputs
Ranges of analog inputs
Forcing analog output ranges
Filtering and isolation issues
Practical Session

Industrial Data
Communications System

Roadmap of different standards

RS-232/RS-485
Profibus and DeviceNet
Industrial Ethernet
TCP/IP
Modbus
Practical Session

Miscellaneous Hardware Issues

Basics of Troubleshooting and

Diagnosing Equipment
Common symptoms, problems and
solutions
How to quickly identify likely causes
Overall basic steps
Communications issues
Earthing, shielding and noise
Practical Session

Processor problems
What to do if you don't have the right
replacement
Are you sure you have the right
problem?!
Confirmation that the system is indeed
operating correctly
Other troubleshooting tips and tricks
Practical Session

idc@idc-online .com

PLC Software issues

How to return the program to its original

state
Modifying an existing program
Modifying a program to trap problems
Practical Session

SCADA Troubleshooting Road

Map
Review of the key SCADA
troubleshooting issues
SCADA system troubleshooting
PLC/SCADA interfacing problems
Practical Session

Human Machine Interface (HMI)

Configuration of database points
Troubleshooting I/O database

SCADA Alarm Configuration

Issues
Configuration of alarms

SCADA to PLC Interface Issues

Drivers, protocols, throughput issues

Key Industrial Data

Communications Problems
and Troubleshooting

Cabling and hardware (switches/routers/

converters)
Fibre optics
Noise and interference
RS-485 issues
Industrial Ethernet
TCP/IP
Modbus
Practical Session

Installation and Commissioning

Control room
MCC requirements
Installation of equipment
Loop testing
Practical Session

Toolkit summary of key

problems to look for
23 common problems with PLCs and
SCADA systems
What to do and how to fix them

SUMMARY, OPEN FORUM

AND CLOSING

www.idc-online .com

Practical

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FLOW ESSENTIALS

You will learn how to:

Design and configure simple flow-based control systems

Tune Flow Control loops
Confidently work with different flow instrumentation systems
Specify flow meters
Troubleshoot and install flow instrumentation
Size and select different control valves
Deal with cavitation and flashing
Troubleshoot control valves
Work with basic fiscal metering concepts

WHO SHOULD ATTEND:

Automation engineers
Building service designers
Chemical and mechanical
engineers
Consulting engineers
Control technicians
Control valve specialists
Data systems planners and
managers
DCS personnel
Design engineers
Electrical engineers
Electrical technicians
Electricians
Energy management
consultants

Instrumentation and control

engineers
Instrumentation technicians
Maintenance engineers,
technicians and planners
Measurement technician
Operations and production
engineers
Plant safety specialists
Power system protection
engineers
Process engineers and
managers
Process operators
Project engineers
Systems engineers

6.75

The Workshop

The Program

This workshop is focussed 100% on flow

from process control, tuning, flow
instrumentation, control valves to fiscal
metering. An introduction is given to the
complete flow control system and methods
of tuning flow loops followed by an
examination of the different flow instruments
with an emphasis on typical real-world
applications. Close attention is given to
special installation considerations and
application limitations when selecting and
installing different flow instruments.

Typical manual control

Feedback and feed-forward control
Block diagrams

BASIC PRINCIPLES OF CONTROL

SYSTEMS

On/off control
Modulation control
Principle of closed loop control
PID control modes

TUNING OF CLOSED LOOP CONTROL

Tuning constants calculation according to
Ziegler and Nichols
Open loop tuning procedure
Closed loop tuning procedure
Damped oscillation tuning method
Fine tuning of practical control loops
Tuning considerations for controllers
with saturation and non-saturation
output limits

INTRODUCTION TO CONTROL VALVE

THEORY

Introduction and definitions

Energy types
What happens inside a control valve
Cavitations and flashing
Choked flow
Valve co-efficient CV

DIFFERENT TYPES OF CONTROL

VALVES

Globe valves
Butterfly
Eccentric disk
Ball
Rotary plug
Diaphragm and pinch

CHARACTERISTICS

Equal percent
Linear
Quick opening
Selection method

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It is claimed that the majority of control

valves installed have not been correctly
sized and that large numbers also operate in
manual mode. We thus focus on the correct
method of sizing and selecting a flow control
valve. The course is rounded off by an
examination of fiscal metering with a simple
introduction to what can be a complex but
critical subject involving revenues of millions
of dollars.

BASIC CONTROL CONCEPTS

Mathematical theory has been kept to a

minimum and the focus is on practical
design,
installation,
commissioning,
troubleshooting and maintenance issues all
focussed entirely on flow issues.

CASCADE CONTROL

Equation types for cascade control

Initialisation and PV tracking
Use of multiple outputs in cascade
control
Tuning procedure for cascade control

PRINCIPLES OF FLOW
MEASUREMENT

Basic fluid properties

Velocity profiles
Multi-phase flows

POSITIVE DISPLACEMENT METERS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Sliding vane
Oval gear meters
Lobed impeller
Oscillating piston

Cavitations control and elimination

Low noise
Diffuser plates
Chokes
Disk stack technology
Pressure balanced trim

VALVE SIZING EXAMPLES OF HIGH

PRESSURE DROP APPLICATIONS
USING COMPUTER PROGRAMS

Water pump bypass

Steam turbine bypass
Gas pressure reducing
Oil choke valve

INSTALLATION AND MAINTENANCE

INFERENTIAL METERS

HIGH PRESSURE DROP APPLICATIONS

Turbine meter
Woltman meter
Propeller type
Impeller meters

Installation, commissioning and routine

maintenance
Fault finding
Modes of failure

DIFFERENTIAL PRESSURE METERS

On-Site Training

Venturi tube meter

Venturi and flow nozzles
Orifice plate
The Dall tube
Pitot tube
Elbow

VARIABLE AREA METERS

Operating principle

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

ELECTROMAGNETIC FLOW METERS

Construction

ULTRASONIC FLOW METERS

Doppler method
Transit time meter

MASS FLOW MEASUREMENT

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

The Coriolis force

Multiple phase flow
Density measurement
Thermal mass meters

OPEN CHANNEL FLOW

MEASUREMENT
The Weir
The flume
Level measurement

idc@idc-online .com

www.idc-online .com

Fundamentals of

Instrumentation, Process Control,

PLCs and SCADA

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for Plant Operators and other

Non-Instrument Personnel

what You will learn:

The fundamentals of instrumentation and process control

The basics of PLCs and SCADA systems

An ability to troubleshoot simple problems with instruments,

PLCs and SCADA systems
An ability to understand simple plant documentation such as
P&IDs
How to work effectively with your instrumentation plant
colleagues

WHO SHOULD ATTEND:

Anybody with an interest in gaining know-how in the full range

of instrumentation, process control, PLCs, SCADA and P&ID
documentation.
This can range from operators, trades personnel, procurement
staff, sales staff, technicians and engineers from other
backgrounds/disciplines, such as mechanical, electrical and civil.
Even the plant secretary who is keen to have a good
understanding of the key concepts would benefit.
Managers who are keen to understand the key workings and the
future of their plants would also benefit from this workshop.

6.77

The Workshop

The Program

The topics covered commence on day one

with an introduction to instrumentation and
measurement ranging from pressure, level,
temperature and flow devices followed by a
review of process control including the all
important topic of PID loop tuning. Day two
is occupied with PLC and SCADA systems
where the important topic of industrial data
communication networks are also examined
again from a very simple understandable
point of view. Finally, the workshop is
rounded off with a hands-on review of
reading and interpreting simple plant
documentation such as P&IDs so that you
can see and understand the operation of the
plant through the documentation. You will
leave this workshop with a strong
understanding
of
the
key concepts in instrumentation, process
control, SCADA and PLCs.

Overview of instrumentation and control

Key building blocks of PLCs and SCADA
systems
Outline of the workshop

INTRODUCTION TO PROCESS
MEASUREMENT
Basic measurement concepts
Definition of terminology
Measuring instruments and control valves
as part of the overall control system
Practical Session

PRESSURE MEASUREMENT
Principle of pressure measurement
Pressure transducers and elements
Practical Session

LEVEL MEASUREMENT
Principles of level measurement
Simple sight glasses
Hydrostatic pressure
Ultrasonic measurement
Electrical measurement
Density measurement
Practical Session

FUNDAMENTALS OF PLCS
Introduction to PLCs
Alternative control systems where do
PLCs
fit in?
Why PLCs have become so widely
accepted
Practical Session

FUNDAMENTALS OF PLC HARDWARE

Block diagram of typical PLC
PLC processor module memory
organisation
Input / output section module types
Power supplies
Practical Session

FUNDAMENTALS OF PLC SOFTWARE

Methods of representing Logic
Ladder Logic basics
The basic rules for programming
Simple PLC programs
Practical Session

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Pre-requisites

INTRODUCTION

The workshop is presented in easy to

understand practical language. All you need
to benefit from this workshop is a very basic
understanding of mathematics and some
electrical
theory.
Contact
us
for
comprehensive pre-course reading and
preparation if you are unsure about your
level of understanding.

TEMPERATURE MEASUREMENT

Principles of temperature measurement

Thermocouples
Resistance Temperature Detectors (RTDs)
Thermistors
Practical Session

FLOW MEASUREMENT

Principles of flow measurement

Open channel flow measurement
Oscillatory flow measurement
Magnetic flow measurement
Positive displacement
Ultrasonic flow measurement
Mass flow measurement
Practical Session

FUNDAMENTALS OF PROCESS LOOP

TUNING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
Practical sessions include:
Twelve hands-on practical
instrumentation, PLC and SCADA labs
with real equipment to demonstrate the
basics
Twelve simple instrumentation design
exercises using software and calculators
Two case studies undertaken in groups
of your colleagues in assessing real
situations with instrumentation and
industrial automation

In addition to working with real instruments,

we will also make extensive use of video
clips, visual effects and simulation software
to help you in the understanding of the key
concepts.

Processes, controllers and tuning

PID controllers
Gain, dead time and time constants
Process noise
General purpose closed loop tuning
method
Practical Session

INTRODUCTION TO CONTROL VALVES

Introduction
Definition of a control valve
Cavitation
Flashing
Practical Session

DIFFERENT TYPES OF CONTROL

VALVES

INTRODUCTION TO SCADA SYSTEMS

Fundamentals
Comparison of SCADA, DCS, PLC and
smart instruments
Typical SCADA installations
Definition of terms
Practical Session

SCADA SYSTEMS HARDWARE

Fundamentals
Comparison of SCADA, DCS, PLC and
smart instruments
Typical SCADA installations
Definition of terms
Practical Session

SCADA SYSTEMS SOFTWARE

Fundamentals
Components of a SCADA system
Software design of SCADA packages
Configuration of SCADA systems
Building the user interface
Practical Session

BASICS OF DATA COMMUNICATIONS

BETWEEN PLC AND SCADA SYSTEMS

Twisted pair cables

Fibre optic cables
Public network provided services
Industrial Ethernet
TCP/IP
Fieldbus
Modbus
LAN connectivity: bridges, routers and
switches
SCADA network security
Practical Session

DRAWING TYPES AND STANDARDS

Understanding diagram layouts and

Globe valves, butterfly, eccentric disk, ball,
formats
rotary plug, diaphragm and pinch
Cross references
Practical Session
P&IDs fundamentals
Practical Session

CONCLUSION

To gain full value from this workshop,

please bring your laptop/notebook
computer.

idc@idc-online .com

Summing up and revision of key concepts

The future

www.idc-online .com

FUNDAMENTALS OF

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PRACTICAL BUILDING
AUTOMATION SYSTEMS (BAS)

what You will learn:

How Building Automation Services (BAS) operate and are

controlled, monitored and maintained
Type of systems used in the HVAC industry i.e. pneumatic,
electric, electronic, Direct Digital Controls (DDC)
How to identify the key building blocks of a BAS

Why DDC and BAS systems are so popular and user friendly
How to undertake design, installation and commissioning of
a simple BAS
How to generate a point schedule

Simple troubleshooting procedures for a BAS

How to describe the key codes and standards relating to a BAS

How to program and configure a simple BAS

The essentials of web based access to your building operation,

monitoring and fault finding and maintenance options
How to troubleshoot and work with SCADA systems

How to implement simple energy efficiency strategies

WHO SHOULD ATTEND:

Control and instrumentation engineers and technicians

Design engineers
Maintenance engineers, technicians and staff
Plant engineers
Mechanical engineers and technicians
Operation, inspection and repair managers, supervisors and
technicians
6.79

The Workshop

The Program

A Building Automation System (BAS) is a

computerised intelligent network of
electronic devices that is used to control and
monitor the mechanical, lighting and security
systems in a building. It is sometimes
referred to as an intelligent building system.
It is most often used for control of heating,
ventilation and air conditioning (HVAC)
systems. A BAS can result in a dramatic
reduction in building energy and
maintenance costs. Building automation
systems can also monitor other parameters
such as temperature, air pollution levels, fire
alarm status and building integrity. Most of
the underlying networks underpinning a BAS
comprise a primary and secondary bus
which connect high-level controllers with
lower level devices which interface to the
digital and analog input/outputs.

What is building automation?

Why building automation is required
Direct Digital Controls (DDC)
Predecessors to DDC controls
Overall topology
Key building blocks
Industrial networks
Overview of the course

CONTROLLERS

Different types
Programmable Logic Controllers/System
Network controllers
Terminal unit controllers
Connectivity with networks
Configuration and programming
Troubleshooting of controllers
Web enabled controllers (AspectFT)

INDUSTRIAL NETWORKS
Different systems
Proprietary versus non proprietary
systems
BACnet (ASHRAE)
LonTalk (Lon works)
Wireless (Zigbee)
Industrial Ethernet
Remote control
Configuration and troubleshooting

WATER SYSTEMS
Chilled water system
Condenser water system
Hot water system

HVAC CONTROLS AND

INSTRUMENTATION
Sensors and elements
Pneumatic, hydraulic, electric, electronic,
direct digital controls
Two position control
PID control
DDC control
Parameters to be controlled (temperature
supply and return air)
Preheat and humidification (winter air
conditioning)
Cooling, dehumidification and reheat
control (summer air conditioning)
Face and by-pass control
All year round air conditioning system
Zone control system

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After an initial overview of the topic, the first

day of the workshop covers controllers,
industrial networks, lighting, air handlers,
water systems and the central plant. The
second day provides you with a solid
understanding of heating, ventilation, air
conditioning (HVAC) and the associated
electrical systems. You will also be exposed to
alarms and security, room automation and
the vital topic of energy efficiency. The
workshop is concluded with the interesting
topic of SCADA systems where all the building
information is brought together. Throughout
the workshop you will learn the essentials in
installing, commissioning and troubleshooting
individual components and systems.

INTRODUCTION

OCCUPANCY

Occupied/unoccupied/morning warm-up
and night-time setback
Monitoring and corrective action in case
of inadequate fresh air, other pollutants
in occupied areas
Requirements of BAS

LIGHTING

Automated systems
Demand response

Air handling units

Constant volume
Variable volume
Variable volume hybrid units
Typical control set ups and monitoring
requirements

CENTRAL PLANT

Operation and troubleshooting of

chillers, boilers, cooling towers, pumps

Practical Sessions

Temperature sensors
Differential pressure sensors
Status alarm (e.g. pumps)
Valve actuators
Carbon monoxide and carbon dioxide
sensors
Refrigerant sensors
Current sensors
Fire suppression and alarm sensors

ROOM AUTOMATION

Corporate boardrooms/presentation
suites
Videoconferencing/video projectors
Lighting control system
Public address systems

ENERGY EFFICIENCY

AIR HANDLERS

ALARMS AND SECURITY

Costs of fuels
Energy performance
Energy audit of your building
Case studies

THE SCADA (OR HMI) SYSTEM FOR

BAS/DDC SYSTEMS

We (and you) know that no matter how good

the instructor is (and ours are very good!)
no one learns from listening to a lecture. The
best way of learning and gaining real skills is
a high level of interaction with your peers
and your instructor and also in undertaking
hands-on exercises which relate to the real
practical world. Hence we have a busy and
enjoyable schedule of useful activities to
help you really learn, including:

Basic implementation
Troubleshooting
Application of ASHRAE
Features
Remote control and monitoring
Basic HMI, small facility HMI, large
facility HMI

25 short, punchy videos on BAS

32 short, practical design exercises on
each topic using simulation software and
calculators
4 case studies on operating and
commissioning a BAS where you will
work in small groups to solve real
electrical engineering problems
Please bring a calculator to get
maximum benefit.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Design of Industrial Automation

Functional Specifications for

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PLCs, DCSs and SCADA systems

You will learn how to:

Detail the key requirements for a Functional Design

Specifications (FDS)
Define the key components for a FDS for an industrial
automation system (SCADA/PLC/ PAC and DCS*)
Define the data communications and networking requirements
Detail the Graphical User Interface (GUI) requirements
Define the requirements for system reliability and availability
Describe the other issues (such as security and operator
involvement) to be covered in the FDS
* These widely used acronyms are: SCADA Supervisory Control and Data
Acquisition System; PLC Programmable Logic Controller; PAC
Programmable Automation Controller; DCS Distributed Control System.

WHO SHOULD ATTEND:

Consulting engineers
Design engineers
Electrical engineers and technicians
Industrial automation engineers and technicians
Instrumentation and control engineers, technologists and
technicians
Maintenance engineers, technicians and staff
Mechanical engineers and technicians
Operation, inspection and repair managers, supervisors and
engineers
Plant engineers
System specifiers

6.81

The Workshop

The Program

The workshop will be useful to both

specifiers and implementers and will
provide a theoretical grounding as well as a
practical guide for preparing a control
system
functional
specification
for
implementation on Industrial control
systems consisting of PLC (Programmable
Logic Controllers), HMI (Human Machine
Interfaces/SCADA
devices)
or
DCS
(Distributed Control Systems).

FUNCTIONAL SPECIFICATION
INTRODUCTION

Pre-requisites

STANDARDS AND CONVENTIONS

Discussion of relevant standards
Definitions, tagging and naming
conventions
Practical session: Tagging and naming

SCADA/PLC/DCS
Process control approaches and their
philosophies
Discussion of SCADA/PLC/DCS systems
PLC coding concepts - IEC 61131-3
Practical session: PLC coding

Options for different communication

media
Suitability of protocols and relevant
standards
RS-485/Ethernet/DNP3/IEC 61850
Practical session: Specification of data
communications systems

GRAPHICAL USER INTERFACE (GUI)

REQUIREMENTS
Process diagrams, modern trends and
alarm systems
Alarms including colour coding, audio
indicators and others
Different kinds of reporting
Practical session: Definition of a GUI

Security aspects
Relevance of security for SCADA systems
Philosophy and different approaches for
security
Practical session: Security specifications

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You do not need to be able to program a PLC

or configure a SCADA system however a
basic understanding of these systems will
be beneficial. Workshop participants are
encouraged to bring along their laptop
computers since the workshop will include
several exercises which can be done
electronically. A basic word processor such
as MS Word or Open Office will help with the
completion of the exercises.

Overview of a Functional Design

Specifications (FDS)
The terms and abbreviations
Naming conventions and standards
Control philosophy needed in guiding the
FDS
Practical session: Control philosophy
outline

DATA COMMUNICATION
REQUIREMENTS

REMOTE TERMINAL UNIT (RTUS)

Introduction to RTU
Standards involved for an RTU design
Defining devices for data acquisition
Practical session: RTU specification

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

WRAPPING UP

Review of a complete FDS

Pitfalls, tips and tricks
Practical Session: Building a complete FDS
from earlier sessions

SUMMARY, OPEN FORUM

AND CLOSING

Throughout this hard hitting one day

course; you will undertake 8 projects/
practical exercises. These are listed in the
program and will be done in groups. Each
group will give a short presentation at the
end of the day.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

This is the best technical

briefing/training course
I have ever attended.
Instructor and attendees are
fully involved throughout.

Colin Jenkins
TAS Engineering Consultants

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

practical

Remote Engineering,
Mechatronics and Robotics

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for Engineers and Technicians

You will learn how to:

Design, build and troubleshoot simple mechatronics systems

Explain robot mechanics and dynamics without excessive mathematical
abstraction
Implement simple pneumatic, hydraulic valve and actuator-based
systems
Select the appropriate electrical and electro-mechanical drives and
actuators for your application
Design basic analog and digital systems, and simulate them with SPICE
software
Develop machine vision software applications (with RoboRealm)
Write BASIC-type programs (using PICAXE) for a Microbric robotic
vehicle
Write simple ladder programs for a PLC and simulate them with LogixPro
Select and interface appropriate sensors for your applications
Detail basic practical power distribution systems
Understand the basics of serial (RS-232/485) and Ethernet networking
Develop software for an industrial robot arm, using RoboLogix

WHO SHOULD ATTEND:

Anyone who wants to gain solid knowledge of the key elements of mechatronics to improve their work skills and to further their job prospects:
Instrument fitters and
Asset management engineer
instrumentation engineers
Automation engineers

Maintenance engineers and
Chemical engineers
supervisors
Consulting engineers

Mechanical engineer
Data logging engineer

Plant engineer
Design engineers

Process engineer
Electrical engineers,
Process monitoring and plant
technologists, technicians and
systems engineer
electricians
Production managers
Electronic engineer
Project engineer and managers
Electro mechanical engineer
Software engineer
Energy management consultants
Systems engineer
Instrument and process control
Technologists
technicians
Even those who are highly experienced in industrial automation may find
it useful to attend some of the topics to gain know-how in a very
concentrated but practical format.
6.83

The Workshop

The Program

Todays markets are extremely competitive

and engineers are continuously engaged in a
struggle to produce complex systems with a
high level of reliability and performance, yet
at a relatively low price. Much of this demand
is brought about by the rapidly-evolving
microprocessor technology. In order to
survive
in
this
highly-competitive
environment, developers have to integrate
several technologies.
Mechatronics is the answer to this dilemma.
It is an interdisciplinary field of engineering
and integrates several technologies such as
mechanical subsystems, sensors, actuators,
instrumentation subsystems, computers,
microcontrollers, PLCs and software. It
therefore provides the basis for the integration
process, right from the earliest stages of the
design process.

What is mechatronics?
Sub-disciplines within mechatronics

MACHINE DYNAMICS
Basic principles of dynamics
Kinematics
Rigid body dynamics
Robotics and multi-body dynamics
Practical Session

PNEUMATICS
Pneumatics fundamentals
Pneumatic circuit design
Practical Session

HYDRAULICS
Hydraulics fundamentals
Hydraulic actuators
Hydraulic control
Auxiliaries
Practical Session

Classical control theory

Control strategies
Digital control
Intelligent control
Practical Session

PROGRAMMING
Programming concepts
BASIC programming
Practical Session

PROGRAMMABLE LOGIC
CONTROLLERS (PLCs)
PLC hardware
Fundamentals of PLC programming
Simulation, testing and HMI
Specification, design and commissioning
Practical Session

MICROCONTROLLERS
Microcontroller hardware
Overview of microcontroller operation
Microcontroller instruction set
Assembly language programming
Practical Session

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Mechatronics is the key to modern video and

CD disk drives, camcorders, avionics, aircraft
fly-by-wire, computerised fuel injection for
motor vehicles, anti-lock braking systems,
and smart weapons such as military drones
used for aerial reconnaissance purposes. In
the process automation field, mechatronics
systems are also found in diverse applications
such as smart conveyer lines and assemblyline robots.

CLOSED LOOP CONTROL

INTRODUCTION

As with Ethernet networking and wireless

(Wi-Fi), the integration of technologies in
engineering applications as embodied in
mechatronics is upon us, and is here to stay.
It is, furthermore, evolving at an exponential
rate that will, in a decade from now, probably
make some of todays technologies look like
museum artefacts. This makes it almost
mandatory for everyone in the engineering
world to become familiar with the underlying
principles and technologies embodied in
mechatronics.

BASIC ELECTRO-TECHNOLOGY

Basic electricity
Resistors, capacitors and inductors
Alternating Current (AC) and impedance
Power and signals
Filters and noise
Practical Session

POWER DISTRIBUTION

Switchgear, transformers and power

factor correction
On-site distribution and grounding
Switching, measuring and protection
Power management and renewable
energy
Practical Session

ELECTRIC ACTUATORS

DC motor control and interfacing

Stepper motor control and interfacing
3-phase motor control and interfacing
Piezo and ultrasonic actuators
Electromechanical actuators
Practical Session

SENSORS

Sensor types and specifications

Signal conditioning for sensors
Interfacing sensors to microprocessors
Sensors for mechatronics applications
Practical Session

COMMUNICATION SYSTEMS
Serial communications
Ethernet and TCP/IP
Field buses
Practical Session

ROBOTIC ARM CONTROL

Robot arm concepts and terminology

Forward and inverse kinematics for robot
arms
Force and motion
Sensing and vision
Practical Session

ANALOG ELECTRONICS

Diodes, transistors, thyristors and triacs

Op-amps and their applications
Analog-to-digital and digital-to-analog
conversion
Practical Session

DIGITAL SYSTEMS

Basics of boolean algebra

Logic functions and gates
Combinational logic
Flip-flops, timers and related circuits
Practical Session

Practical Labs and

Exercises

MACHINE VISION

Twelve exercises taking 55% of the

workshop time
Analog circuit simulation using Multisim
SPICE

Digital image processing basics

Machine vision system components
Lighting
Cameras and sensors
Image processing
Practical Session

Digital circuit simulation using Micro-Cap

SPICE
Image processing using RoboRealm
PLC ladder programming and simulation,
using LogixPro
PICAXE software development
Microbric robotic vehicle

for

Robot arm program development using

Robologix simulator

idc@idc-online .com

www.idc-online .com

Instrumentation Engineering

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for Oil and Gas Facilities

what You will learn:

Skills and competencies in instrumentation oil and gas

engineering

Knowledge of the latest technologies in Instrumentation oil and

gas engineering
Key techniques in operating your facility to the highest level of
safety and in protecting the environment
Decades of real experience distilled into the course
presentations and materials

Guidance from real Instrumentation oil and gas experts in the

field
Hands-on, practical knowledge from the extensive experience
of instructors, rather than the theoretical information from
books and colleges
Networking contacts in the oil and gas industry

WHO SHOULD ATTEND:

This course is ideal for you if you are seeking expertise in the oil
and gas business and are an:
A recent graduate
instrumentation or
mechanical engineer

Instrument and process

control technician or
technologist

Chemical engineer

Instrument fitter

Fire and gas engineer

Mechanical engineer

Instrument and control

systems engineer
Even if you are highly experienced you will find this a great way
to become familiar with the oil and gas technology as quickly as
possible.
6.85

The Workshop

The Program

There is a growing shortage, and hence

opportunity, for instrumentation technicians,
technologists and engineers in the oil and
gas industry. This is due to an increasing
need for higher technology methods of
obtaining and processing oil and gas as it is
a finite declining resource. The price of oil is
heading upwards steadily, thus making
personnel and their associated oil and gas
expertise in these industries even more
valuable. The technical challenges of
extracting oil and gas are becoming ever
more demanding, with increasing emphasis
on more marginal fields and previously
inaccessible zones such as deep oceans,
Polar regions, Falkland Islands and
Greenland. The aim of this program is to
provide you with core Instrumentation
engineering skills to enhance your career,
and to benefit your firm.

Fundamentals of instrumentation,
measurement and process control
engineering

INSTRUMENTATION AND CONTROL

General instrumentation standards in oil
and gas
Process instrumentation
Calibration, installation and maintenance
of instruments
Process control basics
Control valves sizing, selection and
maintenance (including pressure relief
valves)
Programmable Logic Controllers
SCADA systems
Distributed control systems
Industrial data communications
(including Fieldbus and industrial
Ethernet)
Safety instrumentation and emergency
shutdown systems for oil and gas (IEC
61511 and IEC 61508) basic introduction
Wellhead and flowline control control
systems
Emergency wellhead blowout controls

SPECIALISED APPLICATIONS IN OIL

AND GAS
Power generation
Cathodic protection
Compressor control (including surge
control)
Drilling control systems and
instrumentation
Subsea instrumentation and control
systems
Pig launcher/receiver systems
Critical flare knock out drum controls and
instrumentation
Flare flame front generator and ignition
monitoring system
Distributed control systems

SUMMARY, OPEN FORUM

AND CLOSING

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This workshop provides a whole spectrum

of
activities
ranging
from
basic
instrumentation engineering to advanced
practice including hazardous areas, data
communications along with a vast array
instrumentation equipment utilised in an oil
and gas environment as well as practical
treatment of instrumentation within the oil,
gas, petrochemical and offshore industries.
Whilst there is some theory this is used in a
practical context giving you the necessary
tools to ensure that the instrumentation
hardware is delivering the results intended.
No matter whether you are a new
instrumentation or control technician/
technologist/graduate engineer or indeed,
even a practising facilities engineer, you will
find this course beneficial in improving your
understanding, skills and knowledge. This is
a 3-day intensive workshop, covering
considerable material. If you are looking for
a far higher level of knowledge and
competencies, you can undertake our 18
month in-depth Advanced Diploma in Oil
and Gas (E&I).

INTRODUCTION SETTING THE

SCENE IN OIL AND GAS E&I
ENGINEERING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Excellent presentation of a
complex subject in a very
short period.

Terry Hailstones

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

practical

IEC 61850 FOR SUBSTATION

AUTOMATION

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for Engineers and Technicians

You will learn how to:

Explain the basic scope and outline of IEC 61850 (including

Revision 2)
Describe the IEC 61850 hardware architecture for substation
automation
Use the IEC 61850 data model to specify a substation
automation system

Use the IEC 61850 model as data integration platform

Specify the most appropriate networking components for

substation automation
Perform device independent system specification and
engineering
Create SSD, ICD, IID and SCD files

Create, capture and analyse GOOSE messages

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand

the techniques required to use and apply IEC 61850 to substation
automation, hydro power plants, wind turbines and distributed
energy resources as productively and economically as possible.
This includes engineers and technicians involved with:

Consulting

Process control

Control and instrumentation

Process development

Control systems

Project management

Design

SCADA and telemetry

systems

Maintenance supervisors
Electrical installations

6.87

The Workshop

The Program

Older (legacy) substation automation

protocols
and
hardware/software
architectures provided basic functionality for
power system automation, and were
designed to accommodate the technical
limitations of the technologies available at
the time. However, in recent years there
have been vast improvements in technology,
especially on the networking side. This has
opened the door for dramatic improvements
in the approach to power system automation
in substations.
The latest developments in networking such
as high-speed, deterministic, redundant
Ethernet, as well as other technologies
including TCP/IP, high-speed Wide Area
Networks and high-performance embedded
processors, are providing capabilities that
could hardly be imagined when most legacy
substation automation protocols were
designed.

7-layer communication model

8th layer as data
Network topologies
Utility Communication Architecture (UCA)
Client/server concept
Publish/subscribe concept
Key features of IEC 61850
IEC 61850 vs. DNP3 and IEC 60870

SCOPE AND OUTLINE OF IEC 61850

General functional requirements (Parts 3,
4 and 5)
Definition of abstract services (Part 7.2)
Abstraction of data objects (Part 7.4)
Common Data Classes (CDC) (Part 7.3)
Mapping of abstract data objects and
services onto the Manufacturing
Messaging Specification (MMS) (Part 8.1)
Mapping of Sample Measured Values
onto serial links (Part 9.1)
Mapping of Sample Measured Values
onto ISO/IEC 8802-3 (IEEE 802.3/Ethernet)

WAN COMMUNCATIONS ISSUES

Reliability, determinism and speed issues
Multi-Protocol Layer Switching (MPLS)
IP over Dense Wavelength Division
Multiplexing (IPoDWDM)
MPLS Traffic Engineering Fast Reroute
over IP over Dense Wavelength Division
Multiplexing (MPLS TE-FRR over
IPoDWDM)
IEEE 802.1Qav Forwarding and Queuing
Enhancements for Time-Sensitive
Streams

DATA MODELING APPROACH

The information model (IEC 61850-7-x
and IEC 61400-25)
The information exchange services and
mappings (IEC 61850-7-2 and 8-1)
Physical devices
Logical devices
Data elements
Common Data Class (IEC 61850-7-3)

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IEC61850 is a part of the International

Electro-technical Commission (IEC) Technical
Committee 57 (TC57) architecture for electric
power systems. It is an important new
international standard for substation
automation, and it will have a significant
impact on how electric power systems are
designed and built in future. The modeldriven approach of IEC61850 is an innovative
approach and requires a new way of thinking
about substation automation. This will result
in significant improvements in the costs and
performance of electric power systems.

INTRODUCTION

This workshop provides comprehensive

coverage of IEC 61850 and will provide you
with the tools and knowledge to tackle your
next substation automation project with
confidence.

Pre-requisites

A basic working knowledge of data

communications in general, or some
exposure to Ethernet and TCP/IP, would be
useful but is not essential.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

IEC 61850 SUBSTATION

ARCHITECTURE
Merging Units (MUs)
Station Bus
Process Bus

ETHERNET COMMUNICATION WITHIN

SUBSTATIONS

TCP/IP AND RELATED CONCEPTS

RECENT DEVELOPMENTS

IP (L3) addressing: IPv4 vs. IPv6

Subnet masks and default gateways
Basic routing concepts
Routers
Ports/sockets
TCP connections
TCP vs. UDP

Practical Sessions

delivered when and

where you need it.
Contact us for a
free proposal.

Sampled Values (SV) multicast

Generic Object Oriented Substation Event
(GOOSE)
GOOSE messages over L2
GOOSE messages over L3 (IEC 61850-905)
Generic Substation Status Event (GSSE)
Time Sync (SNTP/GPS/IRIG-B)
Manufacturing Message Specification
(MMS)
Application of and comparison between
profiles

Physical Interfaces (10/100/1000 Mbps)

Media (copper, multi-mode fibre, single
mode fibre)
Media access (full duplex vs. CSMA/CD)
MAC (L2) addressing: broadcasting,
multicasting, unicasting
Frame (packet) structure
Differences between ISO/IEC 8802.3, ISO/
IEC 8802.3 Ethertype, and ISO/IEC 8802.2
LLC
Bridges/switches
VLANs
- Port-based vs. tagged VLANs
- IEEE802.1p port prioritisation
- IEEE802.1Q VLAN
Time synchronisation
- IEEE 1588
- SAE AS6802
Network redundancy
- Redundant star
- Redundant ring
- Spanning tree protocols
- Parallel Redundancy Protocol (IEC 62439-3)

your workplace.

Have the training

COMMUNICATION PROFILES

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

MAPPING OF IEC 61850 TO

COMMUNICATION PROFILES

Abstract Communication Service

Interface (ACSI)
Mapping of IEC61850 to MMS
Object mapping
Service mapping

CONFIGURATION

Configuration of IEDs
IEC 61850-6 Substation Configuration
Language (SCL)
Software tools

CONFORMANCE AND TESTING

Documentation and process

Assessment process
Tools
Testing methods
Interpretation of Compliance Certificates

IEC 61850 Edition 2

Object models for hydro power plants,
wind turbines and Distributed Energy
Resources (DER)
Mapping of IEC 61850 on DNP3 and IEC
60870-5-101/-104
The use of IEC 61499 (Distributed
Function Blocks) in conjunction with IEC
61850
Exchanging synchrophasor data between
PMUs, PDCs, WAMPAC and control
centre applications: IEC/TR 618-905:2012(E)
Communication with the control centre
based on IEC 61850 and Harmonisation
with CIM

SUMMARY, OPEN FORUM

AND CLOSING

www.idc-online .com

Hazardous Areas and ATEX

Awareness

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for technical and non-technical staff

what You will learn:

Hazardous area terminology

Consideration of sources of ignition

Flammability concepts of gasses, vapours, mists and dusts

Zoning, equipment groups and temperature class

Equipment identification, certification and labelling/marking

European Directives (ATEX Directives; DSEAR in the UK)
The basic principles of explosion protection

Basic considerations for non-electrical equipment

Requirements for inspection and maintenance including initial

and routine inspections

WHO SHOULD ATTEND:

Anyone and everyone who encounters hazardous areas at any

level, according to the ATEX Directives and the DSEAR, requires at
least a basic understanding of the risks and the management of
those risks in order that they should not be compromised by the
actions of these personnel. This course is aimed at providing a
substantially non-technical introduction suitable for senior
management right through to operators. This includes:
Chemical engineers
Control engineers
Electrical engineers
Electrical and instrument
trades-persons
Instrumentation engineers

Supervision and
management staff
Security and cleaning staff
Technicians
Trades-persons working in
potentially explosive areas

Process engineers
6.89

The Workshop

The Program

This workshop is designed to provide

delegates with an appreciation of the
requirements of explosion protection
applied to hazardous areas. It defines the
terminology, promoting clarity of use in
communications between technical and
commercial
departments
within
organisations and between organisations
involved. The subject matter covered focuses
on how the requirements of the ATEX
Directives (and the DSEAR that is applied in
the UK) are to be met in order to aid
management, technicians and engineers in
the understanding of the necessary
organizational and technical measures taken
to ensure safety.

Pre-requisites

Explosion consequences
The fire triangle
Risk assessment concepts applied and
IEC60079 Standards and Codes of
Practice

UNDERSTANDING FLAMMABILITY
COMBUSTION AND EXPLOSION
Ignition sources
Properties of flammable gases, vapours,
mists and dusts

ZONES AND DEFINITIONS

Definition of hazardous area terminology
Classification of apparatus
Equipment grouping and temperature
rating

PRINCIPLES OF TYPES OF
PROTECTION
Electrical equipment protection IEC60079:
Ex d, e, i, p, and n
Others types: Ex m, o, q and s: use in
combination
Non-electrical equipment protection to
EN13463: fr, d, g, c, b, p and k

PLANT OWNER/USER OF EX
EQUIPMENT
Introduction to Codes of Practice
Equipment selection procedure
General requirements of Installation and
Inspection
Maintenance and permits to work
Repairs

ATEX DIRECTIVES

Equipment category and grouping

Essential safety and health requirements
ATEX compliance marking
Self certification and verifying conformity
Workers cirective summary

DANGEROUS SUBSTANCES AND

EXPLOSIVE ATMOSPHERES
REGULATION (UK)
DSEAR: Application of ATEX and
Chemical Agents Directive in the UK
Summary of employers responsibilities

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Delegates will only require a very basic

understanding of physics for the workshop
to be of greatest benefit. No previous
knowledge of hazardous area installations is
required.

INTRODUCTION

Practical Sessions

SUMMARY, OPEN FORUM

AND CLOSING

EQUIPMENT CERTIFICATION

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Marking and identification

Component certificates
Equipment certificates
Systems certification

To gain full value from this workshop,

please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

One-day Refresher Training

ELECTRICAL EQUIPMENT
for PRACTICAL HAZARDOUS AREAS
for Engineers and Technicians

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(Outside europe)

You will learn how to:

Describe recent developments in Hazardous areas

Comply with the Requirements of IEC 60079
Work safely in Hazardous Areas

Design and install safe working systems in hazardous areas

Explain the terminology used with hazardous areas
Assist in hazardous area classification

Detail the types of apparatus that can be used in a given

hazardous area
Explain the types of equipment that can be used

Detail system limitations in using hazardous areas protection

Detail the key areas of the national codes of practice

WHO SHOULD ATTEND:

Anyone involved in design, specification, installation,

commissioning, maintenance or documentation of industrial
instrumentation, control and electrical systems, including:
Electrical and instrument tradespersons
Electrical engineers
Instrumentation and control engineers
Design engineers
Instrumentation technicians
Tradespersons working in Potentially Explosive Atmospheres
(PEAs)

6.91

The Workshop

The Program

This workshop provides you with an

understanding of the hazards involved in
using electrical equipment in potentially
explosive atmospheres. This refresher
workshop is suitable for you if you have a
good understanding of the requirements for
electrical equipment in hazardous areas (if
not; contact us for further suggestions). It is
based on the international IEC60079 series
of standards that are now replacing many of
the older national standards. Installation
utilising Explosion-Protected (Ex) equipment
can be expensive to design, install and
operate. The wider approaches described in
these standards can significantly reduce
costs whilst maintaining plant safety.

Definition of hazardous area

Flammability concepts
Ignition sources
Properties of gases, vapours, mists and
dusts

CLASSIFICATION SYSTEMS
Area classification into zones
Equipment (apparatus) grouping

TYPES OF PROTECTION



-
-
-
-
-
-
-
-
-

Definitions
Principles
Application of:
Flameproof: Ex d
Increased safety: Ex e
Pressurisation: Ex p
Intrinsic safety: Ex i
Non-incendive: Ex n
Oil filling: Ex o
Powder filling: Ex q
Encapsulation: Ex m
Special: Ex s

INSPECTION AND MAINTENANCE

REQUIREMENTS

Inspection and maintenance definitions

Types of inspection
Initial detailed pre-commissioning
Inspection regimes and documentation
Record keeping

BREAKDOWNS - FAULT FINDING AND

REPAIRS OF Ex EQUIPMENT

Planned maintenance
Use of tools
Procedures
Safe methods
Test equipment suitability

STANDARDS, CERTIFICATION,
CERTIFICATES, MARKING AND
APPROVALS
Authorities
Marking and identification
Component, equipment and systems
certification
Systems descriptive documentation
(for Ex i)
ATEX Directives (Europe)

ID CO
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The associated terminology and its correct

use are explained throughout the workshop.
It covers area classification, selection of
explosion protected electrical apparatus as
well as describing how protection is
achieved and maintained in line with these
international requirements. Standards
require that engineering staff and their
management are trained effectively and
safely in hazardous areas and this workshop
is designed to help fulfil that need.

BACKGROUND TO HAZARDOUS
AREAS

EARTHING AND BONDING

The IEC 60079

Requirements

The International Standard IEC 60079.14

(Electrical Equipment for explosive
atmospheres) requires that the design,
construction, maintenance, testing and
inspection of installations covered by these
standards shall be carried out only by
competent persons. The competent persons
training must include instruction and
experience on the various types of protection
and installation practices, relevant rules and
regulations and on the general principles of
area classification.

Basic principles
Earthing requirements
Static protection
Lightning protection
Noise and interference control
Requirements for IS systems
System earthing approach

CODE OF PRACTICE FOR SELECTION

AND INSTALLATION OF Ex
EQUIPMENT

Application of code of practice

General requirements for all types of
protection
Documentation requirements and the
verification dossier
Cabling
Overview of requirements for individual
Ex protection types
Dust installations overview

SUMMARY, OPEN FORUM

AND CLOSING

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. The practical sessions will
comprise exercises in which you will solve
typical practical problems in groups. Videos
of the key concepts will also be provided.
There will be two assignments where you
will test your knowledge gained during the
one day workshop.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

It is a requirement of this standard that

appropriate continuing training shall be
undertaken on a regular basis; as the
standards and regulations are constantly
being modified and improved.

You will receive a IDCTechnologies Certificate

after successful completion of the training
materials and training assignments. The
instructor will assist you in successfully
completing this one-day course.
In conclusion, it should be noted that no
training course provider can confer any level
of competence on an engineer, technician or
tradesperson. The IECEx competence
scheme is aimed at personal competence;
but does not absolve the employer from
responsibility in assessing competence in
the workplace (under the requirements of
ATEX).

Note: Hazardous Area Classification will only focus on zones and divisions. Details will be
provided on where the IECEx standards can be found. In addition, the IEC 60079.10 is there
for a detailed review; but is outside the scope of this intensive one day session. ATEX is
not required in Australia and many other countries (but is naturally critical in Europe).

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

One-day Refresher Training

ELECTRICAL EQUIPMENT
for PRACTICAL HAZARDOUS AREAS
for Engineers and Technicians

ID CO
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Te YR
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(within europe)

You will learn how to:

Describe recent developments in Hazardous areas

Comply with the Requirements of IEC 60079
Work safely in Hazardous Areas

Design and install safe working systems in hazardous areas

Explain the terminology used with hazardous areas
Assist in hazardous area classification

Detail the types of apparatus that can be used in a given

hazardous area
Explain the types of equipment that can be used

Detail system limitations in using hazardous areas protection

Detail the key areas of the national codes of practice

WHO SHOULD ATTEND:

Anyone involved in design, specification, installation,

commissioning, maintenance or documentation of industrial
instrumentation, control and electrical systems, including:
Electrical and instrument tradespersons
Electrical engineers
Instrumentation and control engineers
Design engineers
Instrumentation technicians
Tradespersons working in Potentially Explosive Atmospheres
(PEAs)

6.93

The Workshop

The Program

This workshop provides you with an

understanding of the hazards involved in
using electrical equipment in potentially
explosive atmospheres. This refresher
workshop is suitable for you if you have a
good understanding of the requirements for
electrical equipment in hazardous areas (if
not; contact us for further suggestions). It is
based on the international IEC60079 series
of standards that are now replacing many of
the older national standards. Installation
utilising Explosion-Protected (Ex) equipment
can be expensive to design, install and
operate. The wider approaches described in
these standards can significantly reduce
costs whilst maintaining plant safety.

Definition of hazardous area

Flammability concepts
Ignition sources
Properties of gases, vapours, mists and
dusts

CLASSIFICATION SYSTEMS
Area classification into zones
Equipment (apparatus) grouping

TYPES OF PROTECTION



-
-
-
-
-
-
-
-
-

Definitions
Principles
Application of:
Flameproof: Ex d
Increased safety: Ex e
Pressurisation: Ex p
Intrinsic safety: Ex i
Non-incendive: Ex n
Oil filling: Ex o
Powder filling: Ex q
Encapsulation: Ex m
Special: Ex s

INSPECTION AND MAINTENANCE

REQUIREMENTS

Inspection and maintenance definitions

Types of inspection
Initial detailed pre-commissioning
Inspection regimes and documentation
Record keeping

BREAKDOWNS - FAULT FINDING AND

REPAIRS OF Ex EQUIPMENT

Planned maintenance
Use of tools
Procedures
Safe methods
Test equipment suitability

STANDARDS, CERTIFICATION,
CERTIFICATES, MARKING AND
APPROVALS
Authorities
Marking and identification
Component, equipment and systems
certification
Systems descriptive documentation
(for Ex i)

ID CO
C P
Te YR
ch IG
no H
lo T
gi
es

The associated terminology and its correct

use are explained throughout the workshop.
It covers area classification, selection of
explosion protected electrical apparatus as
well as describing how protection is
achieved and maintained in line with these
international requirements. Standards
require that engineering staff and their
management are trained effectively and
safely in hazardous areas and this workshop
is designed to help fulfil that need.

BACKGROUND TO HAZARDOUS
AREAS

EARTHING AND BONDING

The IEC 60079

Requirements

The International Standard IEC 60079.14

(Electrical
Equipment
for
explosive
atmospheres) requires that the design,
construction, maintenance, testing and
inspection of installations covered by these
standards shall be carried out only by
competent persons. The competent persons
training must include instruction and
experience on the various types of protection
and installation practices, relevant rules and
regulations and on the general principles of
area classification.
It is a requirement of this standard that
appropriate continuing training shall be
undertaken on a regular basis; as the
standards and regulations are constantly
being modified and improved.

Basic principles
Earthing requirements
Static protection
Lightning protection
Noise and interference control
Requirements for IS systems
System earthing approach

ATEX DIRECTIVES (EUROPE)

Introduction and Explanation

Non-electrical ignition capable
equipment protection
ATEX marking
DSEAR (UK) requirement summary

SUMMARY, OPEN FORUM

AND CLOSING

CODE OF PRACTICE FOR SELECTION

AND INSTALLATION OF Ex
EQUIPMENT

Application of code of practice

General requirements for all types of
protection
Documentation requirements and the
verification dossier
Cabling
Overview of requirements for individual
Ex protection types
Dust installations overview

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. The practical sessions will
comprise exercises in which you will solve
typical practical problems in groups. Videos
of the key concepts will also be provided.
There will be two assignments where you
will test your knowledge gained during the
one day workshop.

You will receive a IDC Technologies Certificate

after successful completion of the training
materials and training assignments. The
instructor will assist you in successfully
completing this one-day course.
In conclusion, it should be noted that no
training course provider can confer any level
of competence on an engineer, technician or
tradesperson. The IECEx competence scheme
is aimed at personal competence; but does
not absolve the employer from responsibility
in assessing competence in the workplace.

To gain full value from this workshop,

please bring your laptop/notebook
computer.

note: Hazardous Area Classification will only focus on zones and divisions. Details will be

provided on where the IECEx standards can be found. In addition, the IEC 60079.10 is there
for a detailed review; but is outside the scope of this intensive one day session. ATEX is not
required in Australia and many other countries (but is naturally critical in Europe). Hence,
ATEX compliance marking needs to be understood because it appears on many products.
The ATEX Equipment Category equates to the equipment protection level concept and the
significance of gas/dust use etc. In the UK many installations have equipment installed to
BS5345 and that includes BS889 and 229 equipment. We also have other BS and EN's that
require explanation in context so we believe that, whilst explaining the principles, the
differences in application and standards will need to be included for the country in which the
course is delivered (naturally related to the particular interests of the course participants).

idc@idc-online .com

www.idc-online .com

master series:

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INSTRUMENTATION AND CONTROL

what You will learn:

Gain a clear picture of the latest developments and future

directions in control and instrumentation from experts in the
field
Make reliable, well grounded and commercially viable technical,
financial and management decisions in the control and
instrumentation business
Understand how successful control and instrumentation
engineers communicate their vision and values to build up a
super effective team

WHO SHOULD ATTEND:

This master series course is for those from a control and

instrumentation background. It has been developed for those
whose time is limited and who work in a critical role or situations
where a lengthy time away for study is impossible. Those who
would benefit most include:
Automation engineers

Engineering managers

Chief engineers

Process control engineers

Control and instrumentation

engineers

Senior technologists and

technicians

Electrical engineers

Superintendents

6.95

About the Master Series

The Program

This is four hard hitting days of intensive training, the instrumentation and control master
series has proved an outstanding success. It delivers a critical blend of knowledge and skills,
covering technology in control and instrumentation, industry analysis and forecasts,
leadership and management everything that is relevant to a modern control and
instrumentation engineer. You will be exposed to four high impact days where you will hear
from an outstanding expert and undertake practical hands-on sessions and exercises.
A key element of the master series is the ongoing case study conducted throughout the four
days that pitches the delegates (in teams of four each) against each other in the design
costing of a state-of-the-art plant. The case study is exciting, intense, useful and fun. You will
however require every ounce of ingenuity to come up with control and instrumentation
solutions appropriate to the design of this process plant.

I&C STANDARDS, DRAWINGS AND

DOCUMENTATION
PROCESS CONTROL
ADVANCED PROCESS CONTROL
INDUSTRIAL DATA
COMMUNICATIONS AND WIRELESS
SAFETY INSTRUMENTATION AND
MACHINERY SAFETY

SESSIONS WILL COVER THE FOLLOWING KEY AREAS:

Setting the scene
Industrial data communications and wireless
Safety instrumentation and machinery safety
Process control
Advanced process control
HAZOPs
Budgeting, ROI and finance of I&C projects
Industrial network security
Hazardous areas and intrinsic safety
SCADA and PLC systems
Project management of I&C projects
Preparation for presentations
Latest instrumentation developments
Case study of design of a real process plant
Forecasts and predictions

HAZOPS
BUDGETING, ROI AND FINANCE OF
I&C PROJECTS
HAZARDOUS AREAS AND INTRINSIC
SAFETY

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SETTING THE SCENE

SCADA, PLC AND DCS SYSTEMS

PROJECT MANAGEMENT OF I&C

PROJECTS

PREPARATION FOR PRESENTATIONS

The I&C master series is split into three focused areas of learning which are all linked together
through the case study of Hi-Tech Inc's plant:

1. MARKET AND INDUSTRY INTELLIGENCE

A review of where control and instrumentation engineering is heading with forecasts on
trends in equipment, technologies employed and personnel.
2. MANAGEMENT AND BUSINESS
Good management, financial and business skills are provided in these modules. These
highly practical interactive sessions provide you with solid skills in this often neglected
area for control and instrumentation engineers.

INSTRUMENTATION AND VALVE

DEVELOPMENTS
DELEGATE PRESENTATIONS

REVIEW OF EXERCISES AND

CASE STUDY

FORECASTS AND PREDICTIONS

SUMMARY, OPEN FORUM
AND CLOSING

3. TECHNOLOGY AND ENGINEERING

A solid overview of the latest trends in instrumentation and control technology and how
to take advantage of these.
Day 1

Day 2

Day 3

Day 4

Setting the scene

Industrial data
communications

Hazardous areas and

intrinsic safety

Latest
instrumentation
developments

Best practice C&I

standards and
drawings

Safety
instrumentation and
machinery safety

SCADA, PLC and DCS

systems

Delegate
presentations

Lunch

Lunch

Lunch

Lunch

Process control

HAZOPs

Project management
and management of
C&I projects

Review of exercises
and plant design

Advanced process
control

Budgeting, ROI and

finance of C&I
projects

Preparation for
presentations

Forecast and
predictions

On-Site Training

Save over 50% by having an IDCworkshop presented at

Case Study

Deciding on the overall strategy:

Considering all the factors involved when

deciding upon overall technology strategy.
In bringing the elite of the control and
instrumentation industry together for four
hard hitting days of intensive training, the
instrumentation and control master series
has proved an outstanding success. It
delivers a critical blend of knowledge and
skills, covering technology in control and
instrumentation, industry analysis and
forecasts, leadership and management
everything that is relevant to a modern
control and instrumentation engineer. You
will be exposed to four high impact days
where you will not only hear from
outstanding experts in each of the key areas
but undertake practical hands-on sessions
and exercises.

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Integrated Programming,
Maintenance, Troubleshooting
and Optimisation of the

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Drill Monitor System (DMS)

what You will learn:

Be able to describe the hardware and software architecture of

the DMS:
Describe the hardware (Unitronics Vision 120, wiring and
sensors) and software (ladderlogic programming)
Be able to apply know-how on programming the DMS

Have learnt how to efficiently troubleshoot and maintain a

typical DMS
Have the skills to write simple DMS ladderlogic programs
Be able to competently install wiring of inputs/outputs from the
DMS to sensors

WHO SHOULD ATTEND:

Consulting engineers

Instrumentation technicians

Design engineers

Process control engineers

DCS personnel

Process control operators

Electrical engineers

Shift electricians

Engineering managers

Trades staff working with or

near PLCs

Instrumentation and control

engineers

6.97

The Workshop

The Program
INTRODUCTION
Fundamentals of operation of DMS
Block diagram of typical DMS system
(processor/memory/I/O)
Power Supplies

DMS HARDWARE






-
-
-
-
-
-
-

Planning of program
Program layout
Data structure
I/O addressing
Processor status registers
Fundamental instruction set
Bit (e.g. coils) and word type instructions
Timers and counters
Comparison operators
Data handling operations
Program control
Editing a program
Documentation of a program
Communications (RS-232/Cell phone)

GOOD PROGRAMMING HABITS

FOR DMS
Keeping track of addresses and data used
Looking ahead how will programs be
maintained
Practical methods to improve program
quality
- Organisation of code
- Thorough documentation
- Simplifying changes

DMS OPERATOR INTERFACE

Creation of simple graphic displays

Configuring of alarms
Organising display data
Linking displays

TROUBLESHOOTING DMS, SYSTEM

CHECKOUT AND TESTING

Typical tips and tricks

Development and verification of code
Testing procedures
Discrete I/O
Analog I/O
I/O channel and power supplies
Processor problems

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This intensive workshop is aimed at assisting

you the engineer and technician working
with the DMS in applying an integrated
approach to maintaining, troubleshooting
and programming the OPLC units. The OPLC
(Operator Interface Programmable Logic
Controller) operates in the same way as a
normal PLC but has a Liquid Crystal Display
(LCD) incorporated in to the front panel. The
V120 OPLC incorporates 10 digital inputs 2
analogue inputs and 6 relay outputs. By
means of the use of an extender module,
further inputs can be input to the OPLC. This
is done through an IO-ATC8 which allows
the connection of eight 4-20 mA input
channels. The OPLC is programmed using a
Windows based ladder logic. This ladder
logic programs the manner in which the
OPLC scans the inputs, processes the data
collected from the inputs, then produces
outputs by either switching on relays, or
displaying text or graphics on the LCD
display.

Pre-requisites

A basic electrical knowledge would be useful

but is not essential and some background in
working with Allen Bradley PLC-5s and SLC500s.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed. Over 65% of the workshop time
is spent on practical sessions and will
focus on:
Configuring and programming a DMS and
testing its operation
Troubleshooting sensors, wiring and DMS
code
Configuration and programming DMS
Operator screen

To gain full value from this workshop, please

bring your laptop/notebook computer.

DMS SENSORS

Location, wiring and operational

description of:
- Key switch
- Engine air filter front
- Engine air filter rear
- Compressor air filter
- Low fuel
- Alternator fail
- Engine coolant level
- Compressor oil filter
- Low water injection water
- Hydraulic oil temp high
- Hydraulic oil filter bypass
- Engine oil temp high
- Low hydraulic oil level
- Compressor oil temp high
- Engine oil pressure low
- Engine coolant temp high

SUMMARY, OPEN FORUM

AND CLOSING

GOOD INSTALLATION PRACTICE

-
-
-

Location of hardware
Good wiring practice
Cable spacing
Power distribution
Wire numbering
Reducing noise and interference
Screening and shielding
Earthing and grounding

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

MECHANICAL ENGINEERING

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TRAINING WORKSHOPS
Practical Fundamentals of Heating, Ventilation and Airconditioning (HVAC) for Engineers and Technicians.... 7.1
Practical Boiler Plant Operation and Management for Engineers and Technicians............................................... 7.3
Practical Cleanroom Technology and Facilities for Engineers and Technicians.................................................... 7.5
Practical Lubrication Engineering for Engineers and Technicians.......................................................................... 7.7
Practical Safe Lifting Practice and Maintenance....................................................................................................... 7.9
Practical Pumps - Design, Operation and Maintenance for Centrifugal and Positive Displacement Pumps........ 7.11
Practical Machinery and Automation Safety for Industry....................................................................................... 7.13
Practical Machinery Vibration Analysis and Predictive Maintenance.................................................................... 7.15
Practical Pumps and Compressors: Control, Operation, Maintenance and Troubleshooting............................. 7.17
Gas Turbines: Fundamentals, Maintenance, Inspection and Troubleshooting...................................................... 7.19
Fundamentals of Mechanical Engineering............................................................................................................... 7.21
Practical Mechanical Drives (Belts, Chains and Gears) for Engineers and Technicians..................................... 7.23
Practical Balancing, Alignment and Condition Monitoring of Rotating Equipment............................................. 7.25
Pipeline Systems - Design, Construction, Maintenance and Asset Management................................................ 7.27
Fundamentals of Process Plant Layout and Piping Design................................................................................... 7.29
Practical Mechanical Sealing with Rotary, Pneumatic and Hydraulic Seal Types plus Gaskets........................ 7.31
Best Practice Design, Maintenance and Troubleshooting of Conveyors and Chutes.......................................... 7.33
Practical Process Compressors................................................................................................................................ 7.35
Performance Monitoring of Pumps and Compressors............................................................................................ 7.37
Fundamentals of Pipe Stress Analaysis with Introduction to Caesar II............................................................. 7.39

Practical Corrosion Management.............................................................................................................................. 7.41

Reliability Centred Maintenance (RCM).................................................................................................................... 7.43
Rigid and Flexible Hose Connections....................................................................................................................... 7.45
Safety Relief Valves - Inspection, Operation and Troubleshooting........................................................................ 7.47
Mechanical Design Concepts for Non-Mechanical Engineers................................................................................ 7.49
Practical Hydraulic and Pneumatic Systems: Operations and Troubleshooting.................................................. 7.51

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Practical Conveyor, Chute and Feeder Design......................................................................................................... 7.53

Practical Fundamentals of

HEATING, VENTILATION and

AIR-CONDITIONING (HVAC)

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Maintain and troubleshoot HVAC systems

Understand and apply the psychrometic chart
Design for good air quality
Perform basic load calculations
Initiate an effective inspection and maintenance program
Minimise forced outages and prevent serious damage to HVAC
equipment
Provide an overview of the legislative requirements plus the
essential steps and responsibilities for the maintenance and
repair of HVAC systems
Outline the technologies available for the efficient energy
management using HVAC systems

WHO SHOULD ATTEND:

Maintenance engineers, technicians and staff

Plant engineers
Operation, inspection and repair managers, supervisors and
engineers
Mechanical engineers and technicians
Design engineers
Electrical engineers and technicians
Consulting engineers

7.1

The Workshop

Practical Sessions

This workshop is designed for engineers and technicians from a wide range of abilities
and backgrounds and will provide an excellent introduction to the fundamentals of
heating, ventilation and air-conditioning. It commences with a review of psychrometric
charts and then examines the factors that influence design choices, indoor air quality, load
calculations and heating/ventilation and air-conditioning systems. Numerous tips and
tricks throughout the course make it very practical and topical to your applications.

Pre-requisites

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Fundamental knowledge of basic mechanical plant and operation thereof.

The Program
INTRODUCTION TO HVAC
General
Principles of thermodynamics
Laws of thermodynamics
Fundamentals of heat transfer
Fundamentals of fluid flow
Temperature and its measurement
Pressure and temperature relationship

PSYCHROMETRY

Introduction to psychrometry
The properties of air
Psychrometric charts
Air conditioning and psychrometric
systems
Psychrometric charts as a tool for
analysis for A/C performance

REQUIREMENTS OF COMFORT AIR

CONDITIONING

Thermodynamics of the human body

Air purification methods
Role of clothing
Temperature and humidity in high heat
load
Inside and outdoor design criteria
Ventilation and ventilation standards
Design of ventilation systems
Air distribution systems
Air diffusion and performance
Air purification methods

HEATING AND COOLING LOAD

CALCULATION PROCEDURE

Design considerations
Load components
Design criteria indoor and outdoor
Heat/load components
Miscellaneous heat sources
Fresh air loads
Design of air-conditioning systems
Heat gains: transmission, solar,
infiltration

HVAC SYSTEMS

DUCT DESIGN, AIRFLOW AND ITS

DISTRIBUTION
Pressure gradient diagrams
Duct sizing and design

INSULATION OF AIRCONDITIONING SYSTEMS

INSTALLATION, COMMISSIONING
OPERATION, TESTING AND
MAINTENANCE

HVAC equipment
Duct work and air outlets
Electrical and controls
Insulation and commissioning process
Other service operations
Economics
Operational activities
Dos and donts

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All air, all water, air water systems

Heat systems
Steam heating systems
Electric heat systems
Components of the air conditioning
systems in practice

CONSTANT VOLUME SYSTEMS

System concepts
Different configurations

VARIABLE AIR VOLUME SYSTEMS

System concepts
Different Variable Air Volume (VAV)
systems

Properties of insulating materials

Factors affecting thermal conductivity
Heat transfer through insulation
Economical thickness of insulation
Insulated systems
Importance of relative humidity for the
selection of insulation

AIR-CONDITIONING EQUIPMENT

Packaged units
Split systems
Chillers
Boilers
Pumps
Cooling towers
Adiabatic coolers
Capacity assessment and selection
Air filters
Humidifiers
Dehumidifiers
Fans and blowers
Grills and registers

REFRIGERATION

Methods of refrigeration
Air refrigeration systems
Vapor compression and absorption
refrigeration systems
Refrigerants
Refrigeration equipment

CONTROLS AND
INSTRUMENTATION

Definitions
Sensors and elements
Pneumatic and hydraulic controls
Electrical and electronic controls
Two position control
PID control
Parameters to be controlled (temperature
supply and return air)

FAULT FINDING AND

TROUBLESHOOTING FAULTS

Improper adjustments and settings

Poor design and installation
Equipment failure
Limitations in operation
Troubleshooting tools

TROUBLESHOOTING TOOLS
(ELECTRICAL AND MECHANICAL)
DOE (Design Of Experiments)
FTA (Fault Tree Analysis)
Cause and effect diagrams

GREEN HOUSE EFFECT AND

FUTURE REFRIGERANTS
Applications
Smart buildings

ENERGY CONSERVATION AND

ENERGY MANAGEMENT

Costs of fuels
Typical rate schedules
Effects on total fuel bill
Cost-in-use
Energy performance
Contracts and incentive programs

SUMMARY, OPEN FORUM

AND CLOSING

TYPICAL CONTROL SYSTEMS

Preheat and humidification control
(winter air-conditioning)
Cooling, dehumidification and reheat
control (summer air-conditioning)
Face and by-pass control
All year round air-conditioning system
Zone control system

idc@idc-online .com

www.idc-online .com

Practical

BOILER PLANT
OPERATION AND MANAGEMENT

ID CO
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for Engineers and Technicians

YOU WILL LEARN:

How to install, operate, maintain and manage boiler plants

Steam and combustion processes
Safe boiler operation techniques

How to use existing technologies to reduce pollution and

emission levels
How to achieve peak boiler plant efficiencies

Identify and troubleshoot boiler problems quickly and efficiently

WHO SHOULD ATTEND:

Senior boiler plant operators, repairers and installers

Boiler plant construction managers
Plant engineers

Operation, maintenance, inspection and repair managers,

supervisors and engineers
Mechanical engineers and technicians
Design engineers

Insurance company inspectors

Consulting engineers

7.3

The Workshop

The Program
INTRODUCTION
Types of package boilers and their
applications
Boiler components, terminology and
definitions
Practical assignment (workshop)

FUEL COMBUSTION AND THE

STEAM GENERATION PROCESS
Overview of the boiler heating and steam
generation process
Influence of the fuel type on the boiler
design operation
Firing appliances
Basics to theory of combustion
Thermal efficiency
Fireside deposits and corrosion
Practical exercises (calculations)

PLANNING AND MANAGING

BOILER MAINTENANCE
Critical importance of maintenance
policies and programs
Setting up an inspection program
Types of boiler inspections
Involvement of the Authorised Inspection
Authority (AIA)
Maintenance information and procedures
Developing a preventive maintenance
program
In-house verse contractor repair
maintenance
Practical assignment (workshop)

MANAGING BOILER REPAIRS AND

MODIFICATIONS

Water treatment plant and dosing

Feedwater pumps
Valves and steam traps
Piping
Fans
Economisers and heat recovery
equipment
Flue gas cleaning and dust removal
Practical exercises (quiz questions)

When does a boiler repair become a

boiler modification?
Importance of historical records
Understanding the legislative
requirements
Steps to be taken when a defect is
identified
Responsibility of the boiler owner
Responsibility of the boiler repair
contractor
The AIA and their inspection points
Practical assignment (workshop)

OPERATION AND CONTROLS

COLD STORAGE OF A BOILER

BOILER AUXILIARY PLANT

ID CO
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The boiler plant operation and management

workshop is an intensive, highly practical two
day workshop. You will gain the most up-todate information and practical understanding
of the installation, operation, maintenance
and management of boiler plants. The
workshop will give you the ability to recognise
and solve boiler problems simply, easily and
with confidence. At the end of this workshop
participants will be able to:
Identify the various types of boilers
Use essential terms and understand their
key applications
Describe the typical characteristics of fuels
fired
Perform basic combustion and process
calculations
Recognise the impact fuels have on the
boiler heat transfer surfaces
Describe the ancillary equipment associated
with steam boiler plants and their integral
role in the safety of the boiler
Discuss the correct operation, control
sequences and procedures for the safe
operation of a typical fire-tube boiler plant
Outline the applicable pressure part design
codes and explain their influence on boiler
pressure parts sizing, inspection and nondestructive examination
Initiate an effective inspection and
maintenance program
Minimise forced outages and prevent
serious damage to boiler equipment
Provide an overview of the legislative
requirements plus the essential steps and
responsibilities for the repair of boilers
Recognise the importance of and implement
the procedures for the protection of a boiler
during cold storage
Outline the technologies available for the
reduction of emission levels and the
applicable international legislative controls

Pre-requisites

Fundamental knowledge of basic mechanical

plant, and operation thereof.

Practical Sessions

Boiler instruments and their purpose

Typical P&I diagrams for coal and oil/gas
fired units
Control systems and system operating
philosophy
Operational sequences and procedures
Safety equipment and interlocks
Safety procedures and emergencies
Operating records and logs
Typical operational problems, the reason
for the problems and trouble shooting
Practical exercises (workgroup)

PRESSURE CONTAINING
COMPONENTS

Basics to codes calculation theory and

assumptions
Overview of design parameters for shell,
furnace, plates and tubing
Importance of pressure part inspection
Practical assignment (exercise and quiz
questions)

Clearly establishing the storage period

Storage period and critical preservation
steps
Storage instructions and procedures
Consequences of no storage plan
Practical exercises (quiz questions)

EMISSION CONTROLS AND

ENVIRONMENTAL CONSTRAINTS
Types of emissions for different fuels
fired
Methods used for controlling boiler flue
gas emissions
Effectiveness of various types of cleaning
equipment
What emission levels are specified in
international standards or legislation?
Practical exercises (quiz questions)

SUMMARY, OPEN FORUM

AND CLOSING

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

CLEANROOM
TECHNOLOGY AND FACILITIES

ID CO
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Te YR
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for Engineers and Technicians

YOU WILL LEARN:

About contamination control, improving yield, product quality

and performance
The importance of cleanrooms in improving product yield in
today's manufacturing climate
The Cleanroom concepts, how to design, operate and maintain
cleanrooms
Techniques for the control of air temperature, air humidity,
vibration, static electricity, particle levels and other
contaminants
The maintenance and work practices allowed in Cleanrooms
The utility and service requirements for Cleanrooms

The statutory codes safety, fire and environmental practices

The codes and legislation used for regulation of Cleanroom
design and operation
About Hi Purity Water - its uses, generation and distribution
Techniques for waste water treatment

About personal safety work practices and general behaviour in

a Cleanroom

WHO SHOULD ATTEND:

Engineers & Technicians

Scientists

Process Engineers

Production Engineers

Operators

Research Engineers

Project Engineers

Maintenance Personnel

Electronic Engineers

Data Storage Personnel

All personnel who work in a controlled environment

All personnel involved with the design and maintenance in and
around a controlled environment
7.5

The Workshop

The Program

Contamination can cause a variety of

problems to materials, processes and
products and it is for this reason that
cleanrooms are becoming a regular feature
of modern industry in its battle to control
contamination. With the demand for higher
productivity and reliability of the
manufacturing process and the everincreasing miniaturisation of equipment,
Cleanrooms have become integral to the
success of the manufacturing process.
It is essential for productivity that people are
trained to work with Cleanroom technology
and facilities. An effective Cleanroom
requires the effective functioning of many
different and complex systems. It is
imperative that these dynamic systems are
operated and maintained correctly so that
their interaction creates a stable controlled
environment.

Pre-requisites

A fundamental knowledge
mechanical issues.

of

basic

The need for a Cleanroom

History of Cleanrooms
Cleanrooms and the semi-conductor
industry
Cleanrooms and the pharmaceutical
industry
Overview of the wafer fabrication process
The Cleanroom as a system and unit
operations

External vibration sources (natural and

man-made)
Internal vibration sources

Cleanroom Codes &

Legislation
Fire protection
Smoke removal

Hi Purity Water Generation &

Distribution

Cleanroom Controlled
Environment Concepts
Cleanroom basics
Particulate standards
Gas and vapour standards
Contamination

The uses of ultra-pure water

Raw water constituents
Water quality standards
Hi Purity Water Systems: typical block
diagrams

Production Materials

Micro Contamination
(Particulate)

The nature of particulate contamination

Particulate contamination flow
Particulate contamination sources
Particulate transport
Particle retention
Contamination monitoring/identification
for particulate contamination

Creating a Cleanroom

Workshop Objectives

Construction materials
Construction practices (Protocols)
Air flow (basics)
Typical Cleanroom layout/configurations
Designing for Cleanroom class level

Facilities & Services

After attending this workshop you will know

how to:
Work in a controlled environment

Handle, store and use hazardous

materials, wet chemicals and gases
Increase your product yield
Understand
concepts

Vibration

Bulk Chemical Storage and Distribution

Systems (BCDS)
Hazardous production materials
The safe storage, handling and use of
wet chemicals and gases
Personal protective equipment (PPE)
Wet chemicals (bulk and speciality)
Gases (bulk and speciality)

ID CO
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This workshop will not only teach you how

to create a Cleanroom but also how to
effectively operate, maintain and work within
this controlled environment. This workshop
will help you manage your cleanroom
investment more efficiently thereby
increasing your productivity through greater
product yields.

Overview of Cleanroom
Technology

different

Electrical systems
Power conditioning
Compressed air
Air conditioning
Air wet side
Air dry side

Cleanroom

Waste water plant

Acid waste neutralisation plant
Hydrofluoric acid waste treatment
Phosphoric acid waste treatment

People & Contamination

Apparel
The use of apparel
Work practices and general behaviour
Cleanroom facilities & practices
Typical specification sheets

Codes and legislation governing the

design and operation of Cleanrooms

Exceeded my expectations.

Hi Purity Water; its uses, generation and

distribution

Chris Barlow

Waste water treatment

in

Control contamination from interfering

with the production of your product and
its end-use performance

Personnel safety practices

Cleanroom environment

Waste Treatment

the

On-Site Training

Practical Sessions

Save over 50% by having an IDCworkshop presented at

Practical sessions include:

your premises.

Air balance calculations

Heat load calculations
Particle loadings
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

LUBRICATION ENGINEERING

ID CO
C P
Te YR
ch IG
no H
lo T
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es

for Engineers and Technicians

YOU WILL LEARN:

How to choose the best lubricant for your application

How to better understand and manage lubricants

How to use lubricants effectively in a proactive maintenance

program
When to select grease or oil as the lubricant of choice
Best practices for oil draining, flushing and charging
How to write equipment lubrication procedures

How to handle lubricants in pumps and reservoirs

The truth about aftermarket additives and oil conditioners

How to best store lubricants and handle them effectively
The latest techniques which are dramatically different
to those of 10 years ago
How to extend the life of your lubricants

Troubleshooting techniques to deal with lubricants effectively

in the future

WHO SHOULD ATTEND:

Supervisors & Foremen

Mechanical Engineers

Consulting Engineers

Design Engineers

Process Technicians

Lubrication technicians

Plant Engineer-Managers & Supervisors

Plant Operations & Maintenance Personnel
Predictive Maintenance Professionals
Artisans & tradespeople
Facilities Engineers & Managers

7.7

The Workshop

The Program

The Lubrication Fundamentals workshop is

a comprehensive, highly practical and
interactive two-day course. With a
bewildering selection of thousands of
lubricant types, base stocks, additive
packages and viscosity grades to choose,
how do you know which one is right for your
machine.
After attending this course and interacting
with your fellow students and instructor,
you will have the tools to and knowledge to
understand the key properties of lubricants
and how to select the right one for your
applications.

TRIBOLOGY
The cause of friction, heat, the result of
friction, what causes wear
The types of lubrication:

- fluid and hydro-dynamic lubrication

- boundary lubrication
The characteristics of the lubricant under
different operating conditions e.g.
material surfaces, temperature
conditions, load and viscosity of the
lubricant
Different types of lubricants for different
applications

THE PROPERTIES OF LUBRICANTS

Viscosity
Flashpoint and Volatility
Oxidation and thermal stability
Demulsibility
Foaming and gas solubility
Corrosion prevention
Compatibility

AUTOMOTIVE DRIVE LINE

LUBRICATION
Viscosity classifications
Automatic transmission fluid

HYDRAULIC SYSTEMS AND

FLUIDS

Hydraulic systems
Viscosity of the lubricant
Chemical stability
Fire resistance
Anti-wear
Anti-rust
Anti-foam

MISCELLANEOUS LUBRICATION
Steam Turbine Pumps and Motor
Lubrication
Air Compressor Lubrication

LUBRICATION SYSTEMS

ID CO
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Modern lubrication programs have

dramatically changed from the old methods
that have been passed down through the
generations. If you arent using the right
lubricant at the right time, in the right place,
in the right quantity you could in fact be
doing more harm than good and losing the
opportunity to save your firm thousands of
dollars with an effective lubrication program.
This workshop collects together the strategic
knowledge of many practising professionals
in this area and gives you the best practice
to work with.

INTRODUCTION & BACKGROUND

Discuss briefly the composition of
lubricants, crude oil derived lubricants and
synthetic lubricants.

You will have an opportunity to discuss

Lubricant management, design-applications,
operations, maintenance and management
issues and be provided with the most up-todate information and best practice in dealing
with the subject. Towards the end of the
workshop, you will have developed the skills
and ability to recognise and solve lubricant
problems in a structured and confident
manner.

Pre-requisites

A basic knowledge of mechanical engineering

principles as applied to lubricants would be
useful. However, this is not essential as it
will be revised at the beginning of the
workshop.

FILTRATION

LUBRICATING OIL ADDITIVES

Oxidation inhibitors
Rust and corrosion inhibitor
Pour point depressants
Viscosity inhibitor (VI) improvers
Anti-wear additives
Extreme pressure (EP) additives
Anti-foam additives
Detergents and dispersants additives
Demulsifiers and Emulsifiers
Tackiness additives

CONDITIONS ASSESSMENT OF
ROTATING MACHINERY
Monitoring techniques
Vibration analysis
Oil analysis

TRIBOLOGY ROOT CAUSES OF

FAILURES

TYPES OF LUBRICANTS
GREASES AND GREASE
LUBRICATION

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Contamination fundamentals
Contamination generation
Cleanliness control
Filter fundamentals
Filter performance and testing
Flashing

Grease characteristics
Lubrication grease classification
Choice of grease
Grease types and performance
Grease application and trouble-shooting
Roller bearing lubrication

Fluid contamination control

Leakage stability
Fluid chemical stability
Temperature stability
Wear stability

STORAGE

Safety Issues
Shelf Life
Contamination Potential

CLOSING AND SUMMARY

INTERNAL COMBUSTION
LUBRICANTS

Petrol and diesel engines

The choice of lubricant by engine type
Lubricant classification
Plain bearing lubrication

Customise the training to

your workplace.

Have the training

Good subject well presented.

delivered when and

where you need it.

Brian Barton

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

ID CO
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Te YR
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SAFE LIFTING
PRACTICE AND MAINTENANCE

THIS WORKSHOP COVERS:

Advanced Lifting Equipment Safety

Slinging, inspection and safe use of lifting equipment

Guides to implementing a total safe lifting program in your

plant & operation
Selection, safe use and maintenance of lifting equipment
Practical Safe slinging and basic rigging practice

Types, selection and features of lifting equipment used

Management of a total safe lifting program
Your lifting equipment - legal or lethal?

WHO SHOULD ATTEND:

Maintenance and Project Managers

Plant Engineers and Technicians
Artisans and Apprentices

Rigging Personnel and Contractors

Inspectors of Lifting Equipment

Safety Officer and Loss Control Personnel

Health and Safety Representatives
Plant Foreman and Supervisors
Lifting Equipment Operators
Lifting Equipment Service Providers
Lifting Equipment Sales Engineers

7.9

The Workshop

The Program

This very timely workshop has been put

together by an expert in the area of lifting
practice and equipment who has observed
and studied the problems in working with
loads. In two concentrated days you will
have the distillation of his experience of
over 30 years in this sometimes dangerous
and demanding field. Lifting Equipment
refers to both the lifting tackle as well as
Lifting Machines.

Chain Slings
Qualities of chain
Types of chain
Specifications
Traceability
Heat treatment
Protective coatings
Configurations of slings
Certification
Markings
Inspection
Safe and correct use
Storage and maintenance
Calculation Exercise

Fundamental principles of
safe lifting practice
Common causes of accidents
Employers responsibilities
Operators responsibilities
Suppliers responsibilities
Suppliers Risk Assessment of product
The Lift - General Procedure
A 20 point guide in planning and
conducting the lift
Elements of a Total Safe Lifting Program
(TSLP)
Lifting Equipment Definitions. Pm 20
Case Study

Steel wire rope slings

Rope construction
Types of ropes
Splices
Types of slings
Accessories
Correct and safe use
Inspection of ropes
Storage and maintenance
Case Study

ID CO
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This is a practical participative workshop

using sample slings and components; new
and old to practically demonstrate features
and correct use. Videos and posters in the
workshop room are used to reinforce the
material covered in the comprehensive 250
page manual which will act as a reference for
your work for years to come. Case studies
throughout the workshop which emphasise
past experience give you a solid practical bias
to the workshop. You will also do simple
calculations on various lifting and loading
situations. It should be emphasised that all
loads are dangerous - a 50 kg load will kill or
m a i m
a s
surely as a 5 tonne load if dropped from a 1
metre distance. Safety is not negotiable;
therefore this workshop drives home the
point that if you use correct lifting equipment
correctly and safely, your operators and
personnel are well trained and in compliance
with the local legislation as well as with a
Total Safe Lifting program you will have a
productive work force.

Introduction
Safe Lifting Statement
Why training is essential
Lifting pyramid triangle

This course is not a replacement for that of

a full rigger's course but it will teach you in
two days what most people will take years
to learn and make you a far safer and more
productive person on the shopfloor.

Pre-requisites

A basic working knowledge of mechanical

lifting problems. Please bring your calculator
along to do simple calculations for some of
the practical exercises.

Workshop Objectives

At the end of this workshop you will be able to:

Maintain Safe Lifting Practice in your
factory and plant
Describe the do's and donts of Lifting
Demonstrate substantial cost savings in
less damage and risk in lifting equipment
Demonstrate practical compliance with
the local Legal requirements
Demonstrate compliance with the your
responsibilities of the LAW
List the elements of a Total Safe Lifting
Program and how to implement this plan
Demonstrate the load - estimation, balance,
centre of gravity, angles, load ratings, mass
of various bodies, safe attachment
Ensure proper safe maintenance of Lifting
Equipment
Design and create your own Code of
Practice for Lifting Equipment
Ensure that your lifting equipment is
always in a safe working condition
Identify and fix Safety Hazards with Lifting
Equipment
Understand the limitations of your Lifting
Equipment

Basic Rigging Practice

Fundamentals

Legal Requirements

Applicable Legislation
Industry: OHS Act, DMR 18
Mines: Minerals Act
Practical implementation of these
regulations
All regulations in the Acts, and how these
regulations need to be implemented in
practice
Case Study

The Load

Load estimation
Centre of gravity
Balance
Angles
Load ratings. Trigonometric and Uniform
methods.
Calculation Exercise

Crane Signals

Lifting Tackle (i.e chain, steel

wire rope and textile
webbing)
Comparisons of types
Features and benefits of types
Typical applications
Sling configurations
Calculation Exercise

Lifting Machines

Types
Methods of operation i.e. gear train
Overload indicators
Limit switches
Assessing the operation and safe use of
Lifting Machines
Case Study

Theory of Inspection of
Lifting Equipment

Textile Slings

Types of textile fabric used

Types of slings i.e. endless roundslings
and flat woven webbing slings
Identification and marking
Typical Applications
Specifications, identification and
markings
Stitching
Colour coding
Safe and correct use
Inspection and maintenance
Case Study

Sling components

Hooks
Shackles
Terminal fittings
Eye bolts
Plate clamps
Lifting points
Correct and safe use, identification,
markings and quality
Case Study

Lifting Machines

Types and use i.e. hand and electric chain

hoists, lever hoists, cable winches,
pendant controlled overhead cranes
Correct and safe use
Inspection procedures for various types
Records and maintenance
Case Study

Summary and conclusion

Maintenance and Storage

idc@idc-online .com

www.idc-online .com

Practical

PUMPS - DESIGN, OPERATION AND MAINTENANCE

ID CO
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FOR CENTRIFUGAL AND POSITIVE

DISPLACEMENT PUMPS

YOU WILL LEARN HOWTO:

Identify the various types of centrifugal pumps

To use relevant pump terminology and understand their key
applications
Understand pump characteristics and interpret pump curves
Perform a number of pump calculations
Describe ancillary equipment associated with pumping circuits
Draw up the correct operation, controls and procedures for
operating pump systems
Understand more about safety with pump systems and the
management of risk
Define pump reliability in terms of availability, criticality and
wear characteristics
Understand pump efficiency in terms of capital costs,
maintenance costs and life cycle costs
Understand the elements considered in selecting the right
pump for a specific application
Tackle issues relating to mechanical shaft seals failures
Understand about pump drive options, alignment and pump
drive sources
Confidently test and commission pump sets
Understand about condition monitoring of pumps and to
optimise pump performance

WHO SHOULD ATTEND:

Plant operations and maintenance personnel

Plant engineers, managers and supervisors
Process control engineers and supervisors
Consulting engineers
Maintenance engineers and technicians
Pump sales and applications personnel
Pump users
Pump service contractors
7.11

The Workshop

The Program

This is a comprehensive, highly practical

and interactive two-day workshop. You will
have an opportunity to discuss pump
construction, design applications, operations
and maintenance issues and be provided
with the most up-to-date information and
best practice in dealing with the subject. You
will develop the skills and ability to recognise
and solve pump problems in a structured
and confident manner.

Practical Sessions
This is a practical, hands on workshop
enabling you to work through practical
exercises which reinforce the concepts
discussed.

TYPES OF PUMPS AND MATERIAL

SELECTION
Terminology
Design considerations to address specific
Pump definition and types
applications
Pump materials and components
What constitutes a good centrifugal pump? Material selection based on process fluid
specifications: hazardous, density,
Overview of statutory requirements
viscosity, temperature, corrosiveness,
Practical tutorial
erosion
Practical tutorial
INTRODUCTION TO MECHANICAL
SEALS

Single and dual seal types

Design considerations to address specific
applications
Troubleshooting failed mechanical seals

PUMPABLE FLUID
CHARACTERISTICS
Impact of:
- Head
- Density
- Viscosity
- Temperature
- Corrosiveness
- Erosion
Practical tutorial

PUMP DRIVES
Pump drives:
- Close coupled
- Direct driven
- Belt driven
- Variable speed drives
- Canned
- Couplings
- Alignment
- Power sources
Practical tutorial

ID CO
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To gain full value from this workshop,

please bring your laptop/notebook
computer.

INTRODUCTION

CONTROLS/SELECTION AND
INSTALLATION

THE PUMP AFFINITY LAWS

The interaction between:

- Head
- Flow
- Power draw
- Implications of performance changes
- System resistance

HYDRAULIC FORCES

This course is excellent for

Technicians, Workshop Managers
and Engineers.

L. Pike

Axial forces
Radial forces
Effect of forces on component life

A TYPICAL PUMP CIRCUIT

Effects on pumping
Head
Velocity
Resistance
Forces
Expansion, contraction and vibration
Environment
Practical tutorial

Pump controls and instruments: safety

and volume controls
Pump selection:
- Performance data
- System flow resistance
- Stability
Pump installation issues:
- Foundations and bases
- Pipe connections
- Vibration and force isolation
- Environmental protection
Practical tutorial

COMMISSIONING AND
PERFORMANCE MEASUREMENT

Testing and commissioning

Condition monitoring
Optimising performance:
- Inspection
- Performance measurements
Practical tutorial

summary, open forum

and closing

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

MACHINERY AND AUTOMATION SAFETY

ID CO
C P
Te YR
ch IG
no H
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for Industry

WHAT YOU WILL LEARN:

How to identify hazards of machines and do risk assessments

The essential design principles for safety-related electrical
controls
The meaning and application of "safety category" and "SIL"
How international standards can help you develop your safety
applications
The principles of safety PLCs and safety networks

The basics of CE marking and the EU safety regulations for

machinery

WHO SHOULD ATTEND:

Control Engineers & Technicians

Electrical Engineers

Instrumentation and Control Engineers & Technicians

Compliance Engineers

Machinery Designers & System Integrators

Safety Professionals, Health & Safety Officers

Production Managers

Automation Engineers

Process Engineers

Process Control Engineers

Electronic Engineers

System Integrator Designers

Design Engineers

Systems Engineers

Test Engineers

Electronic Technicians

Consulting Engineers

7.13

The Workshop

The Program

The technology of safety related control

systems plays a major role in the provision
of safe working conditions throughout
industry. At the same time safety controls
must not be seen as an obstacle to production
performance and efficiency. It pays to have
safety controls that work reliably without
slowing down production or causing
irritation to the operators.
Perhaps your company is wasting money on
inappropriate safety interlocks that waste
production time and still do not satisfy
safety regulations? Perhaps your technicians
and engineers could improve production at
the plant through using smarter safety
systems?

DEVICES: SENSORS AND

CONTROLS

Course outline and objectives

Definition of a machine and the scope of
machinery controls
Examples of common hazards & typical
safety system solutions
Principles of risk assessment and risk
reduction
Introduction to the safety lifecycle
method of engineering
Practical 1: Exercise in calculating risk
parameters

GUIDE TO REGULATIONS AND

STANDARDS
Introduction to European Directives,
Regulations and Standards
CE marking and the EU machinery
directive
Obligations of suppliers and end users
Type A, B and C safety standards
USA Regulations and Standards
Concept of Control Reliability
Practical 2: Questionnaire on CE marking
and compliance

Overview of sensors and safety devices

Choices of protection methods
Fixed & moveable guards
Sensing devices for guards
Application examples: Guard interlocking
systems
Presence sensing devices including
safety mats and proximity sensors
Principles of light beams, light curtains
and laser scanners.
Practical 7: Outline design of an access
guarding system

SAFETY CONTROL APPLICATIONS

How to choose the right safety control
system
Selection factors for the protection
method
Comparison of physical guarding with
other safety methods
Application of hold-to-run and two-hand
controls
Motion detection and run down
safeguarding.
Presence sensing and access guarding
examples for light curtains
Calculation of safety distances
Application examples for muting,
blanking, single-and double-break
operating modes
Practical 8: Calculate safety distance for a
light curtain application

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This workshop aims to provide you with the

knowledge to tackle machinery safety control
problems at a basic and practical level whilst
following the best available international
standards. It begins with an overview of
machinery safety issues, introducing the
concepts of hazard identification and risk
reduction. The workshop highlights the major
international standards that are used to
support compliance with EU regulations and
uses these as a basis for the design procedures.
This approach will assist you to follow best
practices for safety system applications
wherever your plant is situated and is essential
if you are exporting into the EU.

INTRODUCTION TO MACHINERY
SAFETY PRINCIPLES

The workshop looks at the risk assessment

processes used to identify hazards and to
quantify the risks inherent in a machine. This
enables engineers to define the safety
functions to be provided by safety related
electrical controls. The workshop then
introduces the concepts of safety categories
as defined by standard EN 954 and illustrates
the principles of failsafe design, fault
tolerance and self-testing.
With design procedures established the
workshop now provides an introduction to
machinery protection devices such as
guards, enclosures with interlocks and guard
monitoring relays, locking systems, safety
mats, photo electric and electro sensitive
principles and the application of light
curtains. Application examples such as
guard door interlocking applications, twohand controls, muting, area protection of
robot installations and motion detection are
then discussed.

The workshop introduces the principles of

safety-certified PLCs focusing on practical
useful information showing the differences
between PLCs designed for safety and those
for regular control duties. It also provides an
outline of the principles of networking of
safety devices including the integration of
safety and regular control systems in
complete packages.
The workshop introduces the recently
established standards IEC 61508 and IEC
62061 for functional safety of programmable
systems. It explains the concepts of safety
integrity levels (SILs) and their relationship
to safety categories and highlights key
issues associated with software based safety
applications.

Pre-requisites
A basic working knowledge of electrical
engineering concepts is useful but not
essential as there will be a brief revision at
the commencement of the class.

RISK ASSESSMENT & RISK

REDUCTION METHODS

Risk assessment procedure based on

EN1050
How to do risk estimation and risk ranking
Developing risk reduction by design and
by safeguarding
Practical example of a risk assessment
and risk reduction steps
Practical 3: Hazard study and risk
assessment exercise on a power tool
Risk reduction provided by safety control
systems
Documentation and software tools for
risk assessment.
Practical 4: Predict an accident rate using
fault tree analysis

DESIGN PROCEDURES FOR

SAFETY CONTROLS

Introduction to safety control standards

EN 954 and IEC 62061
Procedures for the design of safety
controls
Failure modes and principles of fail safe
design
Explanation of safety categories (EN 954)
and SILs (IEC 62061)
Specification of safety requirements and
selection of categories
Circuit application examples for
categories 1 to 4
Practical 5: Determine the safety categories
for a production line

DEVICES: E-STOPS AND THE

SAFETY RELAY

Emergency stop functions and types.

How does an E-stop safety relay work?
Practical safety relays and typical
applications
Guard monitoring applications
Programmable and electronic
monitoring devices
Bus connected monitors.
Practical 6: Design an Emergency stop
system for a conveyor

idc@idc-online .com

PROGRAMMABLE SYSTEMS FOR

SAFETY CONTROLS
The pros and cons of using of PLCs in
safety
Why a general purpose PLC should not
be used for safety duties
Key performance features of a safetycertified PLC?
Software characteristics of a safety PLC
Application programming using certified
function blocks
PLC types and features
Introduction to safety-related field bus
systems.

NEW STANDARDS FOR

PROGRAMMABLE SYSTEMS

Introduction to IEC 61508 general

standard for functional safety.
Using the safety life cycle method for
management of safety
IEC 62061, a new standard for machinery
controls
How safety integrity levels are defined
for machinery safety

MACHINERY SAFETY
MANAGEMENT

Maintenance and safety issues in the

factory.
Validation and proof testing of installed
safety systems
Upgrading the safety of existing
machines.
Practical 9: Checklist for safety
compliance

REVISION OF KEY POINTS

www.idc-online .com

Practical

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MACHINERY VIBRATION ANALYSIS

AND PREDICTIVE MAINTENANCE

YOU WILL LEARN HOW TO:

Understand the basics of vibration measurement

Demonstrate the basics of signal analysis

Understand measurement and the characteristics of vibration

signals
Use data acquisition equipment for vibration signals

Apply vibration analysis for different machinery faults

Apply specific techniques for pumps, compressors, engines,

turbines and motors
Apply vibration based fault detection and diagnostic techniques
Diagnose machinery related problems with vibration analysis
techniques
Apply advanced signal processing techniques and tools to
vibration analysis
Detect, locate and diagnose faults in rotating and reciprocating
machinery using vibration analysis techniques
Identify conditions of resonance and be able to rectify these
problems
Apply basic allied predictive techniques such as oil analysis,
thermography, ultrasonics and performance evaluation

WHO SHOULD ATTEND:

Instrumentation and control engineers

Control technicians
Electrical engineers
Electricians
Maintenance engineers and technicians
Process engineers
Consulting engineers
Automation engineers
7.15

The Workshop

The Program

This practical workshop provides a detailed

examination of the detection, location and
diagnosis of faults in rotating and reciprocating
machinery using vibration analysis.The basics
and underlying physics of vibration signals
are first examined. The acquisition and
processing of signals is reviewed followed by
a discussion of machinery fault diagnosis
using vibration analysis, and rectifying the
unidentified faults.The workshop is concluded
by a review of the other techniques of
predictive maintenance such as oil and particle
analysis,
ultrasound
and
infrared
thermography. The latest approaches and
equipment used together with current
research techniques in vibration analysis are
also highlighted in the workshop.

Pre-requisites

Evolution of maintenance in process

plants
Classification of plant machinery
Maintenance strategies as adopted to
each class of machinery
Identification of critical machinery and
adoption of CBM
Principles of predictive maintenance, its
utilisation in detection and diagnosis
Various techniques under predictive
maintenance
Vibration analysis as one of the key
techniques

VIBRATION BASICS
Spring mass system mass, stiffness,
damping
Wave fundamentals concepts of
amplitude, frequency, fundamental
frequency, harmonics, phase, waveforms
(sinusoidal, complex) concepts of peak,
peak-peak, rms
Vibration parameters displacement,
velocity, acceleration
Choice of vibration parameters
Using vibration theory to machinery fault
detection
Limits and standards of vibration

VIBRATION ANALYSIS FOR

DIFFERENT MACHINERY FAULTS

Unbalanced
Misalignment, looseness, distortion
Bad bearings, journals
Gears, couplings
Critical
Resonance
Electrical
Miscellaneous

MACHINERY SPECIFIC VIBRATION

ANALYSIS

Pumps
Compressors
Engines
Turbines
Motors

VIBRATION MONITORING AND

ANALYSIS TURBOMACHINERY
Importance of shaft vibration - usage of
eddy current probes
Installation of probes on a
turbomachinery train
Brief description of the turbomachinery
vibration setup
Spectrum plot, cascade plot, waterfall
plot, bode plot, polar plot, shaft
centreline plot, wave form plot, orbit plot,
shaft deflection plot, data trending plot,
axial movement plot, full spectrum
Typical problems associated with
turbomachinery oil whirl/whip,
structural resonance, vane blade passing,
misalignment, rotor rubbing and shaft
crack

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This is not an advanced workshop but one

aimed at the fundamentals. A basic knowledge
of electrical and mechanical concepts would
be useful.

INTRODUCTION

Workshop Objectives

When you have completed this workshop

you will be able to:
Understand the basics of vibration
measurement
Demonstrate the basics of signal
analysis

Understand measurement and the

characteristics of vibration signals

Use data acquisition equipment for

vibration signals

Apply vibration analysis for different

machinery faults

Apply specific techniques for pumps,

compressors, engines, turbines and
motors
Apply vibration based fault detection
and diagnostic techniques

Diagnose machinery related problems

with vibration analysis techniques
Apply advanced signal processing
techniques and tools to vibration
analysis

Detect, locate and diagnose faults in

rotating and reciprocating machinery
using vibration analysis techniques

DATA ACQUISITION SYSTEMS

AND TECHNIQUES

Vibration transducers and their

mountings
Data acquisition equipment hand held
meters, data collectors (single, dual
channel), online monitoring
Equipment setup and data collection
Basic steps in data acquisition,
overlapping, windows

BASICS OF SIGNAL ANALYSIS

Time waveform analysis

Fast courier transform analysis
Phase measurement
Enveloping and demodulation
Orbits
Advanced signal analysis
- Triggered data capture
- Synchronous time averaging
- Peak holding averaging
- Coastdown analysis (bode/Nyquist)
- Enveloped spectras gSE, Peakvue,
SEE.
- Modal shape analysis
- Cross channel analysis coherence,
FRF, TRF
- Cepstrum
- Torsional vibration

RESONANCE IDENTIFICATION
AND RECTIFICATION

APPLICATIONS OF VIBRATION

ANALYSIS - BALANCING OTHER

PREDICTIVE TECHNIQUES

Oil particle and wear debris analysis

Thermography
Ultrasonics
Performance evaluation

summary, open forum and

closing

Identify conditions of resonance and be

able to rectify these problems

Apply basic allied predictive techniques

such as oil analysis, thermography,
ultrasonics and performance evaluation

On-Site Training

Save over 50% by having an IDCworkshop presented at

Practical Sessions

your premises.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

PUMPS AND COMPRESSORS:

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Control, Operation,
Maintenance and Troubleshooting

YOU WILL LEARN HOW TO:

Explain and understand pump/compressor terminology

Identify the various types of pumps/compressors

Understand pump/compressor characteristics and interpret

pump/compressor curves
Understand pump/compressor types and classification
Understand criteria for pump/compressor selection

Perform a number of simple pump/compressor calculations

Confidently test and commission pump/compressor sets
Explain how pumps/compressors are constructed

Detail how to install, test and commission pump/compressor

systems
Explain how to start up a new pump/compressor or one after
strip down for maintenance

WHO SHOULD ATTEND:

Plant operations and maintenance personnel

Consulting engineers
Design engineers
Process technicians

Plant engineering managers and supervisors

Process control engineers and supervisors
Mechanical engineers
Plant engineers

7.17

The Workshop

The Program

The pump/compressor workshop is a

comprehensive course focussing on the
fundamentals of centrifugal pumps and
compressors. You will have an opportunity
to discuss pump/compressor construction,
design-applications,
operations,
maintenance and management issues and
be provided with the most up-to-date
information and best practice in dealing
with the subject. Towards the end of the
workshop, you will have developed the skills
and ability to recognise and solve simple
pump/compressor problems in a structured
and confident manner.
This is not an advanced course but one
focussing on the fundamentals and therefore
will not be suitable for you if you are a pump
or compressor "guru"!

Pre-requisites

PUMP MAINTENANCE

What constitutes a good pump/

compressor or compressor?
Safety
Reliability
Efficiency
Risk consideration
Life cycle cost consideration
Overview of statutory requirements

Pump breakdown and removal

Single stage pump dismantling and
repair
Preparation for re-assembly
Pump assembly
Vertical and multistage pump repairs

CENTRIFUGAL PUMP DESIGN

AND CONSTRUCTION

What is a compressor?
Basic criteria for compressor selection
Compressor definitions

Casings
Impellers
Axial/radial forces
Pump/compressor shafts
Shaft seals balanced/unbalances, seal
wear patterns
Drives and couplings
Supports and pipe connections
Auxiliaries

INTRODUCTION TO
COMPRESSORS

RECIPROCATING COMPRESSORS

Principles and mechanics

Definitions
Parts of a reciprocating compressor
Maintenance and performance of
reciprocating compressors
Mechanical forces

CENTRIFUGAL COMPRESSORS

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A basic knowledge of mechanical engineering

principles and some working knowledge of
pumps and compressors would be useful.
Please note that this course does commence
with a brief overview of the fundamentals.

INTRODUCTION

CENTRIFUGAL PUMP
CHARACTERISTICS AND
OPERATION

Hydraulic properties of pumps

QH curves
PQ curves
Speed changes on curves

PUMP SPECIFICATION AND

SELECTION

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

System analysis
Data sheets
Bid requests/reviews/analyses

Introduction
Principle of operation
Operation
Parts of centrifugal compressors
Casing configurations
Types of compressors
Performance of centrifugal compressor
Polytropic compressor
Characteristic curves
Compressor controls

SUMMARY, OPEN FORUM

AND CLOSING

PUMP TESTING AND INSPECTION

Material inspection requirements

Shop tests
Performance test procedures
Site locations
Pump foundations
Associated piping and fittings
Pre-operational checks
Operation of pump

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

GAS TURBINES:

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Fundamentals, Maintenance,
Inspectionand Troubleshooting

YOU WILL LEARN HOW TO:

Explain the basic thermodynamic principles behind gas

turbines
Understand the basic operation of a gas turbine

Clearly describe the operation and function of gas turbine

components
Perform simple troubleshooting and maintenance

Do a simple review of the successful operation of a gas turbine

and know what characteristics are required for materials and
fuels
Perform simple condition monitoring interpretation and
maintenance

WHO SHOULD ATTEND:

Those new to gas turbines and more experienced technical

personnel who want an overview of the operation and available
technologies of gas turbines.

7.19

The Workshop

The Program

This workshop gives a solid review of gas

turbines with a focus on:
Fundamental thermodynamics
Gas turbine components
Materials of construction
Bearing, seals and lubrication systems
Fuels and fuel supply systems

Industrial heavy duty gas turbines

Aircraft-derivative gas turbines
Medium range gas turbines
Major gas turbine components
Heat recovery steam generators

FUNDAMENTAL
THERMODYNAMICS

Combustion air filters

Control systems and instrumentation
Operations and maintenance
Whilst it is unfortunately not possible to use a real
life turbine in the course due to cost (and perhaps
space considerations!), video clips, exercises and
case studies with actual hardware examples will be
used to make the course as interesting and practical
as possible.

Reversible cycles with ideal gases

Actual gas turbine cycles
Air compressor performance
characteristics
Combustion processes
Gas turbine performance calculations
Comparison of basic specifications

FUELS AND FUEL SUPPLY

SYSTEMS

Fuel specifications
Fuel properties
Fuel treatment
Heavy fuels
Fuel measurement
Fuel supply systems
Cleaning of turbine components

COMBUSTION AIR FILTERS

Combustion air quality requirements

Function of gas turbine air filters
Environment and type of inlet filters
Selection principles
Operation and maintenance

GAS TURBINE COMPONENTS

EXHAUST SYSTEMS

Sound abatement, inspection openings

and chimneys

Axial-flow compressor
Radial-inflow turbines
Combustors, construction and types
Igniters
Fuel nozzles
Hot path components
Axial-flow turbine
Firing concepts and emission control

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3 Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
The practical exercises are:
Components

OVERVIEW OF GAS TURBINES

MATERIALS OF CONSTRUCTION

Thermodynamics

Operation and maintenance

To gain full value from this workshop,

please bring your laptop/notebook
computer.

General metallurgical behaviour

Gas turbine blade materials
Turbine wheel alloys
Corrosion problems
Wear problems
Future materials
Coating technology

BEARINGS AND SEALS

Bearing design principles

Bearing materials
Non-contacting seals
Mechanical seals

LUBRICATION SYSTEMS

Basic components
Oil cooling and warming
Oil cleaning and conditioning
Lube oil selection

On-Site Training

AUXILIARY COMPONENTS AND

SYSTEMS
Starting systems, washing systems, gear
boxes, and couplings

CONTROL SYSTEMS AND

INSTRUMENTATION

Pressure measurement
Temperature measurement
Vibration measurement
Performance measurement
Control systems
Monitoring and diagnostic systems

GAS TURBINE OPERATIONS AND

MAINTENANCE

Operating philosophies
Analytical on-line condition monitoring
Using a borescope
Selecting maintenance approaches
Maintenance planning
Spare parts and special tools
Inspection, overhaul and repair
Maintenance control and documentation
Evaluating gas turbine maintenance
effectiveness
Establishing and tracking performance
Indices

MECHANICAL EQUIPMENT
STANDARDS

Save over 50% by

having an IDCworkshop
presented at your
premises.

Applicable API standards

ANSI standards
International standards (ISO)
Specifications

SUMMARY, OPEN FORUM

AND CLOSING

Customise the training to

your workplace.
Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Fundamentals of

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MECHANICAL ENGINEERING

YOU WILL LEARN HOW TO:

Understand the principles of mechanical drawings and design

Do basic static safety factor mechanical designs

Identify failure modes of mechanical components

Understand the behaviour of engineering materials and do basic

selections
Select manufacturing processes for simple designs

Design and implement simple mechanical automation systems

Understand the principles of fluid engineering

Identify and select basic fluid engineering components

Perform simple fluid engineering designs

Select a maintenance strategy for mechanical machinery

Recognise general mechanical problems and suggest corrective
actions

WHO SHOULD ATTEND:

This introductory seminar is designed for those with little or no

prior formal background, who function as managers, supervisors,
engineers, planners, inspectors, designers, researchers, investors
or procurers, and who seek a basic understanding of the practical
aspects of mechanical engineering.

7.21

The Workshop

The Program
BASICS OF MECHANICAL
ENGINEERING
Basic concepts
Units for engineering quantities
Friction and its importance

MECHANICAL DRAWINGS

Purpose of drawings
Lines, letters
Projections, views
Sections
Conventions
Dimensions
Symbols
Assemblies
Welds, bolts, keyways, rivets, etc.
Shafts and bearings
Fitting and tolerances
Couplings
Transmission components (belts, gears
etc.)
Flow control equipment
CAD
Design and drawing office practices

MANUFACTURING

Metal production - foundry

Casting
Heat treatment
Hot working of metal
Cold working of metal
Press work and tooling
Numerical control
Machining, metal cutting (turning,
drilling, boring, milling)
Shaping, sawing, broaching
Welding, brazing
CAM
Rapid prototyping

MECHANICAL AUTOMATION

Sensors and transducers

Pneumatics
Hydraulics
Mechanical and electrical actuation
Principles of control systems
PLCs

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This workshop introduces the basics and

fundamental concepts and applications of
Mechanical Engineering.The course starts with
an introduction to the basic principles of
mechanical drawings such as tolerances,
symbols, sections, fasteners etc. The use of
computer aided design and good drawing
office practises are also discussed. After this,
the properties and mechanical behaviour of
engineering components are presented.
Phenomena such as stress and strain, fatigue,
fracture, creep and corrosion are discussed.
Mechanical design philosophies are discussed
with the focus on the use of safety factors
during the design for static strength. Delegates
will have the opportunity to gain some insight
in the process of mechanical design for
manufacturing/production.
Various
manufacturing operations will be discussed,
starting with the production of metal and
alloys. The methods to shape metal into its
final desired shape, such as casting, forming,
machining, welding etc. will be discussed.
Delegates will be introduced to the use of
computerised methods of manufacturing
(CNC, CAM) and also the use of rapid
prototyping. Principles of mechanical
automation as it is typically found in industry
will be discussed with the focus on the
application of hydraulic and pneumatic
systems. There is also a discussion on electric
motors, mechanical actuation systems and
common control systems (e.g. PLCs).
The course will also introduce the various
aspects of pipe technology, including types of
pumps, flanges, gaskets, jointing methods,
pipe support and standards. The basic design
and analysis of pipe systems will also be
presented. An introduction of underlying
practical principals of thermodynamics will
also be included. The course closes off with a
discussion on one of the most important
aspects in mechanical engineering, namely
maintenance. A discussion on the various
types of maintenance philosophies and their
underlying principles will enable delegates to
identify the correct maintenance approach for
their workplace.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

ENGINEERING MATERIALS

The processing of metals and alloys

Stress and strain in metals
Normal stress and shear stress
Tensile and hardness testing
Stress and strain diagram
Alloy production and properties (stainless,
copper, aluminium, cast iron etc.)
Fracture of metals
Fatigue of metals
Creep and stress rupture of metals
Types of corrosion
Corrosion control

MECHANICAL DESIGN

Design philosophies/methods/phases
Factor of safety
Codes and standards
Loads (forces, moments)
Static analysis of systems
Design for static strength
Design of fasteners and connections
Design of load-carrying members
Fundamentals practises of design-forfatigue
Design for manufacturing
Tolerance, limits and fits

FLUID ENGINEERING

Pumps
Compressors
Other fluid engineering components
Design/analysis of piping systems
Principles of thermodynamics
(introduction to first and second law)
Power and refrigeration systems

MAINTENANCE OF MACHINERY

Maintenance philosophies
On-line tests/inspections
Time-based maintenance
Condition-based maintenance

THEORY OF HEAT TRANSFER

Heat basics
Heat transfer: conduction, convection and
radiation
Laws of thermodynamics
Thermal cycles
Heat exchangers: types, maintenance and
troubleshooting
Heat pumps
Air conditioning

summary, open forum

and closing

MECHANICAL ENGINEERING
CODES AND STANDARDS

Need for standardization

Overview of standards
Benefits of standardization
Mechanical engineering standardisation
ISO 9000/1
Six sigma

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

MECHANICAL DRIVES

(BELTS, CHAINS and GEARS)

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for Engineers & Technicians

YOU WILL LEARN HOW TO:

Install and maintain drives correctly

Align drives correctly

Apply correct lubrication techniques

Select bearings correctly

Troubleshoot and fix drives

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to

understand the use, care, installation, or the economics
associated with mechanical machinery. Those who will benefit
the most from this workshop include the following:
Consulting engineers
Design engineers

Drive sales engineers

Drive service contractors

Drive operators

Mechanical engineers
Plant engineer, managers and supervisors
Plant operations and maintenance personnel
Process control engineers and supervisors
Process technicians

7.23

The Workshop

The Program

The mechanical drives workshop is a comprehensive,

highly practical and interactive two-day course. You
will have an opportunity to discuss drive designapplications, operations, maintenance and
management issues. You will be provided with the
most up-to-date information and best practice in
dealing with the subject. Towards the end of the
workshop, you will have developed the skills and
ability to recognise and solve drive problems in a
structured and confident manner.

Mechanical Power
Transmission

Laws of motion
Mechanical advantage
Basic machines
Friction

V-belt, flat belt, synchronous/timing

Principles of operation
Determining proper tension
Belt selection
Miscellaneous belts

Gear Drive Systems

Introduction and general types

AC synchronous motors
Induction motors
Operating characteristics
Selection considerations

Square, flat, tapered and woodruff keys

Tapered, QD and split bushings
Splines
Sizing and fit
Symptoms of failure

Open and closed systems

Parallel, concentric and right angle
Load factors and selection
Service factoring
Installation and maintenance
Angular errors, backlash adjustment and
alignment considerations
Lubrication
Gear material
Troubleshooting

Couplings

Oil vs. grease

How much
How often

Bearings

Clutches and Brakes

General Lubrication
Considerations

Rigid and flexible couplings

Universal joints
Load factors
Chain couplings
Installation and alignment
Hydraulic couplings

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Most engineering professionals working with drives

will confirm that there are major benefits in installing
and maintaining mechanical drives correctly. Typical
areas which can be dramatically improved include:
less wear and tear on equipment; minimal unscheduled
downtime and production losses and improved
operating efficiencies.
.

Prime Movers

Bushings, Keys, and Keyways

Overview

Belt Drive Systems

The workshop has been designed to examine most

mechanical drives such as belts, chains, gears in terms
of improved lubrication, proper alignment and
fastening techniques. Finally, there is detailed coverage
of troubleshooting techniques so that you can identify
symptoms of failure well before the event and thus
correct the problem.

Types and construction

Bearing loads
Numbering systems
Installation and removal
Bearing clearance and pre-loading
Bearing failure
Bearing life
Bearing material
Troubleshooting

Chains

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

Precision roller chain

Sprocket selection
Silent chain
Engineering chains
Chain lubrication
Installation and maintenance

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Mechanical, friction, centrifugal and plate

clutches
Clutch selection
Torque converters
Mechanical, hydraulic, pneumatic and
electric brakes

Mechanical Variable Speed

Drives
Open and closed
Variable speed belt drives, gear boxes
and hydrostatic drives
Installation and adjustment
Belt materials
Troubleshooting
Service factoring

summary, open forum

and closing

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

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Balancing, Alignment and

Condition Monitoring of
Rotating Equipment

YOU WILL LEARN HOW TO:

Apply practical techniques for troubleshooting rotating

machinery

Eliminate problems through proven precision maintenance

methods
Identify which machines require precision maintenance
Reduce maintenance costs

Prevent failures from occurring

Manage a precision maintenance program

WHO SHOULD ATTEND:

Plant Operations and Maintenance Personnel

Consulting Engineers
Design Engineers

Process Technicians

Plant Engineer Managers and Supervisors

Process Control Engineers and Supervisors

Mechanical Engineers

Pump Sales Engineers

Pump Service Contractors
Pump Operators

7.25

The Workshop

The Program

This is a comprehensive, highly practical

and interactive two-day course. You will
have an opportunity to discuss precision
maintenance for rotating machinery and
associated
applications,
operations,
maintenance and management issues. The
focus will be on the most up-to-date
information and best practice. Towards the
end of the workshop, you will have developed
the skills and ability to recognise and solve
precision maintenance issues in a structured
and confident manner, in working and
improving the reliability and performance of
your rotating machinery.

Introduction

Alignment

After an introduction to the application of

maintenance and costs of breakdowns, the
important issue of vibration and vibration
measurement is detailed. The important
topic of balancing is then discussed drawing
on practical examples. Alignment and other
machinery faults are then covered. Other
often neglected areas of particle and
chemical analysis, temperature monitoring
and failure analysis are covered in practical
detail. The workshop is concluded with a set
of practical rules for a precision maintenance
program including issues, such as; which
machines to monitor, managing the data
usefully and scheduling maintenance.

Vibration measurement

The mission of maintenance

Maintenance philosophies
Cost of breakdowns
The role of precision maintenance

Vibration basics

Vibration sensors
Which to choose?
Sensor specifications
Sensor mounting
Spectrum analysers
Other instrumentation

Other common machinery

faults

Rotating machinery
Piping, bases and supports
Natural frequencies and resonance
Modal and deflection shape analysis
Troubleshooting unwanted vibration

Related tasks for precision

maintenance

ID CO
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What is vibration?
Vibration waves
Overall vibration
Vibration spectrum
Natural and forcing frequencies

Introduction
Identifying misalignment
Measuring misalignment
Rough methods
Reverse dial method
Face-rim method
Laser alignment
Alignment tolerances

Pre-requisites

A basic understanding of mechanical

processes is not essential, but would be
useful.

Balancing

Why balance?
Identifying unbalance
Practical aspects
Definitions
Single-plane balancing
Four-run method
Two-plane balancing
Overhung rotor
Balancing standards

Tighten, Lubricate, Clean (TLC)

Chemical and particle analysis
Ultrasonic inspection
Temperature monitoring
Performance monitoring
Failure analysis

Managing your precision

maintenance program

Baselines and trending

Which machines to monitor
Managing the data
Scheduling maintenance
Outsourcing
Selling to management: A new mindset

The presentation was excellent

and of excellent value.
Julian Dalesio

Good presentation and very

knowledgeable.
Paul Swales

Excellent workshop.
Knowledgeable and competent
instructor.
Ross Boyd

On-Site Training

Instructor had good background

knowledge that was used well
to support course material.

J Clarke

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

ID CO
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Pipeline Systems Design, Construction, Maintenance

and Asset Management

What YOU WILL LEARN:

Pipeline design standards

Design and construction considerations

Prediction, detection and treatment of corrosion

Environmental and legal requirements

How to meet and exceed key safety issues

Optimum risk and financial considerations

WHO SHOULD ATTEND:

Anyone who deals with design, construction and maintenance of

pipelines including:
Mechanical and Maintenance Engineers
Electrical Engineers

Pipeline Engineers and Contractors

Utility Advisors and Planners

Council and Regional Planners

Operations and Maintenance Managers

Technical and Project Managers
Contract and Asset Managers

7.27

The Workshop

The Program

This two-day workshop covers the practical

aspects of pipeline design, integrity,
maintenance and repair. Applicable codes
and standards will be examined, as will the
issues of mechanical and hydraulic design
and construction practices. The optimum
routing and layout techniques will also be
assessed. You will learn to recognise causes
of degradation in-service, whether
mechanically induced (pressure, fatigue,
pressure transients and external damage)
or due to corrosion for example, wall
thinning, pitting and cracking.
The focus of this workshop is mainly in a
land based environment and will teach you
to use key performance indicators to
measure the performance of your pipeline
system. It concentrates on the consideration
of internal, external and pipeline corrosion
and assess the various inspection and repair
techniques.

CONSTRUCTION PROCESS

Standards development
International and local codes applicable
to pipelines
Changes to the regulations
Steps in pipeline design
Different materials transmitted: gas,
steam and water

Sequential spread
Efficient construction
Hot-tap process
Hydrotesting
Practical Case Study

ROUTING TECHNIQUES AND

ENVIRONMENTAL
CONSIDERATIONS
Investigation of pipeline routing
techniques
Environmental issues to consider during
planning

SAFETY AND RISK

Hazard identification processes
Consequence and probability analysis
Risk management techniques
Practical Exercise

STRATEGY, RISK AND FINANCIAL

CONSIDERATIONS
Strategies for on-time delivery of costeffective projects
Strategic approach to pipeline
construction and management
Life cycle costing
Financial analysis techniques
Practical Exercises

FITNESS-FOR-PURPOSE
ANALYSIS
Pipelines Damage: corrosion,
mechanical, weld defects and ground
movement
Assessment techniques
Practical Exercise

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You will gain valuable knowledge in the

implementation of integrity management
programs, periodic inspections and
evaluation of results, as well as evaluation
of maintenance issues and asset
management. Extensive use will be made of
case studies and practical exercises to
ensure the material is covered as thoroughly
as possible.

PIPELINE DESIGN STANDARDS

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

PIPELINE DESIGN
CONSIDERATIONS

Compressible and non-compressible flow

Discussion of steady state and transient
analysis
Examination of pumps and compressors
Discussion of optimal pipe size vs.
location of pump/compressor stations
Discussion of optimal pipeline
construction material
Practical Exercise

MAINTENANCE PLANNING
PROCESS AND ANALYSIS ISSUES

CORROSION, ASSESSMENT AND

REPAIRS

Basic, intermediate and advanced asset

management plans
Staging the development of plan
improvements
Link between service delivery strategy
and financial considerations
Practical Exercise

Introduction to practical corrosion

Classification of corrosion mechanisms
Internal corrosion
Predictions of corrosion rates
Chemical treatments, inhibitors and
biocides
External corrosion
Coating applications
Cathodic protection, design, operation
and maintenance
CP evaluation
Practical Exercise

PIPELINE CORROSION

On-Site Training

CO2/sweet
Local and generalised corrosion
Soils and microbiologically induced
corrosion
Practical Exercise

Pipeline management and maintenance

strategies
Link between task importance and asset
criticality
Maintenance benchmarking techniques
Practical Exercise

ASSET MANAGEMENT

KEY PERFORMANCE
INDICATORS: MONITORING AND
EVALUATION
Selection of KPIs to measure asset
performance
Selection of KPIs for your infrastructure
business
KPIs how to use them to identify
weaknesses
Practical Exercise Translating KPI results
into action

summary, open forum

and closing

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Fundamentals of

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Process Plant Layout

and Piping Design

WHAT YOU WILL LEARN:

Plant layout fundamentals and procedures

Fundamental principles of chemical process technology

Terminology and symbols used in plant layout
Equipment used in process plants

Piping design and engineering principles

Terminology, symbols and abbreviations in piping design

Documents (bill of materials, equipment specifications etc) and

drawings (PFDs, P&IDs etc) used in plant layout and piping design
3D modeling of plants and piping systems

WHO SHOULD ATTEND:

This course is designed for personnel who want to understand the

design and engineering principles involved in process plant layout and
piping design. Those who will benefit the most from this workshop
include the following:
Personnel from EPC (Engineering, Procurement and Construction)
companies
Chemical (process) engineers
Mechanical engineers

Piping designers and piping engineers

Project engineers

Personnel providing CAD support for plant layout and piping

design
Designers and engineers involved in instrumentation and control
of process plants
Equipment designers and engineers
Structural designers and engineers
Electrical designers and engineers
Consulting engineers
Plant maintenance personnel
7.29

The Workshop

The Program
Introduction to Process
Plant Layout and Piping
Design

Plant Layout and Piping

Design Documentation and
Tools

Plant layout fundamentals

Procedures and workflow
Physical quantities, units, trigonometry

Introduction to Chemical
Processing Methods
Unit operations and unit processes
Process Flow Diagrams (PFDs)
Utilities

Equipment Used in Process

Plants
Process equipment reactors, towers,
exchangers, vessels
Mechanical equipment pumps,
compressors, turbines
Equipment drawings, nozzle
specifications, vendor drawings
Equipment foundations and supports

Line lists
Equipment lists
Bill of materials
P&IDs
Piping isometrics
3D models
Piping specifications
Piping codes

Fundamentals of Pipe

Pipe dimensions
Pipe data
Pipe joining methods
Pipe representation
Common abbreviations

Piping System Components

Fittings elbows, tees, reducers, end
caps
Fitting makeup and dimensions
Flanges
Valves
Pipe racks
Pipe supports
Anchors and guides

ID CO
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The process plant layout and piping design

course is a comprehensive, highly practical
and interactive two-day course. You will have
an opportunity to learn and discuss the
techniques and procedures used in the design
and engineering of complex process plants.
You will learn the fundamentals of plant
layout, the equipment used, design principles
and procedures. You will also learn the
fundamentals of piping system components
and the specification and design of these
components. Practical examples from actual
projects will be used extensively to illustrate
the principles and drive home the point. You
will also be provided with a high quality
course manual that IDC is known for. This
course manual will be useful for many years
after the course.

Plant Layout and Plot Plans

Objectives

Process plants, such as refineries and

petrochemical plants, are complex facilities
consisting of equipment, piping systems,
instruments, electrical systems, electronics,
computers, and control systems. The design,
engineering and construction of process
plants involve a multidisciplinary team effort.
Plant layout and design of piping systems
constitute a major part of the design and
engineering effort. The objective is to design
safe and dependable processing facilities in a
cost effective manner.The fact is that there are
few formal training programs with a focus on
plant layout and design of piping systems.
Therefore, most of the required skills are
acquired while on the job, reducing
productivity and efficiency.

Plant layout specifications

Codes
Safety considerations
Plot plans
Equipment arrangement drawings

Process and
Instrumentation Diagrams
(P&IDs)
Instruments and instrument symbols
Control valve manifolds
Meter runs

Pipe Routing

Piping isometrics
Piping plans, sections, elevations
3D representation

SUMMARY, OPEN FORUM

AND CLOSING

This course will cover the fundamental

principles and concepts used in process plant
layout and piping design. Upon completion of
this course the attendees will have a clear
understanding of the design and engineering
principles used in plant layout and piping
design. The outcome will be a work force with
the required skills and faster learning curves
with minimal on the job training. This will
increase productivity and shorten engineering
and construction schedules. The process
plants will get on stream quicker and operate
with increased safety and reliability, satisfying
the needs of the client.

On-Site Training

Save over 50% by having an IDCworkshop presented at

Practical Sessions

your premises.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your
laptop/notebook computer.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

ID CO
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Mechanical Sealing with

Rotary, Pneumatic and Hydraulic
Seal Types plus Gaskets
YOU WILL LEARN HOW TO:

Demonstrate a sound understanding of the fundamentals of

seal selection
Understand environmental considerations related to seals
See how the experts repair and rebuild seals for outstanding
performance
Troubleshoot seals
Maximise mechanical seal life
Classify various seals, including special seal types
Explain considerations related to the materials used in seal
construction

WHO SHOULD ATTEND:

Consulting engineers
Design engineers
Environmental engineers
Facilities engineers and
managers
Lubrication technicians
Maintenance personnel
Mechanical engineers and
technicians
Operation, maintenance,
inspection and repair
managers, supervisors and
engineers
Operators
Plant engineers, managers
and supervisors
Plant operations and
maintenance personnel

Predictive maintenance
professionals
Process control engineers
and supervisors
Process operators and
technicians
Process technicians
Pump operators
Pump sales engineers
Pump service contractors
Rotating equipment
engineers
Safety specialists
Sales engineers
Service contractors
Supervisors and foremen

Also anyone involved in maintenance who need or specifies, or

uses mechanical seals
7.31

The Workshop

The Program

Whether you consider yourself an amateur

or knowledgeable, practical or theoretical,
you will find this mechanical seals workshop
is jam-packed with useful, easy-to-apply
information. Faced with the bewildering task
of selecting the correct seal type and
materials of construction for a given
application, it's no wonder many end users
leave the job to others. After attending this
workshop, you will have the knowledge and
confidence to select correct seal types,
analyse failed seals, determine the cause/s
of failure and propose practical, remedial
action.

FUNDAMENTALS AND
PRINCIPLES

MECHANICAL SEAL SELECTION

AND STANDARDS

Learn how, with simple modifications, you

can extend seal life and reduce or eliminate
causes of premature seal failure. The
workshop commences with a solid review of
the fundamentals, basic principles and looks
at seal classification and design. Special seal
types are examined and the materials used
to construct seals ranging from elastomeric
materials to cemented carbides are
examined.

GENERAL AND SPECIAL SEAL

TYPES
Static and dynamic seals
Special seal types
Bushing, labyrinth and diaphragm seals
Gas, motion, slurry seals
Carbon seals
Liquid ring and liquid barrier seals
Inflatable, ferrofluidic seals
Positive action type
Self-adhesive compression seals

Selection considerations
Process liquid characteristics
Inboard vs outboard mounting
Rotating vs stationary seal ring
Face loading
Primary seal ring design
Secondary sealing devices
Seal selection rules
Mechanical seal standards

SEAL FAILURES

Factors influencing seal life

Factors affecting seal performance
Categorisation of failures
Seal malfunction and probable causes
Premature failure causes
Seal face symptoms
Friction and wear
Adhesion, abrasion, corrosion and
surface fatigue

ID CO
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Definition of zero leakage

Mechanics of sealing
Leakage
Purpose of sealing
Basics regarding speed and pressure
Temperature considerations
Basic seal requirements
Seal friction
Wear and seal life
Texture

MATERIALS OF SEAL
CONSTRUCTION

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Properties of elastomers
Elastomeric materials
Plastic polymers
Cemented carbides
Miscellaneous sealing materials

SEALS FOR SPECIFIC/SPECIAL

APPLICATIONS

Hydraulic and pneumatic seals

Seals for special applications
Large diameter seals
High-speed sealing applications and
requirements
Sources of excessive hydraulic pressure
Overcoming problems associated with
high-pressure
Vacuum sealing applications

TROUBLESHOOTING FAILED
SEALS

At the pumping site

At the equipment teardown
Leakage types
Discoloration, chipping, cracking,
rubbing, elastomer swelling, stickiness,
hardness what do these mean?

HOW TO MAXIMISE MECHANICAL

SEAL LIFE
Preparing the pump mechanically,
hydraulically
Controlling temperature in the stuffing
box
Controlling pressure in the stuffing box
What seal to choose?
What face combination and elastomer?

SUMMARY, OPEN FORUM

and CLOSING

SEAL SELECTION, APPLICATION

AND STANDARDS
Seal selection guides
Static and dynamic seal applications
Standards-ISO, British, DIN, ASME

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Best Practice Design, Maintenance

and Troubleshooting of

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Conveyors and Chutes

YOU WILL LEARN:

Maintenance practice
The fundamentals of belt conveyor design
Troubleshooting conveyer problems
Splicing techniques
Safety management
Design and installation
Capacity, sizing and power of equipment
A practical emphasis ensures that the above concepts
are put into practice.

WHO SHOULD ATTEND:

Maintenance engineers, technicians and staff

Plant engineers
Operation, maintenance, inspection and repair managers,
supervisors and engineers
Mechanical engineers and technicians
Design engineers
Electrical engineers and technicians
Consulting engineers

7.33

The Workshop

The Program

The workshop will cover basic conveyors,

selection,
safety,
legal
obligations,
terminology and background.
This workshop is designed for engineers and
technicians from a wide range of abilities and
backgrounds and will provide an excellent
introduction to troubleshooting and
maintenance of conveyors and chutes. It is
intended to cover the fundamentals of belt
conveying and would be useful for those with
little experience in this area.
Before commencing a detailed course on
conveyers it is important to have a solid
practical knowledge of the material to be
conveyed. A basic knowledge is provided of
the bulk materials characteristics and
properties.

Fundamentals of bulk materials handling

Nature of bulk solids
Characteristics of generally used bulk
materials
Conveyors and chutes overview
Practical Exercise

BELT CONVEYING

Introduction
Layout
Basic configuration
Components of a standard conveyer
Capacity of belt conveyors and selection
of belt width
Selection of other components
(belt, idlers, pulleys, takeups etc)
Simple calculation of belt tension
Selection of drive
Troubleshooting tips
Take-ups
Operation and maintenance of belts
Tips for cost savings
Practical Exercise

MAINTENANCE AND
TROUBLESHOOTING OF
CONVEYORS
Troubleshooting conveyor problems
Types of joints
Splice failures, inspections and repairs
Typical problems
Root cause process
Systematic approach for tracking
Site specific problems
Case Study
Practical Exercise

CHUTE MAINTENANCE AND

TROUBLESHOOTING

Transfer chutes theory

Laser scanning applications
Best practice design
Boosting flow
Troubleshooting chutes
Spillage and build-up
The awkward marriage of conveyer and
chutes
Practical Exercise

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Numerous tips throughout the course make

it practical and topical. Belt conveyers
frequently provide the most satisfactory and
economical method of transporting materials
such as mine ores, earth, sand, crushed
stone, cement and concrete. The high and
continuous speed of operation of the belt
makes for a high capacity of transport of
materials.

INTRODUCTION

Throughout the course, you will engage in

problem solving and case studies to absorb
the materials as quickly and effectively as
possible.

Pre-requisites

Fundamental knowledge of basic mechanical

plant and operation thereof.

Practical Sessions

SAFETY OF CONVEYORS

Conveyor safety standard

General background on AS 4024.1
(RA and hazard recognition)
Hazard recognition
History of accidents
Key conveyor safety issues
Demonstration of unsafe conveyors
AS 1755 conveyors
Chute doors hazards and controls
Case Study
Practical Exercise

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

FEEDERS MAINTENANCE AND

TROUBLESHOOTING
Belt, apron, screw and other feeders
Optimum draw down
Troubleshooting typical problems
Practical Exercise

STORAGE AND FLOW

Flow properties of materials

Funnel-flow and expanded flow
Flow rate analysis
Gravity reclaim
Bin wall pressures
Practical Exercise

SUMMARY, OPEN FORUM

and CLOSING

To gain full value from this workshop,

please bring your laptop/notebook
computer..

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Practical

ID CO
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Process Compressors

What YOU WILL LEARN:

Different types of compressors used in process industry

Their principle, design, construction, operation and
maintenance

Theoretical basis that helps evaluate the efficiency of their

operation
Operating and Mechanical range and limits of the various
types of compressors
Practical Maintenance Procedures and Techniques

WHO SHOULD ATTEND:

Anyone who deals with design, operation and maintenance of

compressors in the course of their work, including:
Mechanical Engineers

Maintenance Engineers

Reliability Engineers
Electrical Engineers

Professional Engineers

Utility Advisors & Planners

Municipal & Regional Planners
Operations Managers
Maintenance Managers
Project Managers
Contract Managers
Asset Managers
Technical Managers
7.35

The Workshop

The Program

This workshop guides you from the basics of

thermodynamics to every practical aspect of
air and gas compression as used in any
process industry. It covers the principle,
design, construction, operation and
maintenance of the most commonly used
types of compressors.
The compressors covered in this workshop
include the different types of positive
displacement and dynamic compressors. It
discusses the special features of every
compressor type, their range of operation,
applications and limitations. Various aspects
needed to size, select, operate, troubleshoot
and maintain different types of compressors
are covered in great detail.

Screw Compressors

What is a compressor?
Compressor definitions

Gas Properties and

Thermodynamics
Gas Laws and properties
Calculating properties
Thermodynamics basics

Reciprocating Compressors

Mechanics
Parts of reciprocating compressor
Troubleshooting compressor problems
Maintenance of reciprocating
compressors

Centrifugal Compressors

Principles
Parts
Casing configurations
Types of centrifugal compressors
Performance of centrifugal compressors
Performance coefficients
Compressor capacity control
Anti-surge controls
Compressor sizing
Rotor dynamics
Maintenance of centrifugal compressors

Principles
Construction
Characteristic parameters
Sizing and performance
Rotor dynamics
Capacity control
Maintenance

Lobe Blowers

Principles
Construction
Selection of lobe blowers
Maintenance of lobe blowers

Axial Compressors

Principles
Construction
Performance curve
Sizing
Rotor dynamics
Maintenance of axial compressors

ID CO
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The topics attempt to encompass the latest in

compressor hardware and their manufacturing
processes. It covers the various designs and
materials of components and details their
special features.

Compressor Basics

The interactions of components bring about

the dynamics of gas compression. The
correlation of thermodynamics theory to
practical gas compression helps you to
understand the fundamentals of compressor
operation. This association has been done
using many numerical examples. The
behaviour of various compressor under
different conditions is explained in a manner
that makes it very simple to understand the
how and why of their operation. The user
would also be introduced to the various
phenomena in gas compression that limit
operation of compressor beyond certain
limits.

Summary, Open Forum

& Closing

Performance calculations are included and

that enable you to evaluate the efficiency and
energy requirement of compressors. This
helps to benchmark their performance. These
are shown as an important tool to trouble
shoot compressor problems and aid in
operating them in an efficient manner. The
various formulae and empirical relationships
required to size and select the different types
of compressors are also covered.
A special focus is made on the dynamics of
compressor machinery. It introduces the user
to rotordynamic concepts in rotating machines
and various forces and moments in
reciprocating machines.
The workshop covers the practical aspects of
maintenance of the different compressor
types. It covers the key stages of compressor
overhaul and repair.

The workshop raises the knowledge bar by

many notches for someone new to
compressors while at the same proving to be
a very good refresher and reference material
for an expert in gas compression.

On-Site Training
Practical Sessions

Save over 50% by having an IDCworkshop presented at

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Performance Monitoring of

ID CO
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Pumps and Compressors

What YOU WILL LEARN:

Optimising equipment performance

Performance monitoring strategies

General hydraulic concepts in relation to performance

monitoring

Centrifugal pumps - construction, operational principles,

selection criteria, power requirements, efficiencies and losses,
characteristic curves, performance calculations
Gas properties - thermodynamic concepts and processes,
Thermodynamic and gas laws, ideal gases, computation of gas
properties, gas power cycles
Reciprocating compressors - construction, operation,
compression terms, performance calculations, evaluating
efficiencies and methods to estimate them, analysis of PV
diagrams
Centrifugal and axial flow compressors - design and operational
aspects, compression terms, performance calculations,
evaluating adiabatic and polytropic efficiencies and methods to
estimate them

WHO SHOULD ATTEND:

Anyone who deals with design, selection, sizing, operation and

maintenance of pumps and compressors in the course of their
work, including:
Mechanical Engineers

Operations Managers

Maintenance Engineers

Maintenance Managers

Reliability Engineers

Project Managers

Electrical Engineers

Contract Managers

Professional Engineers

Asset Managers

Utility Advisors and Planners

Technical Managers

Municipal and Regional Planners

7.37

The Workshop

The Program

As the process plants have got bigger, the

machines have become larger in terms of
their power ratings and complexity. At the
same time, the demand for efficient operation
and higher availability of these machines
has been on the rise and this in turn has led
to the adoption of modern maintenance
strategies and practices by the industry, so
that these objectives may be achieved.
Condition Monitoring of equipment is one
best practice that has proven itself over the
years. It is now considered an integral part
of an effective plant asset management
strategy. Condition monitoring of plant
equipment comprises of
Mechanical health monitoring
Performance monitoring

Gas Properties and

Thermodynamic Concepts

Equipment degradation and loss in

efficiency
Optimising equipment performance and
establishing best maintenance practices
Introduction to performance monitoring
Performance monitoring strategies and
techniques
Benefits of performance monitoring

Basic thermodynamic concepts

Working substance and thermodynamic
processes
State of a system and its transformations
Ideal gases
Equilibrium state
Overview of the various gas laws
Laws of thermodynamics
Gas power cycles

Hydraulic principles and

concepts
General liquid characteristics and
properties
Concepts related to pressure, volume,
flow, head and resistance
Pascal's law and momentum equation
Hydraulic power and pump efficiency
Specific speed
Cavitation, recirculation and Net Positive
Suction Head (NPSH)
Impact of jet on normally fixed plates,
inclined fixed plates and hinge plates
Impact of jet on a fixed curved vane,
moving curved vane and series of vanes
Velocity triangles

Reciprocating Compressors
Principle of operation and construction of
reciprocating compressors
Classification of reciprocating
compressors
Mechanism of a single-stage
reciprocating compressor
Work done in a single-stage reciprocating
compressor
Multi-stage reciprocating compressors
Work done in a multi-stage reciprocating
compressor
Volumetric efficiency and performance
Achieving maximum efficiency in multistage reciprocating compressors
P-V diagrams and their analysis

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The former includes techniques such as

vibration analysis, oil and wear particle
analysis, thermography, ultrasonics and
others.

Introduction and
Fundamentals

Performance monitoring on the other hand

is the thermodynamic and hydraulic
evaluation of the equipment. This technique
determines the efficiency with which energy
conversions occur in the equipment.

Performance calculations enable the

computation of energy requirements of
equipments. This helps in benchmarking
their performance. In case gaps are noticed,
this technique has the ability to troubleshoot equipment problems. It can also
indicate equipment problems that may not
be normally detected by mechanical health
monitoring. When used together, they help
provide efficient operation of the equipment
and at higher availability levels.

Another utility of the performance monitoring

technique is that the same theory and
concepts can be employed in the sizing,
selection and re-rating of the equipment. It
thus becomes a useful tool especially during
the process of evaluation of technical bids.
This workshop covers in detail, the technique
of performance monitoring as applied to
centrifugal pumps and positive displacement,
centrifugal and axial flow compressors. The
topics of discussion include

Centrifugal Pumps

Principle of working of centrifugal pumps

Centrifugal pump components
Range of operation
Selection considerations
Multi-stage operation in centrifugal
pumps
Abnormal operation
Power requirements, efficiencies and
losses in centrifugal pumps
Pump characteristic curves
Improving pump reliability
Performance calculations

Solved examples and

Practical exercises

Workgroup assignments

Centrifugal and Axial-flow

Compressors
Construction and principle of working of
centrifugal compressors
Classification of centrifugal compressors
Design and operation of axial-flow
compressors
Efficiency and performance
characteristics
Adiabatic and polytropic efficiencies
Methods used to evaluate efficiencies
Practical session comprising quiz questions
and sample performance calculations +
exercises

SUMMARY, OPEN FORUM

and CLOSING

Principles of operation
Thermodynamic
evaluation

and

hydraulic

Important performance parameters and

selection considerations

Methods to derive the above from first

principles and empirical relationships
Handling gas and gas mixture properties
Interpretation of results

The course includes a large number of

practical examples that help to learn and
clarify the concepts. These can then be
readily applied to real machines in plants, to
evaluate their present performance,
benchmark with rated values and analyse
the causes for the gaps. Additionally,
examples involving sizing and selection of
the equipment are also included.
The workshop will be of immense benefit to
those involved in the procurement, operation
and
maintenance
of
pumps
and
compressors.

Practical Sessions
This is a practical, hands on workshop
enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Fundamentals of

Pipe Stress Analysis

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With Introduction to CAESAR II

What YOU WILL LEARN:

How stress analysis is carried out in piping systems

The fundamental aspects related to selection of piping materials

The objective and scope of piping codes

The theory behind piping system stresses and failure theories

The basis for determining the design pressure and temperature
conditions
The methods employed to determine pipe wall thickness

Piping system loads and their characteristics along with code

criterion for designing piping systems
The design criteria for thermal stresses in piping systems
The significance of pipe stress analysis software in general, with
particular emphasis on CAESAR II and the tools and procedures
used in the creation of stress models

WHO SHOULD ATTEND:

This workshop is designed for personnel who want to understand

the engineering principles involved in pipe stress analysis. Those
who will benefit the most from this workshop include the following:
Chemical (process) engineers
Consulting engineers
Equipment designers and
engineers
Mechanical engineers
Personnel from EPC
(Engineering, Procurement
and Construction) companies

Piping designers and piping

engineers
Plant layout and piping
design personnel
Plant maintenance personnel
Project engineers
Structural designers and
engineers
7.39

The Workshop

The Program

Piping system design constitutes a major part

of the design and engineering effort in any
facility. Stress analysis is a critical component
of piping design through which important
parameters such as piping safety, safety of
related components and connected equipment
and piping deflection can be addressed. The
objective of pipe stress analysis is to prevent
premature failure of piping and piping
components and ensuring that piping stresses
are kept within allowable limits.

Need for stress analysis

Consequences of overstress
Physical quantities and units used in
pipe stress analysis

Piping Materials
Introduction
Material classification systems and
specifications
Common ASTM piping materials
Material requirements of codes
Selection criteria for materials
Piping specifications (piping classes)
Material testing and certificates

Codes Governing Piping

Design and Stress Analysis
ASME B31.3, ASME B31.4 and ASME
B31.8
Other codes including applicable local
codes
Role and scope of codes
Information available from codes
Typical organisation of code material

Design of Pipe Wall Thickness

for Internal Pressure
Wall thickness design equations ASME
B31.3, ASME B31.4 and ASME B31.8
Calculation of Maximum Allowable
Working Pressure (MAWP)
Pressure temperature class ratings for
flanges
Determining appropriate flange pressure
class

Loads on Piping Systems

Primary and secondary loads
Self-limiting and nonself-limiting
characteristics of loads
Sustained and occasional loads
Static and dynamic loads
Bending stresses in pipes
Longitudinal stress and torsional stress
Code criteria for design

Thermal Stresses in Piping

Systems

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This workshop is designed for personnel

from a wide range of abilities and
backgrounds and will cover the fundamental
principles and concepts used in pipe stress
analysis. In addition to meeting the needs of
design, the course is structured to provide
you an in-depth understanding of the
engineering principles involved in material
selection, application of code criteria and
the capabilities and tools incorporated in
stress analysis software. The extensive use
of case studies and practical exercises
during the course of the discussion ensures
as comprehensive coverage of the material
as possible.

Introduction to Pipe Stress

Analysis

The pipe stress analysis workshop is a

comprehensive, highly practical and
interactive course. Along with learning the
fundamentals of piping stress, you will also
learn to appreciate the need for stress
analysis in piping systems and the various
design principles and procedures involved.
You will have an opportunity to learn about
the failure theories and codes governing
piping design and stress analysis. Piping
load characteristics and procedures used in
designing pipe wall thickness will be outlined
in sufficient detail. The importance of stress
analysis software in piping system design
will be emphasised through a comprehensive
overview of the CAESAR II software. Practical
examples from actual projects will be used
extensively to illustrate the principles
involved, to enable a better understanding.
You will also be provided with a high quality
course manual that will prove useful for
many years to come.

Principal Stresses and

Failure Theories

Longitudinal, circumferential and radial

stresses
Principal axes and principal stresses
Failure theories:
- Maximum principal stress failure
theory
- Maximum shear stress failure theory

Design Pressure, Design

Temperature and Allowable
Stress

Definition of design pressure and design

temperature
Basis for allowable stress
Allowable at hot and cold
conditions, that is, Sh and Sc
Code tables for allowable stresses

Thermal expansion/contraction of
materials
Stresses due to thermal expansion/
contraction
Thermal fatigue and cyclic stress reduction
factor
Design criteria for thermal stresses:
- Stress Intensification Factors (SIFs)
- Allowable stress range for thermal
expansion
- Calculation of expansion stress range

Pipe Stress Analysis Software

Introduction to CAESAR II stress analysis
software:
- Overview of CAESAR II software
- Piping input and creation of model
- Navigation and toolbars
- Static analysis and output
- Checking for code compliance

CAESAR II Practical Exercises

Piping input creating the model

Running the analysis
Output and interpretation of the results
CAESAR II practical exercises I and II

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

Practical Sessions

delivered when and

where you need it.
Contact us for a
free proposal.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

idc@idc-online .com

www.idc-online .com

Practical

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Corrosion Management

what YOU WILL Learn:

Corrosion mechanism, concepts and types

Metal defects, metallurgical factors and electrical concepts
Oxidation principles and its effect on metals
Corrosion forms and characteristics
Corrosion under specific environmental conditions
Chemical properties of materials and proper material selection for
minimizing the impact of corrosion
Corrosion protection methods, failure analysis and prevention
Evaluation of various techniques used for testing and monitoring
corrosion
Corrosion and its impact with regard to different industries

WHO SHOULD ATTEND:

This workshop is designed for personnel who want to learn, understand

and effectively implement the principles related to corrosion management,
metallurgy and failure prevention. Those who will benefit the most from
this workshop include the following:
Chemical engineers
Consulting engineers
Equipment designers and engineers
Material procurement personnel
Mechanical engineers
Metallurgical engineers
Plant inspection and maintenance personnel
Process control engineers
Project and design engineers
Quality control engineers
Technical managers
Weld inspectors

7.41

The Workshop

Practical Sessions

Process plants such as refineries and petrochemical plants are complex facilities consisting
of a wide range of equipments and system components and their design, engineering and
upkeep involves a multidisciplinary team effort. Corrosion management has a pivotal role to
play in maintaining the integrity of a facility, since a large number of incidents and failures
that occur in process plants are found to be related to the phenomena of corrosion and
erosion. This is more so in the face of increased requirements for improved productivity and
cost effectiveness, combined with an increased emphasis on environmental and safety
related issues. By effectively managing the critical parameters and activities related to
corrosion and material degradation, sufficient cost savings and safety in operation can be
ensured. By paying adequate attention to corrosion in aspects related to material selection,
construction, operation and maintenance of infrastructure facilities, it is possible to achieve
savings to the tune of billions of dollars in repair, maintenance, and replacement costs.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

The Program
INTRODUCTION TO CORROSION

Corrosion Forms

Definition of corrosion
Types of corrosion
Cost of corrosion

Nickel and nickel alloys

Aluminum and aluminum alloy
Magnesium and magnesium alloys
Copper and copper alloys
Titanium and titanium alloys
Zinc and zinc alloys
Tin and tin alloys
Corrosion resistance of non-metallic
materials

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Corrosion Fundamentals

Thermodynamic aspects of aqueous

corrosion
Aqueous corrosion kinetics
Effect of concentration
Electrode potentials, anodic and cathodic
reactions
Utilities Potential measurement with
reference electrode, standard redox
Potential
EMF series
Exchange current density
Mixed potential theory
E-log (i) Evans diagram
Corrosion cells
Tafel equation and Tafel plot for corrosion
rate determination
Linear polarization and Stern-Geary
equation
Types of polarization and rate controlling
step
Passivity and passivation behavior of
iron in nitric acid
Effect of temperature and pressure on
rate of corrosion
Effect of velocity on rate of corrosion
Definition and effect of pH
Dissolved gases and importance of
dissolved oxygen

Basic Metallurgy and

Electrical Concepts

Introduction to metallurgy
Principles of Metallurgy
Defects in metals
Metallurgical factors affecting corrosion
Iron-carbon phase diagrams
Common ferrous and non-ferrous metals/
alloys
Microstructure of common metals/alloys
Weldment metallurgy
Basic electrical concepts

Oxidation

Uniform corrosion
Aqueous corrosion
Atmospheric corrosion
Galvanic corrosion
De-alloying and graphitization
Stray current corrosion
Pitting corrosion
Crevice corrosion
Filiform corrosion
Effects of metallurgical variables on
aqueous corrosion
Effects of metallurgical variables on the
corrosion of stainless steels,aluminum
alloys and de-alloying corrosion
Erosion corrosion, impingement attack
and cavitation damage
Stress corrosion cracking, stress
corrosion
Inter-granular stress corrosion cracking,
weld decay and knife-line attack
Hydrogen damage, hydrogen
embrittlement
Selective leaching
Liquid metal induced embrittlement
Solid metal induced embrittlement
Sulfide stress cracking
Exfoliation
Caustic embrittlement
Corrosion fatigue
Fretting
Microbiologically influenced corrosion in
metals

Oxidation of metal and alloys

Oxidation resistance of low alloy steel
Environments
High temperature corrosion

Corrosion under Specific

Environmental Conditions

Corrosion in atmospheres
Corrosion in portable water, natural
waters and sea water systems
Corrosion in soils
Corrosion of reinforcement and concrete

Design and Material

Selection for Corrosion
Prevention
Introduction to methods of corrosion
protection
Corrosion resistance properties of
stainless steels
Corrosion resistance properties of cast iron
Corrosion resistance properties of carbon
steel and low alloy steels

idc@idc-online .com

Corrosion Protection
Methods

Surface treatment and conversion

coatings
Ceramic, glass and oxide coatings
Metal coatings
Coatings and linings
Electrochemical corrosion control
methods
Cathodic and Anodic protection
Corrosion inhibitors

Failure Analysis and

Prevention

General approach to failure analysis

Rudiments of Corrosion Failure Analysis
General methods of failure prevention
Preventing Corrosion Failures by Design

Corrosion Testing and

Monitoring

Basics of corrosion monitoring

Corrosion testing and monitoring
techniques
NDT for off-line monitoring

Brief Discussion on
Corrosion for Different
Industries

Marine corrosion
Food industry
Pulp and paper industry
Aerospace industry
Mining industry
Electronics industry

summary, open forum

and closing

www.idc-online .com

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RELIABILITY CENTRED
MAINTENANCE (RCM)

what YOU WILL Learn:

Understand the history of RCM, i.e. classical, RCM 2 and streamlined

RCM
Paradigm changes in industry due to the implementation of RCM
Benefits of RCM to your organisation
Planning the RCM process
RCM working groups
Integration of maintenance management with overall business
objectives
Building the RCM principles into new designs
Development of a maintenance strategy blueprint
Key Performance Indicators (KPIs) for RCM

WHO SHOULD ATTEND:

This workshop is intended for all maintenance managers, reliability

engineers and technicians directly involved in maintaining and
preserving the function of assets. Since the RCM process makes use of
cross functional groups as well as the fact that a lasting maintenance
program can only be developed by maintainers and users of the assets,
it is also recommended that operation/production personnel attend this
workshop to ensure an effective RCM program. These should comprise:
Consulting engineers
Key leaders from each maintenance craft
Maintenance managers/supervisors
Operation specialists
Planners
Plant managers
Reliability engineers/technicians

7.43

The Workshop

The Program

The primary objective of the maintenance

function is no longer only to focus on
optimising plant availability at minimum
cost. In modern day, maintenance affects all
aspects of business effectiveness and risk, i.e.
safety, environmental integrity, energy
efficiency, product quality, customer service,
plant availability and cost. Further to this
maintenance is about preserving the functions
of assets, as well as avoiding, reducing or
eliminating the consequence of failure.
Reliability Centred Maintenance (RCM) is a
systematic and structured process used to
decide what must be done to ensure that any
physical asset, system or process continues
to do whatever its users want it to do. It is
taking into consideration the primary
performance parameters of the asset,
possible failure mode and consequence and
lastly a suitable failure management policy.

Pre-requisites

All the principles of RCM will be covered,

including the type of strategies, as well as
the tools that are used to facilitate the
process. A basic knowledge of maintenance
management as well as the practical
operations and maintenance of assets
would be an advantage. This practical
experience will enable the workshop to be
placed in context.
No special knowledge or skills are required
only a technical background so that there is a
better understanding of issues related to
RCM and the application thereof.

Evolution of maintenance
History of RCM
Classical RCM
RCM2
Streamlined RCM

WHY RCM FOR MY

ORGANISATION

Why RCM is different

The new paradigms in maintaining assets
What you should expect from RCM
Who should do RCM

PROJECT INITIATION

Planning and preparation

Setting up review groups
Selecting facilitators
Selecting the systems for RCM analysis

TYPES OF PREDICTIVE
TECHNIQUES AVAILABLE

The Human
Vibration monitoring and analysis
Thermography
Oil analysis rotating and transformers
Ultrasonic
Magnetic flux
Dye penetrant
Radiography
MPI
Eddy current

IF NO PROACTIVE TASK IS
AVAILABLE?
When and how to do failure-finding
(including RCAs)
When to redesign
When to run to failure

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This workshop is designed to familiarise you

with the principles and the process of
implementing a RCM program. It will help
you to apply the rules of RCM through crossfunctional review groups in order to produce
robust and cost effective asset management
programs, by applying the four maintenance
strategies, i.e. corrective, preventive,
predictive and pro-active.

RELIABILITY CENTRED
MAINTENANCE (RCM) AN
OVERVIEW

GATHERING AND BREAKDOWN OF

THE BASIC INFORMATION
Defining functions and performance
standards
Defining failure functional failure
Establish root cause of failures failure
modes
Identify what happens if failure occurs
failure effect
What is the consequence of failure (cost,
throughput, quality, safety, environment
and customer)
FMECA

SELECTING MAINTENANCE TASKS

THROUGH PROACTIVE
MAINTENANCE (PDM, PM)

Implementation

Auditing the analysis

Developing the maintenance program
Continuous improvement
KPIs to measure success

Practical Exercise

Breakdown of plant into systems

Completing a FMECA
Selecting the appropriate tasks for
different scenarios
Developing the maintenance program
blue print

summary, open forum

and closing

Scheduled restoration tasks

Scheduled discard tasks
Scheduled on-condition tasks

Practical Sessions

This is a practical, hands on workshop enabling you to work through practical exercises
which reinforce the concepts discussed.
To gain full value from this workshop, please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

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Rigid and Flexible

Hose Connections

YOU WILL Learn how to:

Obtain a greater understanding of the basic aspects related to hose

design and construction.
Recognize the various hose types from the design as well as
application point of view.
Size and select the right type of hose for a particular application.
Know about the different materials of construction and the use of
reinforced material.
Obtain a detailed perspective on other hose selection criteria based on
parameters such as pressure and temperature and also get to
understand better, concepts such as shelf life and useful life of hoses
in general.
Identify the common hose fittings, adaptors, couplings and clamps
and also other miscellaneous fittings.
Understand the various hose standards and testing procedures.
Demonstrate a sound understanding of standard installation practices
and hose routing.
Be well versed in maintenance and safety practices related to hoses.
Understand the various aspects related to hose failures in general and
learn about the common troubleshooting techniques.

WHO SHOULD ATTEND:

Mechanical engineers and technicians

Plant engineers and supervisors
System and design engineers
Hose manufacturers and suppliers
Project managers and Consultants
Plant layout and safety specialists
Maintenance engineers and technicians

7.45

The Workshop

The Program

Hose design and construction is a very

technical and precise science. Proper
selection and sizing of hoses and allied
fittings is critical to ensuring the efficiency of
a hydraulic system. Good installation and
routing practices not only enhance system
performance and efficiency but also provide
sufficient safeguards under conditions of
extreme pressure and temperature. Proper
material selection is vital to ensuring long
service life of the hose and also goes a long
way in minimizing the possibility of
premature hose failures.

MATERIALS OF CONSTRUCTION

What constitutes a good hose?

Hose design principles
Common hose types
Rigid and flexible applications

CLASSIFICATION AND TYPE

Classification based on the medium used
Hydraulic, Air , Fuel
Classification based on the nature of
application Compressor line, Fuel line,
Brake line, lubrication line, work
equipment control
Classification based on the equipment
type - Plant machinery, Automobile,
Marine, Aircraft
Low, Medium and High-pressure hoses

HOSE DESIGN AND

CONSTRUCTION

Hose requirements
Hose selection and sizing
Pressure surges and drops
Pressure and temperature ratings
Design considerations of common air,
hydraulic and fuel hoses

Common hose materials

Material compatibility
Reinforcement material
Metallic, non-metallic materials used in
the construction of common connectors,
fittings and couplings

HOSE STANDARDIZATION AND

TESTING

Purpose of standardization
Hose standards SAE, DIN, BS
Testing requirements
Test procedures
Prototype and production testing
Bursting and Impulse testing
Service simulation

INSTALLATION AND
MAINTENANCE

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It is also important to strictly adhere to

safety considerations, while deciding on the
type of hose to be used in a particular
application. Hose condition in general can
be effectively monitored through the
implementation of timely maintenance
practices. In the event that any failure
symptoms are identified, remedial measures
must be undertaken well in time, if
catastrophic failures are to be prevented.

INTRODUCTION

Pre-requisites

No specialist knowledge or skills are

required only a technical background so
that there is a basic understanding of various
components comprising a hydraulic system
and for such factors as the difference
between pressure and force.

In fact this course is a good introduction to

someone who has had no dealings with
hoses in the past as well as an important
refresher course for hydraulic system
specialists who benefit from the back
to-basics approach.

HOSE FITTINGS AND ASSEMBLY

Common fittings, connectors, adapters,

couplings and clamps used in hydraulic,
pneumatic and fuel hose lines
Design and type
Assembly and fitting
Commonly used thread types
Miscellaneous hose fittings

Generally recommended installation

practices
Installation procedure on fixed and
flexing applications
Hose routing
General upkeep and maintenance of
hoses

HOSE FAILURES AND

TROUBLESHOOTING

Shelf life and useful life of hoses

Common hose failures
Ways to prevent premature hose failures
General troubleshooting techniques
Safety considerations

summary, open forum

and closing

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Instructor has a great depth of

knowledge to share and made
the topic interesting, useful
and practical.

Customise the training

to your workplace.

Have the training

delivered when and
where you need it.

Doug Forsythe

Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

SAFETY RELIEF VALVES

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Inspection, Operation and Troubleshooting

what YOU WILL Learn:

To increase your awareness and understanding that the mechanical

integrity of relief valves depends jointly on the proper design,
operation, condition assessment, and maintenance of the equipment
To provide you with a clear understanding of the degradation
mechanisms that relief valves could be subjected to over their
operating life, how to identify them, predict and determine their
impact, and what appropriate measures can be taken to prevent and
control the resultant damage
To provide you with the knowledge and failure analysis skills they
need to conduct damage and failure analysis so as to prevent similar
failures from happening

WHO SHOULD ATTEND:

Maintenance, production and other plant engineers and technicians

responsible for pressure relieving devices.

7.47

The Workshop

Practical Sessions

This three day workshop is structured so that the inspection and maintenance personnel will
benefit most from the first two days and the third day will also benefit pressure vessel
engineers and system designers. A safety or safety relief valve can be considered the most
important single safety device on a boiler, piping, pipeline or pressure vessel. If it fails to
function in the manner for which it was intended and an overpressure condition develops,
the result could be catastrophic.
Like all mechanical devices, pressure relief valves require periodic maintenance and repair.
To properly carry out repairs, it is essential that the work be done by trained personnel under
controlled conditions, using proper parts and procedures.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Competencies Emphasised
Working knowledge in design, operation and maintenance of pressure relieving devices
Understanding, prediction and identification of degradation and damage mechanisms
that affect relief valves fitness for continued service and could result in significant
potential failures
NDT methods and their effective application
Your company will be able to enhance its ability to use applicable inspection and
maintenance resulting in lower life cycle costs while complying with codes and standards,
and other regulatory requirements.

Save over 50% by

having an IDCworkshop
presented at your
premises.

ID CO
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Organisational Impact

On-Site Training

Your company will be able to achieve measurable improvement in mechanical integrity

through effective interaction between engineering, operation and maintenance functions.
Your company will be able to enhance its loss prevention and safety performance.

Personal Impact

You will gain sound and practical understanding of the major degradation mechanisms
affecting relief valves in oil and gas plants and refinery process units, how to predict them,
how to assess their impact on relief valves over their operating life, and how to prevent and
control these degradation and damage mechanisms using best industry practices including
API and ASME codes.
Enhance knowledge about inspection and testing strategies and methods and their
effective application to achieve the highest probability of detection of damage and defects
You will achieve a better understanding of the regulations and industry practices
pertaining to repairs and alterations to safeguard against related failure and to avoid
excessive repair costs
Enhance competence and productivity thereby enhancing your competence and
performance level and making additional value added contributions to your organizations

Customise the training

to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

The Program

PRINCIPLE OF PRESSURE RELIEF

VALVES

CAUSES OF IMPROPER
PERFORMANCE

Operation
Development and application
Dimensional characteristics of pressure
relief valves

Mechanical/design (springs, materials

etc)
Process (corrosion, fouling, damaged
seating surfaces)
Maintenance

SAFETY AND RELIEF VALVE TYPES

Conventional safety relief valve

Balanced safety relief valve
Pilot-operated pressure relief valve
Pressure and/or vacuum vent valve
Rupture disk device

RELIEF VALVE STRATEGY

Reasons for inspection

Shop inspection/overhaul
Visual on-stream inspection
Inspection frequency
Time of inspection

TESTING FACILITIES

Selection
Materials
Sizing overview

OPERATIONAL CHARACTERISTICS
System pressures
Device pressures

INSPECTION AND TESTING

Pressure relief device certifications

Pressure relief valve repair
Nameplate data interpretation and
stamping

SIZING RELIEF VALVES

Gas and vapour sizing
Liquid sizing
Multiple valve sizing

CODES and STANDARDS

API RP 576 and API RP 520

ASME Code Sections I and VIII
National Board Inspection Code

QUALITY CONTROL SYSTEMS

Records and reports

The need to keep records
Responsibilities

summary, open forum

and closing

OVERHAUL

Pressure relief valve disassembly

Lapping and grinding
Assembly
Setting, testing and sealing

idc@idc-online .com

www.idc-online .com

mechanical design concepts

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for non-mechanical engineers

what YOU WILL Learn:

Basic mechanical engineering concepts such as force, work,

power, moments and torques
The importance of common engineering material properties in
relation to component life and failure
Basic design for static strength

How to select appropriate gears and bearings

How to perform simple design and selection of piping systems

and related components
How to monitor, control and analyse vibrations

How to set up an effective but simple inspection and

maintenance program (including lubrication)

WHO SHOULD ATTEND:

This workshop is designed for personnel with a need to understand

the use, care, installation, or the economics associated with
mechanical machinery. Those who will benefit the most from this
workshop include the following:
Consultants
Consulting engineers
Electrical and chemical
engineers and technicians
Industrial and commercial
plant and facilities engineers
Military personnel
New graduates
Operators
Plant engineer/managers and
supervisors
Plant operations and
maintenance personnel

Process control engineers,

technicians and supervisors
Process technicians
Professionals who want to
upgrade their knowledge in
mechanical engineering
Project and design engineers
Property managers
Sales engineers
Service contractors

7.49

The Workshop

The Program
MECHANICAL ENGINEERING
BASICS

Introduction and basic concepts

Units for engineering quantities
Interpretation of mechanical drawings
Friction - importance in mechanical
systems, types, static and dynamic
friction coefficients

ENGINEERING MATERIALS
Stress - strain relationship
Properties of engineering materials:
strength, hardness, ductility and
toughness
Thermal processing of metals and how it
affects their properties
Ferrous and non-ferrous alloys
Common failure of modes of materials:
fracture, fatigue, creep and corrosion

MECHANICAL DESIGN

Basic principles
Factor of safety
Static equilibrium
Design for static strength
Threaded fasteners
Keys and keyways
Riveted joints
Design for fatigue strength

FLUID ENGINEERING
Concepts: viscous flow and Reynolds
number
Piping, selection and sizing
Pumps and valves: types and applications
Fluid engineering symbols and diagrams
Analysis of piping systems
Seals, fittings, flanges gaskets and
O-rings
Mechanical seals: types, selection and
maintenance

THEORY OF HEAT TRANSFER

Laws of thermodynamics
Thermal cycles
Heat exchangers: types, maintenance and
troubleshooting
Heat pumps
Air conditioning
Heat: conduction, convection and
radiation

MECHANICAL VIBRATIONS

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Mechanical engineering in simple terms deals

with any equipment that moves; this is what
makes it perhaps the most broad and diverse
of engineering disciplines. The mechanical
discipline essentially derives its breadth from
the need to design and manufacture
everything from small, even nano, individual
devices, such as measuring instruments, to
large systems such as machine tools and
power plants. Easy installation and
serviceability are critical to the success of a
mechanical system as is operational and
design flexibility.
Understanding parameters governing the
selection and design of mechanical systems is
essential for identifying suitable systems for a
particular application. In order to place all
these issues in context, a good working
knowledge of mechanical principles combined
with a solid understanding of key concepts
such as force, energy and heat is important.
Mechanical power transmission is discussed
from the point of view of gears, couplings and
bearings. Proper selection and sizing of these
critical mechanical components is vital to
ensuring optimum performance and improved
efficiency of a mechanical system. Recently,
fluid engineering has undergone significant
change and therefore a detailed overview of
the underlying principles of fluid power and
its applications is vital. The theory behind heat
transfer, the various heat transfer mechanisms
and the design of heat-exchangers is also
examined.
Any study of mechanical systems would be
incomplete without including a review of
mechanical vibrations. This will help you in
monitoring, controlling and analysing
vibrations and in conducting fault diagnoses
in mechanical systems.
The field of maintenance has evolved into a
separate and highly specialised function. An
effective maintenance regime helps identify
failure symptoms and enables initiation of
corrective measures, for preventing
unscheduled and sometimes catastrophic
failures. Lastly, a discussion on the numerous
standards, codes and regulations governing
mechanical systems, helps put the whole
workshop into perspective.

Practical Demonstrations,
Videos and Exercises

We at IDC know that no matter how good the

instructor is (and ours are very good!) no one
learns from listening to a lecture. Hence we
have a busy schedule of activities to help you
really learn.

GEARS AND BEARINGS

Gears: terminologies, types, ratios and

gear trains
Gear selection and gearboxes
Troubleshooting gear problems
Bearings: loads, types, selection and
troubleshooting
Installation guidelines

MECHANICAL DRIVES

Belt and chain drives

Mechanical couplings
Hydrostatic drives
Hydrodynamic drives
Torque converters and fluid couplings
Clutches: types, performance and
selection
Brakes: types, performance and selection

PRIME MOVERS

What is a prime mover?

Internal combustion engines
Electric motors
Hydraulic and air motors
Gas turbines
Mechanical variable speed drives
Hydraulic and pneumatic cylinders
Comparative merits/demerits of different
prime movers
Primer mover selection criteria,
applications

23 short, punchy videos on mechanical

design, materials, drives, vibrations,
fluid, heat transfer and maintenance

Single degree of freedom system

Terminologies: amplitude, phase and
frequency
Natural frequency of vibration
Multiple degree of freedom system
Vibration measurement: sensors,
analysers and interpretation
Use of vibration as a condition
monitoring tool
Troubleshooting and correcting unwanted
vibrations

MANUFACTURING AND
PRODUCTION SYSTEMS

Metal production - foundry process

Cast making and metal melting
Die and precision casting
Heat treatment (hardening and softening)
Hot and cold working of metal
Presses
Numerical control
Machining and metal cutting
Broaching, shaping and sawing
Basics of welding and types of welded
joints
Brazing
CAD/CAM
Rapid prototyping

MAINTENANCE

Objectives, reliability and availability

Breakdown, preventive and predictive
maintenance
Standard practices and tools
Lubrication
Factors influencing equipment downtime
Hazardous failures
Condition monitoring methods
Non-destructive testing and inspections
Planning and inspection schedules

MECHANICAL ENGINEERING
CODES AND STANDARDS

30 short, practical design exercises on

each topic focusing on design, gears,
drives, fluid engineering, heat transfer,
vibrations and engineering codes and
standards

4 case studies on mechanical design,

gears, fluid engineering and maintenance
where you will work in groups to solve
real mechanical engineering problems

Need for standardisation

Mechanical engineering standards
Overview of standards
Benefits of standardisation
ISO 9000/1
Six-sigma

Please bring a calculator to get

maximum benefit. To gain full value
from this workshop, please bring your
laptop/notebook computer.

idc@idc-online .com

www.idc-online .com

Practical

Hydraulic and
Pneumatic Systems:

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Operations and Troubleshooting

YOU WILL Learn how to:

Work with basic hydraulic and pneumatic components

Understand essential hydraulic and pneumatic terms and understand
their key applications
Describe the characteristics of fluid used in hydraulic systems and air
used in pneumatic systems
Understand how the basic hydraulic components function in a
hydraulic circuit and how the basic pneumatic components function in
a pneumatic circuit
Read hydraulic and pneumatic schematics
Perform simple circuit design using standard symbology and functions
such as automatic return, logic control, speed control, pressure
sequencing, reduced actuator forces and timing
Discuss the correct operation, control sequences and procedures for
the safe operation of various simple hydraulic and pneumatic systems
Troubleshoot simple hydraulic and pneumatic system problems
Make simple repairs to hydraulic and pneumatic systems
Minimise forced outages and prevent serious damage to hydraulic and
pneumatic equipment
Outline the latest technologies available for electro hydraulic and
pneumatic systems
This is not an advanced workshop but one focusing on the
fundamentals. You are however expected to have some knowledge of the
topic of hydraulics and pneumatics. Pre-course reading will be provided
for you if you have no knowledge whatsoever.

WHO SHOULD ATTEND:

All those who plan to make
career in hydraulics and
pneumatics
All those working with
hydraulics and pneumatics
systems
Consulting engineers
Design engineers
Mechanical engineers

Mechanical technicians
Operation, maintenance,
inspection and repair managers,
supervisors and engineers Plant
engineers
Plant operations and
maintenance personnel
Process technicians

7.51

The Workshop
This information packed practical course on hydraulics and pneumatics would enhance your knowledge of the fundamentals, improve your
maintenance programs and help you become excellent troubleshooter of the problems in this area. No matter what hydraulics or pneumatics
applications you are working on, and what the level of your knowledge, the workshop will be highly beneficial to you.
The practical hydraulics and pneumatics workshop is a comprehensive, highly practical and interactive two-day course. You will have an
opportunity to discuss construction of hydraulic and pneumatic systems, design-applications, and learn operations, maintenance and
management issues. You will be provided with the most up-to-date information and best practice in dealing with the subject.
During the course sessions cutaways of all major components are brought to visually demonstrate the components' construction and operation.
Developing an understanding of "how" it works leads to an understanding of how and why it fails. Multimedia views of the equipment are given
to give you as realistic a view of hydraulic and pneumatic systems as possible. Towards the end of the workshop, you will have developed the
skills and ability to recognise and solve hydraulic and pneumatic problems in a simple, structured and confident manner.

Pre-requisites
A fundamental knowledge of basic mechanical plant and operation thereof and some exposure to hydraulic and pneumatic systems would
be helpful but is not essential.

The Program
HYDRAULIC SYSTEMS

PRESSURE CONTROL VALVES

Origin of hydraulics and classification

FUNDAMENTALS

Force, work, power, energy, mass,

weight, torque, density, specific gravity,
specific weight, basic hydraulic
principles, properties of fluids, viscosity

PRESSURE, LAWS AND FLOW

Classification of pressure control valves

Pressure relief valves (pressure
regulating and emergency relief)
Pressure reducing valves
Practical Exercise

FLOW CONTROL VALVES

Hydrostatic principles
Pascals Law and applications
Pressure-force relationship
Fluid flow and flow rate
Bernoullis equation
Practical Exercise

Functions of flow control valve

Classification of flow control valves
(Non-pressure compensated and
pressure compensated)
Location of flow control valve (metre-in,
metre-out and bleed-off circuits)
Practical Exercise

HYDRAULIC PUMPS

ELECTRO-HYDRAULIC SYSTEMS

Principle of pump operation

Classification (positive and non-positive
displacement)
Standard parameters for pump selection
Gear, vane, gerotor, lobe pump
Piston: radial piston, axial piston, fixed
displacement and variable volume, bent
axis pumps
Pressure, flow and efficiencies of pumps
Practical Exercise

HYDRAULIC MOTORS

HYDRAULIC CIRCUITS
Types of hydraulic circuits
Symbols used in hydraulic circuits
Pump unloading circuit
Pressure control circuit
Counterbalance circuit
Regenerative circuit
Pre-fill and compression relief circuit
Practical Exercise

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INTRODUCTION TO HYDRAULICS

Spool valve (rotary and sliding valves)

Practical Exercise

Principle of motor operation

Performance characteristics
Classification of hydraulic motors
Gear, vane, piston motors
Difference between hydraulic motors and
hydraulic pumps
Specifications of hydraulic motors
Efficiency of hydraulic motors and their
sizing
Practical Exercise

HYDRAULIC CYLINDERS

Classification (single and double acting)

Construction of cylinders
Sealing systems used in cylinders
Design of cylinders
Common cylinder problems
Practical Exercise

DIRECTION CONTROL VALVES

Functions of direction control valves and
their classification
Valve symbols
Valve elements: reciprocating spools,
rotary spools, poppet type
Spool valve element: characteristics and
position changeover
Centre conditions
Non-Return Valves (NRV)
Check valve

Proportional solenoid valves: technology

and operation
Types of proportional valves (direction
control, flow control and pressure control
valves)
Servo valves: first and second stage use
of transducers in hydraulic systems
Comparison of proportional and servo
valves
Practical Exercise

HYDRAULIC ACCESSORIES

Hydraulic oil reservoirs types (pressure

and non-pressure types)
Hydraulic filters
Hydraulic tubes and fittings
Hydraulic hoses and fittings
Hydraulic accumulators
Practical Exercise

HYDRAULIC FLUIDS

Types of hydraulic oils

Oil additives
Common problems with hydraulic oils
(cavitation, aeration, foaming)
Oil sampling and oil cleanliness
Monitoring oil and removing
contamination
Practical Exercise

SEAL DESIGN IN HYDRAULIC

SYSTEMS
Classification and types
O-rings and their applications
Common seal materials
Reasons for seal failures
Practical Exercise

idc@idc-online .com

MAINTENANCE AND
TROUBLESHOOTING
Commissioning
Maintenance
Troubleshooting
Practical Exercise

PNEUMATIC SYSTEMS

AIR PREPARATION, GENERATION

AND DISTRIBUTION
Characteristics of air
Air generation, preparation and
distribution
Characteristics of pneumatic systems
Practical Exercise

SYMBOLS AND STANDARDS

Standards for pneumatic systems

Symbols used in pneumatic systems
Practical Exercise

PNEUMATIC ELEMENTS

Basic structure of pneumatic control

system
Components of pneumatic systems
Compressors
Directional control valves
Flow control valves
Other control valve types
Actuators and output devices
Cylinders (single and double acting)
Practical Exercise

BASIC CIRCUIT DESIGN

Operation of single and double-acting

cylinders
Timing system for cylinder extend and
retract cycle
Speed and safety control systems
Practical Exercise

TROUBLESHOOTING AND FAULT

FINDING PNEUMATIC SYSTEMS
Maintenance requirements
Guidelines for maintenance of system
components
Troubleshooting problems
Practical Exercise

summary and open forum

www.idc-online .com

Practical

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Conveyor, Chute and

Feeder Design

YOU WILL Learn best practice in:

Maintenance of conveyors

Troubleshooting conveyor problems

Splicing techniques

Safety management

Design and installation

Capacity, sizing and power of equipment

The fundamentals of belt conveyor, chute and feeder design

WHO SHOULD ATTEND:

Consulting engineers

Design engineers

Electrical engineers and technicians

Maintenance engineers, technicians and staff

Mechanical engineers and technicians

Operation, maintenance, inspection and repair managers,

supervisors and engineers
Plant engineers

7.53

The Workshop

The Program

The workshop will deal with the nuts and

bolts of conveyor, chute and feeder design.
Belt conveyors frequently provide the most
satisfactory and economical method of
transporting materials such as mine ores,
earth, sand, crushed stone, cement and
concrete. The high and continuous speed of
operation of the belt makes for a high
capacity of transport of materials.
This workshop is designed for engineers
and technicians from a wide range of
abilities and backgrounds and will provide
an excellent introduction to basic design
rules of conveyors and chutes. It is intended
to cover the fundamentals and would be
useful for those with little experience in
this area.

PRACTICAL CONVEYER DESIGN

Review of bulk material characteristics
Layout
Component selection
Lump size limitation
Capacity
Minimum pulley diameters
Burden cross sectional area calculations
Volumetric capacity
Velocity calculations
Idler spacing and load rating
Belt tension calculations
Drive arrangements
Power demand capacity
Starting and stopping
Start up current calculations
Vertical curves
Gearbox and drive selection
Safety factors
Bearing types and selection
Conveyer design calculations exercises

FEEDER DESIGN
Calculation of loads/drive torques and
power
Feeder selection
Feeder design exercise

APPLICATIONS AND FUTURE

TRENDS
Case studies
Future trends in conveyers and hoppers/
bins and chutes

summary, open forum

and closing

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A basic knowledge is provided of the bulk

materials characteristics and properties. This
will enable you to have a far stronger ability
to troubleshoot and design workable
conveyor systems.

INTRODUCTION and overview

Pre-requisites

Fundamental knowledge of basic mechanical

plant and operation thereof.

CHUTE DESIGN

Liner selection
Use of solidworks
DEM and application to transfer design
Stress analysis using cosmos
Chute calculation exercise

Practical Sessions

To gain full value from this workshop,

please bring your laptop/notebook
computer.

Marius Joubert

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.
Customise the training
to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

idc@idc-online .com

The Instructor put points across

excellently - due to his
personal experience.

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

www.idc-online .com

PROJECT and FINANCIAL MANAGEMENT

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TRAINING WORKSHOPS
Practical Financial Fundamentals and Project Investment Decision Making......................................................... 8.1
How to Manage Consultants........................................................................................................................................ 8.3
Practical Marketing for Technical Professionals........................................................................................................ 8.5
Practical Project Management for Engineers and Technicians................................................................................ 8.7
Practical Specification and Technical Writing for Technical People......................................................................... 8.9
Train the Trainer - Presentation & Instructing Skills for Engineers and Technical Professionals...................... 8.11
Leading your Engineering Team to Top Performance.............................................................................................. 8.13
The Practical Business Engineer.............................................................................................................................. 8.15
People Management Skills for Technical Professionals.......................................................................................... 8.17
Engineering Leadership - Making the Transition from Engineer to Leader.......................................................... 8.19
Practical Shutdown and Turnaround Management for Engineers and Managers............................................... 6.21

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Practical

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FINANCIAL FUNDAMENTALS AND

PROJECT INVESTMENT
DECISION MAKING

YOU WILL LEARN HOWTO:

Understand economic evaluation techniques in engineering

project proposals
Calculate the financial viability of expenditure proposals
Optimise the use of capital on your projects

Understand the essentials of discounting cash flows for a

project and calculate NPV as well as IRR
Manage your company assets more effectively and know when
to replace equipment
Execute sensitivity studies taking into account risk and
uncertainty

Rank alternative investment proposals using discounted cash

flow techniques
Understand different economic evaluation methods
Prepare project expenditure proposals that can win
management approval
Make effective decisions when short of capital
Read and explain financial statements

Communicate with your financial manager and peers

Manage your personal wealth and finances far more effectively

than before

WHO SHOULD ATTEND:

Instrumentation Engineers

Sales Engineers

Mechanical and Electrical

Engineers and Technicians

Plant Engineers, Operators

and Supervisors

Technical Professionals

Technical Specialists

Production Workers

Metallurgists and Scientists

Management Accountants

Consulting Engineers
8.1

The Workshop

The Program

Finance courses are among the most

frequently requested by engineers and
technical professionals. One reason is
rapidly advancing technology, increasing
project complexity and competitive
pressures place enormous demands on you
to do the best possible cost estimation and
economic evaluation of your engineering
projects, products and services. Secondly,
people wish to communicate effectively with
finance personnel and in the board room,
but don't understand the language.

TIME VALUE OF MONEY

Compounding vs discounting
Discount Rate, Hurdle Rate and Cost of
Capital
Present and future values of money
Effect of compounding period
Effective and nominal interest rates
Compounding and discounting multiple
cash flows
Net Present Value vs Internal Rate of
Return
Annuities
Compounding and discounting tables
The use of spreadsheets
Practical Exercise

Recording of financial information

Assets, equity and liabilities
The Balance Sheet
The Profit and Loss Statement
The Cash Flow Statement
Ratio analysis

Liquidity ratios
Leverage ratios
Activity ratios
Profitability ratios
Investment ratios

Cash flow versus profit

Du Pont analysis
Practical Exercise

COST ESTIMATION
Direct and indirect costs
Fixed and variable costs
Breakeven analysis
Practical Exercise

RANKING OF INVESTMENT
PROPOSALS
Undiscounted and discounted payback
method
NPV method
NFV method
IRR method
Benefit/cost ratio and NPV ratio methods
Incremental NPV method
Incremental ROI method
Practical Exercise

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Finance is, in fact, uncomplicated. The main

problem is that accountants (as with other
specialists in their fields) communicate
using a language that has much topicspecified jargon. In today's world financial
decisions are coming under increasing
scrutiny. It is essential therefore that you
have enough information to make effective
choices and to drive your engineering
projects forward with sound justifications.

FINANCIAL STATEMENTS

This course commences with the basics of

finance pertinent to engineers and technical
professionals. Basic accounting and finance
terms are explained in simple English with
an emphasis on the engineering and
technology world. Cash flow concepts are
discussed and the issue of making
appropriate investment decisions is
examined, using such techniques as NPV
and IRR. Finally, capital budgeting and risk
are discussed in an easy-to-understand
manner.

CASH FLOW CONCEPTS

Cash flow models for manufacturing

Depreciation methods

- Straight line
- Declining balance
- Years digits

CAPITAL MANAGEMENT

Cash flow forecasts

Practical Exercise

Capital rationing
Practical Exercise

This is certainly not an advanced course, but

one aimed at providing you with the
fundamentals of Financial Management
from a practical engineering and technology
perspective.

EFFECTS OF INFLATION

Inflation and NPV

Practical Exercise

RISK AND UNCERTAINTY

Pre-requisites

Sensitivity analysis
Monte Carlo analysis
Practical Exercise

A basic knowledge of projects and accounting

concepts would be useful, but is not
essential.

TYING IT ALL TOGETHER

Revision of the key concepts

How to apply this to corporate financial
decision making
How to apply this to personal wealth
creation

Practical Sessions

Seven useful practical exercises which you

engage in to demonstrate the application of
the concepts to your next engineering
project or industry in general.

Well structured and very

informative.

Bruce McLennan

OPEN DISCUSSION AND CLOSING

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

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HOW TO MANAGE CONSULTANTS

YOU WILL LEARN HOW TO:

Recognise the myths and realities about using consultants

Properly define your consulting projects

Select the right consultant for the project

Get what you want from consultants

Communicate your needs more effectively

Manage using effective and flexible methods

Minimise disputes, delays and other problems

Get your projects done on time and within budget

Get the best value for your money

WHO SHOULD ATTEND:

Engineers, Accountants, Supervisors

Project and Maintenance Managers
Human Resources Professionals

Financial and Marketing Managers

Purchasing and Procurement Officers

Occupational Health and Safety Professionals
Contract Administrators
Quality Assurance Co-ordinators
All users of Consulting Services

8.3

The Program
Consultants - who they are
and how they work

Managing consulting
projects

Advantages and disadvantages of using

consultants
Internal consultants - when to use them
and how
10 reasons why you may consider
outsourcing services
Avoiding outsourcing pitfalls - the
warning signs
The right and wrong reasons for hiring
outside consultants
How to recognise qualities of top
consultants
Ten wrong reasons for hiring consultants

What is project management?

5 aspects of each consulting project
Goals of an engineering system or
project - technical, economic, operational
health, safety and environmental
Estimating and budgeting issues
Balancing risk versus cost
Exercise: Budgeting dilemma

Models of consultation

Team issues
Team roles and personalities
3 ways of managing a consulting team
7 most common team problems and how
to overcome them
Teamwork and negotiation exercise:
The road building project

SWOT analysis
Dispute avoidance and minimisation
Signs of trouble
The psychology of a crisis
How to use flexibility and contingency
plans instead of fire-fighting
Strategies for conflict resolution

Focusing on clients
Analysing yourself and your organisation
Various types of clients and where they
go wrong - discover which type is you!
Case Study: The Sydney Opera House
Client's fears about consultants and how
to overcome them
Evaluation: your consulting ethics
Productive and counter-productive
client's attitudes and strategies
Common mistakes clients make and how
to avoid them

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3 types of client-consultant relationship which one should you use and how?
Various roles consultants should and
should not play
Why role-confusions occur

Consulting project teams

Crisis management

Selecting Consultants

How to justify the use of consultants on

your project
Developing the process and criteria for
evaluating and selecting consultants
Establishing your needs and
requirements
Problems with under- and overspecification of requirements
The 7 most common project proposal
flaws and how to spot them
4 things to look for when comparing and
evaluating proposals
Recognising the 7 types of bias in hiring
consultants and minimising its impact
Interviewing and evaluating consultants
Exercise: Assessing the consultant

Managing consulting
contracts

3 ways to create a consulting contract

Types of consulting contracts and
charging methods - which one to choose
and when
How to negotiate favourable consulting
contract terms
6 tactics you can use to reduce
consultants fees
An overview of contract law
14 items you should always include in
your consulting contract
Case Study: Withdrawal of tenders

Dealing with problems. The ice-block

theory.
Fallacies (Faulty reasoning)
2 ways towards finding a solution to
client's problems
Changing your frame of mind - paradigm
shifting in consulting
Problem solving exercise: The case of pokey
elevators

Monitoring and controlling

consultants
10 most common client complaints
5 basic clients' management styles
Methods for effective control of
consultants
Comparing proposals with final reports
Evaluating the evaluation process
Case Study: From negotiation to litigation
in the construction industry

Why consulting projects

fail

Individual factors
Organisational factors
Corporate constraints and resistance to
change
The games consultants play

Review of the course,

questions and close

Questions and answers

Overview of literature and further reading
Exercise: Action steps to be taken from the
workshop to the workplace

Communicating with
consultants

Levels of communication
The impact of your communication
4 types of consultants and how to
communicate with them
Barriers to effective communication how to identify and remove them
7 rules of communicating with
consultants
Progress reports and meetings - practical
communication issues
Exercise: Broken squares

On-Site Training

Friendly but professional in

outlook. A breath of fresh air!
Well paced, not long winded.

Neil Petersen

How consultants solve

problems

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

practical

ID CO
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Marketing for
Technical Professionals

WHAT YOU WILL LEARN:

Find, keep and grow profitable clients

The nuts and bolts of industrial marketing

Identify your product's unique selling points

Create an effective marketing message
Segment your market

Design a professional industrial marketing campaign

Develop and retain long term client relationships

Select and use promotional media to your advantage: print ads,

direct selling, web, email, direct mail, technical articles, press
releases and brochures
Use industrial guerilla marketing to minimise your costs
Harness Public Relations (PR) in your campaigns

Develop and nurture long term client relationships

WHO SHOULD ATTEND:

Engineers

Technicians

Sales Engineers & Technicians

Managing Directors & Managers
All marketing people
Technical people who need an introduction into the commercial
world
Those who need a refresher course
All personnel who are marketing a technical product to
technical people

8.5

The Workshop

The Program
FROM IDEA TO MARKET
How marketing can make the difference
between success and failure

UNDERSTANDING THE PROCESS

Marketing vs Sales
Why is engineering marketing different?
Practical Exercise
What are the essential factors in
engineering marketing?
How can I make these factors work for
me?
Practical Exercise

WHAT IS MARKETING?
Various definitions
Changing your customers' perspective
Practical Exercise

THE MARKETING MIX: THE 4 (OR

MORE) P'S

Sales staff
Distributors
Service/installation staff
Receptionists
Accounts department (debt collection)
Practical Exercise

BARRIERS TO RECEIVING
Non-marketing staff and their role in
marketing
Insufficient technical staff
Difficult order-taking process
Poor reception facilities and staff
Barrier secretaries and your prompt replies
Recognition of problems and their
solutions
Practical Exercise

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Engineers, technicians and other technical

professionals are notoriously cautious about
industrial marketing. Often taught from an
early age that this is a pursuit to be avoided
at all costs. However the most successful
industrial companies have a strong
underlying focus on marketing and sales.
Marketing can be considered nothing more
than astute communicating of your message
about your products - whether they be
services or widgets. This workshop will distil
the instructor's 30 years worth of experience
in industrial marketing into one short day in
applying an integrated marketing approach
to your business. We will show you how to
combine your technical expertise with world
class marketing skills to improve your
company's sales and indeed profits and
make you an indispensable member of your
team. You will leave with an increased level
of skills in improving your marketing for
your industrial products. This workshop will
equip you with the competitive advantage to
prosper in the 21st century to outsmart,
outmarket and outsell your competitors and
indeed to grow the overall market in which
you operate.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed during the workshop.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.

What message do you want to send?

(product)
What value will your customer be getting?
(price)
What is your target market? (place)
Practical Exercise
Which promotional media will you use?
(promotion)

- Print ads: creation to placement

- Direct selling: using the 5 conventional
steps to selling combined with your
technical information; knowing your
industry and your customers
- Resellers: making them an effective
extension of your own sales force
- E-commerce: learn from other people's
mistakes - know what works and what
doesn't work; how to use the Internet to
your best advantage
- Direct mail: from database creation and
maintenance to brochures and mailshot
campaigns
- Technical articles: key points to writing
them and how to get them published
- Press releases: from preparation to print
- Brochures: how to make them work for
you; stop them ending up in the rubbish
bin!
- Stationery: branding and image
- Events: when and how to stage them
- Promotional gifts: their appropriateness
with special reference to company image
- Premises: how they reflect the company
image
- Does your company do what it
promises?
- Word-of-mouth: how to get them to say
what you want them to say!

Measuring response
Practical Exercise

BARRIERS TO OUTGOING
MESSAGES
Noise
Protective subordinates
State of mind
Preconceived ideas
Knowledge level
Lack of credibility
Practical Exercise

PROBLEMS IN THE LOOP

Identifying problems in the marketing

process and how to solve them

ANALYSING ORGANISATIONAL
PROBLEMS

SWOT: How to get the system functioning

properly
Practical Exercise

BRANDING

Creating and promoting brand awareness

with potential customers
Practical Exercise

LEARNING ORGANISATIONS

Personal improvement
Shared vision within the company
Team learning
Scenario planning
Systems thinking with feedbacks and
dead-time
A "learning organisation" will recognise that
they consistently need to build on their
strengths and work on their weaknesses to
become unassailable.
Practical Exercise

TIME AS A DIMENSION

The ongoing nature of marketing, and the

need for consistent messages over long
time periods
Advantages of customer retention
Costs of new customers vs retaining
existing customers
Practical Exercise

CONCLUSION

Understanding and preparing for

economic and business cycles
Making the cycles work for and with you
Sharpening the axe by using the cycles to
your advantage
Practical Exercise

THE RETURN CHANNEL

idc@idc-online .com

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Practical

PROJECT MANAGEMENT

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for Engineers and Technicians

YOU WILL LEARN HOW TO:

Plan to meet deadlines and complete projects within budget

and on time
Manage resources effectively

Develop the personal skills critical to effective project

management

Organise and improve performance to create a productive and

competent team
Evaluate and make use of project management software
packages
Create quality project plans

Generate effective work breakdown structures

Create computerised PERT and Gantt charts for your projects,

add and level resources, and monitor/report on your project
effectively
Define appropriate cost reporting mechanisms for your projects
Define, analyse and manage the risks associated with your
projects
Introduce appropriate quality management procedures

Keep your projects on track using the 'Earned Value Analysis'

method
Exercise an appropriate leadership style and keep team
members creative and motivated
Avoid the pitfalls caused by a lack of understanding of the legal
issues pertaining to projects
Use appropriate software to leverage your time and expertise
Deal with projects that have a large degree of inherent
uncertainty and/or a strong emphasis on timely completion

8.7

The Workshop

The Program

More and more engineering and technical

professionals are making career transitions
from product design into project management.
This, however, requires formal training and a
willingness to learn new skills. All the technical
know-how in the world will not deliver a
project successfully, without proper project
management skills. Unfortunately very few
engineering professionals have any degree of
formal project management training, which
results in a great deal of personal stress as
well as cost blowouts and other woes.

FUNDAMENTALS OF PROJECT
MANAGEMENT
Overview of the project environment
Project life cycle and phases
Project organisations
Project success
Project definition
Project planning
Case study - An exercise in developing a
work breakdown structure

TIME MANAGEMENT
The Precedence Method of schedule
analysis
Presentation of the schedules
Resource analysis
Monitoring and reporting achieved
progress
Selection of software
Case study - Application of the Precedence
Method analysis technique

INTEGRATED TIME AND COST

MANAGEMENT
The Performance Measurement System
(PMS) defined
Determining cost and schedule variance
Computer software PMS tools
Case study - An exercise in integrated time/
cost analysis

CONSTRUCTION CONTRACTS

Procurement strategies
Responsibilities of the parties
Tender and contract documentation
Conditions of contract
Contract disputes

MANAGEMENT OF THE PROJECT

TEAM

Management and leadership

Organisation and project team cultures
Motivation and employment
Authority and power of the project
manager
Required attributes and essential
functions

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To address this problem, the workshop will

focus on the critical project related activities
such as work breakdown, scheduling, cost
control and risk management, and show
how these can be performed with software
to lighten the project manager's workload.
The 'soft' (but equally important) aspects
such as team leadership and contract law
are also covered in detail. All topics will be
supplemented with practical exercises
focussing primarily on the areas of electrical/
electronic (including instrumentation) and
mechanical engineering. If delegates wish to
do so, they can choose small projects from
their work environment as a basis for the
practical exercises.

INTRODUCTION TO PROJECT
MANAGEMENT

Pre-requisites

A basic appreciation for the concepts involved

is desired but not essential.

COST MANAGEMENT

Cost estimating
Budget presentation
Financial control
Change control
Cost reporting
Value management
Case study - Preparation of a project cost
report with variance analysis

QUALITY MANAGEMENT

Defining quality and quality management

Quality systems
ISO 9000
Project quality assurance
Preparation of ITFs
Case study - Preparation of inspection and
test plans

RISK MANAGEMENT

Practical Sessions

Risk
Risk
Risk
Risk

management defined
identification
analysis
management responses

AN INTRODUCTION TO CONTRACT
LAW

The legal system

Essential elements of contracts
Factors destroying the legal force of
contracts
Termination of contracts
Breach of contracts
Time extensions and liquidated damages
Case study - Analysis of contractual
situations

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

PROJECT PLANNING SESSION

Working in teams you will develop an
outline project quality plan for a defined
engineering scenario.

summary, open forum

and closing

Who Should Attend

Engineering professionals
Technical personnel

Information technologists
Maintenance/supervisory managers
Project team members in
- Manufacturing
- Process industries
- Research & development
- Utilities
- Local authorities

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Practical

SPECIFICATION AND
TECHNICAL WRITING

ID CO
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for Engineers and Other

Technical People

YOU WILL LEARN HOW TO:

Systematically design and write accurate and comprehensive

technical specifications
Write realistic specifications, thereby improving project
management and performance

Write clear and concise formal reports, equipment manuals

and other technical documentation
Develop effective communication with technical as well as
non-technical staff at all levels (from top management within
the organisation to the end user in the home environment)
Brainstorm and identify technical problems and solutions
Collect, organise, analyse and evaluate information

Transfer technical information into powerful graphs, flowcharts

and tables
Translate technical documents into captivating oral
presentations

WHO SHOULD ATTEND:

Engineering professionals (e.g. project and design engineers)

Maintenance planning staff

Maintenance/supervisory managers
Technical personnel
Project team members in: manufacturing, process industries,
tendering, contracting, marketing, procurement, feasibility
study, research and development, utilities and local authorities

8.9

The Program

The Workshop
Researching and preparing technical
documents, especially technical specifications
calls for much effort and time. This workshop
is designed to give you step by step guidance
to writing these documents in a professional
manner, working within a cost and time
framework.
The course will demonstrate techniques to
establishing more effective communication
between technical and non-technical staff and
foster skills relating to problem identification
and solutions, plus enhancing skills in
information seeking, research and organising
collected data in a non-conflicting,
unambiguous manner.

Pre-requisites

Fundamentals of technical writing

FORMATS OF TECHNICAL WRITING

Formal report, technical memo reports,
technical proposals, equipment/
maintenance manuals, journal articles

TYPES OF TECHNICAL REPORTS

Periodic, progress, research,
recommendation, field, feasibility

COMPILING THE REPORT

Establish a framework
Terms of reference: subject matter,
purpose for writing it, reader of the report

STRUCTURE OF A TECHNICAL
REPORT
Main sections, elements of technical
writing, other sections
Case Study: Developing awareness of fact
and opinion and substantiating opinions
with facts
Practical Session: Determining terms of
reference and writing an introduction

SPECIFICATION WRITING
Fundamentals of specification writing,
preparing the specification, specification
database
Practical Session: Brainstorming exercise,
creating a specification data input sheet

STRUCTURE OF TECHNICAL
SPECIFICATIONS
Master format (correct numbering and
titling)
Section format; administration, product
information, execution of the
specification
Practical Session: Format outline

SPECIFICATIONS AND
CONTRACTS
Securing a contractor, contract, user
manual, review checklist

SPECIFICATIONS AND THE

PRODUCT

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A fundamental knowledge of basic technical

writing of reports is expected and some
understanding of what you want to achieve
with specification writing.

INTRODUCTION TO TECHNICAL
WRITING

DEVELOPMENT PROCESS

Preparing to write, identify readers,

perform necessary research, organising
the report, methods of development,
overview of conclusion
Practical Session: Applying the four stage
reading process, group discussion on
conclusion and recommendations

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

REPORT OUTLINE

Mind mapping, outline formats, rough

draft, revising the report, activate the
writing, simplify the writing
Practical Session: Investigating faulty
construction methods. Participants to
research design faults and problem areas.
Make observations/findings, mind map and
write a rough draft

FINALISING THE REPORT

Report appearance: white space,

headings/sub-headings, colour,
illustrations, graphic material
Practical Session: Interpreting graphic
material, graphic presentation

VERBAL PRESENTATION OF YOUR

REPORT

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Preparing your presentation, formulating

the central message, arranging the ideas,
mind mapping technique, make a
positive impact, using visual aids
effectively, maximising delivery
Practical Session: Delivery of a two minute
presentation (each delegate delivers a
presentation on a particular aspect of the
technical report)

Detailed descriptions, standards,

performance, property rights

SPECIFICATIONS AND
STATEMENTS OF WORK

Services, products
Practical Session: Writing specification
clauses

CHECKING THE SPECIFICATION

Functional language correctness, theory,
prototypes, realistic specifications,
compliance test, evaluation criteria
Practical Session: Editing the specification

TYPES OF SPECIFICATIONS

Government and industry standards,

specifications for complex goods and
services, performance, design and
cancelled specifications
Practical Session: Creating a specification
template

WRITING THE SPECIFICATION

Time and cost framework, collaboration

with other purchasers, etc
Practical Session: Writing the specification

QUALITY DEPLOYMENT
FUNCTION

Historical background, management and

planning tools, etc
Practical Session: Using the QFD template
as a specification design tool

DO'S AND DON'TS OF

SPECIFICATION WRITING

SPECIFICATION CHECKLIST
summary, open forum
and closing

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Train the Trainer -

presentation and
instructing skills

ID CO
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for Engineers & Technical Professionals

YOU WILL LEARN HOW TO:

Deliver outstanding technical training

Make powerful and convincing presentations
Understand technical training principles and levels of involvement
Overcoming learning barriers in the technical classroom
Evaluate, assess and address audience needs and requirements
Develop effective communication skills
Use appropriate body language and voice projection to reach
your training objectives
Design effective and easy to use technical course material
Systematically design and develop effective and powerful
technical instructional presentations
Integrate text, graphics, audio and video elements into your
presentation
Satisfactorily answer questions and offer solutions to common
problems
Handling difficult situations

WHO SHOULD ATTEND:

Engineering, technical and business professionals

Computer specialists and analysts
Managers and supervisors
Educators and facilitators
Researchers
Course designers
Non-technical managers and decision-makers
In-house trainers who want to organise and present training
workshops
Trainers who need a refresher course on presentation skills
Anybody who wants to improve their public speaking,
presentation or training skills or who needs to train groups of
people effectively and efficiently
8.11

The Workshop

The Program

"What I hear, I forget. What I see, I remember.

What I do, I understand." (Confucius) This
course is designed to equip you with the
skills required to become an effective and
consistent technical instructor. Ever changing
and complex technology requires a constant
need of technical training, which can be
quite intimidating.

Section D

Training

The presentation

Introduction to technical training

Elements of training
Communication
Listening
Learning techniques

Preparation
Successful training with impact
The introduction
Conclusion

Instructor/delegate
relationship

Section B

The trainees
Audience analysis
Cultural diversity
Training environment

Section C

Time management
Supporting material
After the workshop
Participatory exercises
Questions and answers
Myths

Section E

The instructor
Handling anxiety and calming nerves
Voice
Language

Visuals and electronic

equipment

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An effective technical instructor needs a

combination of technical skills and
presentation abilities to help delegates
overcome technical barriers. During this
course, you will be guided on how to
overcome the fear of speaking in public and
addressing technically skilled delegates,
how to deliver spellbinding presentations
and employ practical, memorable and clear
instruction methods. Learning must be
challenging, encouraging, reflective and
entertaining. It requires both the instructor
and the participant to listen, to understand,
to agree and to do.

Section A

This is a highly interactive two-day workshop

that provides delegates with hands-on
opportunities to prepare, organise and
deliver effective and powerful technical
presentations. Delegates will be shown
techniques to arouse and maintain
participants' attention, effectively convey
information, actively involving the audience,
demonstrating concepts and creating
powerful visual presentations.

The secrets of successful

instructors

Integrating text, graphics, visuals and

audio to structure powerful presentations
Using PowerPoint to maximise impact

Attributes and characteristics

Physical appearance
Non-verbal language

We will show you what to do before a

technical training session, how to start a
technical training session and what to do
during, at the end and after the training
session.

Pre-requisites

A technical background with practical skills

is required to convey the know-how and
provide training in a technical environment.

Written material was about the

best Ive seen for this type of
course; the instructor was able to
set an excellent pace and was
very responsive to the class.

Practical Sessions
& Discussions

John Myhill

This workshop contains 7 practical sessions

and discussions:
Handling cultural differences in your
working environment

Use tone and pitch to change emphasis,

inflection, interpretation and emotion

What signals do you send out with your

body language
Identify your presentation weaknesses
and strengths

On-Site Training

Impromptu technical presentations

Save over 50% by having an IDCworkshop presented at

Rephrasing questions and supplying

answers
Creating PowerPoint slides

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
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Leading your Engineering Team

to Top Performance

YOU WILL LEARN HOW TO:

Develop a high performance engineering team

Improve team communications

Grow superb problem solving abilities

Make quicker and better decisions as a team

Resolve team conflicts

Manage and keep a high performance team

Identify team weaknesses and strengths

Improve team productivity and time management

WHO SHOULD ATTEND:

This program is intended for those who want to build up their

engineering team and operate at peak performance. You will learn
how to develop and lead teams and avoid the pitfalls of
unsuccessful teamwork. Individuals will learn how to be effective
team players.
This workshop is aimed at:

Engineering Professionals

Technical Personnel

Maintenance/Supervisory Managers
Project Team Members in:
- Manufacturing
- Mining
- Process industries
- Research and development utilities
- Local authorities

8.13

The Workshop

The Program

One of the great truths of life is our

interdependence. Everything we accomplish
within a company is through the efforts of
people working together. No matter how
technologically advanced we are, especially
in the engineering world, we have to work
together effectively as a team, and effective
teams are made up of effective members.
Engineers and technical professionals are
notoriously bad at working together in teams
and this workshop is a great opportunity to
learn and then apply the skills of working in
a high performance engineering team.

WHAT MAKES AN ENGINEERING

TEAM DIFFERENT
RADIANT THINKING FOR
ENGINEERS
Introduction to radiant thinking
Case Study
Group discussion - how to use and apply
lateral thinking
Group exercise - mind mapping
Practical Session: Race for Truth

EFFECTIVE COMMUNICATION
Communication styles
Barriers to communication
Case Studies
Understanding the skill of listening
Nonverbal behaviours of communication
Speaking effectively and providing
successful feedback
Improved questioning techniques
Team communication
Practical Session: Illusions Meyers-Briggs

On this workshop you will learn the basic

and critical team skills which will enable you
to make a much greater contribution to the
success of your engineering team.

MEYERS-BRIGGS TYPE INDICATOR

Personality types
Benefits for engineers
Group discussion

Practical Sessions

Eight practical and group exercises will be

completed. All exercises focus on engineering
team building and cater to the unique
demands
placed
on
engineering
professionals today.

Group Survival Exercise

Gum Art
Mine Field
Totem Truths
Bafa Bafa
Meyers-Briggs

Four domains of emotional intelligence

Assessing and measuring emotional
intelligence
EI in the engineering context
Case Study
Practical Session: Gum Art

CONFLICT RESOLUTION

Root cause analysis

Assessing conflict styles
Attribution theory
Handling engineering team conflict
Principles and processes of conflict
resolution
Skills for team-based problem-solving
Case Study
Practical Session: Mine Field

GOALS AND OBJECTIVES

Group brainstorming techniques

Decision making principles
Objectives and time frames
Time matrix for engineers
Time wasting activities
Progress reporting
Delegation and follow up techniques
Practical Session: Totem Truths

NEGOTIATION FOR ENGINEERS

TEAM MANAGEMENT PROFILE

Identifying your role in the organisation

Group dynamics in actions
Case Study
Personal improvement plan within the
group process
Strengths and weaknesses
Team management wheel
Practical Session: Group Survival Exercise

How to create win-win negotiation skills

Case Study
Learning about your negotiation style
Guidelines and challenges to effective
negotiation
Practical Session: Bafa Bafa

To gain full value from this workshop,

please bring your laptop/notebook
computer.

I've gained a lot from the workshop and

the instructor was excellent this was an eye opener for me.

Race for Truth

Illusions

EMOTIONAL INTELLIGENCE

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The workshop consists of eight modules

containing instruction on the key principles,
skill assessments, participative discussions
and many, many exercises and case studies
to make the training come alive and ensure
that you can apply your skills to your job
immediately. The program is designed to be
fun and dynamic as well as strongly
beneficial to you working with your
engineering team.

INTRODUCTION TO ENGINEERING
TEAM BUILDING

Monica Mgobhozi

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
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The Practical Business Engineer

YOU WILL LEARN HOW TO:

Deal effectively with the key commercial and business issues

impacting you as an engineer
Communicate with financial managers and business people
Develop and grow your business

Build strong commercial relationships with your clients and

partners
Interpret and draft simple key legal contracts

Prepare expenditure proposals to win management approval

Apply tried and tested tips and tricks in dealing with legal
challenges
Market yourself and your business more effectively

Understand the key issues with financial statements and see

the warning signs

WHO SHOULD ATTEND:

If you are a technical person who wants to gain commercial 'savvy'

then this is the workshop for you. Typical participants include:
Engineers and other technical
professionals working in
industry
Technicians
Engineering Officers
Project Managers

Geologists

Metallurgists

Production Managers
Process and Operational
Personnel

Maintenance Professionals

Electrical, Mechanical and

Civil Engineers

IT Managers

Consulting Engineers

Architects

Operations Managers

Administrators

Plant Managers

Technical Specialists
8.15

The Workshop

The Program

It is a truism that engineers tend to focus on

technical issues to the detriment of the
commercial realities that impact on their
businesses on a daily basis. Engineers and
other technical professionals put enormous
effort into achieving technical excellence in
their jobs and believe that their technical skills
are extremely important. Unfortunately the
reality is considerably different. What enables
you to run a successful business and to get to
the top are possessing excellent commercial
and management skills. Once they have
received the necessary training in the critical
issues, engineers and technical managers are
generally bright, capable, hard working and
highly trained individuals who can effectively
deal with commercial issues they have to
confront on a daily basis.

NEGOTIATING SKILLS FOR A

WIN-WIN

Managing the 7 Ps of negotiation:

people, positions, perceptions, problems,
power, preparation and process
Negotiating issues in business
Developing your negotiating qualities
The importance of a win-win

Overview of the course

Business communication skills
Questioning skills
Giving and receiving feedback
Presenting winning business
presentations
Four typical team structures
Dealing with team problems
In pursuit of excellence
Effective habits of success in business

MAXIMISING YOUR PROFIT

CONSISTENTLY - BASIC
FINANCIAL CONCEPTS

GAIN MORE BUSINESS INDUSTRIAL MARKETING AND

SELLING
Key elements
Advertising - direct mail, web and email
and telemarketing
Contact databases that work
Building relationships
Presenting proposals
Quoting, negotiating and closing deals
Researching and finding new business
and clients
Practical elements of marketing
Lateral thinking

Profit and loss

Balance sheets
Cash flow versus profit
Quick ratios and indicators
Cash is King
Creative accounting
Trends and patterns
Pricing of products and projects
Fixed price versus hourly rate
Business triangulation techniques
Maximising your company's profits and
income
Tracking costs and revenues

ESTIMATION AND COSTING

BUSINESS STRATEGY

Adjusting your sails to maximise the

wind
Business plans and action steps
Sailing close to the wind
Business ethics

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The workshop presents the secrets of many

experienced engineers who have worked in
business and commerce and been involved in
managing cash flow, marketing, drawing up
and negotiating contracts, setting up joint
ventures and a myriad of other testing
commercial challenges. We have distilled all
the key commercial and business issues into
one hard hitting course to enable you to solve
real commercial problems which you will
encounter and enable your business to grow.

BASIC COMMERCIAL AND

BUSINESS CONCEPTS

One of the key ingredients for success in any

business and project is understanding that
"cash is king" and your firm should be able
to generate it effectively and consistently.
Rapidly advancing technology, increasing
project and product complexity and
competitive pressures place enormous
demands on you to do the best costing and
economic evaluation of your products and
projects. You must be able to justify your
costing decisions using a solid framework
should your financial decisions come under
scrutiny.

This workshop is designed to help you build

up strong competencies in business
communications and promotion and
marketing of your business and indeed of
yourself. This workshop will save you years
of learning from experience. Learning from
your own experience whilst very important
and a key part of your development can be
frustrating, risky and expensive and this
workshop will help to expedite your learning
process in the commercial area.
Whilst you will not be an expert in two days
of the course; this workshop will transform
your knowledge and ability to deal effectively
with commercial issues and set your
business and your personal skills firmly on a
sustainable growth path with minimal risk.

Capital costs
Working capital and operating costs
Factors affecting profitability
How to get the estimate right first time
Decision making under capital rationing
What to do if there is not enough money
Costing and estimating

MANAGING COMMERCIAL RISK

Risk and uncertainty
Quantifying project risk
What is risk management
Tools of risk management
Risk and contingency amounts

Tying It All Together

APPLYING BUSINESS LAW TO

ENGINEERING

Commercial law and engineers

Essentials of contract law
Key elements of a contract
Breach of contract and remedies practically speaking
Duty of care
Professional liability
Avoiding conflict
The real value of business law
Using the law and minimising disputes

Practical Sessions

We have tried to make this workshop as

practical as possible and have minimised on
the standard lecturing. It includes 8 case
studies, practical exercises, simulations and
role playing comprising over 65% of the
course content to ensure maximum
absorption by the participants.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

You will emerge from this workshop

confident in your new found commercial
skills and be able to apply your know-how
immediately to your job.

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

People Management Skills

ID CO
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for Technical Professionals

WHAT YOU WILL LEARN:

Gain a clear understanding of the goals and tools of effective

management
Learn the characteristics of the four behavioral styles so you
can understand the needs of your employees and know how to
work with and bring out the best in each one
Learn how to practice effective communication skills when
training, managing and coaching employees
Develop strategies for motivating employees to be more
engaged and productive
Learn proven delegation strategies that will open up more
blocks of time for you, improve the efficiency of your team and
enhance the skills of the entire work group
Receive and practice skills in planning and goal setting to
enhance employee performance
Learn a proven set of skills to address conflict in the workplace
and implement effective solutions
Understand how the principles of emotional intelligence work
within a team environment
Manage poor performance

Improve personal productivity and manage time effectively

WHO SHOULD ATTEND:

Anyone who wants to hone their leadership and management
skills

8.17

The Workshop

The Program

As a skilled professional in today's everchanging business world, you face many

challenges. You must continually evolve
your skills to face the demands of your
profession.
This is dynamic and practical programme
aimed at energising managers into radically
improving their skills and the performance
of their teams. This workshop uses highly
interactive exercises, and case studies in a
way that challenges professional managers
to explore new strategies and develop new
skills to solve typical management problems.

REGISTRATION
STRATEGIC GOALS AND
OBJECTIVES

Group goal objectives

Managing group goals
Goal setting guidelines
Monitoring and improving objectives
Performance measurement

THE FOUR BEHAVIOuRAL STYLES

Dimensions of behaviour
Style profiles
Enhancing team relationships

EFFECTIVE COMMUNICATION

Practical Sessions

The communication process

Barriers to communication
Non-verbal communication
Assertiveness
Keys to active listening
Planning for constructive feedback
Effective feedback
A short case example of effective
communication

Delegation excuses
How to delegate effectively
Lessons in empowerment
Effective control

TAMING CONFLICT

Understanding conflict
Developing trust
Recognising behaviour patterns
Effective probing
Conflict modes
Psyche management
Fighting perceptions to win

EMOTIONAL INTELLIGENCE

What is EQ and why does it matter?

The emotional competencies model
The domains of EQ
The value of EQ
Learning how to apply EQ in the
workplace
EQ and leadership

ID CO
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This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.

DELEGATION AND
EMPOWERMENT

To gain full value from this workshop,

please bring your laptop/notebook
computer.

PERFORMANCE MANAGEMENT

TEAM MOTIVATION

Motivation and your team

Motivating factors
How to improve motivation
Managers role in motivating

Principles of poor performance

Guidelines for managers
Recommendations of application
Employment essentials

PROACTIVE TIME PLANNING

Establishing priorities
Decision making
Avoiding time wasters
Eliminating procrastination
Time planning

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

Customise the training to

your workplace.

Have the training

delivered when and

where you need it.
Contact us for a
free proposal.

idc@idc-online .com

www.idc-online .com

Engineering Leadership -

ID CO
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Making the Transition

from Engineer to Leader

YOU WILL LEARN HOW TO:

Shift from a technical to a people expert

Lead engineers and technical professionals
Gain a valuable toolbox of skills and tools to:
- Assess and identify emerging leaders
- Implement work life balance for yourself and your staff
- Assess the personality types of your people
- Use your knowledge of personality types to communicate to
difficult people
- Use knowledge of personality types align the values of your
team with others
- Use 10 different coaching tools to assess, develop and
motivate everyone on your team
Use 6 straight forward time management steps that can double
your team's productivity
Make conflict work for you and not against you
Apply the 5 steps of a professional coaching framework to
coach the emerging leaders in your organisation

WHO SHOULD ATTEND:

This workshop is designed for mid level managers and technical

professionals who want to update their leadership skills and
position themselves to adopt a leadership role in their
organisation. Those who will benefit the most from this workshop
include the following:
First-line supervisors
Middle level executives and managers
Operations, marketing, human resources and customer service
executives
Project managers
Team leaders and technical professionals
8.19

The Workshop

The Program

The engineering leadership workshop is a

comprehensive, highly practical and
interactive two-day course. The program
begins with an introduction to the
fundamentals of leadership and helps one
distinguish the leadership for engineers
from other forms. The changing paradigms
from engineer to leader are also discussed
in depth. The discussion underlines the
importance of personal leadership and the
subsequent transition to being leader of
people. Related tasks such as setting of
goals, time management and life balance
are covered in detail and their significance in
regard to personal leadership adequately
emphasised. A discussion on the personality
traits and leadership influence of exceptional
leaders is included so that one may
understand how leadership skills can be put
to actual practice.

COMMUNICATION SKILLS
Introduction
Understanding how behavioral styles
affect communication
The communication process
The power of questions
Active listening
Nonverbal communication
Tonality patterns
The power of rapport
Authentic interaction the Johari
window
The power of constructive feedback
Three basic styles of communication
Communication toolbox
Skills application exercises

PERSONAL LEADERSHIP

What is personal leadership?

Cause and effect
Be > do > have
Setting goals
Time management
Life balance
Ten personality traits of exceptional
leaders
Three stages of leadership influence
Essential skills for leadership
Personal leadership toolbox

CONFLICT MANAGEMENT SKILLS

Introduction
Sources of conflict
Five conflict management styles and
when they are appropriate
Assessing your own conflict
management style
Growing with constructive conflict and
reducing destructive conflict
Collaboration as a way of life
Conflict management toolbox

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In order to deliver on the key areas of

leadership, a leader needs to understand the
dominant behavioral styles in people. This
helps in understanding ones strengths and
weaknesses and to identify and align them
in accordance with the relevant roles and in
building a team. Communication skills
convey ones ability to communicate a
message effectively and this includes both
questioning and listening skills. During the
workshop of the discussion one will not only
get to know and understand the basic
communication tools and strategies, but
also know how the power of rapport and
constructive feedback could be utilised for
effective communication.

INTRODUCTION TO LEADERSHIP
Program introduction
How is leadership for engineers
different?
Engineer to leader changing paradigms
The leadership imperative
What is leadership?

Another key area associated with

engineering
leadership
is
conflict
management. This refers to the ability to
reduce and resolve conflict, by applying the
appropriate conflict management style as
demanded by the situation. The workshop
provides a detailed account of the conflict
causes and the various conflict management
styles that can be applied in a particular
situation.
A good leader must possess ample creativity
and problem solving skills, in order to arrive
at or facilitate creative solutions to resolve
conflict or to remove obstacles. This
discussion covers the various aspects of
problem solving and facilitation skills and
how best to employ them in leadership
management. Coaching refers to the ability
to help someone clarify for himself his
current reality, the motivation for moving
from this current reality to the desired
outcome and the options that are available
to accomplish this. The discussion focuses
adequately on the coaching models to be
adopted for growth, with particular emphasis
on performance centered coaching. It also
helps clarify coaching areas that enable the
coach to hold the coachee accountable and
to also monitor and evaluate his/her
progress.
Another advantage associated with this
workshop is the numerous practical
examples from actual projects that are used
extensively to illustrate the principles and
drive home the point. You will also be
provided with a high quality course manual
from IDC that will serve as useful reference
for many years to come.

CARING PEOPLE SMART

Introduction
Understanding behavior
Behavioral summary
Team building
Assessing styles
People smart toolbox
Skills application exercises

CREATIVITY AND PROBLEM

SOLVING

Introduction
Principles of creativity
Brainstorming techniques
Brainwriting
Problem solving
Creativity and problem solving toolbox

COACHING FOR GROWTH

Practical Sessions

Throughout the course you will participate

in hands-on exercises, which will help you
put theory to practice immediately!
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Introduction
Sport and the coaching model
Five areas of coaching
Performance centered coaching
The role of questions
Metaphor outlines
Useful coaching models/tools
Coaching toolbox

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Practical

SAFETY INSTRUMENTed systems

and EMERGENCY SHUTDOWN SYSTEMS

ID CO
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for Process Industries

what You Will Learn:

What your company should be doing to manage safety control

projects in accordance with the international standards IEC
61508 and IEC 61511
The meaning and tasks of "The Safety Life Cycle"

How HAZOPS are done and how they are used to define safety
functions
To understand Safety Integrity Levels (SILs) and to set target
values using the methods described in IEC 61511
How to identify what kind of instruments and PLCs must be
used in safety controls
How networks can be safely used for protection systems
How to design safety systems to meet SIL targets and avoid
spurious trips
How to calculate SIS failure rates and verify SIL performance
To identify where your safety instrumentation practices may
need upgrading

WHO SHOULD ATTEND:

Automation/machinery design engineers

Control systems engineers
Chemical or energy process engineers

Instrument/electrical engineers and technicians

Instrument suppliers technical staff
Maintenance supervisors
Project engineers and project managers

8.21

The Workshop

The Program

For project managers and engineers involved with hazardous processes, this workshop
focuses on the management, planning and execution of automatic safety systems in
accordance with IEC 61511, the newly released international standard for process industry
safety controls. (See over for background to IEC 61511).
IEC 61511 has been recognised by European safety authorities and by USA based process
companies as representing the best practices available for the provision of automatic safety
systems. The new standard captures many of the well established project and design
techniques that have been described since 1996 in ANSI/ISA standard S84 whilst introducing
many newer principles based on the master standard IEC 615108. The newly released standard
IEC 61511 (published in 3 parts) combines the principles of IEC 61508 and S84 into a practical
and easily understood code of practice specifically for end users in the process industries.
This new IDC workshop is structured into two major parts to ensure that both managers and
engineering staff are trained in the fundamentals of safety system practices. The first part of
the workshop, approx the first third, provides an overview of the critical issues involved in
managing and implementing safety systems.
Section 1
A wide-ranging overview of the subject

Overview of safety instrumented

systems for managers

Module 2
Introduction to IEC 61511 and the safety
lifecycle

Module 3
Hazop methods and hazard analysis for
defining risk reduction requirements

Module 4
Principles of risk reduction and safety
allocation

Module 5
Practical SIL determination methods
based on IEC 61511

Section 2
Selected detail topics

Module 6

The role of HAZOP studies and hazard

analysis in deciding what safety
measures are needed. The training
includes an outline of basic HAZOP
methods and trains participants in fault
tree analysis methods used to predict
accident rates.
Understanding safety integrity levels
(SILs) and their impact on capital and
operating costs.
Methods for the determination of SIL
requirements. This subject is known to
cause difficulties and confusion in the
early stages of process development
projects and the subject has now been
covered in depth by IEC 61511. This
workshop examines the various SIL
determination methods presented in IEC
61511 and provides practical exercises to
ensure participants are able to carry out
their own SIL determinations with
confidence.
Why safety PLC's are special and need
to be certified for safety.
Safety system architectures such as
1oo2 and 2oo3 and which versions to
use to meet performance needs of
reliability and availability.
What IEC 61511 requires from
instruments, sensors and valves to
qualify them for safety applications. Are
smart transmitters acceptable for safety?
How can a smart positioner improve
safety performance?
How to perform reliability analysis to
predict and verify safety system
reliability and spurious trip rates.
Guidelines on documentation and
validation of completed installations.
Essentials of maintenance and proof
testing. The benefits of diagnostic
systems in reducing test frequencies.

Practical SIS configurations for both

safety and availability targets

ID CO
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Risk management principles applied to

protection systems.
The legal framework such as major
accident hazard regulations and control
of substances hazardous to health.
An overview of standards IEC 61508
and 61511
An introduction to the safety life cycle
as defined in IEC 61511.
Process hazard analysis and its link to
protection systems.
The meaning of SILs and their cost
implications.
The problems and rewards of SIL
determination
Basics of safety instrumentation.
Why programmable systems need
special treatment
Economics and cost of ownership
Competency requirements and
conformity assessment programmes.
Conclusion: What should management
be doing towards compliance?

Module 1

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Module 7

Practical selection of sensors and

actuators for safety duties

Module 8

Practical reliability analysis methods and

programs to IEC 61511

Module 9

Practical selection of safety controllers

Module 10

Practical system integration and

application software for safety
controllers

Module 11

Practical documentation and validation

of SIS systems

Module 12

Practical diagnostics and proof testing of

safety instrumentation

SUMMARY, OPEN FORUM

AND CLOSING

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

CIVIL ENGINEERING

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TRAINING WORKSHOPS
Hazardous Waste Management and Pollution Prevention .......................................................................................9.1
Structural Design for Non-Structural Engineers .......................................................................................................9.3
Best Practice in Sewage and Effluent Treatment Technologies ..............................................................................9.5
Designing, Specifying and Constructing with Modern Concrete ............................................................................9.7
Transportation Planning and Management................................................................................................................9.9

ID CO
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ID CO
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Hazardous Waste Management

and Pollution Prevention

AFTER THIS WORKSHOP YOU WILL:

Be able to identify potential sources of pollution in and around

your plant
Be acquainted with the latest technologies and techniques for
preventing contamination/pollution
Be acquainted with the latest technologies and techniques for
handling hazardous waste materials
Be able to detect and measure the incidence of contamination
Have the skills for managing hazardous waste materials
Know how to plan for and deal with emergencies

WHO SHOULD ATTEND:

Anyone involved in the handling of hazardous materials, this

includes, but is not limited to:
Project Leaders

Production Managers, Supervisors, Engineers and Technicians

Maintenance Managers, Supervisors, Engineers and Technicians
Consulting Engineers

Chemical Engineers and Technicians

Plant Engineers
Operation, Inspection and Repair Managers, Supervisors,
Engineers and Technicians
Mechanical Engineers and Technicians
Electrical Engineers and Technicians

9.1

The Program

The Workshop
This workshop is designed for engineers
and technicians from a wide range of abilities
and backgrounds and will provide an
excellent introduction to mastering the
management of hazardous waste materials
as well as preventing contamination of the
environment.
This knowledge make participants aware of
the legal and regulatory aspects of pollution
and the handling of hazardous waste
materials within their plants. It will also
allow them to reduce the amount of
hazardous waste produced and save money
through preventing personal injury and
preventing or limiting the effects of accidental
pollution.

Pre-requisites

Day Two

INTRODUCTION

CONTINGENCY PLANNING

Course objectives
Definitions

BASIC CONCEPTS
Pollution monitoring technologies
Environmental effects of pollution/
hazardous waste
Toxicology
Radioactivity

REGULATORY CONSTRAINTS
Environmental laws
Regulations governing storage and
transportation of hazardous materials
(national, provincial, regional, municipal)

WATER SUPPLIES

Planning for emergencies

Training of response teams
Protective equipment and clothing
Dealing with spillage
Dealing with release of hazardous
substances into the atmosphere

MEASURING TECHNIQUES
Measurement techniques
Statistical sampling theory

COSTS AND BENEFITS

Cost-benefit trade-offs
Opportunity costs
Costs of implementing (or not
implementing) safety measures
Ethical issues

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A basic knowledge of electrical, mechanical

and chemical plant environments.

Day One

Water treatment processes

Ground water management
Drinking water management

Delegates will work on a

recommendation addressing a particular
safety concern (related to the handling of
hazardous materials) in their own plant.

AIR

Pollution prevention
Pollution monitoring
Air cleaning

SUMMARY, OPEN FORUM

and CLOSING

PERSONAL SAFETY

PRACTICAL EXERCISES DURING

THE WORKSHOP

Handling flammable materials

Handling corrosive materials
Handing poisonous substances
Handling radioactive materials

POLLUTION/CONTAMINATION
PREVENTION PROCEDURES

Excellent knowledge of subject

and ability to communicate it.

Material balance systems

Building/plant design/layout
Safety codes
Management systems

Mark Moore

The course addresses a very big

need in the industry.
A DSwanepoel

Well presented, excellent material.

Stephen Baron

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.
idc@idc-online .com

www.idc-online .com

Structural
Design

ID CO
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for Non-Structural Engineers

YOU WILL LEARN how to:

Fully understand the role of a structural engineer

Predict the behaviour of structural members under loading

Understand the concept of stress functions such as tension,
compression, shear and bending
Perform a basic analysis of statically determinate as well as
statically indeterminate structures
Analyse the deformation of structural members under loading
Understand the significance of material properties in design
Undertake the basic design of Reinforced Cement Concrete
(RCC) structures
Undertake the basic design of steel structures

Undertake the basic design of masonry and timber structural

members

WHO SHOULD ATTEND:

Anyone associated with the construction industry would be

benefited from the course. In view of the vastness of the sector,
following personnel would typically be able to gain immediate
benefit out of the course.
Architects

Municipal officials

Building inspectors

Project managers

Building maintenance
personnel

Quantity surveyors

Concrete technologists

Structural fabricators

Construction supervisors

Structural rehabilitation staff

Reinforcement detailers

Insurance surveyors

9.3

The Workshop

The Program

Construction is the largest industry in the

world and all structures need to be designed
first. Structural engineering deals with the
analysis and design aspects required to
ensure a safe, functional and economical
structure.
During the design process the designer
constantly interacts with specialists such as
architects and operational managers. Once
the design is has been finalised, the
implementation requires additional people to
handle aspects such as statutory approvals,
planning, quality assurance and material
procurement. The entire exercise can be
undertaken in highly-coordinated way only
if all participants fully understand the project
language. However, in order to understand
this language, it is necessary to first have a
thorough grasp of the principles of structural
analysis and design.

Day TWO

INTRODUCTION TO STRUCTURAL
ENGINEERING

DESIGN OF STEEL STRUCTURES

Elements of structural design

Course objectives
Course outcomes

ANALYSIS OF STATICALLY
DETERMINATE STRUCTURES

Classification of structures
Types of loads
Stress in structural members
Types of supports in structures
Equilibrium of bodies
Bending moment and shear force
Effect of moving loads
Analysis of pin-jointed frames
Influence lines

PRINCIPLES OF STRENGTH OF
MATERIALS

Properties of structural steel

Steel structural sections
Design of steel structures
Joints and fasteners for steel structures
Design of tension members
Design of compression members
Design of beams
Design of truss and allied structures

DESIGN OF RCC STRUCTURES

Properties of concrete
Principle of reinforced concrete design
Design norms for reinforced concrete
beams
Design of reinforced concrete slabs
Design of reinforced concrete
foundations
Design of axially loaded columns
Pre-stressed concrete
Multi-storied buildings

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Participants in the workshop will gain a basic

knowledge of structural engineering that
includes principles of analysis of structures
and their application, behaviour of materials
under loading, selection of construction
materials, and design fundamentals for RCC
as well as steel structures. The emphasis has
been kept on the determination of the nature
and the magnitude of the developed under
loads, and the way structures offer resistance
to it. Being the most widely used construction
materials, RCC and steel has been covered in
detail though masonry and timber are also
discussed.

Day ONE

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

Mechanical properties of materials

Development of internal stresses
Flexural stresses in beams
Relationship between horizontal and
vertical shear
Determination of bending shear stress
Deformation of beams
Combined stresses
Analysis of columns

ANALYSIS OF STATICALLY
INDETERMINATE STRUCTURES

Structural classification based on degree

of indeterminacy
Principle of superposition
Analysis of statistically indeterminate
beams
Multi-span or continuous beams
Slope deflection method
Moment distribution method
Influence line diagram for statically
indeterminate structures

DESIGN OF MASONRY AND

TIMBER STRUCTURES

Masonry structures
Design of masonry structures
Strength of timber
Design of timber structures

LIMIT STATE AND PLASTIC

DESIGN

Limit state theory

RCC design by limit state
Steel structural design by limit theory

summary, open forum and

closing

DESIGN THEORIES AND LOADS

Stress-strain relationship for different

materials
Design philosophies
Combination of loads
Theories of failure

Excellent workshop, very

informative and interesting and
very well presented.
Simon Fleming

Great workshop
- well balanced presentation
and course content.
Richard Turnhout

Instructor had good background

knowledge that was used to support
course material.

J Clarke

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Best Practice in

ID CO
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Sewage and Effluent

Treatment Technologies

YOU WILL LEARN HOW TO:

Maintain and troubleshoot waste water treatment systems

Understand the different waste water treatment systems
available
Understand national and local legislation

Apply knowledge of the latest technologies and best practice

WHO SHOULD ATTEND:

Municipal planners

Sewage operators

Municipal engineers

Consulting engineers

Anyone responsible for managing and operating sewage

treatment facilities
Maintenance engineers, technicians and staff
Plant engineers

Operation, maintenance, inspection and repair managers,

supervisors and engineers
Mechanical engineers and technicians
Design engineers

9.5

The Workshop

The Program

The quality of groundwater used cannot be

compromised any longer and the servicing
requirements of on-site sewage disposal
systems cannot be ignored. With limited
funds available to you the private owner or
regulatory agency who have responsibility for
inspection, the task of on-site sewage
treatment and disposal is becoming very
difficult.
With limited funds available to the owners we
believe this workshop will help you to install
an effective system. You will learn numerous
tips and tricks throughout the workshop to
make it very practical and relevant to your
applications.

Pre-requisites

Day TWO

PLANNING CONSIDERATIONS
PROVINCIAL AND NATIONAL
GOVERNMENT

SUBSURFACE DISCHARGE

Economic, social and environmental

goals of planning
Environmental assessment
Need for Health and Safety
Factors in preparing municipal plans
Protection for stepped up demand

WASTE WATER FUNDAMENTALS

Basic terminology
Contaminant considerations
Biological, phosphorous, ammonia
Pathogens
Effluent objectives
Alternate discharge options
Receiving water capacity-provincial water
quality objectives
Surface discharge
Subsurface discharge

Filter bed
Shallow trench
Leaching bed
Constructed wetland
Recycle, reuse

DIRECT DISCHARGE
Stream assimilative capacity
Mixing zone
Disinfection

BIOSOLIDS DISPOSAL
Hauled waste
Compost
Lime stabilisation

MANAGEMENT OF COMMUNAL
WASTE WATER SYSTEMS
Regular monitoring
Long term satisfactory performance

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Fundamental knowledge of basic waste water

treatment
requirements.
Pre-course
preparation material is available on request.

Day ONE

Practical Sessions

DESIGN CONSIDERATIONS

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

TREATMENT TECHNOLOGIES

DESIGN AND INSTALLATION OF

YOUR OWN SYSTEM

Suspended solids removal

BOD Removal
Nitrification and denitrification
Phosphorous reduction

TREATMENT SYSTEMS

Conventional septic tank

- As the treatment system
- Enhanced septic tanks
- As a primary for other bioreactors
Bioreactors
- Fixed film
- Rotating
- Suspended
- Batch
- Filters-sand, peat, stone, synthetics
- New technologies targeting specific
contaminants

FINANCIAL AND LEGAL ISSUES

Collection of sewage
Aerobic and anaerobic treatments
Critical design parameters for communal
sewage treatment systems

Funding sources
Approval process
Regulatory compliance
Municipal and owner liability

Simple design rules

Implementation of your system
Tips and tricks
The Thirteen Golden Rules of working
with waste water systems

CASE STUDIES

Municipality
Private rondavel in a pristine inaccessible
area
In the middle of suburbia

summary, open forum

& closing

RECIRCULATING SAND FILTERS

YEAR ROUND TREATMENT

Very good, instructor!

Customised the workshop content
to ongoing requirements of the
attendees.

History experimental design

Construction
Operation

David Wood, Air Products

This course gave me a good

foundation to build upon in the
workforce.
Lui Di Bcca, GPA Engineering

Good technical information &

interchange of information
between attendees.

Neil Miller

On-Site Training

Save over 50% by having an IDCworkshop presented at

your premises.

Customise the training to your workplace.

Have the training delivered when and where you need it.
Contact us for a free proposal.

idc@idc-online .com

www.idc-online .com

Designing, Specifying
and Constructing with

ID CO
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Te YR
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Modern Concrete

you will learn how to:

Understand concrete, what it is and why is it used for

construction

Study the ingredients of concrete and their importance in the

quality control of concrete
Learn the chemistry of concrete

Be able to do simple concrete mix designs

Learn about concrete manufacturing

Learn about testing, inspection and the quality control of

concrete
Understand the defects which can occur in concrete at different
stages and their remedies
Study the modern concepts - ready mix concrete, pre-cast
concrete and pre-stressed concrete
Learn the methods of protection and maintenance of concrete
Understand the safety precautions to be taken while working
with concrete
Understand admixtures which can affect the properties of
concrete

WHO SHOULD ATTEND:

Architects

Consulting engineers

Civil engineers

Maintenance engineers and

technicians

Construction site engineers

and technicians

Maintenance planners

Construction planners

Project engineers

Construction supervisors

Structural designers
9.7

The Workshop

The Program

Concrete is everywhere! In pavements,

building structures, foundations, motorways/
roads, overpasses, parking structures, brick/
block walls and bases for gates, fences poles
and many more. Concrete is used more than
any other man-made material on the planet. It
has been said that instead of naming our era
"the nuclear age" it should be named "the
concrete age" as almost all of our modern
lifestyle and constructions depend on this
material.

Day TWO

UNDERSTANDING CONCRETE

TESTING, INSPECTION AND

QUALITY ASSURANCE

The history of concrete

Main constituents of concrete and their
characteristics
- Cements
- Aggregates and mineral additions microsilica, fly ash, etc
- Water
Chemistry of concrete
- Cement chemical properties
- Hydration of cement
Characteristics of concrete
- Strength
- Durability
- Workability
- Permeability
What makes concrete develop strength?
What makes concrete durable?
Effect of weather on concreting

Laboratory and full-scale trial mixes

Quality assurance
- Processes
- Acceptance criteria
Sampling and testing of ingredients
Sampling of concrete
Tests on hardened concrete
Analysis of concrete
Non destructive testing methods for
concrete

READY MIXED CONCRETE

Advantages
Types of RMC
Specifications and tolerances
Quality assurance
Production and transportation

ID CO
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no H
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es

Our new course deals with concrete, its

manufacturing, designing and maintaining. It
includes the details about ingredients, its
quality, quantity and effect on the final product
of concrete. Concrete designing, its
specifications, standards, codes are the parts
of this course and the concrete mix design is
discussed in detail. On field manufacturing of
concrete, various procedures, precautions are
also covered. The defects, investigations and
the remedial measures, repairs are covered in
detail. The modern concepts like ready mix
concrete, precast and prestressed concrete
and their applications are covered in this
course. The admixtures used to get a specific
quality concrete, special purpose concrete etc
is also discussed in detail.

Day ONE

Pre-requisites

No specialist knowledge or skills are required

only a technical background so that there is
an understanding for simple terminologies
like reinforcement. In fact this course is a good
introduction to someone who has had no
dealings with concrete or any kind of
construction in the past as well as an important
refresher course for concrete specialists who
benefit from the backto-basics approach.

Practical Sessions

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

CONCRETE MANUFACTURING

Raw material - storage and handling

Concrete mixing and production
Transportation of concrete
Dealing with temperature
Formwork and its influence on durability
Placement of fresh concrete
Treatment to joints
Consolidation and compaction
procedures
Curing and care of green concrete

DESIGN OF CONCRETE WITH

REQUISITE STRENGTH

Standard specifications, codes and

guidelines
Concrete mix design - fundamentals
- Target strength
- Cement content
- Aggregate sizing
- Water cement ratio
Mix design procedures
Specification development
- Mandatory requirements
- Durability parameters

INVESTIGATING DEFECTS

Deterioration - common reasons

- Related to ingredients chlorides,
sulphates, aggregate-alkali reaction,
etc
- Related to climate temperature (hot/
cold), humidity, etc
- Related to manufacturing and
workmanship mixing, transportation,
compaction, cold joints, large mass,
etc.

CONCRETE ADMIXTURES

Benefits of admixtures
Types of admixtures
- Water reducing admixtures
- Plasticisers
- Accelerator
- Retarder
- Air entraining agents
- Property enhancing admixtures
- Water proofing agents

CONCRETE SHORTCOMINGS
Cracking
Crazing / shrinkage
Creep

PROTECTION OF CONCRETE
ABRASION, CORROSION AND
CHEMICAL ATTACK

Designing a protection strategy

Surface preparation
Improving abrasion and wear resistance
Design and construction techniques
Hardeners
Coatings and toppings
Protection against corrosive
environments
Sealers and coatings
Toppings and linings
Cathodic protection and metallising
Preventive maintenance and monitoring

CONCRETE REPAIR

Inspection and investigation

Procedures of repair or replacement
- Pressure grouting; shot crete; encasing
Demolition of old concrete
Repair of delaminated structure

SPECIAL PURPOSE CONCRETE

High strength concrete
Fiber reinforced concrete
Cellular concrete, Polymer concrete

Customise the training

to your workplace.

summary, open forum

and closing

Have the training

delivered when and
where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
C P
Te YR
ch IG
no H
lo T
gi
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Transportation Planning
and Management

you will learn how to:

Anticipate future traffic problems of a transportation network.

Understand the use and limitations of various modes of
transportation and learn a technique to design an efficient
transportation system by combination of these.
Understand the concept of Level of Service of the transport
system and techniques to maintain those within acceptable
limits.
Obtain guidance in the traffic control systems and their use
during special events as well as during construction.
Develop an intelligent transportation system as well as efficient
parking system
Be aware of and be able to evaluate the effects of any new
development on the adjacent traffic network.
Understanding the concepts of traffic calming, forecasts, traffic
management systems etc
Acquire a basic knowledge of standards of transportation
safety.
Obtain sufficient knowledge to manage traffic in your small
neighborhood/ complex/construction site.

WHO SHOULD ATTEND:

Engineers and Technicians in
charge of a construction site
Builders and Developers
Architects
Traffic controllers

Town Planners
Civil Engineers
Development Control Officers
Construction Project
engineers

Traffic control authorities of

big events
9.9

Practical Sessions

The Program

This is a practical, hands on workshop

enabling you to work through practical
exercises which reinforce the concepts
discussed.
To gain full value from this workshop,
please bring your laptop/notebook
computer.

INTRODUCTION

PARKING

Understanding the need of

transportation, and its demand in urban
and rural areas.
Various modes of transportation, their
uses and limitations
Overview of a Transportation system
Introduction transport planning and
various stages of transport planning.

TRANSPORTATION PLANNING
We begin transportation surveys and
analysis of their results
Study the Transportation Impact Analysis
Study the traffic forecasts, methods of
forecasting
Traffic models, their use and limitations,
model splits
Trip generation and distributions
Traffic assignments and evaluations

Practical Session

TRANSPORTATION MANAGEMENT
UNDER SPECIAL CIRCUMSTANCES
Importance of traffic management under
special situations
Transportation management under
natural disasters
Transportation management during
construction
Transportation management for special
events
Management of constriction site
Management of special event area

Practical Session

ID CO
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Practical Session

Parking requirements
On street parking
Off street parking
Design standards for parking facilities
Loading and unloading facilities
Sheared Parking

TRAFFIC CONTROLS

Traffic Control using physical barriers,

highway geometrics and other controls
Street furniture
Road markings
Intersection Controls roundabouts,
STOP-controls, signals
Grade separated intersectionsinterchanges
Traffic regulations

Practical Session

TRAFFIC SAFETY

Accidents and their analysis

Identification of cause
Cost of an accident
Prevention measures
Street lighting

TRAFFIC MANAGEMENT

Scope of management
Restriction of turning movements
Access controls
One way streets
Tidal Flow operations
Exclusive Traffic Lanes
High occupancy lanes
Traffic claming
Other management measures

Practical Session

Economic evaluation any transportation

or improvement plan
Vehicle operating cost
Value of travel time saving
Accident cost
Road Pricing

OTHER MODES OF
TRANSPORTATION

Railway Transport
Transportation management at Railway
stations
Maritime Transport
Transportation management at Docks and
harbors
Air Transport
Transportation management at airports

Practical Session

MASS TRANSPORTATION
SYSTEMS

Need and importance of Mass

transportation System
Responsibilities of a Mass transportation
System
Common Mass transportation Systems
Paratransit
Comparison of different transit systems

INTELLIGENT TRANSPORTATION
SYSTEM
Use of computer in Transport
management
Use of satellite in Transport management
Use of other modern technologies in
Transport management

On-Site Training

Save over 50% by

having an IDCworkshop
presented at your
premises.

TRANSPORTATION ECONOMICS

Pre-requisites

Basic Knowledge of Transportation and traffic

Engineering Principles and Concepts will be
an advantage.

Practical Session

summary, open forum

and closing

Customise the training

to your workplace.
Have the training
delivered when and
where you need it.
Contact us for a
free proposal.
idc@idc-online .com

www.idc-online .com

ID CO
C P
Te YR
ch IG
no H
lo T
gi
es
Web Site: www.idc-online.com
E-mail: [email protected]