Why this Course?

• To develop expertise in industrial communication protocols for seamless data exchange between PLCs, HMIs, SCADA, and field devices.
• To integrate different automation components with standard industrial networks.
• To troubleshoot and optimize communication systems in real-world industrial automation.
• To understand data exchange mechanisms and protocols in smart factories, IIoT, and Industry 4.0.
• To enhance skills for higher studies (Master’s/PhD) in Automation, Robotics, and Mechatronics.

Course Objectives:

By the end of this course, participants will be able to:

• Understand industrial communication principles, addressing, and data exchange methods.
• Configure and implement MODBUS (RTU/TCP), PROFIBUS, and PROFINET in an industrial setting.
• Establish communication between PLCs, HMIs, and SCADA using these protocols.
• Troubleshoot and diagnose industrial network failures and optimize communication efficiency.
• Design and execute real-world automation projects integrating multiple communication protocols.

Course Outline

1. Fundamentals of Industrial Communication

• Introduction to Industrial Networks & Communication Protocols
• Differences Between MODBUS, PROFIBUS & PROFINET
• Communication Media: RS-232, RS-485, Ethernet, Fiber Optic, Wireless

2. MODBUS Communication Protocol (RTU/TCP)

• Introduction to MODBUS Protocol & Architecture
• MODBUS RTU (RS-485) and (Ethernet)
• MODBUS Registers & Data Frames (Coils, Input Registers, Holding Registers)
• MODBUS Master-Slave Communication Concept
• MODBUS RTU Configuration with PLCs (Siemens, Delta, Mitsubishi, Rockwell)
• MODBUS TCP/IP Configuration with HMI & SCADA
• Reading/Writing Data using MODBUS Functions (Function Codes 01, 02, 03, 04, 05, 06, 16)
• Troubleshooting MODBUS Communication Issues

3. PROFIBUS Communication Protocol

• Introduction to PROFIBUS (DP, PA, FMS)
• PROFIBUS Network Topologies & Wiring Standards
• PROFIBUS DP Master/Slave Communication
• Configuring PROFIBUS DP with Siemens S7-300/400/1200/1500 PLCs
• PROFIBUS PA in Process Automation (Field Instruments, Sensors, Actuators)
• Setting up & Diagnosing PROFIBUS Networks in TIA Portal & Simatic Manager
• PROFIBUS Troubleshooting & Error Handling

4. PROFINET Communication Protocol

• Introduction to PROFINET (RT, IRT) and Ethernet-based Automation
• Differences Between PROFIBUS & PROFINET
• PROFINET Addressing & Network Configuration
• Configuring PROFINET Communication in TIA Portal
• Establishing Communication Between Siemens PLCs via PROFINET
• PROFINET Integration with HMIs & SCADA

    • Diagnosing & Troubleshooting PROFINET Networks

Why this Course?

• To learn how to design, configure, and program HMIs & SCADA for industrial automation.
• To integrate SCADA with different PLC brands (Siemens, Mitsubishi, Delta, Rockwell, Schneider, ABB).
• To create real-time industrial monitoring, control, and data acquisition systems.
• To develop advanced industrial visualization and alarm management techniques.
• To enhance career opportunities in Industrial Automation, SCADA, and IIoT.

Course Objectives:

By the end of this course, participants will be able to:

• Understand HMI & SCADA fundamentals and their role in industrial automation.
• Design HMI screens and SCADA dashboards for real-time monitoring & control.
• Integrate HMI & SCADA with PLCs using industrial communication protocols.
• Configure alarms, event logging, and real-time data acquisition in SCADA.
• Develop secure and user-friendly operator interfaces with multi-user access.
• Troubleshoot HMI & SCADA communication and operational issues.

Course Outline

1. Introduction to HMI & SCADA in Industrial Automation

• What is HMI & SCADA?
• Difference Between HMI, SCADA, and PLC Programming
• Role of SCADA in Industrial Data Acquisition & Control
• HMI & SCADA Architecture (Standalone, Distributed, Cloud-Based)
• Communication Protocols (MODBUS, PROFIBUS, PROFINET, Ethernet/IP, OPC UA)

HMI Programming & Industrial Visualization

2. HMI Hardware & Software Setup

• Overview of HMI Brands: Siemens, Delta, Mitsubishi, Rockwell, Schneider, ABB
• HMI Communication Ports (RS232, RS485, Ethernet, USB)
• Power Supply, Wiring, and Connections for HMI
• Configuring HMI with PLCs using Communication Protocols

3. HMI Software Tools & Development

• Siemens HMI: WinCC (TIA Portal)
• Delta HMI: DOPSoft

4. HMI Screen Development & UI Design

• HMI Screen Design Principles (Color Selection, Layout, Font, Resolution)
• Adding & Configuring Basic HMI Objects (Buttons, Indicators, Switches)
• Designing Navigation & Multi-Screen Interfaces
• User Input Methods: Touchscreen, Function Keys, External Keypads
• HMI Tag Configuration & Mapping with PLC Variables

5. Real-Time Data Monitoring & Control in HMI

• Configuring Real-Time Process Monitoring (Temperature, Pressure, Level, Flow)
• Controlling Industrial Processes via HMI (Start/Stop, Setpoint Adjustment)
• Handling Analog & Digital Data in HMI
• Graphical Representation of Data (Trends, Bar Graphs, Gauges)
• Creating & Configuring Data Entry Fields

6. Alarm Management & Data Logging in HMI

• Designing & Implementing Alarms in HMI
• Alarm Classification (Warning, Critical, System Failure)
• Setting Up Alarm History & Acknowledgment System
• Configuring Real-Time & Historical Data Logging
• Exporting & Retrieving Data from HMI for Analysis

7. Advanced HMI Features

• Creating Multi-Level User Access & Security Settings
• Implementing Password Protection for Critical Operations
• Recipe Management & Data Handling in HMI
• Real-Time Clock & Scheduler for Automated Control
• Energy Monitoring & Efficiency Tracking

8. HMI to SCADA Communication & Integration

• HMI to PLC Communication via MODBUS RTU/TCP, PROFIBUS, PROFINET, Ethernet/IP
• Establishing Connectivity Between Multiple HMIs & PLCs
• HMI & SCADA Integration for Centralized Control

SCADA Programming & Industrial Monitoring

9. Introduction to SCADA Systems

• What is SCADA? Difference Between HMI & SCADA
• Components of SCADA: RTU, MTU, PLC, HMI, Database, Communication System
• SCADA System Architecture (Standalone, Distributed, Cloud-Based)
• Applications of SCADA in Manufacturing, Power, Water, Oil & Gas

10. SCADA Software Platforms

• Siemens SCADA: WinCC Advanced, WinCC Professional

11. SCADA Screen Development & Graphics Design

• Designing Interactive & User-Friendly SCADA Dashboards
• Configuring Real-Time Monitoring, Trends & Graphical Displays
• Setting Up Dynamic Objects & Animations
• Alarm Management & Notification Systems
• Real-Time & Historical Data Logging in SCADA

12. Industrial Communication & SCADA Networking

• SCADA-PLC Integration Using MODBUS, PROFIBUS, PROFINET
• Configuring SCADA to Work with Multiple PLCs & Field Devices

13. SCADA Data Analysis & Report Generation

• Setting Up Data Logging & Trend Analysis
• Generating Custom Reports & Historical Data Analysis

14. Advanced SCADA Features & Cloud Integration

• Implementing SCADA with Industrial IoT (IIoT)
• Cloud-Based SCADA Solutions & Remote Access
• Mobile SCADA: Monitoring & Controlling Processes via Smartphone
• AI & Edge Computing in SCADA Systems

15. SCADA Troubleshooting & System Optimization

• Diagnosing Communication Errors & Hardware Failures
• SCADA Software Debugging & Performance Optimization
• Testing & Validating SCADA Systems Before Deployment
• Case Studies: Real-World Industrial SCADA Applications

Final Project: Industrial SCADA & HMI Implementation

• Designing an HMI & SCADA System for a Complete Industrial Process
• Connecting SCADA & HMI to Real PLCs & Field Devices
• Implementing Alarm, Data Logging & User Access Control

    • Testing & Commissioning the Final SCADA Project

Why this Course?

• To master industrial calibration techniques for various process instruments.
• To learn international standards & best practices in calibration.
• To understand precision measurement & testing procedures for industrial automation.
• To work with calibration tools like pressure calibrators, temperature calibrators, and loop testers.
• To enhance career opportunities in industrial automation, process control, and metrology.

Course Objectives:

By the end of this course, participants will be able to:

✅ Understand calibration fundamentals and industry standards (ISO, NIST, IEC).

✅ Perform calibration on pressure, temperature, flow, and level instruments.

✅ Use calibration equipment (Fluke, Beamex, Druck, Siemens, Yokogawa, etc.).

✅ Maintain traceability and generate calibration certificates.

✅ Troubleshoot faulty instruments and optimize accuracy.

✅ Implement field & laboratory calibration techniques.

Course Outline

1. Introduction to Calibration & Metrology

• What is Calibration? Importance & Standards
• Difference Between Calibration, Verification, and Validation
• International Calibration Standards (ISO 17025, NIST, IEC, ANSI, ASTM)
• Traceability & Measurement Uncertainty

Instrumentation Calibration Techniques

2. Pressure Instrument Calibration

• Types of Pressure Sensors (Gauge, Absolute, Differential)
• Calibration of Pressure Transmitters (DPT, Smart Transmitters)
• Deadweight Testers & Digital Pressure Calibrators
• Calibration Using Pressure Pumps & Manometers
• Industry Application & Troubleshooting

3. Temperature Instrument Calibration

• Types of Temperature Sensors (RTD, Thermocouples, Thermistors)
• Calibration of PT100, K-Type, and J-Type Thermocouples
• Temperature Calibrators: Dry Block, Liquid Bath, Thermocouple Simulators
• Understanding Accuracy, Stability, and Hysteresis
• Case Study: Calibration of Temperature Controllers in HVAC Systems

4. Flow Instrument Calibration

• Types of Flow Meters (Orifice Plate, Coriolis, Magnetic, Vortex, Ultrasonic)
• Flow Calibration Methods: Master Meter, Gravimetric, Volumetric
• Using Flow Calibration Rigs & Ultrasonic Flow Calibrators
• Flow Meter Installation Effects on Accuracy
• Troubleshooting & Verification of Flow Meters

5. Level Instrument Calibration

• Types of Level Sensors (Ultrasonic, Radar, Differential Pressure)
• Calibration of Radar & Ultrasonic Level Transmitters
• Calibration of Float, Capacitance & Conductivity Level Sensors
• Industrial Applications & Case Studies

Advanced Calibration & Loop Testing

6. Signal Calibration & Loop Testing

• 4-20mA Signal Loop Calibration & Troubleshooting
• HART & Fieldbus Calibration Techniques
• Multimeter vs Loop Calibrator: Usage & Best Practices
• Smart Instrument Calibration Using Software (Siemens, Emerson, Yokogawa)

7. Calibration of Control Valves & Positioners

• Control Valve Calibration Process
• Positioner Calibration

8. Advanced Communication & Calibration Software

• HART Communicators & Field Device Manager Software
• PROFIBUS, MODBUS

• Why this Course?

  ✔ To master Open-Loop & Closed-Loop Control Systems

  ✔ To understand PID Controllers (Proportional, Integral, Derivative)

  ✔ To learn real-world PID tuning techniques for industrial processes

  ✔ To work with PLC, SCADA, DCS, and HMI for Process Control

  ✔ To optimize industrial loops for better performance and efficiency

  ✔ To reduce process errors, fluctuations, and downtime

  Course Objectives

  ✅ Understand Process Control Fundamentals

  ✅ Learn how PID controllers regulate temperature, pressure, level, and flow

  ✅ Configure and tune PID loops using manual & automatic methods

  ✅ Implement Feedforward, Cascade, and Ratio Control strategies

  ✅ Develop skills in PLC-based PID control programming

  ✅ Troubleshoot control loop instability & response issues

  Course Outline

  1. Introduction to Process Control & Automation
  • What is Process Control?
  • Industrial Control Systems: PLC, SCADA, DCS
  • Types of Control Loops: Open-Loop vs Closed-Loop
  • Difference Between Manual Control & Automatic Control
  • Basics of PID Control

  PID Controller & Loop Tuning

  2. Understanding PID Control (Proportional-Integral-Derivative)
  •   How PID Controllers Work in Industrial Automation
  • Understanding Setpoint, Error, Process Variable, and Output
  • Tuning Parameters:

          ◦ Proportional Gain (P) – Speed of response

          ◦ Integral Action (I) – Eliminating steady-state error

          ◦ Derivative Action (D) – Predicting & reducing overshoot

  • Practical Examples in Temperature, Pressure, Flow, and Level Control
  3. Open-Loop Control System
  • Understanding Open-Loop Characteristics
  • Open-Loop System Response Analysis
  • Industrial Applications of Open-Loop Control
  • Practical Hands-on: Running an Open-Loop System
  4. Closed-Loop Control System
  • Understanding Feedback Mechanisms
  • Stability & Performance of Closed-Loop Systems
  • Gain Scheduling & Adaptive Control
  • Practical Hands-on: Configuring a Closed-Loop System

  Advanced PID Control & Tuning Techniques

  5. PID Tuning Methods
  • Manual PID Tuning
  • Auto-Tuning Algorithms (PLC & DCS-based Tuning)
  • Industrial Case Study: PID Tuning in a Steam Boiler System
  6. Advanced Control Strategies
  • Feedforward Control
  • Cascade Control
  • Ratio Control
  • Split-Range Control
  • Multi-Loop Control
  7. PLC-Based PID Control
  • Implementing PID Control in Siemens, Mitsubishi, Delta, Rockwell PLCs
  • PID Block Programming in TIA Portal, RSLogix, GX Works, WPLSoft
  • PLC & SCADA Integration for PID Control
  • Real-Time Data Acquisition & Trending

  Field Instrumentation & PID Loops

  8. Industrial Sensors & Actuators for PID Control
  • Temperature Transmitters & RTDs
  • Pressure Transmitters & Control Valves
  • Flow Meters & Level Sensors
  • VFD & Motor Control with PID
  9. Troubleshooting PID Control Loops
  • Identifying Instability, Overshoot, and Hunting
  • Controller Response Analysis
  • Tuning for Process Optimization
  • Case Study: PID Tuning for an HVAC System

  Final Project: Implementing & Optimizing a PID Loop

  🔹 Design a Complete PID Loop for a Real Industrial Process

  🔹 Implement PID Control in PLC & SCADA

  🔹 Optimize Performance Using Advanced Tuning Methods

  🔹 Generate Reports & Troubleshooting Guidelines

Why this Course?

• To learn how to design, configure, and program HMIs & SCADA for industrial automation.
• To integrate SCADA with different PLC brands (Siemens, Mitsubishi, Delta, Rockwell, Schneider, ABB).
• To create real-time industrial monitoring, control, and data acquisition systems.
• To develop advanced industrial visualization and alarm management techniques.
• To enhance career opportunities in Industrial Automation, SCADA, and IIoT.

Course Objectives:

By the end of this course, participants will be able to:

• Understand HMI & SCADA fundamentals and their role in industrial automation.
• Design HMI screens and SCADA dashboards for real-time monitoring & control.
• Integrate HMI & SCADA with PLCs using industrial communication protocols.
• Configure alarms, event logging, and real-time data acquisition in SCADA.
• Develop secure and user-friendly operator interfaces with multi-user access.
• Troubleshoot HMI & SCADA communication and operational issues.

Course Outline

1. Introduction to HMI & SCADA in Industrial Automation

• What is HMI & SCADA?
• Difference Between HMI, SCADA, and PLC Programming
• Role of SCADA in Industrial Data Acquisition & Control
• HMI & SCADA Architecture (Standalone, Distributed, Cloud-Based)
• Communication Protocols (MODBUS, PROFIBUS, PROFINET, Ethernet/IP, OPC UA)

HMI Programming & Industrial Visualization

2. HMI Hardware & Software Setup

• Overview of HMI Brands: Siemens, Delta, Mitsubishi, Rockwell, Schneider, ABB
• HMI Communication Ports (RS232, RS485, Ethernet, USB)
• Power Supply, Wiring, and Connections for HMI
• Configuring HMI with PLCs using Communication Protocols

3. HMI Software Tools & Development

• Siemens HMI: WinCC (TIA Portal)
• Delta HMI: DOPSoft

4. HMI Screen Development & UI Design

• HMI Screen Design Principles (Color Selection, Layout, Font, Resolution)
• Adding & Configuring Basic HMI Objects (Buttons, Indicators, Switches)
• Designing Navigation & Multi-Screen Interfaces
• User Input Methods: Touchscreen, Function Keys, External Keypads
• HMI Tag Configuration & Mapping with PLC Variables

5. Real-Time Data Monitoring & Control in HMI

• Configuring Real-Time Process Monitoring (Temperature, Pressure, Level, Flow)
• Controlling Industrial Processes via HMI (Start/Stop, Setpoint Adjustment)
• Handling Analog & Digital Data in HMI
• Graphical Representation of Data (Trends, Bar Graphs, Gauges)
• Creating & Configuring Data Entry Fields

6. Alarm Management & Data Logging in HMI

• Designing & Implementing Alarms in HMI
• Alarm Classification (Warning, Critical, System Failure)
• Setting Up Alarm History & Acknowledgment System
• Configuring Real-Time & Historical Data Logging
• Exporting & Retrieving Data from HMI for Analysis

7. Advanced HMI Features

• Creating Multi-Level User Access & Security Settings
• Implementing Password Protection for Critical Operations
• Recipe Management & Data Handling in HMI
• Real-Time Clock & Scheduler for Automated Control
• Energy Monitoring & Efficiency Tracking

8. HMI to SCADA Communication & Integration

• HMI to PLC Communication via MODBUS RTU/TCP, PROFIBUS, PROFINET, Ethernet/IP
• Establishing Connectivity Between Multiple HMIs & PLCs
• HMI & SCADA Integration for Centralized Control

SCADA Programming & Industrial Monitoring

9. Introduction to SCADA Systems

• What is SCADA? Difference Between HMI & SCADA
• Components of SCADA: RTU, MTU, PLC, HMI, Database, Communication System
• SCADA System Architecture (Standalone, Distributed, Cloud-Based)
• Applications of SCADA in Manufacturing, Power, Water, Oil & Gas

10. SCADA Software Platforms

• Siemens SCADA: WinCC Advanced, WinCC Professional

11. SCADA Screen Development & Graphics Design

• Designing Interactive & User-Friendly SCADA Dashboards
• Configuring Real-Time Monitoring, Trends & Graphical Displays
• Setting Up Dynamic Objects & Animations
• Alarm Management & Notification Systems
• Real-Time & Historical Data Logging in SCADA

12. Industrial Communication & SCADA Networking

• SCADA-PLC Integration Using MODBUS, PROFIBUS, PROFINET
• Configuring SCADA to Work with Multiple PLCs & Field Devices

13. SCADA Data Analysis & Report Generation

• Setting Up Data Logging & Trend Analysis
• Generating Custom Reports & Historical Data Analysis

14. Advanced SCADA Features & Cloud Integration

• Implementing SCADA with Industrial IoT (IIoT)
• Cloud-Based SCADA Solutions & Remote Access
• Mobile SCADA: Monitoring & Controlling Processes via Smartphone
• AI & Edge Computing in SCADA Systems

15. SCADA Troubleshooting & System Optimization

• Diagnosing Communication Errors & Hardware Failures
• SCADA Software Debugging & Performance Optimization
• Testing & Validating SCADA Systems Before Deployment
• Case Studies: Real-World Industrial SCADA Applications

Final Project: Industrial SCADA & HMI Implementation

• Designing an HMI & SCADA System for a Complete Industrial Process
• Connecting SCADA & HMI to Real PLCs & Field Devices
• Implementing Alarm, Data Logging & User Access Control

    • Testing & Commissioning the Final SCADA Project