Job Role : Supervisor -Industrial Automation

Teacher

Jamaluddin Khan

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Course Name :Job Role : Supervisor -Industrial Automation

Code(Credit) : CUTM3010(2-4-2)

Course Objectives

1. Familiarization with the work environment and challenges for an automation supervisor
2. Familiarization to the principles, materials, components, and tools required
3. Develop an end-to-end technical understanding to execute electrical works in industry
4. Complying to the industry specifications, guidelines and safety standards during work

Learning Outcomes

1. Identify the role and responsibilities of Industrial automation supervisor
2. Implement the knowledge of the basics of electricity, electronics and electro-mechanics
3. Use wiring skills as per the wiring diagram
4. Concept about installation and electrical inspection of equipment
5. Illustrate how to work efficiently with superiors and colleagues
6. Comply with the safety procedures and standards to be followed while working
7. Prioritizing activities and organizing resources to meet desired outcome

Course Syllabus

Module 1:
Introduction to Industrial Automation System and Basic Electricals and Electronics

Theory: Identify the components and technologies involved in a typical automation system.
Describe basic concepts of current, voltage, power factor & power, ohms law, kirchhoff’s laws, line & neutral, single and three phase systems.
Practice:
-Identify basic electronic components viz diodes, triodes, transistors, resistors, capacitors, inductors, LEDs, thermistors etc.
-Identify basic electrical components push buttons, indicating lamps, selector/key switches, limit switches, and proximity switches etc.
-Identify transformers (CT/PT), voltmeter, ammeter, energy meter, terminal blocks & din rails
-Describe basic concept of relays and contactors (NO/NC).
-Describe the properties of shielded & unshielded cables, cable gauges & AWG sizes, IS standards for color codes & application.
-Describe electrical circuits (series / parallel), star & delta connections, bus bars, line chokes & capacitors, ISA Symbols

Module 2:
Install and Commission Control Panel

Theory: Identify the inventory of components and sub systems received at customer location
Practice:
-Identify the wired / unwired control panel according to design
-Carryout installation/positioning of control panel according to drawing and specifications.
-Carryout cable routing and cable termination to control panel according to drawing and specification .
-Carryout testing of earth quality.
-Carryout connection of tested earth system to the control panel .
-Carryout continuity check of all connections.
-Carryout powering of control panel from correct power source (UPS or other source).
-Carryout basic integrity test of the control panel for proper operation, without connecting to the customer system

Module 3:
Integrating Control Panel with Customer Systems Under Guidance

Practice:
-Carryout integration with customer systems such as PLC, DCS, VFD, motor control panel, pump control panel etc. using drawing of the customer system.
-Prepare plan for cable routing and related work.
-Identify the shutdown requirement for the integration work in coordinate with the customer representative.
-Carryout the required installation and connection to the customer system.
-Demonstrate mounting of cable gland, cable end terminations and
labeling etc.
-Follow safety and quality standards of the industry and the organization.
Prepare report of integration work performed in a format specified by the commissioning engineer

Module 4:
Wiring Drawings of Control Panels

Practice:
-Demonstrate use of basic auto CAD commands.
-Demonstrate editing auto CAD drawings of panel wiring.
Demonstrate creating of auto CAD drawings of panel wiring.

Module 5:
Maintaining Control Panel

Practice:
-Carryout testing for continuity
-Demonstrate the correct use of ferrules & cable lugs
-Carryout checking the circuits
-Carryout dressing the cables
Demonstrate the correct use of cable glands (single compression /double compression)

Module 6:
Identifying Faulty Components

Theory:
Description on the power supply and its working procedure, architecture of sensor and basic PB with indicators
Practice:
-Carryout the testing of power supply, CT/PT, relays & contactors
-Carryout testing of instrumentation (temperature/ RH sensors, flow meters, actuators)
-Carryout testing of pushbuttons, indicating lamps & selector switches.

Session Plan

Session 1

LECTURE - Identify the components and technologies involved in a typical automation system.
Describe basic concepts of current, voltage, power factor & power, ohms law, kirchhoff’s laws, line & neutral, single and three phase systems.

WEBLINKS -

Industrial Automation and Control

Session 15

PRACTICE - -Carryout powering of control panel from correct power source (UPS or other source)

WEBLINKS -

Control Panel Build Series

Session 14

PRACTICE - -Carryout continuity check of all connections

WEBLINKS -

What is Continuity and How to Test for it With a Multimeter

Session 13

PRACTICE - -Carryout connection of tested earth system to the control panel .

WEBLINKS -

How to Test Residual Current Devices (RCDs)

Session 12

PRACTICE - -Carryout testing of earth quality.

WEBLINKS -

How to Carry Out Earth Fault Loop Impedance Test - Measuring Zs

Session 11

PRACTICE - -Carryout cable routing and cable termination to control panel according to drawing and specification

WEBLINKS -

🔴Electrical Panel Wiring, Cable Laying Rules, Recommendation🔵

Session 10

PRACTICE - -Carryout installation/positioning of control panel according to drawing and specifications

WEBLINKS -

How to Follow an Electrical Panel Wiring Diagram

Session 9

PRACTICE - -Identify the wired / unwired control panel according to design

WEBLINKS -

Industrial Control Panel Basics

Session 8

LECTURE - Identify the inventory of components and sub systems received at customer location

WEBLINKS -

Introduction to Inventory Management

Session 7

PRACTICE - -Describe electrical circuits (series / parallel), star & delta connections, bus bars, line chokes & capacitors, ISA Symbols.

WEBLINKS -

Star and Delta Connection - Explained

Session 6

PRACTICE - -Describe the properties of shielded & unshielded cables, cable gauges & AWG sizes, IS standards for color codes & application

WEBLINKS -

Wire Gauge - AWG, Amperage, Diameter Size, & Resistance Per Unit Length

Session 5

PRACTICE - -Describe basic concept of relays and contactors (NO/NC).

WEBLINKS -

Relays and Contactors - How Do They Work and What is the Difference

Session 4

PRACTICE - -Identify transformers (CT/PT), voltmeter, ammeter, energy meter, terminal blocks & din rails

WEBLINKS -

Current Transformer and Potential Transforme

Session 3

PRACTICE - -Identify basic electrical components push buttons, indicating lamps, selector/key switches, limit switches, and proximity switches etc.

WEBLINKS -

Switch types - Types of Switches - Types of Electrical Switches

Session 2

PRACTICE - Identify basic electronic components viz diodes, triodes, transistors, resistors, capacitors, inductors, LEDs, thermistors etc.

WEBLINKS -

what are capacitor , resistor , transistor , diode electronic components

Session 16

PRACTICE - -Carryout basic integrity test of the control panel for proper operation, without connecting to the customer system

WEBLINKS -

Understanding your Consumer Unit (Fuse Board) Overcurrent & RCD Protection plus Isolation

Session 17

PRACTICE - -Carryout integration with customer systems such as PLC, DCS, VFD, motor control panel, pump control panel etc. using drawing of the customer system.

WEBLINKS -

What is DCS? (Distributed Control System)