Industrial Automation and Electrical Control Engineering Training Course

Course Introduction

Industrial Automation and Electrical Control Engineering Training Course is designed to provide engineers, technicians, automation professionals, and maintenance personnel with comprehensive knowledge and practical skills in designing, implementing, operating, troubleshooting, and optimizing industrial automation and electrical control systems. The course combines engineering fundamentals with modern industrial practices, enabling participants to improve process efficiency, equipment reliability, operational safety, and productivity across manufacturing, utility, oil and gas, mining, and process industries.

The training delivers an in-depth understanding of industrial control systems, programmable logic controllers (PLCs), human-machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems, electrical control panels, industrial instrumentation, motor control, variable frequency drives, and industrial communication networks. Participants will learn how these technologies work together to create efficient, intelligent, and highly automated industrial operations that meet modern production requirements.

Participants will gain practical expertise in electrical control circuit design, automation architecture, industrial sensors, actuators, process control strategies, control panel engineering, system integration, and electrical protection techniques. The curriculum emphasizes engineering best practices for developing reliable automation systems, minimizing production downtime, improving energy efficiency, reducing operational risks, and ensuring compliance with international electrical engineering and industrial automation standards.

Special emphasis is placed on emerging technologies including Industry 4.0, Industrial Internet of Things (IIoT), artificial intelligence for industrial automation, machine learning applications, digital twins, edge computing, cloud-based automation platforms, industrial cybersecurity, advanced robotics, collaborative robots, and smart manufacturing systems. These innovations are transforming industrial operations by enabling intelligent decision-making, predictive maintenance, and data-driven process optimization.

Throughout the course, participants will strengthen their ability to design automation solutions, commission electrical control systems, diagnose automation faults, integrate multiple industrial technologies, optimize production processes, and evaluate system performance. Practical engineering examples, industrial case studies, and real-world automation scenarios reinforce theoretical concepts and prepare participants to address complex automation challenges in modern industrial facilities.

Upon successful completion of the training, participants will possess the technical competence to design, install, configure, commission, troubleshoot, maintain, and optimize industrial automation and electrical control systems. The knowledge acquired supports improved engineering decision-making, enhanced operational efficiency, increased equipment availability, better product quality, reduced maintenance costs, and successful implementation of advanced automation technologies across diverse industrial sectors.

Duration

10 days

Who Should Attend

• Electrical Engineers

• Automation Engineers

• Control Systems Engineers

• Instrumentation Engineers

• Electrical Maintenance Engineers

• Industrial Engineers

• Plant Engineers

• Process Engineers

• PLC Programmers

• SCADA Engineers

• Commissioning Engineers

• Project Engineers

• Operations Engineers

• Electrical Technicians

• Maintenance Supervisors

Course Objectives

• Develop comprehensive knowledge of industrial automation principles, electrical control engineering, and modern intelligent manufacturing systems.

• Design, implement, and optimize industrial electrical control systems using engineering best practices and international standards.

• Configure programmable logic controllers, human-machine interfaces, and supervisory control systems for efficient industrial process automation.

• Apply industrial instrumentation, sensors, actuators, and measurement technologies for accurate process monitoring and automatic control.

• Design electrical control panels, motor control centers, and power distribution systems supporting reliable industrial operations.

• Integrate variable frequency drives, servo systems, motor starters, and intelligent motion control technologies into automation solutions.

• Analyze industrial communication networks including Ethernet/IP, Modbus, PROFINET, Profibus, OPC UA, and industrial wireless technologies.

• Implement process control strategies including PID control, sequential control, batch automation, and distributed control system applications.

• Perform systematic troubleshooting, fault diagnosis, commissioning, and preventive maintenance of industrial automation and electrical control equipment.

• Improve operational efficiency through energy management, production optimization, predictive maintenance, and intelligent asset monitoring strategies.

• Explore Industry 4.0 technologies including IIoT, artificial intelligence, robotics, digital twins, cloud automation, and industrial cybersecurity.

• Strengthen engineering decision-making through industrial case studies, automation design projects, performance evaluation, and practical implementation methodologies.

Course Outline

Module 1: Fundamentals of Industrial Automation

• Principles of industrial automation, control engineering, and intelligent manufacturing systems.

• Automation architectures used across manufacturing and process industries.

• Industrial automation lifecycle, engineering documentation, and project methodologies.

• International automation standards, safety regulations, and engineering best practices.

Module 2: Electrical Control Engineering

• Design of electrical control circuits for industrial process automation applications.

• Control components including relays, contactors, timers, overloads, and protection devices.

• Motor control circuits supporting industrial production and processing facilities.

• Electrical schematics, wiring diagrams, and engineering documentation standards.

Module 3: Programmable Logic Controllers

• PLC hardware architecture, programming concepts, and controller configuration techniques.

• Ladder logic programming for industrial automation and machine control applications.

• Function block programming, structured programming, and troubleshooting methodologies.

• PLC diagnostics, commissioning procedures, and performance optimization techniques.

Module 4: Human-Machine Interface Systems

• HMI design principles supporting effective operator interaction and process visualization.

• Development of graphical interfaces for industrial monitoring and operational control.

• Alarm management, data visualization, and user access security implementation.

• Integration of HMI platforms with industrial automation controllers.

Module 5: SCADA Systems

• SCADA system architecture for centralized industrial process supervision.

• Real-time data acquisition, visualization, and operational reporting techniques.

• Historical data management, trend analysis, and performance monitoring applications.

• Integration of SCADA systems with enterprise information platforms.

Module 6: Industrial Instrumentation

• Selection and application of industrial sensors for process measurement systems.

• Flow, pressure, temperature, level, and analytical instrumentation technologies.

• Calibration procedures ensuring measurement accuracy and process reliability.

• Instrument installation, diagnostics, and preventive maintenance practices.

Module 7: Industrial Communication Networks

• Industrial Ethernet technologies supporting intelligent automation infrastructure.

• Modbus, PROFINET, Profibus, EtherNet/IP, CAN, and OPC UA communication protocols.

• Network architecture, configuration, diagnostics, and fault management techniques.

• Secure communication strategies for modern industrial automation systems.

Module 8: Motor Control and Drive Systems

• Motor starters, soft starters, and intelligent motor protection technologies.

• Variable frequency drive configuration for energy-efficient motor operation.

• Servo systems and advanced motion control for precision manufacturing.

• Electrical drive troubleshooting and operational performance optimization.

Module 9: Process Control Engineering

• Process dynamics and control loop design for industrial process applications.

• PID controller tuning methods improving process stability and accuracy.

• Cascade, feedforward, ratio, and advanced control strategy implementation.

• Batch process automation and continuous process control optimization.

Module 10: Control Panel Design

• Industrial control panel layout, component selection, and electrical integration.

• Power distribution, circuit protection, and grounding system engineering.

• Compliance with international electrical panel standards and regulations.

• Factory acceptance testing and commissioning of control panel assemblies.

Module 11: Industrial Safety Systems

• Functional safety principles supporting automated industrial operations.

• Emergency shutdown systems, safety PLCs, and machine safety applications.

• Risk assessment methodologies and safety integrity level implementation.

• Electrical protection and safe maintenance procedures for automation systems.

Module 12: Troubleshooting and Maintenance

• Systematic diagnosis of automation and electrical control system failures.

• Preventive, predictive, and reliability-centered maintenance methodologies.

• Root cause analysis supporting long-term operational reliability improvements.

• Industrial case studies demonstrating effective automation troubleshooting.

Module 13: Industry 4.0 and Smart Manufacturing

• Industrial Internet of Things integration with automation and control systems.

• Artificial intelligence and machine learning applications in industrial automation.

• Digital twin technologies supporting operational optimization and predictive analysis.

• Smart factory concepts enabling intelligent production and decision-making.

Module 14: Robotics and Advanced Automation

• Industrial robotics integration within automated production environments.

• Collaborative robot applications supporting flexible manufacturing operations.

• Automated material handling and intelligent production system design.

• Vision systems and robotic inspection technologies for quality improvement.

Module 15: Emerging Technologies and Cybersecurity

• Cloud-based automation platforms supporting remote industrial operations.

• Edge computing technologies improving industrial control system performance.

• Industrial cybersecurity strategies protecting automation infrastructure.

• Future trends shaping intelligent automation and electrical control engineering.

Module 16: Industrial Applications and Capstone Project

• Comprehensive automation engineering case studies from diverse industries.

• Integrated design project combining PLC, SCADA, instrumentation, and control systems.

• Performance evaluation, commissioning, and optimization of automated facilities.

• Final engineering project demonstrating practical industrial automation competency.

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: training@upskilldevelopment.com Tel: +254 721 331 808

Training Venue 

The training will be held at our Upskill Training Centre. We also offer training for a group (at a discount of 10% to 50%) at requested location all over the world. The Onsite course fee covers the course tuition, training materials, two break refreshments, buffet lunch, airport transfers, Upskill gift package, and guided tour.

Visa application, travel expenses, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Upskill certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: training@upskilldevelopment.com, +254 721 331 808

Terms of Payment:

Unless otherwise agreed between the two parties’ payment of the course fee should be done 3 working days before commencement of the training so as to enable us to prepare better.