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ICTD International Centre for Training and Development

Practical Process Control & Instrumentation: Measurement & Sensors

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About the course

Globalization has placed increasing demands on modern process control in terms of quality, safety, flexibility and costs. However, more efficient control can only be achieved through better measurement – when the process instrumentation provides the correct information.

This course, ‘Process Control & Instrumentation - Measurement and Sensors’, is designed to provide engineers and technicians with the theoretical and practical knowledge involved in the selection, application, installation and commissioning of industrial instrumentation and on-line analytical instrumentation. Designed for both novice and experienced engineers and technicians, this workshop provides an insight into modern instrumentation practices covering the elements of pressure measurement, level measurement, temperature measurement, flow measurement, and on-line analytical instrumentation practices – together with the elements of pH, conductivity, turbidity, dissolved oxygen, chlorine, IR spectroscopy and chromatography.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Understand the fundamentals of process control
  • Appreciate the major technologies used in the measurement of flow, temperature, pressure, and level
  • Review the construction and operation of the most important process instruments
  • Evaluate and select the appropriate instrumentation system
  • Install process equipment correctly
  • Optimise control with effective selection and installation of your process equipment
  • Calibrate and troubleshoot instrumentation systems
  • Isolate and rectify instrumentation faults
  • Review the construction and operation of the most important analytical instruments
  • Troubleshoot problems in the measurement of ph, conductivity, dissolved oxygen, and chlorine, etc.
  • Implement procedures for testing and calibration of analytical instruments

Course Outline

Day 1


  • Purpose of instrumentation
  • Location of control functions
  • Variables measured and controlled
  • Final control elements
  • Instrument operating medium


  • Measured and controlled variables
  • Performance terms and specifications
  • Measurement terminology
  • P&ID symbols

Day 2


  • Basic fluid properties
  • Reynolds number
  • Flow measurement
  • Positive Displacement Meters
  • Inferential meters
  • Oscillatory Flow Meters
  • Differential Pressure Meters
  • Electromagnetic Flowmeters
  • Ultrasonic Flowmeters
  • Coriolis meters
  • Thermal mass meters
  • Open Channel Flow

Day 3


  • Basic principles
  • Scales
  • Expansion systems
  • Thermocouples
  • Resistance thermometry
  • Thermistors
  • Radiation thermometry
  • Installation considerations


  • Basic principles
  • Manometers
  • Dead weight testers
  • Bourdon tubes
  • Bellow elements
  • Diaphragm elements
  • Electrical displacement sensors

Day 4


  • Basic principles
  • Visual gauging systems
  • Float systems
  • Displacement systems
  • Conductive level detection
  • Capacitive level measurement
  • Hydrostatic head measurement
  • Ultrasonic level measurement
  • Radar gauging
  • Nuclear level measurement
  • Point level measurement
  • Load cells

Day 5


  • Electrode potentials
  • Simple voltaic cell
  • Polarisation
  • Daniell cell
  • Electrolytic bridges
  • Electrochemical series


  • Measurement of pH
  • Measurement of Redox
  • Conductivity measurement
  • Dissolved oxygen measurement
  • Chlorine measurement

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is intended for all professionals involved in designing, selecting, sizing, specifying, installing, testing, operating and maintaining process instrumentation and control systems such as Automation Engineers, Chemical Engineers, Consulting Engineers, Design Engineers, Electrical Engineers, Electricians, Installation and Maintenance Technicians, Instrument and Process Control Engineers, Instrument Fitters, Maintenance Engineers, Mechanical Engineers and Technicians, Operations Engineers, Process Engineers, Process Operators, Production Managers, Project Managers and System Integrators.

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