Automation and Control Systems Maintenance

Maintenance and Engineering October 25, 2025
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Introduction

The reliability of modern manufacturing and process facilities is intrinsically linked to the health of their automation and control systems. This course focuses on the systematic maintenance, troubleshooting, and lifecycle management of Programmable Logic Controllers (PLCs), Distributed Control Systems (DCS), and associated instrumentation. Participants will learn how to read control system logic, diagnose common faults in sensors and actuators, manage software and firmware revisions, and implement cybersecurity best practices for industrial control environments. The goal is to minimize control system-related downtime and ensure consistent process performance.

Objectives

Upon completion of this course, participants will be able to:

  • Read and interpret common control system logic (e.g., ladder logic, function block).
  • Perform systematic troubleshooting on PLC and DCS hardware modules.
  • Calibrate and maintain critical field instruments (pressure, temperature, flow transmitters).
  • Manage control system software backups, version control, and obsolescence.
  • Apply cybersecurity fundamentals to industrial control systems (ICS).
  • Develop preventive maintenance and calibration schedules for instrumentation.
  • Troubleshoot Variable Frequency Drives (VFDs) and servo control systems.
  • Understand networking fundamentals (e.g., Profibus, Ethernet/IP) for control systems.

Target Audience

  • Instrumentation and Control Technicians
  • Automation and Electrical Engineers
  • Maintenance Supervisors and Planners
  • Reliability Engineers focused on control system integrity
  • IT/OT Convergence Specialists
  • Anyone responsible for maintaining automated production lines

Methodology

  • Practical lab session troubleshooting simulated PLC I/O and network faults
  • Group activity developing a calibration procedure for a critical flow transmitter
  • Case studies on control system-induced shutdowns and cybersecurity failures
  • Discussions on best practices for control system software and backup management
  • Individual exercise in reading and interpreting ladder logic diagrams.

Personal Impact

  • Develop in-demand expertise in industrial control system maintenance.
  • Improve troubleshooting skills for complex automation failures.
  • Gain critical knowledge in industrial cybersecurity (OT Security).
  • Enhance ability to manage control system obsolescence and lifecycle.
  • Become a key resource for reducing process variability and increasing product quality.

Organizational Impact

  • Minimize process-related downtime caused by control system failure.
  • Ensure higher product quality and reduced process variability.
  • Reduce the risk of cyber incidents on critical production systems.
  • Improve the efficiency and reliability of calibration and PM activities.
  • Streamline control system upgrade and migration projects.
  • Increase the security and integrity of the automation environment.

Course Outline

Unit 1: Control System Architecture and Maintenance

PLCs and DCS Fundamentals
  • Understanding the architecture of PLC and DCS systems (CPU, I/O, networking).
  • Best practices for maintaining control cabinets (cooling, cleanliness, terminal checks).
  • Managing obsolescence and life cycle planning for control hardware.
Control System Logic
  • Reading and interpreting ladder logic and Sequential Function Charts (SFC).
  • The process for safely forcing I/O points for troubleshooting and calibration.
  • Understanding control narratives and interlock documentation.

Unit 2: Field Instrumentation and Calibration

Instrument Maintenance
  • Maintenance and troubleshooting for primary field instruments (level, pressure, flow, temperature).
  • The importance of instrument calibration and traceability (ISO 9000).
  • Developing effective calibration procedures and intervals.
Smart Instruments and HART
  • Understanding smart instrument technology and digital communication (HART protocol).
  • Using field communicators for configuration and diagnostics.
  • Maintenance of control valves and positioners.

Unit 3: Troubleshooting and Diagnostics

Control System Diagnostics
  • Systematic troubleshooting methods for hardware and software faults.
  • Diagnosing intermittent faults caused by electrical noise and grounding issues.
  • Using control system software tools for live diagnostics and data logging.
Networking and Communication
  • Troubleshooting industrial network protocols (e.g., Modbus, Ethernet/IP, Profibus).
  • Understanding the impact of network faults on control system reliability.

Unit 4: Software Management and Security

Software Management
  • Implementing a strict backup and recovery procedure for control programs.
  • Managing firmware and operating system patch management.
  • Ensuring accurate documentation and version control for control logic.
Industrial Cybersecurity (ICS)
  • Introduction to ICS security risks and common attack vectors.
  • Implementing security measures (firewalls, segmentation, access control).
  • Developing incident response plans for control system cyber events.

Unit 5: Advanced Control Systems

VFD and Servo Systems
  • PM and troubleshooting for Variable Frequency Drives (VFDs) and DC drives.
  • Understanding and maintaining servo motor and motion control systems.
Alarm Management
  • Principles of effective alarm management and rationalization.
  • The role of maintenance in reducing alarm floods and improving operator response.

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