Complete Plant Design With Plc, Hmi, And Field Devices.

Complete Plant Design and Commissioning – Covering Power Systems, Electrical, Instrumentation, and Plant Automation.

What you'll learn

Learn how to design, test, and commission a complete industrial plant from scratch.

power system design – transformer sizing, cable sizing, breaker selection, and ETAP simulations.

Gain hands-on knowledge of PLC & HMI programming with real-world industrial logic.

Understand instrument selection, sizing, and calibration for pressure, flow, level, temperature and control valves.

Build confidence in VFDs, motors, control circuits, and industrial wiring practices.

Perform loop checking, interlock testing, FAT, SAT, and site commissioning like a professional engineer.

Acquire skills that make you job-ready for power plants, oil & gas, chemical, and automation industries.

Position yourself for high-paying, global career opportunities by mastering complete commissioning.

Requirements

Basic Electrical or Electronics Engineering Concepts

No Programming Experience Needed. You will learn everything you need to know !

Description

This course is a complete journey of Plant Design and Commissioning, specially structured around a Chemical Plant case study. From concept to commissioning, you will learn how to design, model, and implement every critical aspect of an industrial plant.We will start from the Power and Electrical systems, covering:Transformer sizing and designCable selection and sizing using Derating FactorsProtection systems and distribution designETAP modeling and load flow analysisThen we will move into Automation and Instrumentation, including:PLC selection and programming (ladder logic, function blocks, etc.)HMI designing for smooth plant operationInstrument selection, sizing, and installationControl valves, transmitters, and field instruments integrationYou will also gain hands-on knowledge of Drives and Motors, including:VFD selection and programmingMotor control circuits and interlockingComplete wiring design and layoutsBy the end of this course, you will be able to: Design a complete plant from scratch Perform power system studies and ETAP modeling Program and integrate PLCs & HMIs for full plant automation Select and size instruments, control valves, and drives Create wiring diagrams and commissioning plansThis is not just theory – it’s a practical, industry-focused course that prepares you to design and commission any industrial plant with confidence

Overview

Section 1: Introduction

Lecture 1 Introduction

Lecture 2 Process Layout

Lecture 3 Plant Process Layout

Lecture 4 Jobs to Do !

Section 2: IO / Equipment Count

Lecture 5 Motors Count

Lecture 6 Difference Between DOL / ASD / Soft Starter & VFD

Lecture 7 Application of Variable Frequency Drives (VFDs)

Lecture 8 Motor Drive Selection

Lecture 9 RTD Sensor (Begineer)

Lecture 10 Thermocouple Sensor (Begineer)

Lecture 11 Temperature Sensor Count

Lecture 12 Pressure Transmitter Count

Lecture 13 Level Transmitter Count

Lecture 14 Flowmeters Count

Lecture 15 Control Valves Count

Section 3: Plant Load Capacity & Power Factor Correction

Lecture 16 Topics to Cover

Lecture 17 Transformer Sizing & Selection

Lecture 18 Loading Factor & Diversity Factor

Lecture 19 Load Distribution

Lecture 20 Transformer Design Calculations

Lecture 21 Transformer Design Calculations - 2

Lecture 22 Calculation of FLAs

Lecture 23 Vector Group

Lecture 24 Selection of Vector Group

Lecture 25 Vector Group Guide

Lecture 26 Transformer Winding Material Selection

Lecture 27 Transformer Cooling Type Selection: ONAN/ONAF/OFAF/OFWF

Lecture 28 Recommended Transformer Model Based Upon the Selected Parameters.

Lecture 29 Electrical LV Panel Design Introduction

Lecture 30 LV Panel Busbar Designing and Sizing Calculations

Lecture 31 Monitoring & Control Device Selection & Installation

Lecture 32 Cable Selection & Sizing Theory

Lecture 33 Key De-Rating Factors

Lecture 34 Load Estimation for Cable Selection

Lecture 35 Main Cable Selection using Online Tool

Lecture 36 Utilities Section Cable Selection using Online Tool

Lecture 37 Main Plant Cable Selection using Online Tool

Lecture 38 System Designing On ETAP

Lecture 39 Cable Selection On ETAP

Lecture 40 Load Flow Analysis

Lecture 41 Short Circuit Analysis

Lecture 42 MCB, MCCB & ACBs (Begineer)

Lecture 43 Circuit Breaker Rated Capacity Calculation

Lecture 44 Circuit Breaker Addition on ETAP Model

Lecture 45 Voltage Regulation & PF Correction on ETAP

Section 4: PLC Selection

Lecture 46 Introduction

Lecture 47 Digital Vs. Analog IOs (Begineer)

Lecture 48 Analog Signals: 4-20mA Vs. 0-10V (Begineer)

Lecture 49 Numerical

Lecture 50 Motor IO Counts

Lecture 51 Instrumentation IO Counts

Lecture 52 Sensor Vs. Transmitter (Begineer)

Lecture 53 RTD Sensor Vs. Thermocouple Sensor (Begineer)

Lecture 54 Selection Between AI Card or RTD/TC Card

Lecture 55 Selection Between AI Card or RTD/TC Card - 02

Lecture 56 Total IOs Required To Be Connected On PLC

Lecture 57 PLC Brand Selection

Lecture 58 Basic Terminologies: Distributed IOs

Lecture 59 Basic Terminologies: Relay Vs Transistor Output

Lecture 60 Basic Terminologies: Retentive Vs. Non Retentive IOs (Begineer)

Lecture 61 PLC Selection Criteria

Lecture 62 Introduction to the Siemens S7 Controller Family

Lecture 63 S7-1500 PLC Systems

Lecture 64 Selection of PLC CPU and IO Cards

Lecture 65 Selection of PLC Power Supply

Lecture 66 Protective Switchgear Sizing for PLC

Lecture 67 Communication Methods of PLC

Section 5: Instrument Selection

Lecture 68 Introduction To Temperature Sensors

Lecture 69 RTD Sensor Type Selection

Lecture 70 RTD at High Pressure Points

Lecture 71 Sizing & Dimensions

Lecture 72 Thermocouple Sensor Selection

Lecture 73 Types of Thermocouple

Lecture 74 Temperature Transmitter Selection

Lecture 75 Loop Powered Vs. Self Powered Transmitters

Lecture 76 HART Communicators

Lecture 77 Types of Pressure

Lecture 78 Pressure Transmitter

Lecture 79 Types of Pressure Transmitters

Lecture 80 Diaphragm Material

Lecture 81 Pressure Transmitter Selection - 01

Lecture 82 Selection of PT - 01 Using Online Selection Tool

Lecture 83 Capillary Tubing

Lecture 84 Pressure Transmitter Selection - 02

Lecture 85 Pressure Transmitter Selection - 03

Lecture 86 Level Transmitter Selection - 01

Lecture 87 Level Transmitter Selection Using Online Applicator

Lecture 88 DP Transmitter with Level Measurement

Lecture 89 Ultra Sonic Level Transmitters

Lecture 90 Radar Level Transmitters

Lecture 91 DP Transmitter - Open Tank Calculation (Example)

Lecture 92 DP Transmitter - Open Tank With Zero Supression (Example)

Lecture 93 DP Transmitter - Dry Leg Calculation (Example)

Lecture 94 DP Transmitter Wet Leg Calculation (Example)

Lecture 95 Level Transmitter Selection - 02

Lecture 96 Level Transmitter Selection - 02 ( Using Online Applicator)

Lecture 97 Boiler Drum Level Measurement

Lecture 98 Boiler Drum Level - Working Theory

Lecture 99 DP Transmitter Selection - Tail Gas Boiler

Lecture 100 Calculation of LRV & URV For Tail Gas Boiler

Lecture 101 Final Product Tank Level

Lecture 102 Final Product Tank - Selection and Sizing

Lecture 103 Mass Flow Vs Turbulent Flow

Lecture 104 Laminar Vs Turbulent Flow

Lecture 105 Flowmeter Straight Run Requirements

Lecture 106 Coriolis Mass Flowmeter Working Principle

Lecture 107 Liquid Ammonia Flow - Flowmeter Selection Using Online Applicator

Lecture 108 DP Transmitter for Flow Measurement

Lecture 109 Reynolds Number

Lecture 110 Orifice Sizing Parameters

Lecture 111 Types of Orifice

Lecture 112 Venta Contracta

Lecture 113 Beta Ratio

Lecture 114 Veep Hole

Lecture 115 Impulse Line Positioning

Lecture 116 Square Root Extractor

Lecture 117 Example Numerical

Lecture 118 Vapor Ammonia Flow to Converter

Lecture 119 Vapor Ammonia Flow to Converter 2

Lecture 120 Vapor Ammonia Flow to Converter 3

Lecture 121 Vapor Ammonia Flow to Converter 4

Lecture 122 Condensate Water Flow to Economizer

Lecture 123 Condensate Water Flow to Economizer 2

Lecture 124 Condensate Water Flow to Economizer 3

Lecture 125 Finalizing All The Flows

Section 6: Motor Drive and Control Circuit

Lecture 126 Introduction

Lecture 127 Uncompensated Thermal Magnetic Tripping Units

Lecture 128 Compensated Thermal Magnetic Tripping Units

Lecture 129 More Terminologies Regarding Circuit Breakers

Lecture 130 Concept of Inrush Current (Begineer)

Lecture 131 Circuit Breaker Tripping Curves

Lecture 132 Basic Control Theory (Beginner)

Lecture 133 Basic Control Theory-II (Beginner)

Lecture 134 Basic Control Theory-III (Beginner)

Lecture 135 Basic Control Theory-IV (Beginner)

Lecture 136 Basic Control Theory-V (Beginner)

Lecture 137 DOL Circuit Theory

Lecture 138 DOL Circuit Components

Lecture 139 DOL Circuit Wiring Diagram

Lecture 140 DOL Circuit - Circuit Breaker Sizing

Lecture 141 DOL Circuit - Contactor & EOCR Sizing

Lecture 142 DOL Circuit - Overview

Lecture 143 Star Delta Starter Theory

Lecture 144 Star Delta Circuit Components

Lecture 145 Star Delta Circuit Diagram

Lecture 146 ASD Circuit - Circuit Breaker Sizing

Lecture 147 ASD Circuit - Contactor Sizing

Lecture 148 ASD Circuit - EOCR Sizing

Lecture 149 ASD Circuit - Summary

Lecture 150 Cable Selection for Motors

Lecture 151 Cable Selection for Motors - 2

Section 7: Variable Frequency Drives (VFDs)

Lecture 152 Introduction

Lecture 153 What is a VFD?

Lecture 154 Why VFDs are used?

Lecture 155 VFD Applications

Lecture 156 Theory and Working Principle

Lecture 157 Detailed Working Of VFD

Lecture 158 Drive Selection using Online Selection Tool

Lecture 159 VFD Hardware

Lecture 160 Basic Parameter Settings

Lecture 161 IO Parameter Settings

Section 8: Control Valves

Lecture 162 Introduction to Control Valves

Lecture 163 Types of Electric Control Valves

Lecture 164 Electro Pneumatic Control Valves

Lecture 165 Electro Pneumatic Positioners

Section 9: PLC Programming & HMI Designing

Lecture 166 Introduction to the Software

Lecture 167 Downloading Link

Lecture 168 Creating a New Project & Adding a PLC

Lecture 169 Settings of PLC Controller

Lecture 170 Types of Programming Language

Lecture 171 Physical & Memory Address

Lecture 172 Data Types - Bits, Words, Double Words

Lecture 173 Contacts and Coils

Lecture 174 Holding Circuit

Lecture 175 Function Blocks

Lecture 176 Timers - TP Timer

Lecture 177 Timers - TON Timer

Lecture 178 Timers - TOFF Timer

Lecture 179 Timers - TONR Timer

Lecture 180 Counters

Lecture 181 Set Reset Functions

Lecture 182 Comparators - Equals to

Lecture 183 Comparators - Less than or Equals to

Lecture 184 Connection Establishment between PLC and HMI

Lecture 185 Testing the Code through the HMI

Lecture 186 PLC Analog Programming Concepts

Lecture 187 PLC Analog Programming Concepts 2

Lecture 188 Setting the Timers through the HMI

Lecture 189 Programming the Nitric Acid Plant

Lecture 190 Adding the HMI

Lecture 191 Configuration Setting of IO Cards

Lecture 192 Tagging of PLC IOs

Lecture 193 Auto/Manual Switching Buttons

Lecture 194 Motor Control Program

Lecture 195 Motor Feedback Program

Lecture 196 Motor Program Simulation

Lecture 197 Motor Program Review

Lecture 198 Control Valve Program

Lecture 199 Auto Sequence of the Plant - 1

Lecture 200 Auto Sequence of the Plant - 2

Lecture 201 Auto Sequence of the Plant - 3

Lecture 202 Auto Sequence of the Plant - 4

Lecture 203 Auto Sequence of the Plant - 5

Lecture 204 Auto Sequence of the Plant - 6

Lecture 205 Auto Sequence of the Plant - 7

Lecture 206 Simulation of the Auto Sequence 1

Lecture 207 Simulation of the Auto Sequence 2

Lecture 208 Simulation of the Auto Sequence 3

Lecture 209 Programming the Stop Sequence

Lecture 210 Simulation of Stop Sequence

Lecture 211 Analog Input Scaling Using Norm_x & Scale_x

Lecture 212 Analog Alarms

Lecture 213 Analog Alarms Simulation

Lecture 214 Temperature Sensor - RTD Programming

Lecture 215 Temperature Sensor - RTD & TC Programming

Lecture 216 Alarms Set/Reset & Plant Tripping

Lecture 217 Motor Running Hours Calculation Program

Lecture 218 Running Hours Simulation

Lecture 219 Motor Running Hours Using Function

Lecture 220 Simulating the Final Running Hours Program

Lecture 221 Simulating the Final Running Hours Program 2

Lecture 222 Analog Output Programming - VFD and Positioners

Lecture 223 HMI - Main Screen (Homepage) Designing

Lecture 224 Designing the Motor & CVs Manually Start/Stop Pop-Up Screens

Lecture 225 Adding the Numerical Output of Transmitters on the HMI

Lecture 226 Adding the LRV and URV of the Transmitters through the HMI

Lecture 227 Designing the Alarm Setpoint Page for Analog Signals

Lecture 228 Adding the Timers of Auto Sequence on the HMI

Lecture 229 Designing the Alarm Page 1

Lecture 230 Designing the Alarm Page 2

Lecture 231 Designing the Alarm Page 3

Lecture 232 Designing the Alarm Page 4

Lecture 233 Designing the Alarm Page 5

Lecture 234 Designing the Alarm Page 6

Lecture 235 Running the Plant Through the PLC and HMI

Lecture 236 Running the Plant Through the PLC and HMI - 2

Lecture 237 Running the Plant Through the PLC and HMI - 3

Lecture 238 Running the Plant Through PLC and HMI - 4

Lecture 239 Running the Plant Through the PLC and HMI - 5

Lecture 240 Running the Plant Through the PLC and HMI - 6

Lecture 241 Running the Plant Through the PLC and HMI - 7

Section 10: PLC Wiring & Hardware

Lecture 242 Line & Neutral Concept (Basics)

Lecture 243 Sinking Vs Sourcing Concept

Lecture 244 Sinking Vs Sourcing Concept - II

Lecture 245 Digital Input Wiring Basics (Beginner)

Lecture 246 Digital Output Wiring Basics - I (Beginner)

Lecture 247 Digital Output Wiring Basic - II (Beginner)

Lecture 248 Siemens PLC - Digital Input Wiring

Lecture 249 Siemens PLC - Digital Input Wiring - Contactors (1st Way)

Lecture 250 Siemens PLC - Digital Input Wiring - Contactors (2nd Way)

Lecture 251 Siemens PLC - Digital Input Wiring - Summary

Lecture 252 Siemens PLC - Digital Output Card

Lecture 253 Siemens PLC - Digital Output Wiring - For 24VDC Field Devices

Lecture 254 Siemens PLC - Digital Output Wiring - For 220VAC Field Devices

Lecture 255 Siemens PLC - Digital Output Wiring - Summary

Lecture 256 Siemens PLC - Digital Control Wiring Summary

Lecture 257 VFD Digital Input - Control Wiring

Lecture 258 VFD Digital Input - Control Wiring Using External Relay

Lecture 259 VFD Digital Output - Control Wiring

Lecture 260 VFD Digital Output - Control Wiring 2

Lecture 261 Control Valves - Wiring & Connections

Lecture 262 PLC Analog Input - Loop Powered Transmitter Connections

Lecture 263 PLC Analog Input - Loop Powered Transmitter Connections 2

Lecture 264 PLC Analog Input - VFD (Amperes & RPM) Monitoring Connections

Lecture 265 PLC Analog Input Wiring Summary

Lecture 266 PLC Analog Input - RTD Wiring and Connections

Lecture 267 PLC Analog Output Wiring

Electrical Engineers,Electronics Engineers,Mechatronics Engineers,Undergraduate Students,Electrical and Electronics Technicians,Automation Engineers,Instrumentation Engineers