Basic Electrical and Instrumentation Design: 5-Day Comprehensive Training Course

Course Overview

This foundational Electrical and Instrumentation Design Training provides essential knowledge for designing electrical power systems and instrumentation control systems in industrial facilities. This intensive 5-day program covers electrical distribution fundamentals, motor control circuits, instrumentation principles, control systems, P&ID development, cable design, earthing, and industry design standards for process plants, oil & gas, manufacturing, and utility applications.

Who Should Attend This E&I Design Course?

• Junior Electrical Engineers starting in design roles

• Instrumentation Engineers in process industries

• Process Engineers requiring E&I knowledge

• Design Engineers transitioning to E&I discipline

• Project Engineers managing E&I design packages

• Mechanical Engineers interfacing with E&I systems

• CAD Technicians preparing E&I drawings

• Maintenance Engineers seeking design understanding

• Recent Engineering Graduates entering industrial sector

• Plant Engineers involved in facility modifications

Course Objectives

Participants will learn:

• Electrical power distribution design for industrial facilities

• Motor control and protection circuit design

• Instrumentation system architecture and design

• Process control and automation fundamentals

• P&ID symbols, development, and interpretation

• Cable sizing, tray routing, and installation design

• Grounding and lightning protection systems

• Industry standards: IEC, ISA, API, IEEE, NFPA

Day 1: Electrical Distribution System Design Fundamentals

Morning Session: Industrial Power System Basics

Topics Covered:

• Industrial electrical systems overview and architecture

• Voltage level selection: LV, MV systems in process plants

• Power distribution configurations: radial, ring, grid

• Single-line diagram development and conventions

• Load classification: continuous, intermittent, essential, non-essential

• Connected load vs. demand load calculations

• Diversity and demand factors for industrial facilities

• Power factor fundamentals and economic considerations

Industrial Applications:
Understanding electrical requirements for refineries, chemical plants, manufacturing facilities, and utilities.

Afternoon Session: Transformers and Switchgear Selection

Topics Covered:

• Power transformer selection and sizing methodology

• Transformer types: dry-type, oil-filled, cast resin

• Impedance, vector groups, and tap changer selection

• Low voltage switchgear: MCCB, ACB specifications

• Medium voltage switchgear: VCB, vacuum, SF6 breakers

• Motor Control Centers (MCC) design and layout

• Load centers and distribution philosophy

• Emergency and essential load distribution

Design Exercise:
Developing single-line diagrams for small industrial facility with motor loads.

Day 2: Motor Control and Protection Design

Morning Session: Motor Types and Selection

Topics Covered:

• Industrial motor types: induction, synchronous, DC motors

• Motor enclosure classifications: TEFC, ODP, explosion-proof

• Motor duty cycles and service factors

• Hazardous area motor classifications: Class I, II, III / Zone 0, 1, 2

• Motor efficiency classes and energy considerations

• Motor voltage and frequency selection

• Starting torque and load matching

• Variable frequency drive (VFD) applications

Selection Criteria:
Understanding motor specifications for pumps, compressors, fans, conveyors, and agitators.

Afternoon Session: Motor Control Circuit Design

Topics Covered:

• Motor starting methods: DOL, star-delta, autotransformer, soft-starter, VFD

• Motor control circuit diagrams and schematics

• Control transformer sizing and protection

• Push-button stations and selector switches

• Motor protection: thermal overload, phase loss, under-voltage

• Control interlocks and permissive logic

• Emergency stop circuits and safety requirements

• Motor control panel layout and design

Practical Workshop:
Drawing motor control circuits with start/stop, forward/reverse, and interlocking functions.

Day 3: Instrumentation System Design Fundamentals

Morning Session: Process Measurement Instrumentation

Topics Covered:

• Instrumentation system architecture and hierarchy

• Process variables: pressure, temperature, flow, level

• Pressure measurement: gauges, transmitters, switches

• Temperature measurement: RTD, thermocouple, thermowells

• Flow measurement: orifice plates, magnetic, ultrasonic, Coriolis

• Level measurement: differential pressure, radar, ultrasonic, capacitance

• Analytical instruments: pH, conductivity, dissolved oxygen

• Instrument selection criteria and specifications

Key Concepts:
Understanding measurement principles, accuracy, rangeability, and application limitations.

Afternoon Session: Control Valves and Final Control Elements

Topics Covered:

• Control valve types: globe, ball, butterfly, diaphragm

• Valve characteristics: linear, equal percentage, quick-opening

• Valve sizing and Cv calculations

• Actuator types: pneumatic, electric, hydraulic

• Positioners and accessories

• On-off valves and solenoid valves

• Safety instrumented valves and fail-safe positions

• Control valve specifications and datasheets

Application Exercise:
Control valve selection and sizing for flow control applications.

Day 4: Process Control Systems and P&ID Development

Morning Session: Control System Architecture

Topics Covered:

• Process control strategies: feedback, feedforward, cascade, ratio

• Distributed Control Systems (DCS) architecture and components

• Programmable Logic Controllers (PLC) vs. DCS applications

• Field instruments to control system connectivity

• HART protocol and smart instrumentation

• Foundation Fieldbus and Profibus networks

• Control room layout and operator interface design

• Marshalling cabinets and I/O modules

Control Concepts:
PID control fundamentals, tuning basics, and control loop configuration.

Afternoon Session: P&ID Development and Interpretation

Topics Covered:

• Piping and Instrumentation Diagram (P&ID) purpose and usage

• ISA symbology standards: ISA-5.1, ISO 10628

• Instrument tag numbering systems

• Process line identification and sizing

• Equipment symbols and identification

• Control loop representation on P&IDs

• Interlock and shutdown system notation

• Safety Instrumented Systems (SIS) representation

P&ID Workshop:
Reading, interpreting, and developing P&IDs for typical process units.

Day 5: Cable Design, Grounding, and Documentation

Morning Session: Cable Design and Installation

Topics Covered:

• Cable types for power applications: XLPE, PVC, armored cables

• Instrumentation cable types: twisted pair, shielded, multipair

• Cable sizing for motor circuits: voltage drop and ampacity

• Instrumentation cable sizing and circuit design

• Cable tray and conduit routing design principles

• Segregation requirements: power, control, instrumentation

• Cable schedule preparation and management

• Hazardous area cable gland and termination selection

Design Calculations:
Step-by-step cable sizing exercises for motors and instrumentation loops.

Afternoon Session: Grounding and Earthing System Design

Topics Covered:

• Grounding system fundamentals for industrial facilities

• Equipment grounding and safety requirements

• Instrument grounding and signal reference grounding

• Intrinsic safety grounding requirements

• Lightning protection system design basics

• Soil resistivity and earth electrode design

• Ground grid design for substations

• Bonding and equipotential requirements

Safety Focus:
Understanding grounding requirements for personnel safety and equipment protection.

E&I Documentation and Deliverables

Topics Covered:

• Electrical design deliverables: SLD, layout drawings, cable schedules

• Instrumentation deliverables: instrument index, datasheets, loop diagrams

• Hook-up drawings and wiring diagrams

• Junction box schedules and termination diagrams

• Bill of materials (BOM) and requisitions

• Design basis documents and philosophy

• Cause and effect diagrams/matrices

• Equipment layout and plot plans

Drawing Standards:

• ISA drawing standards for instrumentation

• IEC and IEEE drawing standards for electrical

• Company and project-specific standards

• CAD layer management and conventions

Hazardous Area Classification and Design

Topics Covered:

• Hazardous area classification: Class/Division and Zone systems

• Area classification drawings development

• Electrical equipment for hazardous areas: explosion-proof, increased safety

• Intrinsically safe systems design

• Purged and pressurized enclosures

• Temperature class (T-codes) selection

• Equipment protection levels: EPL Ga, Gb, Gc

• ATEX and IECEx certification requirements

Standards Overview:

• NEC Article 500-506 (Class/Division)

• IEC 60079 series (Zone classification)

• API RP 505 (Zone classification)

• ISA 12.00.01 electrical equipment in hazardous locations

Safety Instrumented Systems (SIS)

Topics Covered:

• Safety Instrumented Systems fundamentals and purpose

• Safety Integrity Level (SIL) concepts: SIL 1, 2, 3

• Safety instrumented functions (SIF) design

• Emergency shutdown systems (ESD) architecture

• Fire and gas detection system integration

• Voting configurations: 1oo1, 1oo2, 2oo3

• Separation between BPCS and SIS

• Functional safety standards: IEC 61508, IEC 61511

Industry Standards and Codes

Electrical Standards:

• NEC (NFPA 70): National Electrical Code

• IEEE standards for industrial power systems

• IEC 60364: Electrical installations

• API RP 540: Electrical installations in petroleum facilities

• NFPA 70E: Electrical safety

Instrumentation Standards:

• ISA-5.1: Instrumentation symbols and identification

• ISA-20: Specification forms for process measurement

• IEC 61511: Functional safety - process industry

• API RP 550: Manual on installation of refinery instruments

• API RP 551: Process measurement instrumentation

Practical Design Project

Comprehensive Exercise:
Complete basic E&I design for small process unit including:

• Load list and electrical load calculation

• Single-line diagram development

• Motor control circuit design

• Instrument selection for process measurements

• P&ID development with instrumentation

• Control system architecture definition

• Cable sizing and schedule preparation

• Grounding system design

• Equipment layout drawing

• Bill of materials preparation

Project Presentation:
Groups present design solutions with peer review and instructor feedback.

Final Session: Testing, Commissioning, and Career Development

Commissioning Overview:

• Pre-commissioning inspection and testing

• Loop checking and calibration procedures

• Functional testing of control systems

• Integrated systems testing (IST)

• Performance testing and acceptance

• Documentation and turnover requirements

Career Guidance:

• E&I design career progression pathways

• Continuing education and professional development

• Industry certifications: PE, CAP, PMP

• Software skills development roadmap

• Networking and professional organizations: IEEE, ISA

Assessment Activities:

• Written examination covering electrical and instrumentation fundamentals

• Practical design exercise evaluation

• P&ID interpretation test

• Motor control circuit drawing assessment

• Group project presentation and evaluation

• Interactive Q&A session with experienced designers

• Certificate of Completion in E&I Design

• Course feedback and evaluation

Course Benefits and Learning Outcomes

Upon completion, participants will be able to:

• Understand industrial electrical distribution systems design

• Design motor control circuits and protection schemes

• Select and specify instrumentation for process applications

• Develop and interpret P&IDs per ISA standards

• Design cable systems for power and instrumentation

• Apply grounding and earthing principles

• Understand hazardous area classification and equipment selection

• Prepare basic E&I design documentation and drawings

• Apply industry codes and standards: NEC, IEC, ISA, API

• Communicate effectively with multidisciplinary teams

• Progress toward independent E&I design capabilities

Training Methodology

This E&I design training course employs:

• Clear explanations suitable for beginners

• Step-by-step design procedure demonstrations

• Hands-on calculation exercises

• Real industrial facility examples and case studies

• Drawing and documentation practice

• Group design projects with collaboration

• Interactive discussions and Q&A sessions

• Software demonstrations (AutoCAD, instrument sizing tools)

Course Materials Provided

Participants receive:

• Comprehensive E&I design training manual

• Calculation templates and design aids

• Symbol libraries: ISA, IEC, IEEE standards

• Sample drawings and documentation examples

• Code reference guides: NEC, ISA excerpts

• Equipment selection guides and catalogs

• Certificate of Course Completion

• Digital resource library access

Software and Tools Covered

Introduction to industry tools:

• AutoCAD for electrical and instrumentation drawings

• Microsoft Excel for calculations and schedules

• Instrument sizing and selection software demos

• Cable sizing calculation tools

• P&ID development software overview

Industry Applications

Course examples drawn from:

• Oil and gas facilities: upstream, midstream, downstream

• Chemical and petrochemical plants

• Power generation and utilities

• Water and wastewater treatment

• Manufacturing and process industries

• Mining and minerals processing

• Pharmaceutical and food processing

Prerequisites

Recommended background:

• Bachelor’s degree in Electrical, Instrumentation, or related engineering

• Basic understanding of electrical circuits

• Familiarity with process industry terminology helpful

• No prior design experience required

Keywords: electrical and instrumentation design, E&I design training, industrial electrical design, instrumentation system design, P&ID development, motor control design, process instrumentation, control system design, hazardous area design, cable sizing, grounding system design, ISA standards, instrumentation engineering, electrical design course, process control, DCS PLC systems, instrument selection, motor protection, industrial automation