Introduction

In an era of increasing demand for electrical reliability, energy efficiency, and safe operations, professionals working in modern facilities must understand the full scope of Electrical & Instrumentation (E&I) systems and High Voltage (HV) infrastructure. This training program, designed by Global Horizon Training Center, focuses on bridging E&I with HV operations, providing engineers and technical personnel with essential skills to manage, maintain, and troubleshoot critical electrical systems in industrial, oil & gas, utility, and infrastructure environments.

Program Objectives

By the end of this course, participants will be able to:

1. Apply the principles and best practices of E&I and HV systems.

2. Interpret single-line diagrams, instrumentation loop drawings, and protection schemes.

3. Conduct diagnostics and testing on HV equipment and E&I devices.

4. Understand safety requirements including LOTO, arc-flash protection, and grounding.

5. Integrate instrumentation systems with SCADA and digital communication protocols (e.g., IEC 61850).

6. Develop and implement preventive maintenance and commissioning plans.

Course Methodology

• Instructor-led technical lectures using real-world case examples.

• Practical demonstrations and simulations using software and sample schematics.

• Hands-on group activities to interpret diagrams and troubleshoot systems.

• Interactive discussions and Q&A sessions to apply concepts to participants’ work environments.

• Daily knowledge checks and recap exercises to reinforce learning.

Organizational Impact

Organizations will benefit through:

• Improved operational safety and system reliability.

• Minimized downtime through advanced troubleshooting capabilities.

• Increased compliance with international electrical standards and codes.

• Stronger cross-functional collaboration between electrical and instrumentation teams.

• More effective project delivery through integrated commissioning and testing skills.

Target Audience

• Electrical and instrumentation engineers and supervisors.

• Maintenance and operations professionals in utilities, oil & gas, and process plants.

• HV technicians and substation operators.

• Project and commissioning engineers.

• Facility and plant engineers involved in energy and power distribution.

 Course Outline

Day 1 – Fundamentals of Electrical & Instrumentation Systems

Main Topics:

• Overview of E&I roles in industrial and infrastructure systems.

• Electrical parameters: voltage, current, resistance, power, and energy.

• Instrumentation signal types: analog (4-20 mA, 0-10V) and digital (modbus, Profibus).

• Control systems overview: PLC, DCS, and SCADA.

• Field devices: sensors, transmitters, control valves, actuators.

• Wiring, shielding, and grounding for signal integrity.

Activities:

• Interpret an instrumentation loop diagram.

• Demonstration: Calibrate a pressure transmitter (4-20 mA).

• Group exercise: Identify signal paths between field device and control room.

Day 2 – High Voltage (HV) System Architecture and Equipment

Main Topics:

• Generation to distribution: HV overview (11kV, 33kV, 132kV, 400kV).

• Transformers: core types, vector groups, tap changers, cooling methods.

• HV switchgear: air-insulated vs. gas-insulated (AIS vs. GIS).

• Substation layouts: main bus, incoming/outgoing feeders.

• Circuit breakers, disconnectors, and earthing switches.

• Insulation coordination and dielectric stress analysis.

Activities:

• Workshop: Reading and analyzing single-line diagrams (SLDs).

• Case study: Root cause of insulation failure in a 132kV transformer.

Day 3 – Protection, Control & SCADA Integration

Main Topics:

• Protection principles: overcurrent, earth fault, differential, distance.

• CTs and VTs: selection, accuracy classes, polarity, testing.

• Protective relays: electromechanical, digital, numerical.

• Introduction to SCADA and RTUs.

• IEC 61850 basics: logical nodes, GOOSE messaging, substation automation.

Activities:

• Simulation: Set and test a digital overcurrent relay.

• Hands-on: Configure SCADA data mapping from relay inputs.

• Group task: Design protection settings for a feeder and transformer.

Day 4 – HV Safety, Testing & Maintenance Procedures

Main Topics:

• HV safety protocols: LOTO, safe clearance, isolation, arc-flash analysis.

• Arc-flash PPE and boundary calculations (NFPA 70E).

• HV testing:

  • Insulation resistance (IR) and polarization index (PI).

  • Tan-Delta and partial discharge testing.

  • Contact resistance and circuit breaker timing.

• Maintenance strategies: preventive, predictive, and condition-based.

Activities:

• Demonstration: Perform insulation resistance test using IR tester.

• Workshop: Develop a preventive maintenance checklist for HV switchgear.

• Case analysis: Arc-flash incident and safety failure investigation.

Day 5 – Commissioning, Troubleshooting & System Optimization

Main Topics:

• Commissioning process: FAT vs. SAT, energization protocols.

• Start-up checklists and HV energization sequences.

• Troubleshooting techniques for E&I and HV failures.

• Power quality management: harmonics, flicker, voltage dips.

• System optimization: energy efficiency and reliability improvement.

Activities:

• Capstone group exercise: Investigate and resolve a simulated fault combining HV trip and instrumentation signal failure.

• Course review and final Q&A.

• Develop individual action plans for applying learning to participants’ organizations.