Design, Installation and Troubleshooting of Industrial Data Networks

1. Training Introduction

Modern industrial environments depend heavily on robust, secure, and high-performance data networks to support automation, monitoring, control, and communication. Industrial networks—unlike office IT networks—must withstand harsh environments, electromagnetic interference, real-time communication requirements, and mission-critical uptime demands.

This comprehensive training programme equips participants with in-depth knowledge and practical skills for designing, installing, configuring, maintaining, and troubleshooting industrial data networks. It covers network architecture, Ethernet/IP, PROFINET, Modbus TCP, fieldbus systems, industrial wireless solutions, fiber optics, cybersecurity, and diagnostic tools. Through practical labs and real-world case studies, participants master reliable industrial networking practices that maximize equipment uptime and system performance in industrial facilities.

 

2. Training Objective

The programme aims to equip participants to:

• Understand industrial networking concepts, architectures, and communication protocols.
• Design industrial networks with reliability, redundancy, and scalability in mind.
• Install, configure, and commission both wired and wireless industrial networks.
• Use industrial switches, routers, gateways, and network management tools.
• Diagnose and troubleshoot communication issues using analyzers and diagnostic software.
• Integrate PLCs, SCADA, sensors, actuators, and IIoT devices into industrial networks.
• Apply cybersecurity best practices to protect industrial control systems.
• Ensure compliance with industry standards and improve network reliability and resiliency.

 

3. Targeted Group

This training is designed for:

• Industrial automation and control engineers
• Instrumentation and electrical engineers
• Network technicians and IT/OT integration specialists
• SCADA and PLC technicians
• Maintenance and operations personnel
• System integrators and project engineers
• Industrial plant managers and operations supervisors
• IIoT and smart manufacturing professionals
• Students and trainees in automation, networking, and industrial technology

 

4. Course Duration

14–16 Days, depending on format:

• Technical Workshop: 14 days
• Advanced Professional Programme: 16 days
• Online/Blended Learning: Flexible scheduling with virtual labs

 

5. Training Methodology

The methodology uses a hands-on, technical, and problem-solving approach:

• Expert-led technical lectures and demonstrations
• Practical wiring, configuration, and commissioning labs
• Use of analyzers, Ethernet testers, OT cybersecurity tools
• Network design exercises and simulation
• Case studies of industrial failures and best practices
• Group work, guided troubleshooting challenges
• Quizzes, assignments, and a capstone network design project

 

6. Course Content

Module 1: Introduction to Industrial Data Networks

• Differences between IT and OT networks
• Industrial Ethernet vs. fieldbus systems
• Basic architecture and terminology

Module 2: Network Topologies & Industrial Architecture

• Star, ring, line, mesh, redundant architectures
• Layered industrial network models (ISA-95, Purdue Model)
• Designing for reliability and uptime

Module 3: Industrial Protocols & Communication Standards

• Modbus TCP, EtherNet/IP, PROFINET, OPC-UA
• Legacy protocols (Profibus, DeviceNet, CANbus)
• Protocol selection criteria

Module 4: Ethernet Technologies in Industrial Environments

• Managed vs. unmanaged switches
• VLANs, QoS, IGMP, redundancy protocols (RSTP/MRP)
• Real-time and deterministic Ethernet

Module 5: Industrial Network Hardware & Components

• Switches, routers, gateways, media converters
• Industrial enclosures, connectors, terminations
• Power supplies and environmental considerations

Module 6: Cable Selection, Wiring & Fiber Optics

• Copper cabling (Cat5e, Cat6, Cat7)
• Fiber optic installation, splicing, and testing
• Shielding, grounding, EMI/EMC considerations

Module 7: Wireless Industrial Networks

• Wi-Fi industrial solutions, ISA100, WirelessHART
• Antenna selection and placement
• Troubleshooting wireless interference

Module 8: SCADA, PLC & Field Device Integration

• Communication with sensors, instruments, actuators
• PLC communication configuration
• SCADA data exchange and gateway integration

Module 9: IP Addressing, Routing & Network Configuration

• Subnetting, addressing schemes
• Routing basics for industrial systems
• Device configuration and communication mapping

Module 10: Network Monitoring, Diagnostic Tools & Testing

• Packet analyzers (Wireshark), protocol analyzers
• Cable testers, signal quality meters
• Diagnostic indicators and logs

Module 11: Troubleshooting Communication Problems

• Physical layer faults
• Protocol conflicts, addressing errors
• Latency, jitter, and performance issues

Module 12: Redundancy, Reliability & Fail-Safe Design

• Ring topologies, dual networks, redundant controllers
• Fail-safe PLC communication design
• Designing for minimal downtime

Module 13: Industrial Network Cybersecurity

• Threats to OT networks
• Firewalls, segmentation, zero-trust, secure remote access
• Standards: IEC 62443, NIST, ISA cybersecurity practices

Module 14: IIoT, Edge Computing & Digital Transformation

• IIoT platforms, MQTT, cloud integration
• Edge controllers and gateways
• Data acquisition and analytics

Module 15: Case Studies of Industrial Network Implementation

• Smart factories, process plants, utilities, renewable energy systems
• Real-world failures and lessons learned
• Network optimization and redesign

Module 16: Capstone Project – Industrial Network Design & Troubleshooting Simulation

• Design of a complete industrial data network
• Device configuration and commissioning
• Troubleshooting multi-layer network problems
• Presentation and documentation of solutions

 

7. Expected Learning Outcomes

By the end of the programme, participants will:

• Understand the structure, components, and behavior of industrial data networks.
• Install, configure, commission, and maintain both wired and wireless networks.
• Integrate PLCs, SCADA systems, HMIs, and field devices into robust industrial networks.
• Troubleshoot communication issues confidently using diagnostic tools.
• Design secure, redundant, and high-performance industrial networks.
• Apply industry-recognized standards and cybersecurity principles.
• Document network architecture and develop long-term maintenance strategies.

 

8. Certificate of Completion

Participants who successfully complete the 16 modules, assignments, lab work, and the capstone project will receive:

Certificate of Completion

Design, Installation and Troubleshooting of Industrial Data Networks

Issued by FOTADE Training, Research and Resource Development Centre

This certificate confirms the participant’s competencies in designing, installing, and troubleshooting industrial data networks for advanced industrial and automation environments.