Automation and Controls Design Through Commissioning

Course Description

This course covers the full lifecycle of industrial and commercial automation and controls projects — from initial system design through installation, programming, testing, and final commissioning. Students apply concepts from control theory, electrical design, and programmable logic to plan, configure, and bring automation systems online in accordance with industry standards. The course is taught in a lab-intensive format that mirrors real-world project workflows in building automation, manufacturing, and process control environments.

This course is part of the Engineering Technologies > Mechanics, Fluids, and Heat taxonomy under the Florida Statewide Course Numbering System (SCNS) and is a core course in the Energy Management and Controls Technology (A.S.) program at participating Florida colleges, including Valencia College.

Learning Outcomes

Required Learning Outcomes

Upon successful completion of this course, students will be able to:

• Describe the complete automation project lifecycle, from requirements and design through commissioning and handoff.
• Interpret and develop control system drawings, including electrical schematics, loop diagrams, and point-to-point wiring documentation.
• Design and configure Programmable Logic Controller (PLC) programs using ladder logic and function block diagrams for discrete and analog control applications.
• Develop and configure Human-Machine Interface (HMI) screens for system monitoring, alarm management, and operator interaction.
• Perform field installation verification, including loop checks, I/O point validation, and sensor calibration.
• Execute a systematic commissioning procedure, including pre-commissioning checklists, functional testing, and performance verification against design specifications.
• Identify and correct faults in automation systems through structured troubleshooting methods.
• Apply applicable electrical codes and safety standards (NEC/NFPA) during system design and commissioning activities.
• Produce technical documentation including as-built drawings, commissioning reports, and startup logs.

Optional Learning Outcomes

Depending on the instructor and institutional emphasis, students may also:

• Configure and commission Variable Frequency Drives (VFDs) and motor control systems integrated with PLC control logic.
• Apply SCADA (Supervisory Control and Data Acquisition) concepts and connect field devices to supervisory systems.
• Implement basic network communication protocols (e.g., BACnet, Modbus, or EtherNet/IP) for device-level integration.
• Apply building automation system (BAS) commissioning procedures for HVAC, lighting, and energy management applications.
• Utilize IQ/OQ/PQ (Installation, Operational, and Performance Qualification) frameworks used in regulated industries such as pharmaceutical and food processing.
• Apply lean and continuous improvement principles to evaluate automation system performance and energy efficiency.

Major Topics

Required Topics

• Automation System Design Fundamentals — Control philosophy development, functional requirement specifications, and selection of hardware and software components.
• Control System Drawings and Documentation — Reading and creating electrical schematics, panel layouts, I/O schedules, loop drawings, and instrument lists.
• PLC Programming for Control Applications — Ladder logic, function blocks, timers, counters, analog I/O, and structured control sequences.
• HMI Development — Screen design, tag configuration, alarm setup, trending, and operator interface best practices.
• Sensors, Actuators, and Field Devices — Selection, wiring, and calibration of pressure, temperature, flow, and level instruments; valve and actuator interfacing.
• Control Panel Fabrication and Verification — Panel layout, wiring standards, UL508A considerations, and factory acceptance testing (FAT).
• Pre-Commissioning Procedures — Loop checks, point-to-point verification, instrument calibration records, and safety interlocks testing.
• Commissioning and Startup — Functional testing against specifications, performance verification, setpoint configuration, and system tuning.
• Troubleshooting and Diagnostics — Structured fault isolation techniques for electrical, mechanical, and software faults in live automation systems.
• As-Built Documentation and Handoff — Preparation of commissioning reports, startup logs, revised drawings, and operator/maintenance training materials.
• Electrical Safety and Code Compliance — NEC/NFPA standards applicable to control panels and industrial installations; lockout/tagout (LOTO) procedures.

Optional Topics

• Variable Frequency Drive (VFD) Configuration — Parameter setup, speed control, and integration with PLC systems.
• Industrial Communication Networks — Protocols such as Modbus RTU/TCP, BACnet, EtherNet/IP; network topology and device addressing.
• SCADA System Integration — Connecting field PLCs to supervisory platforms; historian configuration and alarm management.
• Building Automation System (BAS) Commissioning — HVAC controls, zone control, scheduling, and energy monitoring specific to commercial building systems.
• Regulatory Commissioning Frameworks — IQ/OQ/PQ validation for pharmaceutical, biotech, or food and beverage industries.
• Energy Performance and System Optimization — Post-commissioning analysis, KPIs, and energy efficiency reporting.

Resources & Tools

• PLC Hardware & Software: Allen-Bradley (Rockwell Automation) Studio 5000 / RSLogix 5000, Siemens TIA Portal, or equivalent platforms
• HMI Software: FactoryTalk View, Ignition by Inductive Automation, or Wonderware
• SCADA Platforms: Ignition, VTScada, iFIX (for optional SCADA topics)
• Instrumentation & Calibration Tools: Multimeters, loop calibrators, signal simulators, pressure gauges
• Control Panel Lab Equipment: Wired training panels with PLCs, I/O modules, sensors, motor starters, and VFDs
• Documentation Software: AutoCAD Electrical or equivalent CAD tools for schematic and panel drawing creation
• Reference Standards: NFPA 70 (National Electrical Code), ISA-5.1 (Instrumentation Symbols and Identification), ISA-18.2 (Alarm Management)
• Textbooks / References: Programmable Logic Controllers by Frank Petruzella; ISA training publications on commissioning and loop checking

Career Pathways

Graduates who complete this course as part of the Energy Management and Controls Technology A.S. degree or a related program are prepared to enter high-demand technical careers including:

• Automation Controls Technician — Installs, programs, tests, and commissions automated systems in manufacturing and process industries
• Building Automation System (BAS) Technician — Commissions and services HVAC, lighting, and energy management control systems in commercial buildings
• PLC/HMI Programmer — Designs and develops control logic and operator interfaces for industrial automation projects
• Controls Systems Integrator — Works for systems integration firms delivering turnkey automation solutions across multiple industries
• Commissioning Engineer/Technician — Specializes in field verification, functional testing, and startup of automation and controls installations
• Instrumentation & Control (I&C) Technician — Calibrates, maintains, and troubleshoots sensors, transmitters, and control loops in process industries
• SCADA Technician — Maintains and supports supervisory control systems in water/wastewater, utilities, and industrial facilities

Employment opportunities exist across Florida's diverse industrial base, including manufacturing, water and wastewater utilities, commercial construction, healthcare facilities, pharmaceutical production, and theme park/hospitality operations.

Special Information

This course is a hands-on, lab-intensive course (designated by the 'C' suffix in the Florida SCNS, indicating a combined lecture/laboratory format). Students should expect significant time in a controls lab environment performing wiring, programming, and commissioning exercises on live equipment.

Certification Preparation: The skills and knowledge covered in this course support preparation for the following industry-recognized credentials:

• ISA Certified Control Systems Technician (CCST) — Administered by the International Society of Automation (ISA); validates skills in loop checking, instrumentation, and control system commissioning
• Rockwell Automation Certified Technician (RACT) or equivalent vendor-specific PLC/HMI certifications
• OSHA 10-Hour General Industry — Safety certification relevant to industrial commissioning environments
• LOTO / Electrical Safety Competency — In alignment with NFPA 70E standards for work on energized systems

Students completing this course within the Valencia College Energy Management and Controls Technology A.S. program will also complete an industry-based internship, providing real-world commissioning experience with leading employers in Central Florida and beyond.