Automated Process Control

Course Description

ETS1535C – Automated Process Control is a 3-credit, combined lecture and laboratory course within the Engineering Technologies > Specialty Engineering Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). The course introduces students to the principles and practices of automated industrial process control, with emphasis on programmable logic controllers (PLCs), instrumentation, control loop theory, and supervisory control systems. Students gain hands-on laboratory experience configuring, programming, and troubleshooting automated control systems commonly found in manufacturing, utilities, and process industries. The "C" suffix designates that lecture and laboratory components meet together in the same location at the same time.

Learning Outcomes

Required Learning Outcomes

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

• Explain the fundamental principles of automated process control, including open-loop and closed-loop control systems.
• Identify and describe common process variables — temperature, pressure, flow, and level — and the instruments used to measure them.
• Analyze the operation of proportional, integral, and derivative (PID) controllers and tune basic control loops.
• Program and configure a Programmable Logic Controller (PLC) to perform automated process control tasks using ladder logic and/or function block programming.
• Interpret and create basic process and instrumentation diagrams (P&IDs) using standard ISA symbols and notation.
• Demonstrate safe work practices and recognize relevant electrical and industrial safety standards when working with control systems.
• Troubleshoot faults in automated process control systems using systematic diagnostic procedures and test equipment.

Optional Learning Outcomes

The following outcomes may be covered depending on program emphasis and available laboratory resources:

• Configure and navigate a basic SCADA (Supervisory Control and Data Acquisition) or HMI (Human-Machine Interface) system to monitor and control a process.
• Apply fieldbus and industrial networking concepts (e.g., PROFIBUS, Modbus, DeviceNet, Ethernet/IP) to connect control system components.
• Describe the role of variable frequency drives (VFDs) in automated process control and configure a VFD for a motor control application.
• Evaluate data acquisition techniques and explain how collected data supports predictive maintenance and process optimization.
• Discuss emerging trends in Industrial Internet of Things (IIoT) and their impact on process automation.

Major Topics

Required Topics

• Introduction to Process Control: Open-loop vs. closed-loop systems; control system components (sensors, transmitters, controllers, final control elements); process industries overview.
• Process Variables and Instrumentation: Measurement of temperature, pressure, flow, and level; sensor types and selection; transmitter signal standards (4–20 mA, 0–10 VDC).
• Control Loop Theory: On/off control; proportional (P), integral (I), derivative (D) control modes; PID controller operation and tuning methods.
• P&ID Diagrams and ISA Standards: Reading and interpreting process and instrumentation diagrams; ISA 5.1 symbol standards; instrument identification.
• Programmable Logic Controllers (PLCs): PLC architecture and hardware; I/O modules (discrete and analog); ladder logic programming fundamentals; timers, counters, and data manipulation instructions.
• Final Control Elements: Control valves (types, sizing, and operation); actuators; motor starters and contactor control.
• Safety in Automated Systems: Electrical safety standards; lockout/tagout (LOTO) procedures; process safety concepts; alarm management.
• Troubleshooting and Maintenance: Systematic fault diagnosis; use of digital multimeters and loop calibrators; preventive and corrective maintenance practices.

Optional Topics

• SCADA and HMI Systems: SCADA architecture; HMI screen design; real-time monitoring; alarm and event logging.
• Industrial Networking and Fieldbuses: Network topologies; Modbus RTU/TCP, DeviceNet, PROFIBUS, EtherNet/IP protocols; wiring and configuration.
• Variable Frequency Drives (VFDs): VFD principles; parameter configuration; speed and torque control; energy savings applications.
• Advanced PLC Programming: Function block diagrams; structured text; sequential function charts (SFC); PLC-to-PLC and PLC-to-SCADA communication.
• Data Acquisition and Process Optimization: Data logging; trend analysis; introduction to predictive maintenance strategies.
• IIoT and Industry 4.0 Concepts: Connected devices; cloud-based monitoring; cybersecurity fundamentals for industrial control systems.

Resources & Tools

• PLC Hardware: Allen-Bradley (Rockwell Automation) MicroLogix or CompactLogix series; Siemens S7-1200 (platform varies by institution)
• Programming Software: Rockwell Studio 5000 / RSLogix 500; Siemens TIA Portal; software simulation environments
• HMI/SCADA Software: FactoryTalk View, Inductive Automation Ignition, or equivalent
• Instrumentation Lab Equipment: Process trainers (temperature, flow, level, pressure loops); loop calibrators; signal generators; digital multimeters
• Reference Standards: ISA (International Society of Automation) standards; NFPA 70E (electrical safety); OSHA 29 CFR 1910.147 (LOTO)
• Textbooks: Process Control Instrumentation Technology by Curtis Johnson; Programmable Logic Controllers by Frank Petruzella (or equivalent current edition)

Career Pathways

Completion of ETS1535C prepares students for entry-level and advanced technical roles in Florida's manufacturing, utilities, and process industries. Relevant career pathways include:

• Instrumentation and Control Technician – Install, calibrate, and maintain process instruments and control systems in industrial facilities.
• PLC / Automation Technician – Program and maintain PLCs, HMIs, and automated machinery on production floors.
• Process Control Operator – Monitor and adjust automated systems in chemical, water/wastewater, food & beverage, or energy facilities.
• SCADA Technician – Support supervisory control and data acquisition systems for utilities and infrastructure.
• Maintenance Electrician (Industrial) – Perform electrical troubleshooting and preventive maintenance on automated systems.
• Manufacturing Engineering Technician – Assist engineers in designing, testing, and optimizing automated production processes.

This course also supports progression into advanced programs in electrical engineering technology, mechatronics, and industrial management at Florida colleges and universities.

Special Information

Certification Preparation: The content of this course aligns with industry-recognized certification pathways, including:

• ISA Certified Control Systems Technician (CCST) – Level I: Covers process measurement, control loop theory, and instrumentation fundamentals addressed in this course.
• Rockwell Automation (Allen-Bradley) PLC Programming Certifications: Laboratory exercises using RSLogix/Studio 5000 support preparation for vendor-specific credentials.
• OSHA 10-Hour General Industry: Safety content including lockout/tagout and electrical safety aligns with OSHA 10 competencies; some programs incorporate OSHA 10 card completion.

Lab Component: As a "C" (combined lecture/lab) course, a significant portion of instructional time is devoted to hands-on laboratory work. Students should expect to work directly with live process control trainers, PLC hardware, and instrumentation equipment. Appropriate closed-toe shoes and adherence to laboratory safety policies are required.

Industry Alignment: Course content is aligned with the Florida Department of Education's Advanced Manufacturing and Engineering Technology program frameworks and supports stackable credentials leading to Associate in Science (A.S.) degrees in Electronics Engineering Technology or Industrial Management Technology at participating Florida colleges.