Process Control & Automation

Course Description

ETS2535C is a combined lecture and laboratory course in the Engineering Technologies > Specialty Engineering Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). The course prepares students to work in the area of process control automation by providing hands-on experience with industrial sensors, control loops, and automation systems used in high-tech production, manufacturing, distribution, and engineering research and development facilities. Lecture and laboratory assignments provide experience with sensors, level control, flow control, pressure control, temperature control, digital set-point programming, analog processing, and PID (Proportional-Integral-Derivative) control. The “C” suffix indicates a combined lecture-and-laboratory course that meets in the same place at the same time.

Learning Outcomes

Required Outcomes

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

• Identify the basic principles and terminology of process control and describe the primary components of a process control system.
• Explain the operation of open-loop and closed-loop control systems and the role of feedback in maintaining process variables within correct ranges.
• Select, install, and interpret readings from industrial sensors measuring flow, level, temperature, and pressure.
• Configure and tune PID controllers (Proportional, Integral, and Derivative) to control process variables to a desired setpoint.
• Program and troubleshoot Programmable Logic Controllers (PLCs) as applied to process control applications, including ladder logic, timers, counters, and analog I/O.
• Read, interpret, and produce P&ID (Piping and Instrumentation Diagrams) used in process plant documentation.
• Operate, troubleshoot, and maintain pneumatic, hydraulic, and electromechanical components integrated into automated process control systems.
• Apply safe work practices, including OSHA electrical and industrial safety standards, when working on live and de-energized control systems.

Optional Outcomes

The following outcomes may be covered depending on institutional emphasis and available laboratory equipment:

• Configure a basic SCADA (Supervisory Control and Data Acquisition) system interface to monitor and control a process loop in real time.
• Interface a Human-Machine Interface (HMI) with a PLC to create operator control screens for a simulated industrial process.
• Apply Variable Frequency Drives (VFDs) to motor speed control within a closed-loop process control application.
• Utilize industrial communication protocols such as Modbus, Ethernet/IP, or OPC to network controllers and field devices.
• Demonstrate understanding of Distributed Control System (DCS) architecture and contrast it with PLC-based control systems.
• Apply Industry 4.0 concepts including smart sensors, data analytics, and networked automation systems to process control scenarios.

Major Topics

Required Topics

1. Introduction to Process Control — Terminology, process variables (PV), setpoints (SP), manipulated variables (MV); open-loop vs. closed-loop systems; block diagram representations.
2. Sensors and Transmitters — Types and operating principles of sensors for pressure, temperature (thermocouples, RTDs), level (ultrasonic, float, differential pressure), and flow (orifice plate, magnetic, Coriolis); signal conditioning and 4–20 mA current loop standards.
3. Control Valves and Actuators — Final control elements; pneumatic and electric actuators; valve sizing and selection; solenoid valves; variable frequency drives for flow control.
4. PID Control Theory and Tuning — Proportional, integral, and derivative control actions; controller response; manual and automatic PID tuning methods; offset, overshoot, and stability.
5. Programmable Logic Controllers (PLCs) in Process Control — PLC architecture; analog and digital I/O modules; ladder logic programming for process applications; timers, counters, and data manipulation; Allen-Bradley RSLogix/Studio 5000 or equivalent platform.
6. Level, Flow, Pressure, and Temperature Control Loops — Hands-on laboratory setup and tuning of individual control loops; cascade and ratio control concepts.
7. P&ID Diagrams — ISA symbology; reading and interpreting piping and instrumentation diagrams; instrument tagging conventions.
8. Process Control Safety — Safety instrumented systems (SIS); interlock logic; alarm management; OSHA standards applicable to instrumentation and control environments.
9. Troubleshooting Process Control Systems — Systematic fault isolation; use of electrical test equipment; diagnosing sensor failures, loop problems, and controller faults.

Optional Topics

1. SCADA Systems — SCADA architecture (field devices, RTUs, communication network, central host); data acquisition; real-time trending; alarm and event logging; FactoryTalk, Ignition, or WonderWare platforms.
2. Human-Machine Interface (HMI) Design — Creating operator screens; linking tags to PLC registers; alarm display and navigation.
3. Industrial Communication Networks — Modbus RTU/TCP, Ethernet/IP, DeviceNet, OPC/OPC-UA; device-level bus structures and network topologies.
4. Distributed Control Systems (DCS) — DCS vs. PLC-based control; architecture overview; application in continuous process industries (oil & gas, chemical, water treatment).
5. Advanced Control Strategies — Cascade control; feed-forward control; ratio control; split-range control; brief introduction to model predictive control (MPC).
6. Industry 4.0 / IIoT Integration — Smart transmitters; wireless instrumentation (WirelessHART); cloud-based data monitoring; cybersecurity considerations for industrial control systems.

Resources & Tools

• PLC Hardware & Software: Allen-Bradley (Rockwell Automation) ControlLogix or MicroLogix processors with Studio 5000 / RSLogix 5000 software; alternatively Siemens S7 series with TIA Portal.
• Process Control Trainers: Bench-top process control trainers with live flow, level, temperature, and pressure loops (e.g., Festo Didactic, Amatrol, or equivalent).
• SCADA/HMI Software: Rockwell FactoryTalk View, Inductive Automation Ignition, or Wonderware InTouch (educational licenses).
• Instrumentation: Digital multimeters, loop calibrators (e.g., Fluke 715 or equivalent), pressure gauges, manometers, and thermocouple calibrators.
• Reference Standards: ISA (International Society of Automation) standards including ISA-5.1 (P&ID symbols) and ISA-18.2 (alarm management).
• Textbooks (Representative): Process Control Instrumentation Technology by Curtis Johnson; Automating Manufacturing Systems with PLCs by Hugh Jack (open-access).
• Florida SCNS Online Resource: flscns.fldoe.org — statewide course profiles and participating institution listings.

Career Pathways

Completion of ETS2535C supports entry-level and advancement employment in high-skill, high-wage positions across Florida's advanced manufacturing, chemical, food processing, utility, and distribution sectors. Representative job titles include:

• Instrumentation & Control Technician
• Automation Technician / Automation Specialist
• Process Control Technician
• PLC Programmer / Controls Specialist
• SCADA Technician / SCADA Engineer
• Maintenance Technician (advanced manufacturing, food production, utilities)
• Engineering Technician / Engineering Specialist

This course is a core component of the Automation College Credit Certificate (CCC) and the Engineering Technology A.S. degree offered at Florida colleges including Hillsborough Community College, Valencia College, Gulf Coast State College, and College of Central Florida. Credits are transferable within Florida's SCNS articulation framework.

Special Information

Certification Preparation

The competencies developed in ETS2535C align with the following industry certifications, which students are encouraged to pursue:

• MSSC Certified Production Technician (CPT) — The Engineering Technology program technical skills standards at Florida colleges (including Valencia College) align with the Manufacturing Skills Standards Council (MSSC) CPT certification framework.
• SACA Certified Industry 4.0 Instrumentation Specialist — Prepares individuals to install, troubleshoot, repair, and maintain instrumentation and control systems using transducers, transmitters, and PID controllers for industrial fluid processes.
• ISA Certified Control Systems Technician (CCST) — Level I — The International Society of Automation's entry-level credential for instrumentation and control technicians; directly aligned with PID, loop calibration, and P&ID competencies in this course.
• Rockwell Automation Certified Specialist (Studio 5000 / RSLogix) — Vendor certification available for students who pursue Allen-Bradley PLC programming beyond the classroom level.

Lab Fee

A lab fee is typically assessed for this course (approximately $75–$101 depending on institution) to cover consumable materials and equipment maintenance in the process control laboratory. Confirm the current fee with your institution's bursar at time of registration.

Industry Note

The "C" suffix in ETS2535C designates a combined lecture and laboratory course under Florida's SCNS. Students should expect roughly equal time split between lecture instruction and hands-on laboratory work each week. Appropriate closed-toe footwear and safety glasses are required in the lab environment.