Instrumentation

Course Description

ETS4538 – Instrumentation is an upper-division (4000-level) specialty engineering technology course classified under the Florida Statewide Course Numbering System (SCNS) taxonomy of Engineering Technologies > Specialty Engineering Technology. The course provides a comprehensive study of industrial measurement and control systems used in manufacturing, process industries, and automated facilities. Students examine the principles, selection, installation, calibration, and troubleshooting of instruments used to measure and control key process variables including pressure, temperature, flow, and level. Emphasis is placed on both analog and digital instrumentation, process control loops, programmable logic controllers (PLCs), distributed control systems (DCS), and compliance with ISA and ANSI/IEC industry standards. The course is designed to prepare students for upper-level roles in instrumentation and control systems engineering technology and to support preparation for industry certifications such as the ISA Certified Control Systems Technician (CCST).

Learning Outcomes

Required Outcomes

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

• Identify and explain the construction, operation, and application of common sensors and transducers used in industrial process measurement systems.
• Apply principles of measurement to pressure, temperature, flow, and level instrumentation, including selection and calibration of appropriate instruments.
• Interpret and apply P&ID (Piping and Instrumentation Diagrams), wiring diagrams, loop diagrams, and instrument specification sheets in accordance with ISA standards.
• Perform calibration procedures for electronic and pneumatic transmitters, controllers, and control valve actuators using appropriate test equipment.
• Analyze and configure process control loops, including proportional-integral-derivative (PID) tuning and closed-loop feedback control strategies.
• Demonstrate proficiency in troubleshooting and diagnosing faults in instrumentation and control systems using systematic diagnostic techniques.
• Identify and apply industry standards and safety practices, including ISA, ANSI/IEC, and NEC requirements for instrumentation installation and hazardous area classification.
• Interpret both analog and digital signal types (4–20 mA, HART, Fieldbus) and explain signal conditioning and conversion principles.

Optional Outcomes

Depending on institution and instructor, students may also:

• Design, implement, and troubleshoot PLC programs and HMI applications for industrial process control scenarios.
• Evaluate Distributed Control System (DCS) architecture and configure basic control strategies within a DCS environment.
• Assess SCADA systems for centralized monitoring and data acquisition in industrial networks.
• Apply Safety Instrumented System (SIS) concepts including Safety Integrity Level (SIL) ratings and functional safety lifecycle principles (IEC 61511).
• Utilize data acquisition software (e.g., LabVIEW or equivalent) for instrument testing and measurement analysis.
• Examine emerging technologies including wireless instrumentation networks and Industrial Internet of Things (IIoT) integration.

Major Topics

Required Topics

• Measurement Fundamentals: Units and standards (SI/English), measurement error, accuracy, precision, repeatability, and resolution; ISA and ANSI terminology (ISA-S51.1).
• Sensors and Transducers: Operating principles and applications of sensors for pressure, temperature (thermocouples, RTDs, thermistors), flow (orifice plate, Coriolis, magnetic, ultrasonic), and level (float, differential pressure, ultrasonic). Signal conditioning and transmitter output types (pneumatic, 4–20 mA, HART, smart/digital).
• Pressure Measurement: Atmospheric, absolute, gauge, and differential pressure; manometers, Bourdon tubes, diaphragm elements, and electronic pressure transmitters; calibration and troubleshooting.
• Temperature Measurement: Thermocouple types and cold junction compensation; RTD bridge circuits; bimetallic devices; pyrometers; calibration standards and procedures.
• Flow Measurement: Differential pressure flow devices, variable area meters, positive displacement, turbine, and mass flow technologies; flow calculations and unit conversions.
• Level Measurement: Float, displacer, differential pressure, capacitance, ultrasonic, and radar level technologies; calibration and installation considerations.
• Calibration Principles and Procedures: Calibration standards, deadband, span and zero adjustment; documentation (calibration records, instrument data sheets); use of calibrators and test equipment.
• P&ID Diagrams and Documentation: ISA symbols and tag numbering; reading and interpreting loop diagrams, instrument index, and cause-and-effect charts; instrument installation drawings.
• Process Control Theory: Open-loop vs. closed-loop control; feedback, feedforward, and cascade control strategies; control loop components (sensor, transmitter, controller, final control element).
• PID Control: Proportional, integral, and derivative control actions; tuning methods (Ziegler-Nichols, trial-and-error); implementation in pneumatic, analog electronic, and digital controllers.
• Control Valves and Final Control Elements: Valve types (globe, butterfly, ball); actuator designs; valve sizing and flow coefficient (Cv); positioners; fail-safe positions; maintenance and calibration.
• Instrumentation Safety and Hazardous Locations: Hazardous area classification (NEC, IEC); intrinsic safety; explosion-proof and purged enclosures; grounding and shielding; ISA-S12 series standards.
• Troubleshooting Methodology: Systematic fault-finding approaches; use of multimeters, loop calibrators, and HART communicators; identifying common failures in transmitters, controllers, and final elements.

Optional Topics

• Programmable Logic Controllers (PLCs): PLC architecture; ladder logic programming; I/O modules and wiring; troubleshooting PLC-based control systems.
• Distributed Control Systems (DCS): DCS architecture and functional blocks; operator station configuration; comparison with PLC-based systems.
• SCADA and HMI: SCADA system architecture; HMI screen design principles; alarm management; data logging and historian functions.
• Industrial Networks and Fieldbus: FOUNDATION Fieldbus, PROFIBUS, Modbus, DeviceNet; industrial Ethernet; network topologies and diagnostics.
• Safety Instrumented Systems (SIS): IEC 61511 lifecycle; SIL determination; SIS design concepts; proof testing requirements.
• Analytical Instrumentation: pH, conductivity, dissolved oxygen, turbidity, and chromatography analyzers; calibration and maintenance of analytical instruments.
• Data Acquisition and LabVIEW: DAQ hardware and software; virtual instruments; data logging; signal analysis and reporting.
• Wireless and IIoT Instrumentation: WirelessHART and ISA100.11a standards; IIoT sensors and gateways; cybersecurity considerations for control systems.

Resources & Tools

• Primary Textbook: Instrumentation for Process Measurement and Control (Norman A. Anderson) or Process Control Instrumentation Technology (Curtis D. Johnson) — widely used in Florida college programs.
• ISA Publications: ISA-S5.1 (P&ID Symbols), ISA-S51.1 (Process Instrumentation Terminology), ISA-TR84 (Safety Instrumented Systems); available through the International Society of Automation (isa.org).
• NICET Study Materials: Industrial Instrumentation Engineering Technology competency frameworks published by the National Institute for Certification in Engineering Technologies.
• Software Tools: PLC programming software (RSLogix 5000 / Studio 5000 or equivalent), LabVIEW (National Instruments), HART Device Manager, DCS simulation platforms.
• Laboratory Equipment: Loop calibrators, HART communicators, process trainers (pressure, temperature, flow, and level loops), multimeters, oscilloscopes, and instrument test benches.
• Standards References: NEC (NFPA 70), IEC 61511, ANSI/ISA standards series, and OSHA Process Safety Management (PSM) guidelines.

Career Pathways

Completion of ETS4538 supports entry into and advancement within the following career roles:

• Instrumentation Technician — Calibrates, installs, maintains, and troubleshoots field instruments in chemical plants, refineries, power plants, and manufacturing facilities.
• Process Control Technician — Configures and maintains PLC, DCS, and SCADA systems in automated industrial environments.
• Automation Engineer / Engineering Technologist — Designs and supports control system upgrades and integration projects (typically requires baccalaureate-level preparation).
• Instrumentation and Controls Inspector — Performs quality assurance and compliance inspections on instrumentation systems in industrial construction and maintenance.
• Field Service Engineer — Supports instrument manufacturers and systems integrators with on-site installation, calibration, and commissioning.

Key industries employing graduates include: oil and gas, chemical processing, power generation (nuclear and conventional), water and wastewater treatment, food and beverage manufacturing, pharmaceutical production, and pulp and paper.

Relevant O*NET Codes: 49-9012.00 (Control and Valve Installers and Repairers), 17-3023.00 (Electrical and Electronic Engineering Technologists and Technicians), 51-8093.00 (Petroleum Pump System Operators).

Special Information

Certification Preparation

This course provides academic preparation aligned with the following industry certifications:

• ISA Certified Control Systems Technician (CCST) — The ISA CCST credential recognizes professionals who calibrate, document, troubleshoot, and repair instrumentation for systems that measure and control level, temperature, pressure, flow, and other process variables. ETS4538 content maps directly to CCST Level I and Level II examination domains.
• NICET Industrial Instrumentation Engineering Technology — NICET certifications in instrumentation validate technician competencies in pneumatic/electronic calibration, process measurement, and control systems. ETS4538 supports work-element preparation for NICET Level I and II.
• ISA Certified Automation Professional (CAP) — For students pursuing advanced roles; ETS4538 builds foundational competencies in the measurement and control domains of the CAP examination.

Program Context

As a 4000-level course, ETS4538 is typically taken by students near completion of a Bachelor of Science in Engineering Technology (BSET) or advanced Associate in Science (A.S.) pathways at Florida State Colleges and universities. The course reinforces applied technical skills appropriate for immediate workforce entry as well as graduate study in engineering management or systems engineering.