Instrumentation and Control Laboratory

Course Description

ETS4538L is a 1-credit laboratory course in the Engineering Technologies > Specialty Engineering Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). It is the laboratory component paired with ETS4538 (Instrumentation and Control Systems) and meets separately to provide dedicated hands-on practice. Students apply theoretical principles of industrial measurement and process control through structured lab exercises using industry-standard equipment. Emphasis is placed on the installation, calibration, operation, and troubleshooting of sensors, transmitters, controllers, and automated control systems in simulated industrial environments.

This is an upper-division (4000-level) course appropriate for students pursuing an Associate in Science or Bachelor of Applied Science in Engineering Technology with a concentration in instrumentation, control, or advanced manufacturing.

Learning Outcomes

Required Learning Outcomes

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

• Sensor Identification & Application: Identify, select, and properly connect sensors and transmitters used to measure temperature, pressure, flow, and level in industrial process systems.
• Instrument Calibration: Perform calibration procedures on field instruments, including zero and span adjustments, and verify instrument accuracy against known standards using appropriate test equipment.
• Signal Standards: Measure, interpret, and work with standard industrial analog signal ranges (4–20 mA current loops) and digital I/O signals in control system wiring.
• PLC Programming & Wiring: Wire, program, and configure a Programmable Logic Controller (PLC) to perform discrete and analog control functions including combinational logic, counters, timers, and data comparison instructions.
• Process Control Loop Operation: Set up, tune, and evaluate PID (Proportional-Integral-Derivative) control loops for process variables such as temperature, pressure, flow, and liquid level.
• P&ID Interpretation: Read and interpret Piping and Instrumentation Diagrams (P&IDs) using ANSI/ISA symbology to understand process system layout and instrument identification.
• Troubleshooting: Systematically diagnose and correct faults in instrumentation and control system components, including sensors, wiring, transmitters, and controllers, using logical troubleshooting procedures.
• Safety Practices: Demonstrate safe laboratory work practices consistent with industrial standards, including proper lockout/tagout (LOTO) awareness and electrical safety procedures.
• Lab Documentation: Record experimental procedures, instrument readings, calibration data, and results in a professional laboratory notebook or report format.

Optional Learning Outcomes

Depending on institution and available equipment, students may also achieve:

• HMI Configuration: Connect and configure a Human-Machine Interface (HMI) panel to a PLC to display real-time process data and accept operator input.
• SCADA Familiarization: Operate a Supervisory Control and Data Acquisition (SCADA) software environment to monitor and log simulated process variables.
• Data Acquisition Systems: Use a computer-based data acquisition (DAQ) system to collect, record, and analyze process data using software such as LabVIEW or similar platforms.
• DCS Overview: Identify the architectural differences among PLCs, Distributed Control Systems (DCS), and SCADA and demonstrate basic operation within a DCS simulation environment.
• Variable Frequency Drive (VFD) Control: Wire and configure a Variable Frequency Drive (VFD) to control motor speed as a final control element in a process loop.
• Control Valve Operation: Identify types of control valves (globe, ball, butterfly), explain fail-safe positions, and connect a control valve as a final control element in a process loop.
• Pneumatic Instrumentation: Describe the use of pneumatic signal standards (3–15 psi) in process instrumentation and identify where pneumatic systems are preferred for safety reasons.

Major Topics

Required Topics

The following topics are covered in all standard offerings of this course:

• Laboratory Safety & Industrial Standards — PPE requirements, electrical safety, LOTO awareness, ANSI/ISA and NEC code references in lab settings
• Sensor & Transducer Technology — Temperature sensors (RTDs, thermocouples, thermistors), pressure sensors (strain gauge, capacitive), flow sensors (orifice plate, turbine, magnetic), and level sensors (float, ultrasonic, differential pressure)
• Signal Conditioning & Transmission — 4–20 mA current loop wiring, signal scaling and ranging, two-wire vs. four-wire transmitter configurations
• Instrument Calibration Procedures — Zero/span calibration, calibration error calculation, use of deadweight testers, decade boxes, and loop calibrators
• P&ID Reading & Instrument Loop Diagrams — ISA symbol identification, loop numbering, instrument tagging, and loop diagram interpretation
• PLC Discrete Control Lab — PLC hardware identification, I/O wiring, ladder logic programming (contacts, coils, timers, counters), downloading and monitoring programs
• PLC Analog Control Lab — Analog input/output modules, scaling raw counts to engineering units, PID instruction blocks in PLC software
• PID Control Loop Tuning — Open-loop and closed-loop tuning methods, proportional band, integral (reset), and derivative (rate) adjustments, loop performance evaluation
• Process Variable Control Experiments — Hands-on closed-loop control of at least two process variables (e.g., temperature and liquid level or flow and pressure)
• Troubleshooting Exercises — Fault isolation in instrument loops using multimeters, loop calibrators, and process simulation panels; systematic troubleshooting methodology
• Lab Reporting & Technical Documentation — Lab report writing, data tables, calibration records, error analysis, and conclusion writing

Optional Topics

The following topics may be included based on available equipment and program emphasis:

• HMI Panel Programming — Creating graphic display screens, linking process tags to PLC data, configuring alarms in an HMI environment
• SCADA System Operation — Trending, alarming, and historical data logging using SCADA software
• Data Acquisition with Computer Software — Using LabVIEW, FactoryTalk, or equivalent to acquire and visualize process data
• Variable Frequency Drive (VFD) Lab — Motor speed control using VFD as a final control element; parameter setup and fault diagnostics
• Control Valve & Actuator Lab — Bench testing of pneumatic and electric control valves; characterizing valve flow coefficient (Cv)
• Distributed Control Systems (DCS) Introduction — Overview of DCS architecture; comparison to PLC-based control; operator station navigation
• Wireless & Smart Instrument Familiarization — HART protocol communication, smart transmitter configuration using a handheld communicator
• Capstone / Integrated Process Control Project — Student teams design, wire, program, and commission a small-scale automated process control system

Resources & Tools

Students in this laboratory course typically use or encounter the following equipment, software, and reference materials:

• Lab Equipment: Industrial-grade process trainers (temperature, pressure, flow, and level loops); PLC training panels (Allen-Bradley, Siemens, or equivalent); loop calibrators; multimeters; signal generators; pressure gauges and deadweight testers
• Software: PLC programming software (e.g., Rockwell Studio 5000 / RSLogix 500, Siemens TIA Portal); HMI design software (e.g., FactoryTalk View, Weintek EasyBuilder); data acquisition software (e.g., LabVIEW, National Instruments DAQ); SCADA simulation platforms
• Reference Standards: ANSI/ISA-5.1 (Instrumentation Symbols and Identification); ISA-5.4 (Instrument Loop Diagrams); ISA-18.2 (Alarm Management); NEC Article 430 (Motor Circuits) and Article 500 (Hazardous Locations)
• Textbooks / References: Instrumentation for Process Measurement and Control (Considine); Process Control Instrumentation Technology (Johnson & Crain); ISA training manuals

Career Pathways

Successful completion of ETS4538L, as part of an Engineering Technology program, prepares students for technical careers across a broad range of industries that rely on automated measurement and control systems. Common roles and industries include:

• Instrumentation & Control Technician — Power generation plants, water/wastewater treatment facilities, chemical and petrochemical manufacturing
• Automation Technician / Controls Technician — Advanced manufacturing, food and beverage processing, pharmaceutical production
• Process Control Technician — Oil and gas facilities, pulp and paper mills, semiconductor fabrication plants
• Maintenance Technician (Electrical/Instrumentation) — Utilities, aerospace, building automation
• Field Service Engineer (Entry Level) — Industrial equipment manufacturers and system integrators

This course also supports articulation into baccalaureate programs in Engineering Technology (B.A.S. or B.S.E.T.) at Florida state universities, and aligns with workforce needs identified by regional employers including NextEra Energy, Rayonier Advanced Materials, and municipal utility authorities throughout Florida.

Special Information

Certification Preparation

The hands-on competencies developed in this laboratory course support preparation for industry-recognized credentials. Students are encouraged to pursue the following certifications upon program completion:

• ISA Certified Automation Professional (CAP) — International Society of Automation; validates knowledge of automation system design, installation, and management
• ISA Certified Control Systems Technician (CCST) — Validates hands-on skills in calibration, troubleshooting, maintenance, and repair of instrumentation and control systems (Levels I, II, and III)
• PMMI Mechatronics Certification — Industrial Electricity and Controls pathway, recognized in Florida manufacturing programs
• OSHA 10-Hour General Industry Card — Recommended safety credential for all students entering industrial workplaces

This course is part of the Engineering Technology (Advanced Manufacturing) Associate in Science degree sequence and may apply toward technical certificates in Advanced Manufacturing Automation, Mechatronics, and related concentrations at participating Florida colleges.