Second year Instrumentation course sequence

Fall Quarter
INST200 Introduction to Instrumentation (required in students first quarter) or
2 credits
INST205 Job Prep I (students second quarter) or
INST206 Job Prep II (students third quarter) 1 credit
INST240 Pressure and Level measurement

6 credits

INST241 Temperature and Flow measurement

INST242 Analytical measurement

6 credits

5 credits

Winter Quarter
INST200 Introduction to Instrumentation (required in students first quarter) or
2 credits
INST205 Job Prep I (students second quarter) or
INST206 Job Prep II (students third quarter) 1 credit
INST250 Final Control Elements

5 credits

INST251 PID controllers and tuning

5 credits

INST252 Process optimization and control strategies

PHYS 121 General Physics I

4 credits

5 credits

Spring Quarter
INST200 Introduction to Instrumentation (required in students first quarter) or
2 credits
INST205 Job Prep I (students second quarter) or
INST206 Job Prep II (students third quarter) 1 credit
INST260 Data Acquisition systems

4 credits

INST261 Programmable Logic Controllers

INST262 DCS and Fieldbus
ENGT122 CAD 1: Basics

5 credits
6 credits

5 credits

INST 200 (Introduction to Instrumentation)

Lab
Building a simple control loop: Questions 111 and 112, due at the end of day 5
Day 2: Pulling wires throuch conduit
Day 2: Locating wire pairs in loop system
Day 2: Connect controller output to I/P and valve (use single-loop controllers and DCS)
Day 3: Connect transmitter to controller input
Day 3: Creating loop diagrams ; loop inspections
Day 4: Tube fitting and teflon tape application
Day 4: Testing mA signals using loop calibrators
Day 4: Using HART communicators and/or Emerson AMS to access HART instrument parameters
Day 5: Troubleshooting practice
Day 5: Oral review of lab questions
Feedback questions
Questions 101 through 110, due at the beginning of day 5
Recommended daily schedule
Day 1
Theory session topic: Introduction to second-year program objectives, industry expectations
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: General introduction to instrumentation and control systems
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Analog electronic and HART instruments, signals
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Standard diagrams for instrumentation ; Signal wiring and tube connections
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Day 5
Theory session topic: Process troubleshooting
Questions 81 through 100; answer questions 81-95 in preparation for discussion (remainder for practice)
Feedback questions (101 through 110) due at the end of the day

INST 205 (Job Prep I)

Recommended schedule
Day 1
Presentation: Resume and cover letter writing
Independent activity: Work on resume and/or cover letter
Day 2
Presentation: Searching for jobs
Independent activity: Research job search engines and open job listings
Day 3
Major topics: Workplace safety and OSHA
Homework questions: 1 through 10
Independent activity: Work on resume and/or cover letter
Day 4
Guest speakers: Round-table discussion with employer representatives (varies per quarter)
Independent activity: Work on feedback questions
Day 5
Homework questions: 11 through 20
Independent activity: Work on feedback questions
Feedback questions: 21 through 25
R
esum
e due at the end of the day (no spelling or grammatical errors)
Cover letter due at the end of the day (no spelling or grammatical errors)
Feedback questions due at the end of the day

INST 206 (Job Prep II)

Recommended schedule
Day 1
Presentation: How to actively research potential employers and professionally network
Independent activity: Work on feedback questions
Day 2
Presentation: Conducting informational interviews
Independent activity: Research potential employers of instrument technicians
Day 3
Major topics: Industrial safety considerations
Homework questions: 1 through 10
Independent activity: Research potential employers of instrument technicians
Day 4
Guest speakers: Round-table discussion with employer representatives (varies per quarter)
Independent activity: Conduct your own informational interview
Day 5
Independent activity: Work on feedback questions
Feedback questions: 11 through 15
Three company profiles due at the end of the day (questions 16, 17, 18)
Results of informational interview due at the end of the day (question 19)
Feedback questions due at the end of the day

INST 240 (Pressure and Level Measurement), section 1

Lab
Pressure measurement loop: Questions 91 and 92, completed objectives due by the end of day 4,
section 2
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section only a simple calculator may be used!
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Concepts of pressure and pressure unit conversions
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Pressure measurement technologies
Questions 21 through 40; answer questions 21-28 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Instrument calibration
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Electronic pressure measurement
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

INST 240 (Pressure and Level Measurement), section 2

Lab
Pressure measurement loop: Questions 91 and 92, completed objectives due by the end of day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 only a simple calculator may be used!
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Pressure instrument accessories
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Pneumatic pressure instruments
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Pneumatic pressure instruments (continued) and pressure switches
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Review for exam
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

INST 240 (Pressure and Level Measurement), section 3

Lab
Level measurement loop: Questions 91 and 92, completed objectives due by the end of day 4, section
4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Level measurement technologies and liquid densities
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Hydrostatic level measurement
Questions 21 through 40; answer questions 21-31 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Displacer level measurement
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Measuring liquid-liquid interfaces
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

INST 240 (Pressure and Level Measurement), section 4

Lab
Level measurement loop: Questions 91 and 92, completed objectives due by the end of day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Ultrasonic, radar, and laser level measurement
Questions 1 through 20; answer questions 1-9 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Weight, capacitance, and radiation level measurement
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Point-contact and nonlinear level measurement
Questions 41 through 60; answer questions 41-48 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Review for exam
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

INST 241 (Temperature and Flow Measurement), section 1

Lab
Temperature measurement loop: Questions 91 and 92, completed objectives due by the end of day 4,
section 2
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section only a simple calculator may be used!
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Temperature measurement technologies
Questions 1 through 20; answer questions 1-11 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Principles of heat and temperature
Questions 21 through 40; answer questions 21-28 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: RTDs and thermistors
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Thermocouples
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

INST 241 (Temperature and Flow Measurement), section 2

Lab
Temperature measurement loop: Questions 91 and 92, completed objectives due by the end of day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 only a simple calculator may be used!
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Thermocouples (continued)
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Thermocouple and RTD applications
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Non-contact pyrometers, temperature switches, calibration standards, and accessories
Questions 41 through 60; answer questions 41-49 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Review for exam
Questions 61 through 80; answer questions 61-71 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

10

INST 241 (Temperature and Flow Measurement), section 3

Lab
Flow measurement loop: Questions 91 and 92, completed objectives due by the end of day 4, 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Flow measurement technologies
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Fluid dynamics
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Pressure-based flowmeters
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: High-accuracy pressure-based flow measurement
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

11

INST 241 (Temperature and Flow Measurement), section 4

Lab
Flow measurement loop: Questions 91 and 92, completed objectives due by the end of day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Turbine, vortex, and positive-displacement flowmeters
Questions 1 through 20; answer questions 1-9 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Magnetic and ultrasonic flowmeters
Questions 21 through 40; answer questions 21-28 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: True mass flowmeters
Questions 41 through 60; answer questions 41-48 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Open-channel flowmeters and review for exam
Questions 61 through 80; answer questions 61-69 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

12

INST 242 (Analytical Measurement), section 1

Lab
Analytical measurement loop: Questions 91 and 92, completed objectives due by the end of day 4,
section 3
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 3
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 6 of last section
Question 93 previews the capstone assessment
Recommended daily schedule
Day 1
Theory session topic: Chemical concepts, terms, and symbols
Questions 1 through 20; answer questions 1-9 in preparation for discussion (remainder for practice)
Discuss the upcoming capstone assessment due by the end of the course (Question 93)
Day 2
Theory session topic: The Periodic Table, electron shells, and spectroscopy
Questions 21 through 40; answer questions 21-28 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Molecular quantities
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Stoichiometry and energy in chemical reactions
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

13

INST 242 (Analytical Measurement), section 2

Lab
Analytical measurement loop: Questions 91 and 92, completed objectives due by the end of day 4,
section 3
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 3
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 6 of last section
Question 93 previews the capstone assessment
Recommended daily schedule
Day 1
Theory session topic: Conductivity measurement
Questions 1 through 20; answer questions 1-9 in preparation for discussion (remainder for practice)
Discuss the upcoming capstone assessment due by the end of the course (Question 93)
Day 2
Theory session topic: pH and pH measurement
Questions 21 through 40; answer questions 21-29 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: pH measurement
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Chromatography
Questions 61 through 80; answer questions 61-67 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

14

INST 250 (Final Control Elements), section 1

Lab
Control valve rebuild and bench-set: Questions 91 and 92, completed objectives due by the end of
day 4, section 2
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Principles of fluids and fluid pressure
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Fluid power systems
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Pneumatic instruments
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Pneumatic instruments (continued)
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

15

INST 250 (Final Control Elements), section 2

Lab
Control valve rebuild and bench-set: Questions 91 and 92, completed objectives due by the end of
day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Control valves and pneumatic actuators
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Solenoid valves
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Valve failure modes and packing systems
Questions 41 through 60; answer questions 41-47 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Review for exam
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

16

INST 250 (Final Control Elements), section 3

Lab
Split-range control valves: Questions 91 and 92, completed objectives due by the end of day 4,
section 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Valve positioners
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Split-ranged control valves
Questions 21 through 40; answer questions 21-28 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Electric valve actuators and variable-speed pumps
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Valve sizing
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

17

INST 250 (Final Control Elements), section 4

Lab
Positioner split-ranging: Questions 91 and 92, completed objectives due by the end of day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Valve sizing and relief valves
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Valve characterization
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Valve problems
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Review for exam
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

18

INST 251 (PID controllers and tuning), section 1

Lab
Pneumatic PID controller: Questions 91 and 92, completed objectives due by the end of day 4,
section 2
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Feedback control
Questions 1 through 20; answer questions 1-10 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Setting up Desktop Processes
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Pneumatic process controllers
Questions 41 through 60; answer questions 41-50 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Analog electronic process controllers
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

19

INST 251 (PID controllers and tuning), section 2

Lab
Pneumatic PID controller: Questions 91 and 92, completed objectives due by the end of day 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Differential calculus
Questions 1 through 20; answer questions 1-9 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Integral calculus
Questions 21 through 40; answer questions 21-29 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Applications of calculus
Questions 41 through 60; answer questions 41-49 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Review for exam
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Build and test mastery exam circuit (Question 93)
Feedback questions (81 through 90) due at the end of the day
Day 5
Exam
Mastery exam includes the circuit-building activity shown in question 93
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

20

INST 251 (PID controllers and tuning), section 3

Lab
Automatically-controlled process: Questions 91 and 92, completed objectives due by the end of day
4, section 4
Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4
Feedback questions
Questions 81 through 90, due at the end of day 4
Exam
Day 5 of next section
Question 93 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Theory session topic: Proportional-only offset
Questions 1 through 20; answer questions 1-9 in preparation for discussion (remainder for practice)
Day 2
Theory session topic: Integral-only control
Questions 21 through 40; answer questions 21-30 in preparation for discussion (remainder for practice)
Day 3
Theory session topic: Proportional + integral control
Questions 41 through 60; answer questions 41-49 in preparation for discussion (remainder for practice)
Day 4
Theory session topic: Proportional + integral control (continued)
Questions 61 through 80; answer questions 61-70 in preparation for discussion (remainder for practice)
Feedback questions (81 through 90) due at the end of the day

21

INST 251 (PID controllers and tuning), section 4

Recommended schedule
Day 1
Major topics: Proportional + Integral + Derivative control
Required reading: Lessons In Industrial Instrumentation Summary of PID control terms and P,
I, and D responses graphed sections
Question 0: Research sources
Discussion questions: 1 through 10
Lab Exercise: Complete process with electronic controller (question 52 + question 53)
Day 2
Major topics: Pre-tuning strategies
Required reading: Lessons In Industrial Instrumentation Before you tune . . . section
Discussion questions: 11 through 20
Lab Exercise: Complete process with electronic controller (question 52 + question 53)
Day 3
Major topics: Process dynamics
Required reading: Lessons In Industrial Instrumentation Process Characterization section
Discussion questions: 21 through 30
Lab Exercise: Complete process with electronic controller (question 52 + question 53)
Day 4
Major topics: Simple tuning techniques
Required reading: Lessons In Industrial Instrumentation Quantitative PID Tuning Procedures
section
Discussion questions: 31 through 40
Lab Exercise: Lab questions (question 47)
Lab Exercise: Working process due at the end of the day (question 52 + question 53)
Day 5
Feedback questions: 41 through 50
Labwork participation assessment: question 51
Feedback questions due at the beginning of the day
Lab Exercise: Mastery exam performance practice (question 54)
Exam 2: includes circuit-building performance exercise in Mastery portion
Practice problems
55 through end

22

INST 252 (Process optimization and control strategies), section 1

Recommended schedule
Day 1
Major topics: Process dynamics and controller tuning
Required reading: Lessons In Industrial Instrumentation Process characterization section
Question 0: Research sources
Discussion questions: 1 through 10
Lab Exercise: Loop tuning practice (question 81)
Day 2
Major topics: Process dynamics and controller tuning (continued)
Discussion questions: 11 through 20
Lab Exercise: Loop tuning practice (question 81)
Day 3
Major topics: PID controller tuning using computer simulation
Required reading: Lessons In Industrial Instrumentation Quantitative PID tuning procedures,
Heuristic PID tuning procedures, and Tuning techniques compared sections
Discussion questions: 21 through 30
Lab Exercise: Loop tuning practice (question 81)
Day 4
Major topics: Supervisory setpoint and cascade control
Required reading: Lessons In Industrial Instrumentation Supervisory control and Cascade control
sections
Discussion questions: 31 through 40
Lab Exercise: Loop tuning practice (question 81)
Day 5
Major topics: Ratio control
Required reading: Lessons In Industrial Instrumentation Ratio control section
Discussion questions: 41 through 50
Lab Exercise: Loop tuning practice (question 81)
Day 6
Major topics: Feedforward control
Required reading: Lessons In Industrial Instrumentation Feedforward control and Feedforward
with dynamic compensation sections
Discussion questions: 51 through 60
Lab Exercise: Loop tuning practice (question 81)
Day 7
Major topics: Computing relays and advanced control strategies
Required reading: Lessons In Industrial Instrumentation Limit, Selector, and Override controls
section
Discussion questions: 61 through 70
Lab Exercise: Loop tuning practice (question 81)
Lab Exercise: Study for capstone assessment (question 82)
Feedback questions: 71 through 80
Feedback questions due at the end of the day
23

Practice problems
83 through end

24

INST 252 (Process optimization and control strategies), section 2

Recommended schedule
Day 1
Major topics: Physics of heat transfer and phase changes
Question 0: Research sources
Discussion questions: 1 through 10
Lab Exercise: Loop tuning practice (question 62)
Lab Exercise: Team tool locker inventory check
Day 2
Major topics: Steam boiler controls
Discussion questions: 11 through 20
Lab Exercise: Loop tuning due at the end of the day (question 62)
Day 3
Major topics: Combustion controls
Discussion questions: 21 through 30
Lab Exercise: Capstone assessment (question 63)
Day 4
Major topics: Water treatment controls
Discussion questions: 31 through 40
Lab Exercise: Capstone assessment (question 63)
Day 5
Major topics: Review of final control elements
Discussion questions: 41 through 50
Lab Exercise: Lab questions (question 57)
Lab Exercise: Capstone assessment (question 63)
Day 6
Major topics: Certification exam
Lab Exercise: Capstone assessment (question 63)
Day 7
Feedback questions: 51 through 60
Labwork participation assessment: question 61
Feedback questions due at the beginning of the day
Capstone assessment due: (question 63)
Exam (proportional)
Lab Exercise: Each team pull their field device cables out of conduits!
Day 8
Major topics: Tour (oil refinery recommended)
Practice problems
64 through end

25

INST 260 (Data Acquisition systems), section 1

Lab
Data acquisition and transport over Ethernet: Question 71, completed objectives due by the end of
day 5, section 2
Bulleted questions following lab objectives to be reviewed orally during lab time on day 5, section 2
Feedback questions
Questions 61 through 70, due at the end of day 7
Exam
Day 6 of next section only a simple calculator may be used!
Question 72 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Digital Electronic Instrumentation chapter: introduction,
Serial Communication Principles, Physical Encoding of Bits, and Communication Speed subsections
in their entirety.
Answer: First three questions from set (questions 1 through 10)
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Smart field instruments
Different industrial busses in use
SCADA and telemetry systems
Telegraphs and Morse Code
Delimiting bits in serial data
NRZ encoding
Manchester encoding
FSK encoding
The need for data format consistency between transmitter and receiver
Baud versus bps
Team presentations: Each student team chooses a question to comprehensively answer within todays set
Class activity: Watch and comment on HART signals video (on the BTCInstrumentation YouTube channel)

26

Day 2
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Digital Electronic Instrumentation chapter: Data Frames,
Channel Arbitration, Code Sets, and The OSI Reference Model subsections in their entirety.
Answer: All questions from set (questions 11 through 20)
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Synchronous versus Asynchronous data transmission
Analyze a typical Ethernet data frame
Typical terminal program data parameters
Analyze a typical EIA/TIA-232 data frame pay attention to space and mark states, as well as order
of bit transmission!
Parity bits for error-checking
CRC for error-checking
Flow control
Simplex, Half- and Full-Duplex
Definition of channel arbitration
Master/slave
Token passing
CSMA (/CD, /BA, and /CA)
Morse and Baudot codes
EBCDIC
ASCII
Unicode
Many ways to describe data communication
Team presentations: Each student team chooses 2 questions to comprehensively answer within todays set
Demonstration: Open Hyperterminal program and explore serial data parameters such as bit speed (baud),
parity type, number of data bits, number of stop bits, etc.

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Day 3
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, AC Electricity chapter: Transmission Lines section section in its entirety.
Answer: All questions from set (questions 21 through 30)
Gather: Several long spools of two-conductor cable, oscilloscopes, signal generators, 1 k ohm potentiometers,
jumper wires
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Inductive and capacitive elements of a cable
Characteristic impedance
Analyze an open-ended cable to a voltage pulse
Analyze a short-ended cable to a voltage pulse
Using a terminating resistor to eliminate reflected pulses
Velocity factor of a cable
Radar level transmitters as a practical example
Team presentations: Each student team chooses 2 questions to comprehensively answer within todays set
Team activity: Connect a signal generator (set to output square waves) and an oscilloscope (in parallel with
the signal generator) to detect reflected pulses. Answer the following questions:
What shape does the pulse waveform take on when the cable end is open?
What shape does the pulse waveform take on when the cable end is shorted?
What shape does the pulse waveform take on when the cable end is terminated by an adjustable resistance?
How much resistance is required to eliminate reflections?
Assuming a velocity factor between 0.6 and 0.7, estimate cable length based on reflected signal time.

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Day 4
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Digital Electronic Instrumentation chapter: EIA/TIA-232,
422, and 485 networks and Ethernet networks sections in their entirety.
Answer: Any five questions from set (questions 31 through 40)
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Naming conventions (EIA/TIA versus RS)
RS-232 OSI Reference model layers
RS-232 signaling (unbalanced), voltage levels, and connector standards
RS-232 Handshaking functions
DTE versus DCE devices
Null modem connections
Maximum cable length versus maximum data rate for RS-232
RS-422 and RS-485 OSI Reference model layers
RS-422 and RS-485 signaling (balanced) and voltage level standards
Noise immunity of balanced (differential) signaling
Maximum cable length versus maximum data rate for RS-422 and RS-485
Terminal labels
RS-485 full duplex operation
RS-485 multipoint connections
Use of RS-485 as lowest layer of certain standardized networks
Use of termination resistors in RS-422 and RS-485 networks
High-Z mode of RS-485 half-duplex transceiver
Bob Metcalfes invention
Different supplemental Ethernet standards
Ethernet OSI Reference model layers
Ethernet bus arbitration
Repeating hubs
Collision domains
Ethernet cables and connectors
Crossover cables
Switching hubs
Team presentations: Each student team chooses 2 questions to comprehensively answer within todays set

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Day 5
Preparation before theory session:
Research: Rosemount wireless field instrument (wireless HART) datasheets and reference manuals, paying
close attention to setup and configuration procedures for new field instruments.
Research: Rosemount wireless gateway (model 1420) datasheets and reference manuals, paying close attention
to setup and configuration procedures for new field instruments.
Gather: Model 375 HART communicators for use in transmitter commissioning
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Share information sources
IEEE designation of wireless protocol
Meaning of mesh networking
How field devices are powered without wire connections to a power source
Basic steps to configure a field device (e.g. Model 3051S wireless pressure transmitter)
Update rate options
Radio power level options
Maximum distance limitations
Team activity: Each student team sets up a wireless transmitter to communicate with the wireless HART lab
network set devices for minimum update times!
Team activity: Each student team experiments with maximum distance from 1420 gateway in lab that their
transmitter is able to communicate

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Day 6
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Digital Electronic Instrumentation chapter: IP and TCP
and UDP sections in their entirety.
Answer: Any first three questions from set (questions 41 through 50)
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
The role of IP in the world-wide Internet
IP OSI Reference model layer
The concept of large data messages being disassembled into packets then reassembled
IPv4 address range and notation
Distinguishing IP addresses from lower-level (e.g. MAC) addresses
IP address assignments
Loopback address and loopback tests
IPv4 subnetworks
Use of ping utility as a diagnostic tool
IP broadcast addresses
IPv6 address range and notation
DNS
ipconfig network utility
nslookup network utility
tracert network utility
TCP and UDP OSI Reference model layer
Differences between TCP and UDP
TCP and UDP ports
netstat network utility
Team presentations: Each student team chooses a question to comprehensively answer within todays set
Individual activity: Each student uses their laptop computer to experiment with the command-line network
utilities ping, ipconfig, tracert, nslookup, and netstat
Day 7
Preparation before theory session:
Read: All questions from set (questions 51 through 60)
Gather: Hyperterminal program for your computer if it is not already installed. I recommend turning your
laptop computers security firewall off, just for the wired (RJ-45) Ethernet port (not the wireless connection!).
Gather: Three-conductor cables and 9-pin connectors for building RS-232 serial networks in the classroom
or lab. Ethernet hubs and patch cables for building Ethernet networks in the classroom or lab
During theory session:
Team activity: Each student team builds and tests a serial RS-232 network between two personal computers
Team activity: Each student team builds and tests an Ethernet network between two or more personal
computers
Team activity: Each student team reviews the mastery exam circuit-building activity

31

INST 260 (Data Acquisition systems), section 2

Lab
Data acquisition and transport over Ethernet: Question 51, completed objectives due by the end of
day 5
Bulleted questions following lab objectives to be reviewed orally during lab time on day 5, section 2
Feedback questions
Questions 41 through 50, due at the end of day 5
Exam
Day 6 only a simple calculator may be used!
Question 52 previews the mastery exam circuit-building activity
Recommended daily schedule
Day 1
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Instrument Connections chapter, Electrical signal and
control wiring section in its entirety
Answer: Any ten questions from set (questions 1 through 20)
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
The value of neat wiring
Proper and improper wire terminations
Signal coupling (capacitive and inductive)
Analog versus digital noise immunity
Electrostatic shielding
Magnetic shielding
High-frequency cables
Team presentations: Each student team chooses 2 questions to comprehensively answer within todays set
Day 2
Preparation before theory session:
Answer: All questions from set (questions 21 through 30)
Gather: Multimeter for in-class circuit-building exercise
During theory session:
Team presentations: Each student team chooses 2 questions to comprehensively answer within todays set
Team activity: Each student team builds a circuit where a proximity switch energizes an ice-cube relay

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Day 3
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Digital Electronic Instrumentation chapter, Digitization of
analog quantities section in its entirety
Answer: Any 5 questions from set (questions 31 through 40)
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Function of an ADC
Function of a DAC
Meaning and calculation of resolution
Sampling rate
Nyquist frequency limit
Aliasing
Anti-aliasing filter circuits
Team presentations: Each student team chooses 1 question to comprehensively answer within todays set
Day 4
Preparation before theory session:
Read: Lessons In Industrial Instrumentation, Machine Vibration Measurement chapter, all sections except
Non-sinusoidal Vibrations
Research: Datasheet and/or Reference Manual for the Emerson CSI 6500 Machine Health Monitor
During theory session:
Socratic discussion: Summarize reading assignment, discussing all major points including
Function of vibration protection equipment
Mathematical notation for sinusoid and offset
Derivative of displacement is velocity
Derivative of velocity is acceleration
Expressing vibrational acceleration in units of Gs
Proximity probes using eddy current detection
Three axes of measurement
Keyphasor sensors and signals
Vibration sensing hardware
Team presentations: Each student team chooses 2 questions to comprehensively answer within todays set
Demonstration: Start up turbocompressor system to demonstrate the action of a Bently-Nevada vibration
monitoring and shutdown system
Day 5
Preparation before theory session:
Research: Exam topics in INST260 course syllabus
Team presentations: Each student team chooses 2 exam topics listed in syllabus to review
Day 6
Exam
Mastery exam includes the circuit-building activity shown in question 52
Objectives for both mastery and proportional exams listed in the syllabus (beginning on the next page)

33

INST 261 (Programmable Logic Controllers), section 1

Recommended schedule
Day 1
Major topics: Polyphase power and AC electric motors
Question 0: Research sources
Discussion questions: 1 through 10
Lab Exercise: Relay-based air compressor motor control (question 62)
Day 2
Major topics: AC motor control circuits
Discussion questions: 11 through 20
Lab Exercise: Relay-based air compressor motor control (question 62)
Day 3
Major topics: Relay logic and ladder diagrams
Required reading: Lessons In Industrial Instrumentation Relay control systems chapter
Discussion questions: 21 through 30
Lab Exercise: Relay-based air compressor motor control (question 62)
Day 4
Major topics: Binary logic diagrams
Discussion questions: 31 through 40
Lab Exercise: Relay-based air compressor motor control (question 62)
Day 5
Major topics: Programmable Logic Controllers
Required reading: Lessons In Industrial Instrumentation Programmable logic controllers chapter
Discussion questions: 41 through 50
Lab Exercise: Relay-based air compressor motor control (question 62)
Lab Exercise: Install software for PLC programming
Lab Exercise: Install software for HMI programming
Feedback questions: 51 through 60
Feedback questions due at the end of the day
Practice problems
63 through end
Impending deadlines
Mastery assessment due at the end of INST261 Section 2 (in one more week after this section)
Mastery assessment: Truth table implemented in a PLC (question 61)

34

INST 261 (Programmable Logic Controllers), section 2

Recommended schedule
Day 1
Today, we will begin by identifying key PLC programming concepts to learn in this course, and how to
learn them. The instructor will outline the general process of creating demonstration programs for each
concept so that you may teach yourself how different PLC functions work. You will be quizzed twice daily
on these key concepts, once at the beginning of the day and once at the end of the day, both quizzes relating
to the key concept(s) specified for that day or from previous days. These quizzes will be performance-based,
which means you must have your laptop computer, PLC, HMI panel, and (at least) a few switches connected
to your PLCs inputs at all times to be ready for the quiz!
Key PLC programming concept: Creating new programming projects
Key PLC programming concept: Elementary ladder logic (contact & coil) programming
Exploratory questions: 1 through 10
Lab Exercise: Relay-based air compressor motor control (question 52)
Lab Exercise: solder wires to switches, and also to LEDs (with resistors!) so you will have real devices
to connect to your PLCs discrete I/O
Day 2
Key PLC programming concept: Ladder logic (contact & coil) programming
Exploratory questions: 11 through 20
Lab Exercise: Relay-based air compressor motor control (question 52)
Day 3
Key PLC programming concept: Human-Machine Interfaces (HMIs)
Exploratory questions: 21 through 30
Lab Exercise: Relay-based air compressor motor control (question 52)
Day 4
Key PLC programming concept: Counters
Exploratory questions: 31 through 40
Lab Exercise: Relay-based air compressor motor control (question 52)
Day 5
Lab Exercise: Relay-based air compressor motor control (question 52)
Mastery assessment: Truth table implemented in a PLC (question 51)
Feedback questions: 41 through 50
Feedback questions due at the end of the day
Practice problems
53 through end

35

INST 261 (Programmable Logic Controllers), section 3

Recommended schedule
Day 1
Key PLC programming concept: Timers
Exploratory questions: 1 through 10
Lab Exercise: PLC-based air compressor motor control (question 61)
Day 2
Key PLC programming concept: Sequencing
Exploratory questions: 11 through 20
Lab Exercise: PLC-based air compressor motor control (question 61)
Day 3
Key PLC programming concept: Data comparison functions
Exploratory questions: 21 through 30
Lab Exercise: PLC-based air compressor motor control (question 61)
Day 4
Key PLC programming concept: Math functions
Exploratory questions: 31 through 40
Lab Exercise: PLC-based air compressor motor control (question 61)
Day 5
Key PLC programming concept: Data communication
Exploratory questions: 41 through 50
Lab Exercise: PLC-based air compressor motor control (question 61)
Feedback questions: 51 through 60
Feedback questions due at the end of the day

36

INST 261 (Programmable Logic Controllers), section 4

Recommended schedule
Day 1
Lab Exercise: PLC-based air compressor motor control (question 1)
Day 2
Lab Exercise: PLC-based air compressor motor control (question 1)
Day 3
Lab Exercise: PLC-based air compressor motor control (question 1)
Day 4
Lab Exercise: PLC-based air compressor motor control (question 1)
Proportional assessment (first opportunity): (questions 2 through end)
Day 5
Lab Exercise: PLC-based air compressor motor control due at the end of the day (question 1)
Proportional assessment due (second opportunity): (questions 2 through end)
Level 1: 5 points
Level 2: 10 points
Level 3: 15 points
Level 4: 20 points
Your score is the highest level achieved (no cumulative points). You may attempt each exercise only
once; multiple exercises exist for each point level. You choose the point level, and the instructor randomly
chooses the particular exercise (and may choose to randomize certain details in the exercise as well!). If you
damage any equipment during the assessment, 10 points will be deducted from your final score.

37

INST 262 (DCS and Fieldbus), section 1

Recommended schedule
Day 1
Major topics: Basic feedback control theory
Required reading: Lessons In Industrial Instrumentation Basic feedback control principles section
Question 0: Research sources
Discussion questions: 1 through 10
Lab Exercise: Work on project (question 61 + question 62)
Day 2
Major topics: Introduction to PID control
Required reading: Lessons In Industrial Instrumentation Proportional-only control, Proportionalonly offset, Integral (reset) control, and Derivative (rate) control sections
Discussion questions: 11 through 20
Lab Exercise: Work on project (question 61 + question 62)
Day 3
Major topics: Direct control versus distributed control versus fieldbus
Required reading: Lessons In Industrial Instrumentation Digital PID controllers section
Discussion questions: 21 through 30
Lab Exercise: Work on project (question 61 + question 62)
Day 4
Major topics: Overview of FOUNDATION Fieldbus
Discussion questions: 31 through 40
Lab Exercise: Work on project (question 61 + question 62)
Day 5
Major topics: Function block programming for DCS/Fieldbus
Discussion questions: 41 through 50
Lab Exercise: Work on project (question 61 + question 62)
Lab Exercise: Mastery exam performance practice (question 63)
Feedback questions: 51 through 60
Feedback questions due at the end of the day
Practice problems
General: 64 through end
Impending deadlines
Working process controlled by a DCS/Fieldbus system due at the end of INST262 (in
three more weeks)
Project grading: (question 61)

38

INST 262 (DCS and Fieldbus), section 2

Recommended schedule
Day 1
Suggested activity: Work on project (question 11 + question 12)
Day 2
Suggested activity: Work on project (question 11 + question 12)
Day 3
Suggested activity: Work on project (question 11 + question 12)
Day 4
Suggested activity: Work on project (question 11 + question 12)
Day 5
Feedback questions: 1 through 10
Feedback questions due at the beginning of the day
Lab Exercise: Mastery exam performance practice (question 13)
Exam 1: includes circuit-building performance exercise in Mastery portion
Impending deadlines
Working process controlled by a DCS/Fieldbus system due at the end of INST262 (in
two more weeks)
Project grading: (question 11)

39

INST 262 (DCS and Fieldbus), section 3

Recommended schedule
Day 1
Major topics: Principles of combustion, ignition, and stored energy
Question 0: Research sources
Discussion questions: 1 through 10
Lab Exercise: Work on project (question 61 + question 62)
Day 2
Major topics: Area classification and intrinsic safety
Discussion questions: 11 through 20
Lab Exercise: Work on project (question 61 + question 62)
Day 3
Major topics: Fail-safe control system design
Discussion questions: 21 through 30
Lab Exercise: Work on project (question 61 + question 62)
Day 4
Major topics: Probability and its application to instrument systems
Discussion questions: 31 through 40
Lab Exercise: Work on project (question 61 + question 62)
Day 5
Major topics: Safety Instrumented Systems
Discussion questions: 41 through 50
Lab Exercise: Study for capstone assessment (question 63)
Feedback questions: 51 through 60
Feedback questions due at the end of the day
Practice problems
64 through end
Impending deadlines
Working process controlled by a DCS/Fieldbus system due at the end of INST262 (in
one more week)
Project grading: (question 61)

40

INST 262 (DCS and Fieldbus), section 4

Recommended schedule
Day 1
Suggested activity: Work on project (question 31 + question 32)
Lab Exercise: Team tool locker inventory check
Day 2
Major topics: Review
Discussion questions: 1 through 20
Lab Exercise: Loop troubleshooting (question 31 + question 32)
Day 3
Major topics: Certification exam
Lab Exercise: Loop troubleshooting (question 31 + question 32)
Lab Exercise: DCS/Fieldbus project due at the end of the day (question 31 + question 32)
Day 4
Feedback questions: 21 through 30
Feedback questions due at the beginning of the day
Capstone assessment due: (question 33)
Exam 2 (proportional)
Lab Exercise: Each team pull their field device cables out of conduits!
Day 5
Major topics: Tour (wastewater treatment recommended)

41