inst index

Second year Instrumentation course sequence

Fall Quarter

INST200 – Introduction to Instrumentation (required in student’s first quarter) or2 credits

INST205 – Job Prep I (student’s second quarter) orINST206 – Job Prep II (student’s third quarter) 1 credit

INST240 – Pressure and Level measurement 6 credits

INST241 – Temperature and Flow measurement 6 credits

INST242 – Analytical measurement 5 credits

Winter Quarter



INST250 – Final Control Elements 5 credits

INST251 – PID controllers and tuning 5 credits

INST252 – Process optimization and control strategies 4 credits

PHYS 121 – General Physics I 5 credits

Spring Quarter



INST260 – Data Acquisition systems 4 credits

INST261 – Programmable Logic Controllers 5 credits

INST262 – DCS and Fieldbus 5 credits

ENGT122 – CAD 1: Basics 6 credits

1

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


Day 3

Theory session topic: Analog electronic and HART instruments, signals


Day 4

Theory session topic: Standard diagrams for instrumentation ; Signal wiring and tube connections


Day 5

Theory session topic: Process troubleshooting


Feedback questions (101 through 110) due at the end of the day

2

INST 205 (Job Prep I)

Recommended schedule

Day 1Presentation: Resume and cover letter writingIndependent activity: Work on resume and/or cover letter

Day 2Presentation: Searching for jobsIndependent activity: Research job search engines and open job listings

Day 3Major topics: Workplace safety and OSHAHomework questions: 1 through 10Independent activity: Work on resume and/or cover letter

Day 4Guest speakers: Round-table discussion with employer representatives (varies per quarter)Independent activity: Work on feedback questions

Day 5Homework questions: 11 through 20Independent activity: Work on feedback questions

Feedback questions: 21 through 25Resume 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

3

INST 206 (Job Prep II)


Day 1Presentation: How to actively research potential employers and professionally networkIndependent activity: Work on feedback questions

Day 2Presentation: Conducting informational interviewsIndependent activity: Research potential employers of instrument technicians

Day 3Major topics: Industrial safety considerationsHomework questions: 1 through 10Independent activity: Research potential employers of instrument technicians

Day 4Guest speakers: Round-table discussion with employer representatives (varies per quarter)Independent activity: Conduct your own informational interview

Day 5Independent activity: Work on feedback questions

Feedback questions: 11 through 15Three 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

4

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 2Bulleted 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


Day 1

Theory session topic: Concepts of pressure and pressure unit conversions


Day 2

Theory session topic: Pressure measurement technologies


Day 3

Theory session topic: Instrument calibration


Day 4

Theory session topic: Electronic pressure measurement



5


Lab

Pressure measurement loop: Questions 91 and 92, completed objectives due by the end of day 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam

Day 5 – only a simple calculator may be used!Question 93 previews the mastery exam circuit-building activity


Day 1

Theory session topic: Pressure instrument accessories


Day 2

Theory session topic: Pneumatic pressure instruments


Day 3

Theory session topic: Pneumatic pressure instruments (continued) and pressure switches


Day 4

Theory session topic: Review for exam


Build and test mastery exam circuit (Question 93)


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)

6


Lab

Level measurement loop: Questions 91 and 92, completed objectives due by the end of day 4, section4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4

Feedback questions


Exam

Day 5 of next sectionQuestion 93 previews the mastery exam circuit-building activity


Day 1

Theory session topic: Level measurement technologies and liquid densities


Day 2

Theory session topic: Hydrostatic level measurement


Day 3

Theory session topic: Displacer level measurement


Day 4

Theory session topic: Measuring liquid-liquid interfaces



7


Lab

Level measurement loop: Questions 91 and 92, completed objectives due by the end of day 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam

Day 5Question 93 previews the mastery exam circuit-building activity


Day 1

Theory session topic: Ultrasonic, radar, and laser level measurement


Day 2

Theory session topic: Weight, capacitance, and radiation level measurement


Day 3

Theory session topic: Point-contact and nonlinear level measurement


Day 4





Day 5

Exam



8

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 2Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2

Feedback questions


Exam



Day 1

Theory session topic: Temperature measurement technologies


Day 2

Theory session topic: Principles of heat and temperature


Day 3

Theory session topic: RTDs and thermistors


Day 4

Theory session topic: Thermocouples



9


Lab

Temperature measurement loop: Questions 91 and 92, completed objectives due by the end of day 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam



Day 1

Theory session topic: Thermocouples (continued)


Day 2

Theory session topic: Thermocouple and RTD applications


Day 3

Theory session topic: Non-contact pyrometers, temperature switches, calibration standards, and acces-sories


Day 4





Day 5

Exam



10


Lab

Flow measurement loop: Questions 91 and 92, completed objectives due by the end of day 4, 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4

Feedback questions


Exam



Day 1

Theory session topic: Flow measurement technologies


Day 2

Theory session topic: Fluid dynamics


Day 3

Theory session topic: Pressure-based flowmeters


Day 4

Theory session topic: High-accuracy pressure-based flow measurement



Day 5

Exam



11


Lab

Flow measurement loop: Questions 91 and 92, completed objectives due by the end of day 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam



Day 1

Theory session topic: Turbine, vortex, and positive-displacement flowmeters


Day 2

Theory session topic: Magnetic and ultrasonic flowmeters


Day 3

Theory session topic: True mass flowmeters


Day 4

Theory session topic: Open-channel flowmeters and review for exam




Day 5

Exam



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 3Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 3

Feedback questions


Exam

Day 6 of last sectionQuestion 93 previews the capstone assessment


Day 1

Theory session topic: Chemical concepts, terms, and symbols


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


Day 3

Theory session topic: Molecular quantities


Day 4

Theory session topic: Stoichiometry and energy in chemical reactions



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 3Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 3

Feedback questions


Exam

Day 6 of last sectionQuestion 93 previews the capstone assessment


Day 1

Theory session topic: Conductivity measurement


Discuss the upcoming capstone assessment due by the end of the course (Question 93)

Day 2

Theory session topic: pH and pH measurement


Day 3

Theory session topic: pH measurement


Day 4

Theory session topic: Chromatography



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 ofday 4, section 2Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2

Feedback questions


Exam



Day 1

Theory session topic: Principles of fluids and fluid pressure


Day 2

Theory session topic: Fluid power systems


Day 3

Theory session topic: Pneumatic instruments


Day 4

Theory session topic: Pneumatic instruments (continued)



15


Lab

Control valve rebuild and bench-set: Questions 91 and 92, completed objectives due by the end ofday 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam



Day 1

Theory session topic: Control valves and pneumatic actuators


Day 2

Theory session topic: Solenoid valves


Day 3

Theory session topic: Valve failure modes and packing systems


Day 4





Day 5

Exam



16


Lab

Split-range control valves: Questions 91 and 92, completed objectives due by the end of day 4,section 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4

Feedback questions


Exam



Day 1

Theory session topic: Valve positioners


Day 2

Theory session topic: Split-ranged control valves


Day 3

Theory session topic: Electric valve actuators and variable-speed pumps


Day 4

Theory session topic: Valve sizing



17


Lab

Positioner split-ranging: Questions 91 and 92, completed objectives due by the end of day 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam



Day 1

Theory session topic: Valve sizing and relief valves


Day 2

Theory session topic: Valve characterization


Day 3

Theory session topic: Valve problems


Day 4





Day 5

Exam



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 2Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 2

Feedback questions


Exam



Day 1

Theory session topic: Feedback control


Day 2

Theory session topic: Setting up “Desktop Processes”


Day 3

Theory session topic: Pneumatic process controllers


Day 4

Theory session topic: Analog electronic process controllers



Day 5

Exam



19


Lab

Pneumatic PID controller: Questions 91 and 92, completed objectives due by the end of day 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4

Feedback questions


Exam



Day 1

Theory session topic: Differential calculus


Day 2

Theory session topic: Integral calculus


Day 3

Theory session topic: Applications of calculus


Day 4





Day 5

Exam



20


Lab

Automatically-controlled process: Questions 91 and 92, completed objectives due by the end of day4, section 4Bulleted questions following lab objectives to be reviewed orally during lab time on day 4, section 4

Feedback questions


Exam



Day 1

Theory session topic: Proportional-only offset


Day 2

Theory session topic: Integral-only control


Day 3

Theory session topic: Proportional + integral control


Day 4

Theory session topic: Proportional + integral control (continued)



21



Day 1Major topics: Proportional + Integral + Derivative controlRequired reading: Lessons In Industrial Instrumentation “Summary of PID control terms” and “P,

I, and D responses graphed” sectionsQuestion 0: Research sourcesDiscussion questions: 1 through 10Lab Exercise: Complete process with electronic controller (question 52 + question 53)

Day 2Major topics: Pre-tuning strategiesRequired reading: Lessons In Industrial Instrumentation “Before you tune . . .” sectionDiscussion questions: 11 through 20Lab Exercise: Complete process with electronic controller (question 52 + question 53)

Day 3Major topics: Process dynamicsRequired reading: Lessons In Industrial Instrumentation “Process Characterization” sectionDiscussion questions: 21 through 30Lab Exercise: Complete process with electronic controller (question 52 + question 53)

Day 4Major topics: Simple tuning techniquesRequired reading: Lessons In Industrial Instrumentation “Quantitative PID Tuning Procedures”

sectionDiscussion questions: 31 through 40Lab Exercise: Lab questions (question 47)Lab Exercise: Working process due at the end of the day (question 52 + question 53)

Day 5Feedback questions: 41 through 50Labwork participation assessment: question 51Feedback 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 problems55 through end

22

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


Day 1Major topics: Process dynamics and controller tuningRequired reading: Lessons In Industrial Instrumentation “Process characterization” sectionQuestion 0: Research sourcesDiscussion questions: 1 through 10Lab Exercise: Loop tuning practice (question 81)

Day 2Major topics: Process dynamics and controller tuning (continued)Discussion questions: 11 through 20Lab Exercise: Loop tuning practice (question 81)

Day 3Major topics: PID controller tuning using computer simulationRequired reading: Lessons In Industrial Instrumentation “Quantitative PID tuning procedures”,

“Heuristic PID tuning procedures,” and “Tuning techniques compared” sectionsDiscussion questions: 21 through 30Lab Exercise: Loop tuning practice (question 81)

Day 4Major topics: Supervisory setpoint and cascade controlRequired reading: Lessons In Industrial Instrumentation “Supervisory control” and “Cascade control”

sectionsDiscussion questions: 31 through 40Lab Exercise: Loop tuning practice (question 81)

Day 5Major topics: Ratio controlRequired reading: Lessons In Industrial Instrumentation “Ratio control” sectionDiscussion questions: 41 through 50Lab Exercise: Loop tuning practice (question 81)

Day 6Major topics: Feedforward controlRequired reading: Lessons In Industrial Instrumentation “Feedforward control” and “Feedforward

with dynamic compensation” sectionsDiscussion questions: 51 through 60Lab Exercise: Loop tuning practice (question 81)

Day 7Major topics: Computing relays and advanced control strategiesRequired reading: Lessons In Industrial Instrumentation “Limit, Selector, and Override controls”

sectionDiscussion questions: 61 through 70Lab Exercise: Loop tuning practice (question 81)Lab Exercise: Study for capstone assessment (question 82)

Feedback questions: 71 through 80Feedback questions due at the end of the day

23


24

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


Day 1Major topics: Physics of heat transfer and phase changesQuestion 0: Research sourcesDiscussion questions: 1 through 10Lab Exercise: Loop tuning practice (question 62)Lab Exercise: Team tool locker inventory check

Day 2Major topics: Steam boiler controlsDiscussion questions: 11 through 20Lab Exercise: Loop tuning due at the end of the day (question 62)

Day 3Major topics: Combustion controlsDiscussion questions: 21 through 30Lab Exercise: Capstone assessment (question 63)

Day 4Major topics: Water treatment controlsDiscussion questions: 31 through 40Lab Exercise: Capstone assessment (question 63)

Day 5Major topics: Review of final control elementsDiscussion questions: 41 through 50Lab Exercise: Lab questions (question 57)Lab Exercise: Capstone assessment (question 63)

Day 6Major topics: Certification examLab Exercise: Capstone assessment (question 63)

Day 7Feedback questions: 51 through 60Labwork participation assessment: question 61Feedback 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 8Major topics: Tour (oil refinery recommended)


25

INST 260 (Data Acquisition systems), section 1

Lab

Data acquisition and transport over Ethernet: Question 71, completed objectives due by the end ofday 5, section 2Bulleted questions following lab objectives to be reviewed orally during lab time on day 5, section 2

Feedback questions


Exam



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” subsectionsin 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 today’s set

Class activity: Watch and comment on HART signals video (on the BTCInstrumentation YouTube channel)

26

Day 2


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)


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 today’s 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.

27

Day 3


Read: Lessons In Industrial Instrumentation, “AC Electricity” chapter: “Transmission Lines” section sec-tion in its entirety.


Gather: Several long spools of two-conductor cable, oscilloscopes, signal generators, 1 k ohm potentiometers,jumper wires


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 activity: Connect a signal generator (set to output square waves) and an oscilloscope (in parallel withthe 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.

28

Day 4


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)


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 Metcalfe’s 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


29

Day 5


Research: Rosemount wireless field instrument (wireless HART) datasheets and reference manuals, payingclose attention to setup and configuration procedures for new field instruments.

Research: Rosemount wireless gateway (model 1420) datasheets and reference manuals, paying close attentionto setup and configuration procedures for new field instruments.

Gather: Model 375 HART communicators for use in transmitter commissioning


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 labnetwork – set devices for minimum update times!

Team activity: Each student team experiments with maximum distance from 1420 gateway in lab that theirtransmitter is able to communicate

30

Day 6


Read: Lessons In Industrial Instrumentation, “Digital Electronic Instrumentation” chapter: “IP” and “TCPand UDP” sections in their entirety.

Answer: Any first three questions from set (questions 41 through 50)


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 today’s set

Individual activity: Each student uses their laptop computer to experiment with the command-line networkutilities ping, ipconfig, tracert, nslookup, and netstat

Day 7


Read: All questions from set (questions 51 through 60)

Gather: Hyperterminal program for your computer if it is not already installed. I recommend turning yourlaptop computer’s 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 classroomor lab. Ethernet hubs and patch cables for building Ethernet networks in the classroom or lab


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 personalcomputers

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 ofday 5Bulleted questions following lab objectives to be reviewed orally during lab time on day 5, section 2

Feedback questions


Exam



Day 1


Read: Lessons In Industrial Instrumentation, “Instrument Connections” chapter, “Electrical signal andcontrol wiring” section in its entirety

Answer: Any ten questions from set (questions 1 through 20)


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


Day 2



Gather: Multimeter for in-class circuit-building exercise



Team activity: Each student team builds a circuit where a proximity switch energizes an ice-cube relay

32

Day 3


Read: Lessons In Industrial Instrumentation, “Digital Electronic Instrumentation” chapter, “Digitization ofanalog quantities” section in its entirety

Answer: Any 5 questions from set (questions 31 through 40)


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 today’s set

Day 4


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


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 G’s• Proximity probes using eddy current detection• Three axes of measurement• Keyphasor sensors and signals• Vibration sensing hardware


Demonstration: Start up turbocompressor system to demonstrate the action of a Bently-Nevada vibrationmonitoring and shutdown system

Day 5


Research: Exam topics in INST260 course syllabus

Team presentations: Each student team chooses 2 exam topics listed in syllabus to review

Day 6

Exam



33

INST 261 (Programmable Logic Controllers), section 1


Day 1Major topics: Polyphase power and AC electric motorsQuestion 0: Research sourcesDiscussion questions: 1 through 10Lab Exercise: Relay-based air compressor motor control (question 62)

Day 2Major topics: AC motor control circuitsDiscussion questions: 11 through 20Lab Exercise: Relay-based air compressor motor control (question 62)

Day 3Major topics: Relay logic and ladder diagramsRequired reading: Lessons In Industrial Instrumentation “Relay control systems” chapterDiscussion questions: 21 through 30Lab Exercise: Relay-based air compressor motor control (question 62)

Day 4Major topics: Binary logic diagramsDiscussion questions: 31 through 40Lab Exercise: Relay-based air compressor motor control (question 62)

Day 5Major topics: Programmable Logic ControllersRequired reading: Lessons In Industrial Instrumentation “Programmable logic controllers” chapterDiscussion questions: 41 through 50Lab Exercise: Relay-based air compressor motor control (question 62)Lab Exercise: Install software for PLC programmingLab Exercise: Install software for HMI programming



Impending deadlinesMastery 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



Day 1Today, 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 eachconcept so that you may teach yourself how different PLC functions work. You will be quizzed twice dailyon these key concepts, once at the beginning of the day and once at the end of the day, both quizzes relatingto 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 connectedto your PLC’s 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) programmingExploratory questions: 1 through 10Lab 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 PLC’s discrete I/O

Day 2Key PLC programming concept: Ladder logic (contact & coil) programmingExploratory questions: 11 through 20Lab Exercise: Relay-based air compressor motor control (question 52)

Day 3Key PLC programming concept: Human-Machine Interfaces (HMIs)Exploratory questions: 21 through 30Lab Exercise: Relay-based air compressor motor control (question 52)

Day 4Key PLC programming concept: CountersExploratory questions: 31 through 40Lab Exercise: Relay-based air compressor motor control (question 52)

Day 5Lab Exercise: Relay-based air compressor motor control (question 52)Mastery assessment: Truth table implemented in a PLC (question 51)



35



Day 1Key PLC programming concept: TimersExploratory questions: 1 through 10Lab Exercise: PLC-based air compressor motor control (question 61)

Day 2Key PLC programming concept: SequencingExploratory questions: 11 through 20Lab Exercise: PLC-based air compressor motor control (question 61)

Day 3Key PLC programming concept: Data comparison functionsExploratory questions: 21 through 30Lab Exercise: PLC-based air compressor motor control (question 61)

Day 4Key PLC programming concept: Math functionsExploratory questions: 31 through 40Lab Exercise: PLC-based air compressor motor control (question 61)

Day 5Key PLC programming concept: Data communicationExploratory questions: 41 through 50Lab Exercise: PLC-based air compressor motor control (question 61)


36



Day 1Lab Exercise: PLC-based air compressor motor control (question 1)




Proportional assessment (first opportunity): (questions 2 through end)

Day 5Lab 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 pointsLevel 2: 10 pointsLevel 3: 15 pointsLevel 4: 20 pointsYour 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 randomlychooses the particular exercise (and may choose to randomize certain details in the exercise as well!). If youdamage any equipment during the assessment, 10 points will be deducted from your final score.

37

INST 262 (DCS and Fieldbus), section 1


Day 1Major topics: Basic feedback control theoryRequired reading: Lessons In Industrial Instrumentation “Basic feedback control principles” sectionQuestion 0: Research sourcesDiscussion questions: 1 through 10Lab Exercise: Work on project (question 61 + question 62)

Day 2Major topics: Introduction to PID controlRequired reading: Lessons In Industrial Instrumentation “Proportional-only control”, “Proportional-

only offset”, “Integral (reset) control”, and “Derivative (rate) control” sectionsDiscussion questions: 11 through 20Lab Exercise: Work on project (question 61 + question 62)

Day 3Major topics: Direct control versus distributed control versus fieldbusRequired reading: Lessons In Industrial Instrumentation “Digital PID controllers” sectionDiscussion questions: 21 through 30Lab Exercise: Work on project (question 61 + question 62)

Day 4Major topics: Overview of FOUNDATION FieldbusDiscussion questions: 31 through 40Lab Exercise: Work on project (question 61 + question 62)

Day 5Major topics: Function block programming for DCS/FieldbusDiscussion questions: 41 through 50Lab Exercise: Work on project (question 61 + question 62)Lab Exercise: Mastery exam performance practice (question 63)


Practice problemsGeneral: 64 through end

Impending deadlinesWorking process controlled by a DCS/Fieldbus system due at the end of INST262 (in

three more weeks)Project grading: (question 61)

38



Day 1Suggested activity: Work on project (question 11 + question 12)




Day 5Feedback questions: 1 through 10Feedback 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


two more weeks)Project grading: (question 11)

39



Day 1Major topics: Principles of combustion, ignition, and stored energyQuestion 0: Research sourcesDiscussion questions: 1 through 10Lab Exercise: Work on project (question 61 + question 62)

Day 2Major topics: Area classification and intrinsic safetyDiscussion questions: 11 through 20Lab Exercise: Work on project (question 61 + question 62)

Day 3Major topics: Fail-safe control system designDiscussion questions: 21 through 30Lab Exercise: Work on project (question 61 + question 62)

Day 4Major topics: Probability and its application to instrument systemsDiscussion questions: 31 through 40Lab Exercise: Work on project (question 61 + question 62)

Day 5Major topics: Safety Instrumented SystemsDiscussion questions: 41 through 50Lab Exercise: Study for capstone assessment (question 63)




one more week)Project grading: (question 61)

40



Day 1Suggested activity: Work on project (question 31 + question 32)Lab Exercise: Team tool locker inventory check

Day 2Major topics: ReviewDiscussion questions: 1 through 20Lab Exercise: Loop troubleshooting (question 31 + question 32)

Day 3Major topics: Certification examLab Exercise: Loop troubleshooting (question 31 + question 32)Lab Exercise: DCS/Fieldbus project due at the end of the day (question 31 + question 32)

Day 4Feedback questions: 21 through 30Feedback 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 5Major topics: Tour (wastewater treatment recommended)

41

inst index

Documents

dcs day

quarter orinst206 job

end of day

practice day

beginning of day

answer questions

loop calibrators day

loop system day