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High-reliability Control Systems

High-reliability Control Systems

As discussed at the beginning of this chapter, instrumentation safety may be broadly divided into two…


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Velocity-based Flowmeters

Velocity-based Flowmeters

The Law of Continuity for fluids states that the product of mass density (\(\rho\)), cross-sectional pipe area…


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How to Teach Yourself PLC Programming

How to Teach Yourself PLC Programming

Learning PLC programming is a very important skill. If your job involves programming, then you will likely…


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Basic Components Common to all Radio Systems

Basic Components Common to all Radio Systems

“Radio” systems use electromagnetic fields to communicate information over long distances through…


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Chromatography: Methods, Detectors and Species

Chromatography: Methods, Detectors and Species

Imagine a major marathon race, where hundreds of runners gather in one place to compete. When the starting gun…


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FOUNDATION Fieldbus Function Blocks

FOUNDATION Fieldbus Function Blocks

Data-processing modules within FF systems are known as function blocks. Sometimes these blocks serve merely to…


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Numerical Differentiation

Numerical Differentiation

As we have seen, the concept of differentiation is finding the rate-of-change of one variable compared to…


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Examples of PLC Systems

Examples of PLC Systems

Programmable logic controllers are essentially nothing more than special-purpose, industrial computers. As…


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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Although analog electronic process controllers are considered a newer technology than pneumatic process…


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Numerical Integration

Numerical Integration

As we have seen, the concept of integration is finding the accumulation of one variable multiplied by another…


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Split-Range Control

Split-Range Control

There are many process control applications in the industry where it is desirable to have multiple control…


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Calibration Errors and Testing

Calibration Errors and Testing

The efficient identification and correction of instrument calibration errors is an important function for…


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Control Valve Sizing

Control Valve Sizing

When control valves operate between fully open and fully shut, they serve much the same purpose in process…


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Digital PID Controllers

Digital PID Controllers

The vast majority of PID controllers in service today are digital in nature. Microprocessors executing PID…


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Common Control Valve Problems

Common Control Valve Problems

Valves can experience a number of problems, most of them either preventable or repairable. These problems can…


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Ethernet networks: Repeaters, Cabling and Switching Hubs

Ethernet networks: Repeaters, Cabling and Switching Hubs

An engineer named Bob Metcalfe conceived the idea of Ethernet in 1973, while working for the Xerox research…


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Human-Machine Interfaces (HMIs)

Human-Machine Interfaces (HMIs)

Human-machine interfaces, or HMIs, are a critical part of nearly all control systems, complementing the…


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Differential (87) Current Protection

Differential (87) Current Protection

One of the fundamental laws of electric circuits is Kirchhoff’s Current Law, which states the algebraic…


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Directional Overcurrent (67) Protection

Directional Overcurrent (67) Protection

While 50 and 51 (instantaneous and time overcurrent) relay functions monitor line current magnitude and guard…


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Digital Representation of Numerical Data

Digital Representation of Numerical Data

Process measurements are often of an analog nature: the temperature of a furnace, the rate of fluid flow…


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Digital Data Communication Theory

Digital Data Communication Theory

One of the great benefits of digital technology is the ability to communicate vast amounts of information over…


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Understanding the “Normal” Status of a Process Switch

Understanding the “Normal” Status of a Process Switch

Perhaps the most confusing aspect of discrete sensors is the definition of a sensor’s normal status.…


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Functional Diagrams: the Flow of Information within a Control System

Functional Diagrams: the Flow of Information within a Control System

A unique form of technical diagram for describing the abstract functions comprising a control system (e.g. PID…


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Differential Pressure Transmitters

Differential Pressure Transmitters

One of the most common, and most useful, pressure measuring instruments in industry is the differential…


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Teaching Technical Theory

Teaching Technical Theory

Learning is not merely a process of information transfer. It is first and foremost a transformation of…


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Analytical Measurements of Chemical Compositions

Analytical Measurements of Chemical Compositions

A great many chemical composition measurements may be made indirectly by means of electricity, if those…


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Supervisory Control

Supervisory Control

In a manually-controlled process, a human operator directly actuates some form of final control element…


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Zero and Span Adjustments (Analog Instruments)

Zero and Span Adjustments (Analog Instruments)

Linearity of Measurement Instruments The purpose of calibration is to ensure the input and output of an…


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Pressure-based Flowmeters

Pressure-based Flowmeters

All masses require force to accelerate (we can also think of this in terms of the mass generating a reaction…


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Introduction to Optical Analysis

Introduction to Optical Analysis

Light is known to interact with matter in very specific ways, which may be exploited as a means of measuring…


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Understanding Electrical Power Grids

Understanding Electrical Power Grids

The term “grid” refers to the conductors and equipment interconnecting power sources to power…


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Radio-energy Pulse in Guided-wave Radar Level Measurement

Radio-energy Pulse in Guided-wave Radar Level Measurement

The following animation shows how a radio-energy pulse travels down and then up the waveguide of a guided-wave…


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Digital Multimeter (DMM) Tips and Tricks

Digital Multimeter (DMM) Tips and Tricks

The digital multimeter (DMM) is quite possibly the most useful tool in the instrument technician’s…


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Open-ended, Shorted, and Properly Terminated Transmission Lines

Open-ended, Shorted, and Properly Terminated Transmission Lines

Many years ago, when I was first learning about electricity, I happened to discover a length of coaxial…


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Pressure Sensor Accessories

Pressure Sensor Accessories

Multiple accessories exist for pressure-sensing devices to function optimally in challenging process…


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Material Volume Measurement

Material Volume Measurement

A variety of technologies exist to measure the quantity of stored material in a vessel. For liquid…


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Antennas and Resonant Circuits (Tank Circuits)

Antennas and Resonant Circuits (Tank Circuits)

Capacitors store energy in electric fields, proportional to the square of voltage. Inductors store energy in…


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DC Motor Speed Control

DC Motor Speed Control

DC electric motors generate torque by a reaction between two magnetic fields: one field established by…


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Transmitter Damping Adjustments

Transmitter Damping Adjustments

The vast majority of modern process transmitters (both analog and digital) come equipped with a feature known…


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Vibration Sensors

Vibration Sensors

Sensors used to measure vibration come in three basic types: displacement, velocity, and acceleration.…


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Instrument Turndown (Rangedown)

Instrument Turndown (Rangedown)

An important performance parameter for transmitter instruments is something often referred to as turndown or…


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Common Educational Fallacies

Common Educational Fallacies

When I began teaching full-time in 1998, most of what I thought I understood about good teaching was actually…


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Comparison of  Op-Amp Circuits With Analogous Pneumatic Mechanisms

Comparison of Op-Amp Circuits With Analogous Pneumatic Mechanisms

Self-balancing pneumatic instrument mechanisms are very similar to negative-feedback operational amplifier…


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Relating 4 to 20 mA Signals to Instrument Variables

Relating 4 to 20 mA Signals to Instrument Variables

A 4 to 20 mA current signal represents some signal along a 0 to 100 percent scale. Usually, this scale is…


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Interconnected Generators

Interconnected Generators

Any power grid large enough to meet the demand of an entire nation must have multiple generators drawing from…


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Cascade Control

Cascade Control

A simple control system drawn in block diagram form looks like this: Information from the measuring device…


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Analyzer Sample Systems

Analyzer Sample Systems

Some analyzers measure the composition of a process stream by directly immersing the sensing element in that…


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Overpressure Protection Devices

Overpressure Protection Devices

Fluid pressure exerts force on any surface area it contacts, as described by the formula \(F = PA\). One…


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Molecular Quantities

Molecular Quantities

Sample sizes of chemical substances are often measured in moles. One mole of a substance is defined as a…


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Radiative Temperature Measurement

Radiative Temperature Measurement

Temperature measurement devices may be classified into two broad types: contact and non-contact. Contact-type…


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Introduction to Protective Relaying

Introduction to Protective Relaying

Circuit breakers used in residential, commercial, and light industrial service are self-tripping devices: they…


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Rotating Magnetic Fields in Three-phase AC Induction Motors

Rotating Magnetic Fields in Three-phase AC Induction Motors

The following animation shows how the “rotating” magnetic field of a three-phase AC induction…


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Common Diagnostic Mistakes in Control Systems

Common Diagnostic Mistakes in Control Systems

Volumes could be written about poor diagnostic technique. The following mistakes are not intended to comprise…


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Pneumatic Actuator Response

Pneumatic Actuator Response

A limitation inherent to pneumatic valve actuators is the amount of air flow required to or from the actuator…


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Design-based Fortifications

Design-based Fortifications

A design-based fortification is one rooted in technical details of system architecture and functionality. Some…


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Vibration Sensors

Vibration Sensors

Sensors used to measure vibration come in three basic types: displacement, velocity, and acceleration.…


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FOUNDATION Fieldbus H1 Protocol Device Configuration and Commissioning

FOUNDATION Fieldbus H1 Protocol Device Configuration and Commissioning

Fieldbus devices require far more attention in their initial setup and commissioning than their analog…


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Valve Packing

Valve Packing

Regardless of valve type, all stem-actuated control valves require some form of seal allowing motion of the…


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Active Reading and Outlining Documentation

Active Reading and Outlining Documentation

Learning from reading printed text is a kind of problem-solving activity it is own right. The problem is how…


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Understanding How Three-phase Electric Motors Work

Understanding How Three-phase Electric Motors Work

The key to understanding how three-phase electric motors work is to have an accurate mental picture of the…


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