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Controller Output Current Loops

Controller Output Current Loops

The simplest form of 4-20 mA current loop is the type used to represent the output of a process controller,…


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Instantaneous and Time-overcurrent (50/51) Protection

Instantaneous and Time-overcurrent (50/51) Protection

Perhaps the most basic and necessary protective relay function is overcurrent: commanding a circuit breaker to…


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Interposing Relays in PLCs

Interposing Relays in PLCs

In addition to directly performing logic functions, electromechanical relays may also be used as interposing…


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Basics of Bridge Circuits

Basics of Bridge Circuits

A bridge circuit is basically a pair of voltage dividers where the circuit output is taken as the difference…


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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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AC Motor Speed Control

AC Motor Speed Control

AC induction motors are based on the principle of a rotating magnetic field produced by a set of stationary…


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Basic Feedback Control Principles

Basic Feedback Control Principles

Feedback Control System Components Before we begin our discussion on process control, we must define a few key…


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Ladder Diagram (LD) Programming Contacts and Coils

Ladder Diagram (LD) Programming Contacts and Coils

In the United States, the most common language used to program PLCs is Ladder Diagram (LD), also known as…


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Phasors, Phase Shift, and Phasor Algebra

Phasors, Phase Shift, and Phasor Algebra

Phasors are to AC circuit quantities as polarity is to DC circuit quantities: a way to express the…


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Use of Line Reactors

Use of Line Reactors

Regulating the electric power sent to an electric motor is a task performed by high-speed switching…


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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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Non-contact Temperature Sensors

Non-contact Temperature Sensors

Virtually any mass above absolute zero temperature emits electromagnetic radiation (photons, or light) as a…


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Non-dispersive Luft Detector Spectroscopy

Non-dispersive Luft Detector Spectroscopy

Non-dispersive analysis, while newer in discovery than dispersive analysis (Isaac Newton’s 17th-century…


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Limit Switches

Limit Switches

A limit switch detects the physical motion of an object by direct contact with that object. An example of a…


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On/off Electric Motor Control Circuits

On/off Electric Motor Control Circuits

An electric motor is often used as a discrete control element in a control system if driving a pump, conveyor…


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Diagnosing Feedback Control Problems

Diagnosing Feedback Control Problems

Negative feedback systems, in general, tend to cause confusion for those first learning their fundamental…


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Ladder Diagram (LD) Structure Commands

Ladder Diagram (LD) Structure Commands

The simple PLC ladder diagram (LD) commands consist of contacts and coils, arranged in sequences that mimic…


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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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Self-regulating, Integrating, and Runaway Process Characteristics

Self-regulating, Integrating, and Runaway Process Characteristics

Perhaps the most important rule of controller tuning is to know the process before attempting to adjust the…


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AC Motor Braking

AC Motor Braking

There are several different methods useful for causing an AC induction motor to brake, or slow down: DC…


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Fluid Mechanics

Fluid Mechanics

A fluid is any substance having the ability to flow: to freely change shape and move under the influence of a…


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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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Derivative (Rate) Control

Derivative (Rate) Control

The final element of PID control is the “D” term, which stands for derivative. This is a calculus…


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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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Indicators, Recorders, Process Switches and Alarms

Indicators, Recorders, Process Switches and Alarms

So far we have just looked at instruments that sense, control, and influence process variables. Transmitters,…


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Limit Switches

Limit Switches

A limit switch detects the physical motion of an object by direct contact with that object. An example of a…


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How Derivatives and Integrals Relate to One Another

How Derivatives and Integrals Relate to One Another

Like many other mathematical operations, the derivative and the integral perform inverse operations from each…


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Electrical Sources and Electronic Load

Electrical Sources and Electronic Load

By definition, a source is a device delivering energy into a system, while a load is a device extracting…


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Circuit Breakers and Disconnects

Circuit Breakers and Disconnects

Disconnect Switches Disconnects are switches designed to isolate sections of a power system in case of damage…


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National Institute of Standards and Technology (NIST) Traceability

National Institute of Standards and Technology (NIST) Traceability

As defined previously, calibration means the comparison and adjustment (if necessary) of an instrument’s…


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Process Flow Diagrams

Process Flow Diagrams

To show a practical process example, let’s examine three diagrams for a compressor control system,…


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Understanding the Calculus Concepts of Differentiation and Integration

Understanding the Calculus Concepts of Differentiation and Integration

The following animation shows the calculus concepts of differentiation and integration (with respect to time)…


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Logic Programming in PLCs

Logic Programming in PLCs

Although it seems each model of PLC has its own idiosyncratic standard for programming, there does exist an…


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Analog to Digital Conversion and ADCs

Analog to Digital Conversion and ADCs

In order to provide an interface between the internal (digital) world of a computer and the external (analog)…


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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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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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Scientific System diagnosis and Scientific Reasoning

Scientific System diagnosis and Scientific Reasoning

At the root of successful system diagnosis is a rigorous adherence to scientific reasoning. There exists no…


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Phasors, Phase Shift, and Phasor Algebra

Phasors, Phase Shift, and Phasor Algebra

Phasors are to AC circuit quantities as polarity is to DC circuit quantities: a way to express the…


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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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Motives for Compromising the Security of an Industrial Control System

Motives for Compromising the Security of an Industrial Control System

There are multiple motives for compromising the security of an industrial control system, some of which…


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