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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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Introduction to Modbus

Introduction to Modbus

Developed by the Modicon company (the original manufacturer of the Programmable Logic Controller, or PLC) in…


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PID Control Terminology

PID Control Terminology

PID control can be a confusing concept to understand. Here, a brief summary of each term within PID (P. I, and…


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Sequential Function Chart (SFC) Programming

Sequential Function Chart (SFC) Programming

(Will be addressed in future versions of this book)


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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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VSD and VFD Motor Drive Features

VSD and VFD Motor Drive Features

Modern DC and AC motor drives provide features useful when using electric motors as final control elements.…


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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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Legal Code

Legal Code

Creative Commons Attribution 4.0 International Public License By exercising the Licensed Rights (defined…


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Relay Circuits and Ladder Diagrams

Relay Circuits and Ladder Diagrams

Electromechanical relays may be connected together to perform logic and control functions, acting as logic…


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Control Valve Actuators

Control Valve Actuators

The purpose of a control valve actuator is to provide the motive force to operate a valve mechanism. Both…


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Fiber Optic Data Communication

Fiber Optic Data Communication

Light has long been used as a long-range signaling medium. While communication by light through open air is…


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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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Vibration Monitoring Hardware

Vibration Monitoring Hardware

The following photograph shows a large air blower in a wastewater treatment facility equipped with a…


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Memory Maps and I/O Addressing

Memory Maps and I/O Addressing

A wise PLC programmer once told me that the first thing any aspiring programmer should learn about the PLC…


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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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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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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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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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Teaching Technical Practices (Labwork)

Teaching Technical Practices (Labwork)

Labwork is an essential part of any science-based curriculum. Here, much improvement may be made over the…


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Policy-based Fortifications

Policy-based Fortifications

These fortifications focus on human behavior rather than system design or component selection. In some ways…


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The International System of Units

The International System of Units

The very purpose of physics is to quantitatively describe and explain the physical world in as few terms as…


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Valve Seat Leakage

Valve Seat Leakage

In some process applications, it is important that the control valve be able to completely stop fluid flow…


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Assessing Student Learning

Assessing Student Learning

As a general rule, high achievement only takes place in an atmosphere of high expectations. Sometimes these…


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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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General Problem-solving Techniques

General Problem-solving Techniques

A variety of problem-solving techniques have been presented for students over the years which are all helpful…


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Calibration Standards to Produce and Measure Physical Quantities

Calibration Standards to Produce and Measure Physical Quantities

As previously defined, calibration refers to the checking and adjustment of an instrument so that its output…


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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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Formulae for Common Chemical Compounds

Formulae for Common Chemical Compounds

Most of these formulae appear in molecular chemical form rather than structural form. For example, ethanol…


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Mechanical Vibration Switches

Mechanical Vibration Switches

A much simpler alternative to continuous vibration sensors (displacement or acceleration) and monitoring…


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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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Valve Positioners

Valve Positioners

The reason why a pneumatic control valve’s stem position corresponds linearly to the amount of air…


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Electrical Pressure Elements

Electrical Pressure Elements

Several different technologies exist for the conversion of fluid pressure into an electrical signal response.…


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The Stuxnet Virus

The Stuxnet Virus

In November of 2007 a new computer virus was submitted to a virus scanning service. The purpose of this new…


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Standardized Volumetric Flow

Standardized Volumetric Flow

The majority of flowmeter technologies operate on the principle of interpreting fluid flow based on the…


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Pressure Switches

Pressure Switches

A pressure switch is one that detects the presence of fluid pressure. Pressure switches often use diaphragms…


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New Content

New Content

Coy, John J. et. al. (December 2012) Sampled graphic illustrations from his NASA Reference Publication…


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On/off Control (Bang-bang Control)

On/off Control (Bang-bang Control)

Once while working as an instrument technician in an aluminum foundry, a mechanic asked me what it was that I…


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Polyphase AC Power

Polyphase AC Power

“Polyphase” means “many phases,” describing a form of AC electrical system where…


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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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What are Simple Machines?

What are Simple Machines?

A machine in the broad sense of the word is any device designed to translate some form of energy into useful…


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An Analogy for Calibration Vs Ranging

An Analogy for Calibration Vs Ranging

The concepts of calibration (trimming) and ranging are often difficult for new students of instrumentation to…


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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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Phasor Analysis of Transformer Circuits

Phasor Analysis of Transformer Circuits

Three-phase AC is the dominant mode of electric power generation and distribution in modern societies.…


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Vibration Monitoring Hardware

Vibration Monitoring Hardware

The following photograph shows a large air blower in a wastewater treatment facility equipped with a…


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Thermistors and Resistance Temperature Detectors (RTDs)

Thermistors and Resistance Temperature Detectors (RTDs)

One of the simplest classes of temperature sensor is one where temperature effects a change in electrical…


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Sliding-stem Valves

Sliding-stem Valves

A sliding-stem valve body is one where the moving parts slide with a linear motion. Some examples of…


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ANSI/IEEE Function Number Codes

ANSI/IEEE Function Number Codes

In the United States, the ANSI and IEEE organizations have standardized a set of numerical codes referring to…


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Mechanical Vibration Switches

Mechanical Vibration Switches

A much simpler alternative to continuous vibration sensors (displacement or acceleration) and monitoring…


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Instruction List (IL) Programming

Instruction List (IL) Programming

(Will be addressed in future versions of this book)


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LRV and URV Settings, Digital Trim (Digital Transmitters)

LRV and URV Settings, Digital Trim (Digital Transmitters)

The advent of “smart” field instruments containing microprocessors has been a great advance for…


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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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Chemiluminescence Measurement

Chemiluminescence Measurement

Recall that an exothermic chemical reaction is one that releases a net sum of energy, as opposed to an…


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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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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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Variable-area Flowmeters

Variable-area Flowmeters

An variable-area flowmeter is one where the fluid must pass through a restriction whose area increases with…


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Pneumatic Sensing Elements

Pneumatic Sensing Elements

Most pneumatic instruments use a simple but highly sensitive mechanism for converting mechanical motion into…


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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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FOUNDATION Fieldbus H1 Protocol Data Link Layer

FOUNDATION Fieldbus H1 Protocol Data Link Layer

Like so many other industrial data networks, FOUNDATION Fieldbus is an “unswitched” or…


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Positive Displacement Flowmeters

Positive Displacement Flowmeters

A positive displacement flowmeter is a cyclic mechanism built to pass a fixed volume of fluid through with…


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4 to 20 mA Analog Current Signals

4 to 20 mA Analog Current Signals

In modern industry, the most popular form of field-level signal transmission for variable industrial…


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