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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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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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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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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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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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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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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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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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Limit, Selector, and Override Controls

Limit, Selector, and Override Controls

Another category of control strategies involves the use of signal relays or function blocks with the ability…


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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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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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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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The HART Digital/Analog Hybrid Standard

The HART Digital/Analog Hybrid Standard

A technological advance introduced in the late 1980’s was HART, an acronym standing for Highway…


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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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Introduction to Power System Automation

Introduction to Power System Automation

Those familiar with industrial instrumentation will find much within the electric power industry remarkably…


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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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Electrical Signal and Control Wiring

Electrical Signal and Control Wiring

There is much to be said for neatness of assembly in electrical signal wiring. Even though the electrons…


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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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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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Safety Instrumented Functions and Systems

Safety Instrumented Functions and Systems

A Safety Instrumented Function, or SIF, is one or more components designed to execute a specific…


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Rotary-stem Valves

Rotary-stem Valves

A different strategy for controlling the flow of fluid is to insert a rotary element into the flow path.…


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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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Tuning PID Controllers

Tuning PID Controllers

Learning how to tune PID controllers is a skill born of much practice. Regardless of how thoroughly you may…


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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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Temperature Sensor Accessories

Temperature Sensor Accessories

One of the most important accessories for any temperature-sensing element is a pressure-tight sheath known as…


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Laminar Flowmeters

Laminar Flowmeters

A unique form of differential pressure-based flow measurement deserves its own section in this flow…


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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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Atomic Theory and Chemical Symbols

Atomic Theory and Chemical Symbols

The three “elementary” particles of matter comprising all atoms are electrons, protons, and…


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Practical Measures of Reliability

Practical Measures of Reliability

In reliability engineering, it is important to be able to quantity the reliability (or conversely, the…


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Fluid Power Systems

Fluid Power Systems

Given the ability of pressurized fluids to transmit force over long distances, it is not surprising that many…


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Digital Representation of Text

Digital Representation of Text

Binary patterns are not just able to represent numerical values. Given a standardized code, they may represent…


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Bi-metal Temperature Sensors

Bi-metal Temperature Sensors

Solids tend to expand when heated. The amount that a solid sample will expand with increased temperature…


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Unit Conversions and Physical Constants

Unit Conversions and Physical Constants

Converting between disparate units of measurement is the bane of many science students. The problem is worse…


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Safety Gas Analyzers

Safety Gas Analyzers

Process analyzers measure the concentration of specific substances for the purpose of measuring and/or…


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FOUNDATION Fieldbus H1 Protocol Segment Troubleshooting

FOUNDATION Fieldbus H1 Protocol Segment Troubleshooting

Feedback obtained from industrial users of FF reveal a common pattern: Fieldbus is a powerful and reliable…


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Classified Areas and Electrical Safety Measures

Classified Areas and Electrical Safety Measures

Any physical location in an industrial facility harboring the potential of explosion due to the presence of…


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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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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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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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Basics of Electrical Current

Basics of Electrical Current

Current is the name we give to the motion of electric charges from a point of high potential to a point of low…


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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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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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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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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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Circuit Failure Analysis

Circuit Failure Analysis

Perhaps the most valuable skill an instrument technician can possess is the ability to efficiently diagnose…


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Digital PID Algorithms

Digital PID Algorithms

Instrument technicians should not have to concern themselves over the programming details internal to digital…


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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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Flow Measurement in Open Channels

Flow Measurement in Open Channels

Measuring the flow rate of liquid through an open channel is not unlike measuring the flow rate of a liquid…


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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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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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Proportional-only Control

Proportional-only Control

Imagine a liquid-level control system for a vessel, where the position of a level-sensing float directly sets…


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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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Laser Spectroscopy

Laser Spectroscopy

A laser is a light source emitting waves of light that not only share the exact same frequency (color)…


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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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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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Practical PID Controller Features

Practical PID Controller Features

In order for any PID controller to be practical, it must be able to do more than just implement the PID…


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Classical Mechanics

Classical Mechanics

Classical mechanics (often called Newtonian mechanics in honor of Isaac Newton) deal with forces and motions…


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Capacitive Level Measurement

Capacitive Level Measurement

Capacitive level instruments measure electrical capacitance of a conductive rod inserted vertically into a…


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Metric Prefixes and Prefix Scale

Metric Prefixes and Prefix Scale


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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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