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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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Function Block Diagram (FBD) Programming

Function Block Diagram (FBD) Programming

(Will be addressed in future versions of this book)


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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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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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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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Analog Signal Conditioning and Referencing

Analog Signal Conditioning and Referencing

Modern analog-to-digital converters are phenomenally accurate, dependable, repeatable, and surprisingly…


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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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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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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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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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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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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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Sequential Function Chart (SFC) Programming

Sequential Function Chart (SFC) Programming

(Will be addressed in future versions of this book)


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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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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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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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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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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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Error Corrections

Error Corrections

Abdelaziz, Ahmed (June 2014) Identified numerous typographical errors throughout the book, mostly repeated…


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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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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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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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Dimensional Analysis

Dimensional Analysis

An interesting parallel to the “unity fraction” unit conversion technique is something referred to…


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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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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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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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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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Chemical Reactor Temperature Control Example

Chemical Reactor Temperature Control Example

Sometimes we encounter a diversity of instrument signal standards in one control system. Such is the case with…


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Auxiliary and Lockout (86) Relays

Auxiliary and Lockout (86) Relays

An important type of “accessory” relay, especially for legacy electromechanical protective relays,…


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A Comparison of PID Controller Tuning Techniques

A Comparison of PID Controller Tuning Techniques

In this section I will show screenshots from a process loop simulation program illustrating the effectiveness…


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Flow Switches

Flow Switches

A flow switch is one that detects the flow of some fluid through a pipe. Flow switches often use…


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Hand Switches and Stackable Switches

Hand Switches and Stackable Switches

A hand switch is exactly what the name implies: an electrical switch actuated by a person’s hand motion.…


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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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Displacement and Displacer Level Instrumentation

Displacement and Displacer Level Instrumentation

Displacer level instruments exploit Archimedes’ Principle to detect liquid level by continuously…


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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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Fundamental Principles of Industrial Instrumentation

Fundamental Principles of Industrial Instrumentation

Shown here is a partial listing of principles applied in the subject matter of this chapter, given for the…


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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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Input/Output (I/O) Capabilities of PLCs

Input/Output (I/O) Capabilities of PLCs

Every programmable logic controller must have some means of receiving and interpreting signals from real-world…


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Transfer Function Analysis

Transfer Function Analysis

An extremely important topic in engineering is that of transfer functions. Simply defined, a transfer function…


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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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Symbolic Versus Numerical Calculus

Symbolic Versus Numerical Calculus

Calculus has a reputation for being difficult to learn, and with good reason. The traditional approach 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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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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Transfer Function Analysis

Transfer Function Analysis

An extremely important topic in engineering is that of transfer functions. Simply defined, a transfer function…


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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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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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Elementary Thermodynamics

Elementary Thermodynamics

Thermodynamics is the study of heat, temperature, and their related effects in physical systems. As a subject,…


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Glossary of Cyber-security Terms

Glossary of Cyber-security Terms

Cyber-security seems to have its own vocabulary, ranging from unwieldy technical acronyms to slang terms…


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Industrial Instrumentation Summary for Teachers

Industrial Instrumentation Summary for Teachers

To summarize some of the key points and concepts for teaching: Do not waste class time transmitting facts to…


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Principles, not Procedures

Principles, not Procedures

One of the marks of a successful problem-solver is a habit of applying general principles to every new problem…


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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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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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Boiler Water Level Control System Example

Boiler Water Level Control System Example

Steam boilers are very common in industry, principally because steam power is so useful. Common uses for steam…


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Function Block Diagram (FBD) Programming

Function Block Diagram (FBD) Programming

(Will be addressed in future versions of this book)


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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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Force-balance Pressure Transmitters

Force-balance Pressure Transmitters

An important legacy technology for all kinds of continuous measurement is the self-balancing system. A…


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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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Techniques for Analyzing Control Strategies

Techniques for Analyzing Control Strategies

Control strategies such as cascade, ratio, feedforward, and those containing limit and selector functions can…


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