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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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True Mass Flowmeters

True Mass Flowmeters

Many traditional flowmeter technologies respond to the volumetric flow rate of the moving fluid.…


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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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Transmission Control Protocol (TCP) and User Datagram Protocol (UDP)

Transmission Control Protocol (TCP) and User Datagram Protocol (UDP)

At the next OSI Reference Model layer (layer 4) is a set of protocols specifying how reliable communication…


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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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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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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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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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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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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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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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Rotating Phasor in Three-dimensional Form

Rotating Phasor in Three-dimensional Form

The following animation shows a rotating phasor in three-dimensional form. The phasor rotates in a complex…


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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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Actuator Bench-set

Actuator Bench-set

Valve actuators provide force to move control valve trim. For precise positioning of a control valve, there…


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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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Level Switches

Level Switches

A level switch is one detecting the level of liquid or solid (granules or powder) in a vessel. Level switches…


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Pneumatic PID Controllers

Pneumatic PID Controllers

A pneumatic controller receives a process variable (PV) signal as a variable air pressure, compares that…


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Different PID Equations

Different PID Equations

For better or worse, there are no fewer than three different forms of PID equations implemented in modern PID…


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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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Dimensional Analysis

Dimensional Analysis

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


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Analysis of Practical Pneumatic Instruments

Analysis of Practical Pneumatic Instruments

To better understand the design and operation of self-balancing pneumatic mechanisms, it is helpful to examine…


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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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Dampers and Louvres

Dampers and Louvres

A damper (otherwise known as a louvre) is a multi-element flow control device generally used to throttle large…


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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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True Mass Flowmeters

True Mass Flowmeters

Many traditional flowmeter technologies respond to the volumetric flow rate of the moving fluid.…


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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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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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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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the Negative Consequences of Poor PID Controller Tuning

the Negative Consequences of Poor PID Controller Tuning

Much has been written about the benefits of robust PID control. Increased productivity, decreased equipment…


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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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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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Quantitative PID Tuning Procedures

Quantitative PID Tuning Procedures

A quantitative PID tuning procedure is a step-by-step approach leading directly to a set of numerical values…


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Flow Measurement from Differential Pressure

Flow Measurement from Differential Pressure

In our first signal characterization example, we tackle the problem of measuring fluid flow through a pipe. To…


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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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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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Temperature Switches

Temperature Switches

A temperature switch is one detecting the temperature of some substance. Temperature switches often use…


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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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Instrument and Process Equipment Symbols

Instrument and Process Equipment Symbols

This section shows some of the many instrument symbols found in different types of technical diagrams used to…


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FOUNDATION Fieldbus Design Philosophy

FOUNDATION Fieldbus Design Philosophy

To understand just how different FOUNDATION Fieldbus is from other digital instrument systems, consider a…


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Electrical Resistance and Ohm’s Law

Electrical Resistance and Ohm’s Law

To review, voltage is the measure of potential energy available to electric charges. Current is the uniform…


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