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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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Concepts and Laws of Probability

Concepts and Laws of Probability

While the term “probability” may evoke images of imprecision, probability is in fact an exact…


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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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Function Block Diagram (FBD) Programming

Function Block Diagram (FBD) Programming

(Will be addressed in future versions of this book)


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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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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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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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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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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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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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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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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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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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Common Diagnostic Mistakes in Control Systems

Common Diagnostic Mistakes in Control Systems

Volumes could be written about poor diagnostic technique. The following mistakes are not intended to comprise…


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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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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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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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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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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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WirelessHART Radio Communication Standard

WirelessHART Radio Communication Standard

An exciting development in industrial instrumentation is the WirelessHART radio communication standard,…


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What is Internet Protocol (IP)?

What is Internet Protocol (IP)?

I remember first learning about the world-wide Internet, and wondering what it actually looked like. The first…


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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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Function Block Diagram (FBD) Programming

Function Block Diagram (FBD) Programming

(Will be addressed in future versions of this book)


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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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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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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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Level Sensor Accessories

Level Sensor Accessories

Disturbances in the liquid tend to complicate liquid level measurement. These disturbances may result from…


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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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Problem-solving by Simplification

Problem-solving by Simplification

A whole class of problem-solving techniques focuses on altering the given problem into a simpler form that is…


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Physics and Chemistry Terminology and Definitions

Physics and Chemistry Terminology and Definitions

Atom: the smallest unit of matter that may be isolated by chemical means. Particle: a part of an atom,…


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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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Energy in Chemical Reactions

Energy in Chemical Reactions

A chemical reaction resulting in a net release of energy is called exothermic. Conversely, a chemical reaction…


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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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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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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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Distance (21) Protection

Distance (21) Protection

A form of protection against faults on long-distance power lines is called distance relaying, so named because…


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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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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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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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Relation Control

Relation Control

A control strategy similar to ratio control is relation control. This is similar to ratio control in that a…


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