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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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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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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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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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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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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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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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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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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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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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Pressure Sensor Accessories

Pressure Sensor Accessories

Multiple accessories exist for pressure-sensing devices to function optimally in challenging process…


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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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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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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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Instruction List (IL) Programming

Instruction List (IL) Programming

(Will be addressed in future versions of this book)


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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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Feedforward Control

Feedforward Control

“Feedforward” is a rather under-used control strategy capable of managing a great many types of…


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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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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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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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Instrument Identification Tags

Instrument Identification Tags

Up until this point, we have explored various types of instrumentation diagram, each one making reference to…


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Comparison of  Op-Amp Circuits With Analogous Pneumatic Mechanisms

Comparison of Op-Amp Circuits With Analogous Pneumatic Mechanisms

Self-balancing pneumatic instrument mechanisms are very similar to negative-feedback operational amplifier…


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Kirchhoff’s Current and Voltage Laws

Kirchhoff’s Current and Voltage Laws

Two extremely important principles in electric circuits were codified by Gustav Robert Kirchhoff in the year…


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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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Analytical Measurements of Chemical Compositions

Analytical Measurements of Chemical Compositions

A great many chemical composition measurements may be made indirectly by means of electricity, if those…


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Fluorescence Measurement

Fluorescence Measurement

When a high-energy photon strikes an atom, it may eject one of the lower-level electrons from its shell,…


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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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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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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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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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Stoichiometry and the Law of Mass Conservation

Stoichiometry and the Law of Mass Conservation

Stoichiometry is the accounting of atoms before and after a chemical reaction. It is an expression of the Law…


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Equivalent Series and Parallel Circuits

Equivalent Series and Parallel Circuits

Impedance in a series circuit is the orthogonal sum of resistance and reactance: \[Z = \sqrt{R^2 + (X_L -…


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Single-line Electrical Diagrams

Single-line Electrical Diagrams

Electrical power grids primarily consist of three-phase AC circuits. This means most power lines (transmission…


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Process and Instrument Diagrams

Process and Instrument Diagrams

The next level of detail is the Process and Instrument Diagram, or P&ID. Here, we see a “zooming…


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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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Using Manometers for Measuring Pressure

Using Manometers for Measuring Pressure

A very simple device used to measure pressure is the manometer: a fluid-filled tube where an applied gas…


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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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Metric Prefixes and Prefix Scale

Metric Prefixes and Prefix Scale


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Periodic Table of the Ions

Periodic Table of the Ions


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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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