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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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Continuous Float Level Transmitters

Continuous Float Level Transmitters

Perhaps the simplest form of solid or liquid level measurement is with a float: a device that rides on the…


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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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Legal Code

Legal Code

Creative Commons Attribution 4.0 International Public License By exercising the Licensed Rights (defined…


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Overpressure Protection Devices

Overpressure Protection Devices

Fluid pressure exerts force on any surface area it contacts, as described by the formula \(F = PA\). One…


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Pilot Valves and Pneumatic Amplifying Relays

Pilot Valves and Pneumatic Amplifying Relays

Self-balancing mechanisms consisting solely of a baffle/nozzle detector coupled to a feedback bellows, while…


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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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Disassembling a Globe Valve

Disassembling a Globe Valve

The following collection of photographs chronicles the complete disassembly of a Fisher E-body globe valve…


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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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On/off Shut-off Valves

On/off Shut-off Valves

An on/off valve is the fluid equivalent of an electrical switch: a device that either allows unimpeded flow or…


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Proper Care and Feeding of Pneumatic Instruments

Proper Care and Feeding of Pneumatic Instruments

Perhaps the most important rule to obey when using pneumatic instruments is to maintain clean and dry…


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Mathematical Problem-solving Techniques

Mathematical Problem-solving Techniques

Some problem-solving techniques are unique to quantitative problems, involving mathematical calculations. In…


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What are Simple Machines?

What are Simple Machines?

A machine in the broad sense of the word is any device designed to translate some form of energy into useful…


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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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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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Numerical Integration

Numerical Integration

As we have seen, the concept of integration is finding the accumulation of one variable multiplied by another…


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Loop Diagrams (Loop Sheets)

Loop Diagrams (Loop Sheets)

Finally, we arrive at the loop diagram (sometimes called a loop sheet) for the compressor surge control system…


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Wastewater Disinfection Example

Wastewater Disinfection Example

The final step in treating wastewater before releasing it into the natural environment is to kill any harmful…


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Chromatography: Methods, Detectors and Species

Chromatography: Methods, Detectors and Species

Imagine a major marathon race, where hundreds of runners gather in one place to compete. When the starting gun…


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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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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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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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The Basics of Control Relays

The Basics of Control Relays

An electromechanical relay is an electrical switch actuated by an electromagnet coil. As switching devices,…


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Pipe and Pipe Fittings

Pipe and Pipe Fittings

Pipe is a hollow structure designed to provide an enclosed pathway for fluids to flow, usually manufactured…


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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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Introduction to Inductors and Inductance

Introduction to Inductors and Inductance

Any conductor possesses a characteristic called inductance: the ability to store energy in the form of a…


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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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Pressure Switches

Pressure Switches

A pressure switch is one that detects the presence of fluid pressure. Pressure switches often use diaphragms…


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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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The Difference Between Series and Parallel Circuits

The Difference Between Series and Parallel Circuits

In addition to Ohm’s Law, we have a set of rules describing how voltages, currents, and resistances…


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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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Learn Fundamental Principles, not Procedures

Learn Fundamental Principles, not Procedures

“As to methods there may be a million and then some, but principles are few. The man who grasps…


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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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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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Conservation Laws

Conservation Laws

The Law of Mass Conservation states that matter can neither be created nor destroyed. The Law of Energy…


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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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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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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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Pressure Sensor Accessories

Pressure Sensor Accessories

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


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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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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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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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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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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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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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FOUNDATION Fieldbus H1 Protocol Physical Layer

FOUNDATION Fieldbus H1 Protocol Physical Layer

Layer 1 of the OSI Reference Model is where we define the “physical” elements of a digital data…


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Electrical Sources and Electronic Load

Electrical Sources and Electronic Load

By definition, a source is a device delivering energy into a system, while a load is a device extracting…


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Pipe and Pipe Fittings

Pipe and Pipe Fittings

Pipe is a hollow structure designed to provide an enclosed pathway for fluids to flow, usually manufactured…


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Wastewater Disinfection Example

Wastewater Disinfection Example

The final step in treating wastewater before releasing it into the natural environment is to kill any harmful…


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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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Proper Care and Feeding of Pneumatic Instruments

Proper Care and Feeding of Pneumatic Instruments

Perhaps the most important rule to obey when using pneumatic instruments is to maintain clean and dry…


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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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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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Laminar Flowmeters

Laminar Flowmeters

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


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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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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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The International System of Units

The International System of Units

The very purpose of physics is to quantitatively describe and explain the physical world in as few terms as…


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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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Limit Switches

Limit Switches

A limit switch detects the physical motion of an object by direct contact with that object. An example of a…


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DC Motor Speed Control

DC Motor Speed Control

DC electric motors generate torque by a reaction between two magnetic fields: one field established by…


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