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Valve Failure Modes

Valve Failure Modes

An important design parameter of a control valve is the position it will “fail” to if it loses…


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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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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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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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Legal Code

Legal Code

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


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Analyzer Sample Systems

Analyzer Sample Systems

Some analyzers measure the composition of a process stream by directly immersing the sensing element in that…


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Valve Seat Leakage

Valve Seat Leakage

In some process applications, it is important that the control valve be able to completely stop fluid flow…


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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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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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Teaching Diagnostic Principles and Practices

Teaching Diagnostic Principles and Practices

Diagnostic ability is arguably the most difficult skill to develop within a student, and also the most…


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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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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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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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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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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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Fluid Power Systems

Fluid Power Systems

Given the ability of pressurized fluids to transmit force over long distances, it is not surprising that many…


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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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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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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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Velocity-based Flowmeters

Velocity-based Flowmeters

The Law of Continuity for fluids states that the product of mass density (\(\rho\)), cross-sectional pipe area…


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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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Fluid Power Systems

Fluid Power Systems

Given the ability of pressurized fluids to transmit force over long distances, it is not surprising that many…


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The Stuxnet Virus

The Stuxnet Virus

In November of 2007 a new computer virus was submitted to a virus scanning service. The purpose of this new…


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Periodic Table of the Elements

Periodic Table of the Elements

All substances are comprised of various elements in various combinations and proportions. Elements may thus be…


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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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Proportional-only Offset

Proportional-only Offset

A fundamental limitation of proportional control has to do with its response to changes in setpoint and…


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Control Valve Characterization

Control Valve Characterization

Control valves are supposed to deliver reliable, repeatable control of process fluid flow rate over a wide…


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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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EIA/TIA-232, 422, and 485 Networks

EIA/TIA-232, 422, and 485 Networks

Some of the simplest types of digital communication networks found in industry are defined by the EIA…


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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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Classified Areas and Electrical Safety Measures

Classified Areas and Electrical Safety Measures

Any physical location in an industrial facility harboring the potential of explosion due to the presence of…


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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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Thermocouple Types, Junctions, Connector and Tip Styles

Thermocouple Types, Junctions, Connector and Tip Styles

RTDs are completely passive sensing elements, requiring the application of an externally-sourced electric…


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What is Electrical Power?

What is Electrical Power?

Since we often use electricity to convey energy from one location to another, it is important to be able to…


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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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Self-balancing Pneumatic Instruments Principles

Self-balancing Pneumatic Instruments Principles

A great many precision instruments use the principle of balance to measure some quantity. Perhaps the simplest…


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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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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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ANSI/IEEE Function Number Codes

ANSI/IEEE Function Number Codes

In the United States, the ANSI and IEEE organizations have standardized a set of numerical codes referring to…


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Basic Feedback Control Principles

Basic Feedback Control Principles

Feedback Control System Components Before we begin our discussion on process control, we must define a few key…


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Interposing Relays in PLCs

Interposing Relays in PLCs

In addition to directly performing logic functions, electromechanical relays may also be used as interposing…


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Teaching Diagnostic Principles and Practices

Teaching Diagnostic Principles and Practices

Diagnostic ability is arguably the most difficult skill to develop within a student, and also the most…


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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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Tuning PID Controllers

Tuning PID Controllers

Learning how to tune PID controllers is a skill born of much practice. Regardless of how thoroughly you may…


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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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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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Electrical Sensors: Potential Transformers (PTs) and Current Transformers (CTs)

Electrical Sensors: Potential Transformers (PTs) and Current Transformers (CTs)

The two “process variables” we rely on most heavily in the field of electrical measurement and…


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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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New Content

New Content

Coy, John J. et. al. (December 2012) Sampled graphic illustrations from his NASA Reference Publication…


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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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The Concept of Integration

The Concept of Integration

Suppose we wished to measure the consumption of propane over time for a large propane storage tank supplying a…


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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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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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4-wire (“self-powered”) Transmitter Current Loops

4-wire (“self-powered”) Transmitter Current Loops

DC electric current signals may also be used to communicate process measurement information from transmitters…


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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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Feedforward with Dynamic Compensation

Feedforward with Dynamic Compensation

As we have seen, feedforward control is a way to improve the stability of a feedback control system in the…


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Control Valve Characterization

Control Valve Characterization

Control valves are supposed to deliver reliable, repeatable control of process fluid flow rate over a wide…


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Analyzer Sample Systems

Analyzer Sample Systems

Some analyzers measure the composition of a process stream by directly immersing the sensing element in that…


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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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