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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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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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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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Differential Pressure Transmitters

Differential Pressure Transmitters

One of the most common, and most useful, pressure measuring instruments in industry is the differential…


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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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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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Filled-bulb Temperature Sensors

Filled-bulb Temperature Sensors

Filled-bulb systems exploit the principle of fluid expansion to measure temperature. If a fluid is enclosed in…


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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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Integral (Reset) Control

Integral (Reset) Control

Imagine a liquid-level control system for a vessel, where the position of a level-sensing float sets the…


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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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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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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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Difference Between Calibration and Re-ranging

Difference Between Calibration and Re-ranging

What is Calibration? To calibrate an instrument means to check and adjust (if necessary) its response so the…


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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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Fundamental Principles of Industrial Instrumentation

Fundamental Principles of Industrial Instrumentation

Shown here is a partial listing of principles applied in the subject matter of this chapter, given for the…


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An Analogy for Calibration Vs Ranging

An Analogy for Calibration Vs Ranging

The concepts of calibration (trimming) and ranging are often difficult for new students of instrumentation to…


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Controller Output Current Loops

Controller Output Current Loops

The simplest form of 4-20 mA current loop is the type used to represent the output of a process controller,…


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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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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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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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Molecular Quantities

Molecular Quantities

Sample sizes of chemical substances are often measured in moles. One mole of a substance is defined as a…


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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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Electrical Pressure Elements

Electrical Pressure Elements

Several different technologies exist for the conversion of fluid pressure into an electrical signal response.…


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A Comparison of PID Controller Tuning Techniques

A Comparison of PID Controller Tuning Techniques

In this section I will show screenshots from a process loop simulation program illustrating the effectiveness…


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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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Advantages and Disadvantages of Pneumatic Instruments

Advantages and Disadvantages of Pneumatic Instruments

The disadvantages of pneumatic instruments are painfully evident to anyone familiar with both pneumatic and…


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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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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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Calibration Errors and Testing

Calibration Errors and Testing

The efficient identification and correction of instrument calibration errors is an important function for…


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Phasors, Phase Shift, and Phasor Algebra

Phasors, Phase Shift, and Phasor Algebra

Phasors are to AC circuit quantities as polarity is to DC circuit quantities: a way to express the…


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Common Educational Fallacies

Common Educational Fallacies

When I began teaching full-time in 1998, most of what I thought I understood about good teaching was actually…


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Tube and Tube Fittings

Tube and Tube Fittings

Tube, like pipe, is a hollow structure designed to provide an enclosed pathway for fluids to flow. In the case…


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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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AC Motor Speed Control

AC Motor Speed Control

AC induction motors are based on the principle of a rotating magnetic field produced by a set of stationary…


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Pneumatic Actuator Response

Pneumatic Actuator Response

A limitation inherent to pneumatic valve actuators is the amount of air flow required to or from the actuator…


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Radiation Level Measurement

Radiation Level Measurement

Certain types of nuclear radiation easily penetrates the walls of industrial vessels, but is attenuated by…


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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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Numerical Differentiation

Numerical Differentiation

As we have seen, the concept of differentiation is finding the rate-of-change of one variable compared to…


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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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Introduction to Modbus

Introduction to Modbus

Learn about Modbus function codes, the structure of Modbus message packets, and the various types of channels used to transmit Modbus telegrams between controllers.


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Basic Operation of a Gas Chromatograph

Basic Operation of a Gas Chromatograph

This animation shows the basic operation of a gas chromatograph, showing the separation of different molecular…


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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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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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Mechanical Vibration Switches

Mechanical Vibration Switches

A much simpler alternative to continuous vibration sensors (displacement or acceleration) and monitoring…


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