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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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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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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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Practical PID Controller Features

Practical PID Controller Features

In order for any PID controller to be practical, it must be able to do more than just implement the PID…


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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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Control Valve Sizing

Control Valve Sizing

When control valves operate between fully open and fully shut, they serve much the same purpose in process…


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4-wire “Passive” Versus “Active” Output Transmitters

4-wire “Passive” Versus “Active” Output Transmitters

Some self-powered (4-wire) analog electronic transmitters are designed to behave as electrical loads rather…


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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Although analog electronic process controllers are considered a newer technology than pneumatic process…


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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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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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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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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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Diagnosing Feedback Control Problems

Diagnosing Feedback Control Problems

Negative feedback systems, in general, tend to cause confusion for those first learning their fundamental…


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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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Metering Pumps

Metering Pumps

A very common method for directly controlling low flow rates of fluids is to use a device known as a metering…


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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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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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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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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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Chemiluminescence Measurement

Chemiluminescence Measurement

Recall that an exothermic chemical reaction is one that releases a net sum of energy, as opposed to an…


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Vibration Physics

Vibration Physics

One very convenient feature of waves is that their properties are universal. Waves of water in the ocean,…


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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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Techniques for Analyzing Control Strategies

Techniques for Analyzing Control Strategies

Control strategies such as cascade, ratio, feedforward, and those containing limit and selector functions can…


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Digital Representation of Text

Digital Representation of Text

Binary patterns are not just able to represent numerical values. Given a standardized code, they may represent…


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Classical Mechanics

Classical Mechanics

Classical mechanics (often called Newtonian mechanics in honor of Isaac Newton) deal with forces and motions…


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Process/Instrument Suitability

Process/Instrument Suitability

Every flow-measuring instrument exploits a physical principle to measure the flow rate of fluid stream.…


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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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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Although analog electronic process controllers are considered a newer technology than pneumatic process…


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Thermistors and Resistance Temperature Detectors (RTDs)

Thermistors and Resistance Temperature Detectors (RTDs)

One of the simplest classes of temperature sensor is one where temperature effects a change in electrical…


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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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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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Ethernet networks: Repeaters, Cabling and Switching Hubs

Ethernet networks: Repeaters, Cabling and Switching Hubs

An engineer named Bob Metcalfe conceived the idea of Ethernet in 1973, while working for the Xerox research…


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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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Feedforward Control

Feedforward Control

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


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Teaching Technical Theory

Teaching Technical Theory

Learning is not merely a process of information transfer. It is first and foremost a transformation of…


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Structured Text (ST) Programming

Structured Text (ST) Programming

(Will be addressed in future versions of this book)


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Hand Switches and Stackable Switches

Hand Switches and Stackable Switches

A hand switch is exactly what the name implies: an electrical switch actuated by a person’s hand motion.…


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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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Weighfeeders

Weighfeeders

A special type flowmeter suited for powdered or granular solids is the weighfeeder. One of the most common…


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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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Solenoid Valves

Solenoid Valves

A very common form of on/off valve used for pneumatic and hydraulic systems alike is the solenoid valve. A…


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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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Supervisory Control

Supervisory Control

In a manually-controlled process, a human operator directly actuates some form of final control element…


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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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