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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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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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Vibration Monitoring Hardware

Vibration Monitoring Hardware

The following photograph shows a large air blower in a wastewater treatment facility equipped with a…


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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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Proximity Switches

Proximity Switches

A proximity switch is one detecting the proximity (closeness) of some object. By definition, these switches…


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Relay Circuits and Ladder Diagrams

Relay Circuits and Ladder Diagrams

Electromechanical relays may be connected together to perform logic and control functions, acting as logic…


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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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Flow Measurement in Open Channels

Flow Measurement in Open Channels

Measuring the flow rate of liquid through an open channel is not unlike measuring the flow rate of a liquid…


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What is Hydrostatic Pressure?

What is Hydrostatic Pressure?

A vertical column of fluid generates a pressure at the bottom of the column owing to the action of gravity on…


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Level Switches

Level Switches

A level switch is one detecting the level of liquid or solid (granules or powder) in a vessel. Level switches…


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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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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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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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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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Level Gauges (Sightglasses)

Level Gauges (Sightglasses)

Level gauges are perhaps the simplest indicating instrument for liquid level in a vessel. They are often found…


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Non-contact Temperature Sensors

Non-contact Temperature Sensors

Virtually any mass above absolute zero temperature emits electromagnetic radiation (photons, or light) as a…


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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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Change-of-quantity Flow Measurement

Change-of-quantity Flow Measurement

Flow, by definition, is the passage of material from one location to another over time. So far this chapter…


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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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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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Differential (87) Current Protection

Differential (87) Current Protection

One of the fundamental laws of electric circuits is Kirchhoff’s Current Law, which states the algebraic…


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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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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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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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Digital PID Algorithms

Digital PID Algorithms

Instrument technicians should not have to concern themselves over the programming details internal to digital…


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AC Motor Braking

AC Motor Braking

There are several different methods useful for causing an AC induction motor to brake, or slow down: DC…


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Basics of Bridge Circuits

Basics of Bridge Circuits

A bridge circuit is basically a pair of voltage dividers where the circuit output is taken as the difference…


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Electromagnetism Basics

Electromagnetism Basics

The fundamental principle of electromagnetism is that an electric current will create a magnetic field at…


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Basics of Electrical Current

Basics of Electrical Current

Current is the name we give to the motion of electric charges from a point of high potential to a point of low…


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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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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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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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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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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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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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Non-dispersive Luft Detector Spectroscopy

Non-dispersive Luft Detector Spectroscopy

Non-dispersive analysis, while newer in discovery than dispersive analysis (Isaac Newton’s 17th-century…


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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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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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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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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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Null-balance Voltage Measurement

Null-balance Voltage Measurement

A number of different sensors used in instrumentation generate DC voltage signals proportional to the process…


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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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Introduction to Optical Analysis

Introduction to Optical Analysis

Light is known to interact with matter in very specific ways, which may be exploited as a means of measuring…


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Dampers and Louvres

Dampers and Louvres

A damper (otherwise known as a louvre) is a multi-element flow control device generally used to throttle large…


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Interconnected Generators

Interconnected Generators

Any power grid large enough to meet the demand of an entire nation must have multiple generators drawing from…


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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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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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Valve Packing

Valve Packing

Regardless of valve type, all stem-actuated control valves require some form of seal allowing motion of the…


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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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Weight-based Level Measurement

Weight-based Level Measurement

Weight-based level instruments sense process level in a vessel by directly measuring the weight of the vessel.…


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Basics of Electrical Current

Basics of Electrical Current

Current is the name we give to the motion of electric charges from a point of high potential to a point of low…


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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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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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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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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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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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Root Mean Square (RMS) Quantities

Root Mean Square (RMS) Quantities

It is often useful to express the amplitude of an alternating quantity such as voltage or current in terms…


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Safety Gas Analyzers

Safety Gas Analyzers

Process analyzers measure the concentration of specific substances for the purpose of measuring and/or…


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