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True Mass Flowmeters

True Mass Flowmeters

Many traditional flowmeter technologies respond to the volumetric flow rate of the moving fluid.…


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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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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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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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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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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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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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Calibration Standards to Produce and Measure Physical Quantities

Calibration Standards to Produce and Measure Physical Quantities

As previously defined, calibration refers to the checking and adjustment of an instrument so that its output…


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Introduction to Capacitors and Capacitance

Introduction to Capacitors and Capacitance

Capacitance Any two electrical conductors separated by an insulating medium possess the characteristic called…


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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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How Derivatives and Integrals Relate to One Another

How Derivatives and Integrals Relate to One Another

Like many other mathematical operations, the derivative and the integral perform inverse operations from each…


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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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Understanding the “Normal” Status of a Process Switch

Understanding the “Normal” Status of a Process Switch

Perhaps the most confusing aspect of discrete sensors is the definition of a sensor’s normal status.…


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FOUNDATION Fieldbus H1 Protocol Data Link Layer

FOUNDATION Fieldbus H1 Protocol Data Link Layer

Like so many other industrial data networks, FOUNDATION Fieldbus is an “unswitched” or…


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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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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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Insertion Flowmeters

Insertion Flowmeters

This section does not describe a particular type of flowmeter, but rather a design that may be implemented for…


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Elementary Thermodynamics

Elementary Thermodynamics

Thermodynamics is the study of heat, temperature, and their related effects in physical systems. As a subject,…


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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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Flow Switches

Flow Switches

A flow switch is one that detects the flow of some fluid through a pipe. Flow switches often use…


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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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Introduction to Capacitors and Capacitance

Introduction to Capacitors and Capacitance

Capacitance Any two electrical conductors separated by an insulating medium possess the characteristic called…


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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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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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Flow Switches

Flow Switches

A flow switch is one that detects the flow of some fluid through a pipe. Flow switches often use…


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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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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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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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Measuring Electrical Conductivity

Measuring Electrical Conductivity

The electrical conductivity of liquids is an important analytical measurement in many industrial processes.…


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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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Open-ended, Shorted, and Properly Terminated Transmission Lines

Open-ended, Shorted, and Properly Terminated Transmission Lines

Many years ago, when I was first learning about electricity, I happened to discover a length of coaxial…


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Resistance, Reactance, and Impedance

Resistance, Reactance, and Impedance

Electrical Resistance Resistance (\(R\)) is the dissipative opposition to an electric current, analogous to…


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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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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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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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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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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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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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Flow Measurement from Differential Pressure

Flow Measurement from Differential Pressure

In our first signal characterization example, we tackle the problem of measuring fluid flow through a pipe. To…


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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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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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Ions in Liquid Solutions

Ions in Liquid Solutions

Many liquid substances undergo a process whereby their constituent molecules split into positively and…


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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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Flow Measurement from Differential Pressure

Flow Measurement from Differential Pressure

In our first signal characterization example, we tackle the problem of measuring fluid flow through a pipe. To…


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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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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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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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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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Measuring Electrical Conductivity

Measuring Electrical Conductivity

The electrical conductivity of liquids is an important analytical measurement in many industrial processes.…


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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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Electromagnetism Basics

Electromagnetism Basics

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


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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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Practical Topic Coverage

Practical Topic Coverage

Nearly every technical course teaches and tests students on definitions, basic concepts, and at least some…


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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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Proportional-only Control

Proportional-only Control

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


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Radiative Temperature Measurement

Radiative Temperature Measurement

Temperature measurement devices may be classified into two broad types: contact and non-contact. Contact-type…


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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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Pneumatic PID Controllers

Pneumatic PID Controllers

A pneumatic controller receives a process variable (PV) signal as a variable air pressure, compares that…


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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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Elementary Thermodynamics

Elementary Thermodynamics

Thermodynamics is the study of heat, temperature, and their related effects in physical systems. As a subject,…


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