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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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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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Comparison of  Op-Amp Circuits With Analogous Pneumatic Mechanisms

Comparison of Op-Amp Circuits With Analogous Pneumatic Mechanisms

Self-balancing pneumatic instrument mechanisms are very similar to negative-feedback operational amplifier…


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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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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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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 Concept of Differentiation

The Concept of Differentiation

Suppose we wished to measure the rate of propane gas flow through a hose to a torch: Flowmeters appropriate…


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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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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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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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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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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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Assessing Student Learning

Assessing Student Learning

As a general rule, high achievement only takes place in an atmosphere of high expectations. Sometimes these…


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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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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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Pressure Sensor Accessories

Pressure Sensor Accessories

Multiple accessories exist for pressure-sensing devices to function optimally in challenging process…


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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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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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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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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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2-wire (“loop-powered”) Transmitter Current Loops

2-wire (“loop-powered”) Transmitter Current Loops

It is possible to convey electrical power and communicate analog information over the same two wires using 4…


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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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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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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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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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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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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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Calibration Procedures in Linear, Non-Linear and Discrete Instruments

Calibration Procedures in Linear, Non-Linear and Discrete Instruments

As described earlier in this chapter, calibration refers to the adjustment of an instrument so its output…


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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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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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Electromagnetism Basics

Electromagnetism Basics

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


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Sliding-stem Valves

Sliding-stem Valves

A sliding-stem valve body is one where the moving parts slide with a linear motion. Some examples of…


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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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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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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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Auxiliary and Lockout (86) Relays

Auxiliary and Lockout (86) Relays

An important type of “accessory” relay, especially for legacy electromechanical protective relays,…


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Electrical Signal and Control Wiring

Electrical Signal and Control Wiring

There is much to be said for neatness of assembly in electrical signal wiring. Even though the electrons…


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Ladder Diagram (LD) Programming Contacts and Coils

Ladder Diagram (LD) Programming Contacts and Coils

In the United States, the most common language used to program PLCs is Ladder Diagram (LD), also known as…


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Phasor Analysis of Transformer Circuits

Phasor Analysis of Transformer Circuits

Three-phase AC is the dominant mode of electric power generation and distribution in modern societies.…


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Transmitter Damping Adjustments

Transmitter Damping Adjustments

The vast majority of modern process transmitters (both analog and digital) come equipped with a feature known…


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FOUNDATION Fieldbus Function Blocks

FOUNDATION Fieldbus Function Blocks

Data-processing modules within FF systems are known as function blocks. Sometimes these blocks serve merely to…


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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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Understanding Electrical Power Grids

Understanding Electrical Power Grids

The term “grid” refers to the conductors and equipment interconnecting power sources to power…


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2-wire (“loop-powered”) Transmitter Current Loops

2-wire (“loop-powered”) Transmitter Current Loops

It is possible to convey electrical power and communicate analog information over the same two wires using 4…


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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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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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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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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 Gas Analyzers

Safety Gas Analyzers

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


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Kirchhoff’s Current and Voltage Laws

Kirchhoff’s Current and Voltage Laws

Two extremely important principles in electric circuits were codified by Gustav Robert Kirchhoff in the year…


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Electrical Signal and Control Wiring

Electrical Signal and Control Wiring

There is much to be said for neatness of assembly in electrical signal wiring. Even though the electrons…


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P, I, and D Responses Graphed

P, I, and D Responses Graphed

Visualizing the actions of P, I, and D tuning parameters using graphs is extremely useful in predicting the…


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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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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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Active Reading and Outlining Documentation

Active Reading and Outlining Documentation

Learning from reading printed text is a kind of problem-solving activity it is own right. The problem is how…


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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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Supervisory Control

Supervisory Control

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


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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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Boiler Water Level Control System Example

Boiler Water Level Control System Example

Steam boilers are very common in industry, principally because steam power is so useful. Common uses for steam…


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Symbolic Versus Numerical Calculus

Symbolic Versus Numerical Calculus

Calculus has a reputation for being difficult to learn, and with good reason. The traditional approach to…


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