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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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Self-regulating, Integrating, and Runaway Process Characteristics

Self-regulating, Integrating, and Runaway Process Characteristics

Perhaps the most important rule of controller tuning is to know the process before attempting to adjust the…


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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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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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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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Interposing Relays in PLCs

Interposing Relays in PLCs

In addition to directly performing logic functions, electromechanical relays may also be used as interposing…


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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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Colorimetric and Potentiometric pH Measurement

Colorimetric and Potentiometric pH Measurement

pH is the measurement of the hydrogen ion activity in a liquid solution. It is one of the most common forms of…


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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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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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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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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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Scientific System diagnosis and Scientific Reasoning

Scientific System diagnosis and Scientific Reasoning

At the root of successful system diagnosis is a rigorous adherence to scientific reasoning. There exists no…


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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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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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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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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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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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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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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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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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Troubleshooting Current Loops

Troubleshooting Current Loops

A fundamental principle in instrumentation system troubleshooting is that every instrument has at least one…


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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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Concepts and Laws of Probability

Concepts and Laws of Probability

While the term “probability” may evoke images of imprecision, probability is in fact an exact…


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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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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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Fluorescence Measurement

Fluorescence Measurement

When a high-energy photon strikes an atom, it may eject one of the lower-level electrons from its shell,…


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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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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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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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DC Motor Speed Control

DC Motor Speed Control

DC electric motors generate torque by a reaction between two magnetic fields: one field established by…


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Zero and Span Adjustments (Analog Instruments)

Zero and Span Adjustments (Analog Instruments)

Linearity of Measurement Instruments The purpose of calibration is to ensure the input and output of an…


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Control Valve Actuators

Control Valve Actuators

The purpose of a control valve actuator is to provide the motive force to operate a valve mechanism. Both…


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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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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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Transformer Basics and Principles of Operation

Transformer Basics and Principles of Operation

The transformer is one of the most important components in all of AC circuitry. Principally used to…


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Common Control Valve Problems

Common Control Valve Problems

Valves can experience a number of problems, most of them either preventable or repairable. These problems can…


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Limit, Selector, and Override Controls

Limit, Selector, and Override Controls

Another category of control strategies involves the use of signal relays or function blocks with the ability…


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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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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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How to Teach Yourself PLC Programming

How to Teach Yourself PLC Programming

Learning PLC programming is a very important skill. If your job involves programming, then you will likely…


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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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Troubleshooting Current Loops

Troubleshooting Current Loops

A fundamental principle in instrumentation system troubleshooting is that every instrument has at least one…


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Circuit Failure Analysis

Circuit Failure Analysis

Perhaps the most valuable skill an instrument technician can possess is the ability to efficiently diagnose…


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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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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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FOUNDATION Fieldbus H1 Protocol Segment Troubleshooting

FOUNDATION Fieldbus H1 Protocol Segment Troubleshooting

Feedback obtained from industrial users of FF reveal a common pattern: Fieldbus is a powerful and reliable…


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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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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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FOUNDATION Fieldbus Design Philosophy

FOUNDATION Fieldbus Design Philosophy

To understand just how different FOUNDATION Fieldbus is from other digital instrument systems, consider a…


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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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Digital Multimeter (DMM) Tips and Tricks

Digital Multimeter (DMM) Tips and Tricks

The digital multimeter (DMM) is quite possibly the most useful tool in the instrument technician’s…


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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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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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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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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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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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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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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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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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