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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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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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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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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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Transfer Function Analysis

Transfer Function Analysis

An extremely important topic in engineering is that of transfer functions. Simply defined, a transfer function…


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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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Wastewater Disinfection Example

Wastewater Disinfection Example

The final step in treating wastewater before releasing it into the natural environment is to kill any harmful…


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Pilot Valves and Pneumatic Amplifying Relays

Pilot Valves and Pneumatic Amplifying Relays

Self-balancing mechanisms consisting solely of a baffle/nozzle detector coupled to a feedback bellows, while…


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Distance (21) Protection

Distance (21) Protection

A form of protection against faults on long-distance power lines is called distance relaying, so named because…


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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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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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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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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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Classical Mechanics

Classical Mechanics

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


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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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Process Flow Diagrams

Process Flow Diagrams

To show a practical process example, let’s examine three diagrams for a compressor control system,…


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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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Mechanical Pressure Elements

Mechanical Pressure Elements

Mechanical pressure-sensing elements include the bellows, the diaphragm, and the bourdon tube. Each of these…


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FOUNDATION Fieldbus H1 Protocol Physical Layer

FOUNDATION Fieldbus H1 Protocol Physical Layer

Layer 1 of the OSI Reference Model is where we define the “physical” elements of a digital data…


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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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Analyzer Sample Systems

Analyzer Sample Systems

Some analyzers measure the composition of a process stream by directly immersing the sensing element in that…


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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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Classified Areas and Electrical Safety Measures

Classified Areas and Electrical Safety Measures

Any physical location in an industrial facility harboring the potential of explosion due to the presence of…


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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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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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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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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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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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Proximity Switches

Proximity Switches

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


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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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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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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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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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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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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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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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Using Manometers for Measuring Pressure

Using Manometers for Measuring Pressure

A very simple device used to measure pressure is the manometer: a fluid-filled tube where an applied gas…


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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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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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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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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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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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References

References

Lipták, Béla G. et al., Instrument Engineers’ Handbook – Process Measurement and Analysis Volume I,…


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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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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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Logic Programming in PLCs

Logic Programming in PLCs

Although it seems each model of PLC has its own idiosyncratic standard for programming, there does exist an…


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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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Radio-energy Pulse in Guided-wave Radar Level Measurement

Radio-energy Pulse in Guided-wave Radar Level Measurement

The following animation shows how a radio-energy pulse travels down and then up the waveguide of a guided-wave…


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What are Simple Machines?

What are Simple Machines?

A machine in the broad sense of the word is any device designed to translate some form of energy into useful…


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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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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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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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Instrument Identification Tags

Instrument Identification Tags

Up until this point, we have explored various types of instrumentation diagram, each one making reference to…


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Dimensional Analysis

Dimensional Analysis

An interesting parallel to the “unity fraction” unit conversion technique is something referred to…


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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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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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Introduction to Protective Relaying

Introduction to Protective Relaying

Circuit breakers used in residential, commercial, and light industrial service are self-tripping devices: they…


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Antennas and Resonant Circuits (Tank Circuits)

Antennas and Resonant Circuits (Tank Circuits)

Capacitors store energy in electric fields, proportional to the square of voltage. Inductors store energy in…


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Analytical Measurements of Chemical Compositions

Analytical Measurements of Chemical Compositions

A great many chemical composition measurements may be made indirectly by means of electricity, if those…


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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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