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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 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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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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Thermocouple Types, Junctions, Connector and Tip Styles

Thermocouple Types, Junctions, Connector and Tip Styles

RTDs are completely passive sensing elements, requiring the application of an externally-sourced electric…


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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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Design-based Fortifications

Design-based Fortifications

A design-based fortification is one rooted in technical details of system architecture and functionality. Some…


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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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EIA/TIA-232, 422, and 485 Networks

EIA/TIA-232, 422, and 485 Networks

Some of the simplest types of digital communication networks found in industry are defined by the EIA…


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Fiber Optic Data Communication

Fiber Optic Data Communication

Light has long been used as a long-range signaling medium. While communication by light through open air is…


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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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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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What is Internet Protocol (IP)?

What is Internet Protocol (IP)?

I remember first learning about the world-wide Internet, and wondering what it actually looked like. The first…


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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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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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Introduction to Modbus

Introduction to Modbus

Developed by the Modicon company (the original manufacturer of the Programmable Logic Controller, or PLC) in…


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4-wire “Passive” Versus “Active” Output Transmitters

4-wire “Passive” Versus “Active” Output Transmitters

Some self-powered (4-wire) analog electronic transmitters are designed to behave as electrical loads rather…


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Digital PID Controllers

Digital PID Controllers

The vast majority of PID controllers in service today are digital in nature. Microprocessors executing PID…


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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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Industrial Instrumentation Summary for Teachers

Industrial Instrumentation Summary for Teachers

To summarize some of the key points and concepts for teaching: Do not waste class time transmitting facts to…


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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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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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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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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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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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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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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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Introduction to Inductors and Inductance

Introduction to Inductors and Inductance

Any conductor possesses a characteristic called inductance: the ability to store energy in the form of a…


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Function Block Diagram (FBD) Programming

Function Block Diagram (FBD) Programming

(Will be addressed in future versions of this book)


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Phasors, Phase Shift and Phasor Algebra

Phasors, Phase Shift and Phasor Algebra

Phasors are to AC circuit quantities as polarity is to DC circuit quantities: a way to express the…


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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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An Analogy for Calibration Vs Ranging

An Analogy for Calibration Vs Ranging

The concepts of calibration (trimming) and ranging are often difficult for new students of instrumentation to…


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Ratio Control

Ratio Control

Most people reading this book have likely had the experience of adjusting water temperature using two hand…


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Temperature Sensor Accessories

Temperature Sensor Accessories

One of the most important accessories for any temperature-sensing element is a pressure-tight sheath known as…


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Analog Signal Conditioning and Referencing

Analog Signal Conditioning and Referencing

Modern analog-to-digital converters are phenomenally accurate, dependable, repeatable, and surprisingly…


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ANSI/IEEE Function Number Codes

ANSI/IEEE Function Number Codes

In the United States, the ANSI and IEEE organizations have standardized a set of numerical codes referring to…


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On/off Control (Bang-bang Control)

On/off Control (Bang-bang Control)

Once while working as an instrument technician in an aluminum foundry, a mechanic asked me what it was that I…


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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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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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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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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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Metric Prefixes and Prefix Scale

Metric Prefixes and Prefix Scale


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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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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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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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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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Mathematical Problem-solving Techniques

Mathematical Problem-solving Techniques

Some problem-solving techniques are unique to quantitative problems, involving mathematical calculations. In…


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Flow Switches

Flow Switches

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


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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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Supervisory Control

Supervisory Control

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


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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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Pipe and Pipe Fittings

Pipe and Pipe Fittings

Pipe is a hollow structure designed to provide an enclosed pathway for fluids to flow, usually manufactured…


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Atomic Theory and Chemical Symbols

Atomic Theory and Chemical Symbols

The three “elementary” particles of matter comprising all atoms are electrons, protons, and…


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Dispersive Spectroscopy

Dispersive Spectroscopy

The dispersion of visible light into its constituent colors goes all the way back to the 17th century with…


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Solenoid Valves

Solenoid Valves

A very common form of on/off valve used for pneumatic and hydraulic systems alike is the solenoid valve. A…


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Capacitive Level Measurement

Capacitive Level Measurement

Capacitive level instruments measure electrical capacitance of a conductive rod inserted vertically into a…


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A Comparison of PID Controller Tuning Techniques

A Comparison of PID Controller Tuning Techniques

In this section I will show screenshots from a process loop simulation program illustrating the effectiveness…


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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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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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