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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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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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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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Glossary of Cyber-security Terms

Glossary of Cyber-security Terms

Cyber-security seems to have its own vocabulary, ranging from unwieldy technical acronyms to slang terms…


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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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Policy-based Fortifications

Policy-based Fortifications

These fortifications focus on human behavior rather than system design or component selection. In some ways…


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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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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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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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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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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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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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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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Basic Components Common to all Radio Systems

Basic Components Common to all Radio Systems

“Radio” systems use electromagnetic fields to communicate information over long distances through…


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Feedforward Control

Feedforward Control

“Feedforward” is a rather under-used control strategy capable of managing a great many types of…


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Basics of pH Measurement in Industrial Control

Basics of pH Measurement in Industrial Control

Hydrogen ion activity in aqueous (water-solvent) solutions is a very important parameter for a wide variety of…


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General Problem-solving Techniques

General Problem-solving Techniques

A variety of problem-solving techniques have been presented for students over the years which are all helpful…


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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Constructing PID control systems using discrete components is a fairly simple method involving operational…


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Ultrasonic (Sound) Echo Level Measurement

Ultrasonic (Sound) Echo Level Measurement

A completely different way of measuring liquid level in vessels is to bounce a traveling wave off the surface…


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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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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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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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Basics of pH Measurement in Industrial Control

Basics of pH Measurement in Industrial Control

Hydrogen ion activity in aqueous (water-solvent) solutions is a very important parameter for a wide variety of…


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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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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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Feedforward Control

Feedforward Control

“Feedforward” is a rather under-used control strategy capable of managing a great many types of…


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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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Instantaneous and Time-overcurrent (50/51) Protection

Instantaneous and Time-overcurrent (50/51) Protection

Perhaps the most basic and necessary protective relay function is overcurrent: commanding a circuit breaker to…


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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Constructing PID control systems using discrete components is a fairly simple method involving operational…


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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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Human-Machine Interfaces (HMIs)

Human-Machine Interfaces (HMIs)

Human-machine interfaces, or HMIs, are a critical part of nearly all control systems, complementing the…


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Feedforward with Dynamic Compensation

Feedforward with Dynamic Compensation

As we have seen, feedforward control is a way to improve the stability of a feedback control system in the…


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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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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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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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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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Polyphase AC Power

Polyphase AC Power

“Polyphase” means “many phases,” describing a form of AC electrical system where…


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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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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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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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Basic Components Common to all Radio Systems

Basic Components Common to all Radio Systems

“Radio” systems use electromagnetic fields to communicate information over long distances through…


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New Content

New Content

Coy, John J. et. al. (December 2012) Sampled graphic illustrations from his NASA Reference Publication…


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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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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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Basics of Bridge Circuits

Basics of Bridge Circuits

A bridge circuit is basically a pair of voltage dividers where the circuit output is taken as the difference…


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Rotating Phasor in Three-dimensional Form

Rotating Phasor in Three-dimensional Form

The following animation shows a rotating phasor in three-dimensional form. The phasor rotates in a complex…


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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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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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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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Gas Filter Correlation (GFC) Spectroscopy

Gas Filter Correlation (GFC) Spectroscopy

Using filter cells to eliminate wavelengths associated with interfering gases is called positive filtering in…


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Unit Conversions and Physical Constants

Unit Conversions and Physical Constants

Converting between disparate units of measurement is the bane of many science students. The problem is worse…


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“Normal” status of a Process Switch

“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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The HART Digital/Analog Hybrid Standard

The HART Digital/Analog Hybrid Standard

A technological advance introduced in the late 1980’s was HART, an acronym standing for Highway…


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Derivative (Rate) Control

Derivative (Rate) Control

The final element of PID control is the “D” term, which stands for derivative. This is a calculus…


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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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Conservation Laws

Conservation Laws

The Law of Mass Conservation states that matter can neither be created nor destroyed. The Law of Energy…


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Heuristic PID Tuning Procedures

Heuristic PID Tuning Procedures

In contrast to quantitative tuning procedures where definite numerical values for P, I, and D controller…


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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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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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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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