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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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Fluid Mechanics

Fluid Mechanics

A fluid is any substance having the ability to flow: to freely change shape and move under the influence of a…


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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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Digital PID Algorithms

Digital PID Algorithms

Instrument technicians should not have to concern themselves over the programming details internal to digital…


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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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Teaching Technical Theory

Teaching Technical Theory

Learning is not merely a process of information transfer. It is first and foremost a transformation 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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Dimensional Analysis

Dimensional Analysis

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


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Displacement and Displacer Level Instrumentation

Displacement and Displacer Level Instrumentation

Displacer level instruments exploit Archimedes’ Principle to detect liquid level by continuously…


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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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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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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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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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Sequential Function Chart (SFC) Programming

Sequential Function Chart (SFC) Programming

(Will be addressed in future versions of this book)


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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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Instruction List (IL) Programming

Instruction List (IL) 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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Structured Text (ST) Programming

Structured Text (ST) Programming

(Will be addressed in future versions of this book)


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Pressure-based Flowmeters

Pressure-based Flowmeters

All masses require force to accelerate (we can also think of this in terms of the mass generating a reaction…


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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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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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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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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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Human-Machine Interfaces (HMIs)

Human-Machine Interfaces (HMIs)

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


Textbook

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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Polyphase AC Power

Polyphase AC Power

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


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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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Ladder Diagram (LD) Structure Commands

Ladder Diagram (LD) Structure Commands

The simple PLC ladder diagram (LD) commands consist of contacts and coils, arranged in sequences that mimic…


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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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Numerical Integration

Numerical Integration

As we have seen, the concept of integration is finding the accumulation of one variable multiplied by another…


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Calibration Errors and Testing

Calibration Errors and Testing

The efficient identification and correction of instrument calibration errors is an important function for…


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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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Transfer Function Analysis

Transfer Function Analysis

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


Textbook

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.…


Textbook

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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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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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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Feedforward Control

Feedforward Control

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


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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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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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Proportional-only Offset

Proportional-only Offset

A fundamental limitation of proportional control has to do with its response to changes in setpoint and…


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Common Educational Fallacies

Common Educational Fallacies

When I began teaching full-time in 1998, most of what I thought I understood about good teaching was actually…


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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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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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Input/Output (I/O) Capabilities of PLCs

Input/Output (I/O) Capabilities of PLCs

Every programmable logic controller must have some means of receiving and interpreting signals from real-world…


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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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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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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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Principles, not Procedures

Principles, not Procedures

One of the marks of a successful problem-solver is a habit of applying general principles to every new problem…


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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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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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“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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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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Indicators, Recorders, Process Switches and Alarms

Indicators, Recorders, Process Switches and Alarms

So far we have just looked at instruments that sense, control, and influence process variables. Transmitters,…


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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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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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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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Weighfeeders

Weighfeeders

A special type flowmeter suited for powdered or granular solids is the weighfeeder. One of the most common…


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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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