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High-reliability Control Systems

High-reliability Control Systems

As discussed at the beginning of this chapter, instrumentation safety may be broadly divided into two…


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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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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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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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Controller Output Current Loops

Controller Output Current Loops

The simplest form of 4-20 mA current loop is the type used to represent the output of a process controller,…


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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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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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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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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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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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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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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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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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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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VSD and VFD Motor Drive Features

VSD and VFD Motor Drive Features

Modern DC and AC motor drives provide features useful when using electric motors as final control elements.…


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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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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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On/off Electric Motor Control Circuits

On/off Electric Motor Control Circuits

An electric motor is often used as a discrete control element in a control system if driving a pump, conveyor…


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Basic Feedback Control Principles

Basic Feedback Control Principles

Feedback Control System Components Before we begin our discussion on process control, we must define a few key…


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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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Metering Pumps

Metering Pumps

A very common method for directly controlling low flow rates of fluids is to use a device known as a metering…


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Relation Control

Relation Control

A control strategy similar to ratio control is relation control. This is similar to ratio control in that a…


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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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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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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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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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National Institute of Standards and Technology (NIST) Traceability

National Institute of Standards and Technology (NIST) Traceability

As defined previously, calibration means the comparison and adjustment (if necessary) of an instrument’s…


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Functional Diagrams: the Flow of Information within a Control System

Functional Diagrams: the Flow of Information within a Control System

A unique form of technical diagram for describing the abstract functions comprising a control system (e.g. PID…


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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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Dimensional Analysis

Dimensional Analysis

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


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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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FOUNDATION Fieldbus H1 Protocol Device Configuration and Commissioning

FOUNDATION Fieldbus H1 Protocol Device Configuration and Commissioning

Fieldbus devices require far more attention in their initial setup and commissioning than their analog…


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Chemical Reactor Temperature Control Example

Chemical Reactor Temperature Control Example

Sometimes we encounter a diversity of instrument signal standards in one control system. Such is the case with…


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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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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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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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Temperature Switches

Temperature Switches

A temperature switch is one detecting the temperature of some substance. Temperature switches often use…


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Weight-based Level Measurement

Weight-based Level Measurement

Weight-based level instruments sense process level in a vessel by directly measuring the weight of the vessel.…


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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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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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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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Weight-based Level Measurement

Weight-based Level Measurement

Weight-based level instruments sense process level in a vessel by directly measuring the weight of the vessel.…


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P, I, and D Responses Graphed

P, I, and D Responses Graphed

Visualizing the actions of P, I, and D tuning parameters using graphs is extremely useful in predicting the…


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Bi-metal Temperature Sensors

Bi-metal Temperature Sensors

Solids tend to expand when heated. The amount that a solid sample will expand with increased temperature…


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Common Diagnostic Mistakes in Control Systems

Common Diagnostic Mistakes in Control Systems

Volumes could be written about poor diagnostic technique. The following mistakes are not intended to comprise…


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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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WirelessHART Radio Communication Standard

WirelessHART Radio Communication Standard

An exciting development in industrial instrumentation is the WirelessHART radio communication standard,…


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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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What is Electrical Power?

What is Electrical Power?

Since we often use electricity to convey energy from one location to another, it is important to be able to…


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The s Variable: Euler’s Relation and Phasor Expressions of Waveforms

The s Variable: Euler’s Relation and Phasor Expressions of Waveforms

A powerful mathematical concept useful for analyzing practically any physical system – electrical…


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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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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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Periodic Table of the Ions

Periodic Table of the Ions


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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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Introduction to Power System Automation

Introduction to Power System Automation

Those familiar with industrial instrumentation will find much within the electric power industry remarkably…


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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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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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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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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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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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