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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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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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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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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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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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Non-contact Temperature Sensors

Non-contact Temperature Sensors

Virtually any mass above absolute zero temperature emits electromagnetic radiation (photons, or light) as a…


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DC Motor Speed Control

DC Motor Speed Control

DC electric motors generate torque by a reaction between two magnetic fields: one field established by…


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Limit Switches

Limit Switches

A limit switch detects the physical motion of an object by direct contact with that object. An example of a…


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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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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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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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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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AC Motor Braking

AC Motor Braking

There are several different methods useful for causing an AC induction motor to brake, or slow down: DC…


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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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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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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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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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Non-dispersive Luft Detector Spectroscopy

Non-dispersive Luft Detector Spectroscopy

Non-dispersive analysis, while newer in discovery than dispersive analysis (Isaac Newton’s 17th-century…


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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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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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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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Practical Measures of Reliability

Practical Measures of Reliability

In reliability engineering, it is important to be able to quantity the reliability (or conversely, the…


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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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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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Laminar Flowmeters

Laminar Flowmeters

A unique form of differential pressure-based flow measurement deserves its own section in this flow…


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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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Flow Measurement from Differential Pressure

Flow Measurement from Differential Pressure

Take for instance the problem of measuring fluid flow through a pipe. To the layperson, this may seem to be a…


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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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Problem-solving by Simplification

Problem-solving by Simplification

A whole class of problem-solving techniques focuses on altering the given problem into a simpler form that is…


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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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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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Level Switches

Level Switches

A level switch is one detecting the level of liquid or solid (granules or powder) in a vessel. Level switches…


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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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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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Understanding Area, Volume and Common Geometry

Understanding Area, Volume and Common Geometry

Area refers to the size of two-dimensional surface. Volume refers to the size of a three-dimensional space. To…


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DC Motor Speed Control

DC Motor Speed Control

DC electric motors generate torque by a reaction between two magnetic fields: one field established by…


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Standardized Volumetric Flow

Standardized Volumetric Flow

The majority of flowmeter technologies operate on the principle of interpreting fluid flow based on the…


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Laser Spectroscopy

Laser Spectroscopy

A laser is a light source emitting waves of light that not only share the exact same frequency (color)…


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Electronic Structure

Electronic Structure

Earlier in this chapter you were shown a model of a nitrogen atom with a dense nucleus (comprised of protons…


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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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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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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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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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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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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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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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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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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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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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Sliding-stem Valves

Sliding-stem Valves

A sliding-stem valve body is one where the moving parts slide with a linear motion. Some examples of…


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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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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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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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Relating 4 to 20 mA Signals to Instrument Variables

Relating 4 to 20 mA Signals to Instrument Variables

A 4 to 20 mA current signal represents some signal along a 0 to 100 percent scale. Usually, this scale is…


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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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Level Sensor Accessories

Level Sensor Accessories

Disturbances in the liquid tend to complicate liquid level measurement. These disturbances may result from…


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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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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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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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Basic Operation of a Gas Chromatograph

Basic Operation of a Gas Chromatograph

This animation shows the basic operation of a gas chromatograph, showing the separation of different molecular…


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