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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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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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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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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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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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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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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 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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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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Valve Positioners

Valve Positioners

The reason why a pneumatic control valve’s stem position corresponds linearly to the amount of air…


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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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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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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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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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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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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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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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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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Radiation Level Measurement

Radiation Level Measurement

Certain types of nuclear radiation easily penetrates the walls of industrial vessels, but is attenuated by…


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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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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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“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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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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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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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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Pressure Sensor Accessories

Pressure Sensor Accessories

Multiple accessories exist for pressure-sensing devices to function optimally in challenging process…


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Classical Mechanics

Classical Mechanics

Classical mechanics (often called Newtonian mechanics in honor of Isaac Newton) deal with forces and motions…


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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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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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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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Rotating Magnetic Fields in Three-phase AC Induction Motors

Rotating Magnetic Fields in Three-phase AC Induction Motors

The following animation shows how the “rotating” magnetic field of a three-phase AC induction…


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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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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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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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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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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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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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Electromagnetism Basics

Electromagnetism Basics

The fundamental principle of electromagnetism is that an electric current will create a magnetic field at…


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Filled-bulb Temperature Sensors

Filled-bulb Temperature Sensors

Filled-bulb systems exploit the principle of fluid expansion to measure temperature. If a fluid is enclosed in…


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Change-of-quantity Flow Measurement

Change-of-quantity Flow Measurement

Flow, by definition, is the passage of material from one location to another over time. So far this chapter…


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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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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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Capacitive Level Measurement

Capacitive Level Measurement

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


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Applications of Spectroscopy for Analytical Measurement

Applications of Spectroscopy for Analytical Measurement

Much of our knowledge about atomic structure comes from experimental data relating the interaction between…


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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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Null-balance Voltage Measurement

Null-balance Voltage Measurement

A number of different sensors used in instrumentation generate DC voltage signals proportional to the process…


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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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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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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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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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Thermistors and Resistance Temperature Detectors (RTDs)

Thermistors and Resistance Temperature Detectors (RTDs)

One of the simplest classes of temperature sensor is one where temperature effects a change in electrical…


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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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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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Safety Gas Analyzers

Safety Gas Analyzers

Process analyzers measure the concentration of specific substances for the purpose of measuring and/or…


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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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Practical Topic Coverage

Practical Topic Coverage

Nearly every technical course teaches and tests students on definitions, basic concepts, and at least some…


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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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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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