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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Transmission Control Protocol (TCP) and User Datagram Protocol (UDP)

Transmission Control Protocol (TCP) and User Datagram Protocol (UDP)

At the next OSI Reference Model layer (layer 4) is a set of protocols specifying how reliable communication…


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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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Pneumatic PID Controllers

Pneumatic PID Controllers

A pneumatic controller receives a process variable (PV) signal as a variable air pressure, compares that…


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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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“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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Temperature Sensor Accessories

Temperature Sensor Accessories

One of the most important accessories for any temperature-sensing element is a pressure-tight sheath known as…


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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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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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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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Atomic Theory and Chemical Symbols

Atomic Theory and Chemical Symbols

The three “elementary” particles of matter comprising all atoms are electrons, protons, and…


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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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Analytical Measurements of Chemical Compositions

Analytical Measurements of Chemical Compositions

A great many chemical composition measurements may be made indirectly by means of electricity, if those…


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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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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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Polyphase AC Power

Polyphase AC Power

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


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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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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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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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