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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Introduction to Optical Analysis

Introduction to Optical Analysis

Light is known to interact with matter in very specific ways, which may be exploited as a means of measuring…


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Introduction to Protective Relaying

Introduction to Protective Relaying

Circuit breakers used in residential, commercial, and light industrial service are self-tripping devices: they…


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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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Wastewater Disinfection Example

Wastewater Disinfection Example

The final step in treating wastewater before releasing it into the natural environment is to kill any harmful…


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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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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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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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The Concept of Differentiation

The Concept of Differentiation

Suppose we wished to measure the rate of propane gas flow through a hose to a torch: Flowmeters appropriate…


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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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Instrument Identification Tags

Instrument Identification Tags

Up until this point, we have explored various types of instrumentation diagram, each one making reference to…


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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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Temperature Switches

Temperature Switches

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


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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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Pressure Sensor Accessories

Pressure Sensor Accessories

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


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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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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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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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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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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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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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