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Boiler Water Level Control System Example

Boiler Water Level Control System Example

Steam boilers are very common in industry, principally because steam power is so useful. Common uses for steam…


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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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“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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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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Differential (87) Current Protection

Differential (87) Current Protection

One of the fundamental laws of electric circuits is Kirchhoff’s Current Law, which states the algebraic…


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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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Pressure Sensor Accessories

Pressure Sensor Accessories

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


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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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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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Digital Data Communication Theory

Digital Data Communication Theory

One of the great benefits of digital technology is the ability to communicate vast amounts of information over…


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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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Introduction to Modbus

Introduction to Modbus

Developed by the Modicon company (the original manufacturer of the Programmable Logic Controller, or PLC) in…


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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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Human-Machine Interfaces (HMIs)

Human-Machine Interfaces (HMIs)

Human-machine interfaces, or HMIs, are a critical part of nearly all control systems, complementing the…


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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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Fiber Optic Data Communication

Fiber Optic Data Communication

Light has long been used as a long-range signaling medium. While communication by light through open air is…


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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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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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Analog to Digital Conversion and ADCs

Analog to Digital Conversion and ADCs

In order to provide an interface between the internal (digital) world of a computer and the external (analog)…


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Vibration Monitoring Hardware

Vibration Monitoring Hardware

The following photograph shows a large air blower in a wastewater treatment facility equipped with a…


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Industrial Instrumentation Summary for Teachers

Industrial Instrumentation Summary for Teachers

To summarize some of the key points and concepts for teaching: Do not waste class time transmitting facts to…


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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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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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Proportional-only Offset

Proportional-only Offset

A fundamental limitation of proportional control has to do with its response to changes in setpoint and…


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Valve Failure Modes

Valve Failure Modes

An important design parameter of a control valve is the position it will “fail” to if it loses…


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Vibration Sensors

Vibration Sensors

Sensors used to measure vibration come in three basic types: displacement, velocity, and acceleration.…


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Understanding the Calculus Concepts of Differentiation and Integration

Understanding the Calculus Concepts of Differentiation and Integration

The following animation shows the calculus concepts of differentiation and integration (with respect to time)…


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Zero and Span Adjustments (Analog Instruments)

Zero and Span Adjustments (Analog Instruments)

Linearity of Measurement Instruments The purpose of calibration is to ensure the input and output of an…


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Radiative Temperature Measurement

Radiative Temperature Measurement

Temperature measurement devices may be classified into two broad types: contact and non-contact. Contact-type…


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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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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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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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Gas Filter Correlation (GFC) Spectroscopy

Gas Filter Correlation (GFC) Spectroscopy

Using filter cells to eliminate wavelengths associated with interfering gases is called positive filtering in…


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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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ANSI/IEEE Function Number Codes

ANSI/IEEE Function Number Codes

In the United States, the ANSI and IEEE organizations have standardized a set of numerical codes referring to…


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Formulae for Common Chemical Compounds

Formulae for Common Chemical Compounds

Most of these formulae appear in molecular chemical form rather than structural form. For example, ethanol…


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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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On/off Shut-off Valves

On/off Shut-off Valves

An on/off valve is the fluid equivalent of an electrical switch: a device that either allows unimpeded flow or…


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LRV and URV Settings, Digital Trim (Digital Transmitters)

LRV and URV Settings, Digital Trim (Digital Transmitters)

The advent of “smart” field instruments containing microprocessors has been a great advance for…


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Heuristic PID Tuning Procedures

Heuristic PID Tuning Procedures

In contrast to quantitative tuning procedures where definite numerical values for P, I, and D controller…


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