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the Negative Consequences of Poor PID Controller Tuning

the Negative Consequences of Poor PID Controller Tuning

Much has been written about the benefits of robust PID control. Increased productivity, decreased equipment…


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A Comparison of PID Controller Tuning Techniques

A Comparison of PID Controller Tuning Techniques

In this section I will show screenshots from a process loop simulation program illustrating the effectiveness…


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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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Ratio Control

Ratio Control

Most people reading this book have likely had the experience of adjusting water temperature using two hand…


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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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Material Volume Measurement

Material Volume Measurement

A variety of technologies exist to measure the quantity of stored material in a vessel. For liquid…


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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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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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Ultrasonic (Sound) Echo Level Measurement

Ultrasonic (Sound) Echo Level Measurement

A completely different way of measuring liquid level in vessels is to bounce a traveling wave off the surface…


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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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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 Packing

Valve Packing

Regardless of valve type, all stem-actuated control valves require some form of seal allowing motion of the…


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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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The Stuxnet Virus

The Stuxnet Virus

In November of 2007 a new computer virus was submitted to a virus scanning service. The purpose of this new…


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Directional Overcurrent (67) Protection

Directional Overcurrent (67) Protection

While 50 and 51 (instantaneous and time overcurrent) relay functions monitor line current magnitude and guard…


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Policy-based Fortifications

Policy-based Fortifications

These fortifications focus on human behavior rather than system design or component selection. In some ways…


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Ions in Liquid Solutions

Ions in Liquid Solutions

Many liquid substances undergo a process whereby their constituent molecules split into positively and…


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The International System of Units

The International System of Units

The very purpose of physics is to quantitatively describe and explain the physical world in as few terms as…


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Overpressure Protection Devices

Overpressure Protection Devices

Fluid pressure exerts force on any surface area it contacts, as described by the formula \(F = PA\). One…


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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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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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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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Techniques for Analyzing Control Strategies

Techniques for Analyzing Control Strategies

Control strategies such as cascade, ratio, feedforward, and those containing limit and selector functions can…


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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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Radio-energy Pulse in Guided-wave Radar Level Measurement

Radio-energy Pulse in Guided-wave Radar Level Measurement

The following animation shows how a radio-energy pulse travels down and then up the waveguide of a guided-wave…


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Electrical Signal and Control Wiring

Electrical Signal and Control Wiring

There is much to be said for neatness of assembly in electrical signal wiring. Even though the electrons…


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Input/Output (I/O) Capabilities of PLCs

Input/Output (I/O) Capabilities of PLCs

Every programmable logic controller must have some means of receiving and interpreting signals from real-world…


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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 Modbus

Introduction to Modbus

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


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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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Use of Line Reactors

Use of Line Reactors

Regulating the electric power sent to an electric motor is a task performed by high-speed switching…


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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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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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National Institute of Standards and Technology (NIST) Traceability

National Institute of Standards and Technology (NIST) Traceability

As defined previously, calibration means the comparison and adjustment (if necessary) of an instrument’s…


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Digital PID Algorithms

Digital PID Algorithms

Instrument technicians should not have to concern themselves over the programming details internal to digital…


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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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Capacitive Level Measurement

Capacitive Level Measurement

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


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FOUNDATION Fieldbus H1 Protocol Physical Layer

FOUNDATION Fieldbus H1 Protocol Physical Layer

Layer 1 of the OSI Reference Model is where we define the “physical” elements of a digital data…


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Proportional-only Control

Proportional-only Control

Imagine a liquid-level control system for a vessel, where the position of a level-sensing float directly sets…


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Dimensional Analysis

Dimensional Analysis

An interesting parallel to the “unity fraction” unit conversion technique is something referred to…


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Positive Displacement Flowmeters

Positive Displacement Flowmeters

A positive displacement flowmeter is a cyclic mechanism built to pass a fixed volume of fluid through with…


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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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Calibration Standards to Produce and Measure Physical Quantities

Calibration Standards to Produce and Measure Physical Quantities

As previously defined, calibration refers to the checking and adjustment of an instrument so that its output…


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