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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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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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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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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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Concepts and Laws of Probability

Concepts and Laws of Probability

While the term “probability” may evoke images of imprecision, probability is in fact an exact…


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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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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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Different PID Equations

Different PID Equations

For better or worse, there are no fewer than three different forms of PID equations implemented in modern PID…


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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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Capacitive Level Measurement

Capacitive Level Measurement

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


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Self-balancing Pneumatic Instruments Principles

Self-balancing Pneumatic Instruments Principles

A great many precision instruments use the principle of balance to measure some quantity. Perhaps the simplest…


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How Derivatives and Integrals Relate to One Another

How Derivatives and Integrals Relate to One Another

First, let us review some of the properties of differentials and derivatives, referencing the expression and…


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Process and Instrument Diagrams

Process and Instrument Diagrams

The next level of detail is the Process and Instrument Diagram, or P&ID. Here, we see a “zooming…


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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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How to Teach Yourself PLC Programming

How to Teach Yourself PLC Programming

Learning PLC programming is a very important skill. If your job involves programming, then you will likely…


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Level Sensor Accessories

Level Sensor Accessories

Disturbances in the liquid tend to complicate liquid level measurement. These disturbances may result from…


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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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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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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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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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The Difference Between Series and Parallel Circuits

The Difference Between Series and Parallel Circuits

In addition to Ohm’s Law, we have a set of rules describing how voltages, currents, and resistances…


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Resistance, Reactance and Impedance

Resistance, Reactance and Impedance

Electrical Resistance Resistance (\(R\)) is the dissipative opposition to an electric current, analogous to…


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Design-based Fortifications

Design-based Fortifications

A design-based fortification is one rooted in technical details of system architecture and functionality. Some…


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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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Instrument and Process Equipment Symbols

Instrument and Process Equipment Symbols

This section shows some of the many instrument symbols found in different types of technical diagrams used to…


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Control Valve Sizing

Control Valve Sizing

When control valves operate between fully open and fully shut, they serve much the same purpose in process…


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Disassembling a Globe Valve

Disassembling a Globe Valve

The following collection of photographs chronicles the complete disassembly of a Fisher E-body globe valve…


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Digital Representation of Text

Digital Representation of Text

Binary patterns are not just able to represent numerical values. Given a standardized code, they may represent…


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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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Fundamental Principles of Industrial Instrumentation

Fundamental Principles of Industrial Instrumentation

Shown here is a partial listing of principles applied in the subject matter of this chapter, given for the…


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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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Transmitter Damping Adjustments

Transmitter Damping Adjustments

The vast majority of modern process transmitters (both analog and digital) come equipped with a feature known…


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Rotary-stem Valves

Rotary-stem Valves

A different strategy for controlling the flow of fluid is to insert a rotary element into the flow path.…


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Proper Care and Feeding of Pneumatic Instruments

Proper Care and Feeding of Pneumatic Instruments

Perhaps the most important rule to obey when using pneumatic instruments is to maintain clean and dry…


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Thermocouple Types, Junctions, Connector and Tip Styles

Thermocouple Types, Junctions, Connector and Tip Styles

RTDs are completely passive sensing elements, requiring the application of an externally-sourced electric…


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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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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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Vibration Sensors

Vibration Sensors

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


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Valve Seat Leakage

Valve Seat Leakage

In some process applications, it is important that the control valve be able to completely stop fluid flow…


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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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Basics of pH Measurement in Industrial Control

Basics of pH Measurement in Industrial Control

Hydrogen ion activity in aqueous (water-solvent) solutions is a very important parameter for a wide variety of…


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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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Pneumatic Sensing Elements

Pneumatic Sensing Elements

Most pneumatic instruments use a simple but highly sensitive mechanism for converting mechanical motion into…


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