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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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Digital Multimeter (DMM) Tips and Tricks

Digital Multimeter (DMM) Tips and Tricks

The digital multimeter (DMM) is quite possibly the most useful tool in the instrument technician’s…


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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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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Constructing PID control systems using discrete components is a fairly simple method involving operational…


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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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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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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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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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Applications of Spectroscopy for Analytical Measurement

Applications of Spectroscopy for Analytical Measurement

Much of our knowledge about atomic structure comes from experimental data relating the interaction between…


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Antennas and Resonant Circuits (Tank Circuits)

Antennas and Resonant Circuits (Tank Circuits)

Capacitors store energy in electric fields, proportional to the square of voltage. Inductors store energy in…


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Common Control Valve Problems

Common Control Valve Problems

Valves can experience a number of problems, most of them either preventable or repairable. These problems can…


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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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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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Actuator Bench-set

Actuator Bench-set

Valve actuators provide force to move control valve trim. For precise positioning of a control valve, there…


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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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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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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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Auxiliary and Lockout (86) Relays

Auxiliary and Lockout (86) Relays

An important type of “accessory” relay, especially for legacy electromechanical protective relays,…


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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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Teaching Diagnostic Principles and Practices

Teaching Diagnostic Principles and Practices

Diagnostic ability is arguably the most difficult skill to develop within a student, and also the most…


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Hand Switches and Stackable Switches

Hand Switches and Stackable Switches

A hand switch is exactly what the name implies: an electrical switch actuated by a person’s hand motion.…


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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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Analog Electronic PID Controllers

Analog Electronic PID Controllers

Constructing PID control systems using discrete components is a fairly simple method involving operational…


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Feedforward with Dynamic Compensation

Feedforward with Dynamic Compensation

As we have seen, feedforward control is a way to improve the stability of a feedback control system in the…


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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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General Problem-solving Techniques

General Problem-solving Techniques

A variety of problem-solving techniques have been presented for students over the years which are all helpful…


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Understanding How Three-phase Electric Motors Work

Understanding How Three-phase Electric Motors Work

The key to understanding how three-phase electric motors work is to have an accurate mental picture of the…


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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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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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Feedforward Control

Feedforward Control

“Feedforward” is a rather under-used control strategy capable of managing a great many types of…


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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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Weight-based Level Measurement

Weight-based Level Measurement

Weight-based level instruments sense process level in a vessel by directly measuring the weight of the vessel.…


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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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What is Hydrostatic Pressure?

What is Hydrostatic Pressure?

A vertical column of fluid generates a pressure at the bottom of the column owing to the action of gravity on…


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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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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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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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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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Memory Maps and I/O Addressing

Memory Maps and I/O Addressing

A wise PLC programmer once told me that the first thing any aspiring programmer should learn about the PLC…


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Periodic Table of the Ions

Periodic Table of the Ions


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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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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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Energy in Chemical Reactions

Energy in Chemical Reactions

A chemical reaction resulting in a net release of energy is called exothermic. Conversely, a chemical reaction…


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Fluid Power Systems

Fluid Power Systems

Given the ability of pressurized fluids to transmit force over long distances, it is not surprising that many…


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Symbolic Versus Numerical Calculus

Symbolic Versus Numerical Calculus

Calculus has a reputation for being difficult to learn, and with good reason. The traditional approach to…


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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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Measuring Electrical Conductivity

Measuring Electrical Conductivity

The electrical conductivity of liquids is an important analytical measurement in many industrial processes.…


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Error Corrections

Error Corrections

Abdelaziz, Ahmed (June 2014) Identified numerous typographical errors throughout the book, mostly repeated…


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Sliding-stem Valves

Sliding-stem Valves

A sliding-stem valve body is one where the moving parts slide with a linear motion. Some examples of…


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Supervisory Control

Supervisory Control

In a manually-controlled process, a human operator directly actuates some form of final control element…


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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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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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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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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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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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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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Teaching Diagnostic Principles and Practices

Teaching Diagnostic Principles and Practices

Diagnostic ability is arguably the most difficult skill to develop within a student, and also the most…


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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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Pneumatic Actuator Response

Pneumatic Actuator Response

A limitation inherent to pneumatic valve actuators is the amount of air flow required to or from the actuator…


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Level Gauges (Sightglasses)

Level Gauges (Sightglasses)

Level gauges are perhaps the simplest indicating instrument for liquid level in a vessel. They are often found…


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