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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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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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Filled-bulb Temperature Sensors

Filled-bulb Temperature Sensors

Filled-bulb systems exploit the principle of fluid expansion to measure temperature. If a fluid is enclosed in…


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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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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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Interconnected Generators

Interconnected Generators

Any power grid large enough to meet the demand of an entire nation must have multiple generators drawing from…


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Bi-metal Temperature Sensors

Bi-metal Temperature Sensors

Solids tend to expand when heated. The amount that a solid sample will expand with increased temperature…


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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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Chromatography: Methods, Detectors and Species

Chromatography: Methods, Detectors and Species

Imagine a major marathon race, where hundreds of runners gather in one place to compete. When the starting gun…


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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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Transmission Control Protocol (TCP) and User Datagram Protocol (UDP)

Transmission Control Protocol (TCP) and User Datagram Protocol (UDP)

At the next OSI Reference Model layer (layer 4) is a set of protocols specifying how reliable communication…


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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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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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Conservation Laws

Conservation Laws

The Law of Mass Conservation states that matter can neither be created nor destroyed. The Law of Energy…


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Force-balance Pressure Transmitters

Force-balance Pressure Transmitters

An important legacy technology for all kinds of continuous measurement is the self-balancing system. A…


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Velocity-based Flowmeters

Velocity-based Flowmeters

The Law of Continuity for fluids states that the product of mass density (\(\rho\)), cross-sectional pipe area…


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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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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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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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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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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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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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What is Internet Protocol (IP)?

What is Internet Protocol (IP)?

I remember first learning about the world-wide Internet, and wondering what it actually looked like. The first…


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References

References

Lipták, Béla G. et al., Instrument Engineers’ Handbook – Process Measurement and Analysis Volume I,…


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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…


Textbook

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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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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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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Vibration Physics

Vibration Physics

One very convenient feature of waves is that their properties are universal. Waves of water in the ocean,…


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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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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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Differential Pressure Transmitters

Differential Pressure Transmitters

One of the most common, and most useful, pressure measuring instruments in industry is the differential…


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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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Structured Text (ST) Programming

Structured Text (ST) Programming

(Will be addressed in future versions of this book)


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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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Polyphase AC Power

Polyphase AC Power

“Polyphase” means “many phases,” describing a form of AC electrical system where…


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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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The HART Digital/Analog Hybrid Standard

The HART Digital/Analog Hybrid Standard

A technological advance introduced in the late 1980’s was HART, an acronym standing for Highway…


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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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Electrical Resistance and Ohm’s Law

Electrical Resistance and Ohm’s Law

To review, voltage is the measure of potential energy available to electric charges. Current is the uniform…


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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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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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Flow Measurement from Differential Pressure

Flow Measurement from Differential Pressure

Take for instance the problem of measuring fluid flow through a pipe. To the layperson, this may seem to be a…


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Atomic Theory and Chemical Symbols

Atomic Theory and Chemical Symbols

The three “elementary” particles of matter comprising all atoms are electrons, protons, and…


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Legal Code

Legal Code

Creative Commons Attribution 4.0 International Public License By exercising the Licensed Rights (defined…


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Loop Diagrams (Loop Sheets)

Loop Diagrams (Loop Sheets)

Finally, we arrive at the loop diagram (sometimes called a loop sheet) for the compressor surge control system…


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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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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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Temperature Switches

Temperature Switches

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


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Problem-solving by Simplification

Problem-solving by Simplification

A whole class of problem-solving techniques focuses on altering the given problem into a simpler form that is…


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