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Circuit Breakers and Disconnects

Circuit Breakers and Disconnects

Disconnect Switches Disconnects are switches designed to isolate sections of a power system in case of damage…


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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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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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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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Logic Programming in PLCs

Logic Programming in PLCs

Although it seems each model of PLC has its own idiosyncratic standard for programming, there does exist an…


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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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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 Basics of Control Relays

The Basics of Control Relays

An electromechanical relay is an electrical switch actuated by an electromagnet coil. As switching devices,…


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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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Calibration Errors and Testing

Calibration Errors and Testing

The efficient identification and correction of instrument calibration errors is an important function for…


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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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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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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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Non-contact Temperature Sensors

Non-contact Temperature Sensors

Virtually any mass above absolute zero temperature emits electromagnetic radiation (photons, or light) as a…


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Laser Spectroscopy

Laser Spectroscopy

A laser is a light source emitting waves of light that not only share the exact same frequency (color)…


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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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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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Interposing Relays in PLCs

Interposing Relays in PLCs

In addition to directly performing logic functions, electromechanical relays may also be used as interposing…


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Open-ended, Shorted and Properly Terminated Transmission Lines

Open-ended, Shorted and Properly Terminated Transmission Lines

Many years ago, when I was first learning about electricity, I happened to discover a length of coaxial…


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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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Capacitive Level Measurement

Capacitive Level Measurement

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


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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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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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4-wire “Passive” Versus “Active” Output Transmitters

4-wire “Passive” Versus “Active” Output Transmitters

Some self-powered (4-wire) analog electronic transmitters are designed to behave as electrical loads rather…


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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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Distance (21) Protection

Distance (21) Protection

A form of protection against faults on long-distance power lines is called distance relaying, so named because…


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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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Mathematical Problem-solving Techniques

Mathematical Problem-solving Techniques

Some problem-solving techniques are unique to quantitative problems, involving mathematical calculations. In…


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Assessing Student Learning

Assessing Student Learning

As a general rule, high achievement only takes place in an atmosphere of high expectations. Sometimes these…


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Sequential Function Chart (SFC) Programming

Sequential Function Chart (SFC) Programming

(Will be addressed in future versions of this book)


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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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Analyzer Sample Systems

Analyzer Sample Systems

Some analyzers measure the composition of a process stream by directly immersing the sensing element in that…


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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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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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Electronic Structure

Electronic Structure

Earlier in this chapter you were shown a model of a nitrogen atom with a dense nucleus (comprised of protons…


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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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Interposing Relays in PLCs

Interposing Relays in PLCs

In addition to directly performing logic functions, electromechanical relays may also be used as interposing…


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Instruction List (IL) Programming

Instruction List (IL) Programming

(Will be addressed in future versions of this book)


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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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Calibration Procedures in Linear, Non-Linear and Discrete Instruments

Calibration Procedures in Linear, Non-Linear and Discrete Instruments

As described earlier in this chapter, calibration refers to the adjustment of an instrument so its output…


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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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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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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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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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Stoichiometry and the Law of Mass Conservation

Stoichiometry and the Law of Mass Conservation

Stoichiometry is the accounting of atoms before and after a chemical reaction. It is an expression of the Law…


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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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Motives for Compromising the Security of an Industrial Control System

Motives for Compromising the Security of an Industrial Control System

There are multiple motives for compromising the security of an industrial control system, some of which…


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Calibration Procedures in Linear, Non-Linear and Discrete Instruments

Calibration Procedures in Linear, Non-Linear and Discrete Instruments

As described earlier in this chapter, calibration refers to the adjustment of an instrument so its output…


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Troubleshooting Current Loops

Troubleshooting Current Loops

A fundamental principle in instrumentation system troubleshooting is that every instrument has at least one…


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Examples of PLC Systems

Examples of PLC Systems

Programmable logic controllers are essentially nothing more than special-purpose, industrial computers. As…


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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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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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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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Continuous Float Level Transmitters

Continuous Float Level Transmitters

Perhaps the simplest form of solid or liquid level measurement is with a float: a device that rides on the…


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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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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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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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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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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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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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