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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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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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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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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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Classified Areas and Electrical Safety Measures

Classified Areas and Electrical Safety Measures

Any physical location in an industrial facility harboring the potential of explosion due to the presence of…


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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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Ethernet networks: Repeaters, Cabling and Switching Hubs

Ethernet networks: Repeaters, Cabling and Switching Hubs

An engineer named Bob Metcalfe conceived the idea of Ethernet in 1973, while working for the Xerox research…


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Transfer Function Analysis

Transfer Function Analysis

An extremely important topic in engineering is that of transfer functions. Simply defined, a transfer function…


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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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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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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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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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Relay Circuits and Ladder Diagrams

Relay Circuits and Ladder Diagrams

Electromechanical relays may be connected together to perform logic and control functions, acting as logic…


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Introduction to Inductors and Inductance

Introduction to Inductors and Inductance

Any conductor possesses a characteristic called inductance: the ability to store energy in the form of a…


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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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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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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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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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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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Measuring Electrical Conductivity

Measuring Electrical Conductivity

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


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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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Electrical Pressure Elements

Electrical Pressure Elements

Several different technologies exist for the conversion of fluid pressure into an electrical signal response.…


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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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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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Classified Areas and Electrical Safety Measures

Classified Areas and Electrical Safety Measures

Any physical location in an industrial facility harboring the potential of explosion due to the presence of…


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Flow Switches

Flow Switches

A flow switch is one detecting the flow of some fluid through a pipe. Flow switches often use…


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Analog to Digital Conversion and ADCs

Analog to Digital Conversion and ADCs

In order to provide an interface between the internal (digital) world of a computer and the external (analog)…


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Basics of Electrical Current

Basics of Electrical Current

Current is the name we give to the motion of electric charges from a point of high potential to a point of low…


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PID Control Terminology

PID Control Terminology

PID control can be a confusing concept to understand. Here, a brief summary of each term within PID (P. I, and…


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Null-balance Voltage Measurement

Null-balance Voltage Measurement

A number of different sensors used in instrumentation generate DC voltage signals proportional to the process…


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The s Variable: Euler’s Relation and Phasor Expressions of Waveforms

The s Variable: Euler’s Relation and Phasor Expressions of Waveforms

A powerful mathematical concept useful for analyzing practically any physical system – electrical…


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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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Instantaneous and Time-overcurrent (50/51) Protection

Instantaneous and Time-overcurrent (50/51) Protection

Perhaps the most basic and necessary protective relay function is overcurrent: commanding a circuit breaker to…


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Variable-area Flowmeters

Variable-area Flowmeters

An variable-area flowmeter is one where the fluid must pass through a restriction whose area increases with…


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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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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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FOUNDATION Fieldbus Design Philosophy

FOUNDATION Fieldbus Design Philosophy

To understand just how different FOUNDATION Fieldbus is from other digital instrument systems, consider a…


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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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Learn Fundamental Principles, not Procedures

Learn Fundamental Principles, not Procedures

“As to methods there may be a million and then some, but principles are few. The man who grasps…


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4 to 20 mA Analog Current Signals

4 to 20 mA Analog Current Signals

The most popular form of signal transmission used in modern industrial instrumentation systems (as of this…


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Chemiluminescence Measurement

Chemiluminescence Measurement

Recall that an exothermic chemical reaction is one that releases a net sum of energy, as opposed to an…


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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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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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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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Comparison of  Op-Amp Circuits With Analogous Pneumatic Mechanisms

Comparison of Op-Amp Circuits With Analogous Pneumatic Mechanisms

Self-balancing pneumatic instrument mechanisms are very similar to negative-feedback operational amplifier…


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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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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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Fluorescence Measurement

Fluorescence Measurement

When a high-energy photon strikes an atom, it may eject one of the lower-level electrons from its shell,…


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On/off Control (Bang-bang Control)

On/off Control (Bang-bang Control)

Once while working as an instrument technician in an aluminum foundry, a mechanic asked me what it was that I…


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Relation Control

Relation Control

A control strategy similar to ratio control is relation control. This is similar to ratio control in that a…


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Rotating Phasor in Three-dimensional Form

Rotating Phasor in Three-dimensional Form

The following animation shows a rotating phasor in three-dimensional form. The phasor rotates in a complex…


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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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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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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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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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Numerical Integration

Numerical Integration

As we have seen, the concept of integration is finding the accumulation of one variable multiplied by another…


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2-wire (“loop-powered”) Transmitter Current Loops

2-wire (“loop-powered”) Transmitter Current Loops

It is possible to convey electrical power and communicate analog information over the same two wires using 4…


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Analytical Measurements of Chemical Compositions

Analytical Measurements of Chemical Compositions

A great many chemical composition measurements may be made indirectly by means of electricity, if those…


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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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“Normal” status of a Process Switch

“Normal” status of a Process Switch

Perhaps the most confusing aspect of discrete sensors is the definition of a sensor’s normal status.…


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