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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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Integral (Reset) Control

Integral (Reset) Control

Imagine a liquid-level control system for a vessel, where the position of a level-sensing float sets the…


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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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Measuring Electrical Conductivity

Measuring Electrical Conductivity

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


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Techniques for Analyzing Control Strategies

Techniques for Analyzing Control Strategies

Control strategies such as cascade, ratio, feedforward, and those containing limit and selector functions can…


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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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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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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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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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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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Phasor Analysis of Transformer Circuits

Phasor Analysis of Transformer Circuits

Three-phase AC is the dominant mode of electric power generation and distribution in modern societies.…


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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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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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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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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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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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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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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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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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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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FOUNDATION Fieldbus H1 Protocol Data Link Layer

FOUNDATION Fieldbus H1 Protocol Data Link Layer

Like so many other industrial data networks, FOUNDATION Fieldbus is an “unswitched” or…


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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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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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New Content

New Content

Coy, John J. et. al. (December 2012) Sampled graphic illustrations from his NASA Reference Publication…


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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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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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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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Quantitative PID Tuning Procedures

Quantitative PID Tuning Procedures

A quantitative PID tuning procedure is a step-by-step approach leading directly to a set of numerical values…


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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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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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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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FOUNDATION Fieldbus H1 Protocol Segment Troubleshooting

FOUNDATION Fieldbus H1 Protocol Segment Troubleshooting

Feedback obtained from industrial users of FF reveal a common pattern: Fieldbus is a powerful and reliable…


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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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Wastewater Disinfection Example

Wastewater Disinfection Example

The final step in treating wastewater before releasing it into the natural environment is to kill any harmful…


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What are Simple Machines?

What are Simple Machines?

A machine in the broad sense of the word is any device designed to translate some form of energy into useful…


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Digital PID Algorithms

Digital PID Algorithms

Instrument technicians should not have to concern themselves over the programming details internal to digital…


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Diagnosing Feedback Control Problems

Diagnosing Feedback Control Problems

Negative feedback systems, in general, tend to cause confusion for those first learning their fundamental…


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Non-dispersive Luft Detector Spectroscopy

Non-dispersive Luft Detector Spectroscopy

Non-dispersive analysis, while newer in discovery than dispersive analysis (Isaac Newton’s 17th-century…


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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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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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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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Radiation Level Measurement

Radiation Level Measurement

Certain types of nuclear radiation easily penetrates the walls of industrial vessels, but is attenuated by…


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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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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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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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Using Manometers for Measuring Pressure

Using Manometers for Measuring Pressure

A very simple device used to measure pressure is the manometer: a fluid-filled tube where an applied gas…


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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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Digital Representation of Numerical Data

Digital Representation of Numerical Data

Process measurements are often of an analog nature: the temperature of a furnace, the rate of fluid flow…


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Non-dispersive Luft Detector Spectroscopy

Non-dispersive Luft Detector Spectroscopy

Non-dispersive analysis, while newer in discovery than dispersive analysis (Isaac Newton’s 17th-century…


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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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Pressure Switches

Pressure Switches

A pressure switch is one detecting the presence of fluid pressure. Pressure switches often use diaphragms or…


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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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Unit Conversions and Physical Constants

Unit Conversions and Physical Constants

Converting between disparate units of measurement is the bane of many science students. The problem is worse…


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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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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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Capacitive Level Measurement

Capacitive Level Measurement

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


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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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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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