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High-reliability Control Systems

High-reliability Control Systems

As discussed at the beginning of this chapter, instrumentation safety may be broadly divided into two…


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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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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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Process/Instrument Suitability

Process/Instrument Suitability

Every flow-measuring instrument exploits a physical principle to measure the flow rate of fluid stream.…


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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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Mechanical Pressure Elements

Mechanical Pressure Elements

Mechanical pressure-sensing elements include the bellows, the diaphragm, and the bourdon tube. Each of these…


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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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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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FOUNDATION Fieldbus H1 Protocol Device Configuration and Commissioning

FOUNDATION Fieldbus H1 Protocol Device Configuration and Commissioning

Fieldbus devices require far more attention in their initial setup and commissioning than their analog…


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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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Level Sensor Accessories

Level Sensor Accessories

Disturbances in the liquid tend to complicate liquid level measurement. These disturbances may result from…


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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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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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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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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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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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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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Safety Instrumented Functions and Systems

Safety Instrumented Functions and Systems

A Safety Instrumented Function, or SIF, is one or more components designed to execute a specific…


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Controller Output Current Loops

Controller Output Current Loops

The simplest form of 4-20 mA current loop is the type used to represent the output of a process controller,…


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Concepts and Laws of Probability

Concepts and Laws of Probability

While the term “probability” may evoke images of imprecision, probability is in fact an exact…


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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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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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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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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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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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Limit, Selector, and Override Controls

Limit, Selector, and Override Controls

Another category of control strategies involves the use of signal relays or function blocks with the ability…


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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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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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Introduction to Power System Automation

Introduction to Power System Automation

Those familiar with industrial instrumentation will find much within the electric power industry remarkably…


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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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Control Valve Characterization

Control Valve Characterization

Control valves are supposed to deliver reliable, repeatable control of process fluid flow rate over a wide…


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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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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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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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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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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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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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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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Pneumatic PID Controllers

Pneumatic PID Controllers

A pneumatic controller receives a process variable (PV) signal as a variable air pressure, compares that…


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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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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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Understanding the Calculus Concepts of Differentiation and Integration

Understanding the Calculus Concepts of Differentiation and Integration

The following animation shows the calculus concepts of differentiation and integration (with respect to time)…


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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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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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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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Single-line Electrical Diagrams

Single-line Electrical Diagrams

Electrical power grids primarily consist of three-phase AC circuits. This means most power lines (transmission…


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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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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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Molecular Quantities

Molecular Quantities

Sample sizes of chemical substances are often measured in moles. One mole of a substance is defined as a…


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Concepts and Laws of Probability

Concepts and Laws of Probability

While the term “probability” may evoke images of imprecision, probability is in fact an exact…


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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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Basics of Bridge Circuits

Basics of Bridge Circuits

A bridge circuit is basically a pair of voltage dividers where the circuit output is taken as the difference…


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Electromagnetism Basics

Electromagnetism Basics

The fundamental principle of electromagnetism is that an electric current will create a magnetic field at…


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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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Basic Operation of a Gas Chromatograph

Basic Operation of a Gas Chromatograph

This animation shows the basic operation of a gas chromatograph, showing the separation of different molecular…


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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 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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Introduction to Power System Automation

Introduction to Power System Automation

Those familiar with industrial instrumentation will find much within the electric power industry remarkably…


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Calibration Standards to Produce and Measure Physical Quantities

Calibration Standards to Produce and Measure Physical Quantities

As previously defined, calibration refers to the checking and adjustment of an instrument so that its output…


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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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