A Fully Updated, Practical Guide to Automated Process Control and Measurement Systems This thoroughly revised guide offers students a solid grounding in process control principles along with real-world applications and insights from the factory floor. Written by an experienced engineering educator, Fundamentals of Industrial Instrumentation and Process Control, Second Edition is written in a clear, logically organized manner. The book features realistic problems, real-world examples, and detailed illustrations. You’ll get clear explanations of digital and analog components, including pneumatics, actuators, and regulators, and comprehensive discussions on the entire range of industrial processes.  Fundamentals of Industrial Instrumentation and Process Control, Second Edition covers:•Pressure•Level•Flow•Temperature and heat•Humidity, density, viscosity, & pH•Position, motion, and force•Safety and alarm•Electrical instruments and conditioning•Regulators, valves, and actuators•Process control•Documentation and symbol standards•Signal transmission•Logic gates•Programmable Logic controllers•Motor control•And much more

Table of Contents:
Preface Acknowledgment 1 Introduction Chapter Objectives 1.1 Introduction 1.1.1 History 1.2 Process Control 1.3 Definition of the Elements in a Control Loop 1.4 Process Facility Considerations 1.5 Units and Standards 1.6 Instrument Accuracy Summary Problems 2 Pressure Chapter Objectives 2.1 Introduction 2.2 Basic Terms 2.2.1 Density 2.2.2 Impact Pressure 2.3 Pressure Measurements 2.4 Pressure Formulas 2.5 Measuring Instruments 2.5.1 Manometers 2.5.2 Diaphragms, Capsules, and Bellows 2.5.3 Bourdon Tubes 2.5.4 Other Pressure Sensors 2.5.5 Vacuum Instruments 2.6 Application Considerations 2.6.1 Selection 2.6.2 Installation 2.6.3 Calibration Summary Problems 3 Level Chapter Objectives 3.1 Introduction 3.2 Level Formulas 3.3 Level Sensing Devices 3.3.1 Direct Level Sensing 3.3.2 Indirect Level Sensing 3.4 Application Considerations Summary Problems 4 Flow Chapter Objectives 4.1 Introduction 4.2 Basic Terms 4.3 Flow Formulas 4.3.1 Continuity Equation 4.3.2 Bernoulli Equation 4.3.3 Flow Losses 4.4 Flow Measurement Instruments 4.4.1 Flow Rate 4.4.2 Total Flow 4.4.3 Mass Flow 4.4.4 Dry Particulate Flow Rate 4.4.5 Open Channel Flow 4.5 Application Considerations 4.5.1 Selection 4.5.2 Installation 4.5.3 Calibration Summary Problems 5 Temperature and Heat Chapter Objectives 5.1 Introduction 5.2 Basic Terms 5.2.1 Temperature Definitions 5.2.2 Heat Definitions 5.2.3 Thermal Expansion Definitions 5.3 Temperature and Heat Formulas 5.3.1 Temperature 5.3.2 Heat Transfer 5.3.3 Thermal Expansion 5.4 Temperature Measuring Devices 5.4.1 Thermometers 5.4.2 Pressure-Spring Thermometers 5.4.3 Resistance Temperature Devices 5.4.4 Thermistors 5.4.5 Thermocouples 5.4.6 Semiconductors 5.5 Application Considerations 5.5.1 Selection 5.5.2 Range and Accuracy 5.5.3 Thermal Time Constant 5.5.4 Installation 5.5.5 Calibration 5.5.6 Protection Summary Problems 6 Humidity, Density, Viscosity, and pH Chapter Objectives 6.1 Introduction 6.2 Humidity 6.2.1 Humidity Definitions 6.2.2 Humidity Measuring Devices 6.3 Density and Specific Gravity 6.3.1 Basic Terms 6.3.2 Density Measuring Devices 6.3.3 Density Application Considerations 6.4 Viscosity 6.4.1 Basic Terms 6.4.2 Viscosity Measuring Instruments 6.5 pH Measurements 6.5.1 Basic Terms 6.5.2 pH Measuring Devices 6.5.3 pH Application Considerations Summary Problems 7 Position, Motion, and Force Chapter Objectives 7.1 Introduction 7.2 Position and Motion Sensing 7.2.1 Basic Position Definitions 7.2.2 ON/OFF Position Sensing 7.2.3 Motion and Distance Sensing 7.2.4 Rotation Sensing 7.2.5 Position Application Consideration 7.3 Force, Torque, and Load Cells 7.3.1 Basic Definitions of Force and Torque 7.3.2 Force and Torque Measuring Devices 7.3.3 Force and Torque Application Considerations Summary Problems 8 Safety and Alarm Chapter Objectives 8.1 Introduction 8.2 Safety Hazards 8.2.1 Personnel Hazards 8.2.2 Environmental Hazards 8.2.3 Control Equipment Hazards 8.2.4 Process Equipment Hazards 8.3 Safety Sensors 8.3.1 Smoke and Fire Sensors 8.3.2 Heat Sensors 8.3.3 Gas Sensors 8.3.4 Artificial Senses Chemical Sensors 8.3.5 Radiation Detectors 8.4 Process Equipment Safety 8.4.1 Alarm and Trip Systems 8.4.2 Safety Instrumented Systems 8.4.3 Power Loss Fail Safe 8.4.4 Safety Instrumented System Example 8.5 Safety and Protection 8.5.1 Personnel Protection 8.5.2 Environmental Protection 8.5.3 Equipment Protection Summary Problems 9 Electrical Instruments and Conditioning Chapter Objectives 9.1 Introduction 9.2 Instrument Parameters 9.2.1 Basic Terms 9.3 Transducers 9.3.1 Definitions 9.3.2 Visual Display Considerations 9.3.3 Mechanical Motion to Electrical Transducers 9.4 Operational Amplifiers 9.4.1 Voltage Amplifiers 9.4.2 Current Amplifiers 9.4.3 Differential Amplifiers 9.4.4 Converters 9.4.5 Buffer Amplifiers 9.4.6 Nonlinear Amplifiers 9.4.7 Instrument Amplifier 9.5 Signal Conditioning 9.5.1 Offset Zero 9.5.2 Span Adjustment 9.5.3 Linearization in Analog Circuits 9.5.4 Linearization in Digital Circuits 9.5.5 Temperature Correction 9.6 Bridge Circuits 9.6.1 DC Bridges 9.6.2 Current-Balanced Bridge 9.6.3 Strain Gauge Sensors 9.6.4 AC Bridges 9.6.5 Capacitive Sensors 9.6.6 Resistance Sensors 9.6.7 Magnetic Sensors Summary Problems 10 Regulators, Valves, and Actuators Chapter Objectives 10.1 Introduction 10.2 Pressure Controllers 10.2.1 Regulators 10.2.2 Safety Valves 10.2.3 Level Regulators 10.3 Flow Control Actuators 10.3.1 Globe Valve 10.3.2 Flow Control 10.3.3 Butterfly Valve 10.3.4 Other Valve Types 10.3.5 Valve Characteristics 10.3.6 Valve Fail Safe 10.4 Actuators 10.4.1 Operation 10.4.2 Control Valves 10.5 Electronic Devices 10.6 Application Considerations 10.6.1 Valves Summary Problems 11 Process Control Chapter Objectives 11.1 Introduction 11.2 Basic Terms 11.3 Control Modes 11.3.1 ON/OFF Action 11.3.2 Differential Action 11.3.3 Proportional Action 11.3.4 Derivative Action 11.3.5 Integral Action 11.3.6 PID Action 11.4 Implementation of Control Loops 11.4.1 ON/OFF Action Pneumatic Controller 11.4.2 ON/OFF Action Electrical Controller 11.4.3 PID Action Pneumatic Controller 11.4.4 PID Action Control Circuits 11.4.5 PID Electronic Controller 11.5 Digital Controllers Summary Problems 12 Documentation and Symbol Standards Chapter Objectives 12.1 Introduction 12.2 System Documentation 12.2.1 Manuals 12.2.2 Alarm and Trip System Documentation 12.2.3 Safety Documentation 12.2.4 PLC Documentation 12.2.5 Circuit Diagrams 12.2.6 Bussing Information 12.3 Pipe and Identification Diagrams 12.3.1 Standardization 12.3.2 Interconnections 12.3.3 Instrument Symbols 12.3.4 Instrument Identification 12.4 Functional Symbols 12.4.1 Actuators 12.4.2 Primary Elements 12.4.3 Regulators 12.4.4 Math Functions 12.5 P and ID Drawings Summary Problems 13 Signal Transmission Chapter Objectives 13.1 Introduction 13.2 Pneumatic Transmission 13.3 Analog Transmission 13.3.1 Noise Considerations 13.3.2 Voltage Signals 13.3.3 Current Signals 13.3.4 Signal Conversion 13.3.5 Thermocouples 13.3.6 Resistance Temperature Devices 13.4 Digital Transmission 13.4.1 Transmission Standards 13.4.2 Smart Sensors 13.4.3 Foundation Fieldbus and Profibus 13.5 Digital Signal Converters 13.5.1 Analog-to-Digital Conversion 13.5.2 Digital-to-Analog Conversion 13.6 Telemetry 13.6.1 Width Modulation 13.6.2 Frequency Shift Modulation Summary Problems 14 Logic Gates Chapter Objectives 14.1 Introduction 14.2 Digital Numbers 14.2.1 Converting Binary Numbers to Decimal Numbers 14.2.2 Converting from Decimal to Binary 14.3 Digital Logic Gates 14.3.1 Buffer Gate 14.3.2 AND Gate 14.3.3 OR Gate 14.3.4 NOT Gate 14.3.5 Signal Inversion 14.3.6 XOR Gates 14.3.7 Logic Symbols 14.4 Boolean Algebra 14.5 Functional Building Blocks Summary Problems 15 Programmable Logic Controllers Chapter Objectives 15.1 Introduction 15.2 Programmable Controller 15.3 Controller Operation 15.4 Input and Output Modules 15.4.1 Discrete Input Modules 15.4.2 Analog Input Modules 15.4.3 Special Function Input Modules 15.4.4 Discrete Output Modules 15.4.5 Analog Output Modules 15.4.6 Smart Input and Output Modules 15.5 Ladder Diagrams 15.5.1 Input and Output Symbols 15.5.2 Ladder Layout 15.5.3 Ladder Gate Equivalent 15.5.4 Ladder Applications Summary Problems 16 Motor Control Chapter Objectives 16.1 Introduction 16.2 Motor Classification 16.3 Motor Operation 16.3.1 DC Motors 16.3.2 AC Motors 16.3.3 Single-Phase Motor 16.3.4 Three-Phase Motors 16.3.5 Universal Motors 16.3.6 Stepping Motors 16.3.7 Servomotors and Synchro Motors 16.4 Motor Ratings 16.4.1 Electrical Ratings 16.4.2 Control Equipment Ratings 16.4.3 Enclosure Standards 16.5 Motor Control Applications 16.5.1 Two- and Three-Wire Starting 16.5.2 Startup Control 16.5.3 Wound Rotor Motor 16.5.4 Speed Control 16.5.5 DC Motor 16.5.6 Actuator Control 16.5.7 Stepper Motor 16.6 Motor Protection Summary Problems A Units B Thermocouple Tables C References and Information Resources D Abbreviations Glossary Answers to Odd-Numbered Questions Index