The Control Systems Engineer Technical Reference Handbook is a practical, exam-focused reference designed for both aspiring and practicing instrumentation, automation and electrical engineers. It organizes essential engineering topics aligned with the Control Systems Engineering (CSE) Professional Engineering exam.
This handbook covers fundamental mathematics and physics refreshers, measurement and sensor technologies (such as temperature, flow, level and analytical instruments), signals and networking (including cabling, protocols and fieldbuses), final control elements, motors, control system design and documentation, loop tuning, alarm management, safety systems and applicable codes and standards.
Additionally, it explains uninterrupted power supply (UPS) topologies and provides numerous diagrams, tables, formulas and real-world examples. Ideal for students preparing for the CSE PE exam and professionals seeking a compact field reference, the book combines concise theory with practical guidance and recommended resources.
Table of Contents:
PREFACE xiii
ABOUT THE AUTHOR xv
ACKNOWLEDGMENTS xvii
ACRONYMS xix
COMMON ELECTRICAL DEFINITIONS xxiii
1. CSE PE EXAM – GENERAL INFORMATION 1
2. MISCELLANEOUS REVIEW MATERIAL 3
2.1 Mathematics 3
2.2 Thermodynamics 14
2.3 Statistics 22
2.4 Boolean Logic Operations 24
2.5 Conversion Factors 26
2.6 Equations/Laws/Formulas 29
3. MEASUREMENT 35
Topic Highlights 35
3.1 Temperature Measurement Sensors 35
3.2 Pressure Measurement Sensors 45
3.3 Volumetric Flow Measurement Sensors 49
3.4 Level Measurement Sensors 72
3.5 Analytical Measurement Sensors 86
4. SIGNALS, TRANSMISSION AND NETWORKING 107
4.1 Signals/Transmission 107
4.2 Networking 115
4.3 Circuit Calculations 134
5. FINAL CONTROL ELEMENTS 149
5.1 Control Valves 149
5.2 Actuators 166
5.3 Control Valve Sizing 171
5.4 Pressure Regulators 175
5.5 Motors 181
5.6 Variable Frequency Drives (VFDs) 205
5.7 Pressure Safety Devices 207
5.8 Relays/Switches 219
6. CONTROL SYSTEMS 223
6.1 Documentation 223
6.2 Control System - Controller Actions 231
6.3 Controller (Loop) Tuning 238
6.4 Function Block Diagram Reduction Algebra 246
6.5 Alarm Management 250
6.6 Types of Control System Programming 254
6.7 Batch Control 272
6.8 Advanced Control Techniques 279
6.9 Example Process Controls 281
7. ISA-95 285
7.1 ISA-95 Hierarchy Model 285
7.2 ISA-88 Physical Model As It Pertains to ISA-95 286
7.3 Levels 4–3 Information Exchange 286
8. HAZARDOUS AREAS AND SAFETY INSTRUMENTED SYSTEMS 287
8.1 Hazardous Areas 287
8.2 Safety Instrumented Systems (SIS) 299
8.3 Determining PFD (Probability of Failure on Demand) 302
9. CODES, STANDARDS AND REGULATIONS 307
9.1 Standards Listings 307
9.2 NEC 315
9.3 NEMA/IEC-IP Enclosure Classifications 328
9.4 NFPA 70E Electrical Safety in the Workplace: 330
9.5 Lightning Protection 336
10. SAMPLE PROBLEMS 341
11. SAMPLE PROBLEMS - SOLUTIONS 351
12. MISCELLANEOUS TABLES/INFORMATION 357
12.1 Viscosity Equivalency Nomograph 357
12.2 Copper Resistance Table (Table 12-1) 358
12.3 RTD Resistance Tables 359
12.4 Thermocouple milliVolt Tables 369
12.5 Instrument Air Quality 375
12.6 Thevenin & Norton Equivalencies 376
13. UNINTERRUPTIBLE POWER SUPPLY (UPS) 387
13.1 UPS Topologies 387
13.2 Inverter Technologies 388
13.3 Mechanical Flywheel 388
14. RECOMMENDED RESOURCES 391
About the Author :
Charles Cornell is a Senior Process Control Systems Engineering Manager with over 30 years of engineering experience in automation, instrumentation and electrical. Charles is a licensed professional engineer in the state of NC in both Control Systems and Electrical-Power. Charles is also an ISA Certified Automation Professional (CAP) as well as a PMI certified Project Management Professional (PMP).
Charles is a member of ISA, NSPE, PMI and the CSE PAKS Committee.
