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Emergency Handling of DCS Failures in Process Industries

1. Introduction In chemical, petrochemical, and power industries, the Distributed Control System (DCS) acts as the central nervous system of the plant. It monitors process parameters, executes interlocks, and ensures stable operations.A DCS failure often means loss of process control: from partial shutdowns to plant-wide outages, or even major safety incidents. For this reason, operators, […]

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Seismic Protection Guidelines for Instrumentation Systems

To ensure the safety and reliability of instrumentation and control systems during seismic events, the following measures shall be adopted: 1. Anchoring of Instrument Equipment Instrumentation equipment such as control cabinets, auxiliary cabinets, instrument panels, instrument boxes, junction boxes, and field instruments shall be firmly fixed to floors or ground using foundations and supports.This prevents

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Application of Radar Level Meters on Coal Mill Conveyors

In modern coal-fired power plants and coal chemical production, accurate level measurement is critical for ensuring continuous and efficient operations. Specifically, precise monitoring of the material level on coal mill conveyors is essential not only for maintaining the stable operation of equipment but also for enhancing production efficiency and safety. This article will discuss the

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Zero Drift in Level Instruments: Causes, Risks, and Solutions

Level instruments are among the most fundamental and critical process control devices in the process industry. They act as the “eyes of the tank,” continuously monitoring level changes in storage tanks, towers, and pipelines. However, field engineers often encounter a common issue during inspections: “The tank is clearly empty, but the level gauge does not

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Zero Drift in Level Meters: Causes, Risks, and Solutions

1. Introduction In process industries, level meters are among the most fundamental and critical instruments. They serve as the “eyes” of tanks, columns, and pipelines, continuously monitoring liquid level variations. However, many engineers encounter the following issue during routine inspections: “The tank is clearly empty, but the level meter does not indicate zero!” This is

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Environmental Protection in Industrial Instrumentation

Environmental sustainability and occupational safety are inseparable elements of modern process industries. Instrumentation plays a critical role in monitoring hazardous substances, controlling emissions, and ensuring compliance with environmental regulations. The following guidelines summarize best practices for instrumentation in environmentally sensitive applications. 1. Combustible and Toxic Gas Detection 1.1 Fixed Gas Detection In locations where combustible

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Key Considerations for Acceptance of Instrumentation Installation in Chemical Plants

1. Introduction Instrumentation in chemical plants serves as the core of process control, safety monitoring, and quality assurance. The acceptance of instrumentation installation directly affects the stability, safety, and accuracy of subsequent operations.Acceptance must strictly follow the “Code for Construction and Quality Acceptance of Automation Instrumentation Engineering” (GB 50093-2013) and special chemical industry regulations (e.g.,

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SIS Inspection Checklist for Chemical Industries

Introduction In high-risk sectors such as chemical, petrochemical, and gas industries, the Safety Instrumented System (SIS) is the final layer of protection. However, design flaws, poor maintenance, and misuse of bypass functions can render this defense ineffective. This document provides a standardized, lifecycle-based SIS inspection checklist, covering design, installation, operation, maintenance, assessment, and documentation. It

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Maintenance Guide for Pressure Transmitters

1. Introduction Pressure transmitters are widely used in process industries to convert pressure signals of gases or liquids into standardized electronic signals (typically 4–20 mA DC). These signals are then transmitted to secondary instruments such as indicators, recorders, controllers, or DCS systems for process monitoring and control. This guide summarizes practical maintenance insights, common troubleshooting

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Calculating the Volume of Instrument Gas Storage Tanks for Chemical Plants

Calculating the volume of a storage tank used for instrument gas in chemical plants is a crucial step for ensuring the safe and efficient operation of equipment. Accurate volume calculations not only help in meeting operational requirements but also play an important role in adhering to safety standards and optimizing costs. Here’s an in-depth look

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