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Common Failures in Terminal Blocks and How to Address Them

PLC /

Terminal blocks are critical components in electrical and electronic systems, providing secure connections for transmitting voltage, current, or signals. However, various issues can arise during their use, impacting performance and reliability. This article discusses common terminal block failures, their causes, and preventive measures. 1. Contact Failure The metallic conductor within a terminal block is the […]

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Should a DCS System Include an Emergency Shutdown Button?

PLC /

1. Background During a recent safety inspection organized by the Municipal Emergency Management Bureau, one of the reviewing experts insisted that enterprises should add an automatic (emergency) shutdown function in the Distributed Control System (DCS) and configure a corresponding software button on the operator interface. As a participant in this inspection, I raised an objection.

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Understanding the Differences Between Modbus TCP/IP and Profinet

PLC /

Industrial automation relies heavily on robust communication protocols to ensure that devices and control systems work seamlessly together. Among the most widely adopted are Modbus TCP/IP and Profinet. While both leverage Ethernet as their physical layer, their design philosophies, performance characteristics, and application scenarios differ significantly. 1. Origins and Basic Concepts Modbus TCP/IP Originally developed

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Precautions for Installing Instrument Impulse Lines

Instrumentation /

1. Introduction Importance of correct impulse line installation for measurement accuracy, safety, and long-term reliability. Typical consequences of improper installation: gas/liquid accumulation, measurement drift, leakage, or instrument damage. 2. Adaptation to Process Media 2.1 Liquid Service Impulse lines should slope toward the instrument with a minimum gradient of 1:100 to prevent gas accumulation. Pressure tapping

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The Critical Role of Radar Level Meters in Measuring Dissolution Tanks for Food Processing

Level meter /

In the food processing industry, the dissolution process of raw materials in dissolution tanks has a direct impact on the quality of the final product. As an advanced non-contact level measurement technology, radar level meters have become widely used in various complex environments due to their high accuracy, stability, and strong anti-interference capabilities, including in

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How to Select the Proper Waveguide for Guided Wave Radar (GWR) Level Transmitters

Level meter /

Introduction Guided Wave Radar (GWR) transmitters rely on waveguides to direct the propagation of electromagnetic pulses into the measured medium. The choice of waveguide type has a significant impact on signal quality, measurement accuracy, installation feasibility, and maintenance effort. This document introduces the three common waveguide types—rigid rod, flexible cable, and coaxial tube—and provides selection

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Why Two Level Gauges Are Essential: A Case Study on Condenser Hotwell Installation

Level meter /

1. Background In steam turbine operation, condenser hotwell water level is a critical parameter. A stable level ensures: Reliable condensate pump operation without cavitation. Adequate condenser cooling area to maintain vacuum efficiency. If the hotwell level is too low, condensate pumps may cavitate. If it is too high, condenser vacuum deteriorates, leading to unsafe turbine

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Straight Pipe Requirements for Orifice Plate Flowmeters

Flow meter /

1. Basic Requirements The accuracy of an orifice plate flowmeter largely depends on sufficient straight pipe runs upstream and downstream of the orifice plate. General recommendations are: Upstream straight pipe: ≥ 10D (D = internal pipe diameter) Downstream straight pipe: ≥ 5D These values represent minimum requirements under normal conditions. 2. Influencing Factors and Special

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Why PLC Systems Use 24V DC: The Industry’s Golden Standard

PLC /

Programmable Logic Controllers (PLCs) are at the core of industrial automation. Among all supply voltages, 24V DC has become the global standard. This choice is not accidental—it is the result of careful consideration of safety, stability, electromagnetic compatibility, energy efficiency, universality, and cost-effectiveness. 1. Enhanced Safety Safety is the top priority in industrial environments. 24V

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Common Instrumentation Wires and Cables in Industrial Automation

Instrumentation /

1. Introduction Instrumentation serves as the “nervous system” of industrial automation, while cables and wires act as the “blood vessels” that transmit signals and energy. Proper selection and installation of cables directly affect the stability, accuracy, and reliability of measurement systems.This document introduces four commonly used types of instrumentation cables and provides engineering recommendations. 2.

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