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Technical Case Study Failure Indication of RF Admittance Level Switch

Level switch /

1. Case Overview Instrument Type: RF Admittance Level Switch Failure Type: Abnormal indication in control room (intermittent alarms, unstable signal). Application: Installed below a pulverized coal bag filter, used for low-level detection of coal powder mixed with inert gas. Objective: To detect coal powder accumulation and trigger timely discharge to storage silo, preventing excessive build-up. […]

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Step Two of Instrument Management: Periodic Inspection, Calibration, and Preventive Maintenance

Instrumentation /

Introduction After completing the first step of instrument management—establishing a comprehensive and accurate instrument ledger—we hold in hand a precise “map” and “directory” of all devices. However, static data alone cannot ensure reliability. The true value of the ledger lies in transforming this information into systematic actions. The second step of instrument management is to

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Reevaluating Industry Metrics: Advancing PID Tuning and Automation for Optimal Performance

PLC /

Recently, during my service visit to a refining and chemical enterprise in Shandong, I had the opportunity to examine multiple systems where PID tuning had been previously conducted by various companies. It is evident that the industry has made significant advancements in PID tuning practices. However, there remains a considerable gap in the capability to

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Typical Pneumatic Circuit Configurations for Control Valves

Valve /

1. Introduction Control valves are the final control elements in process automation, typically consisting of an actuator, valve body, internal trim, and accessories.Accessories such as positioners, solenoid valves, quick exhaust valves, and air reservoirs are critical in ensuring reliability, safety, and fast response. This document summarizes the key accessories and demonstrates typical pneumatic circuit configurations

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Comparison Between 24V DC and 220V AC Solenoid Valves

Valve /

1. Introduction Solenoid valves are widely used actuators in industrial process control. Their performance and safety characteristics are closely related to the type of power supply. The two most common options are 24V DC (direct current) and 220V AC (alternating current) solenoid valves. This article provides a systematic comparison between the two, covering power supply,

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Level Instrument Selection Guide: Principles, Applications, and Best Practices

Level meter /

1. Definition and Classification of Level In industrial processes, level (liquid level, bulk solid level, and interface) is one of the four key parameters alongside temperature, pressure, and flow. It plays a critical role in production stability, efficiency, equipment safety, energy utilization, and product quality. Liquid Level (Tank/Column/Reservoir): Height of liquid surface. Bulk Solid Level

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Understanding the Components of a Safety Instrumented System (SIS)

PLC /

Safety Instrumented Systems (SIS) play a crucial role in ensuring the safety and reliability of industrial processes. These systems are designed to automatically detect and mitigate hazardous conditions, protecting people, equipment, and the environment. A typical SIS is composed of several key components, each with distinct functions that contribute to the overall safety of industrial

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Operational Management and Control Optimization: Beyond Tools to Real Capability

Instrumentation /

Introduction In operational management and control optimization, I have always emphasized the importance of cross-departmental collaboration and collective problem-solving. A plant that is running steadily already has effective methods in place; what is often missing is a mechanism to identify these methods, standardize them, and then automate them. Advanced tools are not the core contradiction,

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The Importance of Gas Leak Detector Calibration and Verification Methods

Instrumentation /

Abstract Gas leak detectors are critical instruments for ensuring workplace safety, preventing environmental pollution, and protecting human health. However, their accuracy degrades over time due to sensor aging, environmental conditions, or frequent use. Regular calibration is not just a maintenance task—it is a rigorous metrological activity that ensures measurement traceability and reliability. This article explains

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Rethinking PID Loop Tuning: From Isolated Parameters to System Perspective

PLC /

1. Traditional View of PID Tuning In the conventional approach, PID loop tuning is often treated as an isolated single-input, single-output (SISO) problem. The emphasis is placed solely on the controlled process itself. Once the process model is identified, suitable PID parameters can be directly calculated. From this perspective, testing and modeling the process are

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