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Abstract In modern process industries, most equipment and system failures can be traced back to a limited set of underlying causes. This article summarizes the seven most common factors that affect industrial automation and control systems, explains their impact, and provides recommended countermeasures for engineers and maintenance teams. 1. Measurement Signal Problems Accurate measurement is […]

Abstract In modern industrial production, automation instruments are key tools for process monitoring, control, and safety assurance. To ensure accurate identification, rational arrangement, and efficient management of numerous instruments, the industry widely adopts instrument tag numbers as a standardized method of identification.This article explains the significance of tag numbers, common compilation rules, international standards, and

Abstract The immersion depth of industrial temperature sensors such as thermocouples, resistance temperature detectors (RTDs), and bimetallic thermometers directly affects the accuracy and reliability of measurement. Despite clear guidelines in standards such as SH/T 3005-2016, inconsistent practices are often observed in engineering applications. This article summarizes the principles of thermometer immersion depth, analyzes common misconceptions,

In industrial projects such as boilers, pressure vessels, and chemical processing equipment, the same material grade may be specified in different product forms (pipes, fittings, forgings, castings, and plates). To ensure consistency in design and procurement, engineers often need to cross-reference material standards. The following table provides an equivalency overview for commonly used American standards.

Abstract This case study describes a packaging system failure in a polyacrylamide production line, triggered by an accidental disconnection of a weighing sensor during routine cleaning. The incident highlights the importance of preventive maintenance and operational discipline in industrial environments. Root cause analysis, corrective actions, and preventive measures are discussed to provide guidance for similar

Abstract Real-Time Optimization (RTO), Advanced Process Control (APC), and Self-Optimizing Control (SOC) are complementary approaches in hierarchical control structures. While RTO aims to deliver economically optimal setpoints, APC translates them into feasible tactical targets, and PID controllers execute the actions. This paper reviews their interrelationship, practical boundaries, and economic feasibility, with examples from process industries.

Abstract Water hammer (hydraulic shock) is a common yet often underestimated phenomenon in both industrial and municipal fluid systems. It can cause serious damage, including instrument failure, flange deformation, and pipeline rupture. This article explains the principles, mechanisms, case studies, international standards, engineering protection strategies, and future development directions for water hammer prevention and control.

Abstract Instrument lifecycle management is a systematic and digitalized approach that treats the entire process of an instrument—from design to disposal—as one integrated chain. By connecting data and ensuring collaborative management across each stage, organizations can achieve safety, reliability, cost efficiency, and regulatory compliance. 1. Lifecycle Stages of Industrial Instruments 1.1 Design & Selection Requirement