PLC

In the field of industrial automation, many engineers—including myself—often wonder: How should a control optimization project truly be executed? After years of hands-on experience, countless project iterations, and learning from industry veterans, I have developed a clearer understanding of the guiding principles. While this is not a definitive methodology, these insights have significantly improved both […]

From the perspective of process operations, automatic control systems can significantly reduce manual intervention while enhancing safety and efficiency. Consequently, organizations generally strive to implement automatic control wherever possible. However, in practice, many installations fail to achieve the desired level of automation due to various constraints. Simply focusing on increasing the automation rate through performance

Modern industrial automation has evolved significantly from basic single-loop control to advanced, multi-loop control systems. In practice, processes often require more sophisticated control methods due to dynamic interactions, non-linear behaviors, and varying disturbances. This article explores six widely used types of complex control loops, highlighting their principles, structures, benefits, and typical applications. 1. Cascade Control

In industrial automation projects, Distributed Control Systems (DCS) serve as the backbone of plant operations. Proper planning for I/O (Input/Output) modules and controller spare capacity is critical for ensuring system scalability, reliability, and maintenance flexibility. Overlooking this aspect can result in serious challenges during plant expansion or system upgrades. This article provides a detailed guide

To strengthen the management of control systems and ensure the safe, stable operation of instrumentation control systems such as DCS (Distributed Control System), SIS (Safety Instrumented System), and PLC (Programmable Logic Controller), this management policy is established. It aims to improve the environment of the control cabinet room, facilitate system maintenance, and prevent accidents effectively.

IntroductionIn process control design, there are countless “standard solutions” widely accepted in textbooks and control system guidelines. However, real-world applications often present unique constraints, legacy configurations, and operator habits that challenge theoretical ideals. A mature and pragmatic control engineer must learn not to rigidly impose theoretical models but instead respect existing operational knowledge—especially when current

In the realm of industrial automation and process control, safety is paramount, especially when dealing with critical systems where human lives and significant assets are at stake. Three key concepts related to functional safety often come up: SIL (Safety Integrity Level), SIS (Safety Instrumented System), and SIF (Safety Instrumented Function). These terms form the backbone

1. Function of Terminal Boxes in SIS Systems In the wiring process of Safety Instrumented Systems (SIS), terminal boxes are commonly used for connection and signal distribution. They play a crucial role in simplifying wiring structures and enhancing system flexibility, particularly in complex process automation systems. The primary functions of terminal boxes in SIS systems

1. Introduction In industrial process control, ensuring operational safety and stability under abnormal or limiting conditions is a crucial challenge. Traditional methods for handling such non-standard operating conditions typically include emergency shutdowns or manual intervention. However, these approaches are often reactive rather than proactive. Selective control systems represent a more advanced solution by proactively switching

In industrial process control, whether a solution is perceived as “simple” or “difficult” often depends not only on technical complexity but also on how well the underlying problem is understood. Based on our practical experience in chemical plants, here are insights into what makes a control strategy effective—or frustrating—and how engineering mindset, collaboration, and empathy