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Effectiveness of Combining Feedforward and PID Control Strategies in Industrial Applications

PLC /

1. Introduction In industrial process control, disturbances such as sudden changes in input or load conditions can significantly affect system stability. While PID controllers are widely used for maintaining process setpoints, combining them with feedforward control can enhance responsiveness and reduce output fluctuations. This paper discusses how feedforward and PID control can work together, using […]

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Solving Operational Challenges and Internal Leakage in Large-Diameter Globe Valves

Valve /

1. Why Are Large Globe Valves Difficult to Operate? For globe valves with diameters of DN200 and above, manual operation becomes significantly more difficult due to increased resistance. The average horizontal torque an adult can apply is approximately 60–90 kg, depending on physical strength. Standard globe valves are designed for flow direction from low to

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When Do Interlocks Fail? Root Causes and Engineering Countermeasures

PLC /

Overview Safety Instrumented Systems (SIS) are the final line of defense in chemical and process industries. They protect personnel, equipment, and the environment from hazardous events by automatically transitioning processes into safe states under abnormal conditions such as overpressure, overtemperature, or high level alarms. However, interlocks can fail due to various reasons, often resulting in

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Grounding Standards for Instrumentation in Chemical Plants

Instrumentation /

1. Why Instrument Grounding Matters In chemical production environments, instrumentation systems serve as the “eyes and brain” for monitoring and controlling processes, while grounding systems act as the “lifeline” for operational safety and stability. Improper grounding can result in signal interference, data distortion, or even catastrophic incidents such as fires and explosions. Grounding is essential

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When and Why to Use an Inclined Impulse Line for Pressure/Temperature Instruments

Instrumentation /

In industrial environments, especially those involving dusty, viscous, or condensable media, accurate and reliable measurement of pressure and temperature requires more than just selecting the right sensor. The design and installation orientation of the impulse line (short tapping pipe or stub) plays a critical role in ensuring consistent readings and preventing blockage or drift. One

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Maintenance Guidelines for Pressure Switches

Pressure Transmitter /

1. Pre-Operation Preparation and Safety Confirmation 1.1 Communication & Work Permits Coordinate with process personnel to confirm that pressure switch removal will not trigger system interlocks, shutdowns, or abnormal process conditions. Ensure control systems are in “manual” mode or interlocks are bypassed. Obtain necessary work permits such as: Equipment Maintenance Permit Hot Work Permit (if

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Precautions for Pressure Gauge Maintenance and Inspection

Pressure Transmitter /

Pressure gauges are critical instruments for monitoring pressure in various industrial systems. To ensure measurement accuracy, personnel safety, and equipment reliability, it is essential to follow standardized procedures during maintenance and inspection. This guide outlines key precautions and best practices. 1. Safety Preparation 🔌 Power Isolation and Pressure Release Disconnect power supply to related equipment

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How to Select Flowmeters for Different Liquid Media

Flow meter /

In industries such as chemical processing, water treatment, energy, and food manufacturing, liquid flow measurement is a critical part of process automation. However, liquid media can vary greatly in properties—such as conductivity, viscosity, purity, or corrosiveness—so selecting the right flowmeter requires a comprehensive understanding of both the fluid and the working conditions. This guide provides

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Precision in Industrial Temperature Control: The Critical Role of Thermocouple Calibration and Verification

Thermocouples /

From the scorching furnaces of steelmaking plants to the intricate reactors of chemical processing, and even the thermal protection systems of aerospace vehicles, accurate temperature measurement is vital. It directly influences product quality, operational safety, and technological innovation. As one of the most widely used temperature sensors in industry, the metrological performance of thermocouples plays

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