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Tag: PID

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Deep Dive: Calculating Pump Flow Rates and Head Pressure for VFD Control

Calculator 
%%{init: {'theme':'dark', 'themeVariables': { 'background': '#001c38' }}}%%
---
title: Pump System Head Components
---
flowchart TD
    classDef default fill:#1f2937,stroke:#4b5563,color:#f3f4f6
    classDef static fill:#3b82f6,stroke:#2563eb,color:#ffffff
    classDef friction fill:#ef4444,stroke:#b91c1c,color:#ffffff
    classDef total fill:#10b981,stroke:#059669,color:#ffffff
    A["Static Head (Elevation)"]:::static --> C["Total Dynamic Head (TDH)"]:::total
    B["Friction Head (Pipe Loss)"]:::friction --> C
    C --> D["Required Pump Curve"]
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Deep Dive: Calculating Pump Flow Rates and Head Pressure for VFD Control

When an industrial automation engineer is tasked with integrating a Variable Frequency Drive (VFD) for a centrifugal pump, simply wiring the motor and setting a 0-60Hz ramp is insufficient. To properly tune the PID loop and prevent deadheading or cavitation, you must understand the underlying fluid dynamics. The critical metric for sizing and controlling any […]

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PID Controller Tuning: 5 Proven Methods for Stable Control

Learning 
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flowchart LR
    classDef process fill:#1e293b,stroke:#3b82f6,stroke-width:2px,color:#f8fafc
    classDef controller fill:#3b82f6,stroke:#1e293b,stroke-width:2px,color:#f8fafc
    classDef output fill:#10b981,stroke:#047857,stroke-width:2px,color:#f8fafc

    SP["Setpoint"] --> C["PID Controller"]:::controller
    C --> P["Process"]:::process
    P --> PV["Process Variable"]:::output
    PV -->|Feedback| C
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PID Controller Tuning: 5 Proven Methods for Stable Control

Why Control Loops Fail Walk into any process plant, and you’ll find that while PID controllers run over 90% of regulatory loops, a shocking number are left in manual mode by frustrated operators. Why? Because a poorly tuned controller causes more problems than it solves—driving actuators to premature failure, increasing energy costs, and destabilizing the […]

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