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Author Profile
Gregory K. McMillan
271 Results Found
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FeatureHow Can We Improve Data Historian Use?
In the latest edition of the Ask the Automation Pros column, the pros discuss how to set up a data historian to transform data into information that can be used for process monitoring, diagnosis, prediction, optimization and continuous improvement. -
FeatureAsk the Automation Pros: How Can We Enhance Control System Reliability?
In the latest edition of the Ask the Automation Pros column, the pros share strategies for enhancing control system reliability. -
FeatureAsk the Automation Pros: What University Projects Are Needed to Support Process Control?
Like a lot of things in engineering and construction, it’s hard to teach everything and risky not to, but getting it right the first time saves time and money. -
FeatureAsk the Automation Pros: What Are the Process Control Simulation Requirements for Automation Projects?
Simulation of process control can ensure productive automation projects. But how much effort should be allocated to simulation, testing and training. ISA’s Automation Professionals weigh in. -
FeatureAsk the Automation Pros: How Can You Ensure the Best Rate of Change in the PID Manipulated Variable?
What is the best strategy to get the best rate of change in the PID for a manipulated variable, or is there a more elegant solution within the control strategy itself? Answer includes example applications and guidance on how PID tuning can meet objectives. -
FeatureAsk the Automation Pros: What Topics Should Be Covered in an Undergraduate Process Control Course?
In the latest edition of the Ask the Automation Pros column, the pros share their insights on what topics should be covered in an undergraduate first course on process control, particularly in chemical engineering, but possibly also in mechanical and electrical engineering. -
FeatureAsk the Automation Pros: What Are the Prospects for an Autonomous Process Manufacturing Unit?
In the latest edition of the Ask the Automation Pros column, the pros share their insights on prospects for an autonomous process manufacturing unit. -
FeatureData Historians: Turning ‘Digital Landfills’ Into Strategic Assets
ISA Fellows and others discuss what’s needed to turn process data into performance improvement. -
FeatureAsk the Automation Pros: How Can You Get the Most Knowledge from a Data Historian?
In this entry in the Ask the Automation Pros blog series, the pros answer the question of how to get the most knowledge from a data historian. -
FeatureAsk the Automation Pros: What Can Be Done to Improve the Accuracy of Totalized Liquid Mass Charge?
In the latest post in the Ask the Automation Pros blog series, the pros explain what can be done to improve the accuracy of totalized liquid mass charge. -
FeatureAsk the Automation Pros: What Are the Consequences of an Overemphasis on Reducing Project Cost?
In the latest post of the Ask the Automation Pros blog series, the pros discuss potential consequences of an overemphasis on reducing industrial automation project costs. -
FeatureAsk the Automation Pros: How Is Process Control Different from Other Industrial Control Disciplines?
In the latest post of the Ask the Automation Pros blog series, the pros discuss what makes process control different from other industrial control disciplines. -
FeatureAsk the Automation Pros: Useful Books for Process Control
In the latest post of the Ask the Automation Pros blog series, the pros discuss useful books for process control. -
FeatureAsk the Automation Pros: Dealing with Interacting PID Loops
In the latest post of the Ask the Automation Pros blog series, the pros explore how to deal with interacting PID loops. -
FeatureAsk the Automation Pros: The Past and Future of Process Control
In the latest installment of Ask the Automation Pros, the pros take a look at the past and future of process control. -
FeatureAsk the Automation Pros: How Do You Specify the Best Control Valve Characteristics?
The latest installment of the Ask the Automation Pros series from ISA describes what to consider when specifying process control valves. -
FeatureAsk the Automation Pros: Achieving the Best Override Control
The latest installment in the Ask the Automation Pros blog post series addresses how to implement the best override control. -
FeatureAsk the Automation Pros: Achieving the Best Feedforward Control
In the latest installment of Ask the Automation Pros, discover best practices to understand where feedforward control is needed and how to implement it. -
FeatureAsk the Automation Pros: Achieving the Best Cascade Control
In the latest installment of the Ask the Automation Pros blog series, automation professionals share their thoughts on achieving the best cascade control. -
FeatureAsk the Automation Pros: The Use of Artificial Intelligence in Process Control
In the latest installment of the Ask the Automation Pros blog series, experts provide thoughts about the use of artificial intelligence in process control. -
FeatureAsk the Automation Pros: The Need and Use of Simulation in Process Control
In this entry in the Ask the Automation Pros series, automation experts share their thoughts on the need and use of simulation in process control. -
FeatureAsk the Automation Pros: What Are Your Thoughts About the Use of Artificial Intelligence in Process Control?
ISA automation pros including Greg McMillan discuss neural networks, major opportunities for AI today, and potential benefits for enhancing and supporting the daily activities of process control and automation professionals. -
FeatureAsk the Automation Pros: What Are Your Thoughts About the Need for and Use of Simulation in Process Control?
Russ Rhinehart asks the automation pros for their thoughts about the need for and use of simulation in process control. -
FeatureAsk the Automation Pros: What Scan Time Is Needed for Process Control Applications?
Russ Rhinehart asks the automation pros for their thoughts about what scan time is needed in different process control applications. -
FeatureTop 10 Mistakes in pH System Design and How to Avoid Them
This article covers the top 10 major mistakes Greg McMillan has seen in pH design and installation in a neutralizer tank in a waste treatment system. -
FeatureAsk the Automation Pros: How Can We Compute Startup Tuning for New Control Valves?
Greg McMillan discusses how to compute start-up tuning for new control valves. -
FeatureAsk the Automation Pros: How to Best Migrate from Obsolete to Modern Instrumentation and Control Systems?
Greg McMillan discusses how to migrate a project from obsolete to modern versions of instrumentation and control systems. -
FeatureAsk the Automation Pros: How Can We Improve or Eliminate Split Range Control?
Ask the Automation Pros expert Greg McMillan discusses how to improve or eliminate split range control -
FeatureThe 5 W's of Modernizing Control Systems Future
Ask the Automation Pro's Greg McMillan discusses how to modernize control systems -
FeatureWhen are we Modernizing Control Systems?
Greg McMillan of "Ask the Automation Pros" discusses the timeframe on modernization of current control systems -
FeatureDigital Twins for the Virtual Plant
A bioreactor system design example shows a way forward for plant development and process optimization. This feature originally appeared in the December 2023 issue of InTech digital magazine. -
FeatureCan a Primary Loop Manipulate a Secondary Loop Valve?
"Ask the Automation Pros" Greg McMillan discusses if a primary loop can manipulate a secondary loop -
FeatureHow Can we Improve Logic Control Contact Status Awareness and Operator Response?
ISA Mentor Greg McMillan answers the question, "How Can we Improve Logic Control Contact Status Awareness and Operator Response?" -
FeatureHow Do You Get the Best From the People Working on Your Project?
Greg McMillan discusses how to get the best from people working on your project in the "Ask the Automation Pros" -
FeatureAsk the Automation Pros: How Do You Improve Use of Analyzers for Continuous Control?
Greg McMillan discusses how to improve the use of analyzers for continuous control -
FeatureBase, Best, and Ideal Practices for Mill Optimization
Greg McMillan discusses base, best, and ideal practices for mill optimization in his July Mentor post -
FeatureIs Data Noise in Process Control Degrading Performance?
Greg McMillan discusses the topic, "Is data noise in process control degrading performance?" -
Feature
Are We Facing Broad Change?
Greg McMillan and Russ Rhinehart discuss the idea of facing broad change -
FeatureHow Can We Improve Control of Dead Time Dominant Applications?
From Greg McMillan and the ISA Mentor Program team. -
FeatureWhat are Considerations in Combining Process Control and Safety Systems?
From Greg McMillan and the ISA Mentor Program team. -
FeatureWhat are the Diagnostics/Expertise Needed for FOUNDATION Fieldbus?
From Greg McMillan and the ISA Mentor Program team. -
FeatureHow Do We Improve Response to Continuously Changing Conveyor Setpoint?
What would be a good control strategy to regulate a process in which the setpoint is continually changing? -
FeatureWhat Process and Equipment Effects Need More Attention?
How can we better understand how process and equipment design and operating conditions affect automation system design, installation, and performance? -
FeatureWhat is Your Wish List for Achievement and Recognition? Part 2
What is your personal wish list of prospective achievements in process automation? -
FeatureWhat is Your Wish List for Achievement and Recognition? Part 1
What is your personal wish list of prospective achievements in process automation? -
FeatureWhat are the Biggest Mistakes You Have Seen? Part 5
Here we continue our series with some modeling and control mistakes. -
FeatureWhat are the Biggest Mistakes You Have Seen? Part 4
We continue our series with some measurement and final control element mistakes seen by Greg that are widespread. -
FeatureWhat are the Biggest Mistakes You Have Seen? Part 3
What are the biggest mistakes in automation system design, configuration, calibration, installation, checkout, commissioning, and maintenance? -
FeatureWhat are the Biggest Mistakes You Have Seen? Part 2
Mistakes often offer the greatest learning experiences. Mentor program participants share what they have seen in this four-part series. -
FeatureWhat are the Biggest Mistakes You Have Seen? Part 1
Mistakes often offer the greatest learning experiences. Mentor program participants share what they have seen in this four-part series. -
FeatureHow Can We Improve Control Loops with Slow Signal Updates?
What can be done to smooth out the signal with a soft sensor or virtual instrument? -
FeatureHow Can We Improve PID Control Loop Monitoring?
What are the work processes, techniques, solutions, and people who should be involved for comprehensive control loop monitoring? -
FeatureWhat Can be Done to Increase Innovation in PID Control?
How can we facilitate efforts to take advantage of the remarkable increases in the capabilities and opportunities in today’s PID controllers? -
FeatureAre First Principle Models Used for Model Predictive Control?
What commercial providers of MPC use phenomenological dynamic models? -
FeatureHow is Simulation Leveraged for Qualification & Management of Change?
How does one leverage simulation to support qualification and reduce downtime as part of MOC and capital projects? -
FeatureBuilding Rapport with the Maintenance Engineers and Technicians
What things have been found most effective in building a rapport with maintenance technicians? -
FeatureWhat are the Challenges, Troubleshooting, and Future of Industrial IP?
A practical view of what the future looks like for industrial internet protocols (IPs). -
FeatureWhat Are the Aspects of Safe Automation Systems?
In our latest ISA Mentor Program blog, Mike Laspisa asks: What are the aspects of safe automation systems? -
FeatureWhat are the DP Connections for Level Measurement with Wet Leg?
The latest ISA Mentor Program blog answers the question: What is the best way to install a DP in level applications with a wet leg? -
FeatureWhat are the Problems and Solutions with Packaged Equipment?
Our newest ISA Mentor Program blog asks the question: What are the problems and solutions with packaged equipment? -
FeatureIncreases In Instrument Application or Installation Issues
Mike Laspisa shares a Q&A with various experts regarding instrumentation specification expertise, covering topics such as selection and installation. -
FeatureThe Best Level for Optimization and Organization in the Smart Factory
Automation professionals from the ISA Mentor Program answer questions about optimization and organization in smart factories. -
Feature9 Automation Engineers' Ideas and Principles for Everyday Working Life
Automation professionals from the ISA Mentor Program share their ideas and principles for everyday working life as an automation engineer. -
FeatureWhat Are Some Ways to Improve and Prioritize Feedforward and Fast Feedback Control?
Automation professionals from the ISA Mentor Program answer a question about how to improve and prioritize feedforward and fast feedback control. -
FeatureWhat Are Some Opportunities for Wireless Measurement and Control?
An automation professional from the ISA Mentor Program answers the question: 'What are some opportunities for wireless measurement and control?' -
FeatureHow Can We Improve Operator Trust in a PID Controller?
Automation professionals from the ISA Mentor Program answer the question: 'How can we improve operator trust in a PID controller?' -
FeatureElectrical Engineers in Automation: What Are the Success Stories?
Automation professionals from the ISA Mentor Program answer the question: 'Have there been many success stories of electrical engineers in automation?' -
FeatureHow to Quickly Identify Tuning Mistakes
Automation professionals from the ISA Mentor Program address a question they received: 'How can one quickly identify tuning mistakes?' -
FeatureHow Can We Develop and Motivate New Automation Professionals?
Automation professionals from the ISA Mentor Program address a question they received: 'How can we develop and motivate new automation professionals?' -
FeatureWhy Are Engineers So Against Derivative Action?
Automation professionals from the ISA Mentor Program address a question they received: 'Why are engineers so against derivative action?' -
FeatureWhat Factors Affect Dead Time Identification for a PID Loop?
Automation professionals from the ISA Mentor Program address a question they received: 'What factors affect dead time identification for a PID loop?' -
FeatureAlarm Management and DCS Versus PLC/SCADA Systems
There are very few if any chemical or refinery units that would not benefit from state-based alarming. -
FeatureHow to Manage Control Valve Response Issues in the Field
A sensitive flow measurement is needed to identify the installed flow characteristic online. -
FeatureHow to Use Industrial Simulation to Increase Learning and Innovation
New projects expose automation professionals to more learning opportunities to continue to grow their skill sets and expertise. -
FeatureHow to Avoid Using Multivariable Flow Transmitters
Coriolis meters provide the only true mass flow measurements, which offer a very accurate density measurement as well. -
FeatureWebinar Recording: Lessons Learned During the Migration to a New DCS
DCS migration topics: proper setting of tuning parameters, controller output scales, anti-reset windup limits, grounding, wiring, & configuration practices. -
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Webinar Recording: Small Batch Manufacturing
Tips and lessons on the use of anti-reset windup limits, override control, isolation valves, smart alarms, mass flowmeters, and the enforcement of low-flow limits. -
FeatureHow Often Do Measurements Need to Be Calibrated?
The ISA recommended practice is not on the process of calibration but on a calibration management system -
FeatureBasic Guidelines for Control Valve Selection and Sizing
Control valves often determine the capability of the control system. Poorly sized and selected control valves will make tight control impossible regardless of the control strategy or tuning employed. -
Feature
What Are the Opportunities for Nonlinear Control in Process Industry Applications?
MPC for batch operations can be achieved by translation of controlled variable from batch temperature or composition with a unidirectional response to the slope of the batch profile. -
Feature
How to Implement Effective Safety Instrumented Systems for Process Automation Applications
Systematic failures in industrial systems are best addressed through the implementation of a protective management system, which overlays a quality management system with a project development process -
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Webinar Recording: The Amazing World of ISA Standards
ISA standards offer a wealth of knowledge and guidance to provide safer and more reliable and effective automation systems. -
FeatureWebinar Recording: Simple Loop Tuning Methods and PID Features to Prevent Oscillations
Simple tuning methods and the PID features that can be used to prevent the oscillations that plague our most important loops. -
FeatureSolutions for Unstable Industrial Processes
Negative resistance also known as positive feedback can cause processes to jump, accelerate and oscillate confusing the control system and the operator. -
FeatureWhat Skill Sets Do You Need to Excel at IIoT Applications in an Automation Industry Career?
The Industrial Internet of Things offers much greater availability of data to provide the knowledge needed to sustain and improve plant safety, reliability and performance. -
FeatureWebinar Recording: Practical Limits to Control Loop Performance
Learn the contribution of each PID mode, why reset time is orders of magnitude too small for most composition and temperature loops, and other PID controller issues. -
FeatureHow to Get Started with Effective Use of OPC
OPC is a client/server protocol. The server has a list of data points (normally in a tree structure) that it provides. A client can connect to a server and pick a set of data points it wishes to use. -
FeatureWebinar Recording: PID and Loop Tuning Options and Solutions for Industrial Applications
Learn the benefits of knowing your process and PID capability, with a focus on process behavior, loop objectives and different industrial applications. -
FeatureHow to Improve Loop Performance for Dead Time Dominant Systems
Dead time is the source of the ultimate limit to control loop performance. -
FeatureHow to Setup and Identify Process Models for Model Predictive Control
Sometimes the design will need to change during a step test as you learn more about the process. -
FeatureWebinar Recording: How to Use Modern Process Control to Maintain Batch-To-Batch Quality
Understanding the challenges of batch process control can lead to solutions that offer much higher levels of efficiency and capacity. -
FeatureWhat Types of Process Control Models are Best?
First principle models can be used to gain a deeper understanding of cause and effects, process relationships, process gains, and the response to abnormal situations. -
FeatureHow to Get Rid of Level Oscillations in Industrial Processes
Use rate limiting when a ripple is significantly faster than a true change in the process variable. The velocity limit is the maximum possible rate of change of the level. -
FeatureWebinar Recording: Loop Tuning and Optimization
Learn about the importance of process optimization and how to achieve it through better PID control from members of the ISA Mentor Program. -
FeatureHow to Optimize Industrial Evaporators
Model predictive control software identifies the dynamics and automatically incorporates them into the industrial evaporator controller. -
FeatureHow to Calibrate a Thermocouple Temperature Transmitter
For critical industrial measurements, place the thermocouple in a bath or dry block or cross check the reading against another thermocouple. -
FeatureKey Insights to Control System Dynamics
Learn important strategies and concepts that can lead to a better industrial career and significantly improved system performance at your plant or facility. -
FeatureHow to Measure pH in Ultra-Pure Water Applications
Ultra-pure water applications pose special problems because of the exceptionally low conductivity of the fluid from the absence of ions. The consequences are extreme sensitivity to fluid velocity and -
FeatureHow to Optimize PID Controller Settings and Options
Technical guidance on ways to optimize settings and options for PID controllers from industry veteran Greg McMillan and participants in ISA's Mentor Program. -
FeatureWebinar Recording: Feedforward and Ratio Control
Key insights on how feedforward control often simplifies to ratio control. -
Feature
Webinar Recording: Strange but True Process Control Stories
Listen to Greg McMillan's lessons learned the hard way during a 40-year career in process control industries. Many of the mistakes made in the field are still being made today, some posing safety risk -
Feature
Webinar Recording: Temperature Measurement and Control
Temperature is the most important common measurement that is critical for process efficiency and capacity. -
FeatureWhat are New Technologies and Approaches for Batch and Continuous Process Control?
For any type of analysis or prediction, whether using ANN or MSPC, you need to have inputs that show the variability in the process. -
FeatureWhat Are Best Practices and Standards for Control Narratives?
When creating detailed control narratives for existing controls, use established standards and industry best practices. -
FeatureWhen and How to Use Derivative Action in a PID Controller
The least frequently used mode in a PID controller, derivative is more useful when dead time is not pure dead time but is a series of small time constants. -
FeatureHow to Manage Pipeline Valve Positioner and PID Tuning
In general use the highest valve positioner gain that does not cause oscillation. For pipeline flow and pressure control, oscillations are not filtered. -
FeatureWebinar Recording: How to Get the Most Out of Control Valves
The data that is really needed when selecting and sizing a control valve is rarely understood and specified. -
FeatureHow to Overcome Challenges of PID Control and Analyzer Applications via Wireless Measurements
An enhanced PID controller simplifies tuning and improves loop stability and reliability for loops dominated by discontinuous measurement updates. -
FeatureFeedforward Control Enables Flexible, Sustainable Manufacturing
Feedforward provides preemptive corrective action for production rate and grade changes enabling key PID controllers to provide consistent product quality. -
FeaturePID Controller Tuning Rules
Safety, equipment and environmental protection, process efficiency and capacity, product quality, and control system maintenance depend on PID tuning. -
FeatureWhat Are Best Cutover Strategies for Upgrading an Industrial Plant?
When retrofitting an industrial plant, review budget, schedule, financial justification for the project, as well as all areas of concern such as shutdown. -
FeatureHow to Avoid Common Tuning Mistakes With PID Controllers
The success of advanced control depends on the basic control system foundation. The PID controller is the common key component of all control loops. -
FeatureThe Good, Bad, and Ugly of Thermal Mass Flowmeters
Thermal mass flowmeters can be a relatively inexpensive flowmeter that can handle extremely small and large flows -
Feature
PID Tuning for Near and True Integrating Processes
The most important loops on vessels and columns typically have a near or true integrating response. -
FeatureWhat are the Equivalent Methods to Eliminate Proportional Step and Derivative Kick?
There are several methods for eliminating or controlling the proportional step and derivative kick in a PID output resulting from a change of setpoint. -
FeatureWhat Is the Definition of PID Bumpless Transfer?
Bumpless transfer and how a new operating point can be achieved quickly and smoothly after the PID is switched to automatic mode. -
Feature
How Do You Measure Control System Performance?
Seek a suite of practical metrics in terms of key performance indicators that can have an impact on plant control system performance. -
FeatureHow Do You Convert Tuning Settings of an Independent PID?
Considerable confusion exists on how the PID Form affects tuning settings. Lack of understanding of Form & units of settings can lead to disastrous results. -
FeatureHow to Better Understand Integrating and Runaway Process Dynamics
Technical discussion on how to improve industrial automation operations by understanding integrating and runaway process dynamics -
FeatureBetter Process Control by Understanding Self-Regulating Process Dynamics
The three types of processes in the automation industry are self-regulating, integrating, and runaway. -
FeatureBenefits of Good Tuning: Increased Production and Profitability, Reduced Variability
For control loop tuning, the first settings that must be right are the controller and valve actions. If these actions are not right, nothing else matters. -
FeatureHow to Achieve Tight Process Recirculation Temperature Control
How to eliminate oscillations associated with the discontinuity and changes in phase between heating and cooling and make the response of the secondary temperature loop faster. -
FeatureHow to Make Transitions Between Cooling and Heating Smooth and Fast
How eliminate oscillations associated with the discontinuity and changes in phase between heating and cooling and make the response of the secondary temperature loop faster. -
FeatureHow to Optimize Cascade Control Systems in Vessel Heating and Cooling
How to make sure the cascade control system is intelligently designed to meet process requirements in terms of vessel and heat transfer surface temperatures -
FeatureWhat are the Critical Aspects of Jacket and Coil Design in Vessel Heating and Cooling?
Critical aspects of the design of the jacket and coil in vessel heating and cooling. -
FeatureSimple Strategies for Maximizing Biopharmaceutical Product Quality
Use of key PID features, tuning objectives and feedforward control can meet the stringent requirements for biopharmaceutical production. -
FeatureSimple Strategies for Optimizing Ethanol Plants
PID controllers for front-end production rate, slurry concentration & average fermentation time can decrease costs and increase production rates for ethanol plants. -
FeatureOptimizing Multiphase Reactors with a Single Phase Product
Multiphase reactors offer an inherent ability to optimize excess reactant concentration by the proper use of a simple pressure or temperature control loop. -
FeatureGetting the Most Out of Fluidized Bed Reactors
The fast kinetics and composition response of a fluidized bed reactor enable the direct manipulation of reactant feed rate by temperature control to inherently maximize production rate to the coolant -
FeatureMaximizing Production Rate of Single Phase Liquid Reactors
Control schemes for maximizing production rate in liquid reactors -
FeatureAchieving Tight Control of Single Phase Liquid Reactors
How to set up control loops for liquid reactors to achieve their full potential. -
FeatureTemperature Sensor Installation for Best Response and Accuracy
Best practices to get the most out of the inherent capability of a temperature sensor. -
FeatureTemperature Communication for Best Accuracy and Reliability, and Least Noise
How the advent of smart transmitters and wireless communication has opened the door to better temperature communication & process performance improvements. -
FeatureWhat are the Inherent Differences in the Performance of Pure Batch, Fed-Batch and Continuous Reactors?
A look at the differences between pure batch versus fed-batch versus continuous reactors. -
FeatureAn Overview of the Control Loops for Batch, Fed-Batch and Continuous Reactors
A look at how many of the loops can be the same and how all reactors benefit from a more extensive application of feedback control. -
FeatureWhat are the Implications of Industrial Reactor Type on Control?
The effect of reactor type on dynamic response, allowable measurement lags and delays, controller tuning, and control strategies is significant. -
FeatureHow to Obtain Concentration Measurements from Common Inline Sensors
To control the concentration of key components, relatively inexpensive inline measurements can be used under the right conditions to provide concentration measurements -
FeatureInferential Measurement of Cell and Crystal Growth Rate and Reaction Rate
Simple online inferential measurements of cell growth rate, crystal growth rate, and chemical reaction rate are possible using conventional online measurements of flow and temperature. -
FeatureAutomation Project and Startup Humor – How to Laugh Rather Than Fret
Automation Project and Startup Humor – How to Laugh Rather Than Fret -
FeatureHave You Had a Good Automation Industry Laugh Today?
Humor can provide insights by opening the mind to the strange but true aspects of the industrial automation profession. Successful humor can cause a smile before you realize the full nature of the sit -
FeatureHow to Select the Optimal Temperature Sensor for Industrial Applications
How to Select the Optimal Temperature Sensor for Industrial Applications -
FeatureTop 10 Mistakes Made Every Day in pH System Design
In pH control systems reagent piping and injection must minimize transportation delays, volumes must have proper geometry and agitation to maximize the process time constant that filters pH oscillatio -
FeatureWhat are the Essentials of pH in Industrial Applications?
What are the Essentials of pH in Industrial Applications? -
Feature
Continuous Improvement in an Automation Career Requires Continuous Solicitation of Feedback
An individual should never stop learning and improving. You cannot improve unless you know what you are doing wrong. -
FeatureHow to Use Plant-Wide Feedforward for More Flexible and Efficient Production
The use of plant-wide feedforward control can move a plant quickly and smoothly for more flexible and efficient manufacturing. -
FeatureWhy You Should Scrutinize Technical Articles for Bias
If an article is written by the sales and marketing department, be on the lookout for a biased view of a product or service. -
FeatureWhat are the Benefits of Identifying Deadtime and Ramp Rate?
The identification of deadtime and ramp rate can provide tuning, rapid modeling, and future values for smart reset, feedforward, and setpoint responses. -
Feature
High Pay Is Not Reason Enough to Stay in a Bad Industrial Automation Job
When interviewing for a position, interview your perspective boss as hard as he (or she) is interviewing you. -
Feature
How to Smooth the Transition Between Batch and Continuous Operations
The unbalance between continuous operation flow & instantaneous batch flow can be spread over available inventory by an adapted rate limited feedforward. -
FeatureWhy References Are Just the First Step in an Industrial Employee or Control Systems Evaluation
Treat references as a first step toward engaging a wider group who can provide a more realistic picture of the person or product or company being evaluated. -
Feature
How to Determine the Health of an Industrial pH Glass Electrode
The sensor response time is a sensitive indicator of the effects of coatings and aging on glass pH electrodes. -
FeatureWhy You Should Establish a High Level of Trust with Your Automation Co-Workers
Do not lie, and do not tell people “what they want to hear” just to avoid conflict. -
Feature
How to Use an Adjustable Flow Ratio and Feedforward Summer to Optimize Flow Measurement
Set up a ratio station, feedforward summer, and cascade control system for maximum flexibility and visibility to address start-up and abnormal conditions. -
Feature
How to Build Communications Skills as an Engineer
Engineers are not naturally adept at writing and/or presentations. Good writing and presentation skills take training and practice. -
Feature
How to Use External-Reset Feedback for Cascade Control
Use external-reset feedback to prevent oscillations for a slow secondary loop or final control element; meet process objectives with setpoint rate limits, -
Feature
Consider Intangible Costs When Calculating an Industrial Project
When calculating the cost of a project, a decision, or some other activity, do not fail to consider the intangible costs. -
FeatureUse Signal Characterization in the DCS to Linearize the Installed Flow Characteristic of a Valve
Signal characterization in a DCS can solve problems resulting from signal characterization in the valve positioner. -
FeatureWhy You Should Avoid Scripted Control System Demonstrations
Do not let the integrator take the system through a scripted test sequence to prove its functionality. -
Feature
How to Use Valve Position Control to Optimize Process Efficiency and Capacity
Valve position control can be implemented in a matter of hours to start optimizing the efficiency or capacity of a unit operation. -
FeatureTreat Every Industrial Automation Professional with Respect
Set a precedent of mutual respect and professionalism from the very beginning. Once the precedent for a relationship has been set, it is difficult to change. -
FeatureHow to Achieve Process Simulation Fidelity
Use tieback models, modeling objects and online adaptation of dynamics and parameters to achieve the fidelity needed for simulation applications. -
FeatureWhy Engineers Should Foster Relationships with Vendors
An engineer is as dependent on the vendors as they are dependent upon the engineer. -
Feature
How to Determine the Health of an Industrial pH Reference Electrode
Use a smart transmitter & smart electrodes and do standardization and/or periodic buffer calibrations based on electrode life expectancy. -
FeatureWhy Is Instrumentation Critical for the Automation Professional?
A detailed understanding of instrumentation is critical for any automation professional. -
FeatureWhat Are the Benefits of Linear Reagent Demand Control in Managing pH?
For managing pH, use linear reagent demand control when going from a flatter part to a steeper part of a titration curve for tighter control and less wear and tear on the valves and the operators. -
FeatureWhy You Should Teach and Grow the Next Generation of Engineering Talent
Developing direct reports is a fundamental duty of the leader position. Teach and grow the next generation of engineering talent. -
FeatureUse Middle Signal Selection to Improve pH Measurement Reliability
Take three measurements for pH and for any other measurement that can be a probable cause of loss in process efficiency or capacity. -
FeatureThe Benefit of Outlines and Flow Charts for Industrial Project Development
Always take the time to map out a cohesive structure before starting any creative endeavor. -
Feature
How to Use Output Tracking to Improve Setpoint and Abnormal Condition Response
Use output tracking to get the loop consistently started for the best setpoint response and recovery from an abnormal condition. -
FeatureThe Balance Between Risk Avoidance and Need for Change in Process Automation
Automation professionals are trained to avoid risk. However, that is not a reason to avoid making changes. -
Feature
How to Optimize Batch End Points and Cycle Times
Use a feed analysis of predicted yield to create a production rate controller & use a batch profile slope for optimization of batch end point & cycle time. -
FeatureNever Underestimate the Power of Politics and Emotion in an Industrial Automation Career
In an industrial career, you can eliminate conflict by simply avoiding discussing topics which are certain to create conflict in the first place. -
FeatureWhat are the Benefits of Computing and Trending a Future Process Control Variable?
A future PV value can make setpoint response, reset & feedforward smarter and help operations understand consequences of the dynamics on current actions. -
FeatureButterfly and Ball Valves with Positioners Are Not Control Valves
Premature valve failure results from seat erosion under low flow/high pressure drop conditions or when the valve is cavitating or flashing. -
Feature
How to Make Reset Time and Feedforward Action Smarter
Smart reset can reduce overshoot and faltering, and smart feedforward can provide a more complete and accurate feedforward action. -
FeatureAutomation Industry Career Tip: Admit Your Errors
In an automation career, you will be amazed how a quick admission of error can defuse a potentially bad scene. -
FeatureHow to Select the Best Type and Size of Actuator for Tight Control
Where possible, use a diaphragm actuator sized to meet at least 150% of the maximum thrust or torque requirement. -
Feature
How to Build a Successful Project Team in the Automation Industry
Pick your team members wisely, lead by example, and always convey the highest expectations of performance. Your team will deliver. -
Feature
Benefits of Using Sliding Stem Valves for Tighter Process Control
Use a sliding stem valve with diaphragm actuator and digital positioner whenever size and process conditions permit. -
Feature
High Pay Is Great but Life Is Too Short to Stay in an Engineering Job You Dislike
A good paycheck is nice, but if you find yourself dreading the return to work each morning it may be time to consider job options elsewhere. -
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Why You Should Decrease PID Gain and Reset Time for Pipeline and Inline Control
Pipeline and inline control loops have no back mixing and hence no process time constant in the response of the outlet to changes in the inlet. -
FeatureWhy You Should Test Every Communication Network Before DCS Start-up
Find a way to test any communication network prior to installation. About a week before every major DCS start-up, consider performing a “network startup.” -
FeatureBenefits of Increasing PID Gain and Reset Time for Vessels and Columns
Temperature loops on mixed volumes, gas pressure loops, and level loops need much larger than expected controller gains and reset times. -
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How to Reduce Development Time and Industrial Project Risk by Testing and Proving New Code
If a piece of code is to be replicated many times, always have two different people independently test it whenever possible. -
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First Principles for a Deeper Understanding of Industrial Automation
Conceptual knowledge should be sought to see the commonality in seemingly different industrial application requirements. -
FeatureWhy You Should Insist on Documented Code for Every New Process Industry Project
Add comments through the software during programming. People will be very glad that you did. -
FeatureThe Importance of Using Tuned Positioners on All Control Valves
Readback control of valve position compensates for a host of unknowns in connection with valve response but a positioner, like a controller, must be tuned. -
FeatureIf You Have to Tell Everyone How Smart You Are, You Probably Aren’t
If a person is extremely intelligent, it will be obvious to everyone after a casual conversation. -
FeatureWhy Automation Professionals Should Write and Present Technical Papers
As an engineer, your publications are as important for recognition of your expertise as publications of a supplier for recognition of a product’s capability. -
FeatureA College Degree May Not Be a Reliable Indicator of an Engineer's Level of Knowledge
You must earn respect, and show respect to others. An engineering degree (or lack thereof) is a poor indicator of an individual’s knowledge level. -
FeatureWhy You Should Document the Benefits of Process Control Improvements
Capture and report trends of key process variables and metrics immediately before and after process control improvements. -
FeatureAutomation Industry Career Tip: Appearance Matters
From the clothes you wear, to the labels on a panel, to the layout and fonts on a graphic, to the look of your signature – appearance matters. There is a tremendous amount of wisdom in the expression, -
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How to Advance Your Career in Industrial Automation
Making yourself marketable in the automation industry takes initiative, but it is beneficial to you and the company. -
FeatureIndustrial Career Advice: Pain Is Instructive
One of the more frustrating problems is the kind that can only be fixed by someone else. Find a way to have that person feel the same frustration as you. -
FeatureThe Best Process Control Technical Resources May Be Out of Print
The Best Process Control Technical Resources May Be Out of Print -
FeatureWhy Successful Automation Engineers Are Detail-Oriented
Engineering is by definition a detail-oriented profession, but the field of automation requires almost fanatical attention to detail. -
FeatureThe Benefits of Listening Skills for an Industrial Career
The knowledge of individuals can be openly shared environment at an industrial plant or facility is inquisitive and friendly and egos take a back seat. -
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Benefits of Individually Fusing I/O with Indicating Fuse Blocks
The increased cost of using individual fuses will be quickly recovered by the reduced time to troubleshoot and resolve field wiring problems. One or two instances of bringing production back on line w -
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Free Download: Checklists to Manage Instrumentation and Manufacturing Technology
Information needed to take advantage of the best industrial technology and address all of the considerations of an application is often difficult to find. -
FeatureThe Value of Messaging in Industrial Control Systems
If the information is detailed & useful, an operator will be able to run a control system much more independently & resolve problems without outside help.