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Ask the Automation Pros
This long-running series of discussions, curated by 2010 ISA Life Achievement Award recipient Greg McMillan, gathers responses from ISA subject-matter experts on technical topics important to industrial automation professionals, academics and students.
169 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. -
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: What Is the Best VFD Design and Installation Plan?
ISA automation professionals explain key considerations for using variable frequency drives. -
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. -
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 -
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?" -
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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? -
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. -
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?' -
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. -
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. -
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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. -
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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. -
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. -
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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 -
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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 Use Key PID Controller Features
Learn how to use key PID features that can greatly expand what you can achieve. Includes innovative application examples for feedforward and rate limiting. -
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. -
FeatureWebinar Recording: Model-Predictive Controllers for Cost Optimization
How to develop a proper control system for separation of multiple batch components by vacuum stripping. -
FeatureWebinar Recording: Beginner's Guide to Vacuum Control
Understanding fundamental principles & limitations of process equipment is key to developing a proper control system for separation of multiple batch components by vacuum stripping. -
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. -
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 -
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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. -
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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. -
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. -
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 -
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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.