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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 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. -
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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. -
FeatureUse Wireless Transmitters for Diagnostics, Improvements, and Metrics
Wireless transmitters can rapidly prototype, demonstrate, analyze and justify installations of online diagnostics, metrics and improvements. -
FeatureHow to Select the Best Control Valve Location
Locate control valves to be maintainable, provide fast injection into mixing zones, and prevent flashing and cavitation. -
FeatureThe Benefits of Teamwork for a Industrial Project Start-up or Plant Outage
Take the time (and spend the money) to show appreciation to the crews on an industrial project start-up or during a major production outage. -
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How Optimal Measurement Location Maximizes Sensor Sensitivity and Signal-To-Noise Ratio
The best measurement location maximizes the sensor sensitivity and maximizes the signal-to-noise ratio and minimizes deadtime. -
FeatureUse Field Analyzers to Measure Key Component Concentrations
Field analyzers enable a higher level of control, such as model predictive control, to improve product quality and process efficiency and capacity. -
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Industrial Tip: Project Management Is Really Risk Management
As a project manager, continuously monitor everything for signs of problems and immediately inquire if something seems amiss. -
FeatureOpportunities and Challenges for New Automation Engineers
There are many opportunities and some challenges for new engineers entering careers in industrial automation and manufacturing. A Q&A offers many insights. -
FeatureWhy You Should Use the Best Automation Technology, Even if the Price Tag Is Higher
Do not go with cheaper instrumentation unless you are certain the impact on maintenance and process performance is (and will continue to be) negligible. -
FeatureWhy New Engineers Should Get Plant Experience Early
When searching for a job, seek out plants that have at least one seasoned engineer under whom you can work. -
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How to Achieve Greater Manufacturing Efficiency With Online Process Metrics
Add flow measurements to every important stream and compute online metrics for the process efficiency and capacity of each key unit operation. -
FeatureWhy Industrial Engineers Should Learn to Estimate Jobs
Estimate each process industry job before starting it and always follow up and compare the final cost figures against the initial estimate. -
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Always Design in Spare Capacity to Allow for Industrial Plant Expansion
A common rule of thumb for most systems is to add at least 25 percent spare capacity to the original design. -
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How to Improve Setpoints in Industrial Processes
Setpoints in industrial automation and manufacturing processes can be improved by achieving a higher level of control and knowledge. -
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Murphy's Law Is Alive and Well in Industrial Processes
Automation engineers love to create complex solutions. But try not to complicate a solution any more than necessary. -
FeatureHow to Use a Coriolis Meter for Mass Flow and Concentration Control
Coriolis meters can be used for measuring liquid flows in batch, fed-batch and continuous operations. -
FeatureBenefits and Shortcomings of Vortex Flowmeters
Vortex flowmeters are a good choice for measuring the flow rate of any reasonably clean fluid where measurement at very low flows is not required. -
FeatureHow Equipment and Operating Conditions Affect Process Dynamics
Simple material and energy balances can be developed to understand the effects of equipment design and operating conditions on process dynamics. -
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What are the Strengths and Weaknesses of Differential Pressure Flow Devices?
Each type of differential pressure flowmeter has a variety of pros and cons but the sheer number of types provides many options to the engineer -
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Why a Virtual Plant Is Crucial for Process Control Improvement
A virtual plant provides uses the actual plant’s control system & operator interface crucial for training and all levels of process control improvement. -
FeatureThe Benefits of Learning the Industrial Codes
Try to learn at least one relevant industrial code or one code section each year and seek to apply that knowledge often so that it is not lost. -
FeatureHow to Use High Rangeability Flowmeters and Valves to Increase Plant Turndown
To increase plant turndown, use control valves and flow measurements with the best low flow response and precision. -
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How to Specify a Capillary Seal Assembly
Be extremely careful to select knowledgeable technicians to install capillary seals. Many a pipefitter has pulled them out of the box and bolted them up without the proper gaskets and spacers. If this -
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How to Maximize Loop Coordination and Optimization
Employ setpoint filters, velocity limits and external-reset feedback to meet the process control objectives at your plant or facility. -
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How to Eliminate Split Range Oscillations in Process Control
Use precise valves, scheduled tuning, external-reset feedback, directional rate setpoint limits, and an enhanced PID to stop split range oscillations. -
FeatureThe Value of Process in Designing or Improving an Industrial Control System
Designing and/or improving a control system is practically impossible if the team does not understand the process. -
FeatureWhy You Should Not Use On-Off Valves as Control Valves
On-off valves should not be used as control valves (for throttling) and control valves should not be used as on-off valves (for isolation). -
FeatureWhy Operators Can Make or Break an Automation Project
Operator buy-in and approval are critical to automation project success. Get the operators involved in the design process early and listen to what they say. -
FeatureWhy You Should Look for Opportunities to Improve Plant Profitability
Estimate benefits from a decrease in variability & an increase production rate. Implement solutions where an increase in plant profitability is justified -
FeaturePitfalls of Selecting Low-Cost Industrial Instrumentation
Buying high-quality instrumentation does not mean that the buyer has to pay list price. -
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Why You Should Use an Enhanced PID for At-Line and Off-Line Analyzers
An enhanced PID can simplify the tuning and improve the stability for loops with large and/or variable analyzer update times. -
FeatureThe Cost of a Continuous Waste Stream in Process Automation
Any continuous waste stream is an excellent candidate for a money saving opportunity. Always keep an eye out for them. -
FeatureAutomation Industry Career Tip: Be a Team Player
For a successful automation industry career, work together on a one-on-one basis, and seek inspiration and recognition as a team. -
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ISA Mentor Program: The Key to the Future
The ISA Mentor Program is an ad hoc and extra curricula activity worth sacrificing free time to advance the careers of young automation professionals. -
FeatureAutomation Industry Career Tip: Learn New Skills and Explore Technological Advances
An emerging opportunity is learning how to mine information from an asset management system and an instrument management system. -
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Automation Week: Control Performance Track
Effective and accurate measurement and control are essential components of both improved efficiency and profitability of industrial operations. Traditionally, increased efficiency directly translated -
FeatureWhy Control Panels Can Be a Source of Risk in Retrofit Projects
Project management is really just risk management, and a large source of risk to an automation project is the control panels. -
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How to Use Control Loops to Eliminate Manual Actions and Sequences in Process Control
Use a PID control to eliminate manual actions and scheduled actions whenever a reasonable PV measurement is available. -
FeatureThe Importance of I/O Cards When Performing a DCS Retrofit
The electrical analysis of the systems should not be assigned to a junior engineer. -
FeatureThe Importance of Minimizing Dead Time in Process Automation
Minimize the largest sources of dead time in process control applications and consider the use of an enhanced PID developed for wireless and feedforward control for large dead times. -
FeatureAutomation Industry Career Advice: Seek Conversations with Knowledgeable People
Start a conversation with everyone responsible for the successful implementation, maintenance, and operation of your designs. -
FeatureThe Benefits of Lifelong Learning for an Industrial Automation Career
The more knowledge an industrial engineer masters, the more valuable he or she becomes. -
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How to Get the Most out of Your PID Controller
Technical paper shows you how to get the most out of your PID controller, extending its functionality from basic to advanced control. -
FeatureHow to Improve Batch Reactor Temperature Control
Temperature is a critical condition for chemical reactions to take place. In batch process, control becomes more complicated because of the variability of level, pressure and concentrations. -
FeatureWhat Is the Best Approach in Developing a Dynamic Process Model?
The primary objective of a dynamic model of a continuous process for process control is for the open loop gain, open loop time constant, and total loop deadtime be correct for the effect of each proce -
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What Are the Pro and Cons of Different Types of Dynamic Process Simulators?
The best way to classify process simulators is to look at the original intent of the simulator software when first released, who are the software developers, who configures the models, and how are the -
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How to Check out DCS I/O at the Panel Shop
An I/O checkout on a DCS system is rather difficult because there is no means to “force” the I/O as you can most PLCs