2022

JUNE
DIGITAL EDITION

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INTERNATIONAL SOCIETY OF AUTOMATION

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 JUNE 2022

OFFICIAL PUBLICATION OF THE INTERNATIONAL SOCIETY OF AUTOMATION www.isa.org/intech

VALVE STEM SEALING

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 JUNE 2022 | VOL 69, ISSUE 3

FEATURES DEPARTMENTS
PROCESS AUTOMATION
6 Talk to Me
12 Proper Valve Stem Sealing Best Global Collaborations Create

Practices Hybrid Events

By Renee Bassett
By Lisa Miller
Less leakage results in reduced product loss, increased efficiency, and 8 IIoT Insights
improved energy management. Implementing Rapid Roaming
Technology
IIOT AND DIGITAL TRANSFORMATION By Peter Szyszko
16 Bridging On-Premise and Cloud Data 11 Executive Corner
By Megan Buntain FieldComm, OPC UA Collaboration
Hybrid data architectures empower process manufacturers to Benefits Users
more quickly realize the business benefits from their cloud and IIoT By Ted Masters
investments.
28 Automation Basics
FACTORY AUTOMATION Using Flowmeters to Improve
19 Future-Proofing Controls Boiler Efficiency
By Scott A. Rouse
Programming for the Edge
By Darrell Halterman 31 Association News
Achieving traditional control while creating edge readiness. #AutomationProDay Winners, In
Memoriam: Bridget Fitzpatrick,
OPERATIONS AND MAINTENANCE Widely Used ISA Symbols Standard

24 Micro VFDs Gain Macro Features Updated, Meet Graham Nasby,

Return to In-Person Conferences,
By Kevin Kakascik new CAPs and CCSTs, and more
Compelling reasons to use newer and extremely capable micro VFDs.
34 Index of Advertisers
35 The Final Say
Optimize Energy Efficiency and
Sustainability
By Bill Lydon

Cover image courtesy of Emerson

InTech, USPS # 0192-303X, is published bimonthly in Research Triangle Park, NC by the

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INTECH JUNE 2022 4 WWW.ISA.ORG/INTECH

 TALK TO ME | PERSPECTIVES FROM THE EDITOR

Global Collaborations
OFFICIAL PUBLICATION OF THE INTERNATIONAL SOCIETY OF AUTOMATION

Create Hybrid Events EDITORIAL

By Renee Bassett, InTech Chief Editor CHIEF EDITOR
Renee Bassett, [email protected]
With so much disruption in supply building on this
chains, global trade, and workforce success. These CONTRIBUTING EDITORS
availability, manufacturers are forced live events are Bill Lydon, [email protected]
to come up with new ways to attract, being strategically supported around Charley Robinson, [email protected]
train, and retain employees. the world by ISA sections and local Jack Smith, [email protected]
partners in specific regions.”
To support industrial companies in
STAFF WRITERS
their efforts to educate their automa- The upcoming 2022 event schedule
Melissa Landon, Lynn DeRocco
tion, instrumentation, and IT employees, (https://www.isa.org/events-and-
ISA has stepped up. ISA is collaborating conferences) is as follows. Note that
ART & PRODUCTION
with significant global partners to pro- the locations shown indicate the time
Lynne Franke, Production Editor
vide technical content and has added zones during which the virtual events
Bonnie Walker, Art Director
in-person conference components to its will take place:
successful virtual-events programming. Jamie McLendon, Graphic Designer
z Digital Transformation – India, 21
Colleen Casper, Digital Designer
ISA’s first conference of 2022, held June. In-person location: Faridabad,
in March, included a collaboration Haryana, India. Supporting orga-
ADVERTISING & SPONSORSHIP
with the Brazilian national oil company nizations: National Power Training
Petrobras. It was also ISA’s first multi- Institute (NPTI) and Central Electric- PUBLISHER
lingual virtual event, as it featured a ity Authority (CEA). Rick Zabel, [email protected]
translation component with all presen- z Digital Transformation – North
tations delivered in Portuguese with America, 30 August. In-person loca- ACCOUNT EXECUTIVES
English closed captioning. tion: Houston, Texas. Local partner: Richard T. Simpson, [email protected]
ISA Houston Section. Chris Nelson, [email protected]
“The conference offered a wealth
z Digital Transformation – Asia, Gina DiFrancesco, [email protected]
of digital transformation and cyber-
October date TBD. In-person loca-
security content sessions developed MEDIA KIT
tion: Kuala Lumpur, Malaysia. Local
and sponsored by Petrobras, followed https://tinyurl.com/InTechAcom2022mediakit
partner: Petronaus.
the next day by ISA’s IIoT & Smart
z Cybersecurity Standards Implemen-
Manufacturing virtual conference
tation – Middle East, 25 October. In- ISA MEMBER LEADERS
programmed by ISA staff and volunteer
person location: Saudi Arabia. Local ISA PRESIDENT
program committee,” said manager
Partner: Saudi Aramco. Carlos Mandolesi
of conferences and events Kimberly
z Cybersecurity Standards Implemen-
Belinsky. The agenda included a key-
tation – North America, 26 October. PUBLICATIONS VICE PRESIDENT
note by Indranil Sircar, Microsoft CTO
In-person location: Houston, Texas. Joao Miguel Bassa
for manufacturing and supply chain
Local partner: ISA Global Cybersecu-
industry, as well as a panel of experts PUBLICATIONS VICE PRESIDENT-ELECT
rity Alliance.
discussing how manufacturers are Nicholas Sands
z ISA Annual Technical Conference
building organizational readiness for
covering process automation,
scaling up their smart factory projects. INTECH EDITORIAL ADVISORY BOARD
digital transformation, cybersecu-
Joseph Alford, Joao Bassa, George Buckbee,
The 2022 events program is high- rity, IIoT, and more – North America,
Eric Cosman, Acacio Costa, Vitor Finkel,
lighting the “international” aspect of 8–9 November. In-person location:
Dean Ford, Narasimha Himakuntala,
the International Society of Automation Galveston, Texas.
Russ Rhinehart, Nick Sands, David Spitzer,
through such partnerships and adding ISA’s hybrid conferences offer auto-
Sandeep Vysyaraju, Steven Valdez
a welcome in-person component to mation professionals powerful insights
virtual events. “We launched our virtual into key operational and business.
conferences in October 2020, and in All promise to help members of the
2021 attracted more than 12,000 glob- automation industry develop the pro-
al participants,” said ISA senior manager fessional knowledge and digital skills
of events Bill Furlow. “In 2022, we are needed to succeed. 

INTECH JUNE 2022 6 WWW.ISA.ORG/INTECH

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 IIOT INSIGHTS | WHERE THE INTERNET MEETS INDUSTRY

Implementing Rapid Roaming Technology

By Peter Szyszko

Modern factories heavily rely on arti- communication extends to 100 m. Com- ensures good throughput and fast transi-
ficial intelligence–driven processes to monly, this distance is not sufficient, and tions with a switch time less than 150 ms.
optimize every step of production and multiple access points (APs) are installed
also on precise data collected by numer- to cover a large operational area. In a IEEE 802.11r wireless roaming
ous sensors. Historically, factories used scenario of moving wireless, the client Roaming has been a desired feature
slow, cable-driven serial protocols, for (vehicle or robot) needs to switch over in wireless devices for decades, and
example, RS-232 cables or twisted pairs communication to the next strong signal in 2002, the IEEE 802.11r standard
for RS-422/485. With the development AP. The best solution is the implementa- was introduced. It is still under heavy
of new technologies, there has been a tion of 802.11r across the infrastructure. development with major fundamen-
transition to Ethernet-based communi- It manages the switch-over mechanism tals published in IEEE 802.11r-2008.
cation. Two main factors play a key role with transitions of less than 50 ms. In The main goal of 802.11r was to hand
in this process. The price of Ethernet some places, existing Wi-Fi infrastruc- over wireless connections between
nodes went down with the arrival of ture does not support 802.11r, but the numerous APs along a client travel path
cheap microcontrollers that include need for moving installation demands without significant delay. It has been
fully integrated Ethernet communica- fast transition times. particularly important for voice over
tion hardware in one chipset, and the Internet Protocol (VoIP) applications
In this situation, one answer is an
sophisticated sensors that provide the where human conversation requires
enhanced Wi-Fi client that can actively
flow of data are not compatible with transmission times of 50 ms or better
monitor surroundings and prepare new
old serial buses. to avoid noticeable interruptions.
possible AP connection opportunities
Wi-Fi communication (wireless Eth- before classic die-down and drop-off The new 802.11r standard allowed
ernet) is a key technology for delivering connection processes take place, which speed with secure and seamless handoffs
all the necessary metrics from sensors. cause a drop in communication for a where authentication and quality of ser-
It provides freedom from cables, al- minute or longer. Rapid roaming takes vice (QoS) configurations were preconfig-
lowing unrestricted three-dimensional an active approach and seeks a new AP ured ahead of switching to the next AP. It
movement. Typical 802.11ac wireless when communication is still healthy. It allowed a stable data throughput without
delays caused by the regular authentica-
tion process (figure 1).
Rapid Roaming Application
Fast roaming steps
An example of a place where  Authentication and QoS: In this

this scenario has played out step, two technologies are properly
is in a warehouse application transitioning. Not only devices are
with autonomous robots. connected to one AP, but the AP
The robots move about the has the same privileges in respect to
warehouse stocking shelves
and fulfilling orders. Here,
a legacy Wi-Fi network was
already in place to support
employees connecting their
PCs, tablets, and phones, but
the network did not have the
necessary equipment to sup-
port 802.11r. The solution
was fitting each of the robots
with a wireless router that
Figure 1. The 802.11r standard allows speed
could implement rapid roam-
with secure and seamless handoffs, where
ing technology at a fraction authentication and QoS configurations are
of the cost of installing an preconfigured before switching to the next
entirely new wireless net- Figure 3. Fitting each robot with a wireless router AP. This allows stable data throughput with-
work (figure 3). enables rapid roaming technology. out delays caused by the regular authentica-
tion process.

INTECH JUNE 2022 8 WWW.ISA.ORG/INTECH

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 IIOT INSIGHTS | WHERE THE INTERNET MEETS INDUSTRY

communication priority. It is impor- older installations when existing infra- key. When rapid roaming is enabled,
tant for VoIP scenarios when delays structure does not support 802.11r. the client device will be configured to
could affect the human-to-human However, it is not as efficient as having scan for the surrounding APs. It is nec-
conversation. 802.11r; it is attempting to close the essary to set slow scan time intervals
 Exchange 802.11r (2a – cable, 2b – gap with systems that do not have the to specify relatively slow scans when
radio): This special protocol allows roaming technology where conven- received signal strength indication
the exchange of all necessary infor- tional disconnecting and reconnecting (RSSI) signal levels are relatively high
mation ahead of the travel path of a occurs with new APs. This process and the client device can comfortably
client, making the transition smooth may take a long time—sometimes even concentrate on delivering the maximum
and fast. longer than a minute. It is frustrating data throughput. Then, it is necessary
 Travel path: This is the way the client when slow-moving clients operate with to specify the RSSI threshold level that
travels along the available APs. extremely weak AP signals when there indicates an imminent need for a new
Fast roaming is particularly useful in is another AP with a strong signal level connection. When this level is reached,
readily available in range (figure 2). the client device will perform fast
scans to look for a new AP. When it is
Requirements for the rapid roaming
detected, it will authenticate and auto-
infrastructure include:
connect to the new AP while simultane-
 Same service identifier (SSID) ously dropping the current connection.
 Same password
This active process eliminates weak
 Same security mode
signals deprived of links and prepares a
 Same band
new connection ahead when needed. In
 Same channel width.
addition, there are two channel modes for
For the rapid roaming technology to
scanning. One mode is “standard,” and it
Figure 2. AP with a strong signal level work correctly, it is necessary to use
works when all the channels are scanned.
available in range. an AP with the same SSID and security
The other mode is “intelligent,” and it
works when a client device, for example,
goes back and forth along the same APs.
In this scenario, the device is smart and
SIMPLY PUT... can learn those APs channels and look for
them automatically. This further acceler-
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 EXECUTIVE CORNER | TIPS AND STRATEGIES FOR MANAGERS

FieldComm, OPC UA Collaboration Benefits Users

End users benefit when standards organizations designed from the bottom up for machine-to-ma-
collaborate—especially regarding architectures, chine communications between digitally trans-
networks, and protocols—to deliver improved ease formed systems using semantic IDs.
of use, simpler integration, and backward compat-
The FDI standard is another example of col-
ibility. But before discussing collaboration benefits,
laboration to benefit end users. FDI provides a
definitions of leading terms are in order.
common approach for managing the integration of
An “architecture” is a framework of information information associated with intelligent field devices
models and application and communication proto- to higher-level asset management and automation
cols that effectively specifies a complete system. control systems for configuration, commissioning, By Ted Masters
For example, OPC UA is a platform-independent diagnostics, calibration, etc. Masters, presi-
service-oriented architecture. Components of dent and CEO of
FDI—including its specifications, tools, and FieldComm Group,
OPC UA are frequently used in automation sys-
registration procedures—is jointly owned by has supported the
tems.
FieldComm Group and PROFIBUS & PROFINET process industry in
A “network” refers to the physical hardware or International (PI). The OPC Foundation is a co- leadership roles at a
layer, and the associated communication protocols owner of the FDI specification with FieldComm wide variety of tech-
(TCP, IP, UDP) used to transmit data via the hard- Group, and the OPC UA Information Model for nology companies
ware. Ethernet and Wi-Fi are familiar examples. Devices specification is used within the FDI for more than 30
Server host component of the specification. The years. Masters has
An application “protocol,” for example as de- a BSEE degree from
FDT Group is the final collaborator on FDI. All
fined by HART commands, is a software standard the University of
these organizations have a stake in promoting use
defining various aspects of communication over Kentucky.
of the technology with their specific automation
a network. In some cases, one standard defines
networks and protocols standards.
both the communication and application proto-
cols, as with WirelessHART. FDI was designed for openness, including new
automation protocols and incorporating innova-
Collaboration landscape tive technologies. EtherNet/IP, ISA100 Wireless,
A primary example of collaboration between and Modbus TCP are all supported within FDI
standards development groups is the long- technology, and in the past several years, Field-
standing partnership between FieldComm Comm Group has collaborated with ODVA on
Group and the OPC Foundation. This relation- several projects, one of which is FDI.
ship extends back to some of the earliest efforts
toward creating device descriptions for instru-
ments, and more recently, for the process auto- Users need a range of choices to realize the
mation device integration model (PA-DIM) and
the field device integration (FDI) standards.
best price/performance ratio and ease of use.
In 2017, FieldComm Group began work-
ing collaboratively on a new information model FDI is a notable example, but not the only one,
exclusively for devices typically used in process of how member organizations within an industry
automation. Hosted by FieldComm Group, the can collaborate on technology advancement while
first release of the PA-DIM specification was in maintaining support for their unique offerings and
June 2020. The members of the PA-DIM work- installed base.
ing group are currently developing a new release
This type of collaboration and competition
of the specification to include additional device
benefits end users, because no single architecture,
types. OPC UA technology helps define the bits
network, or protocol standard is the best fit for
and bytes of clients and servers that support PA-
every application. Users need a range of choices
DIM.
for the best price/performance ratio and ease of
Another collaborator played a key role in the use. Collaboration among standards development
creation of PA-DIM, as its user requirements were organizations provides the required flexibility by
defined by NAMUR as part of its open architec- supporting FDI across a wide range of architec-
ture model. This is one of the first technologies tures, networks, and protocols. 

INTECH JUNE 2022 11 WWW.ISA.ORG/INTECH

PROCESS AUTOMATION

Proper Valve Stem

Sealing Best Pract ces
By Lisa Miller There are many methods of sealing valve stems increases efficiency by minimizing product loss,
on control and isolation valves. When chosen which in turn reduces energy use, because less
carefully, a valve stem seal provides years of product needs to be made to satisfy demand.
reliable service, reduces environmental emis-
sions, and minimizes product loss. When
inappropriately applied, a valve stem seal can Valve stem seals explained
leak constantly, increase maintenance costs, Before delving into the details of selecting a
create environmental issues, and place operat- valve sealing method, it is best to understand
ing personnel at risk. The right valve stem seal the challenges of sealing a valve stem and

Less leakage results in reduced product

loss, increased e iciency, and improved
energy management.

Figure 1. This control valve is subjected to EPA’s Method 21 “sniff” test to determine the fugitive emission leak rate after a prescribed number
of mechanical and thermal cycles.

INTECH JUNE 2022 12 WWW.ISA.ORG/INTECH

 PROCESS AUTOMATION

explain how this might be done. Control and block valves fall sure and either flushed with a test gas or subjected to a full
into one of two major categories: sliding stem or rotary. vacuum, while the inside of the valve is pressurized with he-
lium. The amount of leakage can then be precisely measured.
A sliding stem valve has a rod protruding from the body
that rises and falls to open and close the valve. A rotary valve When evaluating the performance of a valve stem seal
has a shaft extending out the side of the valve that is con- arrangement, it is important to determine how the valve was
nected to a plug, disc, or ball. As the shaft turns, the rotary tested and what specific classification it met. It is relatively
valve opens and closes. In either design, the valve stem must easy to achieve very low leakage rates if the valve is mechani-
exit the body and be capable of relatively friction-free move- cally cycled a small number of times. It is much more difficult
ment, while containing the process and preventing leaks. to achieve and maintain very low leakage rates when the valve
is mechanically cycled thousands of times, while enduring
The valve stem sealing assembly makes that possible. Seal-
thermal cycles as well. The thermal cycles affect sealing due to
ing is usually accomplished in one of two ways: conventional
the high expansion rate of PTFE (a synthetic fluoropolymer of
packing or bellows seals. Details of how these methods
tetrafluoroethylene, also known as Teflon) and the poor recov-
work, along with pros and cons of each method, follows.
ery rate of graphite, making packing design challenging.

Measuring valve stem seal performance

Sealing valve stems with packing
Valve stem seals must accomplish two contradictory goals. First,
The most common method of valve stem sealing employs a
they must seal the valve stem completely and reduce—and
series of PTFE or graphite rings that encircle the valve shaft
ideally eliminate—any fugitive emissions from the process.
(figure 2 left). The rings are compressed with a combination
Second, they must accomplish this feat while allowing the
of a packing follower, packing flange, and bolts to push down
valve stem to move freely and continue sealing, even as the
and squeeze the packing rings against the shaft. The com-
valve stem cycles thousands of times. Several industrial stan-
pressed rings allow the valve stem to move while maintaining
dards address these requirements, but the required perfor-
a seal against the valve body and shaft to keep process fluids
mance and test methods vary significantly.
from passing through the stem and escaping. In certain appli-
The three main fugitive emissions standards are TA Luft, cations, the packing need only protect against gross process
FCI 91-1, and ISO 15848. TA Luft is the least comprehensive leaks, so relatively minor fugitive emissions are not a concern
of the three, offering leak rate standards based on gasket and free stem movement is considered a more important
size and process temperature. However, it lacks specific test requirement.
parameters for the number of test cycles required or the
To achieve and maintain low emissions, packing must be
travel distance, so it is hard to compare the leakage results
“live loaded” to keep constant pressure on the sealing rings
among different valve designs.
(figure 2 right). This is usually accomplished using com-
FCI 91-1 was created by the Fluid Control Institute and pressed Belleville-type springs. These springs maintain a
is more closely aligned with the leak detection and repair constant force on the packing, ensuring it seals over time,
requirements mandated by the Environmental Protection even as the rings wear from stem movement. Unfortunately,
Agency (EPA). It uses EPA’s Method 21 to “sniff” the valve the increased pressure tends to restrict valve movement, so
packing and determine the leak rate
(figure 1). This standard provides details
on how to test a valve. A valve stem seal
design achieves various classification
ratings based on the resulting leak rate
after a specified number of mechanical
and thermal cycles.

By far, the most comprehensive

standard is ISO 15848. It has a variety
of leakage classification rates for both
control and isolation valves based on
mechanical cycles, thermal cycles, and
stem size. It also allows testing with
either helium or methane, and it dictates
two different ways to measure stem
seal leakage for helium, each of which is
Figure 2. The picture on the left shows a typical rising stem control valve with standard
much more involved than a simple sniff packing. More modern packing designs, shown on the right, employ compressed Belleville-
test. Specifically, the upperworks of the type or other special springs to maintain constant pressure on the packing rings. This
valve are encased in an airtight enclo- ensures the fugitive emissions are limited to 100 ppm or less, even as the rings wear.

INTECH JUNE 2022 13 WWW.ISA.ORG/INTECH

PROCESS AUTOMATION

the sealing materials and valve stem finish must be carefully The biggest advantage of a bellows design is its ability to
chosen to minimize fugitive emissions, while allowing valve deliver zero leakage. Such a specification is critical for lethal
stem movement. service applications. The bellow materials can also be chosen
to handle higher temperatures and corrosive applications.
Because the operational life of a bellows seal is based on the
Sealing valve stems with bellows
number and length of strokes, the estimated time to failure
An alternative to valve packing is a valve bellows seal. A bel-
can be predicted with some accuracy, so replacement can be
lows seal uses a welded or mechanically formed metal barrier
planned.
around the valve stem that can compress and stretch like an
accordion (figure 3). Because the seal is made of metal with Each design has disadvantages as well. The performance
a very low rate of deformation in critical areas, bellows seals and lifetime of packing is based on many variables, which
achieve virtually zero leakage. are not always easily predicted. Small leaks usually can be
addressed by tightening the packing, but at some point, the
Welded leaf bellow seals (figure 3 left and middle) are
packing must be replaced. Also, the surface finish of the valve
manufactured by welding together a stack of washer-like
stem can have a big impact on the life and performance of a
plates of thin metal to make a flexible seal with many folds
packing design. Regardless, all valve packing will leak to some
over a given length. A formed bellows (figure 3 right) uses a
extent, and this may not be acceptable in certain applications.
flat sheet of metal formed and welded into a tube. The tube
is then mechanically and hydraulically formed into a bellows. As mentioned previously, bellows seals will fatigue and
eventually fail. When that occurs, the valve must be fully
Both designs can stretch about the same distance per
disassembled to replace the bellows seal. For this reason,
fold, but because the formed bellows has far fewer folds per
the total cost of ownership for a bellows seal is typically
inch, its overall length is usually three times longer (figure 4).
higher than that of packing.
However, the reduced number of welds and corresponding
mechanical stress allow formed bellows to last significantly
longer in most applications.

Because bellow seals are constructed of relatively thin

metal and subjected to mechanical stress and corrosion, they
can crack and fail over time. For this reason, a bellows seal
valve usually has a standard packing above it to contain the
process should the bellows fail in operation.

Packing versus bellows

Each method of valve stem sealing has pros and cons, so
the best choice depends on the application. Perhaps the
biggest advantage of standard or environmental packing Figure 4. This valve
is its comparatively low cost, along with a wide variety of employs formed
valve packing materials and designs to suit most applica- bellows to achieve
tions. Valve packings can also be adjusted and replaced zero valve stem
leakage. As an added
without disassembling the valve.
precaution, the valve
also includes integral
standard packing
above the bellows.

Figure 3. Bellows seal designs usually employ a welded leaf design

(detail left and middle) or a mechanically formed design (right). A
formed design can withstand many more cycles than a welded leaf
design, but it is usually about three times longer.

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 PROCESS AUTOMATION

Application examples significant reductions in environmental emissions, product

When properly selected and applied, both packing and losses, and maintenance costs. Losing less product improves
bellows seals can handle challenging applications. In one efficiency and is a key component of energy management.
liquified natural gas application in Australia, a 24-inch by
The number of design options are extensive, so end users
30-inch letdown valve used a specially designed environ-
may find it helpful to consult with their valve vendor to
mental packing arrangement and had very low valve stem
determine the best sealing design, materials of construction,
leakage, despite operating at cryogenic temperatures
and other details for their specific applications. 
around –300°F (figure 5). Any fugitive emission from this
valve translated into lost product, lost energy, and environ- All figures courtesy of Emerson

mental damage—so it was critical to minimize leaks.

A Chinese chemical plant had a lethal service hydrogen ABOUT THE AUTHOR
cyanide application requiring virtually zero leakage while Lisa Miller is a senior engineering manager
in operation, so a bellows seal design was selected. Upon for Fisher sliding stem valves at Emerson
commissioning, the plant reported zero measurable emis- Automation Solutions. She has been the pri-
sions, and after six years, still had no reported leakages. mary technical consultant for Fisher packing
The valves went through 50,000 full cycles and more than and bellows for more than 20 years, and she
10,000 partial cycles annually. has 25 years of expertise with cryogenic
valve design, testing, and manufacturing.
Miller is the chairperson of the ISA75.27.01,
Final thoughts Cryogenic and Low Temperature Seat Leakage Testing of Control
Proper selection of valve stem sealing is a critical component Valves committee, and has been a member of ISA for 10 years. She
of the valve specification process. When chosen wisely, the has a BS in mechanical engineering from the University of Iowa.
design will perform reliably for the long term, translating into

Figure 5. This 24-

inch by 30-inch
letdown valve
employs a specially
designed large stem
diameter environ-
mental seal for
extremely low leak-
age rates, as demon-
strated here during
a test at –56°F.

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IIOT & DIGITAL TRANSFORMATION

BRIDGING
On-Premise
and
Cloud Data
By Megan Buntain By 2028, cloud computing and the Internet of While the term “IIoT” was coined just a few
Things (IoT) in manufacturing will be poised to years ago, the large volumes of data associated
achieve the “plateau of productivity,” or the with it are familiar to the process control and
phase when they drive transformational impact automation industries. For decades, manufactur-
on business outcomes, according to business ers have generated and collected more data than
analyst firm Gartner. At this point in their digital they know what to do with via sensors, legacy
transformation journeys, many manufacturers digital networks, and various host systems.

With the right hybrid architecture, manufacturers

can analyze data in its native locations and
formats, avoiding the complexities of data transfer
or replication.
have completed their Industrial Internet of But a great deal of data was stranded in
Things (IIoT) pilot projects and are approaching process historians and other databases,
mid- to late-stage adoption in operations. collecting dust. Today, manufacturers can

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 IIOT & DIGITAL TRANSFORMATION

fully benefit from this data and information in the cloud Hybrid approach to IIoT implementation
by using hybrid data architectures coupled with advanced To address this issue and provide combined access to OT,
analytics applications. IIoT, and other data, process manufacturers use a hybrid data
architecture approach to:

Agile production and the IIoT  effectively leverage on-premise data, regardless of
Transitioning to agile production requires optimizing the whether it is connected to the Internet
entire supply chain, from improving overall equipment  take advantage of ML and advanced analytics opportuni-
effectiveness and asset reliability to reducing inventory. ties by streaming select data to the cloud
IIoT implementations can help organizations clear common  use the process domain expertise and skills of their exist-
optimization hurdles, because they empower staff to access, ing workforce
collect, and analyze more data in near real time. This enables  reduce in-house data acquisition, storage, access, and
process experts and operators to make timely and produc- maintenance costs
tive decisions to enhance product quality, optimize opera-  increase data availability
tions, and reduce waste.  integrate AI/ML into industrial processes.
This is not a rip-and-replace approach but is instead a
With Internet connectivity, IIoT implementations can
bridge connecting traditional manufacturing data infrastruc-
directly access the vast computing power and scalability of
ture with cloud-native data to leverage the best data from
the cloud. Each year, the variability, speed, and volume of
both sides by creating a continuum of access. Process auto-
process data grows exponentially, rendering IIoT architec-
mation systems can continue to use on-premise or edge data
tures as the only suitable options for compute-intensive
for real-time decision making where low latency is required.
Industry 4.0 projects.
Simultaneously, the hybrid model empowers organizations to
Some of the leading cloud applications and components apply global reporting and compute-intensive tasks, like ML,
include digital twins, machine learning (ML) tools, autono- to cloud-native IIoT data (figure 1).
mous robot artificial intelligence (AI) repositories, and aug-
This approach requires a data abstraction layer to facilitate
mented reality simulators. Each of these use cases requires
traffic flow among various data sources (figure 2).
high CPU processing power, which can be difficult for on-
premise servers to provide because information technology Data abstraction indexes and facilitates access to data in
(IT) teams cannot scale up the required computing resources its native locations, a key differentiating point from data-
on demand. lake functionality. Because data is not copied or moved, its
management is significantly simplified. Once data abstraction
is implemented, organizations can add advanced analytics
Cloud computing for manufacturing operations
applications to simultaneously query and make use of infor-
According to Gartner, when it comes to cloud computing
mation from multiple, and often previously disparate, data
for manufacturing operations, the industry is currently in a
sources. This improves awareness and predictive mainte-
“trough of disillusionment,” or a state of lowered expecta-
nance capabilities across the organization.
tions. This mindset is largely a result of the unproven idea
that IIoT and related databases must feed a central data lake,
which is intended to serve as the single source of truth and
common access point for all users worldwide.

If this were true, cloud-based data lakes would need to

replace all existing process historians—along with other host
systems such as those used for asset management, labora-
tory information, or inventory tracking—to provide the data
required for analysis. In reality, this is not the best approach
because many legacy on-premise servers, such as those
hosting process historians, collect and store highly valuable
operational technology (OT) data. The context housed in
these rich data archives is required to ensure Industry 4.0
initiatives, such as predictive maintenance via ML, succeed.
Attempts to move or copy this OT data to the cloud are often
time consuming and costly.

To properly aggregate and analyze the data produced by Figure 1. Hybrid data architectures empower manufacturing organi-
legacy sensors and infrastructure alongside new “born-in- zations to leverage IIoT in the cloud for compute-intensive processes,
the-cloud” IIoT sensor data, a bridge is required. while executing real-time process control using on-premise data.

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IIOT & DIGITAL TRANSFORMATION

For example, when training and executing ML models, taxonomy. Once the hierarchies are in place, assets can be
organizations must access maintenance records and histori- analyzed within process groups, rather than individually, or
cal process data. Staff must then access results to proactively solely as unrelated assets of the same type.
identify issues and adjust the operational model. Abstraction
Next, OT works with IT personnel to ensure the former
makes it easy for personnel and software applications to
group can access this data securely by implementing cloud
access multiple datasets through a single source.
data storage, advanced analytics, and workflow automation
tools. IT and data science teams collaborate with OT subject
Hybrid data architecture for asset monitoring matter experts to configure ML models that create insights
Asset monitoring is a critical task for many process manu- and effectively predict asset failure, generating intelligent
facturers. For common assets—including pumps, valves, heat alerts to improve issue remediation and decrease downtime.
exchangers, and others—manufacturers deploy a variety of
maintenance methods to maximize productivity over the
Consider hybrid data architecture
asset’s life. At the two extremes, these methods include “run
When evaluating hybrid data infrastructure, organizations
to fail” in the most basic case, and condition monitoring for
should consider these questions before implementation:
predictive maintenance in more advanced situations.
 Does the software solution provide access to both OT and
By monitoring asset performance to detect anomalies in
IIoT data sources simultaneously, for both querying and
near real time, manufacturers can identify potential issues before
analysis?
failure, reducing unplanned downtime and maintenance costs.
 Can users generate dashboards and reports in near real time?
When these anomalies are detected, advanced analytics
 Does the infrastructure provide on-premise OT data to the
software can generate alerts to inform personnel, so they can
digital transformation team for use in Industry 4.0 applica-
schedule inspections and maintenance of affected assets.
tions, such as ML and digital twins?
These monitoring applications can be scaled to hundreds  Is there significant cost and effort associated with imple-
of assets across multiple sites. Therefore, it is critical to menting and maintaining the solution?
normalize data before generating alerts and to streamline  Can the infrastructure support the organization’s current
notification paths so the right personnel are informed. and future data architecture as it inevitably changes?
Hybrid data architectures empower process manufacturers
By working together, OT and IT teams can use a hybrid
to more quickly realize the business benefits from their cloud
data architecture to achieve these asset monitoring goals.
and IIoT investments. By using IIoT data and pipelines, on-premise
First, OT teams must deploy suitable sensors, in addition to
process data, abstraction, and advanced analytics, organiza-
data acquisition and storage technologies, to populate asset
tions can quickly pass through the trough of disillusionment
hierarchies with data for grouping equipment and devices of
and reach the digitalization plateau of productivity. 
a common process or location. These asset hierarchies include
sets of metadata collected for each asset of a common All figures courtesy of Seeq

ABOUT THE
AUTHOR
Megan Buntain
is the director of
cloud partnerships
at Seeq Corpora-
tion, a company
building advanced
analytics applica-
tions for engineers and analysts that
accelerate insights into industrial process
data. She was formerly a consultant with
analytics, IoT, and blockchain software
and services companies, and prior to that
worked at Microsoft for 15 years.

Figure 2. Data abstraction layers facilitate

data access and transfer among multiple
data sources, including on premise and
cloud databases.

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 FACTORY AUTOMATION & MACHINE CONTROL

Future-Proofing Controls
Programming for the Edge
Edge computing, new communication methods, service. Controls programming during the edge By Darrell Halterman
and advanced analytics are among the hottest evolution does not have to mean wholesale
topics related to industrial automation, a field change but can instead offer more choices.
more often associated with stoic reliability than
cutting-edge technology. Yet there remains a
fundamental need for creating traditional deter-
ministic control solutions suitable for new and Well-designed edge
retrofit automation projects.
controllers remain highly
compatible with existing PLC/
Designers are often concerned about man-
aging interactions with industrial automation

PAC ecosystems. Embrace

devices, especially as hardware and communica-
tions capabilities rapidly evolve. Fortunately,
by adopting some basic tools and strategies for
abstracting application data, interactions with new strategies and tools to
modern edge controllers can be nearly as easy
as traditional programmable logic controllers adapt and gain
(PLCs).

As hardwired relays yielded to PLCs, which in

new capabilities.
turn were surpassed by programmable automa-
tion controllers (PACs), the means and methods The edge is here
of programming control systems have adapted. Most users have heard terms like “edge com-
The same evolution is occurring as edge con- puting” and “digital transformation,” but many
trollers and other edge devices begin entering may feel unsure how edge computing can solve

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FACTORY AUTOMATION & MACHINE CONTROL

problems in their applications. At

least, users stand to gain improved
visibility into equipment and pro-
cess operations, even via mobile
devices. Streamlined data gather-
ing capabilities support analytics
at the edge and in the cloud, which
provide novel insights for improv-
ing availability, utilization, and
efficiency. In the most advanced
scenarios, edge controllers can
autonomously leverage analyti-
cal results to advise deterministic
control applications for near-real-
time responsiveness.

Even as these Industrial Inter-

net of Things (IIoT) capabilities
become more commonplace,
not every developer or project
is ready to commit to wholesale
edge automation. By architect-
ing a control solution properly,
end users can implement classic
functionality today, while future- Figure 1. Edge controllers are a modern way to provide PLC/PAC functionality, while future-
proofing designs and providing flexibility to enhance operations.
proofing their designs to take
advantage of the edge moving
forward (figure 1). The development of PACs represented an expansion
of PLC functionality to incorporate even more advanced
Developers unfamiliar with edge controllers may feel
application processing and communication functionality.
compelled to stick with tried-and-true control technologies
PACs began to take on tasks we would associate with the
and products. But the immediate impacts of ongoing labor
edge today, although their dedicated real-time operating
and component shortages demand modernized systems
systems (RTOS) imposed some limitations. In many cases,
that counter these challenges by taking advantage of new
users found it necessary to create complex algorithms,
ways of accessing and using data. Developers and end
like machine learning strategies, using modern information
users can embrace making their automation designs IIoT
technology (IT)–type languages like C++ and Python, run-
ready, and rest assured the required programming will build
ning on PCs and industrial PCs (IPCs) working in conjunc-
on past concepts.
tion with PACs.

Now edge controllers are on the scene, combining

Programming evolution
industrial-grade OT control with IT-type computing in one
When discrete automation operational technology (OT)
compact form factor tough enough to survive edge locations.
originally shifted from hardwired systems created with
Programming is evolving again.
electromechanical relay and timer devices to electronically
programmable devices like PLCs, the Ladder Diagram (LD)
language was created to help transition developers and tech- Edge programming concepts
nicians to the new solution. Visually, LD programming looks Some end users may opt to create edge solutions using a vari-
like the wiring diagrams used with hardwired relay and timer ety of hardware platforms and programming methods. This
systems—but it greatly simplified programming, debugging, ad hoc approach introduces risk and requires time-consum-
and modifying sequencing logic with a PLC. ing testing and integration efforts that generate late-stage
changes and potential cost increases unacceptable in today’s
As PLCs gained power and began to perform more
industrial projects.
complex functions like mathematics, analog loop control,
and motion control, the associated languages had to evolve Selecting hardware and software offered as part of a wide
for performing complex expression processing, advanced portfolio of coordinated industrial automation products from
process control, and motion. Languages like Structured Text a single provider ensures compatibility. A compatible port-
(ST) arose to meet the new programming and debugging folio of PLCs, PACs, edge controllers, and the software they
demands, yet LD was still available. run makes it possible for users to learn just a few program-

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 FACTORY AUTOMATION & MACHINE CONTROL

ming tools and apply them to many products. Harmonized PACs from the vendor and uses the same integrated develop-
library objects lead to greater consistency and rapid develop- ment environment toolchain and toolchest of library functions.
ment; proven code is readily reused on projects; and data is An edge controller can be used as a PLC or PAC today, even
more readily transferred among systems. to the extent of using the same logic libraries developed for
PLC/PAC members of the same product family. There is great
To ensure future-proof solutions, users should look
power in using familiar methods tied to new capabilities to
for product portfolios that embrace open programming,
obtain new results.
software, and communication standards wherever possible.
Even open standards may benefit from industrial-centric If the edge compute portion of the edge controllers uses
extensions where appropriate. For an edge controller, this an open standard OS like Linux, users are free, in the future,
requires: to add almost any type of application needed. The immedi-
ate benefits are more compelling if the edge controller is
„ deterministic control engines that support well-known and
available with a curated set of open source and commercial
stable IEC-standard and C languages
applications suiting the most common industrial computing
„ variable programming, with rich standard and user-defined
needs (figure 2).
data types
„ extensive standard and user-defined function blocks Control. The value of using an edge controller as a super-
„ support for object-oriented communications protocols charged PLC/PAC is that the edge controller is natively ready
like OPC UA that can seamlessly transmit data in context to run visualization, data connectivity, analytical applications,
between deterministic and analytic applications and much more whenever the user is ready to take advan-
„ support for OT-centric communication protocols like tage of these functions. No additional hardware is needed;
Modbus, Profibus, and Profinet no cutovers or physical tie-ins are needed; and there is no
„ Linux-based OS for the general-purpose computing part requirement to interrupt execution of the automation applica-
of the edge controller—bootable and upgradable inde- tion. Modern languages can be used where and when they are
pendently of the deterministic control portion. Linux is best suited for an application. End users gain the flexibility to
lightweight and has high performance while using fewer extend their applications with edge capabilities when they are
CPU and RAM resources than other alternatives ready.
„ ability to run open-source apps like Node-RED and
Computing. On the other hand, it is common for manu-
Grafana, as well as commercial and custom apps
facturing facilities to have significant quantities of legacy
„ programmable using C/C++, Python, and other modern
automated equipment already in service. End users at these
languages suitable for applications like machine learning
facilities may want to test the IIoT waters, but simply cannot
and artificial intelligence
jeopardize production.
„ support for IT-centric communication protocols like MQTT
and HTTPS. In this case, using an edge controller only for the IT comput-
ing capabilities and OT connectivity, without even one line of
A true edge controller with these features is the best
control logic, is a practical approach. The edge controller can
choice for implementing traditional deterministic control
be installed anywhere on the factory floor, just like a PLC/
today and taking advantage of the edge computing evolution
PAC, and one edge controller can be networked to many
now and in the future.
PLCs/PACs, sensors, or other instruments to act as a gateway
and information concentrator.
Edge control and computing
Operating in this capacity, users configure the edge control-
Edge controllers are touted by many suppliers, but these
ler to gather data, provide visualization hosting, and prepro-
devices vary significantly in performance and internal opera-
cess the data—such as filtering, averaging, or even executing
tion. For performance and security reasons, the most capable
local analytics—as needed, and to forward the information
implementations use hardware virtualization to ensure the
to higher level systems. Users can add and scale up this IIoT
deterministic controller runs independently of the edge com-
functionality at their own pace, without affecting any underly-
pute activities. Rigorous segregation of OT and IT environ-
ing automation systems.
ments is provided at hardware and software levels.
Control and computing. Although the individual control
Today’s controls designers may be hesitant to apply new
and computing capabilities of edge controllers are important,
edge controllers to equipment and systems usually auto-
users gain maximum advantage by combining them in sup-
mated with PLCs or PACs. They may be concerned about the
port of one application. The deterministic “inner loop” directly
skillset required to make an edge control solution work reli-
accesses field-sourced data and controls devices. The edge
ably. They may feel unsure of the benefits gained from trying
compute “outer loop” combines deterministic data and real-
a new architecture.
time information from outside sources or analytics to advise
These reservations disappear if the deterministic portion the inner loop on operating parameters and tuning to achieve
of the edge controller runs the same kernel as PLCs and optimal efficiency (figure 3).

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FACTORY AUTOMATION & MACHINE CONTROL

Figure 2. Some
edge controllers use
Linux for the edge
computing
platform, so they
can run a wide
variety of user
applications. In
addition, users can
take advantage of
preloaded
industrial edge
platform software,
providing the apps
needed to help
manufacturers
accelerate digital
transformation
projects.

Edge controller drone application Instead, well-designed edge controllers remain highly
Exemplifying the new potential made available by edge compatible with existing PLC and PAC ecosystems, so users
controllers, an end user recently explored using commercial can continue to build on their OT knowledge base. When
drones for inspecting remote pipeline. The user was able to they are ready to extend applications into the IT realm, the
quickly incorporate the standard Linux software develop- same edge controller provides a general-purpose computing
ment kit (SDK) for a popular commercial drone into the edge platform, effectively future-proofing their applications. 
compute portion of the edge controller. Using standard
All figures courtesy of Emerson
OPC UA communications, the company activated the drone
to fly predetermined inspection routes either on default
time intervals or on alarm conditions as commanded by the ABOUT THE AUTHOR
deterministic control portion of the edge controller. The edge Darrell Halterman is a director of PAC-
compute portion captured video and telemetry data and then Systems controls products at Emerson’s
posted it to a secure web dashboard for remote operators to machine automation solutions business. He
assess in real time. is also responsible for the portfolio’s control
solutions modernization strategy.

Looking ahead
Edge programming is more evolution than revolution. Origi-
nally, PLCs performed specific jobs and were programmed
using correspondingly specialized
methods. As PLCs improved and pro-
gressed to become PACs, the program-
ming means and methods preserved
the best aspects of the original Ladder
Logic roots, but gained new languages,
function blocks, and organizational
methods as needed in support of
added capabilities.

Edge controllers represent an expo-

nential capability increase over tradi-
tional PLCs and PACs, so it makes sense
that even more languages and applica-
tions are being added. This does not
mean end users need to discard their
experience or embrace all the added Figure 3. Edge controllers seamlessly combine OT and IT operations, using programming
capabilities at once. methods optimized for integrating each role.

INTECH JUNE 2022 22 WWW.ISA.ORG/INTECH

The Plant Floor in Your Pocket
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OPERATIONS & MAINTENANCE

Micro
VFDs Gain
Macro
Features
Figure 1. Many
industrial
applications and
small machines
with a motor
and limited I/O
requirements can
benefit from using
AC VFDs with an
integrated PLC.

OEMs and hobbyists benefit

VFD progress
Electric motor speed often needs to be con-

from technology’s trickle- trolled for applications involving machinery,

pumps, and other equipment (figure 1). At one

down effect. time, the only way to vary the speed of an

electric motor—while maintaining full torque
below base speed—was to use a DC motor and
By Kevin Kakascik We have witnessed the trickle-down effect of a DC drive. This was because the first AC VFDs
technology. From expensive luxury brand cars only operated in V/Hz mode and lost torque
to the newest mobile phone each year, the top proportionally with any decrease below their
model almost always has exclusive features. base speed. However, once the flux-vector AC
However, frugal and patient consumers—as VFD became available, 100 percent of the motor’s
opposed to early adopters—will eventually see torque could be produced across the entire
these same technologies become available on speed range from zero to base speed.
lower-cost products.
Early flux-vector AC VFDs experienced several
This fairly universal model spans many indus- problems. Limited horsepower ranges were
tries, among them industrial automation. AC available; the units were large and kept in a room
variable frequency drive (VFD) users continue away from other equipment; and long cable
to benefit from new features formerly available lengths caused electrical issues. These were also
only on flagship products. expensive, custom-engineered drive systems.

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 OPERATIONS & MAINTENANCE

Eventually, the trickle-down effect began to occur, and flux- choosing a three-phase motor over a single-phase motor are too
vector VFDs were sold as packaged products that could work lengthy to list, but improved speed control is usually enough to
for many applications. Lower-cost VFDs remained available for convince users that a three-phase motor is the best choice.
basic applications needing only simple V/Hz control.
Torque. Sensorless vector control allows users to reduce
By the early 2000s, fewer custom-engineered systems motor speed to very low speeds without losing torque. On a
drives were sold, and most were prepackaged but had typical lower-cost VFD with only V/Hz control (also known
impressive features in addition to supporting flux-vector as scalar control), the motor loses output torque proportion-
control. Other popular features included advanced network- ally to the reduction in speed. For example, a 0.5 hp motor
ing capabilities, safety features such as safe torque off, with a base speed of 1,725 rpm and a full load torque rating
proportional-integral-derivative (PID) control, and even a of 1.5 lb-ft at 100 percent speed will only provide 1.0 lb-ft
built-in programmable logic controller (PLC) with expansive at 66 percent speed. With sensorless vector control tech-
I/O options to allow for process or machine control in addi- nology, it is possible to produce 100 percent of the motor’s
tion to motor control. torque output at very low speeds.

Before sensorless vector technology was available, design-

The least with the most ers could use a lower rpm motor of the same horsepower to
Just a few years ago, the lowest-cost VFDs on the market achieve the lower fixed speed, or they could use a DC motor
still only supported V/Hz control and were basic, with lower and drive. The former is not adjustable and often involves a
quality to remain affordable for original equipment manufac- larger frame size, which may require higher-cost mechani-
turers (OEMs) and hobbyists. Again, the trickle-down effect cal changes. The latter is robust but calls for higher main-
has taken place, and many higher-end features and improved tenance, such as changing brushes, and many smaller DC
build quality are found on lower-cost VFDs. drives are analog and lower tech. They do not typically offer
communications or fancier control options, at least at the
Today’s entry-level VFDs, within the price range of OEMs
same price point.
and hobbyists, make project design and implementation
much easier with features like: Networking. Advanced networking is a bonus for many rea-
„ single-phase input to three-phase output sons. Many VFDs—even going back to the very first ones avail-
„ sensorless vector control for increased torque at lower able—supported some sort of serial communications but may
speeds have required specialized cables. Today, many VFDs commonly
„ advanced support for networks such as EtherNet/IP and support Ethernet communications, so configuring the VFD is
Modbus TCP
„ PID control for process closed-loop
control
„ an integrated PLC to perform logic,
which in some applications elimi-
nates the need for a separate PLC.
These newly available features can
benefit users in many ways.

Singe phase to three phase. A VFD

with a single-phase input and a three-
phase output is a “no-brainer” when
comparing features for an OEM or
hobbyist. Most hobbyists do not have
three-phase power available in their
shops or garages, but they may need
to control a three-phase motor. For an
OEM, this feature gives the option to
design for a single-phase power con-
nection and is likely to appeal to more
customers, and not just those with
three-phase power available.

Although a VFD is not a phase

converter, it can convert 120 VAC or Figure 2. Many AC VFDs have built-in PLC logic operation with simple programming inter-
230 VAC single-phase to a three-phase faces that will be familiar to those with PLC programming experience. They also include other
output for motor control. The benefits of features such as PID control and Ethernet communications.

INTECH JUNE 2022 25 WWW.ISA.ORG/INTECH

OPERATIONS & MAINTENANCE

more convenient, and if more than one VFD is installed and con- many end users want this machine to work in single-phase
trolled by a separate PLC, they are easily networked together. facilities. Instead of creating two separate designs, the OEM
The ability for human-machine interface and supervisory control could replace the PLC and motor starter assembly with one
and data acquisition systems to monitor and control many VFDs newer VFD that can accept a single-phase power input. With
connected on a manufacturing plant network is attractive to this solution, the OEM solves the problem; costs are reduced;
end users and OEMs alike, providing advanced operation and and there are fewer components and more potential customers.
supporting proactive maintenance to avoid breakdowns.
Even today’s hobbyists have a need for micro VFDs. For
PID control. For applications involving analog process example, many individuals buy a second-hand industrial lathe
control—such as the flow of a pump or fan—it is usually or grinder, which most likely requires three-phase power
necessary to implement closed-loop PID control. This can be for one or more motors. Even if the motor(s) is replaced, the
accomplished in a PLC. However, for many applications, the user should replace it with another three-phase motor, so
VFD can more effectively handle this function locally, while the speed may be varied. If the final use of the machine is a
offering an easy interface to tune the loop, saving substantial residential garage or personal workshop, it is unlikely the user
time during the machine startup. will have three-phase power available. Although the output of
the VFD cannot be used to power the entire machine, some
Most machines require some sort of control even if they
minor wiring changes can be incorporated, allowing the VFD
are not operating an analog process. Originally, this required
to control the three-phase motor with a single-phase input.
hardwired relay logic, which was eventually superseded by
PLCs to a great extent. For many smaller applications— Although basic small VFDs still exist, there are several com-
especially in the OEM or hobbyist realm—a PLC integrated pelling reasons for OEMs, hobbyists, and other end users to use
into the VFD has adequate I/O to control everything needed newer and extremely capable micro VFDs. In many cases, these
and represents a win-win on cost, design/programming labor, micro VFDs have benefited from the trickle-down effect. 
and panel space (figure 2).
All figures courtesy of AutomationDirect

Micro VFD considerations

There are few technical downsides to
using a micro VFD in simple, lower-cost
applications. A good rule to follow is if
you are certain that you will never need
to adjust the speed of a motor, then
do not purchase a VFD. But if there
is even a slight chance that the motor
speed may need adjustment, then a
newer, low-cost, high-feature VFD
should be a top consideration.

Concerns might be the added size of a

VFD compared to a contactor or starter,
but some current models are palm size
and consume about the same space as
a motor contactor and overload combo
Figure 4. A modern micro VFD with advanced
(figure 3). These micro VFDs have a
Figure 3. Micro VFDs can fit into about features and a NEMA 4X rating can provide
built-in PLC, PID control, sensorless the same space as a traditional contactor/ all the necessary logic, process, and motor
vector control, advanced network overload combo, yet provide many benefits control for a compact application, and often
support, and I/O expansion—at a cost and can even reduce costs in many areas. an entire control enclosure can be eliminated.
comparable to that of a motor contactor
and overload combo—but with added
ABOUT THE AUTHOR
benefits and reduced costs in other
Kevin Kakascik is a technical marketing engineer at AutomationDirect.
areas. They are available consolidated
Over his 20-year career he has held controls engineering positions
into a NEMA 4X package suitable for for machine OEMs, entertainment industry systems integrators, and
washdown areas (figure 4). material handling systems integrators. Kakascik has worked at
AutomationDirect since 2013 in technical and marketing roles. He
OEM machines often use a small PLC
holds a bachelor’s degree in computer science and engineering tech-
controlling an across-the-line motor
nology and an associate’s degree in electrical engineering technology.
starter assembly. Traditional designs
typically require three-phase power, but

INTECH JUNE 2022 26 WWW.ISA.ORG/INTECH

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 AUTOMATION BASICS

Using
Flowmeters
to Improve
Boiler E c ency
By Scott A. Rouse

Know your options when selecting the appropriate

flowmeter technology to measure natural gas,
water, and steam in power generation.
In many chemical plants, the electricity depends on the fluid being measured. determine steam production efficien-
the plant uses is derived from a natural When discussing boiler efficiency im- cy and to identify waste.
gas power plant or a cogeneration plant provements, three primary applications 3. Measurement of outlet steam pro-
burning waste gas streams. In large are involved: duction.
boilers (figure 1), power plants bring Optimize fuel-to-air ratio
1. Accurate inlet air and fuel (natural
together air and fuel (natural gas, waste
gas, waste gas, oil, or coal) measure- Power generation requires inlet air and
gas, oil, or coal) for combustion, which
ment for efficient combustion. fuel for combustion. Engineers must
creates heat. The heat boils the water,
2. Inlet feedwater measurement to measure the air and gas ratio accurately
creating steam. The steam runs through
a turbine, which causes the turbine to
spin, thus generating electricity.

Measuring the flow energy—flows of

fuel that cost money—in these boiler
applications is critical for improving en-
ergy efficiency, identifying waste, and
minimizing the greenhouse gases (GHG)
going into the atmosphere. Only with
accurate flow measurement can users
make informed decisions to improve
energy efficiency.

How do users decide which flowmeter

technology is best to measure the gas,
water, and steam for boiler applica- Figure 1. In typical boilers, air and fuel are combined for combustion, which creates heat to
tions? Choosing the right flowmeters boil the water, creating steam. The steam causes a turbine to spin, generating electricity.

INTECH JUNE 2022 28 WWW.ISA.ORG/INTECH

 AUTOMATION BASICS

for efficient combustion in the boilers.

Too much gas is wasteful, dangerous,
and costly; too little creates insufficient
flame to boil the water efficiently.

Orifice and turbine meters. Tradi-

tionally, monitoring fuel gas to the
boiler units is accomplished with an ori-
fice or turbine meter. However, these
are not the best measuring devices
for this application because they are
subject to failure and require frequent
skilled maintenance to provide an accu- Figure 2. Typical differential pressure flowmeter with additional pressure, temperature, and
differential sensors to infer mass flow.
rate and reliable measurement. Con-
strained piping conditions also can give
engineers headaches. For example, an
orifice meter requires 10 to 50 diameters
of upstream piping to eliminate the ef-
fect of flow disturbances. Because long
straight pipe runs are hard to find, most
flow measurement systems are affected
adversely by varying flow profiles
within the pipe.

The biggest cause for concern is that Figure 3. Direct mass flow measurement using thermal mass flowmeters.
orifice and turbine meters measure
volumetric flow. Additional pressure,
thermal sensor cools down, while accuracy at less cost. Onboard software
temperature, and differential pressure
the temperature sensor continues to apps also enable gas-mixing capability,
sensors, as well as a flow computer, are
measure the flowing fluid’s relatively in situ validation, and dial-a-pipe.
required to calculate or infer mass flow
constant temperature. The amount of
(figure 2). This not only degrades the
heat loss depends on the fluid’s thermal Measure inlet feedwater accurately
flow measurement accuracy, but the
properties and its flow rate. By measur- Water is also an expensive flow energy
installation and maintenance costs with
ing the temperature difference between and limited resource. In boiler applica-
this type of compensated measurement
the thermal and temperature sensors, tions, it is important to measure the
increase the cost of ownership.
the flow rate can be determined. inlet feedwater flow to the boiler accu-
Thermal mass flowmeters. In con- rately, because users need to measure
New developments in four-sensor
trast, thermal mass flowmeters are the efficiency at which the boiler turns
thermal technology, coupled with
suitable for direct mass flow measure- this feedwater into steam (figure 1).
stable “dry sense” sensor technology as
ment of gases, not volumetric flow.
well as advanced thermodynamic mod- Clamp-on ultrasonic flowmeters.
Because thermal mass flowmeters
eling algorithms, enable some thermal Although users could measure inlet
count the gas molecules, they are im-
flowmeters to attain ±0.5 percent read- water with a volumetric vortex flow-
mune to changes in inlet temperature
ing accuracy, rivaling Coriolis flowmeter meter, clamp-on ultrasonic flowmeters
and pressure, and measure mass flow
directly without compensation. In inlet
air and gas flow boiler applications,
thermal flowmeters perform well be-
cause the optimal fuel-to-air ratio for
efficient combustion in boilers is calcu-
lated on a mass basis, not a volumetric
one (figure 3).

In a thermal flowmeter’s simplest

working configuration, fluid flows past
a heated thermal sensor and a tempera-
ture sensor. As the fluid’s molecules
flow past the heated thermal sensor,
heat is lost to the flowing fluid. The

INTECH JUNE 2022 29 WWW.ISA.ORG/INTECH

 AUTOMATION BASICS

are ideal for water flow applications the steam’s mass flow rate. Even a simultaneously. Saturated steam’s den-
due to their ease of use and application “small” change of 10 percent in steam sity varies with either temperature or
flexibility. They achieve high accuracy pressure will result in a 10 percent error pressure, while superheated steam var-
at low and high flows, save time with in noncompensated mass flow. This ies with temperature and pressure, so
no pipe cutting or process shutdown, means that, in a typical differential pres- multivariable vortex flowmeters ensure
and are not affected by external noise. sure measurement installation, the volu- the flowmeter’s density calculations are
Advances in ultrasonic technology now metric flow rate must be compensated correct, and therefore, the mass steam
have onboard software and apps that by measuring temperature and pressure. flow measurements are correct. 
make the meter easy to install, provid- These three measurements (ΔP, T, and P)
All images courtesy of Sierra Instruments
ing a visual signal that it has been done are integrated with a flow computer to
correctly. calculate mass flow.

Insertion multivariable vortex flow- ABOUT THE AUTHOR

Optimize steam production
meters. Insertion multivariable vortex Scott A. Rouse (s_rouse@sierrainstruments.
The boiler’s steam must be measured
flowmeters measure steam output pro- com) is vice president of product manage-
accurately to determine whether
duction from boilers more accurately. ment at Sierra Instruments.
the boiler is producing the expected
One insertion
amount of steam or needs to be tuned
vortex flowmeter
for increased efficiency (figure 1). Tradi-
with one process
Case Study: Thermal Flowmeters Improve
tionally, steam flow has been measured
connection mea- Boiler Efficiency at a Chemical Plant in China
with a differential pressure device, typi-
sures mass flow
cally an orifice plate. Purified terephthalic acid (PTA) is the precursor to poly-
rate, temperature,
ethylene terephthalate (PET), the ubiquitous material
However, such devices are inherently pressure, volu-
used worldwide in plastic bottles, textiles, and elsewhere.
volumetric flow measurements. Changes metric flow rate,
A PTA chemical plant in China generates steam and elec-
in pressure and temperature will change and fluid density
tricity from its on-site power plant using coal as a fuel.
It also has a wastewater treatment station that produces
methane, which was flared off. Both processes are major
GHG emitters.

New government regulations required the company to

reduce its CO2 emissions. The plant decided to modify its
four boilers to burn both coal and the previously flared-
off waste gas (methane), for a savings of approximately
$0.5 million in coal each year. Working with a single-
source supplier, engineers reworked the boilers’ designs
and installed industrial insertion thermal flowmeters to
measure its combustion air and waste gas fuel.

One thermal flowmeter measures the waste gas flow,

while the other four thermal flowmeters provide sub-
metering of this gas stream to each boiler. Another four
meters measure preheated (200°C, 392°F) combustion
air to each boiler, allowing the boiler control system to
optimize the fuel-to-air ratio. The flowmeters provided
both precision flow data for complying with government
regulations and helped the company reduce waste while
increasing efficiency.

Other potential metering applications are under review,

including:
z Feedwater to the boilers using clamp-on ultrasonic
flow: Because this is a preexisting feed piping system, a
clamp-on ultrasonic meter is a flexible solution.
z Steam flow measurement: Measurement of steam flow
delivered from the boilers to the turbine generator and
submetering to the other plant processes.

INTECH JUNE 2022 30 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

#AutomationProDay Winners
Everyone was a winner on 28 April Valentina Freire said, “What a joy to
1945, which was the day The Instru- have a day only for industrial automa-
mentation Society of America got tion professionals! Congratulations to
started. In honor of that anniversary, these thousands that I know and cher-
ISA this year christened April 28th as ish so much!”
Ryan Kershaw toasted the job that
Automation Pro Day. Its social media
(among other things) proves that you Winners of the social media contest
outreach gathered pictures and stories
can wear dressy clothes under Nomex for their submissions were:
and congratulated those professionals
coveralls; needs you to constantly
(and students) for making the world a  Srinath Krishnamoorthi, Professional
learn just to keep up; dedicates a
better place through automation. Ryan Kershaw, Professional
good portion of your phone photo 

Felipe Sabino Costa submitted a storage to cool sites, random electri-  Prabhu Soundarrajan, Professional
picture “doing a cybersecurity training cal and process equipment, parts of  Ritam Mondal, Student
at the U.S. Department of Homeland stuff to be identified later, and wiring
Security facility to better protect our setups; and usually means a lengthy Visit ISA’s Facebook, Twitter, LinkedIn,
industrial control systems. #cyber- explanation whenever you are asked Instagram, or Pinterest accounts to see
security #training.” what you do for a living. all the stories and pictures. 

In Memoriam: Bridget Fitzpatrick

Bridget Ann Fitzpatrick, ISA Fellow and work in developing the first ISA standard Fitzpatrick was born in Portland,
process automation technical expert, on alarm management. Maine on 27 December 1964 during an
died suddenly last month while travel- ice storm, the eighth child (sixth surviv-
Fitzpatrick served the wider automa-
ing for work. She was 57. ing) of Ada Fraser and James Fitzpatrick.
tion community as a member of the
As her obituary said, “she entered the
Fitzpatrick was a highly knowledge- ISA84, ISA101, ISA105, ISA106, and
world determined. Her determination,
able professional with deep expertise ISA112 standards committees, and as
kindness, and brilliance were always a
in control and automation. She had a a member of the board of directors for
part of who she was. . . . Always at the
BS in chemical engineering from MIT, a UniversalAutomation.org.
back of her mind was a desire to solve
graduate degree in chemical engineer-
She also served as a U.S. expert to an big problems and ‘save the world.’”
ing from Michigan State, and an MBA
International Electrotechnical Commission Donations in memory of Bridget Fitzpat-
in technology management from the
committee developing an architecture for rick may be sent to the ISA scholarship
University of Phoenix. She worked most
distributed industrial automation systems. fund (www.isa.org/donation). 
recently for Wood, a global consulting
and engineering firm.

Fitzpatrick was an active and enthu-

siastic ISA volunteer who was named an
ISA Fellow in June 2016 for “innovative
improvement of alarm management and
human machine interface [HMI] design
practices.” She was a member of the
ISA Standards and Practices Board, as
well as managing director of the ISA18,
Instrument Signals and Alarms standards
committee.

In 2010 she received ISA’s Standard

and Practices Department Award (ISA-
18.2) in recognition of her outstanding
contributions as a technical editor in the
development of ANSI/ISA-18.2-2009,
Management of Alarm Systems for the Bridget Fitzpatrick (left) gives her ISA Fellow 2016 acceptance speech; shown with Peggie
Process Industries, and for pioneering Koon, PhD, 2014 ISA President.

INTECH JUNE 2022 31 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

Meet Graham Nasby, ISA Standards Excellence

Award Winner
ISA annually gives certification in 2012, and obtained his consensus-based technical standards
out a range of functional safety engineer designation committees within both ISA and other
awards honoring in 2015. Since then, he has worked for organizations. These include the CSA
its volunteers for the City of Guelph managing a team of P125 OT Functional Safety & Security
the professional specialists who look after the super- Committee; the IEC TC65/TC65A Indus-
work they do. visory control and data acquisition trial Process Measurement, Control,
ISA Standards, of (SCADA) system for the city’s drinking and Automation committees; AWWA
which there are water utility. Automation committee; and ISA com-
more than 150, reflect the work of mittees such as ISA18 Alarm Manage-
Nasby says he “cannot underscore
more than 4,000 industry experts from ment, ISA99 Cybersecurity, ISA101
enough the positive impact that ISA
around the world. The 2021 Standards HMI Design, ISA105 Commissioning,
standards work has had on my career.”
Leader of the Year, announced ear- and ISA112 SCADA Systems.
lier this year, is Graham Nasby, water
In search of useful best practices
SCADA & security specialist for the
City of Guelph, Ontario, Canada. Here
“It was back in 2010 that I first got To become an expert in a
involved with a standards committee,”
are some things he has been working
Nasby says. “At the time, I was designing
field, seek out the best-
on, and how he feels about his stan-
dards work with ISA.
automatic control systems for high- of-the-best.
purity water systems in the pharmaceu-
Nasby seems to have come naturally tical industry. I was having a hard time “It is primarily from my involvement
to his current job, having started at six finding useful best practices on how to with standards committees and the re-
years old with a succession of summer design both the control system and its sulting relationships with other experts
jobs rewiring boats at a local marina. process alarms. Seeing an article in InTech that has enabled me to build my career,”
This led to a lifelong interest in electri- about an ‘alarm management commit- Nasby adds. “I learned very early that
cal systems and to obtaining a degree tee,’ I contacted the article’s author one must always be learning, and, for
in electrical engineering and automatic [Nick Sands, now an ISA Fellow] and me, standards-committee involvement
control systems at the University of asked if I could get involved. Through is a big part of that. My participation in
Guelph. Nasby’s career took him into the ISA18 committee, I was able to work ISA standards committees has also giv-
a range of consulting and manufactur- with world-renowned experts in alarm en me great opportunities to practice
ing jobs in several industries: software management, as well as contribute back my communication, writing, consensus-
development, structural engineering, to the committee by sharing my own ex- building, and leadership skills.”
semiconductor manufacturing, ready- periences. The committee also gave me
Nasby adds: “One of the major
mix concrete, pharmaceutical manu- an opportunity to develop my technical
takeaways I have learned from being
facturing, construction, and municipal skills, and get experience with techni-
involved with ISA standards, is that
water/wastewater. cal leadership, consensus building, and
if you want to become an expert in a
communication skills.”
Nasby earned his professional engi- field, you need to seek out the best-
neer (PE) license in 2010, received ISA’s Fast forward to the present, and of-the-best for that field and find a
certified automation professional (CAP) Nasby is now involved with multiple way to work with them. Don’t restrict
yourself to just learning from people at
your own company or from a specific
ISA42, Nomenclature for Instrument geographic area. Being involved with
consensus-based technical standards
Tube Fittings RP to Be Updated work, such as with the ISA, has enabled
me to build my technical career.”
ISA42, Nomenclature for Instrument Tube tube fittings as commonly used in instru-
Learn more about Nasby’s role as
Fittings, is being reactivated to update a ment tubing systems. The purpose is to aid
2001 ISA recommended practice of the in the proper specification and application co-chair of the ISA112 SCADA Sys-
same name. The document defines nomen- of instrument tube fittings by standardizing tems standards committee and why
clature for tube fittings most commonly nomenclature. Those who are interested in the ISA 112 standard is important in a
used in instrumentation, and is intended participating are asked to contact Charley related post on the ISA Interchange blog
to apply to mechanical flared and flareless Robinson, [email protected].  (https://blog.isa.org).  –By Renee Bassett

INTECH JUNE 2022 32 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
STANDARDS

Widely Used ISA Symbols ISA & IEC In-Person Standards

Standard, ISA-5.1, Updated Meetings Reinstated
The most widely used of all ISA standards, ISA-5.1, Instrumenta- ISA95, Enterprise-Control System Integration, will hold
tion Symbols and Identification, has been published in a 2022 the first face-to-face ISA standards meeting since 2019 on
version that provides clarifications and corrections to the 9–10 June in conjunction with the ARC Forum in Orlando.
previous 2009 version. For information on the event, visit https://www.arcweb.
com/events/arc-industry-forum-orlando. For information on
Originally published as ISA Recommended Practice RP-5.1
ISA95, contact [email protected].
in 1949, the document was revised and expanded to become
an ISA and American National Standard in 1984, and then The Geneva-based International Electrotechnical
reaffirmed without change in 1992. Most of the identifica- Commission (IEC) will hold its 2022 general meeting 31
tion letter and symbol meanings or definitions that were October – 4 November in San Francisco, hosted by the
contained in ISA-RP5.1-1949 and ISA-5.1-1984 became American National Standards Institute (ANSI). The general
and remain accepted practice across the worldwide process meeting brings together IEC delegates from across the
industry sectors. globe for meetings and forums. Some 1,500 attendees are
expected.
In 2009, a major revision and update of the standard
was completed in which the symbology and identification The primary IEC technical committee with which ISA stan-
systems as described accommodated various advances in dards committees interact, IEC TC 65 – Industrial-Process
technology and reflected the collective industrial experience Measurement, Control and Automation, will not hold meet-
gained. That 2009 revision involved a detailed review by a ings in San Francisco. However, a committee in which several
large, multi-industry group of practitioners in the field of ISA standards leaders are active will meet. For information on
instrumentation and control, with an emphasis on the use of the IEC event, visit www.iec.ch. 
identification and symbol systems as a means of communi-
cating the intent of measurement and control systems to all
that need such information.

The 2022 revision of ISA-5.1 is intended to provide usage

clarifications and to correct typographical and technical
errors that have been uncovered over the years since the
2009 version. As such, this 2022 revision will serve as a
basis on which the ISA5 standards committee can begin
a more regular maintenance/revision cycle for this widely
used international standard.

To that end, a new working group is now forming to begin

work on the next revision of ISA-5.1. The overriding goal
will be to continue strengthening the role of the standard
as a communication tool in all industries that depend on
measurement, control, and automation systems to operate
and safeguard their manufacturing processes, machines,
and other equipment. This standard and future versions
will build on that foundation to serve the global process
industry sectors.

All who are interested in actively participating in the new

working group to begin the next revision of ISA-5.1 are asked
to email Charley Robinson, ISA Standards, [email protected].
Access ISA-5.1-2022 at www.isa.org/findstandards. 

This update was provided by Jim Federlein, retired PE and

principal of Federlein & Associates, Inc. He is an ISA Life Mem-
ber and a director on the ISA Standards & Practices Board. He is
chair of the ISA5.1 working group and of ISA105, Commission-
ing, Loop Checks, and Factory & Site Acceptance/Integration
Tests for Industrial Automation Systems. Federlein also serves
on IEC SC65E WG3, Commissioning.

INTECH JUNE 2022 33 WWW.ISA.ORG/INTECH

ASSOCIATION NEWS
HIGHLIGHTS & UPDATES AD INDEX

ISA Launches Indian Power

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Certified Control System Technicians Cole Neufeld, SaskPower, Canada www.opto22.com
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Level 1 Devin Payne, U.S.
Joseph Barrett, Alyeska Pipeline Service Company, U.S. ProComSol, Ltd.................................................33
Joseph Storer, American Refining Group, U.S. www.procomsol.com
Derek Belkofer, U.S.
Gary Wheaton, Pacific Business Partners, U.S.
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Seth Young, MillerCoors, U.S.
District, U.S. Real Time Automation ....................................10
Robert Allen Houtman, Jr., Kalsec Inc., U.S.
Level 3 https://www.rtautomation.com
William Joseph MacClain, Hollyfrontier
Harold D. Daniels, U.S.
Tulsa Refining LLC, U.S.
Gregory F. Gagnon, Advanced Control Systems, U.S. SME .....................................................................27
Mitchell Mann, Alyeska Pipeline Service Company, U.S. www.smartmanufacturingexperience.com
Sean W. Marsh, U.S.
Brandon Mastey, Xcel Energy – Sherco, U.S. Certified Automation Professionals Tadiran .................................................................. 9
Gunnar D. McConnell, Xcel Energy, U.S. Ote Amuta, Schneider Electric System Limited,
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Success
Juan Negrete, Akorn Pharmaceuticals, U.S. Malaysia
Enrique Ochoa, Flint Hills Resources, U.S. Ibnu Munzir, KIPIC, Kuwait
Desmond Paxton, U.S. Onome Omene, Bendel Automation and
Miguel A. Renteria, U.S. Controls Inc., Canada
Jesse Shepherd, Alyeska Pipeline Service Scott E. Owen, MWRDGC, U.S.
Company, U.S. Alaa Hussein Owis Mohamed, Egypt
Jesse Sherman, Associated Electric Hernan R. Patino, ECOPETROL S.A., Colombia
Cooperative Inc., U.S. Panisa Polpattana, U.S.
Michael Thorn, U.S. Yusuf Pribadi, Indonesia
Christopher L. Thrower, U.S. Luis Guillermo Rodriguez Alvarez, Instrumentos y
Julian Trott, Bermuda Controles S.A., Colombia
Branden Williams, Messer, U.S. Sankarsan Sahoo, Republic of Korea
David Sanchez, Ecuador
Level 2 Jesse Sherman, Associated Electric Download the ISA
Christopher P. Criblez, U.S. Cooperative Inc, U.S.
Paul Kaczorowski, MillerCoors, U.S. Anil Manohar Shinde, Canada InTech/Automation.com
Drew Lopez, Metropolitan Water District of Wei Hong Tai, Excel Marco Industrial Systems
Southern California, U.S. Pte. Ltd., Singapore Media Planner:
Antonio Mar, U.S. Wee Siam Tan, Singapore
Zulamin Masahod, Emirates Global Aluminium – Chengyu Wang, U.S. https://tinyurl.com/InTechAcom-
Alumina Refinery, Philippines Tyler Watson, BSI Engineering, U.S. 2022mediakit
Seth Milne, Bureau of Land Management, U.S. Joshua Welch, U.S.

INTECH JUNE 2022 34 WWW.ISA.ORG/INTECH

 FINAL SAY | VIEWS FROM AUTOMATION LEADERS AND

Optimize Energy Efficiency and Sustainability

Energy conservation is being pushed to the top load and output levels. Accurately measuring
of the priority list, driven by world events, rising demand and using the efficiency curves can help
energy prices, and supply chain issues. Pursuing select part loading of the boilers to achieve the
energy conservation is compatible with achieving most efficient energy use while serving the needs
climate improvement and sustainability goals to of the process. This can be done easily in existing
which automation and control professionals can systems and does not take artificial intelligence or
make even more meaningful contributions. highly elaborate algorithms to accomplish.

Manufacturing is a significant energy user

Practical solutions
worldwide, making conservation efforts a priority. By Bill Lydon
Ongoing monitoring provides the data to create
For example, the U.S. Energy Information Adminis- Lydon (blydon@
profiles and reports that are a foundation for
tration (EIA) reported in 2020 that the industrial isa.org) is an InTech
reporting energy data and identifying deviations
sector accounted for 33 percent of total U.S. ener- contributing editor
and areas for improvement. Analyzing patterns of
gy consumption. Energy is generally a hidden cost with more than 25
this data analysis permits plants to make better years of industry
that is part of factory overhead and not tracked as
decisions about controlling energy costs and mak- experience. He
part of the bill of materials for production. Out of
ing investments. regularly provides
sight, out of mind. In addition to lowering con-
news reports,
sumption, the return-on-investment (ROI) analysis Fundamental monitoring and control methods
observations, and
for energy saving expenditures should factor into are the first step, and later, other investments can
insights here and on
increasing company competitiveness. be made after analyzing the data to develop ROI Automation.com.
for more sophisticated energy savings invest-
Awareness and engineering ments. These might include minimizing peak
Automation professionals can achieve more demand by applying an electrical load-manage-
efficient energy use starting with awareness, ment system to monitor and
followed by engineering to save energy. The same control electrical consump-
engineering logic used to control the production tion of selected equipment,
process applies to energy management. Using automatically turning off air
Recent energy price
energy input and output and real-time measure- supply lines when product escalation, supply chain
ments, the efficiency of production processes can is not being produced, and
be calculated and optimized. using compressed air control
issues, and world events
An important first step is measuring and
systems to optimize opera- are putting renewed
tions.
tracking where, when, and how much energy is emphasis on more
being consumed. Before making investments in When data is not tracked
energy and power monitoring devices, automation and related to production
efficient energy
use.
professionals can use existing data in supervisory output, it can appear that
control and data acquisition, human-machine the initial energy consump-
interfaces, and historians. They contain a wealth tion investments are not paying off. Sustaining an
of information to develop meaningful profiles effective energy program requires ongoing data
of energy consumption and deviation without collection and analysis. Several methods can be
adding more hardware. For example, by tracking useful:
motor run times and using the nameplate power
z continue to reinforce energy as a priority in
consumption information, power consumption can
operational decision making
be calculated to track approximated energy use
z communicate program successes as they occur
without adding more hardware. Add to this alarm
z extend power- and energy-monitoring solutions
limits to detect unusual run times, and unusual
to support continuous-improvement efforts
start/stop cycles can be used to infer problems
z build in alarm advisories for energy key perfor-
that are wasting energy.
mance indicators.
Using sound application engineering to improve Energy conservation is essentially another type
efficiency can reduce energy. For example, multiple of control application engineering task to achieve
boilers serving a process plant typically each have production requirements efficiently and reliably at
different nonlinear efficiency characteristics–based the lowest energy consumption. 

INTECH JUNE 2022 35 WWW.ISA.ORG/INTECH

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ISA MEMBERS - CREATING A

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