Industrial IoT Control Panel Design

Industrial IoT Control Panel Design

Introduction: What is IIoT and Why is it Important?

IIoT (Industrial Internet of Things) is the network of physical devices, sensors, vehicles, buildings, and other items in an  industrial realm—embedded with electronics, software, sensors, actuators, and connectivity that enables these objects to collect and exchange data. Process control IIoT applications used for measuring and monitoring flow, pressure, temperature, vibration and level are found in manufacturing, supply chain management, and smart factories.

Wireless Networking for Connected Devices

A wireless network is a system that allows devices to communicate with each other without the use of a wired connection. Wireless networks are becoming increasingly popular as they are easy to set up, cost-effective, and provide high performance and security for data transmission. They also offer mobility and versatility for users who need to access their data from multiple locations.

Control Panel Design for IIoT Systems

The control panel is the physical interface between the operator and the industrial automation system. It provides local control and monitoring of the process.  Wireless industrial control panels are replacing wired panels in many industries because of the benefits to users and companies:

Industrial IoT Control Panel Solutions:
  • Solve issues with costs and difficulties in traditional hard-wiring.
  • Quickly and locally identify process conditions and alert, alarm, or correct outputs to normalize the process.
  • Efficiently deploy various instruments and controls to interact with the process.
  • Provide easy-to-understand displays showing in-depth information.
  • Provide real-time information to corporate information systems.
  • Are easy to install anywhere, even in remote locations with no power supply.
  • Are more flexible with their use and have applications in many industry types.

Discuss Your IoT Control Application with Process Technology, Inc.

    Process Technology, Inc. Industrial IoT control panel solutions improve operational efficiency and lower costs. They safely and accurately monitor your analytical, flow, level, pressure, level, or vibration for compressors, generators, conveyors, tanks, and pipelines on a wireless or wired panel and offer options customized for your application.

    PTI sales engineers will discuss your requirements on-site and evaluate your precise needs. Factory engineers and service technicians provide design, manufacturing, and implementation for a complete, cost-efficient solution package to automate your process and factory automation needs.

    Contact Process Technology for more information. Call them at 801-264-1114 or visit them at

    SITRANS P Pressure Instrumentation by Siemens

    Siemens SITRANS P is a comprehensive line of measurement instruments for assessing absolute, differential, and relative pressure. Along with excellent operational ease and practicality, high measurement precision, and robustness, the modular system performs as a perfect safety concept.

    Process Technology, Inc.

    Process Refractometers for Petrochemicals and Oil & Gas Refining

    Process Refractometers for Petrochemicals and Oil & Gas Refining

    Vaisala K PATENTS® Process Refractometers provide precise in-line measurements of refractive index, concentration, and density that enhance oil and gas refining and petrochemical processes such as sulfuric acid alkylation, amine gas treatment, gas dehydration, and lubricating oil manufacturing. 

    Measurement Theory 

    Critical angle measurement is the measuring method. The refractometer has three primary parts: a light source, a prism, and an image detector. 

    The light source sends light rays at different angles to the prism and process interface. Rays with a steep angle are partly reflected to the image detector and partially refracted to the process. Rays with a low angle reflect totally to the detector. The angle from which the total reflection starts is called the critical angle. 

    The CCD camera detects bright and dark fields, which correspond to partially and fully reflected light. The critical angle, a function of the refractive index that corresponds with the concentration of the solution, determines where the boundary between the brilliant and dark region is. 

    An internal temperature sensor measures the temperature T during the liquid contact process. The sensor transforms the temperature T and refractive index nD into concentration units. Refractometers made by Vaisala K-PATENTS may display data on various scales, including Brix, liquid density, and concentration by weight. The diagnostics software guarantees the accuracy of the measurement.

    Process Technology, Inc.

    The Equilibar® Flow Control Valve

    Equilibar® Flow Control Valve

    The Equilibar® control valve is a precision back pressure regulator configured to control flow in a control loop with an electronic controller and a flow meter. 

    Over a broad range of flow rates, Equilibar® control valves enable accurate flow control for gases, liquids, and mixed-phase fluids. The unique dome-loaded multiple orifice design adapts swiftly to changes in upstream and downstream process disturbances to maintain the setpoint.

    The Equilibar® control valve functions differently than typical regulators and valves. The control valves are dome-loaded, and pilot operated, which means that gas is supplied to the dome (top) of the valve via a pilot controller to set the process setpoint. In the dome, a direct sealing diaphragm covers a field of orifices and adjusts its position allowing flow through the orifices while maintaining the desired setpoint. 

    Equilbar Control Valve Loop

    The Equilibar® flow control valve links to an electronic pilot pressure controller and a flow meter in a control loop. (See Fig.A.) To control flow, a proportional-integral-derivative (PID) controller monitors input from a flow transmitter (FT) and adjusts the pilot pressure. The electronic signal from the PID converts into a pressure signal for the pilot controller by an electro-pneumatic transducer (E/P). Increasing the pilot pressure reduces flow, and decreasing the pilot pressure increases flow. The system performs best when the supply pressure is stable.

    Equilibar® valves may be an ideal closed-loop flow control option under challenging situations where typical flow control techniques fail. Equilibar® valves increase performance in a wide range of demanding applications such as:
    • Flow coefficient (Cv) ranges wider than conventional valves (>100:1)
    • Extremely low DP and extremely high DP
    • Two-phase, phase-change, and supercritical states
    • Continuous flow chemistry
    • Sanitary applications
    For more information about Equilibar® products in Utah, Western Wyoming, Idaho, Northern Nevada, Arizona, New Mexico, Colorado, Eastern Wyoming, and Montana, contact Process Technology, Inc.

    Process Technology, Inc.

    Tutorial for Setting the Siemens SITRANS P320/P420 for Level Measurement Applications

    When used to determine fluid levels, pressure transmitters work on the following principle: the pressure at the bottom of a liquid body is proportionate to the height of the fluid above it. The transmitter measures the hydrostatic head pressure to get the fluid level measurement.

    SIEMENS SITRANS P320/P420 pressure transmitters are digital pressure transmitters known for user-friendliness. SITRANS P hydrostatic level technology is suitable for use in harsh environments in the environmental, chemical, and petrochemical sectors. SITRANS P pressure/differential pressure transmitters are highly resistant to chemical and mechanical stresses and common electromagnetic interference. 

    SITRANS P320/420 is the first pressure transmitter with remote safety handling. The remote safety management of the instruments through SIMATIC PDM saves time during SIL commissioning since operators may access transmitters from the control room rather than physically configuring each device across a facility. In situations needing functional safety, this decreases commissioning time. Both pressure transmitters feature a longer proof test interval than comparable devices on the market, with testing periods lasting up to fifteen years instead of every two, drastically reducing maintenance expenses.

    Process Technology, Inc.

    Control Performance Analytics - CPA

    Control Performance Analytics - CPA

    Control Performance Analytics - CPA

    As the complexity of industrial process applications grows, so do production management requirements for process safety, adaptability, and product quality. More openness is required to recognize the possibility for process improvement and fine-tuning.

    Control performance is critical in process industries for meeting production objectives. Each process application begins with a single control loop. According to studies, around 50% of all control loops are not well-tuned, whether owing to non-optimal settings, manual operation, oscillating controlled systems, or mechanical faults with control valves.

    Furthermore, process engineers are generally in charge of hundreds of control loops in large-scale process facilities. Evaluating control performance across several process stages for alarms takes a significant amount of effort and knowledge. Due to continuous process changes and equipment wear and tear, detecting potential areas for improvement and modifying control loops is not a one-time activity.

    Automated Control Loop Analysis for Efficient Plant Optimization

    CPA is a cloud-based managed service that improves the transparency of process data and the optimization of control loops. The collection and analysis of plant-wide data provide the client with comprehensive product control. Automatic KPI (key performance indicators) computation identifies control loop states, which can recognize setpoint tracking, steady-state difficulties, and even static or sliding friction in-process valves. The tool also enables automated testing of new parameter sets to test control loops without interfering with plant operations.

    CPA - What Is It?

    CPA takes data from SIMATIC PCS 7 or any other process control system, for example, in CSV format, and sends it to Siemens' cloud-based IoT operating system, such as MindSphere, through a secure connection. CPA creates reports and recommendations for the customer's support teams or Siemens' process consulting specialists to analyze based on the data. Finally, optimization ideas help to enhance the process.

    Benefits of Control Loop Optimization Through CPA

    • Increased product quality due to lower fluctuation in process variables
    • Maximized equipment lifetime due to reduced variability in actors
    • Improved set points raise throughput by going closer to the limits
    • Resource savings thanks to improved set point tracking behavior (e.g., energy, raw material)
    • Reduced manual mode of control loops allows overlaying control optimizations such as Advanced Process Control
    • Fewer alarms and fewer operator interactions reduce operators‘ workload

    Siemens CPA User Advantages

      • Includes hierarchical plant overview, from management view to single control details for Siemens SIMATIC PCS 7 and other DCS.
      • Identification of optimization potential as a result of correlating process data automatically with possible asset problems.
      • Intuitive interface enabling customer to use the application without extensive training.
      • Messaging behavior, service factor, steady state accuracy, set point tracking and static friction probability for various control states.
      • Long-term process optimization and flexible managed service approach – pay only when you use the application.
      • CPA is part of Siemen's Asset and Process Performance Suite for industrial applications and advanced analytics.
    Contact Process Technology for all your Siemens Process Control products. Call them at 801-264-1114 or visit them at