Predictions for Process Control Instrumentation in 2024

Here are some leading technology predictions for the direction and focus of process control instrumentation in 2024:

• Remote Monitoring and Control Solutions:

The continued adoption of remote monitoring and control solutions through new software technologies will enable earlier detection of performance issues in process control systems, sending early warnings and diagnostic reports to facilitate quicker response times and improve operational flexibility​​. 

 

• Artificial Intelligence (AI) and Machine Learning:

AI and machine learning will revolutionize process control by enabling systems to learn and adapt autonomously. Advanced algorithms will analyze vast data to identify patterns, anomalies, and optimization opportunities. Tools will optimize PID control loops on the fly, improving efficiency and reducing downtime without intrusive plant step-tests​​. 

 

• Edge Computing:

Edge computing is a distributed computing paradigm that brings data processing closer to the data source or "edge" of the network. Edge computing will become more prevalent in process control, bringing data processing closer to the start of data generation, reducing latency, and improving system response times, which is particularly valuable in industries where milliseconds can make a significant difference, like robotics and high-speed manufacturing​​. 

 

• Cybersecurity Measures:

As process control systems become more interconnected and reliant on advanced technologies, robust cybersecurity measures will be paramount. Investments in encryption, intrusion detection systems, and comprehensive employee training programs will increase to protect sensitive industrial control systems from cyberattacks​​. 

 

• Sustainability and Energy Efficiency:

Sustainability concerns will continue driving advancements in process control technology. Advanced control algorithms will optimize energy usage, and real-time monitoring will help identify areas for improvement in energy consumption and resource utilization. This focus on sustainability will lead to more energy-efficient operations and reduced environmental impact​​.

These predictions indicate a significant shift towards more intelligent, secure, and sustainable process control environments. As these technologies develop and integrate, they will offer new opportunities for optimization, collaboration, and protection in various industrial sectors.

Process Technology, Inc.
https://process-tech.com
801-264-1114

What Are Temperature Control Valves and Temperature Regulators?

Temperature control valves and temperature regulators, often known as TCVs, actively maintain the temperature of a process. They achieve this by regulating the pressure or flow of thermal fluid in various components such as compressors, tank jackets, and heating coils. These devices are essential in processes requiring stable temperatures unaffected by fluctuations in the surrounding environment.

Temperature regulators fall into two main categories: self-actuated and externally actuated. Self-actuated temperature regulators operate independently without the need for an external power source. They use a thermally sensitive material that expands and contracts in response to temperature changes. This expansion and contraction drive the actuator, adjusting the valve's position and altering the flow path of the thermal fluid toward the heating element. This mechanical actuation provides precise temperature control, particularly suitable for applications where the setpoint remains constant and does not require frequent adjustments. Additionally, self-actuated temperature regulators offer a cost-effective solution for effective temperature management. These regulators are also known as self-operated temperature regulators.

Externally actuated temperature control valves often play a critical role in complex control systems, integrating an external temperature sensor and a Proportional-Integral-Derivative (PID) controller. These valves necessitate an external power source for operation. In a typical setup, the operator sets a desired temperature on the PID controller, continuously receiving feedback from the temperature sensor monitoring the process. The PID controller then compares the set temperature with the actual process temperature reported by the sensor. Based on this comparison, it sends an electronic or pneumatic signal to the temperature control valve, instructing it to adjust its position. This adjustment ensures the maintenance of the process temperature at the set point. This type of valve is beneficial in applications requiring frequent adjustments of temperature set points for automation purposes.

How Does the Jordan Valve Mark 80 Series Temperature Regulator Function?

The Jordan Valve Mark 80 Series Temperature Regulator operates independently, eliminating the need for an external power source or costly additional instruments. This self-sufficiency is due to its unique design: the actuator connects to a sensing bulb via a capillary system containing a volatile fluid. When this fluid heats up, it vaporizes, creating pressure within the system. This pressure acts on the diaphragm, prompting the valve to open (in reverse-acting models) or close (in direct-acting models). The Mark 80 Series, featuring a seal welded actuator (SWA), results from extensive research, ensuring the most accurate temperature control. When paired with Jordan Valve's sliding gate valve technology, the Mark 80 regulator achieves superior control. For added versatility, it allows field adjustments of the set point and can accommodate different temperature ranges without removing the valve from its installation.

The Jordan Valve Temperature Regulator Series also presents various self-operated regulator configurations to cater to higher flows, fail-open or fail-close settings, tracing lines, and pilot operations.

Process Technology, Inc.
https://process-tech.com
801-264-1114

From Raw Materials to Finished Goods: The Pivotal Role of Process Weighing

Process weighing plays a pivotal role in industrial applications and manufacturing. It forms the backbone of many production processes, ensuring products adhere to specific quality and safety standards. In industries where precision is crucial, minor discrepancies in weight can significantly impact product quality, safety, and efficiency.

There are two main types of process weighing: continuous weighing and static weighing.

Continuous weighing tracks materials as they flow or move continuously through a system. This approach is common in bulk material handling applications, such as food and beverage or chemical industries, where raw materials flow non-stop through a production line. Continuous weighing ensures that materials remain consistent in quantity and quality throughout production.

On the other hand, static weighing pertains to weighing stationary items used when goods need to be checked or verified against a set weight or standard. For example, in packaging applications, static weighing can ensure that packages contain the correct amount of product before shipping to consumers.

Batching technology complements these weighing methods by ensuring that raw materials or products are grouped in specific, predetermined quantities. Batching provides the correct proportion of each component in industries where products are mixed from various ingredients, leading to consistent product quality. It's an integral process, particularly in the food and pharmaceutical industries, where accuracy and consistency can be a matter of health and safety.

Siemens industrial weighing systems stands out as an excellent choice for these technologies. They offer a combination of precision, durability, and advanced technology, making them ideal for a wide range of industrial applications. Siemens has a history of innovation and reliability, which means their weighing systems come with the assurance of high-quality engineering and robust performance. Their systems integrate seamlessly into existing production environments, and they offer versatile solutions tailored to meet each application's unique demands. Moreover, with the support of Siemens' global service network, businesses can rely on expert assistance and timely maintenance.

Process weighing in industrial applications is a critical process variable. It guarantees the quality, safety, and efficiency of products. And with the technological prowess of Siemens industrial weighing systems, industries can achieve the precision and reliability they need to excel in today's competitive market.

Process Technology, Inc.
https://process-tech.com
801-264-1114

PTI and Siemens Process Instrumentation: A Strategic Alliance Driving Dynamic Growth for Industries in the Mountain States and Southwest

In the vast expanse of the industrial sectors spanning Utah, Western Wyoming, Idaho, Northern Nevada, Arizona, New Mexico, Colorado, Eastern Wyoming, and Montana, one partnership stands out for its unparalleled commitment to progress and quality: the alliance between Process Technology, Inc. (PTI) and Siemens Process Instrumentation.

Building on Legacy and Expertise

PTI has long been known for its unwavering dedication to innovation and quality, providing industries with top-tier products and solutions. Siemens, a global giant in process instrumentation, has a reputation for being on the cutting edge of technology, offering world-class solutions that enable industries to remain competitive and efficient.

The convergence of these two companies' strengths provides Mountain State industries with cutting-edge advancements in process instrumentation. Together, they enhance quality and efficiency.

The Solutions and Their Impacts

The collaboration focuses on crucial process control variables that determine efficiency and product quality:

• Flow Control: Proper flow control ensures that processes run smoothly without waste. The PTI-Siemens partnership offers an array of advanced flow meters and controllers, paramount in industries such as water treatment, oil and gas, and chemical processing.
• Temperature Monitoring: With cutting-edge sensors and devices, enterprises can now monitor temperature accurately, ensuring that processes requiring precise temperature conditions remain optimal.
• Pressure Control: From basic applications to highly critical ones, the pressure control solutions offered by the duo cater to all needs, ensuring safety, reliability, and efficiency.
• Level Monitoring: Ensuring that tanks and vessels maintain proper fill levels is paramount for safety and quality. The advanced-level monitoring solutions from PTI and Siemens ensure just that.
• Weighing Solutions: Precision in weighing is vital for many industries. With high-quality weighing solutions, enterprises can provide accurate measurements that lead to consistent product quality.
• Valve Positioning: Valves control many process parameters. Precise valve positioning means better control over the process, leading to enhanced efficiency and product quality.

Beyond Products - A Complete Ecosystem

Their commitment beyond mere product delivery makes the PTI-Siemens alliance even more exceptional. They provide an entire support ecosystem, including training, after-sales services, and software solutions. Such a holistic approach ensures that industries are not just buying a product but investing in a partnership committed to their growth and progress.

A Future-Ready Partnership

As industries evolve, so do the challenges they face. With the combined might of PTI and Siemens Process Instrumentation, industries across the mentioned regions can be assured of a partner always at the forefront of technology, ready to tackle new challenges head-on.

The PTI-Siemens partnership is more than just a business collaboration; it's a commitment to improving industries, delivering unparalleled quality, and a vision of a more efficient and sustainable industrial future. In the regions they serve, they are not just setting standards but defining the future.

Process Technology, Inc.
https://process-tech.com
801-264-1114

From Quality Control to Regulatory Compliance: The Power of Process Analytics

In industry, the significance of process analytics is paramount. Various industries, from water treatment and chemical processing to food and beverage production and pharmaceutical manufacturing, rely on it. For these operations, the intricate dance of monitoring and controlling complex process parameters is not just desirable – it's indispensable. The stakes? Optimal process conditions, impeccable product quality, and adherence to environmental and safety regulations.

Core Process Parameters

pH: 

A system's measure of acidity or alkalinity plays a pivotal role in many industrial processes. For instance, in water treatment, the correct pH ensures the effectiveness of disinfectants and prevents corrosion or scaling in pipes.

Oxidation-Reduction Potential (ORP): 

This parameter measures the ability of a solution to either gain or lose electrons. In water treatment and chemical processing, it aids in understanding the disinfecting power of solutions.

Dissolved and Gaseous Oxygen: 

Oxygen levels are crucial in various industries. For example, specific oxygen levels are essential in food and beverage production to prevent spoilage and ensure freshness. Meanwhile, sufficient oxygen levels are necessary for microbial degradation of pollutants in wastewater treatment.

Dissolved CO2: 

In beverage industries for example, the concentration of dissolved CO2 is a significant factor in determining the carbonation level in drinks.

Ozone: 

Often used as a potent disinfectant in water treatment, monitoring ozone levels is vital to ensure adequate disinfection without creating harmful byproducts.

Conductivity: 

This measures a solution's ability to conduct electricity, often indicating the amount of dissolved salts or impurities. In processes like desalination, monitoring conductivity to determine water purity is crucial.

Turbidity: 

This refers to the cloudiness or haziness of a fluid. In industries like water treatment, turbidity is a tell-tale sign of the number of particles present, affecting the efficacy of disinfection.

The Need for Accurate Measurement and Regulation

Process analytics isn't merely about knowing the numbers. It's about understanding these numbers and making informed decisions based on them. Here's why:

Maintaining Optimal Process Conditions: 

The right conditions are paramount whether brewing the perfect beer or producing a life-saving drug. Even slight deviations can lead to suboptimal outcomes or render a batch useless.

Ensuring Product Quality: 

Consistency is vital. For instance, nobody wants a flat soda one day and overly fizzy the next. Accurate process analytics ensures every product meets the required standards every time.

Regulatory Compliance: 

Failing to meet established standards can have serious consequences, especially in sectors like pharmaceuticals or food production. Not only can it lead to hefty fines, but it can also endanger consumers' lives.

Process analytics is more than just a set of numbers. It's the backbone of numerous industries, ensuring that processes run smoothly and products meet standards and meeting regulations. As industrial operations evolve, so will the tools and techniques of process analytics, always striving for perfection in every drop, bite, or pill.

Process Tech, Inc.

https://process-tech.com

801-264-1114

Siemens Process Instrumentation: Elevating Product Quality with Advanced Measurements

Process instrumentation is at new heights through the groundbreaking solutions provided by Siemens Process Instrumentation. Utilizing state-of-the-art technology, Siemens has developed a suite of innovative measurement systems designed to revolutionize operations in manufacturing plants and similar facilities. These solutions aim to increase plant efficiency by streamlining processes and reducing potential waste areas or slowdown.

One of the primary ways Siemens achieves this is by enhancing product quality. They do this by implementing advanced monitoring and controlling systems for various factors, including flow rates, temperature, pressure, and levels in a plant. By maintaining these factors at optimal levels, the products' quality can be greatly improved, reducing defects and increasing overall yield.

But Siemens doesn't stop there. In addition to the aspects above, they provide precise weighing and valve positioning solutions. These capabilities offer additional layers of control and precision in production processes. Whether it's ensuring the correct amount of material is used in a process or that a valve is positioned just right for optimal operation, Siemens Process Instrumentation is on the front line, elevating the standards of process control and optimization. Through their comprehensive suite of measurement tools, they continue to play a vital role in advancing industrial operations globally.

For more information about Siemens Process Instruments in Utah, Western Wyoming, Idaho, Northern Nevada, Arizona, New Mexico, Colorado, Eastern Wyoming, and Montana contact Process Technology, Inc.

https://process-tech.com

801-264-1114

Duckbill Check Valves: Ensuring One-Way Fluid Flow in Water Treatment, Mining and Industrial Systems

Duckbill check valves, also known as rubber check valves or elastomer check valves, allow fluid to flow in one direction but close to prevent backflow when the fluid direction reverses. The bill of a duck inspires their design, hence the name "duckbill."

Construction:

Duckbill check valves are constructed mainly from flexible materials like rubber or elastomers. The valve's shape resembles a duck's bill or a pipe tapering into a flattened or cylindrical end. This end is split into two halves lengthwise, forming the "lips" of the duckbill.

When pressurized from one side (the inlet side), the lips of the duckbill valve open to allow the fluid to flow through. When the pressure on the outlet side is higher or the flow ceases, the lips close to prevent backflow. The closing mechanism relies on the material's elasticity, which brings the lips back together when there's no differential pressure.

The simplicity of this design means there are no mechanical parts to maintain or fail over time, which contributes to the valve's durability and long lifespan.

Application:

Duckbill check valves have a wide range of applications, including:

• Water and Wastewater Treatment: Duckbill valves are commonly used in water and wastewater treatment plants to prevent backflow, which ensures that treated water doesn't mix with untreated water.
• Sewage Systems: They can be used in sewer systems to prevent the escape of unpleasant odors and stop pests from entering the system.
• Stormwater and Flood Control: Stormwater drainage systems can prevent floodwaters from flowing back into the drainage system.
• Industrial Process Lines: In various industrial processes where backflow must be prevented.
• Mining: In mining operations, duckbill check valves are used to control the flow of materials.

In short, the duckbill check valve is a simple, robust, and effective solution for managing fluid flow in a system, particularly in applications where backflow prevention is essential.

Process Technology, Inc.

https://process-tech.com

801-264-1114

V-Cone DP Flow Meters: Precision in Gas, Liquid, and Steam Flow Measurement

Flow measurement is an essential aspect of various industrial processes, ensuring the effective and efficient use of resources. There are numerous types of flow sensors available, each with its unique advantages and drawbacks. However, V-Cone Differential Pressure (DP) flow meters have emerged as a popular choice for measuring the flow of gasses, liquids, and steam in various industries.

V-Cone DP Flow Meters: A Brief Overview

V-Cone DP flow meters utilize the principles of differential pressure measurement to determine the flow rate of fluids. The V-Cone, a cone-shaped object placed in the flow path, creates a controlled disturbance, leading to a pressure differential. The flow rate is accurately calculated by measuring this differential pressure and applying specific equations. The V-Cone DP flow meters are highly versatile, capable of handling various flow conditions for gasses, liquids, and steam.

Comparative Advantages of V-Cone DP Flow Meters

Accuracy and Reliability

V-Cone DP flow meters have a reputation for exceptional accuracy and reliability, with typical accuracy rates ranging from ±0.5% to ±1.0%. This precision is attributed to the flow conditioning effect of the V-Cone, which reduces the need for a long upstream straight pipe run, minimizing the impact of flow disturbances. The result is consistent and reliable measurements across a broad range of applications.

Versatility

V-Cone DP flow meters offer unparalleled versatility, accommodating various fluids, including gasses, liquids, and steam. This adaptability enables industries to use a single type of flow meter for numerous processes, reducing the need for multiple flow measurement devices and simplifying maintenance and calibration procedures.

Low-Pressure Loss

The design of V-Cone DP flow meters ensures a low permanent pressure loss, providing energy savings and reducing the overall cost of operation. The cone's shape and position create a stable, self-conditioning flow profile, reducing the pressure loss associated with other flow sensors.

Wide Turndown Ratio

V-Cone DP flow meters boast a wide turndown ratio, often reaching 10:1 or higher, allowing for accurate measurement over a broad range of flow rates. This broad operating range enables industries to optimize their processes, reducing waste and ensuring efficient resource utilization.

Low Maintenance and Longevity

The robust design and construction of V-Cone DP flow meters contribute to their low maintenance requirements and extended service life. With no moving parts, V-Cone flow meters are less prone to wear and tear, reducing the need for frequent maintenance and replacement. The V-Cone's resistance to erosion and debris buildup makes it suitable for harsh environments and applications involving corrosive or abrasive fluids.

V-Cone DP flow meters offer numerous advantages over other flow sensors, making them a preferred choice for measuring the flow of gasses, liquids, and steam in various industries. With exceptional accuracy, reliability, versatility, low-pressure loss, wide turndown ratio, and low maintenance requirements, V-Cone DP flow meters have become indispensable for optimizing industrial processes and ensuring efficient resource utilization.

McCrometer, a leading flow instrumentation company, has succeeded remarkably with its V-Cone flow meter. Leveraging over six decades of industry expertise, McCrometer has designed the V-Cone flow meter to deliver unparalleled accuracy, reliability, and versatility in measuring gasses, liquids, and steam. The company's innovative approach to flow measurement has made the V-Cone a popular choice in various industries, including oil and gas, chemical, power, and water management. Through continuous research and development, McCrometer remains committed to providing advanced flow measurement solutions that meet the ever-evolving needs of its customers.

Process Technology, Inc.

https://process-tech.com

801-264-1114

Why is Turbidity Measurement Important in Industrial Manufacturing Processes?

Turbidity measurement is essential to measure and control industrial manufacturing processes for several reasons:

1. Product quality: In many industries, such as food and beverage, pharmaceutical, and cosmetic manufacturing, the clarity and appearance of the final product are essential for meeting quality standards and customer expectations. High turbidity can indicate the presence of impurities or contaminants, which may negatively impact the product's quality, safety, and shelf life.
2. Process efficiency: Monitoring and controlling turbidity can help optimize manufacturing processes, ensuring efficient use of raw materials and resources. High turbidity levels may indicate that filtration or separation processes are not working effectively, leading to increased waste and higher production costs.
3. Regulatory compliance: Many industries have strict regulations regarding their products' turbidity levels or wastewater discharges. Failure to comply with these regulations can lead to fines, penalties, and damage to a company's reputation. By monitoring and controlling turbidity, manufacturers can ensure they stay within regulatory limits and maintain a positive relationship with regulatory agencies.
4. Environmental impact: In some cases, high turbidity levels can harm the environment, mainly if a manufacturing facility discharges its wastewater into natural water bodies. High turbidity can reduce light penetration in water, negatively impacting aquatic life and ecosystems. Monitoring and controlling turbidity levels can help companies minimize their environmental impact and adhere to sustainable practices.
5. Equipment maintenance: High turbidity levels can lead to the accumulation of particles and contaminants in equipment, which can cause wear and tear, reducing the efficiency and lifespan of the machinery. By controlling turbidity, manufacturers can extend the life of their equipment and reduce maintenance costs.

Measuring and controlling turbidity in industrial manufacturing processes is essential for maintaining product quality, optimizing process efficiency, complying with regulations, minimizing environmental impact, and reducing equipment maintenance costs.

METTLER TOLEDO, a leading provider of precision instruments and services, offers a range of in-line turbidity sensors designed to deliver accurate measurements across a spectrum of turbidity levels, from low to high concentrations and in various industrial applications, such as monitoring fermentation processes in biotechnology and pharmaceutical manufacturing, observing crystallization in chemical and petrochemical industries, tracking phase separation in oil and gas production, evaluating post-filtration clarity in beer brewing, and assessing the quality of wastewater treatment in environmental management.

METTLER TOLEDO's in-line turbidity sensors offer an effective and reliable solution for monitoring and controlling turbidity levels in various industrial processes. By providing accurate, real-time measurements, these sensors help manufacturers maintain product quality, optimize process efficiency, comply with regulations, and minimize environmental impact.

Process Technology, Inc.

https://process-tech.com

801-264-1114

Enhance Your Facility's Performance with Local Expert Process Instrumentation Support

A plant's process control instruments are crucial for many industries, including oil and gas, power generation, water treatment, and pharmaceuticals. The management of these assets is complex and resource intense. Contracting the instrument management to a qualified local firm often makes excellent sense. Choosing a locally certified service company that will consult, commission, start up, and provide ongoing service is often a wise decision, as they offer benefits that help optimize your facility's performance. 

Let's break down each segment of a comprehensive instrumentation support program:

Consulting

Process instrumentation consulting involves a comprehensive assessment of a facility's process control systems and instrumentation, identifying areas for optimization and improvement. This service thoroughly evaluates the existing control infrastructure, performance analysis, and recommendations for system enhancements or upgrades. Consultants work closely with facility operators to develop and implement strategies that improve efficiency, reliability, and regulatory compliance, ultimately contributing to the operation's overall success.

Commissioning

Process instrumentation commissioning is a vital phase in the lifecycle of a control system, ensuring that all components are correctly installed, calibrated, and functioning as intended before being put into operation. This process includes rigorous tests, inspections, and adjustments to verify that the instrumentation and control systems meet design specifications and performance requirements. Commissioning helps to identify and resolve any potential issues before the system is fully operational, reducing the risk of future downtime and ensuring a smooth transition to ongoing production.

Start Up

Process instrumentation start up is the critical phase during which a facility's control systems and instrumentation are brought online and integrated into production. This stage involves carefully coordinating the activation of various components, ensuring that they function seamlessly together and operate according to established parameters. Start up procedures may include:

• Initial calibration.
• Tuning of control loops.
• Gradual ramping up of production levels to verify system stability and performance.

A successful start up ensures a smooth transition from commissioning to full-scale operation, minimizing potential disruptions and maximizing overall efficiency.

Ongoing Service

Instrumentation service agreements between a facility and a service provider define the scope of ongoing maintenance, support, and optimization of the facility's process control systems and instrumentation. These agreements typically include regular inspections, preventive maintenance, calibration, and system upgrades to ensure reliable and efficient operation. Additionally, service contracts often provide priority access to technical support, emergency response services, and expert advice for system improvements or expansions. By engaging in a service agreement, facility operators can maintain optimal performance, minimize downtime, and extend the life of their process control systems.

Process Technology, Inc. is a Local, Certified SIEMENS Instrumentation Service Provider

PTI is a locally SIEMENS certified service company with extensive knowledge and experience in many process control industries in the Mountain West, Front Range, and Southwest regions of the USA. They are familiar with your facility's unique challenges and requirements, as well as the local regulations and standards. PTI tailors instrumentation and maintenance programs to meet your specific needs and schedule. Additionally, PTI will always support your unplanned service needs, providing troubleshooting and a local inventory of instrumentation and analyzers to get you back up and running with minimum downtime. By partnering with PTI, you leverage their expertise to ensure that your process control instrumentation design, installation, and maintenance aligns in a way that maximizes efficiency and safety and complies with regional guidelines.