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Contents
A4 Getting stronger process
readings
Getting an accurate process variable measure-
ment depends on many factors, but it must
begin with the right instrumentation.

A10 Three phases of industrial

digital transformation
Manufacturing, packaging, and logistics compa-
nies are unlocking new potential through digital
transformation with the power of the Internet of
Things (IoT) and advanced analytics.

A4
C OMMENT
Enhancing automation systems

E
ven though they are about different topics,
both articles in this issue are about enhanc-
ing automation systems.
Regardless of the medium being con-
trolled—flow, pressure, temperature, level—
every control scenario begins with the sensor.
There is no way to close the loop without it.
The cover story in this issue is about how to get
Jack Smith stronger readings from process instrumenta-
Editor tion. Although its focus is primarily on measur-
ing pressure, the concepts apply across much
of the range of process instrumentation. The
author explains in detail how pressure sensors
develop signals and the issues that can impede
that process.
In addition, she also explains the role and
operation of the transmitter. “The transmitter
takes the raw analog signal from the sensor and
cleans it up. Depending on the type of sensor,
it might generate a resistance, voltage, capaci-
tance, or some other type of signal in response
to the process variable. The transmitter must
measure the signal and compare it against the
desired range according to how the device is
configured.”
The author also discusses what to do with
instrumentation measurements from the trans-
mitter. “It may be something as basic as a
remote display with simple alarming functions,
or a more elaborate platform such as a pro-
grammable logic controller (PLC) or a distrib-
uted control system (DCS).”
The other article in this issue focuses on how
manufacturing, packaging, and logistics compa-
nies are unlocking new potential through digital
transformation with the power of the Internet
of Things (IoT) and advanced analytics. The
author proposes three phases to unlocking full
digital transformation: visualizing through fac-
tory connectivity and data integration; forecast-
ing using predictive production modeling and
responsive machine design; and self-regulating
data-driven manufacturing and ongoing transfor-
mation.

ON THE COVER Rosemount wireless pressure gauges use a sophisticated sensor with transmitter electronics to provide the capabilities of a full
electronic transmitter, but in an analog gauge form factor with a traditional needle display. Courtesy: Emerson Automation Solutions

Applied Automation December 2018 • A3

 P R O C E S S I N S T R U M E N TAT I O N

Getting stronger process readings

Getting an accurate process variable measurement depends on many factors,
but it must begin with the right instrumentation.

By Megan Wiens • The process fluid must have a path to reach the
Emerson Automation Solutions sensor.

C
onsider this typical situation: a process unit
in a chemical plant needs a pressure reading
from a reactor. The unit’s automation system
uses the reading to help determine reaction
rate, and the operators in the control room
want to see it on their human-machine inter-
face (HMI) screen. If the reading is lost, the process must
be shut down. How should the plant’s instrumentation
engineer make sure the reading is correct and always
available to the operators and the automation system?
For the purposes of this article, the focus is on measur-
ing pressure, but the concepts apply across much of the
range of process instrumentation. Think for a moment
about what must happen to get the reading from one end
of the chain to the other:
• The pressure sensor must be deflected in a
measurable way in proportion to the fluid pressure
against atmosphere.
• An electrical element must convert the deflection into
an analog signal.
• The transmitter must clean up the raw signal, scale it,
and transmit it using a prescribed format, either analog
or digital.
• Wires, or perhaps radio, must carry the signal to the
input/output (I/O) card of the automation system.
• The automation system must convert the signal into
appropriate engineering units for display and use the
data in whatever equations it is performing for the
larger control effort.
All of those elements must work correctly to capture
the right value in real time to support control and moni-
toring. Let’s pull on the chain
a little and look for potential
weak links.

Through to the sensor

The sensor itself is the one
moving part of the entire pic-
ture. It must flex in response
to the pressure in a predict-
able and consistent manner.
Usually, it involves a metallic
isolator diaphragm with a strain
gauge, or the movement is
measured through capacitance
(see Figure 1). For a strain
gauge, movement must be lin-
ear enough to deflect the same
amount for the same degree
of pressure change, and return
to its original form when the
pressure is relieved. It must be
sensitive, but at the same time
able to withstand pressures far
higher than its reading range.
Figure 1: The sensor diaphragm is the only moving part of the measurement chain. It must deflect For the sensor to be dis-
in a repeatable and reliable way in response to changing pressures. All images courtesy: Emerson placed, there must be a mecha-
Automation Solutions nism to allow the process fluid

A4 • December 2018 Applied Automation

to press against it, which means there must
be a process connection. The process fluid
must have a path to the sensor, or the
pressure gets transmitted via an uncom-
pressible intermediate fluid, in which case
there will be two isolator diaphragms with
a fill fluid trapped in between. There also
may be an impulse line so the sensor can
be mounted some distance from the actual
process equipment.
The path to the sensor or isolator dia-
phragm must be clear and unimpeded.
Any blockage can slow response or
decrease accuracy. Some transmitters
have the ability to determine when an
impulse line is plugging and can alert
operators of the problem forming.
Slugs of gas in a liquid line, or vice-
versa, can cause reading inaccuracy.
Impulse lines should be clear and bled,
although it can be beneficial to have
some condensate in a steam pressure line.
The physical and mechanical elements of the read-
ing chain are pretty well understood and established.
Sensor technology has not changed much over recent
years, but there have been more dramatic advances in
the next stages.
The busy transmitter
The transmitter of a process instrument has a lot to do,
so much that we tend to refer to a complete instrument as
a transmitter. Technically though, the transmitter is a spe-
cific part of the larger unit, with the sensor being the other
main part.
The transmitter takes the raw
analog signal from the sensor
and cleans it up. Depending on
the type of sensor, it might gener-
ate a resistance, voltage, capaci-
tance, or some other type of
signal in response to the process
variable. The transmitter must
measure the signal and com-
pare it against the desired range
according to how the device is
configured.
This can be an involved pro-
cess (see Figure 2). For example,
the transmitter often needs an
internal temperature sensor because the output of the
pressure sensor is affected by temperature in addition to
pressure. Additional corrections must be made for any
nonlinearity of the sensor. All of these elements, and more,
must enter into the signal processing.
Figure 2: Today’s transmitter is a small
computer capable of highly sophisticated
calculations, able to run without interruption
for many years.
The transmitter might even have a local
display to show the primary variable in appropri-
ate engineering units, and perhaps secondary
variables such as temperature. Ultimately, the final
output is the result of calculations and/
or look-up tables to scale the reading
according to the transmitter’s con-
figuration. The development of more
sophisticated electronics has made
this much easier, often without users recog-
nizing the improvements.
This in itself is impressive, but only part
of the picture. Today’s transmitters have addi-
tional capabilities such as self-diagnostics. While
the main signal processing functions are going on, there
also are internal functions evaluating the quality of power
coming into the transmitter, the condition of the internal
electronic components, sensor functionality, and other
items, including plugged impulse lines as just mentioned.
If a problem is present or developing, the diagnostics can
send a warning via a digital wired or wireless protocol.
Getting to the I/O point
Somewhere the processed electronic signal must be
turned into something a human being can understand. If
the reactor pressure is 110 psi, it must be converted and
displayed as that value or 7.59 bar or whatever the opera-
tors need. The local display on the transmitter is handy for
assisting with configura-
tion and troubleshooting,
but there are few applica-
Figure 3: Many transmitters have an on-board display to show the
current variable value and for configuration.
Applied Automation December 2018 • A5
 P R O C E S S I N S T R U M E N TAT I O N
Figure 4: A WirelessHART network can form a sustainable mesh with fewer than 10 instruments.
Retro design with today’s
sophistication
M
any users like the functionality of a tradi-
tional pressure gauge, but not its fragile
Bourdon tube, finicky mechanism, and
instability. Some wireless pressure gauges use a
sophisticated sensor with transmitter electronics to
provide the capabilities of a full electronic transmit-
ter, but in an analog gauge form factor with a tradi-
tional needle display (see Figure 5). A small stepper
motor moves the needle in real time. Add basic
diagnostic functions and WirelessHART communica-
tion, and it checks the most-wanted feature boxes
without the problems of traditional pressure gauges.
A6 • December 2018 Applied Automation
tions where a human will be close enough to the trans-
mitter to see it on a regular basis and react as required
(see Figure 3).
Some sort of automation system invariably enters into
the picture. It may be something as basic as a remote dis-
play with simple alarming functions, or a more elaborate
platform such as a programmable logic controller (PLC)
or a distributed control system (DCS). Traditionally, this
involves wiring to transmit a 4-20 mA analog plus HART
signal or digital fieldbus data, but WirelessHART now is
being used quite frequently.
For traditional users with the wired analog approach,
there are different ways in which the automation system
can process what it’s getting from the transmitter. Some
can read HART natively, but if the I/O only has the ability
to read the analog signal alone, all the other diagnostic
information will be stranded in the transmitter. It can warn
of problems, but the system won’t be able to hear it.
One way to address this issue is by adding a
WirelessHART converter to the transmitter. This allows
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 P R O C E S S I N S T R U M E N TAT I O N

the 4-20 mA signal with HART imposed to still Figure 5: Rosemount wireless pressure gauges
be transmitted to the automation system, use a sophisticated sensor with transmitter
with an additional WirelessHART signal electronics to provide the capabilities of
transmitted elsewhere, such as an asset a full electronic transmitter, but in an
management system, with all diagnostic analog gauge form factor with a tradi-
information intact.
tional needle display.
Some of the most sophisticated diag-
nostic capabilities extend beyond the
device itself and examine the larger con-
trol loop. Where smart I/O is available, the
diagnostics can detect and report conditions
capable of distorting the reading and creating
a false value. This warns operators of situa-
tions that appear to be correct but are wrong.
As straightforward as wiring is, it often emerges
as the weakest link. In a traditional wired environment,
the path from the actual transmitter to the I/O card of the
DCS easily can include multiple marshalling cabinets,
hundreds of feet of cable and perhaps 20 terminations.
If the wiring is 15 to 25 years old,
which is certainly not uncommon in
today’s facilities, the insulation is Some of the most
probably getting brittle and terminal
strips are quietly oxidizing. If left sophisticated diagnostic
undisturbed, these connections can
work for a long time, but if cable capabilities extend beyond the
bundles are moved around to solve a
problem or if marshalling cabinets are device itself and examine
opened for troubleshooting, problems cluster of wireless transmitters
can develop. For example, shorts and the larger control loop. can establish a sustainable
signal drop-outs can occur, disrupting network and support a variety
the control room and automation system. of instruments that do not depend on legacy wiring, or
Fortunately, new wiring and I/O systems can drasti- even need to interface with the DCS using conventional
cally reduce the number of terminations while adding I/O cards (see Figure 4).
native HART connectivity. Moreover, using WirelessHART
can reduce the terminations to perhaps two or even Strengthening the links
zero. Particularly when working in legacy environments, It’s important to know the weak links of a system, but
WirelessHART can have a higher reliability rating than building strong links is just as important. In many respects,
wired networks. having the best possible transmitter is the most important
element. If the source of data is not reliable and accurate,
Sum of the parts the best infrastructure in the world won’t make it any better.
As can be seen, all the elements must work together for The instrumentation available today from a variety of
effective measurements. Any part performing badly can suppliers is sophisticated, stable, accurate, and reliable. If
impede communication or cause it to break down alto- used in an environment capable of interacting with it fully,
gether. Some companies try to solve the situation by treat- it can provide secondary variables and diagnostic informa-
ing the symptoms rather than root cause. If a critical value tion in addition to its primary variable.
can’t get through to the DCS, the solution may be adding As companies rely more on automation in a growing
a redundant instrument on the same faulty infrastructure. variety of ways, reliable instrumentation is foundational.
It might improve the chances of data getting through, but it
is like a bandage. Megan Wiens is a global pressure product engineer
This is not always the best approach, but sometimes it for Emerson Automation Solutions in Shakopee, Minn.,
is a practical one. However, adding a redundant path via where she is responsible for advanced diagnostic capa-
WirelessHART is a much better option. If it isn’t possible bilities across the Rosemount pressure portfolio. In this
to upgrade existing infrastructure, simply adding another role, she works to implement product solutions that
path subject to the same problems is not the best option. improve plant safety, increase process efficiency, and
Even if there is no existing WirelessHART network, a small enhance process insight.

A8 • December 2018 Applied Automation

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 D i g i ta l t r a n s f o r m at i o n

Three phases of industrial

digital transformation
manufacturing, packaging, and logistics companies are unlocking
new potential through digital transformation with the power of the internet of things (iot)
and advanced analytics.

By Daniel Repp The goal is no longer about just automating the move-
Lenze Americas ment of physical product, but fully automating the data

T
he digital transformation of the manufacturing
industry is well underway but what that means
for plant engineers, specifically, is still a little
unknown. For many companies it is unclear
how to best implement the new digital technolo-
gies and how to determine which implementa-
tion partners will be the most reliable and experienced.
However, two things are clear: digitalization is critical if
companies want to stay competitive in the future, and
automation plays a key role.
as well. This requires moving from manual, human-
generated information workflows to a more real-time
process. Digital transformation is about digitalization,
networking, process analysis, and deep information
automation.
Transformation is the right term. While it won’t be
easy, digital transformation has the potential to unlock
formerly unattainable benefits for all aspects of manu-
facturing from a machine builder to factory floor to end
customers. There are three areas of potential to unlock
full digital transformation, many of which are already
well within reach.

Figure 1: Using intelligent, networked parts allows data to come directly out of the machine, eliminating human error and enabling a
much faster flow of information and business intelligence. All images courtesy: Lenze Americas

A10 • December 2018 Applied Automation


Bringing harmony to harmonics:
The standards and the challenges
W
ith the rapid increase in
both plant floor computers
and sophisticated electron-
ics, harmonics are getting
a lot of attention. Chris Jaszczolt of Yaska-
wa’s Matrix drives management team looks
at the IEEE 519 standards as well as the
practical challenges of harmonics:
Q: Harmonics have always been an
issue for manufacturers, but it seems
to be a more critical issue in today’s
plants. Why?
JASZCZOLT: Electric motors make up
over 45% of the world’s electrical energy
usage. In the past, only a small portion of
a pant used drives to control their mo-
tors. More and more of these motors are
being controlled by drives for their ener-
gy savings and process control benefits.
Having more drives on a system means
they will have a bigger harmonic impact
to the overall system.
Harmonic currents lead to conductor
heating, transformer heating and sizing
issues, power factor reductions, and low-
er efficiency. Also, high harmonic cur-
rents leads to the distortion of the input
voltage, which is what the recommended
practices outlined in IEEE 519 is trying
to mitigate. More recently, utility com-
panies are starting to fine their custom-
ers for high harmonic currents, citing
non-compliance with IEEE 519.
Q: Is there such a thing as an IEEE 519
compliant device?
JASZCZOLT: Non-linear loads like drives
are neither compliant nor non-compli-
ant with IEEE 519. IEEE 519 is a “rec-
ommended practice to be used for guid-
ance in the design of power systems with
non-linear loads.” In other words, the en-
tire system dictates whether or not
a system is compliant. However, it
can be stated that a drive facilitates
IEEE 519 compliance.
Advertisement
This means that the current harmon-
ics at the input of the drive is very low,
usually less than 5% iTHD (total har-
monic current distortion) at rated power.
If these drives are replacing an existing
drive system, they will reduce total har-
monic current draw for the system. For
new installations, using drives that fa-
cilitate IEEE 519 compliance virtually
guarantees that the new device will not
be the cause to a system non-compliance.
In other words, they will add much more
good load than bad (harmonic) load to
the system, which will reduce the percent
harmonic content of the overall system.
However, adding these devices does
not guarantee system compliance be-
cause they do not correct harmonic con-
tent of the pre-existing system. To obtain
system compliance, the entire system
should be analyzed to determine what
devices will need harmonic mitigation to
bring the entire system into compliance.
Q: Where should plant managers be-
gin to look for solutions to address
harmonic concerns?
JASZCZOLT: All drives should be looked
at to see if they can benefit from harmon-
ic mitigation. The focus should be on the
higher horsepower drive loads since they
will have the biggest impact on total har-
monic distortion for the system. Smaller
horsepower drives may not need high
level mitigation, since they have little im-
pact to the overall system distortion lev-
els. Typically smaller horsepower drives
can benefit from a simple, low cost ad-
dition of an input AC line reactor or DC
reactor.
Adding a reactor can improve harmon-
ic content from over 80% iTHD to less
than 40% iTHD at the input of the drive.
Most large horsepower drives already
have reactors built into the drive, which
means higher level harmonic mitigation
solutions would be needed to reduce the
total system harmonic distortion levels.
Finally, be aware that drives are not the
only non-linear load on a system.
Electric ballasts (lighting), arc furnac-
es, and all other switch mode power sup-
plies (servers, computers, etc) also draw
non-linear current and will affect total
system harmonic distortion levels.
Q: What tools are available to assist
plant managers in identifying and
managing their harmonics issues?
JASZCZOLT: Many drive manufacturers
understand the need for harmonic mit-
igation. Many submittals require a har-
monic report on the drive before being
quoted. Therefore, these drive manufac-
tures offer harmonic estimation software
to provide estimated harmonic content
of a specific device or an entire system.
Since the true harmonic content is
affected by more than just the load
(wire type, wire size, wire rout-
ing practices, grounding prac-
tices, etc.), these tools can only
offer an estimate.
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 D i g i ta l t r a n s f o r m at i o n
1. Visualizing: factory
connectivity and data integration
Today, the information flow at many plants is still man-
ual or semi-manual. Machine operators or engineers col-
lect data on paper or mobile devices—about things such
as how long it takes to prepare a machine for production,
to change from status A to status B, or to transfer part X
to part Z. That information is then loaded into a computer
program that can assess the data.
This process is light years ahead of where we were
just two decades ago, but still takes significant time and
effort, and there is the undeniable risk of human error
in the process—both accidental and intentional. How
do we get from the analog, linear model of the past and
reach the digital, platform-based model of the future? The
Internet of Things (IoT) and full-factory connectivity are
tools that will help enable the digital transformation.
Using intelligent, networked parts means data can
come directly out of the machine, eliminating human error
entirely and enabling a much faster flow of information
and business intelligence (see Figure 1). It also relieves
operators and engineers from having to collect data
manually and enter it into the existing process software
themselves. Instead, they can focus on their core work.
With a more connected and integrated data stream,
information can be pulled together from different process
steps or from different parts such as a motor or gear-
box or from entire production lines, which may contain
components and machines from various manufacturers.
The data can then be used to create a complete repre-
sentation of the existing production process—spanning
machines, plants, and even production sites.
Figure 2: Capturing and under-
standing the existing behavior
of a machine, machine line, or a
site is the foundation on which
more advanced analytics are built.
This provides visibility into part,
machine, and system trends.
2. Forecasting: predictive production
modeling and responsive machine design
Capturing and understanding the existing behavior of a
machine, machine line, or a site is only a small sliver of
what is possible. However, it is the foundation on which
more advanced analytics are built that provide visibility
into part, machine, and system trends. These trends
include predictive models to reduce or eliminate unex-
pected downtime or unforeseen problems (see Figure 2).
Instead of simply capturing linear values to assist in
visualizing what is happening at any moment, the system
captures complex, nonlinear developments or trends that
forecast problems. Warning systems can then be set up
to enable intervention in the production process before
critical values such as impermissible quality factor of
overloading of a machine occurs.
Advanced analytics often combine factory-level data
with other data streams such as business administration
information or weather data to account for external fac-
tors that can impact production. Factors such as ambient
temperature, humidity, differences in raw materials, or
shift management can easily be added into the digital
process.
The full potential of the IoT only can be realized if
there is a new level of coordination within a company,
including changes to the work environment and the
creation of a collaborative workforce. It also requires
OEMs, suppliers, data scientists, and engineers to work
collaboratively, a development which has resulted in
additional benefits.
Applied Automation December 2018 • A13
 D i g i ta l t r a n s f o r m at i o n

change how everyone within the industry functions,

3. Self-regulating: data-driven manufacturing
and ongoing transformation
One step beyond predictive lies total automation, in
which systems adjust themselves based on forecasting
models without manual interventions. Such systems rely
on innovative and ultra-efficient methodologies such as
statistical process control to optimize production on the
fly by tweaking various aspects that, to date, have been
onerous, manual adjustments. For example, changing the
setpoint values or even the whole process sequence of a
machine could be done without any human involvement.
Additionally, the ability to gain an abundance of criti-
cal information quickly through Cloud computing will
One step beyond predictive lies total
automation, in which systems adjust
themselves based on forecasting models
without manual interventions.
from suppliers to end users. The more machines and
systems that are analyzed, the more collective data that
can be used to identify which changes to a system or a
machine, or even a particular industry, might have the
most impact.
In the foreseeable future, we could see computer-
generated trends and predictions flowing directly to the
OEM so machines can be improved in real time, result-
ing in a stable, high-speed production process based on
the optimal use of the machine.
Data-driven manufacturing is the future. Companies
can only reach full digital transformation and realize all
the benefits if they’re willing to automate their informa-
tion data flow just as well as they automate their pro-
duction, printing, or packaging lines.
Daniel Repp is a business development manager for
automation solutions at Lenze Americas. In 2000 he began
working in the controls technology department for the
company’s German headquarters, and in 2011 relocated
to China as a business developer for automation solu-
tions. Repp moved to the U.S. in 2015 to begin working for
Lenze Americas.

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