JUNE 2023

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

AUTOMATION
FUNDAMENTALS

Fundamentals of PID Control

ISA-TR5.9-2-23: Achieving the Best PID

Basics of Control Valve Flow

Characteristics

Remote-Site Data in Real Time:

A Case Study

Industrial Computers: Robust and Ready

 2023 JUNE
DIGITAL MAGAZINE Advertisers Index
To obtain further information, please contact
the advertiser using the contact information
contained in their ads.
FROM THE PUBLISHER: WELCOME!
As the official publication of International Society of Automation
International Society of Automation
(ISA), InTech digital magazine serves ISA members and the wider Setting the Standard for Automation™

automation community with practical, in-depth coverage of Page......................................................................... 8, 47

automation technologies, applications, and strategies that help
automation professionals succeed.

InTech is written for engineers, managers, and other automation

decision makers, and is brought to you 6x per year with the
Page................................................................................ 7
support of the advertisers shown at the right. Topics include
industrial cybersecurity, process and machine control, smart
manufacturing, Industry 4.0, IIoT and much more.

InTech advertisers support ISA and are pleased to provide ad-

Page..............................................................................33
ditional information about their automation products and services.
To obtain more information, click the logos shown to see the ads
in the magazine. Then, on the ad page itself, click through to the
vendor websites.
Page................................................................................ 3
Don’t Miss a Single Issue
InTech digital magazine publishes six times per year. ISA Members
receive InTech digital magazine as part of their annual membership
and get access to archived issues. Non-members can subscribe to
Page................................................................................ 5
InTech and InTech Plus newsletters through ISA’s automation news
and information subsidiary, Automation.com.

Rick Zabel, Managing Director

InTech, Automation.com & Events Sponsorships
International Society of Automation (ISA)
Page..............................................................................11

International Society of Automation

Setting the Standard for Automation™ Page..............................................................................34
company/internationalsocietyofautomation

InternationalSocietyOfAutomation

ISA_Interchange

Page..............................................................................10
Trademarks used in this document are the property of their respective owners.
 We offer process application expertise

SUPPORT
through our products, solutions and services.

+ SUCCESS You optimize your process for maximum safety, reliability

and efficiency, with minimum impact on the environment.

Customers around the world trust us when it comes to

process automation. Our shared goal is plant safety, availability
and efficiency. We are with you every day, everywhere.

People for Process Automation

Do you want to learn more?

www.us.endress.com
JUNE 2023 | VOL 70, ISSUE 3

FEATURES
PROCESS CONTROL

12 Fundamentals of PID
Control
By Jon Monsen
Proportional-integral-derivative (PID)
is the most common industrial technol-
ogy for closed-loop control.

PROCESS CONTROL

22 ISA-TR5.9-2-23:
Achieving the Best PID
By Peter Morgan and Greg McMillan
New ISA Technical Report distills PID
expert thought to improve process
performance.

OPERATIONS

29 Understanding
Control Valve Flow
Characteristics
By Joao Bassa MACHINE CONTROL
Learning the basics can ease loop tun- 41 Industrial Computers:
ing frustration and ensure stability.
Robust and Ready
CONNECTIVITY By Jack Smith

35 Remote-Site Data in Industrial PCs differ from consumer

PCs in ways that are vital to industrial
Real Time: A Case Study automation applications.
By Jack Smith
Wireless devices reduce road trips for
pulp and paper mill workers.

INTECH JUNE 2023 4 WWW.ISA.ORG/INTECH

Connect The Dots With
The Unlimited Platform for Total System Integration

ALL YOUR
DEVICES
ALL YOUR
DATA

ALL YOUR
OPERATIONS

ALL YOUR
PEOPLE

ONE PLATFORM TO CONNECT

ALL YOUR PROCESSES,
PEOPLE & PROGRAMS
ALL YOUR Learn more
LOCATIONS about Ignition:
ia.io/platform
 OFFICIAL PUBLICATION OF THE INTERNATIONAL SOCIETY OF AUTOMATION

EDITORIAL & PRODUCTION

JUNE 2023 | VOL 70, ISSUE 3 CHIEF EDITOR: Renee Bassett, [email protected]
SENIOR CONTRIBUTING EDITOR: Jack Smith, [email protected]

DEPARTMENTS
CONTRIBUTING EDITORS: Bill Lydon, [email protected]
Charley Robinson, [email protected]
PRODUCTION EDITOR: Lynn DeRocco
9 Talk to Me ART DIRECTOR: Bonnie Walker
By Renee Bassett
GRAPHIC DESIGNER: Jamie McLendon
Training on the Fundamentals of Automation
DIGITAL DESIGNER: Colleen Casper
46 Association News
z ISA Pub Hub: Member Access to a Wealth of
ISA MEMBER LEADERS
Technical Content ISA PRESIDENT: Marty Bince
z ISA Connect Wins Award for Best Community ISA PAST PRESIDENT: Carlos Mandolesi
Design ISA PRESIDENT-ELECT & SECRETARY: Prabhu Soundarrajan
z OT Cybersecurity Summit Successfully Debuts ISA TREASURER & PUBLICATIONS COMMITTEE CHAIR:
48 Final Say Steve Mustard
By Steve Mustard
The Future of Workforce Automation Competency
ADVERTISING & SPONSORSHIP
Rick Zabel, PUBLISHER
[email protected]
Chris Nelson, ACCOUNT EXECUTIVE
[email protected]
Richard T. Simpson, ACCOUNT EXECUTIVE
[email protected]
Gina DiFrancesco, ACCOUNT EXECUTIVE
[email protected]
Cathi Merritt, ADVERTISING PRODUCT MANAGER
[email protected]
Matt Davis, DIGITAL MEDIA PROJECT MANAGER
[email protected]

2023 Media Planner

To order reprints of InTech print or digital articles, contact

[email protected] or 800-428-3340.

©2023 International Society of Automation (ISA) ISSN 0192-303X

Editorial and advertising offices are at 3252 S. Miami Boulevard, Suite 102, Durham, NC 27703; phone 919-549-8411;
email [email protected].

InTech digital magazine publishes six times per year. ISA Members receive InTech digital magazine as part of their annual
membership and get access to archived issues. Non-members can subscribe to InTech and InTech Plus newsletters through ISA’s
automation news and information subsidiary, Automation.com. InTech and the ISA logo are registered trademarks of ISA.

Trademarks used in this digital magazine are the property of their respective owners. Opinions expressed or implied are those of
the persons or organizations contributing the information and are not to be construed as those of ISA.

INTECH JUNE 2023 6 WWW.ISA.ORG/INTECH

| PC11-51USA |

Inside the cabinet? Outside?

You choose with our powerful,
ultra-compact IPCs

www.beckhoff.com/c6015
www.beckhoff.com/c7015
Small enclosures. Harsh environments. Evolving requirements. As engineers, we know these factors must be
addressed constantly. Every new machine presents unique challenges and opportunities to innovate. So our
ultra-compact Industrial PC series gives you freedom to choose the perfect controller for every machine. Maybe
it’s the C6015 with dimensions of just 82 x 82 x 40 mm and outstanding installation flexibility. Or maybe your
machine calls for the IP65/67-rated C7015 for cabinet-free installation. All IPCs in this series deliver powerful
control to simultaneously run automation, HMI, edge computing/IoT and other communication – all on one
controller. They make ideal gateways to the cloud and support flexible I/O system expansions – inside or
outside of the cabinet. The choice is yours.
 International Society of Automation
Setting the Standard for Automation™ isa.org/alc

AUTOMATION
LEADERSHIP
Conference

4–6 October 2023 | Colorado Springs, CO, USA

The ISA Automation & Leadership Conference (ALC) is the automation event WHO SHOULD ATTEND?
of the year—combining ISA’s leadership conference with the best technical
presentations from its automation conference series into an unparalleled • Automation Engineers
event experience.
• Process Control Engineers
You will have the opportunity to network with ISA leaders and automation
International
professionals Society
from around the of Automation managers, engineers,
world—including • Security Engineers
Settingand
technicians, the Standard
subjectfor Automation
matter ™ This conference includes:
experts.
• QA Engineers
• Society meetings and leadership presentations
• Vital technical sessions and access to an array of technical subject matter • Plant Engineers
experts from the US, Canada, Middle East, Brazil, Malaysia, Spain, and India
• Manufacturing Engineers
• Interaction with other conference attendees—in person or virtually
• ICS Cybersecurity Engineers
• Exhibitor booths with insight and information on the latest products and
technology in the industry • Digital Transformation
• The ISA Honors and Awards Gala Managers
• Engineering Managers
KEYNOTE SPEAKER ISA TRAINING COURSES
• Security Operations Center
Mark Weatherford • Using the ISA/IEC 62443 (SOC) Managers
CSO and SVP of Standards to Secure Your
Regulated Industries, Control Systems (IC32) • Compliance and Risk Managers
AlertEnterprise
and Chief Strategy • Introduction to Data • Chief Information Officers (CIOs)
Officer, National Visualization (DT103)
• Chief Information Security
Cybersecurity
Officers (CISOs)
Center

INTERESTED IN SPONSORING?

Check out our sponsorship prospectus at isa.org/sponsor or contact:

Kim Belinsky Morgan Foor
+1 919-990-9404
[email protected]
+1 919-990-9267
[email protected]
Learn More
 TALK TO ME | PERSPECTIVES FROM THE EDITOR

Fundamentals: Not Only for Beginners

By Renee Bassett, InTech Chief Editor

More than 11 million people currently are measure—primarily temperature, pressure,

employed in manufacturing in the U.S., and level, and flow, plus other things—how to
according to the U.S. Chamber of Commerce, measure it, what technologies exist for
the latest data shows 9.9 million manufactur- measurement and control, and other basic
ing job openings. On top of that, about 17 building blocks of how industrial process
percent of the general U.S. population is 65
works.
years old or over—a figure that is expected
to reach 22 percent by 2050. Globally, given Rothkopf points out that the course is

the retirements, shortages of qualified new fundamental, but not necessarily only for
workers, and millions of existing workers beginners. “For someone who has success-
whose job requirements may be changing, fully operated as a technician for 5+ years, it
training is more important than ever and would be more of a review. I would typically
fundamentals are essential. That’s why this direct a more seasoned professional like
July 2023 issue of InTech focuses on automa- that to a more advanced course. But for
tion fundamentals. someone changing positions, or who might
Fundamentals have been a staple of ISA have technical but not necessarily industrial
Training, so I talked with Matt Rothkopf, ISA’s experience, this course can provide essen-
manager of learning consultation, about a tial context,” he says. “It covers essential
course that has become a best-seller among concepts and terminology, which is good for
ISA’s wide range of training, certifications, someone with less experience who will be
and publications designed to enable industrial
undertaking more intensive training, like ISA’s
companies and their workers to adapt to
very popular Bootcamps.”
changes and challenges.
The workforce is aging out and businesses
Fundamentals of Industrial Process
have learned that they cannot hire their way
Measurement and Control (FG05M) is a
out of experience shortages. They have to
modular, self-paced, computer-based training
course derived from the FG05 Traditional, organically grow their workforce with formal

or classroom, course that ISA has offered training and structured programs. ISA is the
for more than 30 years. Course content place to find programs ranging from on-site,
has evolved over the years, says Rothkopf, instructor-led training to self-paced online
but it is “foundational.” It defines what to courses.

INTECH JUNE 2023 9 WWW.ISA.ORG/INTECH

We bring color into view!
Compact capacitive level switches with
360° custom-color status display

256 colors
Individually selectable:

Measurement in progress
Sensor switching
Process malfunction

Hygienic
adapter system

▪ Completely flush sensing element

▪ Works on pastes and viscous media
▪ No spray cleaning shadows
Adjustment via ▪ Very small installation dimensions
smartphone

$484
VEGAPOINT 24 G½"

www.vega.com/vegapoint
Edge devices are transforming the way we connect and control our world. With a library of over 140
Ethernet and Serial protocols, MSA FieldServer offers universal access to your vital controls and device
data. Exchange information, push out alarms, capture historical data, make calculations, and feed your IoT
applications. All in a compact platform that meets stringent cybersecurity requirements and has no OS to
maintain. Experience the power of edge computing today. Learn more at msasafety.com/fieldserver.

21-6657-MCP / 04.2023
PROCESS CONTROL

Fundamentals
of PID Control

Proportional-integral-derivative (PID) is
the most common industrial technology for
closed-loop control.

By Jon Monsen
A proportional-integral-derivative (PID) controller can be used to
control temperature, pressure, flow, and other process variables. A
PID controller combines proportional control with additional inte-
gral and derivative adjustments to help a controller automatically
compensate for system changes.

INTECH JUNE 2023 12 WWW.ISA.ORG/INTECH

PROCESS CONTROL

Proportional
Using the error to reduce the error

Figure 1. Proportional only controller.

The basic control mode is “proportional,” change in input.” For a proportional controller,
which “uses error to reduce error.” The dia- the output is the controller output (abbreviated
gram in Figure 1 illustrates how proportional “C.O.”). The input is the error between setpoint
functions. Shown is a mechanical propor- and measurement. Throughout this article, “e” is
tional controller consisting of a float that the error between the setpoint and the process
operates a valve to maintain the level at the variable measurement. The symbol for gain is
desired setpoint (SP) of 50 percent. usually “K.” Here, the focus is on “proportional”

Consider what would happen if the ful- gain, so the symbol is “K” with a subscript “p”

crum point was set at the left most position for “proportional.”
(for now ignore the other two fulcrums). For the fulcrum in the left-most position
The operation of the controller is graphically and the resulting graph of error versus valve
represented by the blue line with the steep- position with the steepest slope when the
est slope. The horizontal axis is the percent error changes from minus 25 percent to
error from the setpoint of 50 percent full. The plus 25 percent (a total of 50 percent), the
vertical axis is valve position. If this were a valve position changes by 100 percent. The
pneumatic or electronic controller, the verti- proportional gain is 100 divided by 50, or 2.
cal axis would be the controller output signal, With the fulcrum in this far left position, the
but because this is a mechanical controller, result is the largest change in valve position
the controller output is the valve position. for a given change in float position. Of the
The definition of gain of any device is three fulcrum positions, this one will give the
“change in output divided by the corresponding highest gain (or the greatest sensitivity).

INTECH JUNE 2023 13 WWW.ISA.ORG/INTECH

PROCESS CONTROL

If the fulcrum is moved to the center “Offset” is the difference between the
position, the valve travel does not change as setpoint and the actual measurement—in this
much for the same amount of error, and the case, tank level. If the valve is not in the right
action of the controller is represented by the position for the load from the very beginning,
red line on the graph. In this case, a change or once there is a change in load (in this
in error from minus 50 percent to plus 50 example, the flow out of the tank), there will
percent (a total of 100 percent) causes the be some offset. For the valve to open farther
valve travel to change by 100 percent. So, the so that the inflow will match the new higher
gain is now 100 divided by 100, or 1. outflow, the float will have to be lower than it
was originally.
Moving the fulcrum to the far-right position
yields the least sensitivity. The controller’s action This is a characteristic of all controllers
is represented by the graph with the green line. that only have the proportional mode. The
In this case, a change in error from minus 50 per- proportional mode uses the error to reduce
cent to plus 50 percent (a total of 100 percent) the error, so it is necessary for there to be an
causes the valve travel to change by 50 percent. error (in control terms called “offset”) for the
The gain is now 50 divided by 100 or 0.5. error reduction to occur.

Sometimes, instead of talking about The two graphs on the left in Figure 2
proportional gain, people talk about “propor- show the relationship between the mea-
tional band,” abbreviated “P.B.” in the figure. surement and the controller output from a
Mathematically, the proportional band is the proportional controller. As soon as an error
reciprocal of the proportional gain times 100 (e) occurs between the measurement and
and expressed as a percent. the setpoint, the controller output changes

Figure 2. Proportional only controller response to a change in load.

INTECH JUNE 2023 14 WWW.ISA.ORG/INTECH

PROCESS CONTROL

to exactly mirror the error, except that the a step change in load while being controlled
magnitude of the controller output change by a proportional controller. The important
depends on the proportional gain of the point here is that with proportional control,
controller. In this case, the proportional gain the error is being used to reduce the error,
is less than one since the change in output is so there will always be some residual error,
less than the change in error. The direction of which we call offset.
the controller output change is chosen to be
The water heater shown in Figure 3 il-
in the direction that will tend to correct the
lustrates the behavior of the various control
error. The graphs on the left show the “open
modes. Although the water heater consists
loop” interaction between error and control-
of several dynamic subsystems (control valve,
ler output—in other words, how the controller
the heating vessel, the temperature element,
responds to an error—but the output is not
and the temperature transmitter), when a
connected to the process. Shortly, graphs will
step test is performed with the controller in
show what happens when the loop is closed,
manual, the response (for all practical purpos-
and the controller is regulating the process.
es) can be treated as a first-order response
The graph on the right of Figure 2 shows
with dead time.
how a first-order process would respond to
To get a reference point for evaluating the
performance of the controller, the control-
ler has been left in manual, and then a step
change in load was introduced. This was done
by suddenly decreasing the demand for hot
water. Since the steam flow does not change,
the measured temperature increases to a new
value following the approximately first-order
plus dead time response is shown by the
Figure 3. A simple control loop. green line in Figure 4.

Figure 4. Process variable response to a load step change with varying proportional gain settings.

INTECH JUNE 2023 15 WWW.ISA.ORG/INTECH

PROCESS CONTROL

The controller is next placed into auto- In calculus, the “integral” of a function is
matic mode with a small amount of propor- “the area under the graph” of that function.
tional gain (Kp = 0.3). The controller reduces Figure 5 shows an arbitrary complex function
the error slightly, but there remains a large of time and its graph. If the exact function
residual error, or offset. that produces this graph is known, the area
under the curve could be determined, but it
Increasing the proportional gain to 1.5
often takes methods that students spend a
causes a smaller offset. Further increasing the
whole year in calculus learning. Fortunately,
proportional gain to 3 gives an even smaller
this is a simple function, and one that is easy
error and thus better control. Note that there
to calculate the area under the graph without
is a small oscillatory transient at first. At this
any advanced techniques is all that’s needed
point, it is tempting to assume that the higher
to make sense out of how the integral control
the gain, the better the control, and that
mode works.
it might be possible to decrease the offset
to a very small value by setting a very large A time function whose value is always 1.0

proportional gain. However, when we try is shown in Figure 6. Since the function’s

increasing the gain to see what happens, at value remains constant, the area under its

some point, with increasing proportional gain, graph is always a rectangle, and the area of

the system becomes unstable. a rectangle is easy to calculate without using

advanced techniques.

Integral, when proportional Imagine starting at time equal to zero,

gain is not enough and then watching what happens as time
If some offset cannot be tolerated, some way of progresses. At exactly time = zero, the length
supplementing the proportional control mode of the rectangle is zero and its width is 1.
must be ascertained. To remove the offset of The area is zero times one or zero. After one
the proportional control mode, the integral second has passed, (time is now equal to
(sometimes called reset) mode is introduced. 1 second), the length of the rectangle is 1,

Integral (Reset)
The integral of a function is the area under its graph The integral of a function is the area under its graph

Figure 5. Definition of the mathematical integral. Figure 6. In an open loop, the integral of the error
continues to increase with time.

INTECH JUNE 2023 16 WWW.ISA.ORG/INTECH

PROCESS CONTROL

and the width is 1, so the area is 1 times 1, not connected to the process). At the moment
or 1. The graph on the right shows how the the error first occurs, there is an immediate
integral (area under the curve in the left-hand proportional action in the controller output.
graph) has changed during the first second. Then the controller output starts ramping
As time continues to progress and the area down (integral action) in proportion to the area
of the rectangle increases, the graph on the under the graph (error times the constantly
right continues to track what the rectangle’s increasing time). The parameter that is set into

area is at any moment. Since the area under the controller to tell it how strongly the inte-

the curve is increasing in a linear fashion gral action is to act on the controller output

with time, the graph of the integral is a ramp, is called the “integral time,” or TI. The integral
time is the time it takes the integral action to
also increasing in a linear manner with time.
repeat the correction produced by the propor-
Adding the integral control mode to the pro-
tional action. A short integral time means the
portional mode makes it possible to remove
controller ramps its output quickly to eliminate
the offset left by the proportional mode. This
the error, and a long integral time means the
controller has been configured so that both
output ramps slowly to eliminate the error
the proportional and integral actions are
(or offset). The units are minutes (or seconds
downward instead of upward because that is
depending on the controller manufacturer)
the direction that will eliminate the error.
per repeat. Some controller manufacturers
Figure 7 shows how a proportional plus use “integral gain,” which is the reciprocal of
integral controller reacts to a step change in integral time. In that case, the units are repeats
load in an open loop (the controller output is per minute (or second).

Integral (Reset)
Using the integral of the error to eliminate offset

Figure 7. Proportional plus integral controller response to a load change in an open loop.

INTECH JUNE 2023 17 WWW.ISA.ORG/INTECH

PROCESS CONTROL

Figure 8 is the same graph as Figure 4, but

Derivative, when error must be
starting when the proportional controller was
eliminated faster
running in closed loop with a proportional
The next question might be: can the
gain of 1.5. When considering the effect of
integral time be decreased to make the
various values of proportional gain, there was
error be eliminated more quickly? As with
better (but slightly oscillatory) control with
proportional gain, some integral is good,
a gain of 3, but because it is known that this
but too fast an action destabilizes the
integral action is destabilizing, and would
process.
have resulted in an oscillatory response, the
slightly lower proportional gain was chosen Before discussing the derivative (some-
for this example. times called rate) control mode, consider
this brief review of the meaning of the
In Figure 8, some integral action has
derivative. In calculus, the derivative of a
been added. Initially, the proportional action
eliminates part of the error, then the integral, function can be interpreted as the instan-

or reset, action continues to drive the control taneous slope of that function’s graph at

valve until all the offset has been removed. any point. Students spend the better part of
In closed loop, once all the error has been a year in calculus class learning how to do
eliminated, the proportional action settles out this for all sorts of functions. Fortunately,
at the new value required to hold the error at for purposes of discussing the derivative
zero, and since there is no error, the integral control mode, all that’s needed is to review
of the error is zero, thus there is no further the behavior of the derivative of straight
integral action. lines.

Integral (Reset)
Using the integral of the error to eliminate offset

Figure 8. Process variable responses to a load step change with various integral settings.

INTECH JUNE 2023 18 WWW.ISA.ORG/INTECH

PROCESS CONTROL

The graph of a function of time whose shape rate (its slope still has a finite and constant
consists entirely of straight lines with different value, but a smaller one). Again, this smaller,
slopes is shown in Figure 9. Starting at time = but constant rate of change (slope or deriva-
zero and continuing for a while, the functions tive) is graphed in the lower graph. Finally, the
value is zero. Its slope is also zero and thus its time function stops growing, and levels off
derivative is zero, as shown in the lower graph. at a constant value. At this point, there is no
The value of the function suddenly begins more change in the function’s value (its rate of
increasing at a steady rate. Its derivative (slope) change or slope or derivative becomes zero)
instantly becomes a finite (and constant) value, and is graphed on the lower graph of derivative
again portrayed in the lower graph. Next, the as a derivative of zero.
function continues to increase, but at a lesser
When examining the proportional control
mode and the integral control mode, their
The derivative of a function is the slope (or rate actions are based on the assumption that a fairly
of change) of its graph.
fast control process was discussed. The discus-
sion was made simpler (without loss of meaning)
by assuming that upon a process disturbance,
the measurement made a step increase (like in
the line in the upper graph in Figure 2).

Some processes, such as the water heater

used as an example, respond slowly to pro-
cess upsets. In such a case, the ramp in the
Figure 9. Definition of the mathematical derivative. upper graph of Figure 10 is a simplified but
more realistic depiction of what happens

Derivative (Rate)
Using the derivative of the error to anticipate future error

Figure 10. Proportional plus derivative controller response to a load change in an open loop.

INTECH JUNE 2023 19 WWW.ISA.ORG/INTECH

PROCESS CONTROL

when in open loop, that is, the controller out- to act on the controller output is called the
put is not connected to the process. In this “derivative time,” or TD. The derivative time is
example, the process upset could have been a the time it would have taken the proportional
nearly instantaneous decrease in the demand action to produce the correction that was im-
for hot water from the water heater. At the mediately produced by the derivative action.
point where the ramp just starts, the damage (This description presumes the error remains
has already been done and the process is constant, independent of any control action.)
heading toward a large error. The problem A short derivative time means the control-
here is that because the process responds ler adds only a small derivative output to
slowly, the controller does not immediately anticipate a future error. A long derivative time
see the large error that is on its way. The means the controller adds a large derivative
controller only sees a small error at first. output to anticipate a future error. The units
are minutes (or seconds depending on the
In the upper graph of Figure 10, the er-
controller manufacturer). Also, some controller
ror starts out being very small, and with
manufacturers use “derivative gain,” which is
proportional only control, the controller’s
the reciprocal of derivative time. In that case,
output would only be a small correction at first
the units are 1 divided by minutes (or seconds).
represented by the sloping dashed line. In a
slow process, the disturbance was likely a large
one, but because the process responds slowly,
Adding the integral control
the large disturbance is not seen right away.
At the point where the measurement begins mode to the proportional
to deviate from the setpoint, the slope of the mode makes it possible to
measurement (its derivative) makes a sudden
remove the offset left by the
jump from zero to a value equal to the slope
of the measurement’s graph. This provides an proportional mode.
instantaneous jump in the controller output,
in anticipation of the large error that isn’t seen
Some controllers take the derivative from
yet but is coming. The proportional correction
the measurement rather than the error. This
gets added to the derivative correction, so
prevents a large derivative correction (called
that after the initial “boost” of the derivative,
a “derivative kick”) if the setpoint is manually
the controller output continues with a cor-
changed suddenly. Noise spikes in a noisy
rection proportional to the error. (To avoid
measurement can cause undesired large out-
unnecessary complication to the explanation,
puts form the derivative mode. Derivative
the integral action was not included in the
correction must be used with caution when
discussion of derivative action.)
the measurement is noisy. Filtering the
The parameter set into the controller to signal before it goes to the derivative func-
tell it how strongly the derivative action is tion can help.

INTECH JUNE 2023 20 WWW.ISA.ORG/INTECH

PROCESS CONTROL

Using the derivative of the error to anticipate future error

Figure 11. Process variable responses to a load step change with various derivative settings.

In Figure 11, the upper two traces show a response that is better than what we would
what could be accomplished with propor- have gotten with just P+I or with P+I+D using
tional only and with proportional plus integral the proportional gain that would have been
(P+I). Here, derivative (P(1.5) + I + D) has optimum had the derivative not been added.
been added to the earlier P+I to further
Derivative controls may also be sensitive
reduce the maximum error.
to fast, short-term process signals, including
The derivative mode—unlike the integral sensor noise or process noise. For example, if
mode, which tends to destabilize control—adds there were waves in the tank, the level signal
stability. Because of this, it is possible to would be constantly moving up and down,
increase the proportional gain from 1.5 to 2. and the derivative action could amplify those
If the gain had been increased to 2 with just waves into valve movements. For this and
integral, there would have been a response with other reasons, derivative action is much less
too much oscillation in it. However, with the common in practice, and P+I controllers are
stabilizing effect of the derivative, the result is most often seen.

ABOUT THE AUTHOR

Jon Monsen, PhD, PE, is a control valve technology specialist with more than 45
years of experience in the control valve industry. He has lectured nationally and
internationally on control valve application and sizing. Monsen hosts a website,
www.Control-Valve-Application-Tools.com, where he shares articles, training,
professional development materials, and Excel worksheets that might be of interest
to those who use or specify control valves.

INTECH JUNE 2023 21 WWW.ISA.ORG/INTECH

PROCESS CONTROL

ISA-TR5.9-2023: Realizing and

Achieving Best
PID

By Peter Morgan and Greg McMillan

New ISA technical report distills thousands

of pages of PID references for improving
process performance.

Even though controllers using the proportional- help all realize and achieve the largely unde-
integral-derivative (PID) algorithm have been rutilized PID potential for improving process
used for more than a century, a standard performance. Sections within this larger-
describing PID fundamentals, terminology, than-usual report include Scope; Normative
best practices, and special functions does not References; PID Algorithm; PID Structures;
exist. ISA’s new ISA-TR5.9-2023 Proportional- External-reset Feedback; PID Performance;
Integral-Derivative (PID) Algorithms and PID Signals; Annex A Signal Characterization;
Performance technical report, released this year, Annex B Dynamic Simulation; Annex C
lays the foundation for that standard. Valve Positioners; Annex D Dead Time
The technical report captures the expertise Compensators; Annex E Enhanced PID;
of prominent PID practitioners and distills the Annex F First Principle Process Relationships;
tens of thousands of pages of references found and Bibliography. This excerpt is from the
in the bibliography into a guide designed to Historical Perspective section.

INTECH JUNE 2023 22 WWW.ISA.ORG/INTECH

PROCESS CONTROL

The proportional plus integral plus mechanical and hydraulic methods designed
derivative (PID) control algorithm is the to achieve integral action proved impractical
workhorse of virtually all closed-loop control for continuous use until the 1900s.
applications. It has been the go-to algorithm
since its inception in the early 20th century.
Generations of control practitioners have
The proportional plus integral
used it. The algorithm has seen (and survived) plus derivative (PID) control
implementation on every technology platform algorithm is the workhorse of
ranging from pneumatics, electronic analog,
centralized digital control, distributed control
virtually all closed-loop control
systems (DCS), programmable logic control- applications.
lers (PLCs), and distributed loops on Fieldbus
and other distributed bus platforms. Electro-mechanical. In 1911, Elmer Sperry
The technology platform timeline starts applied proportional plus integral action to
with mechanical/hydraulic and progresses automate ship steering. Through observation,
through DCS. Sperry determined that the ship’s course
could be held by adjusting the rudder posi-
Mechanical/mechanical hydraulic. The
tion in proportion to the error in the bearing
PID controller’s history would be incomplete
with additional feedback based on the rate
without mentioning James Watt’s flyball
of change in the bearing. Because rudder
governor introduced almost 250 years ago
position determines the rate of change in
(1788) for steam engine speed control by
the ship’s bearing through ship dynamics,
regulating steam flow. Providing proportional
the net effect is equivalent to P plus I action
action only, the flyball governor might be
(although not known as such at the time).
considered the genesis of PID control, wait-
Interestingly, two notable features of Sperry’s
ing only for technology to develop to allow
controller were that the algorithm was the
for error correction (integral action) and
velocity form of PI as we know it today, and
dynamic compensation (derivative action).
the structure was “proportional action on PV.”
Not surprisingly, since the focus toward the
end of the 19th century was engine speed In 1923, Nicolas Minorsky (in addition

control, H.N. Throop, in 1857, devised a to providing the first analysis of Sperry’s

governor to incorporate adjustment based on ship steering system) introduced the second

acceleration and speed, thereby introducing derivative of the ships bearing as a third ele-

the first proportional plus derivative control- ment and, in so doing, implemented the first
PID velocity algorithm.
ler. Although it was widely known that the
offset was a limitation of the flyball governor Pneumatic. PI and eventually PID control
and isochronous control was not possible actions have been (and still are) imple-
without integral action, the various ingenious mented in pneumatic controllers through

INTECH JUNE 2023 23 WWW.ISA.ORG/INTECH

PROCESS CONTROL

the imaginative use of bellows, levers, and a pressure analog of valve position. Several
orifices. For integral action, any persistent contemporary platforms offer this feature’s
error is corrected by a continuous adjustment equivalent for its advantage in dealing with
in output pressure that is proportional to external limits and lost motion.
the error through the action of the positive
Electronic analog. Development of the
feedback bellows. For derivative action, a
integrated circuit high gain operational ampli-
rate-of-change in error results in a propor-
fier (OP amp) in the 1960s allowed the PID
tional adjustment in output pressure through
algorithms to be readily implemented using
the action of the negative feedback bellows.
resistor and capacitor (RC) networks without
In 1922, the flapper nozzle was patented. the functional limits and nonlinearities associ-
The flapper nozzle converted small nozzle ated with the pneumatic controller. Notably,
displacements to large pressure changes all three forms of the PID algorithm could
at the output to balance reaction forces be implemented without limitations. The
exerted by the feedback bellows with the electronic analog implementation provided
force equivalent to the control error. The features such as gain adaption, deadband,
flapper nozzle foreshadowed the use of the feedforward, and bumpless transfer. It
electronic high-gain operational amplifier in allowed the implementation of application-
the implementation of the PID algorithm in specific strategies through modules with
electronic analog control systems. specific functions such as high/low selector,

Most of the PID capability has been underutilized due to the lack
of knowledge of PID algorithms and performance implications. This
situation has been severely aggravated by the loss of expertise.

Throughout the 1930s, there was much rate limit, and so on.
effort to improve the pneumatic control-
Foxboro chose to implement the P+I term
ler’s characteristics. Linearity, for example,
for the series algorithm by using positive
was improved by the introduction of the
feedback for integration, applying a first-order
pneumatic relay. In the mid-1930s, the first
lag to the controller for use as the feedback
pneumatic controller with derivative action
signal, thus replicating the action of the positive
was implemented by throttling the flow to a
feedback bellows of the pneumatic control-
negative feedback bellows.
ler. This provided the benefit of simplifying
The year 1933 may well have been the first the implementation of provisions to prevent
application (by Taylor Industries) of external- integral windup when the controller output is in
reset feedback by supplying the integral limit, and when the feedback signal is derived
bellows with air from a transducer providing as the position of downstream elements

INTECH JUNE 2023 24 WWW.ISA.ORG/INTECH

PROCESS CONTROL

(so-called external reset), improved response To circle back to James Watt’s flyball
when the final element is in rate limit or prone governor, it is entertaining to note that pro-
to travel deadband. portional (droop) control is still the favored
method of governing turbogenerators on
The PID velocity algorithm, whose output
interconnected systems but is implemented in
was a velocity (speed and direction) command,
digital systems using a PID control algorithm
was implemented using a variety of integrating
to proportionally adjust generator output
devices as the final element allowing fixed
according to turbine speed variation. In this
pulse-width variable-frequency or variable
case, the PID controller acts to eliminate
pulse-width variable space output forms.
variation in the droop due to the nonlinear
Convergent development of electronic ana-
characteristics of the governor valve.
log computers using the same OP amps used in
the electronic PID controller allowed real-time
Adopted naming convention
(and faster than real time) performance and
Technical Report TR5.9 recognizes three
stability studies to be performed for complex
commonly used PID algorithms. These forms
plant/processes employing PID algorithms.
have been variously described by vendors
Direct digital control. The mid-1960s and practitioners, sometimes based on an
direct digital control (DDC) used mainframe interpretation of behavior in either the time
computers (sometimes redundant) to imple- domain or frequency domain, other times
ment a PID control velocity algorithm, for on mathematical forms, such as the Laplace
example, for nuclear reactor rod control. transform. The lack of a consistent naming
convention has led to some confusion within
DCS. In 1975, the first DCS was introduced
the industry, which could only be resolved
(by Honeywell and Yokogawa) with widespread
by examining the structure of the offered
technology adoption through the late 1970s.
algorithm. The TR5.9 working group estab-
With the integration of Boolean logic and regu-
lishes in the report, a naming convention
latory control, the precision of the DCS in the
that will avoid the widespread confusion
execution of strategies and virtually no limit
that exists today.
to functionality (for example the implementa-
tion of override control), the platform allowed In the following equations for each PID
complex strategies to be easily configured and form, PV, SP, and CO are assumed to be
made possible innovative PID implementations expressed in dimensionless values as percent
such as the 2DoF (two degrees of freedom) of engineering unit (EU) range, the norm
PID structure and PID tuning parameter for industrial systems. The few industrial
optimization. Notably, the platform allowed the PID algorithms that use a PV, SP, and CO in
PID algorithm form to be user selectable since engineering units are disruptive of tuning
the digital implementation severed the depen- methods and without great care can lead to
dence on hardware/module physical design. tuning problems.

INTECH JUNE 2023 25 WWW.ISA.ORG/INTECH

PROCESS CONTROL

Parallel. Proportional, integral, and derivative Ti is the controller integral action time
terms are individually added to form the con- (time units for example seconds, minutes, or
troller output with a time domain equation of: hours).

Td is the controller derivative action time

= + · +
(time units for example seconds, minutes, or
Where: hours).
1 ( )
( )= ( )+ ( ) +
ε=PV-SP is the control error for a direct The standard and series algorithms are
acting controller. close in form to that for the equivalent pneu-
(ε=SP-PV
) = ( )is+the control
( ) error for a reverse matic controller since the gain on a pneu-

acting controller. matic controller is adjusted by positioning the

1 flapper pivot point, which equally affects the
( )= ( )+ ( )
CO is the controller output.
integral and derivative bellows.
kc is the controller proportional gain
It is important
1 to note that the nomen-
(dimensionless). ( )= 1+ ( )+ clature
( )+ ( )
“standard” is not meant to imply that
ki is the controller integral gain (reciprocal this version of the PID controller is to be the
of time, for example per second, per minute, standard, preferred, proper, or best practice.
or per hour). Note that some vendors refer It is a conventional and frequently used form
to the units for this parameter as repeats that gained widespread use through early
per minute drawing on the behaviour of the = in electronic
adoption + · analog systems.
+
controller for a constant error. = + · +
Series. The derivative term applied before
kd is the controller derivative gain (time 1 ( )
proportional
( )= plus
( ) integral
+ terms
( ) is+repre-
unit, for example seconds, minutes, 1 ( )
( ) = or hours).
( ) + sented
( ) by the
+ following equations:
ti is the time at the last initialization of the
( )= ( )+ ( )
integrator, for example when (the
) =controller
( )+ ( )
was last in manual. 1
( )= ( )+ ( )
Standard. Gain adjustment applied 1
( ) = to ( ) + ( )
proportional,
= integral,
+ · and derivative
+ terms to Or
form controller output. 1
( )= 1+ ( )+ ( )+
1
1 ( ) ( )= 1+ ( )+ ( )+ ()
( )= ( )+ ( ) +

Where: Where:
( )= ( )+ ( )
ε=SP-PV is the control error for a direct ε=PV-SP is the control error for a direct
acting controller. 1 acting controller.
( )= ( )+ ( )
ε=SP-PV is the control error for a reverse ε=SP-PV is the control error for a reverse
acting controller. acting controller.
1
( )= 1+ ( )+ ( )+ ()
INTECH JUNE 2023 26 WWW.ISA.ORG/INTECH
PROCESS CONTROL

Like the standard algorithm, gain adjust- External-reset feedback (ERF) from the
ments apply to proportional, integral, and positive feedback implementation of integral
derivative terms; the derivative term is action lost in the transition from pneumatic to
best described as a “phase advance” term electronic controllers has been retained by one
acting on the error prior to it being pro- supplier and restored by another. ERF has been
cessed by proportional and integral terms. recognized as having inherent capability in mini-
Note that if the derivative action time, Td mizing oscillations from unnecessary crossings
is zero, the series from is identical to the of the split range point, slow valves, and slow
standard form. secondary loops plus offering better override
control, valve position control, and dead time
Features and opportunities compensation. ERF has also led to an enhanced
PID has been proven to be the most ef- PID that can handle large and variable analyzer
fect algorithm for minimizing the impact cycle times and signal failures.
of unmeasured process input disturbances
(load disturbances) that have by far the most
prevalent detrimental effect on loop perfor-
mance. Recent advances in algorithm fea-
tures have enabled the best load disturbance
rejection while meeting other objectives.
For example, after tuning for load response,
setpoint lead-lag, or setpoint weights can
enable the best setpoint response. The
scheduling or adaptation of tuning settings
enables PID to better handle the inevitable
nonlinearities. Cartoon by Ted Williams

ISA Standards and Technical Reports

ISA standards help automation professionals streamline processes and improve industry
safety, efficiency, and profitability. More than 150 standards reflect the expertise of more
than 4,000 industry experts around the world. One of the many benefits of ISA member-
ship is free viewing of most ISA standards and technical reports. The ISA-TR5.9-2023,
Proportional-Integral-Derivative (PID) Algorithms and Performance technical report is
available for purchase from ISA.

INTECH JUNE 2023 27 WWW.ISA.ORG/INTECH

PROCESS CONTROL

Most of the PID capability has been un- most notably of the PID form. Particularly
derutilized due to the lack of knowledge of detrimental is the misconception that the PID
PID algorithms and performance implications. algorithm works with signals in engineering
This situation has been severely aggravated units and that disturbances are on the pro-
by the loss of expertise and the inconsisten- cess output. ISA-TR5.9 can put us all on the
cies in the nomenclature and implementation right track.

ABOUT THE AUTHORS

Peter Morgan has more than 40 years’ experience in the design and commissioning
of regulatory and discrete control systems for the power and process industries.
Among his publications are instructive articles on Fuzzy PI, Layer of Protection
Analysis, and Markov modeling for reliability analysis. Peter is a Professional
Engineer, an ISA senior member, and a contributing member of the ISA 5.9 PID
Standards Committee.

Gregory K. McMillan is a retired senior fellow from Solutia and an ISA Fellow. He
is presently working part-time as a senior principal software engineer in Process
Simulation Development at Emerson Process Systems and Solutions. McMillan was
an adjunct professor in the Washington University Saint Louis Chemical Engineering
department from 2001 to 2004. He received the ISA Kermit Fischer Environmental
Award for pH control in 1991, received the Control magazine Engineer of the Year
Award for the Process Industry in 1994, and was inducted into the Control magazine Process Automation
Hall of Fame in 2001. Greg would like to acknowledge cartoonist Ted Williams, a longtime friend
who did all the cartoons in Greg’s numerous humorous ISA books dating back to the 1980s. He has
illustrated Greg’s Control Talk columns for the last 20 years and provided the cartoon on page 25.
McMillan was honored by InTech Magazine in 2003 as one of the most influential innovators in
automation, and received the ISA Life Achievement Award in 2010. He is the author of numerous
ISA books on process control, his most recent being Advances in Reactor Measurement and Control,
and New Directions in Bioprocess Modeling and Control, second edition. McMillan is the founder and
co-leader with Hunter Vegas of the ISA Mentor Program for industry practitioners and started and
guided the ISA Standards and Practices committee on ISA-TR5.9-2023 PID Algorithms and Performance
technical report. McMillan received the ISA Mentoring Excellence award in 2020. He has a Bachelor
of Science degree in engineering physics from Kansas University and a Master of Science degree in
control theory from Missouri University of Science and Technology.

INTECH JUNE 2023 28 WWW.ISA.ORG/INTECH

OPERATIONS

Understanding Control
Valve Flow Characteristics
By Joao Bassa

Learning the basics

the frustration and ensure loop stability. But
can ease loop tuning first, some basics about why this happens.

frustration and ensure Controlling the desired variable

stability. Typically, process control loop feedback
strategies use “flow” as the manipulated
variable to control the desired variable. To
During plant operations, it seems that tuning
achieve this, a controller output signal is sent
control loops is an ongoing task, which can be
a continual frustration to control engineers to a control flow valve that will deliver the

and technicians. Process control valve flow necessary flow amount (manipulated variable)
characteristics make regular loop tuning a to keep the controlled variable as close as
necessity. Understanding the basics can ease possible to the setpoint.

INTECH JUNE 2023 29 WWW.ISA.ORG/INTECH

OPERATIONS

The ideal expectation is that the flow

Controlling flow through a
through the control valve is proportional to
centrifugal pump
the controller output signal such that the
Referring to the pump flow control example in
loop feedback “gain” remains nearly constant
Figure 2, the pump outlet pressure will decay
for all process flow conditions and the loop’s
as the amount of flow increases. In addition,
required tuning parameters remain the same
the pipeline pressure drop will increase as the
for all operational conditions. However, this
flow increases. Consequently, the Δp across the
does not happen in all cases.
valve will be reduced as the flow increases. The
Referring to the temperature control amount of flow through the valve will not have
example in Figure 1, the steam inlet pressure a proportional relation to the valve opening
is usually constant. Therefore, the pressure position if the same valve type as in the tem-
differential (Δp) across the valve is also almost perature control example (Figure 1) is used. That
constant, and the steam flow amount through means the relationship between the controller
the control valve is approximately propor- output signal versus the control valve flow rate
tional to the valve opening position (if the will be changing throughout all the different
valve characteristic is linear) or, consequently, operational conditions and the loop tuning
proportional to the controller output signal. parameters will need to be retuned, depending
This is the desired control loop operation. on the actual process operational condition.

Figure 1. Example of a temperature control loop.

Figure 2. Example of a centrifugal pump flow-control loop.

INTECH JUNE 2023 30 WWW.ISA.ORG/INTECH

OPERATIONS

Some modern digital control systems have ensure that the pressure drop across the test
self-tuning/auto-tuning functionality that valve is held constant at all valve openings
can reduce or minimize the inconvenience and flow rates. The “installed characteristic”
of loop tuning. However, the correct valve (Figure 4) is the relationship between valve
flow characteristics selection will save a lot of position and flow in the specific system being
trouble and money. considered, considering any changes in the
Δp available to the control valve due to the
Control valve flow approximately flow squared relationship
characteristics between flow and piping pressure losses and/
For continuous process control valves, there
or a centrifugal pump head curve.
are three inherent flow characteristics that
can be specified when ordering the valve. It The three control valve characteristics are:

is important to note that there is a difference z Linear

between “inherent valve characteristics” and z Modified parabolic

“installed valve characteristics.” z Equal percentage
The “inherent characteristic” of a valve Inherent control valve flow characteristics
(Figure 3) is the characteristic published by are established assuming a constant Δp across
the manufacturer, based on tests performed the valve. If the valve Δp is reduced as the
in a system where great care is taken to flow increases, meaning that there is a valve

Figure 3. Typical
inherent control valve
flow characteristics.

INTECH JUNE 2023 31 WWW.ISA.ORG/INTECH

OPERATIONS

Figure 4. Installed
control valve
characteristic for
a 0.5 vpdd.

pressure drop decay (vpdd), then the “installed flow and low flow valve pressure drop Δp can
control valve characteristic” will be different, yield an indication of how to choose a valve
changing the proportion from controller signal flow characteristic for a given application.
output to the control valve flow.
∆p(qmax)
vpdd =
∆p(qmin)

where:
Some modern digital control vpdd=valve pressure drop decay
∆p(qmax)=valve pressure drop at maximun flow
systems have self-tuning/
∆p(qmin)=valve pressure drop at minimun flow
auto-tuning functionality
Using the vpdd calculation, the control
that can reduce or minimize
valve characteristic can be chosen according
the inconvenience of loop to the following:
tuning. z For linear valve characteristics, vpdd is
between 0.60 and 1.0.
z For modified parabolic valve characteris-
A simple way to choose among the inher- tics, vpdd is between 0.35 and 0.60.
ent control valve flow characteristics is to cal- z For equal percentage valve characteristics,
culate the vpdd. The ratio between the high vpdd is between 0.20 and 0.35.

INTECH JUNE 2023 32 WWW.ISA.ORG/INTECH

 OPERATIONS

If vpdd is less than 0.20, review the pipe valve positioner. Control valve positioners
or other specs. There should be a minimum can typically transform a linear control valve
of 0.20 vpdd to reach a reasonably linear flow characteristic to a modified parabolic or
control loop. equal percentage characteristic, or vice-versa.
It is also possible to manage control valve However, it is better to have the correct
characteristic requirements through the control valve in place.

ABOUT THE AUTHOR

Joao Bassa, MSc, senior consultant, MAHAM Serviços de Engenharia Consultiva,
Brazil, has 40 years of international industrial experience in automation and pro-
cess controls. He is a professor at Mauá Technology Institute and a member of ISA
District 4 (Brazil).

Navigating the World of PLM:

Your Burning Questions Answered!
Your Ultimate Guides to
Making the Right Choice

GET THE GUIDES

INTECH JUNE 2023 33 WWW.ISA.ORG/INTECH

Where power is hard to find, PROVEN
Tadiran has the solution.
40
YEAR
OPERATING

LIFE *

Don’t let the cost and inconvenience of hard-wired

AC power send you up a tree. Instead, be as
remote as you want to be with the ONLY lithium
cells to offer PROVEN 40-year service life without
recharging or replacing the battery.
When it comes to wireless power
solutions, Tadiran is taking
innovation to extremes.

Tadiran Batteries
2001 Marcus Ave.
Suite 125E
Lake Success,
NY 11042
1-800-537-1368
516-621-4980
* Tadiran LiSOCL2 batteries feature the lowest annual self-discharge rate of any competitive battery, less than 1% per year, enabling these
batteries to operate over 40 years depending on device operating usage. However, this is not an expressed or implied warranty, as each
application differs in terms of annual energy consumption and/or operating environment.
www.tadiranbat.com
CONNECTIVITY CASE STUDY

Remote-Site
Data in Real Time:
A Case Study

Wireless devices reduce road trips

for pulp and paper mill workers.
By Jack Smith

State regulations require pulp and paper while reducing employee workload and
companies to monitor and record daily ef- maintaining state regulatory compliance.
fluent water rates. An employee from the
main control site of a leading pulp and paper Problem details
company in the Pacific Northwest went to The pulp and paper company needed to
a remotely located pond three times a day monitor effluent water flow as it drains into a
to manually record water levels to fulfill this remote pond at its facility. Because of a new
requirement. This process was inefficient government regulation, personnel had to drive
and time-consuming, and it didn’t provide a truck three times a day to the remote site,
operators of the pulp and paper facility with log the height of the water along with the
real-time data. By installing digital and wire- date and time, and return to the office. The
less technology, the company implemented a company realized this was not an efficient use
system that is scalable for future installations of time and wanted to automate the process.

INTECH JUNE 2023 35 WWW.ISA.ORG/INTECH

CONNECTIVITY CASE STUDY

This was done by calculating changes in water pulp and paper managers access to additional
level in a V-neck weir entering the pond and process variable data and critical diagnostic
using this data to calculate flow rate. data about the transmitter’s health and perfor-
mance. The HCS also converts this HART data
In addition to automating flow data col-
directly to an industry standard MODBUS RTU
lection, the company also wanted this data
format, a serial communication standard that
to be displayed on an Ethernet-based human
almost all industrial radios support.
machine interface (HMI) panel in its boiler
room. Since the data was required by the The HART radar level transmitter has a
state, it needed to implement a historical front panel display for local viewing and
collection and archiving system that allowed connects to the HCS’s input via a two-wire
operators to easily view historical data and twisted pair cable. The radar gauge sensor
produce reports when required. Seeking a measures the water height in the weir and
quick and efficient solution, the company publishes this data along with other process
turned to Autoline Controls, a full-service variable and diagnostic data to its internal
process instrumentation manufacturer’s HART memory location. This HART data is
representative with expertise in the pulp and then polled by the HCS two to three times
paper industry. per second. The data is then mapped to a
MODBUS memory map that resides in the
Solution HCS. This constant polling process ensures
Dale Stepper at Autoline Controls first sug- that data is continually updated on both the
gested implementing a system at the pond HART and MODBUS sides of the HCS.
site that uses a HART radar level transmitter
Using the HART radar transmitter con-
(Figure 1) with precise measurement capabili-
nected to the HCS solved the problem of
ties and a HART concentrator system (HCS).
measuring the water level; the next step
The HCS is a HART-to-MODBUS RTU con-
was transmitting this data to site operators.
verter that serves as a HART master and polls
In this case, the data needed to go to an
the HART radar level transmitter to obtain its
primary variable (PV) data—in this case, water
flow level. In addition, the HCS receives and
converts the level transmitter’s secondary
variable (SV), tertiary variable (TV), and fourth Figure 1. The HART
variable (FV) to MODBUS RTU along with radar level transmitter
diagnostic data. is connected to a HART
concentrator system (HCS)
There were two main reasons why Autoline to send weir flow level and
Controls chose an HCS for this solution. First, diagnostic information to
the boiler control room.
the HCS accurately gathers the digital level
data from the transmitter along with giving the

INTECH JUNE 2023 36 WWW.ISA.ORG/INTECH

CONNECTIVITY CASE STUDY

Ethernet-based host HMI panel and a histori-

cal collection system. There were no Ethernet
networks, fiber lines, or twisted pair wires
available from the pond site to the control
room, so installing a local wireless network
was chosen as the best method for acquiring
these signals.

An initial wireless site survey done using

photos of the site showed potential problems
in establishing a direct line of communica-
tions from the field site to the host system
due to either tree growth in the forest or
accumulated snow on tree branches that may
diminish the wireless radio’s signal strength. Figure 2. The omnidirectional antenna situated
on the boiler room rooftop offers complete radio
Since there was potential for future RF signal
signal coverage for the entire site.
path attenuation, Autoline Controls recom-
mended the following wireless components:

z Wireless network module (WNM) ra-

dios from Moore Industries were used.
Frequency hopping spread spectrum (FHSS)
900 MHz radios were used instead of 2.4
GHz models as their longer signal wave-
length tends to better penetrate foliage.
z Ethernet versions of WNM radios were
installed to meet the customer’s existing
preference to use Ethernet communica-
tions throughout the facility. While the
remote pond site previously had no com-
munications links, using Ethernet com-
munications at the pond site is a desirable
forward step in extending the ability to
add future assets with minimum added
investment.
z The 900 MHz Yagi antennas were installed
at both the boiler site (Figure 2) and at the
Figure 3. The Yagi-directional antenna was used
pond site (Figure 3) with the narrow RF at the pond site to transmit level signals from the
beams directed toward each other. After HART level transmitter to the boiler room.

INTECH JUNE 2023 37 WWW.ISA.ORG/INTECH

CONNECTIVITY CASE STUDY

this was proven to be successful, the boiler MODBUS RTU slave, or MODBUS/TCP slave.
site antenna was changed to an omnidi- The NCS also provides myriad math and logic
rectional antenna to enable expansion of solutions through its embedded control and
the boiler site to communicate via wireless logic program.
Ethernet with all locations of the facility. The heart of the NCS system is the
z Low-loss coax antenna cables with light- Ethernet/MODBUS module (EMM), which is
ning arrestors were used. the NCS’s CPU and communications center
The last piece of the solution involved (Figure 4). The EMM takes on various roles in
delivering the level transmitter’s signals this application. It first acts as the MODBUS
to their host system in a manner that met RTU master and polls the HCS at the pond site
their total requirements. The site operators through the serial port of the WNM radio. The
expressed a desire for the level transmitter’s MODBUS RTU data collected from the HCS
data to be represented by both digital and contains the HART data from the level trans-
analog signals. mitter and is then placed into the EMM’s local

While this could get quite expensive with memory map. Here it is stored as MODBUS

traditional programmable logic controller RTU and MODBUS/TCP compliant registers.

(PLC) or distributed control system (DCS) The EMM is polled as a MODBUS/TCP

solutions, Autoline Controls recommended slave by the Ethernet-based HMI at the boiler
adding a small net concentrator system (NCS) room so that site operations can view the level
to the host site. The NCS is a dynamic input/ and diagnostic data. The EMM is then pro-
output (I/O) system that can act as an ex- grammed with ISaGRAF logic to assign process
pandable I/O system, MODBUS RTU master, variables to the NCS’s analog output module

Figure 4. The wireless

receiving panel installed
at the boiler room of
the pulp and paper mill.
An Ethernet/MODBUS
interface module
(EMM) of the NCS
serves as a MODBUS
master to retrieve
HART data from the
HCS at the pond site.

INTECH JUNE 2023 38 WWW.ISA.ORG/INTECH

CONNECTIVITY CASE STUDY

(AOM). The AOM provides up to four 4-20 mA left off, transmitting and making available
or voltage signals (ranging from 0 to 10 V) that real-time process variable and diagnostic data
can be taken to any analog receiving device, from the level transmitter.
such as a historical data collection system.
End results
Site operations also requested that a
Autoline Controls expedited the installation.
full-time communication link with the pond
Moore Industries application engineers
site be established and verified. A simple
preconfigured the electronics and bench
communication watchdog routine residing in
tested the solution using a similar radar level
the EMM was written to monitor the wireless
transmitter kept at its headquarters for such
connection and instruct the MODBUS RTU, customer applications. This allowed Autoline
MODBUS/TCP, and 4-20 mA values from the Controls to install the system quickly and
AOM to go to predefined limits if there is a have confidence that it would work with
wireless link failure to the EMM. This allows minimal adjustments needed. The system is
site operations at the boiler room to immedi- now enabling the pulp and paper company to
ately tell when the wireless communication efficiently get accurate and required readings
link has failed. Once the link is re-established, on the levels of their effluent water system
the system automatically picks up where it (Figure 5).

WNM WNM
900MHz 900MHz
FHSS FHSS
Ethernet Radio Ethernet Radio

NCS
Ethernet (EMM & AOM) Ethernet

HART Level
NCS (EMM) and HCS Transmitter

4-20mA
with HART
Ethernet 4-20mA

HMI Display DCS/Historian Pond with V-Notch Weir

Figure 5. HART flow level measurements at the pond site are converted to MODBUS RTU by an HCS and
sent from a WNM at the pond to a receiver radio at the boiler control room. The information is relayed
from the wireless radio to an HMI display and DCS/historian by the NCS.

INTECH JUNE 2023 39 WWW.ISA.ORG/INTECH

CONNECTIVITY CASE STUDY

Frequency hopping spread spectrum (FHSS) 900 MHz radios

were used instead of 2.4 GHz models as their longer signal
wavelength tends to better penetrate foliage.

“Part of their license with the state measurement and documentation require-
required them to send an employee to the ment process, and lets their employees focus
site to write down numbers three times a on other critical aspects of their operation.”
day, seven days a week,” Stepper said. “That’s
essentially one-half of the work of a full-time NOTE: This article is compiled from information
employee—including having to work week- provided by Moore Industries.
ends. This system automates their formal Images courtesy of Moore Industries

ABOUT THE AUTHOR

Jack Smith is senior contributing editor for Automation.com and ISA’s InTech maga-
zine. He spent more than 20 years working in industry—from electrical power gen-
eration to instrumentation and control, to automation, and from electronic commu-
nications to computers—and has been a trade journalist for more than 25 years.

CYBERSECURITY & CONNECTIVITY

AUTOMATION 2023
EBOOK VOLUME 2
The latest ways to protect
and connect industrial
operations

SUBSCRIBE
to not miss an issue.

INTECH JUNE 2023 40 WWW.ISA.ORG/INTECH

MACHINE CONTROL

Industrial Computers:
Robust and Ready
Possibly more similarities than differences
exist between consumer/commercial comput- Industrial PCs differ
ers and industrial computers. Industrial PCs
(IPCs) leverage many of the advances that
from consumer PCs in
come from the consumer tech world but ways that are vital to
add the software, programming, determin-
ism, and connectivity essential to industrial industrial automation
applications.
applications.
“From increased memory to the exponen-
tial growth of processing power described by
Moore’s Law, industrial controls only stand to By Jack Smith

INTECH JUNE 2023 41 WWW.ISA.ORG/INTECH

MACHINE CONTROL

benefit from the evolution of PC technology. factors as shock and vibration, which can
But IPCs must be hardened to withstand be detrimental to commercial PCs; thermal
harsh production environments,” said Eric extremes, which can affect performance and
Reiner, IPC product manager, Beckhoff hardware lifespan; dirt and humidity; IP rat-
Automation LLC. ing; and electromagnetic interference (EMI),
which is common in industrial environments.
“Commercial computers are often far more
powerful and cheap, easier for POC [proof of IPC-based control systems increase con-
concept], and AI [artificial intelligence] appli- nectivity capabilities for industrial applica-
cations,” added Oliver Wang, product market- tions. They also provide powerful, flexible,
ing manager, Computing Division at Moxa and cost-effective control. IPCs typically
Americas Inc. “But they are problematic when operate in real time and are deterministic. For
deploying to scale in industrial environments example, highly accurate and deterministic
[due to] reliability in supply and hardware, or cyclical updates enable increased accuracy for
additional support for industrial use cases, coordinated motion control and data samples
industrial voltage/certs, and the like.” at precise time intervals. In contrast, pro-
grammable logic controllers (PLCs) typically
IPC characteristics offer scan rates in milliseconds, as opposed to
IPCs are similar to commercial PCs in terms of the IPC’s microsecond level.
receiving, storing, and processing information “IPCs are definitely not direct replace-
to perform operation sequences based on ments for PLCs, but the younger generation
software instructions. Hardware components
such as motherboard, CPU, RAM, expansion
slots, and storage media are also similar.
However, IPCs differ from consumer PCs in
terms of ruggedness, reliability, performance,
compatibility, expandability, and long-term
availability. Perhaps the biggest differentia-
tor from commercial PCs is that IPCs have
industrially hardened exteriors (Figure 1) and,
therefore, offer an advantage over personal
computers in industrial environments because
they enable equipment that can withstand
temperature fluctuations, noise, vibration,
and other industrial harshness.
Figure 1. Components are selected for ruggedized
IPCs must operate in harsh, aggressive, IPCs based on performance, long-term availability,
and dirty environments. Operating in tough and then price.

conditions, industrial PCs can withstand such Image courtesy of Beckhoff

INTECH JUNE 2023 42 WWW.ISA.ORG/INTECH

MACHINE CONTROL

seems to be taking to the PC approach and The evolution of industrial control technol-
are finding lower barriers to entry,” said ogy has sometimes accentuated differences
Wang. “Consider this: It’s clunky and unre- between PLCs, programmable automation
sponsive and expensive to use an app on controllers (PACs), and IPCs. Other times, it
your iPhone to change the channel of your has blurred them. But there are some general
TV versus using the purpose-built remote differences.
control. Purpose-built controllers and devices
are often superior because they are designed
to do that specific thing.”
IPCs enable equipment
that can withstand
IPC benefits temperature fluctuations,
IPC-based control systems provide benefits
for industrial applications, including perfor-
noise, vibration, and other
mance, decreased costs, and an increased industrial harshness.
system lifecycle. IPC-based control systems
can integrate faster, with more powerful pro-
“PLCs are designed with a single processor
cessors than a hardware PLC. Many machines
to execute machine control logic determinis-
and equipment benefit from centralized
tically,” said Reiner. “They were the evolution-
control, while there are cases where decen-
ary step immediately following hardwired
tralized control is advantageous. In general, it
relays. Ladder logic is the prevailing program-
is most beneficial to access all software and
ming language for traditional PLCs. They
data from one central location and use one
typically communicate just one protocol,
central communication method for all devices
with any additional fieldbuses or protocols
on the control system.
requiring an additional piece of hardware.
When a PLC becomes obsolete, the PACs can use multiple processors per rack
software may also require upgrading. In an for higher performance. They accommodate
IPC-based control system, the end of a pro- more programming languages and even some
cessor’s lifecycle does not mean the system third-party software for increased functional-
architecture or software becomes obsolete. ity. However, the system is still fairly closed
By incorporating more functionality into the compared to true PC-based control.
software and running that on an IPC, users
can replace the aging IPC with a new one IPC applications
without any changes to the rest of the control More industrial users are taking greater con-
system—including the software. Automation trol over software. “They are looking for ways
programs and fieldbus configurations can be to use Linux, cloud, and PCs to hedge against
downloaded to a software system on the new reliance on traditional specialized, purpose-
IPC with no need for code changes. built HMIs [human-machine interfaces] and

INTECH JUNE 2023 43 WWW.ISA.ORG/INTECH

MACHINE CONTROL

Figure 2. Flasheye is
using rugged IPCs to
create LiDAR-based
monitoring solutions
for the mining industry
to prevent dangerous
conditions and
downtime.

Image courtesy of
OnLogic via Flasheye

proprietary technology to stay competitive our clients are using our hardware for a nearly
and flexible,” Wang said. limitless number of applications,” said Darek
Fanton, communications manager at OnLogic.
He adds that many of these applications
“Industries we’re seeing on the rise now include
are in the power and transportation sectors.
energy management, smart cities and buildings,
There are also applications in edge computing
smart agriculture, mining (Figure 2), autonomous
for Modbus data acquisition and aggregation
vehicles—from self-guided warehousing robots
in renewable energy and energy storage, as
to autonomous tractors and concierge robots
well as those that exist for “onboard rail and
that move items around a hotel, hospital, or mail
bus for fare collection, GPS-based fleet track-
room—and medical devices. And, in addition to
ing, onboard video surveillance, and machine-
SCADA applications, our systems are used for
learning-based visual track inspection.”
IoT [Internet of Things] gateway applications,
“PC-based control was foundational digital twin setup, and model building, which is
for Beckhoff,” said Reiner. “We’ve been essentially edge to cloud communication, data
successfully executing applications with logging, edge servers, and the like.”
IPCs since the early 1980s. The first OEM
Fanton added that industries having high
[original equipment manufacturer] to inte-
regulatory requirements and standards are
grate Beckhoff controls was a woodworking
turning to IPCs that can often be standardized
machine builder, but we have decades of
and made available with longer lifecycle com-
experience using PC-based control in just
mitments “to avoid costly and time-consuming
about every industry: packaging, fabrica-
recertification that can crop up when con-
tion, assembly, logistics, test and research,
sumer PCs go through a generational revision.”
etc. Now, a single CPU can handle machine
control logic, vision, safety, HMI, and much
Software and operating systems
more, compared to the many single-purpose
According to Wang, the continued trend is
black boxes required in legacy architectures.”
to enable industrial users to build their own
“Automation in a factory setting is definitely tailored solution on a “host device” or IPC-
a key use case for industrial computers, but based platform. “The impact of supply chain

INTECH JUNE 2023 44 WWW.ISA.ORG/INTECH

MACHINE CONTROL

and cybersecurity concerns is still developing. connectivity, and integration with devices
Best practices for secure supply chain, secure from other vendors.”
boot, and OS [operating systems] are new
challenges for both manufacturers and users,” IIoT-ready IPCs
he said. Implementing IIoT and Industry 4.0 functional-
ity with IPCs is the logical next step to estab-
Reiner echoes this sentiment. “IPCs pro-
lishing more connected enterprises. PC-based
vide deterministic control for industrial equip-
control provides the most logical control
ment, and the use of wide-ranging multi-core
platform with an unobstructed migration path
processors enables extreme scalability,” he
to add higher levels of connectivity today or
said. “Programming of Beckhoff IPCs takes
at any time in the future, even if users are not
place in TwinCAT 3 automation software, an
ready to embrace IIoT and Industry 4.0.
end-to-end engineering and runtime platform
that supports programming in IEC 61131-3 Historically, adding IoT communication with
languages and their object-oriented exten- PLCs has become increasingly difficult. Doing
sions, predefined or custom function blocks, so typically entails adding third-party IT hard-
and computer science standards like C, C++, ware and software to make it work. However,
JavaScript, Python, and more. Other third- this type of connectivity has been possible with
party software—for everything from HMI to PC-based control, even before many modern
historians—can run alongside the machine buzzwords emerged. Internet and Ethernet con-
control logic on the same controller hardware. nectivity has been built into PC-based control
platforms for decades, which has enabled con-
“In the past, many believed PLCs were
nectivity with little or no additional hardware.
more secure and deterministic, but this has
not stood the test of time,” continued Reiner. “More companies are adding IoT capabili-
“PLCs, PACs, and IPCs all use a modified ties out of the box as a standard feature for
version of commercially available OS and machines and systems,” said Reiner. “With the
BIOS rather than the proprietary firmware of inherent open connectivity of IPCs, this is no
yesteryear. The key differentiator is that IPCs problem. Our controllers can connect to the
provide greater openness to best fit [users’] cloud or enterprise level securely and without
requirements for flexibility in programming, the need for an additional IoT gateway.”

ABOUT THE AUTHOR

Jack Smith is senior contributing editor for Automation.com and ISA’s InTech maga-
zine. He spent more than 20 years working in industry—from electrical power gen-
eration to instrumentation and control, to automation, and from electronic commu-
nications to computers—and has been a trade journalist for more than 25 years.

INTECH JUNE 2023 45 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

ISA Pub Hub: Member

Access to a Wealth of
Technical Content
ISA has introduced the ISA Pub Hub, a new ISA
Member benefit. Pub Hub provides access to
valuable technical information including ISA
standards, best practices and technical reports,
InTech magazine archives, white papers,
navigate. You can highlight important infor-
webinars, e-books, e-magazines and more.
mation, make annotations, and even save files
Content is organized in a user-friendly for offline use. The Pub Hub is accessible on
format, so it’s easy to browse, search, and both desktop and mobile devices.

OT Cybersecurity Summit Successfully Debuts

ISA chose Aberdeen, Scotland, as the launch “Attracting more than 120 in-person and
venue for its Operational Technology (OT) online delegates to our first-ever UK event of
Cybersecurity Summit given the city’s strate- this kind is a clear demonstration of the appe-
gic position in the energy sector. The Summit tite which exists for learning and networking
brought together in-person and online at- opportunities focused on cybersecurity in
tendees to discuss where vulnerabilities lie operational technology environments.”
and to gain insight into better protection for
themselves and their companies.

After two days of cybersecurity training,

the conference welcomed Aberdeen Lord
Provost Dr. David Cameron as well as keynote
speakers Cheri Caddy, deputy director at the
US Office of the National Cyber Director, and
Megan Samford, VP and chief product security
officer–Energy Management from Schneider
Electric. They were joined by subject matter
experts from the US and UK who presented From left to right: Steve Mustard, ISA Treasurer
and ISA OT Cybersecurity Summit conference
real-world applications of ISA/IEC 62443, the
committee chair; Cheri Caddy, Deputy Assistant
world’s only consensus-based automation and National Cyber Director, The White House;
control systems cybersecurity standards. Megan Samford, Vice President and Chief Product
Security Officer for energy management at
Commenting on the success of the event, Schneider Electric; and Dr. David Cameron, Lord
Claire Fallon, ISA Executive Director, said: Provost of Aberdeen.

INTECH JUNE 2023 46 WWW.ISA.ORG/INTECH

 ASSOCIATION NEWS
HIGHLIGHTS & UPDATES

ISA Connect Wins Award for Best Community Design

ISA is proud to announce that its member com- With an international membership base of
munity and discussion platform—ISA Connect— nearly 14,000 automation professionals, ISA
has won the prestigious Best Community needed a platform that could bring its diverse
Design Award from platform vendor Higher community together for high-quality and en-
Logic. Launched in 2020 and updated in July gaging technical discussions. “ISA Connect is
2022, ISA Connect is built upon the Higher a trusted resource I can count on to provide
Logic Thrive platform, used by many different reliable, unbiased answers and views on any
associations across industry sectors. What automation-related topic, including control,
makes the ISA Connect design and implementa- safety, cybersecurity, and digital transforma-
tion stand out is its visual and experiential tion,” says ISA Treasurer Steve Mustard.
integration with other ISA web properties.
“The member home page is a great one-
ISA has created an experience that earns stop shop for all of my ISA involvements,”
continuous positive feedback from its mem- says Mary’beth Ramey, an Automation
bers on ease and usability. “If you need to and Process Control Engineer at Celanese
find an answer to a technical problem at your Engineered Materials. “The feed brings
work, the right place to go is the Technical together updates from all the communities I
Discussion Forum on ISA Connect,” says ISA am in and makes it easy to navigate wherever
Past President Carlos Mandolesi. I need to go.”

International Society of Automation International Society of Automation

Setting the Standard for Automation™
Setting the Standard for Automation™

Learn the latest New from ISA!

in control valve Manufacturing
technology! Execution Systems:
An Operations Management
This easy-to-read reference Approach, Second Edition
from Hans D. Baumann
provides shortcuts for
Plus... BONUS Workbook
complex formulas and new This book teaches practitioners
methods for sound-level and students of manufacturing
prediction. Learn to apply operations management
valves for safety and (MOM) how to implement
stability, reduce energy and utilize manufacturing
costs, and simplify execution systems (MES)
maintenance. This is a effectively. This is an excellent
must-read for anyone resource for manufacturing
designing control loops professionals interested in
optimizing data collection,
and selecting final control increasing process efficiency,
elements. and improving product
quality.
Order your copy today Buy the Book

INTECH JUNE 2023 47 WWW.ISA.ORG/INTECH

 FINAL SAY | VIEWS FROM AUTOMATION LEADERS

The Future of Workforce Automation Competency

By Steve Mustard

In the early days, automation professionals need to look like to embrace all the benefits of
would need to understand a world of analog Industry 4.0, also called “smart manufacturing.”
computers, pneumatic control, and relay logic.
An article by Deloitte, The Future of Work
Today’s automation professional needs to have
in Manufacturing, examines “what future
a broad range of skills and knowledge—from
manufacturing jobs will be like in the digital
more conventional aspects such as PLC pro-
era.” To help explain their predictions, they
gramming and instrumentation to networking
created 10 personas, each describing a future
protocols, databases, and virtualization.
job in manufacturing. Four of the personas
If this were not enough, Industry 4.0 as- are conventional manufacturing jobs (e.g.,
sumes the use of newer technologies and “Quality Assurance (QA) manager”) with the
concepts such as augmented reality (AR), the word “smart” added. The remainder are a mix-
industrial Internet of Things (IIoT), and digital ture of new job titles for existing roles that
twin. Various organizations are attempting to use new technology in that role (e.g., “digital
understand what the future workforce will twin” engineer) and very narrowly defined

Industry 4.0 - Technological Pillars

Cybersecurity

Cloud Cloud
Cognitive Computing
Computing
Computing

Mobile
RFID Technologies
Technologies RFID

4.0
Internet Machine
of Things IoT Technology M2M To Machine

Big Data/ BIG

Analytics 3D Printing
DATA

Advanced Robotics

INTECH JUNE 2023 48 WWW.ISA.ORG/INTECH

 FINAL SAY | VIEWS FROM AUTOMATION LEADERS

jobs that may exist or be part of another role technologies is that organizations can achieve
(e.g., "drone data coordinator”). their core mission more efficiently and deliver
better quality output. As a result, the skills and
knowledge requirements for existing roles will
Digital twin and augmented need to change and personnel in those roles
reality systems are no more will need additional training.

core business for manufacturing A simple example is the QA engineer.

Today’s QA engineer’s toolkit includes 2D
organizations than are
drawings, manufacturers data books, and a
manufacturing execution and tape measure. The role has developed over
enterprise resource planning the years and has moved further away from
hardcopy toward electronic documents, in-
systems. Roles cannot be so
cluding 3D models. Future QA engineers will
specialized that they only continue to develop and be able to utilize:
support one technology. z A digital twin that combines an accurate
3D model of equipment with the manufac-
turer’s data fully integrated
MxD (Manufacturing x Digital) is a non-profit
z Smart glass technology to allow the over-
organization where major manufacturers, in part-
lay of a 3D model on the actual equipment,
nership with the U.S. Department of Defense,
simplifying the process of tie-in point
are identifying the tools and expertise they
validation and dimensional control
need to enhance their capabilities. Its report The
This is the Deloitte Smart QA Manager
Digital Workforce, Succession In Manufacturing,
role—although it would be more helpful to
identifies 165 roles, although each role is nar-
focus on the new skills and knowledge the
rowly defined, and the skills and knowledge
QA manager needs, rather than dwell on
overlap with several others. For example, there
the name of the role. This is a minor issue.
are eight roles with IT/OT in the title (application
The more significant concern is that Deloitte
developer, systems analyst, systems architect,
and MxD both foresee manufacturing
systems technician, etc.). In reality, there are
organizations creating roles such as digital
probably two roles here (technician, engineer),
twin engineer and virtual reality/augmented
and a variety of company-specific names or
reality software engineer. Digital twin and
activity-specific roles (e.g., during a project).
augmented reality systems are no more core
business for manufacturing organizations
A more likely reality
than are manufacturing execution and enter-
The approaches by Deloitte and MxD can cer-
prise resource planning systems.
tainly stimulate good discussion, but manufac-
turing organizations are unlikely to change so Of course, manufacturing organizations
dramatically. The real benefit of Industry 4.0 will employ personnel who can support the

INTECH JUNE 2023 49 WWW.ISA.ORG/INTECH

 FINAL SAY | VIEWS FROM AUTOMATION LEADERS

business with technology, most likely in their assess gaps in skills and knowledge in the
IT departments. But even then, these roles existing workforce.
cannot be so specialized that they only sup-
With the ACM skills and knowledge descrip-
port one technology. As technology inevitably
tions, it is possible to define a training cur-
evolves, the role needs to be one that can
riculum. ISA’s existing training portfolio covers a
keep up (or ahead) and continue to evolve.
significant portion of the ACM skills and knowl-
Therefore, organizations should update the
edge, and work is underway to review the gaps.
skills and knowledge requirements for their
This will also include identifying the gaps in new
relevant roles to include the new technolo-
skills and knowledge areas, such as Industry 4.0,
gies that need supporting.
and identifying a strategy for closing those gaps.

This may involve the development of a

Automation competency model
new training (or certification) program or
ISA, representing the automation profession,
partnering with other like-minded organiza-
has been working with the U.S. Department
tions that are better suited to a particular set
of Labor since 2008 on the development
of skills and knowledge. Either way, ISA will
and ongoing maintenance of an automation
be able to offer all the relevant training and
competency model (ACM). The model identi-
certification needed for the future automa-
fies the knowledge and skills needed in the
tion professional and help manufacturing
automation profession. The ACM defines the
organizations achieve their ambitions to
totality of skills and knowledge needed in the
deliver better-quality output more efficiently
automation profession. To identify a specific
through the use of Industry 4.0 technologies.
profile for a role, users are able to employ
the needs analysis matrix. This can be used A version of this column originally appeared
to screen applicants for roles, as well as to on the ISA Interchange blog.

ABOUT THE AUTHOR

Steve Mustard is an independent automation consultant and a subject matter expert of
the International Society of Automation (ISA). Backed by more than 30 years of engineer-
ing experience, Mustard specializes in the development and management of real-time
embedded equipment and automation systems. He serves as president of National Auto-
mation, Inc., and served as the 2021 president of ISA. Mustard is a licensed Professional
Engineer in Texas and Kansas, a UK registered Chartered Engineer, a European registered
Eur Ing, an ISA Certified Automation Professional (CAP), a certified Global Industrial
Cybersecurity Professional (GICSP), and a Certified Mission Critical Professional. He also
is a Fellow in the Institution of Engineering and Technology (IET), a Senior Member of ISA,
a member of the Safety and Security Committee of the Water Environment Federation
(WEF), and a member of the American Water Works Association (AWWA).

INTECH JUNE 2023 50 WWW.ISA.ORG/INTECH