Control - August 2026

AU G US T 2026

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AU GUST 2026

PRACTICAL SOLUTIONS TO IMPROVE SUSTAINABILITY SIMPLIFYING WASTEWATER ANALYTICS HOW TO KEEP AN OLD BUS GOING

HOW TO BUILD

process engineers and operators System integrators, educators and suppliers weigh in on what it takes

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AUGUST 2026  VOLUME 39  NUMBER 4

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WORKFORCE DEVELOPMENT

How to build process engineers and operators System integrators, educators and suppliers weigh in on what it takes

by Jim Montague

Pixels Stock / genererated with AI / stock.adobe.com

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Sustainability reaches out

UV-visual meter eases wastewater analytics

SUSTAINABILITY

System integrators and suppliers measure and mix the ingredients for sucessful sustainability cocktails

by Jim Montague

PROCESS ANALYZERS

Martinez Refining simplifies total organic carbon monitoring with ABB’s UviTec portable field meter

by Jim Montague

Control ® USPS Permit #4853 (ISSN 1049-­5541) is published 6 times (Feb, Apr, Jun, Aug, Oct, Nov) per year by Endeavor Business Media, LLC. 201 N. Main Street 5th Floor, Fort Atkinson, WI. 53538. Periodicals postage paid at Fort Atkinson, WI. 53538 and additional mailing offices. POSTMASTER: Send address changes to Control, PO Box 3257, Northbrook, IL 60065-­3257. SUBSCRIPTIONS: Publisher reserves the right to reject ­non-­qualified subscriptions. Subscription prices: U.S. $124 per year; Canada/Mexico $258 per year; All other countries $258 per year. All subscriptions payable in U.S. funds. Send subscription inquiries to Control PO Box 3257, Northbrook, IL 60065-­3257. Customer service can be emailed at customerservice@controlglobal.com for magazine subscription assistance or questions.

Printed in the USA. Copyright 2026 Endeavor Business Media, LLC. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopies, recordings, or any information storage or retrieval system without permission from the publisher. Endeavor Business Media, LLC. does not assume and hereby disclaims any liability to any person or company for any loss or damage caused by errors or omissions in the material herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. The views and opinions in the articles herein are not to be taken as official expressions of the publishers, unless so stated. The publishers do not warrant either expressly or by implication, the factual accuracy of the articles herein, nor do they so warrant any views or opinions by the authors of said articles.

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3:02 PM

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CONTENTS

Departments 9 EDITOR’S PAGE Let’s get physical AI Can it be a foundation for safe, reliable autonomous operations in the process industries?

10 OTHER VOICES Industry shifts from automation to reasoning The next wave in industrial technology closes the gap between insight and action

12 ON THE BUS Keeping the old bus going Control engineers must audit every configuration layer, not only the device-level settings, to avoid compounding errors

13 WITHOUT WIRES What’s driving the muddled mix of IoT and IIoT As global electrification increases, control engineers must be prepared for the convergence

14 DEVELOP YOUR POTENTIAL The best control engineers have scars from the shop floor Why R&D engineers should work in manufacturing first, and what’s lost when they don’t

15 EXCLUSIVE

37 RESOURCES

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16 IN PROCESS Endress+Hauser expands U.S. presence Schneider Electric buying Cognite; Ethernet-APL flowmeters to help digitalize China refinery; Water/ wastewater treatment drive magmeter market

31 EXCLUSIVE Top-­shelf, cost-­effective flame detection Smart flame detector uses infrared sensors to distinguish hydrocarbon fires from non-­flame radiation

36 EXCLUSIVE Flow sensor helps data centers keep cool under pressure Control liquid-cooling systems with assists from Emerson’s magmeters, shortrun software and expertise

Analyzers, detectors and instruments aplenty Control’s monthly resources guide

38 ROUNDUP Tailor-­made protections Enclosures, workstations and purge systems balance essential shielding with pragmatic access

40 CONTROL TALK The control and instrumentation symposium ‘no one’s heard of!’

The long-running Instrumentation & Automation Symposium is positioning itself as a critical forum for passing on the fundamentals of process control, instrumentation and safety systems

42 CONTROL REPORT Don’t be a parrot Master artificial intelligence (AI) before AI masters you

CONTROL AMPLIFIED Listen to our podcast series.

Find it at controlglobal.com

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EDITOR’S PAGE

Endeavor Business Media, LLC 30 Burton Hills Blvd, Ste. 185 Nashville, TN 37215 800-547-7377 EDITORIAL TEAM

Let’s get physical AI Can it be a foundation for safe, reliable autonomous operations in the process industries?

Editor in Chief Len Vermillion lvermillion@endeavorb2b.com Executive Editor Jim Montague jmontague@endeavorb2b.com Digital Editor Madison Ratcliff mratcliff@endeavorb2b.com Contributing Editor John Rezabek Columnists Greg McMillan R. Russell Rhinehart Ian Verhappen DESIGN & PRODUCTION TEAM Art Director Meg Fuschetti Production Manager Rita Fitzgerald Ad Services Manager Jennifer George PUBLISHING TEAM Group Sales Director Mitch Brian 208-521-5050 mbrian@endeavorb2b.com Account Manager Greg Zamin 704-256-5433 gzamin@endeavorb2b.com Account Manager Jeff Mylin 847-533-9789 jmylin@endeavorb2b.com Subscriptions Local: 847-559-7598 Toll free: 877-382-9187 Control@omeda.com

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Jesse H. Neal Award Winner & Three Time Finalist Two Time ASBPE Magazine of the Year Finalist Dozens of ASBPE Excellence in Graphics and Editorial Excellence Awards Five Time Winner Ozzie Awards for Graphics Excellence

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THIS ARTIFICIAL INTELLIGENCE (AI) stuff is coming at us fast, isn’t it? Just a year ago the talk of large-language models (LLM) was all the rage. And before I could fully wrap my head around it, I found myself interviewing experts about agentic AI. Now, I’ve spent a the last month knee deep in physical AI trends.

Physical AI is artificial intelligence grounded in the laws of physics, chemistry and thermodynamics. The concept is different than LLMs and agentic AI, which have no inherent understanding of why, for example, a distillation column can’t violate component mass balances, or why a compressor has hard operating limits.

When design limits are respected, reliability constraints can be honored, and decades of engineering standards become guardrails embedded in AI. So, it’s easy to see why many consider it a significant leap forward.

I recently sat in on a joint presentation by Honeywell Technologies’ (www.honeywell.com) Rahul Negi and Nvidia’s (www.nvidia. com) Ahsan Yousufzai at Honeywell User Group in Phoenix, and they put the benefits and the journey of physical AI in context (www.controlglobal.com/physicalAIjourney). About AI up to this point, Negi, the company’s head of AI and industrial autonomous operations, explained, “Small step changes brought us to where we are, but they’re not going to get us that next step forward.”

Across the globe from Phoenix, in Taipei, experts at Advantech’s Edge AI conference reported the edge has great advantages over the cloud in enabling physical AI. Miller Chang, president of embedded sector for Advantech, said the U.S. market alone for edge AI is projected to grow to $197 billion by 2034.

While all this seems exciting, there are reasons for pause. Before physical AI is adopted full steam, real-world models must be consistently accurate, and most experts agree we aren’t quite there yet. Another hindrance is the continued and persistent disconnect between operational and information technology architectures. Until these issues are solved physical AI use probably won’t take off in industrial settings.

But that doesn’t mean anyone should abandon their quest for physical AI. It offers promise and safeguards against many of the fears that keep humans awake at night these days.

We may be a half century into this AI journey, but in many ways, we’re still just getting out of the starting blocks. Autonomous operations are the ultimate destination. Physical AI just may be the enabling technology to get us there.

LEN VERMILLION Editor-in-Chief lvermillion@endeavorb2b.com

“ Physical AI is artificial intelligence grounded in the laws of physics, chemistry and thermodynamics.”

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OTHER VOICES

Industry shifts from automation to reasoning The next wave in industrial technology closes the gap between insight and action

JAGADISH GATTU Founder and CEO, UptimeAI

“Put simply, automation made plants faster.

Reasoning makes plants smarter.”

FOR HALF A century, industrial technology has moved on a single trajectory: do more, faster, with less human effort. Distributed control systems (DCS) automated our loops, historians captured our data, and predictive analytics flagged our anomalies. Each wave delivered real value, yet each one stopped at the same wall—the moment a machine had to think rather than detect or take a rule-based action—and a human had to step in.

Now, that wall is coming down. The shift from automation to reasoning is the largest change to process operations since the DCS—and it’s happening at exactly the moment that industry is running out of the people it has always relied on to do the thinking.

Automation and reasoning are often discussed together, and while describing them as points on a continuum works in analogy, they should be delineated by the differences in objectives and capability.

Put simply, automation made plants faster.

Reasoning makes plants smarter.

The expertise cliff The technology industry evolves to meet the needs of the markets it serves. So why now for reasoning technology? It’s because the human side of the equation is collapsing faster than most operators care to admit. Senior

Detection Data

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Digital tools

Insights, alerts

ion

lat

Decision

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Expert bottleneck

A visual representation of the decision latency created by the expert bottleneck.

Source: UptimeAI

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engineers, who learned their plants by walking them for 30 years, are retiring faster than industry can replace them, and the pipeline behind them has thinned to a fraction of what it was a decade ago. Some contributing factors: J Petroleum engineering enrollment in the U.S. has collapsed. Undergraduate enrollment peaked at roughly 11,000 students in 2014 and has fallen by more than 75% since, with several major universities now graduating only single-digit cohorts.

J Instrumentation and control engineering has nearly disappeared as a standalone discipline. In most North American universities, it’s been folded into broader electrical or mechatronics programs that rarely produce graduates who understand a working plant.

J Manufacturing is short on people. Deloitte and the Manufacturing Institute estimate up to 2.1 million unfilled U.S. manufacturing jobs by 2030, and the process industries are hit hardest because the work is rural, shift-based, and increasingly invisible to the next generation.

J The people who do the thinking are leaving. In many North American plants, the average age of operators and reliability engineers is now over 50. Within 10 years, the people who know why a particular column behaves differently will be gone.

There’s no realistic plan to replace tacit plant expertise the way it was originally built. This expertise must be captured and operationalized in a way that doesn’t rely on the experiences of the individual. The answer to tackling this is reasoning.

Why reasoning is a big deal A modern plant generates orders of magnitude more data than its engineers can inspect. Automation handles the routine. Predictive models handle the obviously abnormal, www.controlglobal.com

7/28/26 8:16 AM

OTHER VOICES

Automation

Reasoning

Executes pre-programmed responses to known conditions

Interprets ambiguous, multi-source evidence to form hypotheses

Scales human action

Scales human judgment

Brittle in novel situations–needs an engineer to extend the rules

Adapts to situations it’s never seen before

Answers: What should the system do when a predetermined state X occurs?

Answers: For an undetermined state Z, what’s happening, why is it happening, and what should we do about it?

Output is a pre-programmed, determinant action

Output is a diagnosis, an explanation, and a recommendation

detecting alerts, anomalies and insights. But it’s that next step in the decision-making process—between identifying an anomaly and investigating, diagnosing and prescribing the optimal action—where most incidents, downtime and lost yield occur. Completing that step gets bottlenecked by relying on human expertise that can’t scale. It creates decision latency that costs margin. This bottleneck is what reasoning unlocks.

The way reasoning overcomes the expert bottleneck in critical plant decision-making starts with being evidence-based, not rules-based. Reasoning systems assemble the evidence, propose root causes, and rank hypotheses. These ranked hypotheses are explainable. Engineers see the chain of logic and the data sources analyzed, so they trust the system instead of fighting alert fatigue. Institutional knowledge compounds when every incident becomes a teachable case, and expertise is captured rather than lost when senior engineers retire. When one engineer with a reasoning system covers what previously required a team, it fundamentally changes the economics of the control room. It does so, not by replacing people, but by elevating how they spend their days.

Why reasoning is hard to achieve If reasoning is valuable, why don’t we have it already? Because reasoning over a process plant isn’t one problem—it’s multiple problems that historically lived in different worlds, and solving any one of them independently isn’t enough.

J Plants speak in many languages at once: sensor time-series, alarm logs, P&IDs, work orders, operator notes, vendor manuals, lab samples and inspection photos. These data sources aren’t compatible. They weren’t designed to be analyzed together. Reasoning helps fuse it into one coherent view of the asset that’s interpretable by anyone—no coding skills or spreadsheet gymnastics required.

J Real root-cause analysis braids together process engineering, control theory, instrumentation, mechanical reliability, metallurgy and safety. No single model or human, covers all the domains. Reasoning systems must encode pieces of each and know when to apply them. www.controlglobal.com

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J

Even with the right skills and the right data, the hardest part is knowing which model to apply, to which signal, at which moment, and how. A vibration analysis is useless when the real story is a controller saturating. A controller analysis is useless when the real story is a clogged restriction orifice.

Orchestration is what separates a generic data platform from an industrial-grade, decision-support system.

This is why earlier waves stopped at automation, monitoring dashboards and anomaly detection. Each of those waves solved one of the problems above, while ignoring the others.

Reasoning is the first architecture capable of handling all three at once. That’s what makes it a genuine technology inflection point rather than another analytics layer.

Hidden opportunity living at the intersections Plants are organized by function—reliability, process, instrumentation, safety, controls, maintenance—and so is their data.

Each team operates excellently within the boundary of their lanes and almost blind across lanes. However, failures rarely respect functional lanes. A bearing failure can trace back to a process upset that triggered control loop oscillation that masked an instrumentation drift that finally fatigued the asset.

This one root cause propagated symptoms across six teams, and no single person saw the whole chain.

By looking across all functions at once, reasoning brings top the surface causal links no single discipline would catch on its own. These are the losses that never show up cleanly on any one dashboard because they don’t belong to any one function.

Reasoning makes the previously invisible visible, and the visible avoidable.

Reasoning will accelerate the leaders and laggards divide Every prior wave of process technology produced a gap between leaders and laggards that took a decade to close. Plants that adopted DCSs early ran cleaner and safer for the next 20 years. Reasoning AI will be no different—except the curve is steeper because AI technology learns and adapts at a pace unlike any technology revolution we’ve experienced in history.

Each month a reasoning system runs, it gets better and widens the divide between those who break the expert bottleneck and those who fight the losing battle against a shrinking human expertise pool. Starting late means starting from zero against operators with a year or two of compounding advantage and a workforce that’s shrinking beneath your feet.

The question is no longer whether reasoning AI will redefine process operations. It will. The question is where each plant falls on the adoption curve—whether it will define the next decade of industrial operation, or try to catch up to it, with a shrinking pool of experts and a growing mound of insights to interpret.

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ON THE BUS

Keeping the old bus going Control engineers must audit every configuration layer, not only the device-level settings, to avoid compounding errors

JOHN REZABEK Contributing Editor JRezabek@ashland.com

“One wonders, is ‘just drive the car’ achievable when joining disparate devices, each configured in its own silo, or not configured at all?”

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RECALLING A PRESENTATION from an end user conference more than a decade ago, Juan surmised, “Some folks just want to drive the car.” This revelation came from a pharmaceutical company faced with maintaining the supplier’s distributed control system (DCS).

Similar to a motor vehicle, some end users just want to hop in and use it for its intended purpose—to get from point A to point B. In Juan’s world, the culture of tinkering or “puttering around” with one’s car was vanishing.

Likewise, there’s a segment of instrument and controls (I&C) professionals, who are curious about settings, filtering, tuning, etc, often out of necessity. If the technician configures a first-order filter in the transmitter, a second one in the I/O, and another in the PID block, the efficacy and stability of the ultimate control loop might be adversely affected. Is “just drive the car” achievable when joining disparate devices, each configured in its own silo or not configured at all?

Juan remembered the befuddled turbomachinery specialist, who struggled to reconcile his horsepower curves with measured admission and extraction steam flows. It seemed like years before someone noticed there was a square root applied to a vortex flowmeter’s analog input block. Whoever configured the blockware early on must have assumed they were connecting a differential pressure flowmeter.

Could Juan give his successors sufficient guidance or procedures to ensure all important parameters were scrutinized?

More than a decade ago, NAMUR (namur. net) an international user association for automation technology in the process industries, published recommendations (NE131), which were woven into FieldComm Group’s Process Automation Device Information Model (PA-DIM). They aim to better standardize and focus on the essential parameters end users must scrutinize to obtain a useful measurement. Some manufacturers develop methods

or wizards, which automate aspects of device configuration, but require mindful input from users. Both technologies rely on platforms like electronic device description (EDD), once the bane of early fieldbus adopters, which has now been visited upon HART and WirelessHART. Also, users might download a device type manager (DTM) or a field device integration package to support their EDD. Juan was struggling to turn off the analog output block of a positioner he wanted to use in discrete (on-off) mode, but even the DTM didn’t provide the options he needed. He was going deep in the weeds, and worried whether his technicians would even know where to start. He also noted how massive the DTM downloads were. Even his relatively state-ofthe-art field communicator required periodic updates. The tinkerer could figure out how to load DDs on the Trex without a subscription, but all Juan could envision was the frustration when a device wouldn’t connect.

What about AI? Microsoft’s CoPilot gave him the idea to disable the analog output block in his fieldbus positioner, so he could get the discrete blocks to function—the parameter tweak he couldn’t get to work. When prompting CoPilot to set up his flowmeter, the advice was detailed, verbose and useful.

While he already knew most of the answers in advance, CoPilot highlighted nuances about filtering/signal conditioning that were new to him. He was surprised that engineers at his suppliers were working to bake-in features that defied the commoditization of field devices, but Juan needed AI to find them.

The day may come when Juan’s Bluetooth-connected device interfaces directly with cloud-based AI to guide configuration.

Whether that technology will extend the life of legacy fieldbus systems remains uncertain. Knowledgeable practitioners motivated to delve under the hood will be essential for decades to come. www.controlglobal.com

7/28/26 8:16 AM

WITHOUT WIRES

What’s driving the muddled mix of IoT and IIoT As global electrification increases, control engineers must be prepared for the convergence

THE ISO/IEC 20924:2018 definition of an Internet of Things (IoT) device is, “entity of an IoT system that interacts and communicates with the physical world through sensing or actuating.” Interaction with the IoT system means automated data exchange and interaction with other elements to create the system.

Unfortunately, developing IoT standards interpret IoT very broadly as meaning, “any device with a processor and IP address to exchange data” regardless of what “space” it’s used in, such as monitoring individuals or controlling industrial processes, substations, railways or buildings.

As automation and control professionals, we likely use IoT devices in one form or another in our personal lives. They’re part of the consumer market. Despite IoT devices appearing “almost everywhere” with billions of devices, they only represent about 25-­30% of the total IoT device market by value. The balance is part of the business-­to-­business (B2B) or Industrial Internet of Things (IIoT) market, which is growing at rates approaching 20% compound annual growth (CAGR).

The IIoT market is driven by large-­scale asset digitization and the benefits/ROI associated with predictive maintenance and automation, as well as modernizing transportation, utilities and related infrastructure that underly the smart city concept.

So, what makes IoT industrial?

The most obvious difference between IoT and IIoT is being able to operate for extended periods in a range of temperatures, humidity/rain, dust and vibrations. These environments also drive more expensive enclosures, as well as the need to meet area classification requirements. These safety and electrical certifications are more rigorous than in the consumer IoT space. Depending on the application, IIoT devices may update infrequently, while others update on a regular scan cycle like wireless sensor networks.

www.controlglobal.com

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IIoT also requires better accuracy, typically ±0.1–1% versus ±1–5% for an IoT device. IIoT devices also need to be calibrated to maintain accuracy over their 10-­to 30-­year lifespans.

To achieve this level of reliability, especially when used in safety applications, IIoT devices require graceful degradation, rather than abrupt failures. Consequently, they incorporate features such as redundancy of critical components to achieve continuous operation without interruption.

As indicated earlier, the number of IoT sensors is orders of magnitude greater than IIoT sensors. However, the market value is flipped the other way. Why? Because IoT sensors are available from $5 to a top range of about $300. IIoT sensors, because of their requirements, start at about $100.

IoT interoperability and integration is API-­ driven through the cloud, while IIoT systems use protocols to support real-­time, reliable messaging to connect to real-­time, data-­ driven environments.

I believe renewable energy and the electrification of society will drive broader demand for IIoT. Solar panels and electric vehicles (EV) show how consumer decisions impact the grid. However, most home systems aren’t connected to buy and sell electricity into the grid, and must be integrated with the control plane of grid operators, aggregators and utility companies.

Energy companies and utilities represent about 25% of the IIoT space, with renewables occupying about 25% of it. As electrification increases, not only in North America but also other parts of the world, the need for consumer and industrial integration will continue to grow. This growth will drive convergence of IIoT capabilities to IoT devices, muddling the line between them. The same happened when commercial off the shelf (COTS) technologies were repurposed for operations technology (OT) environments.

IAN VERHAPPEN Solutions Architect Willowglen Systems Ian.Verhappen@ willowglensystems.com

“The most obvious difference between IoT and IIoT is being able to operate for extended periods of time in a wide range of temperatures, humidity/rain, dust, vibration and dusty installations.”

AUGUST 2026  13

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DEVELOP YOUR POTENTIAL

The best control engineers have scars from the shop floor Why R&D engineers should work in manufacturing first, and what’s lost when they don’t

I STARTED MY career in industrial R&D be-

R. RUSSELL RHINEHART russ@r3eda.com

“It’s important that people in design and R&D have significant plant experience, so they can understand the myriad issues manufacturing must address.”

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cause I wanted to invent things and make things better, not simply keep things running.

I enjoyed the innovation and creativity of the process development function, but found that plant professionals were reluctant (usually opposed) to implement things we proved in the lab or pilot plant.

After about three years, I was transferred by my company to a manufacturing plant to work in its technical support group. Despite my reluctance to leave the personal affirmation of R&D, I came to enjoy the plant. This included the magnitude of the impact of slight process improvements to the company, process controls, statistical analysis, economics and analytical troubleshooting. Unexpectedly, I learned a lot.

Then R&D folks, with their naive certainty, came to to tell us about the improvements they wanted to implement. “Lock the gates!

Turn off the lights! Nobody’s home!” was our cry. However, upper management had approved plant trials. What happened? They came, made changes, then left on their nine-­ to-­five schedule. We were left to fight process complications and soothe operators, which happened at 2 a.m. on weekends.

I think it’s important that people in design and R&D have significant plant experience, so they can understand the myriad issues manufacturing must address. They should shape their innovations to accommodate the context of manufacturing’s reality.

On the other hand, naivety permits creativity. Because significant real-­world experience knows a possible innovation will not work, this knowledge can hamper transformation. So, it might be a good idea to have some inexperience and out-­of-­the-­box creativity on design teams. However, design novices need to be well-­supervised by experienced coaches. If experience supervises novices, then realism can be embedded in creative solutions.

For many graduates seeking employment, the design environment (attractive space, use of simulators, comfortable dress, landscaped building) is much more attractive than the often-­uncomfortable field or manufacturing environments. As a parallel, the capstone design course is usually much more enjoyable for students than the unit operations course (noisy, dirty, PPE, aggravating reality). So, if a company wants to hire office-­or development-­oriented students, they may have to offer them entry into design or R&D jobs, and be sure their supervision has a comprehensive reality balance.

At a third stage in my career, I was in the product development group. My job was to direct innovations in our products to make them more competitive in our customers’ manufacturing processes. Here, my manufacturing experience was essential to establish credibility with our customers. Also, the joys making our products more competitive were unexpected, and seeing how our customers ran their business gave me insight as to how we might also run ours.

When I returned to supervising technical support engineers in my old manufacturing plant, the insights from marketing and R&D were beneficial.

The last part of my career was as a chemical engineering professor, where I believe these diverse industrial experiences gave me relevance and creativity advantages in teaching and controls research.

Maybe the question should be broadened to, “Does diverse engineering experience contribute to effectiveness in other engineering jobs?” I say it does, and very much so.

To develop your potential, after building competency in one engineering function, accept transfers to others. Embrace the experience you’ll bring to the new function and the benefits that new experiences will give you in your career future. www.controlglobal.com

7/28/26 8:16 AM

PRODUCT EXCLUSIVE

All-in-one, clamp-on, ultrasonic flowmeters for liquid, gas and steam Portable, non-intrusive for measurement, verification and condition monitoring

ANYONE CAN MULTITASK when it’s easy. Doing it in hot, noisy, cramped, and other problematic and distracting locations is more difficult—and more valuable if accomplished. So, while it’s still logical to assume that measuring media like gases, liquids and steam requires multiple components, at least one new device can take on all of them.

Emerson’s Flexim Fluxus 631 portable, non-intrusive, clamp-on, ultrasonic flowmeters provide flexible, precise and reliable measurement of liquids, gases and steam in one platform. The fivemodel series performs quick, temporary, on-demand flow measurement without interrupting operations, and supports flowmeter and equipment verification, condition monitoring, leak detection and energy-performance analyses.

“Fluxus 631 gives users full flow transparency everywhere in their plants. They can configure, operate, monitor and control each line, and it doesn’t matter if they’re measuring gases, steam or liquids because this flowmeter can handle all of them,” says Eike Schwede, industry manager for Flexim at Emerson. “This is a big difference because 95% of regular, portable, clamp-on, ultrasonic flowmeters can only measure liquids, while previous meters that measure gases couldn’t measure steam.”

By eliminating measurement blind spots and avoiding unplanned downtime, Fluxus 631 series maintains operational continuity, lets users independently verify flow installations, and assesses the performance of pumps, compressors and other equipment under actual operating conditions. This allows highly accurate flow measurements when permanent meters are unavailable.

www.controlglobal.com

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Fluxus 631’s flow measurement capabilities are presented via its simple, consistent, intuitive and quick-to-setup HMI, which includes a large, integrated display with installation graphics, live values and trend visualizations. Advanced compensation mechanisms enable accurate measurements in disturbed flows, and even in constrained installation conditions with limited, straight-pipe runs.

“Since they were introduced in 1990-91, clamp-on, ultrasonic flowmeters have pushed forward with new capabilities. Now, we’re extending them to measure high-temperature steam, up to 630 °C, which is approximately 1,166 °F,” explains Schwede. “We also worked with Germany’s national metrology institute, Physikalisch-Technische Bundesanstalt (PTB), to research and implement computational flow dynamics (CFD) corrections in Fluxus 631, which enable flowmeter installations, even in very short inlet conditions.”

Different measuring principles combined with electronics enable Fluxus 631 to make precise, repeatable measurements of diverse media, such as low-pressure gases, liquids with entrained gas or solid contents, high-viscosity liquids, and saturated and hightemperature steam. Its Dynamic Gas Meter ensures reliable flow measurement despite varied gas compositions, and determines gas density and concentration without a chromatograph.

“If a user’s line has a double or single bend out of plane within 20 cm of a location that needs to be measured, the meter can correct the flow to allow accurate measurements,” adds Schwede.

“Likewise, reducing or extending lines can impact readings, and CFD can

Flexim Fluxus 631 portable, non-intrusive, clamp-on, ultrasonic flowmeters. Source: Emerson

correct those conditions, and help read any oil and gas, water/wastewater or chemical flow in any location.”

Schwede reports Fluxus 631’s measurement and HMI functions are supported by its durability, which is exemplified by its IP65/67-rated enclosure, that’s NEMA 4X compliant. It also offers dual measurement channels and update rates up to 20 milliseconds. Its lithiumion battery enables more than 25 hours of autonomous operation, while its lowpower mode extends operating time up to 80 days for long-term monitoring.

“This allows Fluxus 631 to gather all the information about a plant, and gain full transparency into its processes.

Traditionally, many of these devices and measurements were inaccessible, and it was too costly to reach them anyway.

Now they can. Users can get quick-shot measurements because Fluxus 631 only takes 5 minutes to set up. Now, they can find out if pumps, compressors and heat exchangers are working without having to cut a line.”

For more information, visit www.Emerson.com/FLUXUS631 AUGUST 2026  15

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Endress+Hauser expands U.S. presence Opens USA Innovation Center and George E. Booth Headquarters in Greenwood, Ind., and campus in Edgmont, Pa., with Eastern Controls IN THE SPACE of three days,

The second opening near Philadelphia is a 100,000-square-foot campus in Edgmont, Pa., which will also serve as a new headquarters for Eastern Controls LLC of PA (www.easterncontrols.com), which has served the mid-Atlantic region since 1969.

“As a family-owned company, we stand for long-term thinking, reliability and partnership-based collaboration— values that are also reflected in these construction projects,” said Steven Endress, president of Endress+Hauser’s Supervisory Board, during the opening festivities in Greenwood.

Peter Selders, Endress+Hauser’s CEO, reported that investing in the two buildings is part of its long-term, threepart strategy, which includes serving a broad-based portfolio of industries that can offset fluctuations in each, taking a partnership approach with its customers to enable continuity, and maintaining a stable framework in the U.S., which is

Source: Endress+Hauser

Endress+Hauser (www.endress.com) opened two major, U.S.-based facilities on June 23 and 25, which are colocated with two of its longtime Midwest and East Coast technical, sales and service partners—one collaborating with the company for 56 years. Both new facilities are expected to expand Endress+Hauser’s U.S. presence, and strengthen its collaboration with regional sales and service representatives.

The first opening was the $50.9 million Endress+Hauser USA Innovation Center and new George E. Booth (www.gebooth.com) Headquarters at the company’s campus in Greenwood, Ind., near Indianapolis. George E. Booth has worked with Endress+Hauser since 1971. This 108,000-square-foot facility consists of offices and workspaces for 190 employees from both companies’ sales, services, quality, legal, project and solutions teams.

Wielding the traditional, big, shiny scissors, ribbon cutters inaugurating Endress+Hauser USA Innovation Center and new George E. Booth Headquarters on June 23 include (l. to r.) Mark Myers, mayor of Greenwood, Ind., Laurent Malley, chief sales officer at Endress+Hauser, Todd Lucey, managing director at Endress+Hauser USA, Peter Selders, CEO at Endress+Hauser, Steven Endress, president of Endress+Hauser’s Supervisory Board, George E. Booth II, and Scott Young, president of George E. Booth.

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Endress+Hauser’s largest market, far ahead of China and Germany.

“With these new buildings, we’re strengthening our local presence and ensuring we’re close to our customers.

In doing so, we’re laying the foundation for sustainable growth,” explained Selders. “Customer proximity is key to building long-term relationships and a strong regional market presence. Likewise, George E. Booth’s new headquarters is also strengthening our relationship because of the additional insights, innovations and manufactured-to-order products we’ll produce by collaborating more closely.”

Skids and STEM Because it houses their project and solutions teams, the Innovation Center will enable both companies to expand their customer bases, and allow them to build customized process skids and analyzer packages more efficiently, according to Todd Lucey, managing director at Endress+Hauser USA. “Customers want to know more about the material flows related to the products they’re buying, and our new Innovation Center enables this, along with our other manufacturing facilities in California and Ann Arbor, Mich.,” said Lucey. “We’re also super focused on maintaining a strong talent pipeline. We want to fill 80% of job openings from within, but this process starts by bringing in elementary, middle and high school students for field trips and events like our 12th annual Community Career + Education Forum (CCEF) on Sept. 10, which can hopefully attract them, and give them the idea of pursuing science, technology, engineering and math (STEM) careers.”

Beyond its sales, service and solutions functions, the center also features an integrated Design and Innovation Studio www.controlglobal.com

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IN PROCESS

Schneider Electric buying Cognite Schneider Electric (www.se.com) reported June 30 that it’s agreed to acquire industrial data and AI software provider Cognite Holding B.V. (www. cognite.com) for $3.1 billion in cash.

Once the closing is completed, Cognite will be integrated with Aveva, Schneider’s wholly owned industrial software company, and will be consolidated and financially reported within its industrial automation business. Schneider adds this transaction complements the capabilities of Aveva’s Connect industrial intelligence platform, and reinforces its industrial intelligence solutions including design, build, operations and optimization.

“Cognite has built something rare, a truly industrial-grade AI platform that turns the complexity of operational data into a competitive advantage. This acquisition strengthens Aveva in the highest‑growth market segments, and centers Schneider Electric on the next industrial intelligence phase,” says Olivier Blum, CEO at Schneider Electric. “By bringing Cognite into Schneider Electric and Aveva, we unite the world’s most comprehensive energy-management www.controlglobal.com

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and automation infrastructure with the software and AI capabilities to make it natively intelligent. Together, we go beyond connecting systems. We give them the ability to think, adapt, and act. This is what industrial intelligence looks like at scale.”

Schneider reports industrial AI is shifting from supporting analytics to executing operations, from describing what’s happening in industrial infrastructure to deciding and acting on it.

It adds that capturing this shift requires more than models, and demands a unified, contextualized foundation of industrial data on which AI can be trusted to operate at scale. Schneider believes Cognite provides this foundation. Its cloud-native platform combines a unified, industrial data model with agentic AI capabilities, enabling users to operationalize AI directly within plant operations, asset management and engineering workflows.

For example, Cognite’s core technologies will act within Connect as an industrial data foundation and an AI-enabling platform: J Cognite’s Data Fusion software and knowledge graph will enable integration, modelling and contextualization of engineering, operational and enterprise data at scale.

J Cognite’s Atlas AI will introduce modelling capabilities, and generative and agentic AI, enabling automation of industrial workflows combined with accelerated and improved decision‑making.

Ethernet-APL flowmeters to help digitalize China refinery ABB (go.abb/automation) reported July 2 that it’s providing ProcessMaster FEP600 electromagnetic flowmeters with Ethernet- Advanced Physical Layer (APL) to upgrade a large refining

and petrochemical complex in China.

Located at the Zhoushan Green Petrochemical Base project on Yushan Island, the new facility is operated by Zhejiang Petroleum & Chemical (www.zhejiangpetroleum.com), and has a total refining capacity is 40 million tons per year.

ProcessMaster flowmeters will be deployed in a chemical production facility at the complex. It also has an annual production capacity of 450,000 tons of adipic acid, which is a raw material used to make nylon 66, specialty engineering plastics and polyurethane.

The flowmeters’ Ethernet-APL instrumentation will enable high-speed, real-time data transmission across the facility, supporting efficient and reliable plant operations. They’ll monitor flows of high-temperature, corrosive acidic fluids.

Zhejiang plans to use the flowmeters’ enhanced data sensing and transmission capabilities to improve its understanding of operating conditions, and enable

Source: ABB

to promote developing young talent in STEM fields. It will also facilitate handson learning formats, and focus on collaborating with local schools and colleges.

“We’re expecting about 3,000 students to come through the Innovation Center this year,” added Lucey. “Everyone wonders where technical talent comes from and where they can get it.

Well, there are many great opportunities for jobs, including at Endress+Hauser, and many don’t require four-year degrees. The Innovation Center showcases our technologies and what we can do, but it also lets students get their hands dirty with applications and installations, and see how they’re implemented in the real world.”

Zhejiang Petroleum & Chemical is using ABB’s ProcessMaster FEP600 electromagnetic flowmeters with EthernetAPL to upgrade a 40-million-tons-peryear-capacity refining and petrochemical complex at the Zhoushan Green Petrochemical Base project on Yushan Island in China.

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IN PROCESS

smarter, more efficient operations.

ProcessMaster FEP600s are designed for a pipe sizes, ranging from DN 15 mm to DN 300 mm. A single twowire cable provides power and highspeed Ethernet-APL communications, enabling the highest level of safety protection (Ex ia), and reliable data transmission up to 1,000 meters. ABB also uses PFA linings to protect the flowmeters, and ensure measurement accuracy and equipment longevity.

Water/wastewater treatment drive magmeter market The world market for magnetic flowmeters is projected to grow at a 4.9% compound annual growth rate (CAGR) from $2.1 billion in 2025 to more than $2.6 billion through 2030, according to

“The world market for magnetic flowmeters,” 8th edition (www.flowresearch. com/mag), published July 6 by Flow Research Inc. The study includes segmentation by region, industry, line size, liner type, power type, coil power type and other market segments.

The study also determined that magmeters generated more revenue and sold more units worldwide in 2025 than any other type of flowmeter. While the magmeter market is a mature and stable, technical advances such as wireless and battery-powered are contributing to growth. In addition, two-wire magmeters that can be plugged into other powered devices are slowly encroaching on the market share of traditional fourwire designs.

The study reports that the water and wastewater industry remains the dominant segment for magmeters, surpassing food and beverage and chemical in

total sales worldwide. The growing need for clean water and expansion of water infrastructures worldwide are the most important long-term drivers of the magmeter market.

At the same time, aging water infrastructures also drive magmeter demand, especially in North America, Europe and Japan, where most municipal water systems were built decades ago, and much of their instrumentation is obsolete. As a replacement, magnetic flowmeters offer higher reliability, better diagnostics, lower maintenance and digital communications. Likewise, in many municipalities, as much as 14% percent of treated water is lost before reaching customers, so utilities increasingly use magnetic flowmeters to establish district metered areas. This enables them to monitor flows throughout their distribution networks, and identify leaks more quickly.

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SIGNALS AND INDICATORS J

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ei3 released an educational guide on July 8 to help machine builders deal with European Union’s Cyber Resilience Act (CRA).

The guide, “Preparing for the Cyber Resilience Act: a guide for machine builders” (ei3.com/iiot-insights/preparing-for-thecyber-resilience-act-a-guide-for-machine-builders), explains how CRA may affect OEMs and industrial automation suppliers as connected machines, gateways, embedded software, remote access systems, and cloud-connected applications become part of cybersecurity attack surfaces.

The Measurement, Control & Automation Association (themcaa.org) announced June 30 the immediate integration of member services and activities from the Canadian Process Control Association (cpca-accp.org). This move is intended to strengthen MCAA’s position representing the North American measurement, control and automation industry, and reflects a shared commitment to advancing member success through greater collaboration, expanded resources and stronger industry engagement across Canada, the U.S. and Mexico.

IMI (www.imiplc.com) reported July 1 that it will supply a wireless vibration monitoring solution to reduce unplanned downtime for a

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refinery operator in Oman. The contract covers engineering, supply and deployment of more than 500 IMI TWTG Neon battery-powered triaxial vibration sensors in ATEX Zone 0 / Class 1 Div 1 applications, battery-powered triaxial vibration sensors, and SolidRed condition monitoring software at two refineries. It’s IMI’s largest wireless vibration deployment awarded in Oman so far, and installation is scheduled to begin later this year.

Weidmuller USA (www.weidmuller.com) announced July 7 an organizational alignment to enhance collaboration, streamline decision-making and position the company for continued growth in an increasingly dynamic industrial landscape. The company reorganized July 1 around three core business models that reflect how customers design, build and scale operations, including: cabinet and field components. systems and solutions, and connectivity for device manufacturers.

Fortifi Food Processing Solutions (www.FortifiFoodSolutions.com) reported July 2 that it’s purchased Deighton Manufacturing U.K. Ltd. (www.deightonmanufacturing.co.uk), a provider of forming, portioning, coating and frying equipment. The acquisition reflects Fortifi’s broader strategy of offering complete, full-line solutions serving the needs of food processors of all sizes.

Highly robust and waterproof level measurement at a cost-effective price OPTIWAVE 1520 and OPTIWAVE 1540 – Compact radar (FMCW) level transmitters with IP68 • Compact 80 GHz radar with flush-mounted PVDF Lens antenna • OPTIWAVE 1520 – for (waste)water basins, pumping stations etc.

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products solutions services

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WORKFORCE DEVELOPMENT

Pixels Stock / genererated with AI / stock.adobe.com

HOW TO BUILD

process engineers and operators System integrators, educators and suppliers weigh in on what it takes

BY JIM MONTAGUE

WHAT’S NEEDED TO inspire, educate, recruit, train/retrain and retain process control engineers and operators these days? If you don’t know, you’d better find out because there are some epic obstacles in the way.

First, tens of thousands, if not hundreds of thousands, of Baby Boomers have retired from the process industries, and more are following them. Many veteran operators and engineers have already been replaced by younger, less-­ experienced counterparts. However, vast amounts of hard-­worn experience and precious know-­how have been lost in many individual processes, disciplines and industries.

Second, this already Grand Canyon-­ sized knowledge gap is widening even further due to accelerating digitalization

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and other technical advances. These consist of migrations from operations technologies (OT) such as dedicated, hardcoded I/O and PLCs and other rigid hardware to more flexible information technologies (IT) such as software-­ based controls, increasingly dynamic simulations and digital twins and cloud-­ computing services.

Even highly experienced engineers and operators have found themselves with new job descriptions that require them to perform new tasks, and typically learn and apply entirely new skills.

On the other side of the experience coin, the need for process operators and engineers is so great that many candidates with zero experience are transitioning in from unrelated and less-­ promising jobs, though they obviously

they need extra training to have a chance of success.

Third, there continue to be millions of unfilled jobs in U.S., North American and European process industries, manufacturing, agriculture, service industries and elsewhere. Even worse for the U.S., mindless attacks by the Trump Administration on immigrants and ethnic minorities are choking off one the nation’s best sources of willing, potential employees just when they’re needed most.

Faced with this triple-­threat of continuing brain drains, tectonic technical shifts, and self-­destructive federal policies, how are process industry managers, owner-­operators and other leaders responding—not to mention the engineers and operators themselves? www.controlglobal.com

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And lest we forget

trades. That said, it seems easier to find maintenance and reliability candidates and harder to find people for operations,” explains Hall. “Plants require onsite work and 24/7 shift coverage, which isn’t ideal for some. There also isn’t a widely established educational path for most operations roles, so much of the training needs to happen on the job.”

Plus, even though the COVID-19 pandemic ended more than three years ago, its severe shrinking of the average tenure of process industry professionals and other manufacturing employees continues to this day, especially for operations teams, according to Jon Hall, VP at Adatafy (Adatafy.com), Novaspect’s data management, data analytics/AI and workflow brand.

“It used to be common for end users to have veteran team members with 20-plus years of experience, but we saw an accelerating decline in tenure during the pandemic,” says Hall. “There were so many retirements that many manufacturers had to bring new people into critical roles faster, which increased the need for consistent training, mentoring and knowledge transfer to help staffers succeed in their new positions.”

Hall reports another response to workforce shortages is increased interest in and use of process simulators for training, and augmented reality (AR) environments to allow support from remote subject matter experts (SME), though these tools aren’t mainstream yet. Training managers are trying different techniques, but they must also contend with inherent differences in training needs for operations roles compared to maintenance and other positions.

“Manufacturers are hopeful that more young people will want to get into the

A matter of degrees While four-­year degrees in electrical, chemical or mechanical engineering remain minimum requirements for many process control and automation positions, and two-­year associate degrees or similar certificates are typically needed for operator and technician roles, these qualifications don’t guarantee success or long-­term effectiveness working with real-­world production processes.

“After 35 years in the engineering and system integration business, we’ve learned that many people with engineering degrees can’t cut it working with controls,” says Sam Hoff, president and CEO of Patti Engineering (www.pattiengineering.com) in Auburn Hills, Mich., a certified member of the Control System Integrators Association (www.controlsys.org). “It isn’t brain surgery, but it does require strong problem-­ solving and logical thinking. Traditional, academic education is valuable, but I’ve known many great controls engineers who didn’t have degrees.”

INSTRUCTION PARTY AT THE ISA The International Society of Automation (ISA.org/training) offers a boatload of different types of training in industrial automation, process control and related technologies. Its unbiased, vendor-­neutral training courses, bootcamps, applicable hands­on equipment and exercises are developed by real-­world, control and automation experts, cover relevant topics and technologies, are delivered in flexible formats, let participants earn certificates and professional development credits, and provide documentation of acquired skills and credentials. Overall topics include: J J J J J

Connectivity and cybersecurity, Process automation and control, Operations and management, Digital transformation and Industry 4.0, Factory automation and machine control,

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J J J J J

Certification and exam preparation, Certificate training programs, Standards-­based training, Technician training Automation professional training

However, because control, automation and related technologies are becoming increasingly complex and interconnected, Hoff cautions that engineers and operators need to become masters of some skills rather than jacks-­ of-­all-­trades. “Because control software and hardware are more interdependent now, we also rely on our colleagues and partners more than in the past,” explains Hoff. “Likewise, if a proposed strategy, design or practice goes too far outside practical boundaries, we depend on them to speak up, so we can let our clients know. This is especially important because the boundaries of our expertise—and what’s technically feasible—are shifting faster and more often than ever.”

Curiosity crucial for careers Despite their obvious, physical differences, process industries and applications share many common objectives, such as striving for efficiency and safely. Digitalization has expanded and deepened these commonalities, of course, so even the new engineers and operators sought by manufacturers also have many of the same skills and other attributes.

“We work with process, discrete and machine-­building applications, and they share more similarities than differences.

So, when we’re looking to hire, we try to find self-­motivated, self-­starters, who are curious, and can also see what additional knowledge training they’ll likely need when presented with opportunities,” says Daniel Clark, architecture and engineering director at Abelara (abelara.com), a year-­and-­a-­half-­old coaching, consulting and system integration firm in the Cleveland area. “My degree is in accounting, so I know it takes people with different skills. That’s why we start by seeking analytical minds that can solve problems.”

Dylan DuFresne, cofounder of Abelara, reports potentially worthwhile engineering and operations candidates aren’t necessarily required to have any particular technical education, so long AUGUST 2026  21

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WORKFORCE DEVELOPMENT

IN-­HOUSE PREPARATION PUTS PERSONNEL PARTS TOGETHER While many system integrators logically organize training and workforce development within their human resources department, Interstates (www. interstates.com), a system integrator in Sioux Center, Iowa, recently decided to split them out, so it could focus, specialize and prepare its teams with technical and leadership skills. It recruits four-­year undergraduates and two-­year vocational graduates, but it also relies on its own apprenticeship program.

“We have to answer the same questions for everyone, including do they have the basic knowledge, interest and communication skills? And, do they have the hunger and desire to learn new technologies?” asks Andrew Roelfs, training and development manager at Interstates, which is a certified member of the Control System Integrators Association (www.controlsys.org).

“If they have that willingness, we can help them develop the technical and leadership skills needed to succeed at Interstates.”

For instance, Interstates’ in-­house apprenticeship program puts individuals with those desires in an 18-­month course that supplements their existing education with further training on instrumentation, PLCs and electrical systems—and lets them earn a living wage while they’re learning. It started its apprenticeships two or three years ago, and usually trains two to five individuals each year. Meanwhile, two and four-­year graduates are typically hired as entry-­level, automation team members.

“We work with and hire from local community colleges, and we value the hands-­on experience many students bring,” explains Roelfs. “At the same time, our workforce needs continue to grow, so we’ve intentionally built mul-

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tiple talent pipelines, including military transitions and employee referrals.”

Communicate with questions As digitization becomes more complex, the ability to understand how different systems and processes connect has become increasingly important.

“We learn to understand processes and how pieces come together. We talk with each other about how to get two functions to work together, rather than simply producing code,” explains Roelfs. “This applies to energy and ethanol production, food and flour mills, food and beverage processes, and building data centers. Lately, we keep returning to traditional markets, where there’s plenty of recent growth and construction to add capacity for emerging technologies.”

Beyond a willingness to explore and learn new technologies, Roelfs adds that Interstates also seeks people who can communicate well, and handle moving lots of information across clients’ organizations.

“We need people who won’t hesitate to pick up the phone, troubleshoot together, and collaborate on projects,” adds Roelfs. “This is the true value of bringing together parts and people. However, it’s harder than it looks because engineers and other technical professionals are typically independent-­minded and often introverted, even though they’re passionate and value expertise.”

One of the most essential skills for system integrators like Interstates is simply taking a few minutes to ask questions about how a project is intended to work and what it needs, according to Roelfs. Consequently, it spends significant time training new employees how to inquire about projects, and understand a user’s goals

and the overall situation in which they’ll be operating, such as how a malfunctioning PLC could hinder an entire production process.

“Learning to ask really good questions leads to better project results,“ says Roelfs. “This may seem obvious, but it’s also counterintuitive. It also isn’t initially the responsibility of an entry-­level person to be on a project without guidance, which is why they’re usually partnered with an experienced person, who can model better ways to communicate, and then let them give it a try.”

Once a process or plant starts up, and all its automation components start working together, Roelfs reports this is where even more difficulties emerge, and where good communication skills become even more essential and valuable.

“Even the best plants have issues and stress at startup, so it’s equally important for new folks to see what, how and why they’re happening,” adds Roelfs. “Initially, the new team member once again shadows an experienced colleague. However, they also do more independent work, and check in with their mentor frequently. As they gain experience, they can check in less often, until finally, they know enough to start teaching the latest group of new hires. In short, everyone coaches each other, which is a big help because you can learn a lot from teaching others.

“Of course, I don’t think we ever actually arrive at full mastery, especially because technology is changing so fast that a lot of what we know becomes obsolete sooner. This is why we want to stay excited about learning, and keep growing our expertise. We may not get to be final masters, but we hope to create a legacy of well-­trained successors and successful projects.”

www.controlglobal.com

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WORKFORCE DEVELOPMENT

as they have active minds and a desire to analyze problems.

“One of the last guys I hired at my previous systems integration company had most recently been a store manager, but he could immediately see how we were programming a start button, and how its sensors and HMI were supposed to work within its larger system,” explains DuFresne. “He obviously made mistakes, but after about 50-­60 minutes, he said, ‘Oh, I can see why you’re doing this,’ and he’d never programmed a PLC before.”

Even though their backgrounds may vary widely, DuFresne adds that successful engineering candidates must also have a combination of curiosity in how they think combined with stubbornness in how they react to circumstances and setbacks, including a willingness to be uncomfortable.

“When a problem happens, do you freeze and run away from it, or do you run towards it and try to figure it out?

Some of this persistence and logical, systems thinking can be taught, but it’s easier if it’s innate,” says DuFresne.

“What experienced engineers can teach rookies is how to handle processes going badly. If they see veterans responding calmly during unplanned, chaotic or even dangerous situations, they’ll learn to react calmly, too.”

Similarly, DuFresne reports his three most successful engineering hires at his two prior jobs included a law school dropout, a power systems and circuit-­ breaker testing technician, and a tire salesman.

“Within a year of being hired, the technician learned Ladder Logic principles and was a top performer; the tire sales guy was a solid controls programmer; and the former law school student was performing better than most of our veteran controls engineers,” says DuFresne. “None of these three even knew what a PLC was before they were hired, but they plugged into teams, did control side tasks and PLC programming, trained on other small projects that grew progressively larger, and achieved small www.controlglobal.com

2608CT20-27_cover story.indd 23

Figure 1: Two students get some hands-­on time monitoring the equipment and systems in the glycol distillation unit at LyondellBasell’s Center for Petrochemical Energy & Technology (CPET) at San Jacinto College in Pasadena, Texas. The unit has a 32-­f t, eight-­tray column, DeltaV distributed control system (DCS), embedded utilities, including cooling water, boiler and reverse osmosis, and 72 I/O with smart Rosemount transmitters. Source: San Jacinto College

wins that also got larger. Within that first year, each was working on large, batch-­ processing projects, which included integrating valves, pumps, alarms, logic gates, conveyors and scales.”

Stand-­in for hands-­on Most system integrators and other sources agree that direct, hands-­on experience is the greatest teacher of all about process control and pretty much any other subject. This is because it engages more of the senses, and makes deeper, long-­lasting impressions on students, which they’re more likely to retain and can reuse more effectively later.

For example, students get vivid instruction on the glycol distillation unit at LyondellBasell’s Center for Petrochemical Energy & Technology (CPET) at San Jacinto College in Pasadena, Texas.

The unit has a 32-­f t, eight-­tray column, DeltaV distributed control system (DCS), embedded utilities, including cooling water, boiler and reverse osmosis, and 72 I/O with smart Rosemount transmitters (Figure 1).

“One of the most effective resources we offer has been a laboratory environment that closely reflects what professionals will encounter in industry. Simulation is especially valuable because it gives people the opportunity to work through real operating scenarios, make decisions and see the results in a controlled setting with much lower repercussions,” says James Griffin, senior VP for petrochemical and energy technology at CPET. “However, those labs and simulations must be designed with input from industry professionals. This ensures the training is relevant, practical and connected to the situations people will face on the job. Classroom instruction is important, but process control and automation are fields where people also need the chance to apply what they learned. The more realistic and hands­on the training environment is, the better prepared they’ll be.”

If a physical, hand-­on lab like CPET isn’t available nearby, there are still many training opportunities for process industry applications, and they can AUGUST 2026  23

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WORKFORCE DEVELOPMENT

typically be tailored to whatever skills are required. These include industryspecific courses on standards and norms, onsite instruction and virtual equivalents, and engineering and enduser support for individual companies’ applications.

“Students, candidates and new hires can learn about process and final control elements, such as valves, process control and optimization, and preventive maintenance and condition monitoring of critical assets,” adds Hall. “However, the best way to deal with all this change and progression is to provide as much training and mentoring as we can because mastering these disciplines requires intention,” explains Hall. “We can help this process by training board operators in simulated environments, which helps them gain confidence by

putting them in scenarios and upset situations they can practice with and be tested on. These simulations can be built for any type of process, and the training consoles, interfaces, instruments, drives and vessels that are used look and respond like those used in the real operating processes.”

While dynamic simulation software such as DeltaV Mimic or AspenTech Hysys support training for specific operating scenarios, Hall reports that Adatafy also helps manufacturers apply connected worker and daily work software, which include learning and skills-management support along with AR functionality for remote support.

These platforms also track team members’ skill levels and certifications, help develop, adjust and ease access to standard operating procedures (SOP),

VIRTUAL TRAINING GETS REAL AT MXD The Manufacturing times Digital (MxD, mxdusa.org) institute in Chicago provides instruction in digitalized tools, cybersecurity and workforce expertise. Its largest Curriculum and Pathways Integrating Technology and Learning (CAPITAL) skills development program has five role-­based curriculums and 15 courses taught at MxD’s Learn Virtual Training Center (VTC, vtc.mxdusa.org), which presently has 25,000 enrollees across 35 states. These five curriculums include data annotation, data analytics, augmented and virtual reality (AR/VR), cybersecurity analysis and cybersecurity supply chain.

and determine the best ways to guide, train and develop employees whether they have four weeks, 18 months or five years of experience.

AI is OK if guided by basics Just like everyone else, Abelara’s DuFresne confirms that digitalization and artificial intelligence (AI) are popping up everywhere. However, he cautions AI isn’t a cure-­all, and stresses that mindset, skills, attitude, generosity and personality are what make good engineers. “These first principles are the same as always, and they won’t change, even if the tools around them are different,” he says.

Clark agrees it’s important to remember that AI is just a tool, much like a handheld calculator, so it can likewise help rookies or veterans working in new areas if they’re trained to use it properly.

“It’s an easier way to do things, but users still need to know basic engineering principles to extend their applications,” says Clark. “Instead of spending a day writing boilerplate code, AI can generate much of it in minutes, leaving engineers more time to solve actual problems.”

For example, it used to take Clark days to dive into a system to understand its application and database structure, including table structures, foreign key

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WORKFORCE DEVELOPMENT Pioneering Achievement in Hazardous Areas: Ethernet-­APL-­Based Enclosures

Precision Temperature and Humidity Monitoring for Data Centers

Pepperl+Fuchs offers a comprehensive control cabinet solution tailored to your application needs. Ethernet-­APL rail field switches connect seamlessly with modern Ethernet-­APL devices, while our remote I/O solutions interface with legacy field signals—all packaged in a sleek, custom-­designed stainless-­steel enclosure.

The HTZ Smart HART Humidity and Temperature Transmitter is a compact, loop-­powered device that accurately measures temperature and humidity with exceptional long-­ term stability. Easy to configure and install, it’s ideal for semiconductor cleanrooms and data centers where precise environmental monitoring and maximum uptime are essential.

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The EJX S Series is Yokogawa’s flagship pressure transmitter, delivering industry-­leading accuracy, long-­term stability, and enhanced durability. Built on decades on proven DPharp technology and enhanced with the latest sensor innovations, it provides exceptional measurement confidence for mission-­ critical applications in the most demanding process environments.

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Ethernet-­APL Field Switch for Process Plants

New Smart ESD* Device for Safety Instrumented System

The aplSwitch Field enables direct Ethernet-­ APL connectivity for field devices in hazardous areas. Supporting PROFINET with MRP redundancy and FDI, it simplifies commissioning and diagnostics while providing reliable power over a 2-­WISE connection. The aplSwitch Field PA variant also integrates existing PROFIBUS PA devices into Ethernet-­APL networks.

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Azbil Corporation’s Smart ESD Device 700 series (700SIS) is now available. Devices in this series act as the interface for an emergency shutdown valve in a safety instrumented system.

They’re compliant with the IEC61508 international standard for functional safety.

The 700SIS has been certified for applications that require SIL (Safety Integrity Level) 3 according to IEC 61508. *ESD: Emergency Shut Down

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WORKFORCE DEVELOPMENT

relationships, triggers and other parts before building visualizations and isolating changes he wanted. Now, he can provide requirements to an AI prompt and quickly generate diagrams, database structures and visualizations. “I can do 10 revisions, and that cycle will

take hours instead of days. This is now standard procedure,” says Clark. “Likewise, for the table structure, I define the things it can be, indicate what I want, and it’s returned to me.”

Beyond its speed, and the boost it can give to new recruits and other

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less-­experienced users, AI’s other advantage is it improves with practice, according to Clark.

“As I continue providing context and examples, AI gets better at producing results that match my style and what I’m trying to accomplish,” explains Clark. “I can tell ChatGPT what I need visually on a whiteboard, add pictures and explain further, and it will provide a demo envisioning what I’m seeking, such as a database or table structure. I can use these results to explain a project, situation or other details to my coworkers or clients. Meeting people where they’re at in their journey and helping them become more self-­sufficient are huge parts of any system integrator’s job, and AI can help us do them.”

Beyond internal checks and balances, Patti Enginereering’s Hoff says his team increasingly uses simulations and virtual commissioning to accelerate projects. “It’s OK to have pretty models, but we need simulations with accurate kinetics to reflect the physical operations we’re dealing with,” says Hoff. “We also need more personnel with the skills to use these simulations, so it doesn’t matter as much whether their original engineering background was mechanical, electrical or chemical. No matter what, everyone will be doing more coding and programming.”

Hoff adds that system integrators and their clients can’t afford to fear AI. “We need to use AI as a tool and keep humans in the loop because too much reliance on it can make you stupid,” says Hoff. “The question is: will we use AI in ways that make us smarter or not? It can process that information even faster.

However, it’s not as good at proofreading and verification, and it leaves us with a lot of hallucinations that we have to sort through and validate. Likewise, we recently video interviewed a candidate, and we could tell when they were using AI to generate responses. Their eyes looked away, they delayed answering, and many of their replies sounded canned and clichéd.”

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WORKFORCE DEVELOPMENT

Willingness is the way Hoff reports that Patti Engineering’s problem-­solving ethos leads the company to favor candidates, new hires and colleagues with varied backgrounds and outside interests.

“We love people who’ve worked on cars, are PC gamers, played with Legos, been on their high school robotics teams, or had different kinds of internships. All these experiences can produce great engineers.” adds Hoff.

“Plus, whatever degrees they have, and whatever initial training they receive, they can all benefit from additional, continuous, online education. The common thread for success—whether for rookies or veterans—is a willingness to learn.”

Even though virtual commissioning and simulations let Hoff and his staff travel far less than 130-­180 days per year they used to, they still work hard at preventing burnout by regularly checking in with team members, and allowing comp time or breaks between projects.

“Many engineers work long hours, but we’ve seen too many young engineers burn out by age 30 and seek other jobs with less travel or stress,” says Hoff. “Millennials and Gen Z want better work/life balance. They work to live, rather than live to work, and that’s a good lesson for everyone.”

Teach the teachers While it takes more time and patience, Clark agrees that curiosity can be sparked and nurtured from scratch.

He recommends that mentors can save up relatively simple tasks for new team members, such as writing simple software code for a pushbutton-­t ype function, and let them put it into production, so they can directly experience its effect.

“Seeing something work that you’ve created inspires curiosity because individuals who didn’t think they could program get excited when they can, and then they want to do more,” explains Clark. “This is something we can build on for the next activity. This process

builds momentum and fuels desire because participants want that next win.

It’s like bowling with bumpers—you’re guaranteed to knock down at least a few pins, but once it happens, you want to knock down more.”

While bad managers will arbitrarily give interns and new staffers nothing but menial tasks, usually with no thought about their development, Clark reports that good managers will give them similarly basic jobs, but do it with an eye towards helping them learn and grow.

“A bad manager yells at you, but a good manager walks you through the steps to reach a good resolution,” says Clark. “Good managers also teach their staffs, who teach their co-­op employees, who teach the summer interns, who will go back to school and get their classmates excited about maybe becoming future interns. It’s the good

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experience starting at the top that drives this whole process.”

Perhaps the best part of consciously and thoroughly recruiting and training new employees is they quickly gain the know-­how and abilities to train the next new hires, according to DuFresne.

“When a problem gets solved or even a small project succeeds, participants may say, ‘This is why I do it.’ Well, for some of us, training the next person is the reason we do it,” adds DuFresne.

“We like watching that spark come back on and helping others get it. For instance, humans have gone through inventing and learning to use waterwheels, steam, electricity, pneumatics, relays, semiconductors, PLCs, databases, Internet and now AI. Tomorrow it will be something else, but the skills needed to learn, understand, apply them, and convey them to others will be the same.”

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SUSTAINABILITY

Sustainability reaches out Shutterstock AI / Shutterstock.com

System integrators and suppliers measure and mix the ingredients for successful sustainability cocktails

by Jim Montague

SUSTAINABILITY GETS ITS mitts into everything. It’s supposed to be mainly about alleviating global warming by reducing carbon dioxide (CO2) and other greenhouse gases (GHG), burning less fossil fuels, and switching to solar, wind and other alternative energy sources. Because it’s such a huge subject, however, it overlaps and overspills into many other areas and efforts.

History, melting icecaps, slowing ocean currents, and worsening hurricanes, wildfires and heatwaves will judge which, if any, efforts produce better long-­term results, including much of humanity’s survival. Of course, just like voting and other small endeavors, every little bit helps, and each piece may be the one that ensures victory. As usual, one contributor riding to the rescue is process control and automation.

“Process control and automation are some of the most practical ways to improve sustainability because they directly affect how efficiently a facility runs every hour of every day,” says Heath Stephens, PE, digitalization leader at Hargrove Controls & Automation (www.hargrove-­ca.com) in Mobile, Ala., a division of Hargrove Engineers & Constructors, and a certified member of the Control System Integrators Association (CSIA, www.controlsys.org). “Better control strategies can improve utility consumption, optimize batch or continuous processes, and help operators respond faster to changing process conditions. Modernizing DCS, PLC and HMI platforms creates better visibility into energy-­intensive assets and makes continuous improvement more achievable. Meaningful reductions in energy use, raw materials and emissions usually come from cumulative, small operational improvements rather than one large initiative. These capabilities support a practical sustainability approach—use data to identify losses, automate responses where appropriate, and make operations more predictable, efficient and resilient.”

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Eternal efficiency—and side benefits The first and best-­known way to pursue sustainability is still process efficiency, which focuses on overall system performance over entire product lifecycles from raw materials to finished goods. This begins by collecting raw data, understanding data points, integrating automation, and gaining efficiencies.

For instance, waste-­to-­energy and biogas stabilizer developer Zero3 (www.zero3.cloud) in Cesena recently helped a landfill in northern Italy increase its biogas production by up to 32%, reduce its carbon footprint by 7,800 tonnes, and protect its staff by enabling remote operations (Figure 1). Not only were leaking methane (CH4) and carbon dioxide (CO2) emissions from the landfill foul smelling and potentially dangerous, but the landfill’s owner/operator was also losing potential revenue due to insufficient extractions and collection.

Consequently, Zero3 deployed a gas stabilizer with Emerson’s (www.emerson.com) Movicon HMI/SCADA software serving as the control interface on the landfill’s biogas collection system, which includes PLCs running autonomous programs to control the stabilizers. It also deployed Movicon because its modularity lets it scale up as more wells and controllers are added. Employing Microsoft SQL server to store field data, Movicon allows real-­time interaction with the landfill’s gas stabilizers, including remote control with only 0.05 msec latency. This maximizes gas collection efficiency, reduces leaks and emissions, and increases useful energy production and revenue.

Similar to dealing with resource constraints like environmental rules and tariffs, pursuing sustainability can contribute to better outcomes and products, according to Jeremy Anderson, president of Process and Data Automation (PDA, www.processanddata.com), a system integrator in Erie, Pa., wholly owned subsidiary of Krones Group, and a certified CSIA member. He explains www.controlglobal.com

7/28/26 8:16 AM

that ESG goals can shift participants’ focus from mundane tasks, and even encourage them to integrate quality-­of-­life goals for their staff and clients. This can be accomplished via better use of automation that reaches into devices, achieves better reporting, identifies efficiencies sooner, and reduces waste.

“North American shoppers want variability in their consumer packaged goods (CPG), and this means manufacturers must seamlessly change over their processes, and identify other efficiencies,” says Anderson. “More specifically, soda pop and other carbonated beverages are seeking more consumable CO2, so producers need more adaptable CO2 technologies to achieve required specifications, while also avoiding over-­carbonating their products. They’re working on aseptic filling technologies, which will let them get closer to ambient temperature filling that doesn’t require an additional drying step to prevent condensation. The traditional method is heating the beverages, filling the containers, and drying their exteriors in a tunnel, so their labels will have a dry surface to adhere to. However, this costs more, uses more energy, and requires 20 more feet of conveyor space.”

Coordinate, cohere and conserve Because its businesses include an engineering, procurement contractor (EPC), system integrator and operations, Stephens reports that Hargrove can provide more cohesive solutions, especially in hydrogen, clean fuels, electrification, renewable

Figure 1: Zero3 in Cesena, Italy, recently implemented biogas stabilizers at a local landfill, which increases its biogas production by up to 32%, reduces its carbon footprint by 7,800 tonnes, and protects its staff by enabling remote operations. Source: Emerson and Zero3 www.controlglobal.com

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power integration and energy storage applications. For example, one of Hargrove’s energy clients wanted to supplement its traditional power generation during peak consumption hours after sundown. It developed programming to safely collect excess energy from the client’s solar fields, and store it using a battery energy storage system (BESS) at several sites. Stored power could then be transferred to the local grid at specified, safe discharge rates. This project conducted virtualized factory acceptance testing (FAT) with simulated code, onsite site acceptance testing (SAT), remote commissioning of Ignition SCADA software, and data collection by KEPServerEX software at each facility.

“Collaborating with third-­party vendors helped create custom workarounds for equipment irregularities, monitor intake and output of energy to ensure rates were consistent with equipment specifications, and remotely monitor installations, while implementing any requested changes,” explains Stephens. “These changes ranged from PLC control to SCADA control to data collection. The sites were implemented with automated scheduling algorithms that require minimal remote operator intervention. Once the project was complete, its users could maintain a more consistent demand curve of their power-­ generation methods.”

Innovation enters in The second major way of achieving sustainability is adopting new ideas and technologies, including those that rely on renewable energy sources, as well as planning production around variable demand periods and costs. For instance, Reverion GmbH (reverion.com) reports it’s developed a compact, fuel cell-­based, biogas power plant that can remove tons of atmospheric CO2 and bottle it, use surplus solar and wind energy, and operate in reverse to store biogas or green hydrogen, as well as generate power. Its high-­temperature fuel cell technology converts biogas or hydrogen into electricity, and switches to electrolysis mode to make green hydrogen or methane (Figure 2).

The company’s solid-­oxide fuel cells (SOFC) electrochemically convert energy stored in fuel gas into electricity, while in reversible operation, they act as solid-­oxide electrolyzer cells (SOEC). Its containerized, transportable, biogas units are reported to achieve 80% electrical efficiency during well-­ insulated operations at approximately 600-­750 °C by employing a high level of system integration, which lets it exploit all potential optimization from interactions among its different process sequences.

To coordinate its sensors, monitoring and control functions, Reverion relies on PC-­based control from Beckhoff (www.beckhoff.com) and its TwinCAT software, networking, communications and visualization technologies. The modular biogas plants use two computers, including CX2043 embedded PC as its main control computer, and C6930 control-­cabinet, industrial AUGUST 2026  29

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SUSTAINABILITY

PC (IPC), or C6030 compact IPC in the future. The biogas plant has more than 450 EtherCAT terminals serving approximately 1,200 sensors and 300 actuators. Data from these I/O is evaluated via TwinCAT, which can map complex systems.

“The idea of using two IPCs to communicate with each other came up during system development as the biogas plant’s complexity increased. This approach made it easy to scale up controller performance, and adapt it to our platform,” says Sven Bettendorf, application engineer at Reverion. “Its redundancy also improves operating reliability.”

Reverion reports its first biogas power plant prototypes achieved 100 kW output. It adds that series production was expected to start in 2024, and that larger 500-­kW output systems are already in development.

PDA’s Anderson reports that one recent Krones greenfield project in Germany combines multiple, alternative energy sources to power a brewing process, including using wood chips for heat and photovoltaics. “We’re taking pieces of what we learn in Germany, and applying them to North America.

However, we need to plan for optimal demand rates in both locations, and identify suitable energy sources based on those strategies,” says Anderson. “Our clients can use whichever strategies are suitable, but they’re more incentivized when resources are limited, or when consumers and government organizations like the European Union (EU) encourage them.”

Steps to sustainability Because sustainability shows up in so many technical disciplines, each user or organization must adopt a workable combination that suits their particular needs. PDA’s Anderson recommends that manufacturers first look closely at the entire lifecycle of their equipment and products, and then ask where they can source, design, build, operate and maintain their equipment and products more sustainably.

“A filling operation may find it can save 50% on expenses with a better dryer. However, it would be even better if they could identify an upstream efficiency that could eliminate the need for a dryer,” explains Anderson. “Looking at overall lifecycles is important because it can uncover these overall ‘why’ questions—and point to better answers—rather than settling for incremental efficiencies. However, big questions and answers can only happen by leveraging a lot of data.”

Once all available data is gathered, however, the work doesn’t stop there. Anderson reports that, after participants can see all their variables, they must tear them apart to learn where they can make better decisions. This usually means using available data to test assumptions for possible improvements, such as monitoring dewpoints, temperatures and other variables, and investigating whether local environmental factors got pulled through to impact the facility’s process monitoring.

“Layering environmental information on top of existing data can help show that otherwise random low yields or other events 30  AUGUST 2026

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Figure 2: Reverion’s biogas power plants are housed in a compact container (right), allow reversible operations, and can reportedly achieve 80% efficiency. It’s control architecture uses two computers, including a CX2043 embedded PC (left, bottom) and a C6930 control cabinet industrial PC (left, top), which is expected to be replaced in the future by a C6030 ultra-­compact industrial PC. Source: Beckhoff and Reverion

may be due, for example, to outside wind plugging filters more quickly. However, situations like these aren’t visible until enough data points from enough places is gathered together,” adds Anderson. “Examining process, equipment, and product lifecycles creates those initial ‘why’ questions, and gathering raw information into big data feeds the business case that lets users pursue sustainability wins. Our clients often use cloud-­ computing services like AWS to analyze their data, and are starting to use AI-­based tools like Claude to integrate and interpret results. This is enabling sustainability to become a performance metric for some manufacturers, where they previously just looked at rate, yield and top and bottom lines.”

Stephens adds Hargrove would recommend treating sustainability in the same way as safety, quality and production goals—define them clearly, measure them consistently, and connect them to day-­to-­day operating decisions.

“Companies are most successful when they begin with a practical baseline of current performance, identify their biggest sources of energy loss or emissions, and prioritize projects that offer operational and environmental value,” adds Stephens.

“Controls and automation improvements are often a strong starting point because they can generate measurable gains often with little or no capital investment. Other improvements may require investment in new equipment or other engineering solutions. Another important lesson is that sustainability efforts should be cross-­functional. Operations, engineering, maintenance, EHS, electrical, instrumentation and controls teams all need to be aligned, so solutions are technically sound and supportable over time. Fortunately, since most sustainability projects and programs result in reduced expenses or higher efficiency, they often have an attractive financial payback in addition to their social/environmental impact.” www.controlglobal.com

7/28/26 8:16 AM

PRODUCT EXCLUSIVE

Top-­shelf, cost-­effective flame detection Four-sensor infrared technology helps distinguish hydrocarbon fires from non-flame radiation

INDUSTRIAL FACILITIES NEED flame

detection that can respond quickly and reliably without creating frequent nuisance alarms, but not every application requires a top-tier system at a top-tier price. Emerson’s Rosemount 965 flame detector offers advanced hydrocarbon flame detection, dependable performance and flexible deployment options in a more cost-effective package.

Emerson is expanding its flame detection portfolio with Rosemount 965, a reliable hydrocarbon flame detection solution for non-hazardous locations, with a flameproof model certified for hazardous-location applications. It incorporates QuadSense technology introduced in 2021, factory-calibrated-for-life operation, broad integration options and rugged enclosure protection to support fire-protection strategies tailored to individual application requirements.

“Rosemount 965 retains the premium-tier technology of its counterpart, but it’s more cost effective,” says Evgeny Rivkin, product manager for flame detection at Emerson. “This is not a conventional detector. It’s a smart detector with a built-in algorithm that discriminate actual thermal radiation from background heat sources like ambient solar radiation and heating equipment.”

QuadSense technology relies on four infrared sensors to help distinguish hydrocarbon fires from non-flame radiation, which enables more reliable detection, and minimizes nuisance alarms that can be annoyingly frequent in many locations. Under specified conditions, Rosemount 965 can detect hydrocarbon fires at up to 150 feet (45 meters) and usually responds in less than five seconds. Five selectable sensitivity www.controlglobal.com

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levels help users align its performance with their needs.

“In Rosemount 965, QuadSense uses two channels, each with two infrared sensors tuned to specific radiation waveforms, and measure their peaks to identify genuine flame profiles,” explains Rivkin. “The two channels act like two Triple-IR detectors, and the adaptive algorithm combines those channels into one certain decision, which is much more reliable than traditional methods.

It’s immune to false alarms.”

Rivkin reports that QuadSense technology also lets Rosemount 965 see and identify fires in harsh environments, including fog and rain, while still discerning false alarms. It’s also solar blind, so it’s not affected by sunlight, and can likewise tell the difference between a flame and lightning.

Rosemount 965 uses its built-in optical sensor and Built-In Test (BIT) diagnostic to monitor for lens contamination, optical obstructions or internal hardware failure, helping verify the detector is not “blind” and indicating when the lens likely needs cleaning.

In addition, Rosemount 965 is factory-calibrated for life, so no field calibration is required. Built-in, infrared test capabilities continuously verify optics and electronics integrity, maintaining confidence between manual inspections. Multiple output options, including HART connectivity, support integration with standard communication infrastructures, while universal wiring helps simplify specifications and streamlines plantwide deployments. Its IP66 and IP68 enclosure protection further supports its performance in demanding environments.

Rosemount 965 flame detector.

Source: Emerson

“Automated, lifetime, factory-based calibration means users don’t have to worry about Rosemount 965’s performance,” adds Rivkin. “It’s designed for users, who don’t need as many bells and whistles, but need and would benefit from industry-standard flame detection that they couldn’t always afford previously.”

While its new flameproof model can serve in oil and gas, chemical and petrochemical facilities, storage tanks and hazardous materials areas, and explosives or munitions sites, Rosemount 965 also supports non-hazardous. light-industrial applications, such as transportation, public buildings, cable tunnels, semiconductor plants and warehouses, where dependable hydrocarbon flame detection is needed. Rosemount 965 is available with an aluminum body for these lighter applications.

Rivkin adds that Rosemount 965’s other accessories include: • A flame simulator, • Pole-mount option for field use, • Air shield for connecting to air-pressure devices to help clean its lens, and • USB adapter for communicating with laptop PCs, as well as accessing Modbus networks to adjust settings, access its internal event logs, and easily pull raw data if and when a fire is detected.

For more information, visit www.emerson.com/Rosemount965 AUGUST 2026  31

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PROCESS ANALYZERS

UV-visual meter eases wastewater analytics Martinez Refining simplifies total organic carbon monitoring with ABB’s UviTec portable field meter

by Jim Montague

EVERYONE GETS PARCHED in the desert. Even halfway up the California coast, it’s still mostly desert to the east and a liquid desert to the west. Thirst lies in either direction. At the same time, lots of fresh, clean water is needed to refine oil into gasoline, diesel and jet fuel. Unfortunately, if you’re close to San Francisco Bay, you can’t use its water either because it’s brackish and far too salty.

What to do? Well, Martinez Refining Co. (MRC) reports it manufactures the world’s cleanest motor fuels, providing an affordable and reliable supply of gasoline, diesel and jet fuel to the Bay area. Successful and efficient water reuse/recycling and wastewater treatment makes it possible to produce its products.

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Covering 860 acres and containing 35 process units, the refinery expanded in the 1960s, 1980s and 1990s, and prides itself on being a modern operation that uses advanced automation, controls and other technologies (Figure 1). Built to process heavy crude oil from California’s San Joaquin Valley, MRC is one of the most complex refineries in the U.S., which lets it source and process various crude oils from Alaska to South America.

The refinery can produce up to 2 billion gallons of fuel per year. Its production scope includes providing: J 25% of the Bay Area’s gasoline, J 55% of Oakland and Sacramento airports’ jet fuel, and J 40% of San Jose and San Francisco airports’ jet fuel.

As a proud member of the Bay Area community, MRC also makes sure its operations comply with all state and federal air and water regulations. Similar to all refineries, it uses water throughout the facility for heat exchange, process treatment and utilities, such as steam production during the refining process to make clean-­burning fuels. MRC reports one of its key goals is being mindful of its water use, and seeking ways to reduce, reuse and conserve water in its operations in safe, reliable, environmentally responsible and community-­ friendly ways.

Many process units in the refinery contain water that reaches very high temperatures. To continually reuse and conserve water, it’s sent to be cooled in the www.controlglobal.com

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Figure 1: Martinez Refining Co. covers 860 acres near San Francisco Bay, contains 35 process units, was built to process heavy crude oil from California’s San Joaquin Valley, presently sources crude oils from Alaska to South America, and can produce up to 2 billion gallons of gasoline, diesel and jet fuel per year. Martinez Refining Co.

refinery’s cooling water towers. As hot water enters the towers, it’s cooled to 95-­ 100 °F by an airstream that’s blown onto it. This process enables some heat exchanger water to be recycled and reused throughout the refinery, or discharged to the effluent treatment plant. Other excess water at the refinery, such as collected storm water, water removed from crude oil during processing, and regular wastewater from the facility’s more than 500 employees, must also be monitored and treated before being discharged to the environment as effluent.

Corralling carbon to keep bugs comfy MRC’s onsite wastewater treatment facility is critical to making sure all its www.controlglobal.com

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wastewater meets regulatory requirements, and fulfills its sustainability commitment to the local community.

The refinery discharges about 5 million gallons of treated wastewater effluent per day in conjunction with its national Pollutant Discharge Elimination System permit. Treatment methods include various stages of oil/water separation, solids removal, biotreating, carbon polishing and others.

MRC reports it complies with hundreds of regulations from the U.S. Environmental Protection Agency, California Regional Water Quality Control Board, Bay Area Air District, California Dept. of Toxic Substances Control, Contra Costa Health Services and others. It’s Joel Hawes’ job to make sure the company

complies with these environmental regulations. MRC has dozens of procedures to manage compliance, and all its employees and contractors are trained regularly to help it achieve continued compliance.

Hawes is senior coordinator for quality assurance (QA) at MRC, where he has been employed for more than 12 years. He works with chemist Robin Segala in the company’s QA lab, which focuses on wastewater treatment.

Similar to most industrial and municipal effluent-­producing facilities, the refinery’s wastewater treatment plant uses a biological treatment process that employs microbes or “bugs” to help break down organic pollutants in the wastewater. One of the critical measurements this treatment process requires is routinely checking total organic carbon (TOC) at various points. Biotreater feeds typically aim to maintain 100-­300 ppm TOC for optimal treatment.

“We need to know the TOC range in the feeds to the biotreaters to make sure we’re not overloading their treatment capacity,” explains Hawes. “We also need to ensure we’re not too low on carbon, which can starve the bugs. They have a delicate range, and if there’s not enough carbon to transform, they’ll begin to die off. Both cases can lead to a failure in the treatment process, which could potentially result in an effluent discharge that doesn’t meet federal and state regulations, and result in significant fines.”

Because monitoring TOC is so important, the QA team needs regular tests performed at different sections of the refinery, which feed into the biological treatment facility. MRC has 18 lab AUGUST 2026  33

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PROCESS ANALYZERS

technicians with scientific backgrounds, who work 10 hours per day conducting TOC and other tests. However, due to the refinery’s size, they also rely on process operators in different parts of the plant to take samples and conduct local tests, such as pH, ammonia, total suspended solids and hydrogen sulfide, which are then reported to the lab team.

Hawes reports there were some challenges with traditional testing. “MRC had been using combustion catalytic oxidation analyzers, which were the long-­time industry standard for TOC analysis,” he says. “These analyzers are complex, with a catalyst, ovens and a dedicated air supply. Testing samples must be free of particles and oil. They also have a complicated interface. So, we’d run into issues all the time with plugged filters and switched-­off ovens that resulted in contaminated samples and dead detectors.”

simple button presses, and about five seconds later, the TOC measurement is displayed on an easy-­to-­read display.

Because the sample doesn’t touch the detector, no filtering or other treatment of the sample is required. Given its low price compared to the existing combustion catalytic oxidation analyzers, Hawes bought a UviTec TOC field meter in January 2025 to try it out and test it with his operators. Its success was immediate.

“I love that it’s small and portable, very easy to use, only requires a small sample size, requires no filters, ovens or reagents, and we get our analysis in 90 seconds from powering it on,” says Hawes. “It’s been amazing so far.”

ABB’s UviTec family of analyzers delivers fast, accurate measurement by employing UV and visible LEDs across multiple wavelengths of light. Organic

compounds absorb light in the UV-­vis spectrum at specific wavelengths, and that data can be used to calculate TOC levels in seconds, instead of hours or even days when using lab-­based analyzers. UviTec analyzers are deployed in a variety of municipal and industrial wastewater applications to quickly measure TOC, dissolved organic carbon (DOC), biochemical oxygen demand (BOD) or chemical oxygen demand (COD), again, in about 5 seconds, which saves time and operating expenses (Figure 3).

TOC measurements are calculated based on UV-­vis absorbance, so they can vary depending on which types and amounts of organic compounds are in the sample. Consequently, when the UviTec field meter is used for the first time, it’s important for users to employ a calibration model that

An UV-­visible vision Because MRC primarily deals with organic carbon, without much inorganic carbon, Hawes started to seek a tool that could measure total carbon and TOC more easily. After some research, he found ABB’s UviTec TOC field meter, which is a portable, lightweight analyzer that can measure TOC from 0 to over 3,000 mg/L. It relies on ultraviolet-­ visible (UV-­vis) spectroscopy, which measures how much ultraviolet and visible light a chemical substance absorbs.

To take a measurement, a sample is poured into a small, tube-­like, quartz cuvette, and inserted into a slot on the top of the analyzer (Figure 2). A few

Figure 2: UviTec total organic carbon (TOC) field meter is a portable, lightweight analyzer that can measure TOC from 0 to over 3,000 mg/L by employing UV and visible LEDs across multiple wavelengths of light. To take a measurement, a sample is poured into a small, tube-like, quartz cuvette, and inserted into a slot on the top.

ABB and Martinez Refining Co.

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Figure 3: Organic compounds absorb light in the UV-visual spectrum at specific wavelengths, and UviTec can use that data to calculate TOC levels in seconds compared to hours or even days required by lab-based analyzers. It can quickly measure TOC, dissolved organic carbon (DOC), biochemical oxygen demand (BOD) or chemical oxygen demand (COD) in about 5 seconds. ABB and Martinez Refining Co.

matches the location’s site-­specific water characteristics to achieve the most accurate results. The analyzer is shipped with a selection of common calibration models, and others can be set up by ABB or users based on their local requirements.

Hawes reports setting up his initial calibration, and hasn’t touched it again for more than a year. By running 15 samples from the refinery’s various wastewater streams on both the combustion catalytic oxidation analyzer and the UviTec field meter, he was able to create a calibration model in the lab’s longtime Liquid Ai data management software from ABB that continues to provide accurate results.

Liquid Ai lets users create customized data models or calibrations for their processes, in this case, with UviTec field meter. The software analyzes absorbance data from the field meter, and creates correlations based www.controlglobal.com

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on corresponding lab data. Once the device is adjusted and validated using the software, operators can use the field meter to perform spot checks and obtain results in seconds.

“I go and check UviTec periodically against the certified reference material, and it’s incredibly stable and accurate,” explains Hawes. “We’ve had no issues at all. It’s just a win-­win all around, and easy to maintain for the operators to run. I periodically have issues with operators crushing cuvettes, but if that’s the only problem, I’ll take it!”

Building on savings Hawes adds that UviTec field meter won’t replace the catalytic combustion TOC analyzer entirely because MRC still needs it to measure inorganic carbon and other parameters like total nitrogen. However, he plans to buy more of the new field meters to make regular TOC measurements, and gain early

indications of any changes in TOC load that could impact the refinery’s wastewater treatment plant.

Beyond helping the refinery avoid non-­compliance costs from overloading, Hawes adds that UviTec field meter also helps save operational expenses.

“Compared to using a catalytic combustion TOC analyzer, it’s not only much less costly to buy, but less expensive to operate and service, too,” he says. “For instance, it doesn’t need a multi-­thousand dollar annual service contract because there are no ovens, filters or other items needing service.

Using UV-­vis light means the sample only comes into contact with its very low-­cost quartz cuvette that’s easy to stock and replace if needed. In addition, because it’s portable and easy to use by anyone at the site, we don’t need to staff our lab 24 hours a day to have constant reliable TOC monitoring.

I’m also saving up to 15 hours of my time a month on training and troubleshooting the catalytic combustion TOC analyzers used by our operators.”

In short, Hawes sees many other uses for UviTec field meters at MRC. For example, it enables a quick 90-­second TOC check of the refinery’s storm water ponds after heavy rainfalls, which would otherwise take an hour with the catalytic combustion TOC analyzer due to its start-­up process and rinses required for dirtier samples. In addition, he envisions having a UviTec field meter in his main lab to test samples contaminated with very fine, sub-­micron particles that ruin the detector in the catalytic combustion TOC analyzer, which occurred recently and cost thousands of dollars to replace.

In fact, avoiding one detector failure means UviTec field meter can pay for itself overnight. Finally, from a quality control system perspective. UviTec field meters provide a stable measurement check to compare the lab’s TOC analyzers with to validate performance, and help identify any detector degradation issues.

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PRODUCT EXCLUSIVE

Flow sensor helps data centers keep cool under pressure Control liquid-cooling systems with assists from Emerson’s magmeters, short-run software and expertise

BASED ON ITS decades of expertise, Emerson is introducing its purpose-built Rosemount 8795 magnetic flow sensor for hydronic cooling of data center applications. This sensor provides accurate, repeatable flow measurements for high reliability and uptime in mission-critical data centers, while improving power usage effectiveness (PUE). It’s designed for building management system (BMS) settings, and fulfills common specifications to simplify selection, installation and commissioning.

Optimized for chilled-water and water-glycol cooling loops, Rosemount 8795 provides consistent performance across the 2-inch to 16-inch line sizes typically used in data center cooling loops. Its polytetrafluoroethylene (PTFE) liner and stainlesssteel electrodes are specifically intended to serve in thermal management applications, and ensure dependable operations in closed-loop cooling systems. The sensor also has 5 µS/cm minimum conductivity, and optional universal power compatibility for AC or DC sources.

“We’re taking our reputation for quality, efficiency, reliability and 24/7 availability, and applying it to data centers that are increasingly liquid-cooled,” says Laura Chemler, product manager for magnetic and vortex flow meters at Emerson. “In the same way, we’ve used industrial problem-solving to create a robust, high-availability sensor like Rosemount 8795, which can better meet data centers’ specifications and BMSs’ requirements.

“The capabilities of this sensor and its magnetic flow transmitters make it easier for data center personnel to move cooling liquids with confidence. Users benefit from Emerson’s longtime reliability and installed base. Rosemount magmeters have been installed for decades, and they require virtually no maintenance because they have no moving parts like turbine meters. They also experience no pressure losses like insertion magmeters or DP flowmeters.”

Data center designs are highly modular and scalable, and extensive straight runs in piping can sometimes be limited.

Chemler adds that Rosemount 8795 can be invaluable here, too, because it supports Emerson’s new Short Run Install software. By using Emerson’s propriety algorithm, Short Run Install can provide 0.5% accuracy at zero diameters of pipe run without pressure loss or additional leak points. It helps users maintain accurate measurements despite short pipe runs, which are common in the often tight spaces in data centers, just as they are in many process facilities.

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Rosemount 8795 magnetic flow sensor. Source: Emerson

“This capability reduces design and installation risks because users know their system accuracy in a short-run design, and won’t need a specialty sensor for flexible installation and commissioning,” adds Chemler.

Rosemount 8795 can be paired with three types of compatible Rosemount magnetic flow transmitters, providing a base accuracy of 0.2% at ±2 mm/sec for hydronic applications over 5µS/cm conductivity. This magmeter trio includes 8732 that can be integrally mounted or remotely mounted, 8712 that’s wall-mounted with a 12-button interface, and 9732 that’s more advanced with multiple outputs and data logging capabilities.

All three transmitters have built-in diagnostics and verification capabilities that help users reduce commissioning risk and stay confident in their system performance.

For more information, visit Emerson.com/magneticflowmeters www.controlglobal.com

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RESOURCES

Analyzers, detectors and instruments aplenty Control’s monthly resources guide 3 SPECTROMETRY POSTS

MASS SPECTROMETRY STEPS

This online blog series, “A beginner’s guide to mass spectrometry” by Baljit Bains, covers principles, components, functions, benefits, and limits. It’s at www.acdlabs.com/blog/a-beginnersguide-to-mass-spectrometry-mass-analyzers/ The second post on ionization types and techniques is at www. acdlabs.com/blog/a-beginners-guideto-mass-spectrometry-types-of-ionization-techniques/ And the third post on mass analyzers is at www.acdlabs.com/ blog/a-beginners-guide-to-mass-spectrometry-mass-analyzers

This webpage, “What is mass spectrometry?,” covers terminology, ionization, analyzer types and molecular dissociation, and links to related documents on gas and liquid chromatography, application areas and a technology overview. They’re at www.thermofisher. com/us/en/home/industrial/mass-spectrometry/mass-spectrometry-learningcenter.html

ACD/LABS www.acdlabs.com

This 28-page document, “Emission monitoring solutions—broad portfolio and longstanding experience,” covers applicable industries and solutions, compares in situ and extractive analysis technologies, and details measurement principles, such as scatter light backward, UV spectroscopy, Zeeman atomic absorption spectroscopy (ZAAS), and selection criteria and products. It’s at tinyurl.com/47jh7498

GAS ANALYZER PAPERS This webpage, “Gas analyzers for in situ and extractive installations,” links to several useful whitepapers, including “Gas analysis made easy,” “HCL monitoring in stacks and scrubbers,” and “Five ways in situ gas analyzers improve safety.” They’re at www.mt.com/us/en/ home/products/Process-Analytics/gasanalyzer.html METTLER TOLEDO www.mt.com

DETECTION, ANALYSIS VIDEOS This 47-minute video, “Process gas analyzers 101” from Siemens, covers analyzer and sample system components, rationale, budgets, processes, expectations, compatibility and safety.

It’s located at www.youtube.com/ watch?v=ZgrF94b_BQM A second, 45-minute video, “Fixed gas detection 101” from Honeywell, covers gas hazards, strengths and weaknesses of detection technologies, and detecting combustible, toxic and asphyxiate gases. It’s located at www.youtube.com/ watch?v=aTMgy6oOSHQ LESMAN INSTRUMENT CO. https://www.lesman.com

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THERMO FISHER SCIENTIFIC www.thermofisher.com

IN SITU AND EXTRACTIVE

ENDRESS+HAUSER www.us.endress.com

SAMPLE SYSTEM ESSENTIALS This classic online article, “Basics of analyzer sample systems” by Ian Verhappen, covers process conditions, dead spaces, lag times, compressibility, sample flow calculations, personnel, simplification and selction. It’s located at iceweb.eit.edu.au/process-instrumentation/analysers/sample-systems/ basics_of_sample_systems.html ENGINEERING INSTITUTE OF TECHNOLOGY iceweb.eit.edu.au

NOTABLE RAMAN CASES This webpage for Horiba’s Process Raman analyzers includes a library of application notes detailing how they were implemented in applications, such as

alkylation, olefins, p-xylene, post-combustion CO2 capture, refinery monitoring, reformates monitoring, jet fuel production, amine treating and sulfate monitoring. They’re at www.process-instruments-inc.com/resources HORIBA PROCESS INSTRUMENTS www.process-instruments-inc.com

BASIC TYPES DEFINED This short glossary, “Understanding different analyzer types,” defines 14 types of process gas and other analyzers, including NOx, SO2, O2, CO, PID, NH3, H2S, PM2.5, VOC, CO2, in situ, TDL, stack flue gas ammonia and gas chromatographs. They’re at tricoreims. com/types-of-analyzers/ The company also offers a three-minute video, “Understanding different types of analyzers— NOx, SO2, O2 and CO2 analyzers and more,” that compares these three types. It’s at www.youtube.com/ watch?v=Cuwled64Dh4 TRICORE IMS https://tricoreims.com

LAST TIME AROUND The previous version of this column, “Ins and outs of process analyzers,” includes resources from Yokogawa, Swagelok, Mangan, Emerson, and Hanna. It’s at www.controlglobal.com/ measure/analyzers/article/55129485/ ins-and-outs-of-process-analyzers CONTROL www.controlglobal.com

CHEMILUMINESCENCE PARTS This 29-minute video, “Chemiluminescence—310404g,” covers chemical reactions related to analysis, components of a nitric oxide analyzer, and analysis and application principles. It’s at www.youtube.com/ watch?v=VRJY6_Qihpw WAZITV www.youtube.com/@tylerwasilenko8485

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ROUNDUP

Tailor-­made protections Enclosures, workstations and purge systems balance essential shielding with pragmatic access WALL-­MOUNT WITH SOLAR SHIELD

DOUBLE-­DOOR SYSTEM

NEMA 1 wall-­mount enclosures from Saginaw are designed for indoor use, and feature carbon-­steel construction, convenient knockouts on all sides for streamlined wiring, 180° door opening for easy access, and compatibility with common subpanels and accessories. For outdoor installations, enclosures with solar shields reduce heat gain and internal temperatures, protect against rain and snow, extend component life, and improve system reliability in exposed locations. Added accessories include top-­mount, counterbalance suspension arms for smooth HMI positioning, and support loads, while keeping cables neatly routed.

VX hybrid, double-­door enclosure combines a modular, easily configurable design with a simple, easy-­to-­use, standalone, closed system. Its streamlined frame lets users quickly reposition VX with as few as two people.

Designed for minimal assembly with its single-­footprint frame, VX can easily set into place, while its removable center mullion makes adding a mounting panel quick and simple. It also features a rigid, fold-­over frame that matches the durability of traditional heavy-­gauge steel, but remains light enough to manage safely.

AUTOMATIONDIRECT www.automationdirect.com/enclosures

RITTAL https://tinyurl.com/mww2rsup

SPACE FOR THIN CLIENT, SMALL PC

CUL/UL-­LISTED, 4X POLYCARBONATE

Thin client/small PC enclosures provide a sealed, clean, cool space, even in full-washdown settings. Users can create a standalone workstation by adding a universal-­mount monitor, industrial keyboard and pedestal mount. Each enclosure is made of heavy-­gauge stainless- or black powder-­coated steel, and is sealed to NEMA 4/4X, IP65/IP66 requirements. Built-­in DC power supplies, a removable pre-­drilled mounting plate and internal cable routing aid installation.

Internal, fan-­based cooling distributes heat without circulating outside air.

Arca JIC 30 x 30 x10 (AR303010CHSSL) is a cUL/UL-­listed, 4X polycarbonate enclosure for industrial and outdoor applications. Its lightweight, corrosion-­resistant construction provides a durable alternative to painted steel, while maintaining impact resistance. Featuring a low-­profile, continuous hinge and secure latching system, Arca JIC protects electrical and automation controls from water, dust and harsh environments. Its spacious interior, optional CNC machining and printing services simplify installation, and support rapid panel integration.

HOPE INDUSTRIAL https://store.hopeindustrial.com/products/ computer-enclosures/thin-client-enclosure

FIBOX USA 410-­760-­9 696; www.fiboxusa.com/ar303010chssl

POLYCARBONATE, TYPE 4X/6P

HAZARDOUS-­AREA PC WORKSTATION

Polycarbonate, type 4X/6P enclosures feature a 6P submersible rating, and resist impacts and fire. Their corner elevator system consists of back-­panel depth that’s easily adjustable, and accommodates many design configurations in one enclosure. Polycarbonate, type 4X/6P also provides non-­metallic and metallic latches, as well as a hinged screw cover, which are both padlock-­able.

4360 X-­Purge hazardous-­area PC workstation is designed for safe, reliable operation in Class I, Division 1 hazardous locations. Utilizing an X-­Purge pressurization system, it enables using commercial-­grade PC components in classified environments. Its rugged enclosure protects against harsh conditions, while supporting configurable processors, memory, storage and I/O options.

NVENT HOFFMAN www.nvent.com/en-us/hoffman/products/ polycarbonate-type-4x6p-enclosures-0

DAISY DATA DISPLAYS INC. www.daisydata.com/viewitems/life-science/x-purgehazardous-area-personal-computers

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ROUNDUP

MODULAR, ALUMINUM FRAMING

FLEXIBLE SENSOR HOUSINGS

EcoSafe modular aluminum framing includes ergonomic workstations, industrial enclosures and assembly stations. This protective-­guarding portfolio features a 22.5 x 45 mm profile for building suspended and direct mount panels, which reduces installation time and streamlines layout modifications. MTpro free design tool helps users design enclosures and other shop-­floor, safety solutions for their specific needs.

Monitoring Case System (MCS) are flexible housings with an angled, clamshell housing edge design for sensor, IoT and IIoT applications. These wall-­, pole-­, and DIN rail-­mountable enclosures enable PCB installation, mounting and maintenance.

IP65 and IP67 variants protect electronics in harsh settings, while a more affordable IP40-­rated option is available for less demanding applications. An IK07 rating ensures the housings can withstand a 2-­joule impact from a height of 20 centimeters.

BOSCH REXROTH boschrexroth-­us.com/shopfloor-­safety-­solutions

PHOENIX CONTACT www.phoenixcontact.com/en-us/products/electronicshousings/field-housings/mcs-empty-enclosure

HIGHER-­CURRENT PURGING

HI-­AIRFLOW, COMPACT FILTER FANS

6000 Series electronic processing control unit (EPCU) has two enclosure contacts rated up to 12 A per contact. This increased capacity lets the unit switch enclosure power directly for a broader range of uses. For example, higher-­load applications, such as gas analyzers or enclosures with integrated heating, can be implemented at reduced cost because they don’t need added Ex-­rated contactors or breakers. Also, by integrating switching function directly into the control unit, 6000 Series’ system architecture is simplified, which reduces installation effort and supports compact designs.

Slim Line Filterfans 4.0 from Pfannenberg deliver high-­efficiency thermal management for industrial enclosures, offering airflow rates up to 427 CFM. Engineered with flow-­optimized fins and rotor blades, these units achieve superior air circulation.

A patented, four-­corner click mechanism enables tool-­free, rapid installation and quick filter replacement. Their fluted filter mat’s folded design extends filter lifespan by up to 300% over traditional materials.

Rated IP55/NEMA Type 12, Filterfans protect against dust and moisture, meeting UL/cUL (NITW2) and CE standards.

PEPPERL+FUCHS www.pepperl-­fuchs.com

GALCO www.galco.com

RASPBERRY PI ANTENNA KIT

SEALED COOLING

Multicomp Pro MP015781 is a rugged, all-­in-­one, omnidirectional antenna enclosure kit, which lets users deploy Raspberry Pi in harsh settings. Featuring embedded 2x2 MIMO antennas for 4G/LTE, 5G, RedCap, Wi-­Fi, Bluetooth (optional GPS), it offers wideband coverage (600 MHz–6 GHz) and IP67/NEMA6 protection. Compact and lightweight with a Gore vent for humidity control, Multicomp Pro MP015781 is compatible with Raspberry Pi models 3, 4B and 5, Pico, Zero and the range of compute modules. It’s also ideal for industrial, remote and smart monitoring applications.

Heat sink cooler (HSC) series sealed-­ enclosure cooling units use a patent-­ pending design with thermally efficient, air-­impingement technology and heat sink components. This provides high-­ performance-­to-­cost ratios among sealed industrial enclosure coolers, while letting users keep their power electronics or electrical enclosure clean, cool and operational. HSC is NEMA-­rated and suitable for indoor and outdoor electronics cabinets. It can serve in automation, food processing, oil and gas, and wastewater applications.

NEWARK www.newark.com/multicomp-­pro/mp015781/dev-­ kit-­raspberry-­pi-­lte-­wifi/dp/27AM6352

ADVANCED COOLING TECHNOLOGIES INC. 717-­2 95- ­6 061; www.1-act.com/product/acthsc-22-heat-sink-cooler-22watts-c

www.controlglobal.com

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CONTROL TALK

The control and instrumentation symposium ‘no one’s heard of!’

The long-running Instrumentation & Automation Symposium is positioning itself as a critical forum for passing on the fundamentals of process control, instrumentation and safety systems

GREG McMILLAN Gregory K. McMillan captures the wisdom of talented leaders in process control, and adds his perspective based on more

GREG: There’s been a serious decline in industry expertise due to retirements, and a lack of academic courses, training and presentations on the practical knowledge needed. There’s also the misconception that more data analytics and artificial intelligence (AI)will provide the solutions. However, these tools need guidance and input from engineers and technicians, who understand fundamentals, realities and possibilities.

Michael Taube, a consultant at S&D Consulting Inc., explains the situation, and provides motivation and opportunity to address the need to learn and expand our expertise. This is immediately valuable and critical for the future of more useful data analytics and AI. Michael, what’s the historical backdrop?

Lindsay must have recognized how this new and novel technology would affect the operations and designs of process plants.

His goal for this fledgling chemical engineering department was to produce engineers with practical understanding of the theoretical principles they learned. So, he must have felt compelled to provide a forum in which vendors, practitioners and academics could come together to share knowledge, insights and experiences with this new and evolving technology. Now, 80 years later, the Instrumentation & Automation Symposium (IAS, www. mkosymposium.org) continues to provide a venue to help current and future generations of engineers better understand and utilize this foundational technology which all forms of advanced control rely on.

MICHAEL: Process control and its symbiotic discipline, instrumentation, continue to be the worst taught subjects in engineering education, particularly in chemical engineering, even though economical, stable and safe operations of all chemical plants and refineries rely on the proper design and maintenance of their control and instrumentation (C&I) components, such as sensors, transmitters, valves and control applications/loops. Understanding the historical backdrop of PID control development provides insight into why Texas A&M University’s first Chemical Engineering Dept. head, J. D. “Doc” Lindsay, initiated the Instrumentation Symposium in 1946. At the time, automatic, closed-loop control (ACLC) was practically non-existent.

Refinery workers made manual adjustments to a valve wheel on a process pipe or a pneumatic valve modulating the air flow/pressure to a pneumatically adjusted valve to affect some process parameter—flow, pressure, etc. As ACLC became more prevalent, these “valve operators” became known simply as operators.

GREG: Why don’t more people know about the symposium?

than 50 years of experience, cartoons by Ted Williams, and (web-only) Top 10 lists. Find more of Greg’s conceptual and principle-based knowledge in his Control Talk blog.

Greg welcomes comments and column suggestions at ControlTalk@endeavorb2b.com

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MICHAEL: While it’s now convened under the auspices of the Texas A&M Engineering Experiment Station (TEES, www.mkosymposium.org/about-tees) and the Mary Kay O’Connor Process Safety Center (MKOPSC, www.mkosymposium. org/about-mko), previous iterations were sponsored and run by Texas A&M’s Chemical Engineering Dept. Since the faculty was very engaged with industry, word of mouth marketing, and maybe some print advertising, were sufficient.

As academic/industry collaboration faded, so did enthusiasm for the symposium from the academic community. Then, with only word of mouth from previous attendees and vendors, attendance at the symposium also declined. Nevertheless, it was kept alive by an enthusiastic core group, and is currently organized and run by an all-volunteer group of mostly industrial practitioners from OEMs, operating companies, service providers and www.controlglobal.com

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CONTROL TALK

independent consultants. Now in its 81st year, IAS retains its focus on practical design and implementation issues affecting instrumentation for both control and safety systems.

GREG: What topics are covered?

MICHAEL: While the specific presentations vary, overarching themes include foundational topics, such as PID controller design and tuning, instrument specifications and selection, and given the development of and emphasis on safety instrumented systems (SIS) in recent decades, SIL/SIF evaluation, implementation practices and standards.

One new addition to the symposium is its workshops. These are longer than typical oral presentations, and are intended to provide more detailed coverage of specific topics.

GREG: What can symposium attendees expect to see and hear?

MICHAEL: Because the symposium is co-located with the MKOPSC event, there are several parallel tracks addressing process safety management (PSM), operational excellence (OE), SIS and control, instrumentation and automation (CI&A). The presentations in each track address their subjects from a practical industrial perspective, and include new and/or updated standards development, as well as some pertinent academic research.

GREG: What’s different about the symposium compared to other events?

GREG: Why should PI employees attend the symposium?

MICHAEL: One of the biggest differences is, true to Lindsay’s intent, the symposium’s focus on education and knowledge sharing about how CI&A helps process facilities perform more reliably, efficiently and safely, as opposed to academic research on esoteric topics that are years away from implementation. There are presentations on developing design and implementation standards and new technologies.

Another difference is that participants don’t have to submit a paper, which is helpful for busy technical folks. As you know, writing a detailed, technical paper takes considerable, focused effort and time, which is in short supply for folks at the “sharp end.”

Finally, because the crowd is smaller and more focused, the symposium’s program committee provides networking opportunities, so vendors and attendees can meet at social mixers during the conference, as well as the barbecue dinner which has been a longstanding tradition.

MICHAEL: As training and development budgets are slashed, if not eliminated altogether, and with the resulting decline in training offerings, engineers and technicians have very few opportunities to gain valuable practical insights and knowledge from other practitioners and experts. The symposium addresses that gap, and is where PI companies can invest in their employees’ technical knowledge and development.

GREG: Where and when is the symposium held?

MICHAEL: The symposium and the MKOPSC Conference will held in Houston on Oct. 20-22, making it convenient for folks who work along Texas and Louisiana’s Gulf Coast.

GREG: Where can people register or find more information?

MICHAEL: At the conference website, which is www.mkosymposium.org.

GREG: What about the plenary speakers?

MICHAEL: As with the overall conference, there will be an array of plenary speakers and panel discussions from industry leaders, academics and the military addressing topics affecting the process industries (PI). Their talks will focus on technical and organizational factors affecting ability to ensure safe, reliable and profitable operations of the facilities our livelihoods, the nation and the world rely on. www.controlglobal.com

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To read an extended version of this column and to read the Top 10 things missing in process control courses, visit www.controlglobal.com.

AUGUST 2026  41

7/28/26 8:16 AM

CONTROL REPORT

Don’t be a parrot Master artificial intelligence (AI) before AI masters you

JIM MONTAGUE Executive Editor jmontague@endeavorb2b.com

“AI is just a tool like a handheld calculator, so its capabilities must be directed by users trained to employ it properly, along with their enduring mindsets, attitude, generosity, personality and critical thinking.”

42  AUGUST 2026

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JUST IN CASE it’s not obvious, I really enjoy hearing about people’s jobs. I didn’t know why at first, but I’ve realized it’s because these sources give me more insights and encouragement. They’re also better at sparking my memory, and helping me make better connections between topics I’m covering.

For instance, I got to cover U.S. physicians wrestling with early managed care issues in a cover story for Hospitals & Heath Networks magazine way back in about 1995. They reported on transitioning from traditional feefor-service medicine that encouraged over utilization to HMOs that incentivized them to do less. The nation’s health care system is still struggling to find a middle way, and free itself of parasitic insurers, but the doctors at the time didn’t even have the language to describe how their practice and hospitals could reorganize themselves.

Luckily, some found they could use the “hang out a shingle” entrepreneurial skills they and earlier doctors used to start independent practices, and redeploy them to form or join physician hospital organizations (PHO) and affiliated medical groups like Kaiser Permanente, Geisinger, Cleveland Clinic and others. I remember several physicians reported that calling on their familiar, traditional, smallbusiness values enabled them to understand how to participate in these new organizations and deal with managed care.

Pile on another 30 years, and the system integrators I interviewed for this issue’s “How to build process engineers and operators” cover story (p. 20) had some equally great advice, in this case, for developing and training new personnel. More and better staffers are desperately needed to stop continuing brain drains in the process industries; offset bigoted federal policies persecuting immigrants, who could help fill millions of unfilled U.S. jobs; and cope with breakneck technical shifts like artificial intelligence (AI) and digitalization.

In response to all the recent fear, loathing and epic hoopla surrounding AI, Daniel Clark and Dylan DuFresne, of consultant and system integrator Abelara, reminded readers that AI is just a tool like a handheld calculator or a Swiss Army knife. Consequently, its capabilities must be directed by users trained to employ it properly, along with their enduring, personal mindsets, attitudes, generosity, personalities and critical thinking.

Sam Hoff, of system integrator Patti Engineering, added it’s crucial for users to master AI, so it doesn’t master them. For example, he reported that a job candidate during a recent video interview was apparently reading AI-generated responses. Not a good look. If you’re just repeating sounds like a parrot, or reading cue cards like Saturday Night Live’s humorless cast members in recent years, then what good are you?

Granted, I know I’m just a conduit for editorial content and other information. I’m also aware that I’m dangerously close to being a total hypocrite when I warn others about being a parrot, when much of my career is doing something very close to exactly that. I can almost feel the humming and rumbling of divine justice over my shoulder.

However, similar to any good refinery, I try prove my value by turning all the raw material I gather into content that’s prioritized, concentrated, useful, easily consumable and hopefully entertaining. I try hard to sort through mountains of typically self-serving, overlypromotional baloney, and find the few useful wheatberries in all the chaff.

Most of all, I rely on willing experts like Hoff, DuFresne, Clark and all the other sources I interview to clue me in about their experiences, provide some best practices from further along the learning curve, and give me and Control’s readers some muchneeded advice, good news and optimism.

Thanks, guys. www.controlglobal.com

7/28/26 8:16 AM

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7/24/26 10:23 AM

The Next Evolution in Process Automation is Here

Emerson.com/DeltaV16

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3/25/26 7/24/26 11:07 10:23 AM AM