Control – February 2025

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WANT WIRELESS WITH THAT?

GENERATING WIND TURBINE OPTIMIZATION

UNDERSTANDING AI REALITIES

Edge borders on the move

Simpler networks, software tools and mobility help edge computing burst former boundaries

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Process improvement is like a trapeze act. You need a trusted partner who lends a hand at the right moment.

Just as athletes rely on their teammates, we know that partnering with our customers brings the same level of support and dependability in the area of manufacturing productivity. Together, we can overcome challenges and achieve a shared goal, optimizing processes with regards to economic efficiency, safety, and environmental protection. Let’s improve together.

Edge borders on the move

Simpler networks, software tools and mobility help edge computing burst former boundaries by Jim Montague

Multiplying and gaining mobility, wireless still needs onsite surveys and other best practices for success by Jim Montague

CONTROL TALK

The AI reality – part 1

Large language models can do amazing things, just don't confuse them with human thoughts by Greg McMillan

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A re-energized market

Oil and gas producers will be drilling again; they'll want updated, automated process

Understanding wind energy collection

How to better control turbines to unleash their full potential

14 ON THE BUS Fieldbus 'switch' to APL considerations

A look at the challenges of migrating from Foundation Fieldbus to Ethernet-APL

16 WITHOUT WIRES

Y2K to today

Wireless has gone from almost nothing to a key technology

18 SMART INSIGHTS

Industrial mobile robots and the data challenge Advanced users have learned how to make the most of the data provided by robots

21 IN PROCESS

Mass-flow market growing 6.3% per year

ODVA's CIP Safety adds communication redundancy; Aker BP picks Aucotec to digitizalize North Sea project; Aramco, Carbon Clean, Samsung demo CO2 capture 36

LEADERS IN AUTOMATION

Recognizing innovation, leadership and excellence of automation technology suppliers

51 RESOURCES

Final word (for now) on valves and actuators

Control 's monthly resources guide

52 ASK THE EXPERTS

Generating successful wind turbine optimization

Our experts explain the best options for maintaining control and measuring wind speed and direction

54 ROUNDUP

Flow goes deep and wide Flowmeters expand capabilities and operating ranges

58 CONTROL REPORT

Bad language

Mind-numbing buzzwords can serve much darker purposes

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A re-energized market

Oil and gas producers will be drilling again; they'll want updated automated processes

AMONG the executive orders signed by President Donald Trump immediately following his inauguration were those that resumed processing LNG export permits and reopening parts of Alaska and federal waters to oil and gas development. In short, he set out to fulfill his campaign promise to let the nation’s oil and gas companies “drill, baby, drill.”

Of course, I have thoughts on what I believe all that means in practical and political parlance. But that’s a discussion for a different day or column. What can’t be argued is that the re-establishment of the U.S. as an unfettered oil and gas producer is another business opportunity for the process automation market.

It’s no secret that oil and gas producers have been among the early adopters of process automation, test and measurment, and wireless/remote operations technologies—as I recently discussed with Ian Verhappen on the Control Amplified podcast (www.controlglobal.com/podcasts). Oil and gas producers and refiners are highly motivated to be efficient and safe, whether driven by government regulations or competitive market forces. Just because the regulatory fears figure to take a back seat for the next four years doesn’t mean the global oil and gas market won’t be an even scarier motivator. So, expect oil and gas producers and refiners to look to increase their investment in industrial autonomy as they ramp up drilling both offshore and onshore.

The opportunity for process control instrumentation and automation systems suppliers will quickly follow. Now is a good time to re-engage with the oil producers of the Permian Basin and the natural gas producers in Appalachia, in particular. Construction of a new LNG export terminal near Philadelphia just became a more realistic possibility. More operations around the U.S., particularly in Alaska and offshore, will be re-energized, no pun intended. They're going to need and want advanced controls to increase production in an efficient, and yes, sustainable manner.

If there’s one thing that I learned from more than a decade interviewing global oil and gas executives, their ears quickly perk up when the talk turns to efficient operations and safety. Now is a good time to show them how they can achieve both. But don’t dawdle. Who knows what might happen again four years from now.

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

" Oil and gas producers and refiners are highly motivated to be efficient and safe, whether driven by fears of government regulations or competitive market forces."

Understanding wind energy collection

How to better control turbines to unleash their full potential

BÉLA LIPTÁK liptakbela@aol.com

"The main advantages of using wind energy are that its fuel is free and there are no carbon emissions."

WIND energy is one of the least expensive and cleanest methods of electricity generation. Automating wind turbines operations is an interesting challenge for our profession. In my "Ask the Experts" column (p. 52), I not only discuss wind turbines, but also focus on the sensors and control loops used to guarantee their safe and optimized operation. Here, I focus on the process of wind energy collection because it must be fully understood before it can be properly controlled.

Wind is fueled by solar energy because it’s generated by temperature differences in the atmosphere, which causes pressure differences that move air towards the poles. The driving force is combined with the effects of Earth's rotation, the Coriolis effect, and the consequences of humidity and land-surface variations, which result in the complex wind patterns we experience. The total kinetic energy content of these air flows is immense compared to mankind's total energy needs, which it exceeds by about a million times.

The main advantages of using wind energy are its fuel is free and there are no carbon emissions. Disadvantages include aesthetics, noise (older units), low energy density (area requirement = 10 times that of solar parks), and relatively short life spans (about 20 years).

Areas with high wind energy potential include a 50-mile wide strip on seashores. Because the wind is often blowing at night or when solar energy isn’t available, total energy production becomes more continuous if the solar and wind farms are combined. This not only reduces the size of the needed energy storage, but also reduces the land requirement for combined hybrid plants, an important financial consideration in locations where land is expensive.

The Adani Green Energy Ltd. (AGEL) power plant in India combines wind and solar power to provide clean electricity to more than 1 million homes in the region. AGEL’s energy plant

at Khavda, Gujarat, begins with wind-energy generation of an initial 250 megawatts (MW), enhancing Khavda’s combined operational capacity to 2,250 MW, which is similar to a nuclear power plant.

Compared to the size of other energy producers, the share of wind-based electricity generation capacity is still small. In the U.S., it’s about 4% of the total. Until the most recent U.S. election, it was planned to reach 30 gigawatts (GW) by 2030, but that is now unlikely. Total global, solar electricity generation capacity is about 600 GW.

Globally, the use of the free, clean and inexhaustible wind and solar generation capacities were quickly increasing because the cost of both wind and solar electricity costs were dropping. This was the case until recently. Today, the costs of installed wind sytems are increasing, and only solar system costs are decreasing. Fossil fuels and nuclear electricity costs are nearly twice as high, and they too will probably continue to rise.

Wind turbine components and operation

As shown in Figure 1a, turbine blades are curved, so wind blowing over the top must travel a longer distance, and therefore the pressure drop over the curved surface is higher than on the fl at side below. This causes a pressure difference that generates the lifting force that spins the blades. The energy generated increases with the area swept by the blades (longer blades equal more area). Because wind speed is slower near the ground, it generates more power as hub height increases. As a result, if wind speed doubles, generated power increases eight-fold (cubic relationship). The lifting force also increases if the angle of the "chord line" of the blades is increased. This is the case up to an angle of around 10° to 15°. Any greater angle, and "drag" forces start to exceed lift and the turbine stalls.

Figure 1a: Increasing the chord line angle ( ) first increases the lift force spining the blades, but after reaching a maximum, the drag force exceeds it and the turbine stalls.

Figure 1b: The main components include the blades that turn the lowspeed shaft, which rotates the high-speed shaft of the generator. The controller manipulates the pitch ( ) and the motor that controls yaw.

Electric power generation begins when wind speed exceeds a minimum "cut-in" value. As wind speed increases, electricity production also increases, until the turbine blades reach the maximum (nominal or rated) speed, which corresponds to the maximum power generation of the turbine. When wind speed increases further, rotation is slowed by increasing the chord line angle ( the blade pitch) to prevent the speed of the blade tips from exceeding safety limits. The longer the blade, the more difficult it is to maintain tip integrity. Such a breaking accident occurred recently, when a blade on a GE Vernova turbine broke at the Vineyard Wind farm off the coast of Massachusetts. Rated power production continues throughout Region III, until wind speed reaches the maximum allowed (cut-out) velocity and the turbine is stopped.

When assessing the actual yearly power production of one of today's largest offshore wind turbines, production naturally varies with the yearly average wind speed at that location.

The faster the blade rotation, and the larger the hub height and rotor diameter, the higher the wind turbine's nameplate capacity, which today can be up to about 3.5 MW or more. The speed of the blade tips must not exceed about 80 m/s (180 mph) because, as the Vineyard Wind accident showed, higher speeds can damage blade tips. Operating noise level is also a consideration. In most locations, it must be kept under 40-60 dB. Sonic booms that occur at speeds of 761 mph must always be prevented.

Today, the hub heights on utility-scale, land-based units is around 100 m and their heights are also increasing.

Turbine efficiency increases with hub height because the blades reach higher, where wind speeds are faster than near the ground (where vegetation, etc, slows it). On the other hand, increasing hub heights requires stronger structures to support the weight of the nacelle.

Offshore wind farms

The design and control requirements of wind turbine installations become more challenging when a wind farm is moved from solid ground onto the ocean. This is because landbased units only need to respond to changes in the wind’s aerodynamic thrust forces, while offshore units must also respond to the changing, hydrodynamic thrust forces of waves, and account for interactions with mooring lines.

Types of offshore installations vary with ocean depths. Besides keeping the hub stable, another control challenge is protecting the cable that transports generated electricity to the grid. One condition to protect against is keeping the cable from twisting due to turbine rotation. Eventually, a total control package will have to be developed, serving the optimization and safety of wind turbines. The overall goal of this optimization envelope, which is to maximize electricity production up to but not exceeding safety limits, is like those in other industries. However, because aerodynamic and hydrodynamic forces are large and unpredictable, development of the required algorithms will represent a major challenge to our automation profession. Otherwise, accidents like the one at Vineyard Wind will keep happening.

Wind vane

Nacelle High-speed shaft

Tower Blades

Yaw motor

Yaw drive

Brake

Wind direction

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" One can only hope APL field switches that are fault-tolerant, redundant and hotswappable are on someone’s roadmap."

Fieldbus ‘switch’ to APL considerations

A look at the challenges of migrating from Foundation Fieldbus to Ethernet APL

IN all the years I’ve used Ethernet switches in various control systems, I don’t recall a single failure. Ethernet switches have been replaced through upgrades and obsolescence, and as security concerns spurred more industrial options. However, there’s never been an instance where a network switch had a detectable hiccup, let alone a complete loss of function. For our relatively small control networks, it might be surmised that we’re just not stressing them very much.

Fault tolerance, robustness and single points of failure will weigh on our choices when designing a Foundation Fieldbus (FF)to-advanced physical layer (APL) migration. With FF and Profibus PA, field networks were considered robust because the two-wire, power-plus-communications physical layer could be free of active devices—microprocessors executing code—from the field devices back to the host interface cards, which could also be redundant. Redundant power conditioners for segments further hardened individual networks against single points of failure.

What new challenges await with APL? Available products require either fiber or copper, and conventional Ethernet backhauls from the field switch to the host system. The hardware for using FF infrastructure for APL—twistedpair Type A cable—is under development.

If we use existing FF trunk cable for APL, a device for coupling two-wire APL to conventional Ethernet will be necessary—somewhere. Last year’s FF-to-APL migration concept (FCG TR10365) proposes that redundant APL “power switches” can be redundant. While consuming two twisted-pair trunk cables, they’re an improvement over dual-redundant FF power conditioners, which typically use a single twisted-pair on the field side. Unlike passive FF power conditioners, APL power switches are active Ethernet devices. Some redundancy firmware must be used to determine which of this pair is actively online.

Out in the field junction box, the APL field switch is taking the place of the FF (or PA) coupler. Users preserving a strictly star-network topology will have an advantage because migrating a multidrop or hybrid “star plus multidrop” will have more hurdles. Common FF or PA couplers have few or zero active components, and there’s no silicon running firmware. Aside from short-circuit protection and (sometimes) accommodations for extending spurs into hazardous areas (Zone 1 / Division 1), the coupler is effectively a terminal block.

Having consumed two FF trunks for power redundancy, the FF-proxy APL field switch must integrate into many devices. Though uncommon, fieldbus segments can have 16 spurs (some systems support 32), so strategic combinations of heavily and lightly loaded segments are required. So far, the most spurs I’ve seen on an APL switch is 24. If you take your total fieldbus devices divided by the number of segments, and it’s greater than 12, you might be pulling in more twisted-pair cable if you want redundant power from the house/rack room.

Another factor will be the power consumption of field devices. There’s only so much current you can push out on 18 AWG conductors. APL devices promise to be considerably more power-hungry.

Finally, how do you feel about letting up to 24 devices share a single point of failure— the APL field switch? It’s unclear whether the power to field devices will be maintained, for example, during a firmware flash. If diagnostics indicate an issue, how would you exchange it for a replacement without all the attached field devices powering down?

One can only hope APL field switches that are fault-tolerant, redundant and hot-swappable are on someone’s roadmap. Otherwise, end users that serve large continuous processes may be a bit shy about switching to APL.

Solutions Architect

Willowglen Systems

Ian.Verhappen@ willowglensystems.com

" One thing I've seen with industrial networks is it takes about 10 years from when a technology enters the market until it's adopted and incorporated into normal engineering practices—at least in the process industries."

Y2K to today

Since the turn of the century, wireless has gone from almost nothing to a key technology

AS we reach the quarter century, rather than look forward, we instead look at the wireless advances that affected us since the Y2K fears that brought us into the 21st century.

As the century began, 3G networks and CDMA networks were emerging, with 4G and LTE to follow about a decade later. Then, the first 5G arrived in about 2015. Now, the 3G journey is nearing its end, and will likely fully retire this year.

Similarly, WLAN technology, defined by the IEEE 802.11 standards, introduced 802.11a (11 Mbps) in 1999 and 802.11g (54 Mbps) in 2003. Today, 802.11be (Wi-Fi 7, 23,000 Mbps) is just being rolled out.

Industrial wireless sensor technologies follow a similar path, but with fewer revisions:

• Zigbee was beginning at the turn of the century with the first specification released by the Zigbee Alliance (Connectivity Standards Alliance 2021). Meanwhile, Matter was introduced in 2004, and Zigbee 3.0 in 2014. Zigbee PRO 2023, the most recent release, adds cybersecurity.

• Bluetooth followed a similar timeline with the Bluetooth Special Interest Group formed in 1998. Bluetooth Low Energy (BLE) arrived in 2014, followed by Bluetooth mesh in 2014, and Bluetooth 5.0 in 2017.

• WirelessHART entered the market with the release of the standard in 2007, which was approved as IEC 62591 in 2010.

Wi-Fi 6 and Wi-Fi 6E, which can use the 6 GHz spectrum band for Wi-Fi, is available in 54 countries. It provides several deterministic quality of service (QoS) capabilities, such as traffic prioritization, which is a key component of time-sensitive networking (TSN) for Industry 4.0 applications. Wi-Fi 6 TSN supports applications requiring latencies of 2 msec or less, such as remote control of industrial robots and material handlers. Wi-Fi 6/6E/7 networks can meet demanding requirements such as sub-20 msec latency, sub-1 msec

jitter, 99.999% uptime, and throughput in the tens of megabits.

Another example of wireless technologies used for mission-critical applications is rail communication-based control systems (CBTC) for metros, including autonomous train systems. They're proven examples of how wireless solutions have reached new heights in terms of reliability.

There's a general trend in wireless networks toward hybrid networks, with mesh-based networking becoming the more commonly used base configuration instead of star topologies.

Wireless is a key enabler of digitization, including enabling IoT because it can connect remote, mobile and difficult to access applications. Wireless offers users the ability to run their operations more efficiently, increase productivity, reconfigure operations more easily, and reduce costs.

Other trends driving industrial wireless today and its continuing importance include:

• Integration with other technologies such as cloud computing, artificial intelligence (AI) and edge computing;

• Improved security measures to protect sensitive data;

• Lower power consumption that enables longer battery life and reduced maintenance; and

• Integration with advanced analytics such as leveraging data for predictive maintenance and process optimization.

All of these will take time. One thing I've seen with industrial networks is that it takes about 10 years from when a technology enters the market until it's adopted and incorporated into normal engineering practices—at least in the process industries. This was certainly the case with HART, fieldbus technologies and wireless sensor networks, and appears to be true for the new Open Process Automation Standard (O-PAS) principles, 5G and Ethernet Advanced Physical Layer (APL).

IAN VERHAPPEN

PENNY CHEN Senior Technology Strategist Yokogawa penny.chen@yokogawa.com

" Compared to human operators or technicians making rounds, robots offer the advantages of accuracy and timeliness."

Industrial mobile robots and the data challenge

Advanced users have learned how to make the most of the data provided by robots

IN prior installments of this column on industrial mobile robots, we established that an emerging shortage of personnel to operate plant equipment and process units resulted in a growing need for robots and drones that can travel throughout facilities and take over data collection, inspection and other tasks. In addition to the labor shortage, the most common challenges in routine inspections and maintenance activities today include safety risks due to work in hazardous areas, and limits of human capabilities to accurately and efficiently acquire and process information.

Their ability to reach dangerous areas quickly, easily and safely enables robots and drones to improve the overall safety of plant operations and maintenance. They also allow the human workforce to focus on value creation tasks, which are far more attractive to prospective employees. (Hereafter, I’ll only mention robots, but it's with the understanding that, in practically all cases, my comments apply to drones as well.)

Advanced robotic technologies can even help end-users perform unattended operations, while also augmenting human capabilities to solve common challenges in daily plant operations and routine inspections. Among the most promising robot capabilities is the ability to provide insightful data, that is, bringing the right data to the right viewers, such as key decision-makers. Robots can be equipped with sensors and individually designed payloads to meet operational objectives.

Data integration

Data integration is always a challenge. While robots can collect lots of data, some prospective users have asked, “but is it useful? What can we do with it?”

This isn't really the best way to look at it. The most advanced users have distinguished

themselves by their ability to make the most of data provided by robots. They specifically define the data collection requirements for each mission, match the payloads, and send the robots on their way.

Data collected by robots falls into two fundamental categories: operations and maintenance. An example of the former is a process variable such as a pressure gauge reading. Although the gauge is “disconnected,” the value typically makes its way to the process control system. An operator manually enters it upon completion of the round. Often, this sort of data is only for recording purposes in the historian. An example of maintenance information is vibration measurement, which could indicate that equipment repairs will be needed soon. The ultimate destination of much maintenance information is an asset management application.

Compared to human operators or technicians making rounds, robots offer the advantages of accuracy and timeliness. Robots eliminate the human error that might affect manual measurements during rounds and data entry afterward. If a robot resides on a wireless network, it can immediately report data recorded during a round. There’s no need to wait until the round is completed.

Since data collected by a robot is destined for asset management applications, historians and process control systems, significant processing is required within the robot to arrive at a data format that’s appropriate for those platforms. For example, when a robot reads a pressure gauge or measures vibration, it converts those data points to the same digital formats that the destination platforms use.

Data analytics and uses

Robots typically activate applications based on their missions and payloads. To read gauges, a robot uses an application, such

as a plant image analyzer (PIA), which processes image data from plant sites using artificial intelligence (AI). PIAs analyze images of devices, such as gauges, and converts readings into digital values. It includes a gauge calibration function, which lets the robot determine the minimum or zero value, maximum value and engineering units.

In addition to converting data to digital formats, robots record audio, photos and video. This information is valuable to process operations and maintenance management because, not only can the various formats be viewed and heard on HMI devices and web browsers, but AI applications can also offer much deeper analyses.

An example of a specialized AI application is a color-degradation diagnosis system, which employs a robot integrated with an AI image analyzer to assess objects such as process pipes for color changes. The sensors capture data on hue and brightness, which AI algorithms interpret to diagnose degradation severity. The system flags items for maintenance, offering fast and accurate assessments to preserve object quality and value.

Data transportation

To transport data collected by robots to destinations such as asset management applications and process control systems, industrial companies use specialized platforms, which evolved from SCADA systems. Modern versions, for example, Collaborative Information (CI) Server, can reside on premises

“ To transport data collected by robots to destinations such as asset management applications and process control systems, industrial companies use specialized platforms, which evolved from SCADA systems.”

or in the cloud. It integrates robot fleet management with an array of communication interfaces and protocols, offering compatibility across OT technologies.

Among numerous emerging applications for industrial mobile robots, these capabilities enable a first-responder scenario. When the CI Server detects alarms from field devices, a robot can be dispatched to a field location, and the real-time field situation can be checked with image data from the robot.

In emergency situations, deploying robots as first responders offers several advantages, including supporting operators to assess the situation, gather critical data, and execute tasks, such as deactivating equipment or assisting in rescue efforts. When integrated with the control system, a robot can continuously provide real-time feedback to the command center, enabling responders to formulate effective strategies and mitigate safety risks.

Data collected by robots falls into two fundamental categories: operations and maintenance.

Source: Yokogawa

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Mass-flow market growing 6.3% per year

Controller sector expected to top $2.0 billion by 2029

PARTLY driven by shifts in the semiconductor sector, the world market for mass-flow controllers is projected to grow at a 6.3% compound annual growth rate (CAGR) from a total of $1.5 billion in 2024 to more than $2.0 billion during 2029, according to a new study, “The world market for mass-flow controllers," 4th edition, released Jan. 30 by Flow Research (www.flowmfc.com). Four technologies are used in massflow controllers: thermal, Coriolis, differential pressure and ultrasonic, with the thermal type dominating the market.

The study covers both the semiconductor market and the industrial market for mass-flow controllers. It found that, while the semiconductor market is larger, the massflow market serves industries that are growing faster. These sectors include lab-grown diamonds, alternative fuels, solar photovoltaic cells and gas distribution. Meanwhile, the semiconductor market is traditionally a cyclical one, often with 12-18-month market cycles. Flow Research reports that suppliers invest in industrial market segments partly to counteract the semiconductor industry’s cycles.

“Mass-flow controllers have a bright future. In the semiconductor industry, increased industrialization will create greater demand for computers, smartphones, wearable technology and electronic devices. While this trend is especially

ODVA’s CIP Safety adds communication redundancy

ODVA (www.odva.org) reports that its Common Industrial Protocol (CIP) for Safety on EtherNet/IP has been enhanced to allow using its CIP Concurrent Connections for applications requiring high availability and functional safety. Concurrent Connections allow communication redundancy between multiple producing and consuming devices.

CIP Safety provides failsafe communication between nodes, such as safety I/O blocks, safety interlock switches, safety light curtains and safety controllers in machine and process automation safety applications up to Safety Integrity Level (SIL) 3 according to IEC 61508 standards. Employing Concurrent Connections with CIP Safety on EtherNet/IP allows redundancy and functional safety to be integrated. Concurrent Connections are CIP connections that support fault tolerance via redundant devices. They enable CIP connection paths that let data be sent multiple times over multiple paths—independent of how the devices are physically connected. Originators, routers and targets can have multiple devices participating, and the Concurrent

Total Shipments of all mass flow controllers worldwide (millions of dollars)

strong in China and the Asia/Pacific region, it applies to other regions as well,” says Dr. Jesse Yoder, president of Flow Research. “In industrial segments, mass-flow controllers are widely used in alternative fuels, solar photovoltaic (PV) cells and fuel cells. The move towards renewable energy will benefit the mass flow controller market. While the industrial market is growing faster than the semiconductor market, all signs point to solid growth in both markets over the forecast period.”

Connection and the duplicated device pairs can fulfill the role and connection. This reduces time that would otherwise be needed to detect failures, and eliminates time that would have to be spent switching between paired devices. The redundant pair send and receive data continuously, so even if a failure is detected, the control process can continue uninterrupted.

New profiles for temperature sensors

ODVA also reported that new process device profiles for temperature sensors are available as a part of its EtherNet/IP specification. These profiles help system integrators and end users commission new devices and more easily replace devices. They also standardize process variables and diagnostics for smoother device interoperability and easier controller data integration from EtherNet/IP-capable field devices. Device profiles are available for Coriolis, electromagnetic and vortex flows, standard and scaled pressure, and now resistance temperature detector (RTD) and thermocouple temperature devices. ODVA adds the value of the profile’s standard formatting of process variables, data totals and diagnostics is enhanced by adding temperature profiles.

Source: Flow Research

Aker BP picks Aucotec to digitalize North Sea project

Aker BP (akerbp.com) reported Jan. 30 that it’s selected Aucotec (www.aucotec.com) to help implement its digital infrastructure at the Yggdrasil oil and gas development project in the Norwegian North Sea. The offshore operator will enhance the project’s operational efficiency by using Aucotec’s Engineering Base software for seamless, cooperative, datadriven workflows. As part of the company’s engineering, design and data management (EDDM) program, the software is intended to accelerate Aker BP’s modification processes thanks to its minimal customization.

Yggdrasil is reported to be the largest ongoing oil and gas development in Norway, and is expected to play an important part in Aker BP’s production from 2027 onward. Due to the project’s scale and complexity, the company requires Engineering Base to provide seamless collaboration across its teams and contractors. By consolidating and validating vast amounts of engineering and lifecycle information (LCI), Engineering Base lets all stakeholders work from a unified, reliable data foundation, which also accommodates

many AI-powered, downstream processes. The software’s change-management capabilities also allow modifications to be seamlessly integrated into Yggdrasil’s as-built model, ensuring data integrity throughout its lifecycle. It also enables digital twins, such as Aker BP’s Cognite Data Fusion, for safer, more efficient offshore operations.

“At Yggdrasil, Aker BP is setting a new standard for remote operations, periodically unmanned and unmanned installations, low-activity-set offshore and new technology,” says Lars-Erik Ydstie, VP for digital at Yggdrasil and Aker BP. “Data availability is important for our operations

RELIABLE MEASUREMENT SOLUTIONS

Source: Aker BP

strategy. EDDM will serve as a foundational solution supporting LCI and engineering data, thus driving operational excellence at Yggdrasil. Aucotec and its ready-to-deploy functionality in Engineering Base lets us centralize and optimize engineering data immediately.”

Aramco, Carbon Clean, Samsung demo CO2 capture

Aramco (www.aramco.com), Carbon Clean (www.carbonclean.com) and Samsung E&A (www.samsungena. com) agreed Dec. 4 to demonstrate a new carbon-capture technology. It will deploy Carbon Clean’s modular CycloneCC unit to capture CO 2 from natural gas turbine exhaust streams containing approximately 4% CO 2 . Because it has a 50% smaller footprint than conventional carbon-capture processes, CycloneCC is estimated to reduce the total installed costs by up to 50%, while maintaining high performance and process efficiency even at low CO 2 concentrations.

Samsung will deliver the engineering, procurement and construction (EPC) of the plant. The unit will be installed on

the sales gas compressor turbine exhaust gas stack, providing critical data on performance under real-world conditions. CycloneCC’s performance, even at low CO2 concentrations, is achieved by combining two process-intensification technologies. They include rotating packed beds (RPB) and Carbon Clean’s proprietary APBS-CDRMax solvent.

Perfect Match.

VisuNet FLX—The New Modular HMI Platform for Use up to Zone 2/22, Div. 2

The one-in-a-million HMI system that perfectly fits your application.

For more information, visit pepperl-fuchs.com/flx

Source: Carbon Clean

SIGNALS AND INDICATORS

• HIMA Group (www.hima.com) recently celebrated the opening of its first facility in India for process and rail safety. This expansion is a step in the company’s international growth strategy, and aligns with India's Vision 2047 (Viksit Bharat) initiative for becoming a more developed nation by 2047.

• The National Center for Manufacturing Sciences (NCMS) has released a whitepaper (ncms.org/ news/ai-white-paper) about using artificial intelligence (AI) to improve supply chain resilience. Presenting two case studies of solutions that can be adapted by small- and medium-sized manufacturers (SMM),

the document seeks to help them harness AI to improve operations by preventing supply chain disruptions.

• Yokogawa Electric Corp. (www. yokogawa.com/solutions/solutions/ asset-management-and-integrity/ subsea-power-cable-monitoring) has introduced its OpreX subsea system for monitoring power cables from offshore wind farms. By employing Yokogawa’s DTSX fiberoptic temperature sensor, OpreX can constantly monitor the temperature of subsea power cables and pinpoint abnormalities.

• Opswat (www.opswat.com) has acquired Fend Inc. (www.fend. tech), which supplies protec -

tive data diode and unidirectional gateways. Its products perform multi-scanning by up to 30 anti-virus engines, Deep CDR for zero-day threats, sandboxing, and Proactive DLP that prevent data leaks.

• Hottinger Brüel & Kjær (HBK, www.hbkworld.com) reports that its parent company, Spectris plc (www.spectris.com/) has purchased Piezocryst Advanced Sensorics GmbH (www.piezocryst.com) for €133.5 million. It will be integrated into HBK's In-Process business unit as “Piezocryst by HBK.”

• DwyerOmega’s (www.dwyer-inst. com) recent acquisition of Process Sensing Technologies Ltd. (PST) means it also owns Fluid Components International (www. fluidcomponents.com), which makes thermal mass flowmeters and level and flow switches.

• The Control System Integrators Association (CSIA, www. controlsys.org) reported Dec. 10 that CEO Jose Rivera plans to step down after a decade of dedicated leadership. Under his guidance, CSIA modernized, increased its overall resilience, and established a strong financial position.

• Pipeline inspection software developer PipeLogix (pipelogix. com) announced Dec. 3 that it’s partnering with AI-driven solutions provider PipeAId (pipeaid.co) to automate and improve condition assessment. They plan to let users of PipeLogix’s Phoenix software automate recognition and coding of sewer and stormwater system defects and features within their workflows for greater data accuracy and operational efficiency.

Fixated on the details. Known for performance.

Industrial computers that thrive wherever you need them.

by Jim Montague

Edge borders on the move

Simpler networks, software tools and mobility help edge computing burst former boundaries

THINK you know what edge computing is and where it happens? Think again. Increasingly digitalized, simpler and more mobile technologies are blurring its definitions, and shifting its boundaries. Of course, edge computing has always been a matter of perspective. Control-room staff think it's on the plant-floor or in the field, production staff place it at the sensor and device levels, and corporate managers believe fleets of distributed plants are all on the edge.

However, the flexibility enabled by digitalization and its continuing transition from rigid hardware to fluid software is allowing simpler, easier and faster programming. It’s also letting software run in even more remote and widely distributed locations, as well as granting many edge devices greater mobility, and letting them establish closer networking ties with cloud-computing services and their analytics.

“The desire to move lots of data, combined with low-cost, edge-compute hardware, allowed adding intelligent edge devices alongside on-prem and cloud servers,” says Ryan Gerken, principal engineer at Eosys Group Inc. (www.eosysgroup.com), a system integrator in Smyrna, Tenn., near Nashville, and a certified member of the Control System Integrators Association (CSIA, www.controlsys.org). “Improvements to remote management and deployment technologies further enable the viability of edge compute at scale.”

Gerken reports that a new class of DataOps software is available. “While this software is marketed to facilitate unified namespace (UNS) deployments, in practice, it usually adds another layer and added cost to edge-data movements,” he explains. “While this software can be a good value to some, in our experience, many customers aren’t excited about the prospect of additional, recurring subscription fees.”

Because these factors can make it hard to generate and promote savings, Gerken reports that Eosys uses products, such Rockwell Automation’s Embedded Edge Compute or Inductive Automation’s Ignition software on large projects. “Ignition can serve as both a connectivity and DataOps platform. And, when used in a distributed fashion, it can move the compute load closer to the edge, improving calculations times for real-time key performance indicators (KPI) and metrics.” says Gerken. “Traditionally, these calculations were done at the server, but they can get overloaded and out of scope. Consequently, they need to find better ways to push calculations to the edge, where they can use software like Ignition Edge that runs on mini PCs or other small IPCs.”

Least-resistant path

The accelerating reach and impact of digitalization makes it even more crucial for potential users to define the problems

Photo: Derek Chamberlain /

they need to solve to guide their search for appropriate data processing, power and locations.

For instance, Dallas-based Goodnight Midstream (www. goodnightmidstream.com) builds and operates collectedwater infrastructures for shale oil and gas producers, and maintains more than 450 miles of gathering and transportation pipelines linked to 50 disposal wells for saltwater with chemicals and heavy metals from fracking sites across the Williston Basin, Permian Basin and Eagle Ford Shale areas. These pipelines generate huge amounts of data about pipewall thickness, leaks, water flowrates, pressure fluctuations, inflow and outflow volumes, and coordinated control of devices, such as valves, pumps and instruments.

However, gathering and analyzing information from Goodnight Midstream’s pipelines became difficult as its operations expanded. Its supervisory control and data acquisition (SCADA) system relied on multiple virtual private network (VPN) tunnels to securely connect to its central hub and facilities, but managing each VPN connection’s firewall became complex because they required configuration, monitoring and maintenance. This traditional, point-to-point VPN setup also stunted Goodnight’s infrastructure due to the added resources needed to individually connect and reconfigure every existing site to a new VPN.

“For anyone who’s done large-scale networks, especially distributed out to edges in the middle of nowhere, VPN tunnels can be the bane of your existence,” says Kevin Cooper, CTO at Goodnight Midstream. “It wasn’t uncommon for us to come into work, and have seven or eight tickets at because

Figure 1: To replace the VPNs and SCADA system managing its saltwater transportation pipeline for shale oil and gas clients, Goodnight Midstream implemented Cirrus Link’s Chariot MQTT publishsubscribe broker and web-based Ignition Edge software on Moxa’s AIG Edge Intelligence gateways, which are also preloaded with Debian’s Linux-for-the-edge software.

Source: Inductive Automation and Moxa

reports weren't working right, and we’d inevitably trace them back to a VPN tunnel.”

To decrease complexity and administrative chores by removing VPNs, Goodnight enlisted system integrator CSE Icon (www.cse-icon.com) to design a gateway architecture, implement a message queuing telemetry transport (MQTT) publish-subscribe broker, and replace its SCADA system during the first eight months of 2023 with web-based Ignition software. Located in the Woodlands, Tex., north of Houston, CSE Icon is a certified CSIA member.

Migrating to MQTT and Ignition was expected to let the pipeline network perform data mining and business intelligence on the system’s backend, deploy Linux at the edge, upgrade easily, use an external database for location data, and improve template support. Goodnight Midstream also wanted MQTT to help it create user-defined types (UDT) and instances for Ignition, migrate data from the former SCADA system, and streamline patch management. To find the right MQTT broker, CSE Icon and Goodnight also conducted load testing to assess performance under varying demand levels, and settled on Cirrus Link’s Chariot MQTT broker because the results showed it exceeded the project’s requirements.

Solid network foundation

On the hardware side, Goodnight Midstream deployed five Windows servers at its enterprise level and approximately 50 of Moxa’s AIG-501 programmable IoT gateways with Ignition Edge software, as well as Modbus gateways, INJ-24 power over Ethernet (PoE) injectors to run cameras and other

Controls up to 30 miles away

Non-OT Modbus device

Cameras beyond 300'

Inlet header controls 600' away Moxa ethernet extender

Moxa ethernet extender Moxa ethernet extender IEX-402

Moxa media converters IMC-21GA+SFP

PLC Moxa modbus gateway MGate MB3180

Moxa IIoT gateway AIG-501

Ignition edge enabled device Edge sensors

devices, very-high, digital subscriber line (vDSL) Ethernet extenders, and fiber-optic, and small form factor pluggable (SFP) transceivers. AIG-501 also provides a ThingsPro gateway software library and Linux OS for immediate compatibility with Azure’s runtime, prebuilt software and instructions for running Ignition (Figure 1).

"Moxa helped us expedite the process, allowing us to set up a new unit in less than 20 minutes, which was a gamechanger. It's incredibly helpful when we need to deploy or replace a unit in the field,” explains Rick Hornung, senior IT manager at Goodnight Midstream. “We also chose Moxa’s gateways because they were preloaded with Debian’s Linuxfor-the-edge software. Plus, Moxa provides tools to manage those endpoints centrally. We were able to leverage this platform because of Ignition’s portability.”

Conversely, with the previous SCADA network, every tag had to be manually created, so each part of the saltwater pipeline network had its own unique tag list. Using Ignition for SCADA lets CSE Icon employ its UDT iterative tag data types to standardize tags from the start. It implemented more than 100,000 tags, each of which included the software’s Open Platform Communications (OPC) item path.

Safety on four legs at LNG plant

At just 10 years old, Woodside Energy’s (www.woodside.com) Pluto liquid natural gas (LNG) plant on the northwest coast of Australia is just a kid compared to most similar facilities. And, because it’s so young, it’s also more technically advanced than its peers, which aids in producing 4.9 million tons of LNG per year from two offshore gas fields.

To identify issues that could cause downtime earlier and more often, Woodside recently added to Pluto’s advances by launching a new, data-capture service at the plant. This project included deploying Boston Dynamics’ (www. bostondynamics.com) four-legged Spot robot as part of its Spector program. The robot is assigned to conduct routine, sitewide inspections. Its payloads include Spot Cam+IR with a 30x optical zoom camera and a thermal camera to detect if equipment may overheat. Spot captures images that complete regulatory, visual inspections for electrical devices.

Woodside also worked with DroneDeploy (www.dronedeploy.com) to implement the robot’s link with Pluto’s in-house digital twin. Spot moves autonomously through the plant, navigating obstacles, and righting itself when it stumbles.

“Spector goes and finds information, and we access it and run analytics,” says Shawn Fernando, remote operation delivery manager at Pluto. “This gives our operators a detailed view of what they need to do next.”

Dealing with distances

Because water/wastewater operations are often widely distributed, Actemium-Avanceon (www.actemium.us/actemium-avanceon), is using more edge computing for data collection, analytics and management. In particular, it’s employing edge-based PCs for monitoring, maintenance, prevention and even some remote-control, according to Brandon DeFanti, principal engineer for controls and water/wastewater at Actemium-Avanceon, which is a system integrator in Exton, Pa., that’s also a founding and certified CSIA member.

“Edge-based PCs can monitor and enable remote control, but they can also run in island-mode to keep operations running when outside interactions aren’t available, as well as archive their own data, and report later when external connections are restored,” explains DeFanti. “Our water/ wastewater clients must also comply with local department environmental protections (DEP). This information is typically gathered from remote terminals that include PLCs for pumps and other distributed equipment, edge-based HMI screens, and other devices that report to the historian.”

Actemium-Avanceon works on the edge because its water/wastewater clients have so many remote sites based on

Source: Boston Dynamics

Spot also has a customized safety payload that allows it to operate in classified, hazardous locations in accordance with legal requirements and Woodside’s risk assessment procedures and policies. For example, if the robot senses gas during an inspection or elsewhere onsite, the safety payload will immediately shut it down by electrically isolating the battery.

Before the Spector program, it could take up to 90 minutes to find equipment and complete an end-to-end visual inspection of it. With Spot, inspectors can review images first to determine their response and bring exactly what they need.

“One of the biggest benefits of robot-captured images is that they can be used to identify issues before we arrive in the field,” adds Bruce Hill, electrical inspection coordinator at Woodside. “This means we can bring spares, fix any issues as soon as possible, and save even more time.”

Smart, AR glasses assist at paper plant

To optimize its processes and improve working conditions for maintenance teams at its plant in Ružomberok, Slovakia, paper and packaging manufacturer Mondi (www.mondigroup.com) deployed RealWear’s Navigator 500 hands-free smart glasses with TeamViewer Frontline xAssist software for faster response times.

Source: RealWare

equally remote water feeds. Because they’re usually moving water among locations, they’re also moving data, and gathering, manipulating or converting it to other forms and formats. This makes formerly, nice-to-have data about pump efficiencies and power levels more important than before.

“As municipalities and their utilities consolidate and/ or privatize, they want to make their water/wastewater assets more efficient due to new rules, addressing end-of-life equipment, and planned upgrades to 21st-century controls and networking,” says DeFanti. “These days, even the smallest water districts managed by one guy and his brother need to access local, county and state data.”

These consolidating utilities and expanding communities need more data than traditional water levels and chemical information. For instance, they’re comparing influent and clean-water-discharge flows to help identify leaks.

“We’ve been collecting this data for 15-20 years, but now we can do something more useful with it,” explains DeFanti. “We can answer questions like what happens to chemical levels when certain conditions occur? We can check amps used per run, or monitor power used per gallon of flow. We’re also adding context from other sources, such as labor, financial, weather, and maintenance. We have a data operations and analytics (DataOps) division at Actemium-Avanceon that’s deep diving on the data to provide operational insights to augment regulatory reporting and cost analyses.”

Previously, maintenance was inconsistent due to variations in applying training, communicating requirements, and input from foreign suppliers.

“Some of the maintenance team’s work couldn’t be performed, or it was done in a very complicated and a bit amateurish way using videos made with mobile phones,” says Samuel Dvorštiak, digital specialist at Mondi SCP Slovakia. “These videos were downloaded to computers, and sent with comments by e-mail, which was a bit clumsy. Thanks to smart glasses, this whole process is much more professional.”

Navigator 500 also has a voice-activated operating system with speech recognition that works in noisy environments, soundproof microphones with clear sound quality at 100 dB of background noise, integrated speakers, 3.5 mm audio jack, and a high-resolution display.

“The possibility of quickly establishing connections between a technical expert and our people is a big advantage,” adds Dvorštiak. “Thanks to RealWear’s smart glasses the expert operating remotely sees exactly what the technicians at our plant see with real-time [picture and sound, and can provide support without having to come to the plant.”

Streamline with metadata and hashtags Gerken reports that two Eosys clients with multiple plants are using closer-to-the-edge computing and Ignition to improve their operations. The first is a large construction materials manufacturer with many, geographically diverse, U.S. production sites, which maintains a light IT footprint in the field by running lots of functions from its corporate headquarters, and describes itself as a “cloud-first company.” While many users think of the edge as their front-line operations and sensing devices, this organization considers each of its remote facilities as its edge, and manages then with Dell Edge Gateway 5000 Series running Ignition software.

The second client is a large automotive manufacturer with fewer total plants that are also geographically distributed, though each is larger than the construction materials company’s sites, and has greater data density because they move more real-time KPIs and require more edge computing. Because they’re taking in data from millions of tags, these automotive plants report data by exception via MQTT.

“One lesson from these two types of plants is that it’s crucial to figure out how to organize their data,” says Gerken. “If not, it will be very messy when they try to scale up.”

Gerken reports that the five-layer ISA-95 standard for developing automated interfaces between enterprises and control systems can help provide an initial model for organizing data from facilities, areas within them, and individual shops

PROTECT PUMPS

•

•

Two Adjustable Set Points Relay Outputs

• Adjustable Delay Timers

Software pushes the edge envelope

4-20 Milliamp Analog Output

Only 3.25” x 6.25” x2”

Numerous software devices and support functions can make it simpler and easier to develop, install and manage edge-based processes. The following are just a few of the newest:

• Open-source Docker (www.docker.com) platform as a service (PaaS) uses visualization on an operating system (OS) to deliver chunks of software known as containers that run operations and programs. Containers are segregated, but can merge files like software, archives and configurations.

• Consisting of multiple hosts that run in a group, Docker Swarm deals with member issues and assigns tasks, while users carry out swarm-related services or both.

• EdgeIQ delivers software that’s component-independent to monitor and handle the lifecycles of groups of linked items and their data, and provide a framework for coordinating edge-computing software, hardware and operations.

• As a management service added to Microsoft Azure’s IoT Hub cloud-based platform, IoT Edge allows users to implement jobs in the cloud, and operate them on IoT Edge components using common software receptacles.

• IoT Greengrass software from Amazon Web Services (aws. amazon.com) provides cloud-based functions to plant-floor or inthe-field devices, allowing them to collect and analyze information nearer to where they’re generated, respond independently to operational conditions, and exchange data securely.

• A language-agnostic, open-standard, information-file method, JavaScript object notation (www.JSON.org) employs text to send data items consisting of attribute duos, and array information styles or other values that can be expressed as a series.

• Open-source, containerized orchestration platform Kubernetes (Kubernetes.io) automates, implements and scales data-processing applications by groups of hosts and software containers.

• A publish-subscribe protocol that uses message-brokering to communicate with a server, Message Queuing Telemetry Transport (mqtt.org) operates on TCP/IP. Standardized as ISO/ IEC PRF 20922, it was created for connecting far-flung devices with little programming or via reduced-capacity networks.

• A flow-based development tool for visual programming, NodeRED employs flow editor-programming to build JavaScripts.

• Allowing general-purpose, interpreted, high-level programming, Python (python.org) stresses readability of code by relying on whitespace, and uses an object-oriented method to help users write concise, logical software.

• A software framework for distributed, hypermedia systems, Representational state transfer (REST) details constraints for developing online services. When they comply with REST's six recommended constraints, they're named RESTful web services (RWS) and permit interoperability.

or work cells. However, he adds that relying on ISA95 levels to identify the data won’t cover all cases in the UNS. For example, it’s possible to have operations nested within unit operations, or perhaps a sensor (such as a weather station at a site) that would be defined at ISA-95’s Site level.

To solve this problem, Gerken adds users can employ metadata tags and tag properties to classify and identify information. This can help users query the UNS without needing advance knowledge of the data.

Deploying edge compute at scale is also possible by using zero-configuration platforms to assist with provisioning, orchestrating and updating edge devices. These platforms combined with application-level, remote provisioning allow quick commissioning.

“Users want more data from their equipment, and edge-compute, deployments help implement quicker network connections, device templates and online, device-communication configurations to facilitate data collection, which saves on travel to the field,” concludes Gerken. “These templates let users get data flowing in hours, where getting teams into the field previously took a week or two.”

Simple and fast

Back at Goodnight Midstream’s saltwater pipeline, its network upgrade was planned for 12 months. However, thanks to the project’s database-driven metadata model and collaboration between CSE Icon and Goodnight, it was completed in eight months. The partners report this was an impressive feat because they replaced the pipeline network’s entire architecture.

“I don't think we pulled one item out of that scope document,” says Goodnight Midstream’s Cooper.

Ignition Edge is now deployed at multiple Goodnight Midstream sites, pulling data directly from PLCs in addition to a polling gateway at the enterprise level for high-speed,

cellular-enabled skids that measure pipeline flows. The company no longer needs its former, point-to-point VPNs because communications are transmitted via MQTT with transport layer security (TLS). Not only is its architecture simpler, but the new SCADA system is more secure, reduces complexity for IT, and allows remote acknowledgements among gateways via Twilio.

“Ignition let us move to MQTT that’s optimized for low-bandwidth connections, and let us remove those VPNs,” adds Hornung. “We pump it out over the networks via its secure protocol, and it simplifies deployment.”

Cooper reports Ignition also let Goodnight Midstream overcome many common concerns for oil and gas processes. “The reservoirs determine where you are, not where you want to be,” he explains, stressing the often

extreme, -40 °F to 120 °F temperatures at its remote sites. “Ignition runs well on Linux devices, and if you pair them, then robust software and hardware lets you deploy low-power, temperature-stable devices in harsh environments.”

Finally, Ignition’s SCADA system lets Goodnight Midstream use the same platform across its entire operation, and primes its expected expansion to 30-50 sites in the future. With the old system, it was necessary to pull up the development environment and add objects to a screen. Now, Ignition uses an automatically populated tree view driven by metadata, allowing Goodnight Midstream to enter new data by simply filling in a database table. This task used to take half a day, but now it only takes 15 minutes, which lets Goodnight Midstream’s staff add new sites on their own.

Even though wireless applications are multiplying and gaining mobility, they still need onsite surveys and other best practices for success

WHAT’S left

to do for wireless? Plenty. Wireless technologies from Bluetooth to Wi-Fi to cellular have become so prevalent and always-on that it can seem like they require no thought— but they still need it.

There’s lots of evidence that wireless is ubiquitous, but several crucial tasks must be completed to deploy it successfully, safely and securely. This is especially true because wireless-enabled sensors, instruments, I/O, switches, gateways, access points and other devices are multiplying quickly—with many on automatic guided vehicles (AGV) and other mobile devices.

“When technologies reach maturity and ‘just work,’ they become expected commodities. Wireless is reaching this point, but site surveys and assessments, and individualized designs and implementations are still required for successful wireless applications,” says Corey Schoff, senior network security engineer and team lead at Malisko Engineering Inc. (malisko.com), a system integrator in St. Louis, and a certified member of the Control System Integrators Association (CSIA, www.controlsys.org). “This is why we do wireless surveys for clients with existing operations, so we can determine what they’ve got, and develop recommendations and designs to improve it. This is also important for greenfield projects, so we can predict what they’ll need to quote and assemble. Surveys also enable

troubleshooting, remediation and homing in on performance targets.”

On-the-ground design

Because onsite assessments are still essential, Schoff reports at least one full day should be spent at each facility, even if floorplans and predictive materials are already available. “Onsite time is crucial for identifying challenges that floorplans don’t show,” he says. “These include large tanks, new piping and ceiling heights."

Schoff adds that useful aspects of wireless networks include:

• Positioning access points at the same height, and attempting to have I/O, laptops, AGVs and other devices sending data at about the same heights, which can enable better transmissions;

• Arranging antennas and the distances between them for optimal coverage patterns, just as antennas focus signals like a lens to aid communications;

• Deploy more wireless devices than initially estimated to enable redundancy, and avoid relying on just one access point to cover any area.

• Because the power levels of sensors, I/O and other devices can vary depending on how often or intensely they’re used, maintain medium power levels for access points, so they can reach end-point devices and be found by them,

• Beyond obvious device characteristics, evaluate the contents of larger

settings, buildings and environments where the wireless network is located. This includes what their walls are made of, and how often their tanks, racks and other structures are full or empty.

Because their coverage areas should overlap for effective communications, Schoff reports that wireless networks should use a higher density of access points in case one fails.

“You don’t want transmitting components, access points, or other devices running at maximum power all the time,” explains Schoff. “Access points can operate at a maximum, average power output of about 23 decibel milliwatts (dBm), which is a logarithmic scale. You also want to run access points at lower power, so they’ll continue to outdistance their client/ sending devices. This is because a 10 dBM sensor or I/O may scan successfully for a 23 dBm access point, but the access point may not be able to hear those 10 dBm components.

“This situation is just like buying a residential access point with an integrated antenna for a home network. Users typically have 15-17 dBm laptops or other devices running at about 5 GHz over distances of 100-150 feet, so their access point creates a small-scale, enterprise-like, wireless network. This is why it’s important for access points to maintain medium power levels, so they can match the power and distances of client devices and serve them properly.”

Security is not a side dish

Even though many wireless standards like Wi-Fi’s IEEE 802.11 have built-in security and encryption, other multiplying and mixed-in methods may present more risk, especially when antennas and access points get into closer proximity—along with potential intruders. Fortunately, more useful protections are emerging, and applying them logically gives users their best chance to stay safe.

For instance, when Florence, Ariz., decided to upgrade the SCADA system for its water-distribution operations in 2023-24, it chose to deploy Apple’s industrial-grade servers because they’re reportedly less vulnerable. This residential water district sources mainly from a series of 350- to 800-ft deep wells, and its managers understandably wanted to isolate and protect the network monitoring and managing them. They also planned to use Inductive Automation’s web-based SCADA software on their new servers, and wanted to add a heavy-duty, wireless, microwave-backhaul network.

Florence enlisted local system integrator Ripple Industries (rippleind. com) to assist with the upgrade because it previously helped the district revamp its radios and Allen-Bradley SLC 5/05 PLCs. This facility’s headworks and filtering area consist of three sequential batch reactors (SBR) and one digester, which treat about 2 million gallons of water daily, and rely on 2,000-2,500 I/O points controlled by 10 PLCs.

“Florence may be a small town, but size doesn’t matter when it comes to being vulnerable to cyber-intrusions and incidents. Plus, it’s growing quickly, and wanted to secure its networks against the types of attacks we’ve all seen in the media,”

says Jeromy Peterson, president and owner of Ripple, an end-to-end system integrator and CSIA member.

“Many of the town’s water/wastewater networks and I/O were already isolated, but it also replaced some wireless links with in-ground cabling, gathered all its I/Os onto their own Ethernet network with managed switches, and used separate network interface cards (NIC) where possible.”

To manage its segregated I/Os, Florence’s water distribution network also expanded by implementing Rockwell Automation’s CompactLogix PLCs and 1768 ENBT network modules, which meant the I/Os wouldn’t have to interact directly with any external networks. In this case, CompactLogix is used as a communications backplane, which still lets Ethernet-based I/Os talk to a PLC, but makes sure they only address their assigned controller.

“By nature and design, Ethernetbased I/O is universally accessible.

While this is incredibly convenient, it can also increase security risks, especially given that unsecured network applications are common. At Florence, we mitigated these risks by isolating all I/O networks with 1768 networking modules,” explains Peterson.

“Over time, communication protocols steadily evolved toward faster and more open data structures, such as the shift from RS232 to Data Highway Plus. When Ethernet arrived in the controls world, it was revolutionary— you could plug in anywhere and access any device on the network. One way to reduce the risks is to separate and isolate networks across the ControlLogix backplanes. This isn’t a silver bullet for security, it does add another layer of protection. It’s not the same as whitelisting or using a data diode strategy, but it is an important first step.”

Every wireless technology has its own coverage and distance range, power requirements, speed and throughput bandwidth for moving data.

• IEEE 802.15.1 (Bluetooth) uses 2.4 GHz ISM in RF band, up to 64 kB with 672 bytes on one of 79 channels, and at 10 m, recently upped to 30 m.

• IEEE 802.11ac (Wi-Fi) uses 2.4 ISM, 5, 6 and 60 GHz RF bands, and moves 433-6,933 Mbps at 35 m indoors, while IEEE 802.11ax sends 600-9,608 Mbps at 30 m.

• ANSI/ISA100.11a and IEC 62734 (ISA100) uses 2.4 GHz at 250 kbps and about 10 m.

• IEEE 802.15.4 and IEC 62591 (WirelessHART) at 250 kbps and about 10 m, or up to 707 m with a point-to-point directional antenna.

• Long-Range Wide Area Network (LoRaWAN) at 2.4 GHz worldwide and 3-27 kbps with up to 5 km or 15 km with line-of-sight.

• Radio includes lower-frequency 900 MHz at typically 10-15 Mbps and up to about 500 m, and high-frequency 2.4 GHz at up to 450-600 Mbps and 46 m indoors and 92 m outdoors.

• Cellular includes broadband 3G at 7.2-14 Mbps and up to 120 km unobstructed, but only 5-8 km obstructed; ultrabroadband 4G at 150 Mbps and up to about 16 km; and Internet protocol (IP)-based 5G at reportedly more than 1 Gbps and possibly up to 20 Gbps, but only at about 333 m.

Likewise, Peterson reports the water utility also maintains secure, remote access to its operations via separate NICs running on PCs located on the other side of the firewall between its servers. This prevents the SCADA system with Ignition from ever connecting to the business network, and only gives external PCs and users remote data via an authorized link. The first firewall in this system is a softwarebased version that protects the server in its interactions with the remote PC, which uses a hardware firewall for protection from the rest of the world. This lets users regulate traffic between the server and the remote PC and between the PC and the larger, mainstream Internet.

“In this situation, the remote PC functions like a managed Ethernet switch, which could be hacked and attacked, but the firewall between it and the server is the protection point,” adds Peterson. “This is an old-school method that can eliminate a lot of convenience. However, if a firewall is the only protection, then an unauthorized smart phone might be able to access the VPN and log on, so users must still fight to keep their firewalls secure. Only this authorized list of users can access the remote PC, and only this PC can use this particular network to work with the servers. We could get rid of this remote PC, and let users go right to the servers, which would allow more, new capabilities. However, we only need a few, basic functions, and we only want to grant limited access for the one or two operators that need it.”

Get up and ride out

More recently, wireless is also affected by mobile equipment that’s ballooned in industrial settings. Where wireless networks in most facilities previously, mainly dealt with trucks driving in and out, now they have to face multiplying AGVs, robots and support devices rolling around, and potentially impacting wireless signals.

Figure 1: When Florence, Ariz., upgraded the SCADA system for its water-distribution operations, system integrator Ripple Industries helped it replace some wireless links with in-ground cabling, gathered all its I/Os onto their own Ethernet network with managed switches, and used separate NIC where possible.

Malisko's Schoff points out that AGVs are similar to laptop PCs because they operate at about 15 dBm, and their suppliers each have different wireless requirements that end-users and their facilities need to support. For example, Malisko recently worked with a consumer packaged goods (CPG) client to redesign the wireless network for its mostly discrete production, assembly, packaging and shipping operations, along with some metal-plating and other process applications. This client runs about 2,000 connected devices, including I/O, PLCs, switches, machines, torque screwdriver and other tools, and went from 37 access points to 103 in the same space.

“This increase in access points wasn’t because the user needed to reach more client devices. It was because they needed greater density to provide better coverage and more consistent signals,” explains Schoff. “Thirty-seven access points weren’t enough to give them the consistency they needed, plus they had some dead spots in their plant. Even though the physical space was the same, using only 37 access points meant that each client device and access point were effectively further away from each other, which reduced speed and bandwidth.

Using more access points over shorter distances also allowed the client to go from 2.4 GHz to 5 GHz communications, which further improved signal penetration and consistency.”

To upgrade the CPG client’s wireless network, Malisko conducted its onsite survey, analyzed the results to determine that 103 access points were needed, cut over to 5 GHz after they replaced the previous 37 access points, and even added a secondary, 5GHz network. The new components included Cisco’s Catalyst 9130 access points running on 802.11ax WiFi, two high-availability Catalyst 9800 wireless local area network (WLAN) controllers, and several antenna models, including internal, external omnidirectional, external directional, and ceiling-mounted directional that can cover more circular planes.

“The new network improved wireless coverage, eliminated dead zones, and provided more consistent signals,” adds Schoff. “However, some spots still had issues despite the new design. These spots didn’t match the simulation for the new network, so we resurveyed to identify and remediate them. We readjusted some antennas, moved some access points, and returned and adjusted some software settings.”

Source: Town of Florence

DigiKey is a global leader in the cutting-edge commerce distribution of electronic components and automation products. We provide an industry-leading breadth and depth of product in stock and available for immediate shipment while supporting engineers and buyers with a wealth of digital tools and resources to make their jobs more efficient.

Accelerating progress for engineers and designers

DigiKey is a leader and continuous innovator in the worldwide high-service distribution of electronic components and automation products. The global distributor offers more than 15.9 million electronic and automation products from over 3,000 quality namebrand manufacturers. The company’s reputation extends worldwide as the original industry pioneer and provider of more than 1.9 million in-stock parts ready for immediate shipment. With products available in both design and production quantities, DigiKey is the best resource for designers and buyers alike.

Through digital tools, industry-leading supplier partnerships, and an unrivaled breadth of products, DigiKey paves the way as a one-stop shop to serve customers in a unique automation landscape. DigiKey is the preferred supplier for industrial automation, control and safety products, carrying a broad portfolio of products, including advanced controls like PLCs, HMIs, motion, safety and robotics.

In addition to its core stock, DigiKey offers more than 3.6 million additional parts from more than 1,400 suppliers through the DigiKey Marketplace, augmenting the types of products they don’t currently have in their in-stock inventory.

DigiKey provides detailed technical resources and robust search functionality to help customers find the exact parts they need. It also offers a range of digital tools, an on-demand multimedia library, a comprehensive article library, community forums and more.

DigiKey’s 3+ million square feet of product distribution space in Thief River Falls, Minn., allows it to more efficiently meet and exceed customers’ expectations. They provide top technology components to leading and up-and-coming companies in 180+ companies worldwide.

From prototype to production, DigiKey has the resources and products to take your design to the next level. Learn more at www.digikey.com/automation.

We drive innovation that makes the world healthier, safer, smarter and more sustainable.

Emerson is a global leader in automation technology and software. We help customers in critical industries, like energy, chemical, power and renewables, life sciences and factory automation operate more sustainably while improving productivity, energy security and reliability.

With an unparalleled portfolio of measurement and analytical instrumentation, software, integrated systems, and services, Emerson offers the solutions you need to help take your business to bold new heights. These pioneering technologies and innovative solutions provide the actionable insights you need to meet the changing demands of the process industry while reaching your safety, productivity, and sustainability goals.

Emerson’s field-proven brands – such as Rosemount™, Micro Motion™, Roxar™, Plantweb Insight™ and Flexim, – have been helping manufacturers transform their operations and exceed performance expectations for over 50 years.

Key technologies include:

• Measurement Instrumentation: Pressure, Level, Temperature, and Corrosion & Erosion

• Flow Instrumentation: Coriolis, Magnetic, Differential Pressure, Ultrasonic, Vortex, and Multiphase

• Analytical Instrumentation: Gas Analysis, Flame & Gas Detection, and Liquid Analysis

• Industrial Wireless & Connectivity: Wireless Gateways, Networks, and Data Analytics Software

EMERSON

We support our customers in improving their products and in manufacturing them even more efficiently.

Endress+Hauser is a global leader in measurement instrumentation, services and solutions for industrial process engineering. They provide process solutions for flow, level, pressure, liquid analysis, gas analysis, temperature, recording and digital communications, optimizing processes in terms of economic efficiency, safety and environmental impact. The company serves a variety of industries, including chemical, oil & gas, food & beverage, water & wastewater, life sciences, power & energy, and primaries & metals.

Endress+Hauser, a Switzerland-based company, was founded in 1953, and expanded operations to the U.S. in 1970. More than 80% of all Endress+Hauser instruments ordered and shipped within the U.S. are manufactured in the U.S. This means customers can rely on Endress+Hauser to deliver the products they need quickly. This strong manufacturing base is complimented by a complete network of sales partners and service locations to support its customers – wherever their instruments are installed.

Premium services, customized solutions, project management and IIoT applications round out Endress+Hauser’s offering, helping customers gain efficiency, increase quality and maximize plant availability.

INDUCTIVE AUTOMATION

At Inductive Automation, our mission is to create industrial software that empowers our customers to swiftly turn great ideas into reality by removing all technological and economic obstacles.

Inductive Automation produces industrial automation software that reduces frustration and increases efficiency. Ignition by Inductive Automation® is a universal industrial application platform. It empowers users to connect to all of the data across their enterprise, rapidly develop any type of industrial automation system, and scale their systems in any way, without limits. Ignition also offers unlimited extensibility through the addition of fully integrated modules. With Ignition, users can create a variety of seamlessly integrated industrial solutions.

SCADA: Control, track, display, and analyze your process.

IloT: Make your data more accessible and efficient with MQTT.

Enterprise: Empower teams with better data to make smarter decisions.

Digital Transformation: One platform for collecting data, connecting devices, integrating systems, visualizing operations, and deploying solutions all across your organization.

HMI: Build optimized screens to monitor and control your machinery.

Alarming: Build complex alarming systems and get notifications instantly.

Reporting: Create and deliver dynamic, database-driven industrial reports.

Mobile: Easily build full-fledged monitoring and control applications in HTML5 with the Ignition Perspective Module.

MES: Track your production, manage recipes, calculate OEE, and more.

Power Monitoring: Centrally monitor, control, and optimize your power supply.

Ignition Edge: Capture, process, and visualize critical data at the remote edge of your network.

Ignition Cloud Edition: Extend your enterprise operations, leverage elastic architectures, and securely host and deploy solutions on leading cloud platforms.

Inductive Automation

For nearly 80 years, Massa Products Corporation has distinguished themselves as the leader in SONAR and Ultrasonic technologies through their expertise in electro-acoustics, focus on innovation, and commitment to delivering application-specific products.

Massa Products Corp. designs, engineers, and manufactures SONAR and Ultrasonic sensing solutions for Defense & Industrial applications. Massa’s full line of line of sensors and transducers, in addition to our robust customization capabilities, allows us to provide the industry with critical tools to increase efficiency, awareness, and agility.

Founded 80 years ago by industry pioneer Frank Massa, Massa’s robust experience and commitment to innovation has pushed the boundaries of acoustic sensing beyond what was previously thought possible. False echoes, turbulent and uneven surfaces, harsh environments, unique form factors, and precise performance are just a few challenges Massa routinely overcomes. Our pragmatic approach to product development allows us to make practical, task-specific improvements that allow our solutions to thrive where alternative products and technologies fail.

Located in Hingham, MA, Massa is a 3rd Generation Family-owned certified small business. By controlling the design, engineering, and manufacturing efforts all under one roof, Massa ensures quality and performance every step of the way from concept to final testing. It also provides for the unique ability to develop bespoke solutions and bring them to market quickly through superior collaboration in each phase.

The bottom line: Massa’s unique combination of acoustical expertise, industry experience, and manufacturing agility allow us to provide task-specific solutions that are durable, accurate, and more reliable than competing solutions.

Massa Products Corp. is ISO9001 Certified

Our mission: Making tough and reliable products. Continue being a world leader in the design and manufacture of interface instruments for industrial process control, system integration, and factory automation. Provide nothing less than the best quality in process industry products and exceptional services as our success isn’t possible without loyal customers and relationships.

Moore Industries-International, Inc. is a world leader in the design and manufacture of exceptionally rugged, reliable and high-quality field and DIN rail-mounted instrumentation for the process monitoring and control industries. Product lines include temperature transmitters and assemblies; functional safety solutions; signal isolators and converters; alarms trips and trip amplifiers; I/P and P/I converters; remote I/O and RTUs; HART® gateways, monitors and interfaces; and more. Our worldwide sales and support offices provide excellent customer service and solutions for many industries including: chemical, petrochemical, utilities, petroleum extraction and refining, pulp and paper, food and beverage, mining and metal refining, pharmaceuticals, and biotechnology.

At OnLogic, we’re creating advanced, powerful, highly-configurable small form factor computers that thrive where others fail. We empower innovative companies around the world to solve their most complex technology challenges, making the seemingly impossible, possible. We empower innovators across industries to solve complex computing challenges with systems engineered to last. Founded in 2003, our global presence helps ensure fast delivery We understand that every moment you spend searching for a reliable computing solution your business is losing time and money. That’s why we offer state-of-the-art systems with the features you need for both current and future applications. Our technology solutions are flexible enough to power everything from hyper-modern deployments of AI at the edge, to integration with existing legacy systems. We provide reliable, secure, and scalable systems that help you minimize costly downtime. How can we help you overcome your technology challenges?

As a pioneer in electrical explosion protection and a recognized expert in functional safety, Pepperl+Fuchs has been developing components and solutions for over 70 years. Our expertise in hazardous areas enables us to offer a complete range of technologically advanced solutions that are tailored to individual applications and geared toward future requirements.

Our wide-ranging process automation portfolio includes intrinsic safety barriers, signal conditioners, fieldbus technology, remote I/O, HART interfaces, E-APL and Fieldbus, level measurement, purge and pressurization systems, Human Machine Interfaces (HMI) for hazardous environments, mobile computing and communications for hazardous areas, surge protection, custom cabinets, and junction boxes.

In addition, the Pepperl+Fuchs Solution Engineering Centers (SECs) around the world offer customized system solutions complete with hazardous-location certification and documentation. We create customer-focused solutions for a large variety of industries including oil and gas, petrochemical, chemical, and pharmaceutical, as well as wastewater treatment plants and power technology.

Whether conventional applications or complex tasks—turning forward-looking concepts such as Ethernet-APL into real innovations, integrating mobile devices for hazardous areas into your processes, and providing new digital products and services for automation—this is how we pave the way for the future of automation.

Pepperl+Fuchs continuously optimizes its processes to supply you with stateof-the-art technology and high-end products you can count on. Our technical experts provide automation solutions to virtually every area of the world in our more than 40 subsidiaries on 6 continents. Around the world and in our own backyard, Pepperl+Fuchs sets the benchmark for excellence in automation, and has been named by the ARC Advisory Group—the leading technology research and advisory firm for industry, infrastructure, and cities—as one of the Top 50 Global Automation Companies.

Known around the world as a pioneer and innovator in electrical explosion protection and sensor technology, your individual requirements are at the heart of everything we do: with a passion for automation and groundbreaking technology, we understand the demands of your markets—developing specific solutions and integrating them into your processes.

SCHNEIDER ELECTRIC

Schneider’s purpose is to empower all to make the most of our energy and resources, bridging progress and sustainability for all. We call this Life Is On.

Our mission is to be your digital partner for Sustainability and Efficiency.

At Schneider Electric, we drive digital transformation by integrating world-leading process and energy technologies, end-point to cloud connecting products, controls, software and services, across the entire lifecycle, enabling integrated company management, for homes, buildings, data centers, infrastructure, and industries.

We are the most local of global companies. We are advocates of open standards and partnership ecosystems that are passionate about our shared Meaningful Purpose, Inclusive and Empowered values.

Our drive: keeping the world moving—for over 90 years. From conveyor belts to container cranes, our technology powers modern engineering. We’re constantly innovating, shaping the future of drive technology while keeping industries and our company in motion. Every day. Now and in the future.

Nearly 100 years of driving the world. Since 1931, SEW-EURODRIVE has designed and engineered the world’s finest machine automation products and systems. SEW-EURODRIVE has built its global reputation as a leader in motion control and automation by consistently delivering innovative solutions that empower industries worldwide. For over 90 years, SEW has remained at the forefront of engineering excellence, crafting products that combine reliability, precision, and energy efficiency. We create drive. We move business.

With solutions like the MOVI-C® automation platform, SEW offers a true endto-end solution. MOVI-C integrates software, controllers, inverters, and drive components into a seamless, scalable system that meets the demands of modern manufacturing.

There’s nothing basic about our core gear units. SEW-EURODRIVE’s classic gearmotors stand out for their robust design, reliable performance, and versatility across various applications.

An Industrial Super Power. With solutions designed for extreme torque, heavy loads, and challenging environments, SEW-EURODRIVE’s Heavy Industrial Gear group is the powerhouse behind some of the most demanding applications in the world.

There are no hazard conditions, only robust components. SEW-EURODRIVE engineers everything for the long haul. we use premium-grade materials like robust alloys and heat-treated metals to ensure resistance to wear, corrosion, and heavy mechanical stress, regardless of the environment.

To solve and to serve. While SEW-EURODRIVE engineers the finest industrial automation systems in the world, it is our drive to solve problems and serve customers - that distinguishes SEW-EURODRIVE around the world. First build relationships, then solutions. Let’s get to work.

TADIRAN BATTERIES

Tadiran is the world’s leading manufacturer of ultra-long life lithium batteries for industrial applications. Nearly 50 years ago, Tadiran pioneered bobbin-type lithium thionyl chloride (LiSOCl2) batteries for low-power applications at remote sites and harsh environments. Common applications include Industrial IoT, SCADA, asset tracking, AMR/AMI utility metering, infrastructure, medical, mil/aero, oceanographic, energy harvesting, toll tags and general automotive, oil & gas, flow metering, and cold chain, to name a few.

Tadiran bobbin-type LiSOCl2 batteries operate for up to 40 years with an annual self-discharge rate as low as 0.7% per year, while also delivering the high pulses required for two-way wireless communications.

Tadiran products include:

XOL Series –delivering up to 40-year operating life with low pulses

iXtra Series –delivering up to 10-year operating life with moderate pulses

PulsesPlus Series –delivering up to 40-year operating life with very high pulses

Extended temp –operating reliably in harsh environments ranging from -80°C to +125°C

TLM Series –delivering up to 20-year shelf life with high pulses of short duration

TLI Series –Rechargeable Li-ion cells featuring 20-year operating life and 5,000 charging cycles with high pulses

Tadiran industrial grade batteries are safe, environmentallyfriendly, and UL-listed with numerous third-party certifications. To choose the right battery, start by visiting tadiranbat.com and submitting an online applications questionnaire.

VEGA AMERICAS

With innovative technologies and services, VEGA develops solutions that inspire. Through our sense of simplicity and our focus on people, we are looking to the future with curiosity. Locally grounded and globally connected, together we give values – measurement values as well as human values – a home. VEGA is the HOME OF VALUES.

For more than 70 years, VEGA has provided industry-leading products for the measurement of level, pressure, density, and weight. Through constant innovation, the company has become the market leader in radar level measurement instrumentation.

VEGA has sensors in use in over one million applications around the world. Their latest innovation is the VEGAPULS 6X non-contact radar sensor, the one sensor for any application. Each VEGAPULS 6X is configured to the customer’s applicationno more navigating confusing model numbers and frequency ranges. Powered by VEGA’s new radar chip, it is VEGA’s first radar sensor with both SIL certification and IEC 62443 cybersecurity compliance, ensuring unmatched safety and security.

VEGA manufactures hygienic pressure sensors and point level devices with a brilliant advantage. The VEGABAR pressure sensors and VEGAPOINT level switches use a universal hygienic adapter system, which provides the flexibility to keep installation effort and parts inventory to a minimum. Process fittings can be selected as needed to meet application-specific requirements.

The VEGABAR 20 and 30 series come standard with a 360° switching status display, which can easily be seen from any direction. The color of the illuminated ring can be customized with one of 256 different colors, all of which remain clearly visible, even in daylight. At a glance, users can see when the process is running, if the sensor is switching, or if the sensor requires maintenance.

Standard IO-Link protocol is built into every pressure sensor and point level switch, ensuring universal, simple communication. This gives these instruments a standardized communication platform, enabling seamless data transfer and simple system integration.

VEGA Americas designs, manufactures, and sells these products throughout North, Central, and South America and is a wholly-owned subsidiary of VEGA Grieshaber KG, headquartered in Schiltach, Germany. VEGA employs more than 2,700 people around the world, 350+ of which are employed with VEGA Americas.

At Yaskawa, we help you explore what’s possible, and open new doors to opportunity. Rather than accepting the status quo, we invite you to wonder, “What if …?” And then we make it possible. That dedication to engineering and innovation is what makes us different.

Experience is often the difference between solving a problem the right way and settling for “good enough.” Our global expertise is unmatched and unquestioned, with 100+ Years of manufacturing excellence, 30 countries with sales, service, and manufacturing locations, and $4.5 billion in global sales per year.

We provide both standard products and tailor-made solutions, all backed by proven quality and reliability. We continuously work to save you money, time, and energy because we believe your machine can always run faster, smoother, and more productively. It’s about making the correct diagnoses, creating the right automation machinery, and implementing it in the best way possible.

Yaskawa low- and medium-voltage AC Variable Frequency Drives cover every automation application in the industrial plant. With outputs ranging from fractional to 16,000 HP, they have a legendary reputation for reliability and advanced technology. Our latest variable frequency drives provide simple motor setup with highly flexible network communications, embedded functional safety, no-power programming, and easy-to-use tools featuring mobile device connectivity with our Drive Wizard mobile app.

Yaskawa AC Servo Systems come to a precise position with a speed and consistency that is unmatched in the industry. Connect our rotary, linear, and direct drive motors to an advanced Yaskawa iC9200 machine controller to manage motion, logic, kinematics, safety, security, and more from a single EtherCAT-based controller utilizing our iCube Control™ platform.

Over 600,000 Yaskawa Robots are at work worldwide, with 150+ models to choose from and the strength of decades of application expertise. Our industrial robots increase efficiency, provide consistent quality, and boost productivity to deliver outstanding ROI.

Final word (for now) on valves and actuators

Control ’s monthly resources guide

SIZING AND PRESSURE DROP

This short, three-minute video, "Control valve sizing basics,” covers press-drop definition and calculation, and shows how they’re important in control valve sizing calculations and selection. It’s at https://www.youtube. com/watch?v=CNTs3xH_WHw EMERSON www.emerson.com

SINGLE- AND DOUBLE-ACTING

This 15-page document, “Your complete guide to valve actuators,” covers types, failsafes, single- and double-acting, as well as pneumatics, hydraulics, manual and electric. It’s located at www.geminivalve.com/ valve-actuator-ebook

GEMINI VALVE

www.geminivalve.com

PARTIAL STROKE TEXT DEMO

This six-minute video, “Partial stroke testing demonstration,” shows how safety instrumented systems (SIS) conduct periodic proof testing. It’s at www.youtube.com/ watch?v=N4cPx1YEXPk ABB www.abb.com

ABOUT

SPRINGS FOR FLOWS

This online article, “Guide to heavyduty actuator springs and valves springs,” shows how springs in process valves and actuators are the “silent, systematic superheroes behind flow control of fluids.” It covers actuators types, in-the-field applications, and differences between valves and actuators. It’s located at lesjoforssprings.com/insights/actuatorvalve-guide

LESJOFÖRS HEAVY SPRINGS www.lesjoforssprings.com

ESSENTIAL DEFINITIONS

This six-minute video, “What is a control valve?,” cover basic concepts like actuators, valve bodies, linear and rotary motion, and pneumatic, electrical or hydraulic control. It’s at www.youtube.com/watch?v=KtsiM1st0KA.

REALPARS www.realpars.com

SHUTOFFS AND SIGNALING

This six-minute video, “What is a control valve actuator and positioner,” covers shutoffs, signaling and positioners. It’s located at www.youtube.com/ watch?v=PsZOtcdVG6o

INSTRUMENTATION ACADEMY www.instrumentationacademy.com

SELECTION, ACTUATORS AND ACCESSORIES

This 25-page e-book, “Comprehensive guide to valves, actuators and controls,” covers design and selection, actuators and automation accessories. They were developed from the book, Valve and actuator technology, by Wayne Ulanski. It’s at svf.net/application/files/5017/0895/9789/SVF_ eBook_A_Comprehensive_Guide_to_ Valves__Actuators_and_Controls.pdf

SVF FLOW CONTROLS www.svf.net

GLOBE, GATE, BALL AND BUTTERFLY

This 12-minute video, “Control valve types,” explains how ball, butterfly, diaphragm, gate, globe, needle, pinch, plug, relief and safety valves work, explains the advantages and disadvantages of each, and discusses rotary and linear motion designs. It’s at www. youtube.com/watch?v=DVd0TW7HffU SAVREE courses.savree.com

CLASSIC HANDBOOK TURNS

50

Now in its 6th edition, Emerson’s 355-page Control Valve Handbook includes 15 chapters on types, performance, accessories, selection, special and severe service, desuperheaters, steam conditioning, turbine bypass, installation and maintenance, standards, isolation, sustainability and safety instrumented systems. It’s at https://www.emerson. com/documents/automation/controlvalve-handbook-en-3661206.pdf EMERSON www.emerson.com

CASTING VALVES IN KOREA

This 16-minute video, “Manufacturing process for industrial valves,” demonstrates how Samyang industrial, process valves are produced at a 62-year-old cast valve plant in South Korea. It's at www.youtube.com/ watch?v=9TdkyVc9R_A FACTORY MONSTER www.youtube.com/@Factory_Monster

CHECKS AND SAFETY TYPES

This 17-minute video, “Valves basic types and operation,” covers symbols, swing and lift checks, relief and safety. It’s at www.youtube.com/ watch?v=W5gC-y7aEO8 RUSSELL HILLS www.youtube.com/@russellhills2419

MOSTLY RECENTLY

The 2021 version of this Resources guide on valves, actuators and positioners also features 10 useful items. It’s at www.controlglobal.com/manipulate/actuators/article/11293627/ resource-guide-valves-actuators-positioners-get-moving CONTROL www.controlglobal.com

This column is moderated by Béla Lipták, who also edits the Instrument and Automation Engineers’ Handbook, 5th edition , and authored the recently published textbook, Controlling the Future , which focuses on controlling of AI and climate processes. If you have a question about measurement, control, optimization or automation, please send it to liptakbela@aol.com

When you send a question, please include your full name, job title and company or organization affiliation.

Generating successful wind turbine optimization

Our experts explain the best options for maintaining control and measuring wind speed and direction

Q: I’m working on a wind turbine control system and would like your advice on selecting the best wind direction sensor for yaw positioning and the best wind speed detection anemometer for turbine blade pitch control. I’m looking at mechanical anemometers and noncontacting sensors (ultrasonic, LiDAR, etc).

Z. FRIEDMAN control engineer solarh2cell@aol.com

A1: In 1450, Italian architect Leon Battista Alberti invented the first mechanical anemometer. Today, designs include mechanical (vane, cup, propeller, turbine) units. They also include thermal, ultrasonic, pitot and laser-Doppler types.

Mechanical anemometers: In this design, vanes rotate with an angular velocity proportional to wind speed. The three-cup anemometer is insensitive to wind direction. Usually, its shaft drives a direct current (DC) tachometer. These designs often include a wind direction sensor (Figure 1).

Impeller designs: These use a shaft-driven speed transducer and a tail, which always points the impellers into the wind. This type of instrument detects both wind speed and direction. The response speed of an anemometer is expressed in terms of the length of wind that must pass through the meter before the

velocity sensor response amounts to 63% of a step change in velocity. This is known as the distance constant, and is generally expressed in feet. A typical distance constant for commercially available units is 6 ft (1.8 m).

Thermal anemometers: These hot-wire anemometers operate as heated thermopiles that are cooled at a rate proportional to the air velocity passing by their probe tips.

Ultrasonic anemometers: Here, the time of flight of sonic pulses between pairs of transducers are measured. They’re suitable for exposed, automated wind-turbine applications, where the accuracy and reliability of traditional cup-and-vane anemometers are adversely affected by salty air or dust. One of their disadvantages is reduced accuracy caused by precipitation and temperature changes because they change the speed of sound.

Acoustic resonance anemometers: These traditional, ultrasonic anemometers rely on time-of-flight measurement, while using ultrasonic waves in small cavities to perform their measurements. In their cavities are arrays of ultrasonic transducers, which create sound patterns at ultrasonic frequencies. As wind passes through these cavities, changes in wave property occur, which the sensors use to provide accurate horizontal measurement of wind speed and direction.

Pitot tubes: These are differential-pressure devices with a pitot opening in the center of the tube pointing into the direction of the wind. This total pressure port detects a higher pressure than the static pressure of the atmosphere, which is detected by the static ports on the sides of the outer tube. The difference between the two pressures indicates the wind velocity. Because of their low cost, these types of wind velocity sensors are popular, but they have low accuracy, low rangeability, and are limited to clean and ice-free applications, which wind turbines can seldom provide because plugging of the pitot opening can result in serious errors.

Figure 1: Combined wind speed and direction detector

Wind vane

Angle transducer

Revolution speed transducer

Three-cup anemometer

Laser-Doppler anemometers (LDA): When light is beamed into the atmosphere, dispersing particles reflect it, resulting in the Doppler shift in the returning frequencies, which indicates wind velocity. That’s because particles under 5 microns move at the same velocity as air.

I asked Dr. Eric Simley, a senior researcher at the National Renewable Energy Laboratory (NREL), to offer further informtion based on his much deeper knowledge of the field.

BÉLA LIPTÁK liptakbela@aol.com

A2: The challenge with sensors that measure the wind on the nacelle is they measure flow in the wake of the rotor, and are disturbed by the presence of the nacelle (Figure 2). For wind speed, a nacelle transfer function is usually determined and applied to the measurements, so they better represent undisturbed, freestream wind speed. However, there’s uncertainty in the nacelle transfer function correction.

The relative wind direction measured on the nacelle usually must be corrected to remove biases caused by the wake rotation or skew behind the rotor. This correction generally varies with wind speed or rotor speed, and might not completely remove the error. Sometimes a single bias correction is applied to remove the overall bias, but there could be positive errors for some wind speeds and negative errors for others.

One other issue I’ve observed with nacelle-based, wind-direction measurements is that, in addition to biases, they can overestimate the magnitude of the wind direction relative to nacelle orientation. For some of our wake steering experiments, where wind turbines are intentionally misaligned with the wind to deflect their wakes away from downstream turbines, we’ve noticed that the nacelle wind vane measures a larger misalignment than measured by a nacelle

LiDAR, so the true achieved yaw misalignment appears to be lower than intended. I expect this only causes issues for wake steering. For standard yaw control, where the objective is to orient the nacelle into the wind, measuring the sign of the relative wind direction is more important than perfectly measuring the magnitude.

Because of uncertainties related to the nacelle transfer function, and because the wind measured at a single point on the nacelle might not represent the effective wind speed the entire rotor experiences due to wind shear or veer, nacelle-based, wind-speed measurements are only used for supervisory control purposes to determine when the wind speed is above cut-in or cut-out speeds. Model-based, wind-speed estimators are used for torque and blade-pitch control purposes. These estimators use an aerodynamic model of the rotor together with the measured generator speed, generator torque and blade pitch to estimate the rotor-effective

wind speed. The use of wind speed estimators for wind turbine control is discussed in a paper that also provides an overview of wind turbine control in general (wes.copernicus.org/ articles/7/53/2022).

Anemometers are traditionally only installed on top of the nacelle Based on my experience, modern turbines from the past five years use sonic anemometers for nacelle wind speed and direction measurements. I believe they’re more accurate because they react faster to changes in wind speed or direction, and are probably more reliable, but I don’t have direct experience comparing the two technologies.

DR. ERIC SIMLEY senior wind energy control researcher National Renewable Energy Laboratory Eric.Simley@nrel.gov

For an extended version of this article, including more explanation of measurment and speed control options, visit www.controlglobal.com.

Figure 2: Nacelle system and components Source: Lindy Energy

Flow goes deep and wide

Flowmeters expand capabilities and operating ranges to find higher-resolution details in real-time

PARTICLE

MONITOR FINDS ENTRAINED

SAND

Rosemount SAM42 acoustic particle monitor can detect extremely low concentrations of entrained sand in real-time with high repeatability and sensitivity. Its compact, nonintrusive, all-in-one design features onboard data processing, explosionproof protection, and installation with no pipe penetration or modifications. It’s available in two versions that accommodate -40 °F (-40 °C) to 554 °F (290 °C) pipe surface temperatures. SAM42 can be mounted on 2- to 48-inch diameter pipes.

SENSORS MEASURE UP TO 50 GPM AND 212 °F

ProSense FSC mechatronic digital flow sensors monitor liquids, and provide flow sensing up to 50 GPM and 212 °F. They're available with 3/4-, 1- or 1.5-inch, female national pipe tapered (FNPT) connections, and provide two analog, frequency or switch outputs based on flow or temperature. A pushbutton allows quick, easy setup, while a bright, two-color, digital display shows variable data. ProSense sensors are UL Listed, CE marked, RoHS compliant and IP65/67 protection rated.

EMERSON www.Emerson.com/RosemountSAM42

SINGLE-USE CORIOLIS FOR BIOTECHNOLOGY

AUTOMATIONDIRECT

www.automationdirect.com/flow-sensors

PADDLEWHEEL WITH SOLID-STATE ELECTRONICS

Proline Promass U 500 single-use, Coriolis flowmeter has an installed or tabletop base unit containing its power supply, exciter, sensors and other electronics. It specifies 0.12 to 75 l/min flow rates, and covers this range with one nominal diameter without compromising accuracy of 0.5% of mass flow. Its disposable components comply with regulations, such as biocompatibility defined by USP <87> and <88> and ISO 10993.

ENDRESS+HAUSER eh.digital/3BaGUD7

STABLE VORTICES + SSP = LESS NOISE

VY Series vortex flowmeters have a sen sor design that identifies and eliminates noise using spectral signal processing (SSP) to capture a stable vortex. With sizes up to 16 inches, the flowme ter delivers what’s reported to be the shortest face-to-face length for reducing upstream, straight-pipe-length require ments. VY’s Total Insight Health Check software self-diagnoses parts like the vortex shedder bar and sensor element. It complies with explosion-proof standards and is SIL2 certified.

YOKOGAWA tinyurl.com/3xbewtuc

RFO flow-rate monitors from Gems combine a compact paddlewheel design with solid-state electronics, offering accurate measurement and integral visual confirmation. With brass, stainless-steel or polypropylene construction, they can handle diverse settings and pressures up to 500 psi. Featuring pulsed outputs of 4.5 to 24 VDC, RFO is suitable for water purification, chemical metering and semiconductor processing.

GALCO www.galco.com

THERMAL FOR H2 HAS 100:1 TURNDOWN

Hydrogen (H2) ST flowmeters feature 100:1 turndowns and flow ranges from 0.25 to 1,000 SFPS (0.07 NMPS to 305 NMPS). Their transmitter can be integrally or remotely mounted at 1,000 feet (305 m); they’re available with DC or AC power; display flow rate and totalizer on an LCD touchscreen; and use HART, Modbus, Foundation Fieldbus and Profibus protocols. They're globally approved for iDiv.1/Zone 1 with a NEMA 4X/IP 67 aluminum or 316 stainless-steel enclosure.

FLUID COMPONENTS INTERNATIONAL www.fluidcomponents.com/products/mass-flow-meters

LEVEL AND GEOMETRY FOR FLOWS

Optiwave 1540 is a compact, 80 GHz radar level transmitter that measures flows by determining a channel's level and geometry. It's ideal for wastewater, ca nals, flood-warning, non-contact level measurement in IBCs, and chemical tanks up to 5 bar (72.5 psi). Optowave 1540 is also waterproof in accordance with IP68. Its measuring range is 0 to 15 m (49.2 ft), and it networks via two-wire, 4-20 mA HART7.

KROHNE

krohne.com/en/products/level-measurement/level-transmitters/radar-fmcw-level-transmitters/optiwave-1540

FLOW, DENSITY, VOLUME, TEMP AND SOLIDS

All in one device, VersaFlow Coriolis mass flowmeter measures mass flow, density, volume, temperature and sol ids content. It’s designed for liquids, gases, high/gradually varied flows (GVF) and dual-phase fluids. It has straight and bent tube designs, secondary pres sure containment around its sensor, two-phase flow indication, NAMUR NE107 compliant diagnostics, easy draining and cleaning, stable and repeatable measurements with 100% gas entrainment, and immunity to cross talk.

HONEYWELL www.honeywell.com

DP TRANSMITTER HAS ±0.1% ACCURACY

1800DP differential pressure transmitters provide accurate measurement in flow applications. All units include external pushbuttons for device setup and calibration, enabling users to configure the devices in hazard ous areas. They’re also available with three- or five-valve manifolds. 1800 Series conventional transmitters for continuous process monitoring achieve standard ±0.1% accuracy.

SOR INC.

www.sorinc.com/products/conventional-differential-pressure-transmitters-flow-transmitters/1800-series-differential-pressure-transmitter

MAGNET-CONTROLLED FLOW SWITCHES

VHS06 flow switches have metal construc tion, magnet-controlled switching for repeatable, longtime performance, and a plug connector for easy setup. They can be deployed in heating, cool ing circuits, water treatment or drinking water applications, and can be tailored to specific needs with custom flow-switching points. VHS06 also features low pressure drop, immediate response, high repeatability, setpoint that depends only on flow, and longterm, stable setpoints without spring fatigue.

SIKA www.sika-usa.com

ULTRASONIC, NON-INVASIVE, BUDGET-FRIENDLY

Dynasonics non-invasive flowmeters easily and efficiently measure flows by clamping onto the outside of pipes, and use ultrasound to measure flow and thermal energy without pipework or process interruptions. Budget-friendly because they’re non-invasive, these sensors require minimal implementation effort. Dynasonics have no contact with media they measure and no moving parts, so they’re virtually maintenance-free.

BADGER METER www.badgermeter.com

IO-LINK AND BIDIRECTIONAL FLOW

DUK ultrasonic flowmeter offers integral temperature measurement, IO-Link, bidirectional flow capabilities, switching, batching and transmitting functions, two configurable outputs, and a digital touchscreen that rotates the display in 90 increments depending on the installation position. In addition, DUK is designed for water and viscous media up to 68 cSt. It’s designed with the future in mind, offering easy onsite repair and replacement.

KOBOLD INSTRUMENTS INC. 412-788-2830; www.koboldusa.com

The AI reality – Part 1

Large language models can do amazing things, just don’t confuse them with human thoughts

GREG MCMILLAN

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

GREG: In this column, we’ll learn what can and can’t be done with artificial intelligence (AI) to help us deal with the challenges in our profession. We’re fortunate to have a longtime associate, Randolf Riess, offer insights on what works and what doesn’t when it comes to AI. Randy, how can we reduce confusion and understand the AI we see today?

RANDY: I've been working with AI for the last few years, and it's been interesting because the hype of what AI can do has it orbiting the moon, so to speak. However, what AI can actually do is closer to an altitude of a few thousand feet.

Specifically, most of what people call AI are large language models (LLM), and they do exactly what they sound like—they model language. They’re trained in language to be word predictors. They take a set of words as an input (prompt), and generate words that most fit the input based on the model’s training. For example, if the prompt is a question about quantum physics, the LLM generates the words that are most often associated with an answer to that question about quantum physics. But the LLM doesn’t understand quantum physics. It just regurgitates words.

The problem arises because the answer is in the form of conversational natural language that people associate with a human. Thus, they start to associate human-like thinking with the human-like response, even though there is no thinking going on in the AI. So, people start to extrapolate beyond what AI can do. It’s personification.

Smaller LLMs can be trained with an individual’s data to perform specific tasks. However, smaller size also means they may not perform as desired compared to the massive AI models, but can sometimes return better results because they’re trained using specific data. Using smaller models requires a data scientist to train and test them.

GREG: What does AI do well?

RANDY: Mostly, generate words. AI can be used to translate from one language to another (see the original use of LLMs from Geoffrey Hinton at https://bit.ly/ghinton).

AI does a good job of consuming various types of disparate text data in a prompt, generating a summary. This is the so-called retrieval-augmented generation (RAG), which uses other technology to search for information, provide that information in the prompt, and use the LLM to summarize it.

AI does a great job of sounding human and even sounding like it knows what it’s talking about. However, it's like getting advice/information from Tik-Tok. You have no idea where the information came from or if it's accurate.

GREG: What does AI do poorly?

R ANDY: Anything analytical. Specifically, anything that can be figured out to be the right answer, including math, logic and logistics. LLMs are built to sound and act like a human as their primary function, while being correct is secondary (or tertiary). LLMs introduce variations of answers to sound more human, even when that variation includes incorrect answers.

LLMs do a poor job when results need to be consistent. Even by setting LLM parameters to minimize randomness, it’s almost impossible to get the same answer every time. Expect LLMs to be wrong 10-20% of the time.

Please note that this excludes any feedback control application from a purely analytical perspective.

GREG: What is an AI technology win?

RANDY: A multimodal LLM can take, as an input, data that’s more than text. Specifically, it can take images, audio and some say video,

but I’ve never tried it. The ability to take one or more images as an input is groundbreaking, though still very new. Multimodal LLMs started to be useful with the release of OpenAI’s GPT4o and Anthropic’s Claude 3.5 Sonnet, as well as a few others introduced around the same time. What I’ve seen multimodal LLMs do with respect to computer vision tasks, without any special training, is amazing.

Multimodel LLMs can send an image, ask a question, and, generally, return an answer. The more information available and about what you want it to do, the better the results. It's technology that’s as close to “thinking” as I’ve seen from any AI. Of course, it's not actually thinking and can be easily fooled. However, no training is required. You write the prompt, send the image, and the AI returns text results about what’s in the image in a few minutes.

GREG: What are possible wins for industrial applications in maintenance and grounds monitoring?

R ANDY: I worked with several industrial companies that spent a lot of money on people and equipment for capturing images from drones or walking rounds that could be processed into visual, digital-twin reconstructions. However, the vast amount of that imagery goes into storage because the companies lacked the human power to look through it all. Multimodal LLMs are an extra set of eyes on images.

Multimodal LLMs look through images for a wide range of use-cases including:

• Detecting routine maintenance issues, such as insulation missing from pipes, conduit body covers missing, rust and corrosion on pipes and tanks over time, slow leaks, unsafe equipment, and people/vehicles/equipment in areas where they shouldn’t be;

• Using drones to detect faults in hard-to-reach locations, damaged devices, equipment inventories, animal nests, or to inspect powerlines, cell towers and distillation columns;

• Reading identification tags on equipment and locating them with the image GPS;

• Estimating volume of ditches and mines, tree counts and vegetation, or animal identification; and

• Grounds maintenance, including fencing upkeep, downed trees, erosion, etc.

GREG: What are some AI limitations in industrial applications?

RANDY: These are mostly offline applications that rely on many responses over time to determine a condition, which also mitigates the error rate of LLMs. Multimodal LLMs don’t handle time-critical, safety issues well. They aren’t reliable for lifesaving or safetyrelated uses. They can indicate a safety-related condition that must be verified by a human. That is, if a plume of smoke is detected in a tank farm, they can send an alert, but must not be

relied on as the only means of detecting a fire on a tank farm. Multimodal LLMs are, at best, better-than-nothing technology for time-critical safety.

The main reason multimodal LLMs can’t be used as safety systems is because they’re massive models hosted on cloud computers by companies such as OpenAI, Anthropic, Meta, etc. They must be accessed by an application program interface (API) call over the Internet. Large, hosted LLMs aren’t highly available and response time isn’t guaranteed. OpenAI serves requests from an eighth grader researching New Zealand with the same response time, accuracy and reliability as it would an image of a burning tank farm. LLMs or connections to them can go down at any time. The hosting company simply doesn’t charge you for requests it can’t respond to when it’s down, restricting it to offline usecases that aren’t time-sensitive.

GREG: Stay tuned for the next column to learn about how we can capture process control knowledge that’s in the heads of all the gray-hairs who are retiring.

JIM MONTAGUE Executive Editor jmontague@endeavorb2b.com

"Some clichés and common phrases are used to halt discussions and choke off debate, and can be repeated over and over to keep repressed populations docile and compliant."

Bad language

Mind-numbing buzzwords can serve much darker purposes

IF you checked out this month’s “Edge borders on the move” cover article (p. 26), it may be apparent I’m struggling with the edgecomputing concept. The edge used to be data processing on the plant-floor, out in the field, and removed from the centralized control rooms where it used to be stuck.

However, microprocessors everywhere let software process data anywhere, and simpler networking via MQTT and other formats shorten distances between data producers and users—giving the right hand a better shot at knowing what the left is doing.

This flexibility to crunch numbers and data anywhere also renders the edge pretty much meaningless. It, along with cloud-computing and even digitalization, are being shown up as just more ridiculous and distracting buzzwords like Big Data, Industrial Internet of Things and Industry 4 point whatever.

Of course, artificial intelligence (AI) is the big “it” phrase lately. And, while I’m sure it can assist or perform many useful tasks, their combined numbers are a few pebbles next to the mountain of hype and over-promises, which will obviously never come anywhere close to being fulfilled no matter how capable AI actually turns out to be.

So what’s the point of spouting baloney? As always, talk is cheap and easy. We can look like we’re doing something—and reassure ourselves we are, if we’re unconscious enough—even though we’re not really contributing anything. Plus, there’s a chance we might find a rookie or a sucker to listen to us, though it’s unlikely to be for very long.

Now, I know some buzzwords are needed to serve as social lubricant, and allow people to approach and adapt to new and unfamiliar topics. It’s especially understandable at a time when technologies are changing so quickly, and many of us are grating on each other so much more as the Internet shrinks the world, and often punctures how terrific we used to

think we are. Unfortunately, they’re almost instantly overused in place of solid action and progress, and immediately and inevitably go from being an aid to a crutch.

Personally, my objection to buzzwords and clichés it that they’re unspecific, so they get in the way of relaying useful facts and telling good stories that will keep eyeballs on pages or screens. However, I’ve been learning they’re potentially even more destructive than I previously thought.

The late, great comedian George Carlin reported on this in his stand-up routines on euphemisms and their deadening effects. Maybe check YouTube for his excellent diatribe on how simple words like “shell shock” evolved into lengthy, soulless phrases like “post-traumatic stress disorder."

More recently, I ran across the thoughtterminating cliché introduced in the 1960s by psychologist Robert Jay Lifton. It was reintroduced recently by author Amanda Montell as part of her “Sounds like a Cult” podcast. Their observation is that some clichés and common phrases are used to halt discussions and choke off further debate. Some examples include: “You’re thinking too much,” “Here we go again,” “It’s all good,” and “It is what it is.” These and so many other bromides are mindnumbing enough on their own, but this problem is compounded when they’re repeated over and over to keep repressed populations docile and compliant.

As a long-time, professional pest, I think you know how I’d recommend responding. Keep questioning and pushing for useful solutions, if you’re still able. I’m just thankful that clichés are so boring that human brains can’t wait to move on the something more exciting —and hopefully constructive. I’m also glad that Futurama ’s Hypnotoad character is popular beyond his recent gig as Texas Christian University’s rogue mascot. All glory to the Hypnotoad!