Data Acquisition - A Step in the Direction of Process Improvement

Data acquisition, like an equipment acquisition, is the procurement of an asset. Data is an asset. It helps an operator evaluate process or business conditions and make decisions that impact the success of the organization. Let’s define data acquisition as the sampling of signals that represent a measurement of physical conditions and the conversion of those signals into a numeric form that can be processed by a computer. A data acquisition system will generally consist of sensors, transmitters, converters, processors, and other devices which perform specialized functions in gathering measurements and transforming them into a usable form.

DAQ incorporating data acquisition, process
control, recording, display and networking
in a single compact unit
Courtesy Yokogawa Corp.

Industrial process operators and stakeholders benefit from the collection and analysis of data by enhancing performance of valuable facets of the process or activity. Data acquisition, commonly known as DAQ, is widely employed in high stakes and sophisticated processes where there is a true need to know current conditions. A desire for increased profit drives the need for increased process output and efficiency. A desire to reduce risk of loss drives the need for reduced downtime and improved safety. Today, there are likely many useful applications for data acquisition that are not being tapped to their fullest potential. The modest cost and simplicity of putting a data acquisition system in place, compared to the benefits that can be derived from a useful analysis of the data for your operation or process, makes the installation of a data acquisition system a positive move for even small and unsophisticated operators in today’s market.

What we call DAQ today started in the 1960’s when computers became available to businesses of large scale and deep pockets. By the 1980’s, personal computers employed in the business environment could be outfitted with input cards that enabled the PC to read sensor data. Today, there is an immense array of measurement and data collection devices available, spanning the extremes of price points and technical capability. For a reasonable cost, you can measure and collect performance data on just about anything. You can get an impression of the simplicity, modularity, and compactness of a modern system with a quick review of this product.

Data acquisition has an application anywhere an operator or stakeholder can benefit from knowing what is occurring within the bounds of their process or operation. Here is a partial list of the many physical conditions that can be measured in industrial settings:

Other examples of industrial data acquisition equipment
Courtesy Yokogawa Corp.

• Temperature
• Pressure
• Flow
• Force
• Switch Open or Closed
• Rotational or Linear Position
• Light Intensity
• Voltage
• Current
• Images
• Rotational Speed

Consider your industrial process or operation. Are there things you would like to know about it that you do not? Would you like to increase your insight into the workings of the process, how changes in one condition may impact another? Do you know what operating condition of each component of your process will produce the best outcomes? Is reducing maintenance, or heading off a failure condition before it occurs something you would like to have in your operation? Applying your creativity, ingenuity and technical knowledge, along with the help of a product expert, will help you get the information you need to improve the outcomes from your industrial process or operation.

Miller Energy - Industrial Instrumentation and Process Control Solutions

Miller Energy is a Manufacturer's Representative and Distributor of industrial instrumentation and process control equipment.  Miller is committed to exceeding customers expectations by providing an unparalleled level of customer service and local technical support.

Miller offers the most comprehensive line of measurement, control, and communication solutions in industry today. The products provided by Miller solve challenging applications in the industrial gas, power, refining, chemical / petro-chemical, food & beverage, water/wastewater, and pharmaceutical markets.

Valve Selection - When to Choose a Butterfly Valve

Industrial process control valves are available in a staggering array of materials, types, and configurations. An initial step of the selection procedure for a valve application should be choosing the valve type, thus narrowing the selection field to a more manageable level. Valve "types" are generally defined by the closing mechanism of the valve.

Butterfly Valve
Courtesy Crane CPE

A butterfly valve has a disc that is positioned in the fluid flow path. It rotates around a central axis, the stem, through a 90 degree arc from a position parallel to the flow direction (open) to perpendicular (closed). A variety of materials are used in the valve body construction, and it is common to line the valve with another material to provide special properties related to the process media.

What might make a butterfly valve a beneficial selection over another valve type?

• The closure arrangement allows for a comparatively small size and weight. This can reduce the cost, space, and support requirements for the valve assembly.
• Generally low torque requirements for valve operation allow for manual operation, or automation with an array of electric, pneumatic, or hydraulic actuators.
• Low pressure drop associated with the closure mechanism. The disc in the flow path is generally thin. In the fully open position, the disc presents its narrow edge to the direction of flow.
• Quarter turn operation allows for fast valve operation from fully closed to fully open.
• Some throttling capability is provided at partially open positions.
• Small parts count, low maintenance requirements.

What may be some reasons to consider other valve types?

Butterfly Valve
Courtesy Crane CPE

• Butterfly valve throttling capability is generally limited to low pressure drop applications
• Cavitation can be a concern.
• Some sources mention the possibility of choked flow as a concern under certain conditions.

Butterfly valves, like other valve types, have applications where they outperform. Careful consideration and consultation with a valve expert is a first step toward making a good selection.

Process Measurement and Control Essentials – Industrial Pressure Transmitters

Industrial Liquid Level
Transmitter
Courtesy Yokogawa Corp.

The measurement and control of fluid pressure is ubiquitous throughout many industrial processes. Measurements of pressure, directly and indirectly, provide real time information about what is happening in places that cannot be seen, such as inside a pipe, tank, or machine. The very nature of “process” suggests movement and change, the control of which is necessary to produce a consistent desirable outcome. Industrial pressure transmitters employ specific technologies and physical principals to derive a measurement of process pressure, then deliver or transmit, the measured value to a controller or recording device.

Fluid pressure tells a process operator much about what is currently happening. The pressure variable can be used to determine, among many industrial process elements:

• Degree to which the process is conforming to a recipe or specification
• Whether machinery is performing within its specified operation range
• If conditions of the process remain within the bounds established for safety
• A quantity measurement of flow, mass, or volume

Differential Pressure
Transmitter
Courtesy Yokogawa Corp.

Global industrial processes have widely varying physical arrangements, operating environments, and measurement requirements. Manufacturers of industrial pressure transmitters have responded with an immense array of transmitter technologies, arrangements, and configurations. When selecting the best suited pressure transmitter for your application, consult a sales engineer and consider some of the following:

• Signal requirements – Type, distance, possible sources of interference
• Device environment – Hazards, extreme conditions of temperature or corrosion
• Accuracy and stability of measurement
• Response time to changes in the process condition
• Ratings and certifications required for the device
• Configuration, arrangement, and mounting aspects of the transmitter device

Explore the differing technologies and how they can be best applied to implement or improve your process. Experienced sales engineers can be a useful sounding board for discussing your needs. Take advantage of their extensive experience with a wide array of process applications.