Process

Instrumentation
& Sensors
WINTER EDITION
Contents
3 — Tips on sensor selection

10 — (EN) Weighing module Novego

11 — Temperature sensors: Make the right choice, RTD vs. TC

15 — High Precision, hygienic design weighing solution

impresses the pharmaceutical industry

19 — Inertial measurement unit sensors lower risk for

autonomous vehicles

24 — Process sensors and advanced analytics efficacy

28 — Get flow measurement right the first time

32 — Innovative, hygienic, precise and easy to install:

weighing module Novego®

2
Tips on sensor selection
 Back to TOC
Many types of sensors are available to manufacturers, and knowledge
about the application type and basic operation conditioning requirements
can create a more informed and accurate sensor selection choices for
factory automation and machine control. How to find sensors, operating
requirements, sensor explanations are provided.

A t the beginning of my engineering career, a sales engineer from a sensor compa-

ny came to our plant, thumped a substantial and well-worn sample case down on
our conference room table, flipped the case open to expose dozens of neatly packed
sensors and said, “Let’s test your part.”

He knew what he was talking about. Engineers must test the sensor with the part.

Three ways to find the right factory automation or machine

control sensor
Locating the right sensor for the application requires:

1. Narrowing the search to a short list of sensors

2. Ordering samples, and

3. Testing the sensor with the part, the actuator, or the machine under conditions
similar to where the sensor will be installed.

3
Tips on sensor selection

Top six operating condition requirements for sensor selection  Back to TOC

When identifying the short list of sensors to sample, make sure the set—based on the
manufacturer’s data sheet—meets the basic operating conditions of the application.
Here is my list of the top six operating condition requirements:

1. Temperature range

2. Size

3. Protection class

4. Voltage range

5. Discrete or analog output

6. Answering the question: Will it be beneficial to be able to change parameters? If

the answer is yes, then an IO-Link enabled sensor should be considered.

Six more requirements for factory automation sensor selection

Here are an additional six requirements for more specific considerations:

1. Response speed

2. Sensing range

4
Tips on sensor selection

3. Repetition accuracy  Back to TOC

4. Electrical connection

5. Mounting type

6. Answering the question: Is on-sensor visual display required?

Eight must-know factory automation sensor terms, sensor

technologies, sensor selection tips
The most common types of sensors used in manufacturing, factory automation, and
machine control are proximity sensors, position sensors, inductive sensors, flow
sensors, optical sensors, and vision sensors. A signal converter is a critical related
technology. See tips for sensor selection and other sensor technology insights for
each.

What is a proximity sensor? Prox sensor selection tips

A proximity sensor detects the presence of nearby objects without physical contact.
Presence sensors are discrete output devices. Typically, a magnetic proximity sensor is
used to detect when an actuator reaches a specific position by sensing a magnet locat-
ed in the actuator.

It is not a good idea to purchase actuators from one company and magnetic proximity
sensors from another. While the sensor manufacturer may say the sensor is compatible
with X, Y, and Z actuators, the reality is variations in magnets and mounting positions
can cause sensing issues. For example, the sensor may activate when the magnet is not
5
Tips on sensor selection

in the correct position or it may not activate at all. If the manufacturer of the actuator  Back to TOC
offers a matched proximity sensor, it should be the first-choice sensor.

Transistor-based proximity sensors have no moving parts and long service lives. Reed-
based proximity sensors use a mechanical contact and have shorter service lives and
cost less than transistor models. Reed sensors are best applied in high-temperature
applications and applications where ac power supply is needed.

What is a position sensor? Position sensor selection tips for

factory automation
Position sensors have analog outputs indicating the position of the actuator based on
the position of the magnet on that actuator. Position sensors provide flexibility from a
control standpoint. The control engineer can determine a range of set points to con-
form to component variations. Since these position sensors are based on magnets, like
proximity sensors, it’s a good idea to purchase the sensor and actuator from the same
manufacturer if possible. Position sensors can be acquired with IO-Link functionality,
which also can simplify control and parameterization.
What is an inductive sensor? Inductive sensor selection tips for factory automation

Inductive proximity sensors utilize Faraday’s law of induction to indicate presence of an

object or an analog output position. The most critical aspect of selecting an inductive
sensor is determining what type of metal the sensor is detecting because that deter-
mines sensing distances. Nonferrous metals can reduce the sensing range by more
than 50% compared to ferrous metals. Sensor manufacturer data sheets should provide
the necessary information for sample selection.

6
Tips on sensor selection

metric. Specify the form factor most suitable for the allotted space. Consider whether  Back to TOC
machine mounted sensors should have indicator lights or a display screen as an aid for
operations personnel. If changing setpoints quickly is necessary, investigate IO-Link
enabled pressure and vacuum sensors.

Flow sensor selection tips for machine control applications

Like pressure and vacuum sensors, flow sensors are specified by flow range, size, and
setpoint variability. They can be ordered with on sensor display options. Flow sensors
can be specified for relatively low flow rates for one area of the machine and for whole
machine applications.

Optical sensor- sensor types and sensor option, selection tips

The most common optical sensor options are photoelectric—diffuse, reflective, and
through beam. Laser sensors and fiber-optic sensing units also fall under the optical
sensor category. Photoelectric sensors are mostly presence sensors.

Photoelectric sensors detect the presence of an object via reflected light or an inter-
rupted beam of light. These sensors are among the most applied sensors in manufac-
turing due to their low cost, versatility, and reliability.

Diffuse photoelectric sensors do not require a reflector. They are used for sensing the
presence of nearby objects and are inexpensive sensors.

Through beam offers the longest sensing range and is installed at two points with an
emitter unit and receiver unit. Garage door safety sensors are through beam sensors.
Presence is indicated when the beam is interrupted. One interesting variate of the
7
Tips on sensor selection

through beam is the fork  Back to TOC

light sensor that features
an emitter and receiver
in one compact unit. Fork
light sensors are used for
sensing the presence and
absence of small parts.

Reflective photoelectric
sensors have a sensor and
a reflector and are used
for mid-distance presence
sensing. For accuracy
and cost, they sit mid-
way between diffuse and
through beam.

Fiber-optic sensing units

are used for presence and
distance sensing. Param-
eters on these versatile
sensors can be adjusted
to detect various colors,
backgrounds, and dis-
tance ranges.

8
Tips on sensor selection

Laser sensors are used for long distance presence sensing and are the most accurate in  Back to TOC
short distance measurement applications.

Vision sensor use and application tips

Vision sensors can be used for bar code reading, counting, shape verification, and
more. Machine vision sensors are a cost-effective use of vision system where camera
systems would be too costly and complex. Vision sensor bar code reading can be used
for tracking individual components and applying the processes identified for that com-
ponent. In terms of counting, the vision sensor can verify, for example, the exact num-
ber of features present on a part.

A machine vision sensor can ascertain whether a specified curve or other shape has
been achieved. Since these sensors are dealing with light, it is vital to test the sensor in
as close to the operating environment in terms of ambient light and background reflec-
tivity as possible. In most applications, it is recommended to place the machine vision
sensor in an enclosure to isolate it from external sources of light. It is a good idea to
enlist the aid of a vision sensor manufacturer in sensor testing. Make sure the right
fieldbus is specified.

Signal converter helps with sensor output

The signal converter changes the analog output signal from a sensor into switching
points on the signal converter, another option is to convert to IO-Link process data.

Sandro Quintero
Sandro Quintero, product marketing manager, electric automation, at Festo.

9
(EN) Weighing module Novego

 Back to TOC


(EN) Weighing module Novego
The weighing module Novego® was specifically developed
to meet the increasingly stringent requirements of the food
industry. This hygienic all-in-one solution boasts a range of
innovative properties to ensure simple, error-free installation
and maximum resistance to lateral forces.

10
Temperature sensors: Make the
right choice, RTD vs. TC  Back to TOC

When you need a temperature measurement, one of the most basic

decisions is choosing which kind of sensor to deploy. The application
should guide your decision.

T emperature variances in process industries can have significant impact on profits,

safety, and quality. A variety of industries and applications are affected, including
oil and gas, power, refining, petrochemical, pharmaceutical, and more. Monitoring
temperature accurately is dependent upon several factors, including selecting the right
sensor for the specific application and process.

Two of the most common temperature measurement devices are resistance tempera-
ture detectors (RTDs) and thermocouples (TCs). The technology behind them is differ-
ent, each having its own benefits that drive appropriate selection.

An RTD uses the principle that the electrical resistance of a metal increases as tem-
perature increases—a phenomenon known as thermal resistivity.

In comparison, a TC is a closed-circuit thermoelectric temperature sensing device con-

sisting of two wires of dissimilar metals joined at both ends. A voltage is created when
the temperature at one end of a wire or junction differs from the temperature at the
other end. This phenomenon is known as the Seebeck effect. That voltage depends
on the particular metal as well as the temperature difference. Comparing the different
voltages created by the different metals is the basis for TC temperature measurements.

11
Temperature sensors: Make the right choice, RTD vs. TC

Comparing the differences  Back to TOC

RTDs are constructed of a resistive material with leads attached and usually placed into
a protective sheath. The resistive material may be platinum, copper, or nickel; the most
common is platinum because of its high accuracy, excellent repeatability, and excep-
tional linearity over a wide range. It exhibits a large resistance change per degree of
temperature change. The two most common RTD sensor styles are wire-wound and
thin-film.

Wire-wound RTDs are manufactured either by winding resistive wire around a ceramic
mandrel or by winding it in a helical shape supported in a ceramic sheath—hence the
name wire-wound. For thin-film RTDs, a thin resistive coating is deposited on a flat
(usually rectangular) ceramic substrate. Thin-film RTDs are typically less expensive than
wire-wound RTDs because fewer materials are needed for their construction.

Normally, RTDs are much more repeatable and have better sensitivity than TCs. Long-
term drift of an RTD is predictable, while a TC drift is often erratic. This provides the
benefit of less frequent calibration and therefore lower cost of ownership. Finally, RTDs
provide excellent linearity. When coupled with the linearization performed in a quality
transmitter, a precision of about 0.1 °C is possible, which is much better than what is
possible with a TC.

In comparison, a TC is a closed-circuit thermoelectric temperature sensing device

consisting of two wires of dissimilar metals joined at both ends. Various combinations
of metals are classified as types and have specific characteristics. The most common
types are J (which uses iron and Constantan) and K (which uses Chromel and Alumel).
TCs have faster response times and higher temperature ranges than RTDs, but are also
12
Temperature sensors: Make the right choice, RTD vs. TC

less accurate. TCs have heavy gauge wire construction for durability and therefore can  Back to TOC
withstand high vibration (see Figure 1). Chart A compares key sensor characteristics.

Choosing the right sensor technology

When choosing the right sensor for your process and application, there are a few basic
questions that you should ask. The answers will provide valuable insight for selecting
the appropriate sensor.

1. What temperature range you are trying to measure? When selecting a sensor,
it is important to determine the correct temperature range. If the temperature is
above 850 °C, you must use a TC. If it is below 850 °C, you can select either an
RTD or a TC. Also, keep in mind that wire-wound RTDs have a wider temperature
range than thin-film RTDs (see Chart B).

2. What is your required sensor accuracy? Determining the level of accuracy need-
ed is also an important factor in the selection process. In general, RTDs are more
accurate than TCs, and wire-wound RTDs are more accurate than thin-film RTDs.
Assuming there are no other factors driving the selection of one technology over
the other, this guideline will help you find the most accurate sensor technology.

3. Is process vibration a concern? The amount of process vibration also needs to

be considered when selecting a sensor. TCs have the highest vibration resistance
of all of the sensor technologies. If you have a known high vibration, TCs will give
you the highest reliability. Thin-film RTDs are also resistant to vibration; however,
they are not as robust. Wire-wound RTDs should not be used in high-vibration
environments.
13
Temperature sensors: Make the right choice, RTD vs. TC

The right choice brings the right results  Back to TOC

The overall key to success is asking basic questions and matching up the information
with the right sensor for your applications and process. An example would be adding a
temperature measurement to a pipeline where the measurement is under varying con-
ditions with constant vibration and a process temperature variance of 200 to 300 °C.
The goal is to have the best possible accuracy despite these challenges.

To determine what type of sensor to use, first consider the differences between TCs
and RTDs. The temperature range makes both sensor technologies feasible for this
application. TCs are known for their higher vibration tolerance, so at a first glance TCs
would appear to be a good option. However, in this specific instance the measurement
requires the best possible accuracy. The right choice for this application would be a
thin-film RTD. Thin-film RTDs are known for their higher tolerance to vibration than
wire-wound RTDs, and will provide a higher accuracy than a TC.

A second example would be the temperature in a reactor that ranges between 550
and 900 °C with little vibration. The goal is to gain accuracy within ±5 °C. RTDs pro-
vide consistent accurate measurements, especially in environments with little vibration.
However, don’t forget the temperature range. RTDs typically should not be used above
850 °C. Since the process temperature can range up to 900 °C, a TC would be select-
ed. Sensors are more susceptible to failure and inaccurate measurements when used in
improper temperature ranges. That is why it is critical to select the correct sensor.

Ashleigh Hayes
Ashleigh Hayes is a marketing engineer for Emerson Process Management.

14
 High Precision,
hygienic design
weighing solution
impresses the
pharmaceutical Various installation heights, compliance with
hygienic design directives, total weighing

industry reliability, and reproducible weighing solution

results presented a difficult task for the plant
manufacturer Pharmatec.

Key facts
The pharmaceutical manufacturer Pharmatec GmbH
tasked Minebea Intec with the installation of six vessel
scales in its production process for liquid medicines. The
application was carried out based on the premise of ob-
serving a hygienically clean production environment while
achieving precise measurement results.

Application
Liquid medicines are produced in the customer’s plant in
High Precision, hygienic design weighing solution impresses

Middle-East-Asia, which means special standards in terms of measurement accuracy,  Back to TOC
hygiene and above all, reproducibility are required.

Products
• Weighing module Novego “Thanks to the
hygienic design
• Cable junction box PR 6130 and the integrated
height adjustment,
• Weight indicator X3 with ProfiNet interface the weighing module
Novego was simply
Customer benefits the perfect solution
• High process reliability and precision for us.”
(Pharmatec)
• High insensitivity to transverse forces

• Hygienic design ensures efficient cleaning processes

• High resistance against cleaning agents and corrosion

The customer
Pharmatec GmbH is part of Robert Bosch Pack-
aging Technology GmbH and is the competence
centre for pharmaceutical process systems in the
group. The company is a technology leader in
the sector of plant manufacturing for the pro-
duction of liquid substances and medicines.
16
High Precision, hygienic design weighing solution impresses

Project goal and implementation  Back to TOC

The plan was to build a plant for the production of a medicine in the Kingdom of Bah-
rain. The plant manufacturer Pharmatec won the tender, but faced a challenging task:
the smallest possible quantities had to be accurately dosed from tanks, which had a ca-
pacity of several tonnes, to the millilitre. Not only highprecision dosing measurements,
but also reliable reproducibility of the measurement results had to be guaranteed.

High-precision and reliable weighing technology was an essential prerequisite to en-

sure all requirements were met. Even the smallest deviations can lead to potentially
harmful consequences in the production of medicines. Pharmatec therefore decided
on the weighing module Novego from Minebea Intec.

In addition to the process require-

ments, the local conditions also pre-
sented additional challenges and
several visits by specialist staff were
required just for the constructive plan-
ning. Among other issues, the plant
manufacturer had the problem that
an inconveniently placed pump made
construction more difficult. Pharmatec
was able to benefit from Minebea
Intec’s equipment here: the weighing
module Novego has an integrated The installation of the weighing
continuously variable height adjustment of up to 8 cm, module was particularly simple thanks

17
allowing for different installation heights. The integrat- to the integrated height adjustment
of the Novego.
High Precision, hygienic design weighing solution impresses

ed mounting kit consisting of a 360° constrainer, lifting and tipping protection elimi-  Back to TOC
nates the need for time-consuming constrainer adjustment.

Further criteria included the special insensitivity to transverse forces and the hygienic
design of the weighing module. In a production plant in the pharmaceutical industry,
simple and residue-free cleaning must be ensured for maximum sterility. The accura-
cy class C3 according to OIML also
ensures that the measuring accuracy
and reproducibility of recipes are
maintained.

The cable junction box PR 6130, which

is sealed according to the Goretex
principle, was another impressive
component: moisture arising inside
the box escapes to the outside with-
out any moisture penetrating from
the outside. This feature is particularly
Hygienic design is crucial in the
essential in temperature-sensitive environments.
pharmaceutical industry in order to
enable maximum sterility.
Once the ideal components for the vessel scales were
found, nothing stood in the way of building the plant. Minebea Intec provided support
for the design process as well as the installation and calibration. Pharmatec’s conclu-
sion: “We are sure that with Minebea Intec’s components, we have found an extremely
precise and durable weighing solution for our process containers. All our expectations
were met, and sometimes even exceeded.”
18
Inertial measurement unit
sensors lower risk for  Back to TOC

autonomous vehicles
Inertial measurement unit sensors lower risk for autonomous vehicles

T he future of vehicles is autonomy, and advanced position sensor technologies are

helping vehicles designed to drive themselves—safely and accurately. There are
many predictions regarding when truly autonomous cars will become a reality.

However, while we wait, many of today’s vehicles are equipped with a variety of ad-
vanced driver assistance systems (ADAS) like lane departure warnings, assisted park-
ing, and automatic braking. Although these technologies are very useful, they are con-
sidered an SAE autonomy level of just 1 or 2, which means that they still require driver
engagement 100% of the time.

The big question is when will we see the technological leap to level 5, or fully autono-
mous vehicles that require no driver interaction. Unfortunately, we are still several years
away from this technology becoming widely accepted and adopted into any type of
vehicle. Why? The critical challenge is ensuring safety.

To achieve full autonomy requires absolute confidence that a vehicle will continue to
safely and accurately operate in any type of weather or road conditions and will avoid
significant injury to passengers, pedestrians, or property.

This would require a built-in guidance and navigation technology that can ensure the
vehicle will operate safely if and when vehicle perception sensors like LiDAR, radar, or 19
Inertial measurement unit sensors lower risk for autonomous vehicles

 Back to TOC

cameras fail, or if there is an intermittent IMU sensors rely on gravity and physics of motion.
Unlike vision, radar, LiDAR and other perception
disruption in GNSS satellite signals due to
sensors, as well as steering systems based on GNSS
weather, terrain, or environment. signals from satellites, IMU based guidance systems
are not affected by harsh environmental conditions
and physical obstructions like tunnels and foliage and
Safe-stop sensing system for will continue to operate. Courtesy: Aceinna—Inertial
autonomous vehicles Measurement Systems

This vehicle sensing technology is the iner-

tial measurement unit sensor, or IMU sensor. Because an IMU sensor is based on gravi-
ty and the laws of physics rather than external conditions, it can continue to send data
so the vehicle can safely maintain course until it can come to a secure stop or the other
navigation systems start functioning again, even if the perception sensors fail because
of weather. By eliminating data interruption and increasing operational safety, the IMU
will expedite the reality of Level 5 fully autonomous driving.

The bottom line is this: Without IMU sensors to provide the safety cushion, autono-
mous vehicles will never be able to effectively work in city streets and highways.
20
Inertial measurement unit sensors lower risk for autonomous vehicles

What is an IMU sensor, and how  Back to TOC

does it work?
Most IMU sensors are composed of two differ-
ent sets of sensors—accelerometer sensors and
gyroscope sensors. The accelerometer sensors
measure linear acceleration in three orthogonal
axes. Integrating acceleration over time will pro-
vide velocity, and integrating velocity over time
will change result in a change in position.
An IMU uses its accelerometer
and gyroscope sensors to capture
The gyroscope sensors measure the angular rate of three
measurements over six degrees of
orthogonal axes. Integrating the angular rate along the freedom, three axes of movement
three axes over time will generate change in roll, pitch, (forward and backward, left and
right, and up and down), as well as
and yaw, which is the change in attitude of an object. three axes of rotation (roll, pitch and
yaw). Courtesy: Aceinna—Inertial
An IMU module with gyroscopic and accelerometer sen- Measurement Systems

sors can provide measurement over 6 degrees of free-

dom (often called 6-DOF, see above).

Why do some IMUs also include a magnetometer?

An accelerometer can be used to successfully calculate roll and pitch values with re-
spect to earth’s gravitational force, and correct gyroscope drift.

However, it cannot be used to detect absolute heading (yaw) because the change of
yaw is orthogonal to the gravity vector. A magnetometer measures the magnetic field
strength in three dimensions. By using the Earth’s magnetic field, it can help to deter-
21
Inertial measurement unit sensors lower risk for autonomous vehicles

mine heading (i.e., yaw) as well as roll and  Back to TOC

pitch of the object.

Integrating a magnetometer in the IMU can

help with detection of the initial heading of
an object and correct integration errors of the
yaw gyroscope in the sensor fusion algorithm.

IMU performance measurement;

IMU triple redundancy
Bias instability is one of the most critical per-
formance parameters of the gyroscope.
It is a direct measure of how much the gyroscope drifts
over time. Because the rate output of the gyroscope
is being integrated to calculate change in angles (roll,
pitch, and yaw), any error associated with drift results in
accumulated error in relative angles. Furthermore, these
Aceinna’s Triple Redundant IMU
sensors provide the extra level of
safety, accuracy and reliability that is
required to ensure safe operation of
autonomous vehicles on highways
and in dense urban environments.
Courtesy: Aceinna—Inertial
Measurement Systems

angular errors translate into position errors over time.

For automotive applications a high performance IMU is a necessary component for the
autonomous vehicle to achieve high accuracy positioning.

In a triple redundant IMU, three IMUs are used to construct a triple-redundant sensor
architecture that provides additional levels of reliability and accuracy.

If for some reason one or more sensors is not accurately functioning, the system can be
22
Inertial measurement unit sensors lower risk for autonomous vehicles

programmed to recognize the defective sensor data and avoid using it. The defective  Back to TOC
sensor output or errant dataset will be ignored or de-rated in importance. This archi-
tecture ensures the reliability of the system and simultaneously improves the perfor-
mance.

IMU sensors may not attract the same amount of attention and media coverage as oth-
er sensors— i.e. LiDAR Radar, and cameras. However, in many ways IMUs are the criti-
cal safety sensor component required for the successful operation of the Level 4 and 5
autonomous vehicles that will be appearing on streets within the next decade.

James Fennelly
James Fennelly received his BS EET from the University of Massachusetts. He has
been working for the past 15 years with MEMS inertial sensors including component
level acceleration sensors and system level products. He is responsible for defining
new products at ACEINNA Inc. to meet the needs of emerging applications in the iner-
tial sensing market.

23
Process sensors and advanced
analytics efficacy  Back to TOC

Sophisticated sensors rely on predictive analytics for process and equipment

monitoring. See examples of present and emerging process sensor applications.

D ata is everywhere, but from where do they come? The first modern sensors
started in 1860, when Wilhelm von Siemens used a copper resistor1 to measure
temperature. That idea gave rise to the first thermostat in 1883, generally recognized
as the first human-made sensor.

Since then, we have seen a proliferation of such devices especially for the measurement
and control of manufacturing processes. The sophistication of sensors and their pricing
has changed dramatically as their deployment entered transportation and consumer
markets. So, too, has the nature of their deployment to measure and control processes,
which used to be quite simple combinations of sensor signals in human-made calcula-
tions or logic such as in proportional, integral and derivative (PID) control.

These examples were followed by computer applications supporting simulations and

process optimization. In the last few years, new techniques have emerged with highly
technical capabilities driven by artificial intelligence (AI) and machine learning (ML).
The result is a far more complex amalgamation of data streams across multiple dimen-
sions as well as time to learn patterns of behavior instead of estimating behavior with
computational digital models based on engineering first principles and statistics. As a
result, the machines are writing the programs instead of humans.

Process manufacturing, sensors are intersecting

The advent of the Internet of Things (IoT) has spawned huge growth in connected
24
Process sensors and advanced analytics efficacy

things. According to the National Science Foundation (NSF), the IoT is on track to  Back to TOC
connect 50 billion smart things and 1 trillion sensors. Perhaps the most well-known
deployment of such sensors and AI/ML technologies is in motor vehicles – especially
electric vehicles. For example, the autopilot system in a Tesla 3 uses eight cameras, 12
ultrasonic sensors, and forward radar to read lane lines and detect nearby cars.

Process manufacturing industries have been developing new uses of such sensors
steeped in AI and ML to measure the condition of assets and processes, including
learning their explicit behavior from data streams gathered from sensors on and
around machines. Such implementations can supersede older techniques to bring
easier, faster deployment, and greater accuracy and outcomes without the need for
intense engineering skills. The best applications can abstract data science, allowing
regular personnel at plants to implement complex strategies without intense learning.

What’s changed is a shift from single point measurements and simple logical expres-
sions to automatically combined streams of data gathered every few minutes. Data is
processed using AI/ML in multi-dimensional/temporal ways to develop patterns of be-
havior in many more dimensions than humans can perceive. The technology sees those
patterns with great clarity to recognize explicit behavior knowing what is normal, what is
abnormal, and what are the actual advanced patterns of degradation in equipment and
processes that, if left unattended, will result in poor outcomes and possibly asset failures.

Application examples: criticality of data for manufacturing

The reality is these deployments are data-driven solutions. No data means no solution.
This leaves users wondering how much data and what data is required?

25
Process sensors and advanced analytics efficacy

Consider the example of a large slurry pump at a mine, which was instrumented with  Back to TOC
only four sensors: Pressure in, pressure out, the fluid temperature and the amps drawn
by the motor. In this case the predictive maintenance (PdM) solution provided two
weeks’ notice the motor would fail, which it did.

However, a large charge pump at a refinery had 50 sensors, including the process mea-
surements upstream and downstream, and mechanical sensors on the machine includ-
ing many vibrations sensors. In this case, the PdM solution provided instant notice of
degradation and 16 weeks’ notice of an imminent failure.

As a result, the ML-based sensor analysis can work effectively with a few sensors, but
can be far more effective in accuracy and much earlier warning with more and higher
quality sensors. It’s rare to add new sensors since the most critical assets are usually
well-instrumented with many sensors.

The detected sensor data also streams patterns for imminent failure. It has a one-to-
one relationship with the root cause of a failure and the precise failure mode, but those
patterns are developed by selecting the group of appropriate sensors capable of de-
veloping those exact patterns.

In such cases, organized sensor selection kits indicate the precise collections needed
to detect specific failure such as a bearing failure on a pump or compressor. Contin-
uously monitoring the selected sensors will notify if the explicit degradation pattern
occurs with extreme advanced warnings.

The future of process sensors, new applications

Sensor types and availability continue to change over the years. It started with simple
26
Process sensors and advanced analytics efficacy

temperature, flow, pressure and level sensors. Now, there are sophisticated analyzer  Back to TOC
sensors for product quality such as viscosity, water content, solids, color, weight and
even inline mass spectrometers to give a full product breakdown. All are useful in pre-
dictive analytics for process and equipment monitoring.

However, emerging fields of sensor measurements may provide additional assistance.

Think of the experienced operator who developed a deep understanding of equip-
ment behavior by listening to the sounds it makes. It appears new acoustic sensors
inside and outside of the human hearing range may assist. Microphones are quite inex-
pensive to install and do not need to sit on the machines themselves. There also have
been developments in hyperspectral imaging using videos and high-powered graphics
computing to interpret gas content and even smells.

Such devices can replace older analyzers for example in furnaces and stacks to see and
measure temperature and exhaust gas composition. Another is interpreting vibrations
on fiber cables, like the ones carrying phone calls, to detect temperature, proximity
and intruders. The cable installation is non-intrusive (needs only to be close) and is a
very valuable application for detecting leaks and theft, which on a perimeter fence, can
detect anything coming close.

These are only a few examples of the ways in which sophisticated sensors are relying
on predictive analytics for process and equipment monitoring. The future uses of such
sensors are exciting and endless.

Mike Brooks
Mike Brooks is global director of APM solutions for AspenTech.
27
Get flow measurement right the
first time  Back to TOC

Understanding, monitoring and controlling flow rate are essential elements

to the viable operation of production systems and must be done right. See
five key flow considerations.

U nderstanding, monitoring and controlling flow rate, as part of industrial processes,

are essential elements to the viable operation of production systems. There are
many elements involved in getting such measurements right and the hazards of getting
it wrong can be severe for the plant and the workers.

Fundamentally, the selection of appropriate measurement technology and its cost, ac-
curacy and proper use will affect the result. For example, a recent measurement audit
of an alcohol bottling plant found classic manual procedures were in place for both
sampling and for offline density measurement, subsequently used to infer the alcohol
by volume (ABV) of the product.

Unknown to the plant operators, the Coriolis meters used to measure flow rate also
were capable of measuring density. Using these Coriolis meters to measure both flow
and density would allow immediate online alcohol content monitoring along with
prompt action and enhanced product control.

The reluctance to change is a powerful barrier throughout industry. However, this

should be balanced with an understanding of the available technology, including the
importance of flow measurement, and its assessment in a cost-benefit analysis accord-
ing to requirements. When operating a process that relies on measurement systems for
28
Get flow measurement right the first time

monitoring productivity, control or safety, the ability to prove the accuracy of the mea-  Back to TOC
surement system is vital.

This requires an understanding of measurement uncertainty, calibration and traceabili-

ty, as well as a management system incorporating a measurement policy and a mainte-
nance schedule. This leads to confidence in the measurement process and the result.

To achieve the target accuracy, which is critical to trade and commerce, most countries
have a dedicated regulatory framework that supports the national measurement infra-
structure and is designed to facilitate and regulate good measurement practice.

Metrology traceability, including flow determination, plays a vital role in national infrastructure
since accurate results and confidence in measurement are impossible to achieve without it.

Traceability is the technical proof a measurement device has the appropriate pedigree,
normally through calibration records, referenced back to a national standard.

The traceability chain

As we move up the traceability chain toward a given measurement standard, the un-
certainty in measurement reduces (becomes more accurate). However, to achieve lower
uncertainty it is necessary to invest more money in the system by way of increased
capital, maintenance costs and experienced staff. This is important to consider, as the
most accurate system is not always the correct solution for a given application.

Owing to the cost penalty associated with achieving and maintaining low uncertainty,
the requirements for a given application need to be considered prior to system design
and component selection.
29
Get flow measurement right the first time

Despite the work invested in maintaining and regulating the NMS, when performing a mea-  Back to TOC
surement audit, a common finding relates to instruments not installed or operated in accor-
dance with the requirements, or in some instances are no longer traceable to the appropri-
ate standard. It is not uncommon to find flowmeters in service where the operator has no
record of when the device was calibrated and no planned maintenance for the system.

What is restricting industry from investing in such powerful diagnostic tools and trace-
ability? A key factor is the required level of measurement uncertainty. If we consider
the oil and gas petrochemical industries, the needs usually are well established. These
organizations typically have dedicated metering departments to support the measure-
ment of flow for hydrocarbon-based products of high value, where even small uncer-
tainties can lead to large financial exposure over short timescales.

Another key factor is these industries are regulated much more tightly than others,
due to the fiscal value of the metered product. The same degree of stringent regula-
tion does not often apply to flow measurements in other industrial environments. So,
companies in sectors such as food and beverage, power or chemical may rarely under-
take complete flow measurement audits and instrumentation is often underutilized.
Conversely, the development and application in medical and pharmaceutical areas are
potentially a matter of life or death.

Five key flow considerations

Regardless of the industry, there are five key considerations that need to be asked:

1. Do you understand the uncertainty in the measurement systems that you require
for your business, and can you prove it?
30
Get flow measurement right the first time

2. How does your measurement system perform over time?  Back to TOC

3. How frequently do you calibrate?

4. Do you have any past performance data that would allow you to improve the per-
formance or establish an optimal calibration period?

5. Are these points recognized in your quality system?

Traceable and good measurement practice is critical in achieving accurate and re-
peatable flow measurement. However, selecting the appropriate solution depends on
understanding the operation and the measurement uncertainty required for a given
application. This requires a fundamental understanding of metrology as well as the
process to which it is applied. Given the sophistication and capability of modern flow
measurement technology, such systems may not simply measure flow rate but also
provide powerful diagnostic capability and valuable data. This can provide insight into
both the efficiency of the measurement system and the effectiveness of the process,
which has the potential to yield substantial commercial benefits including improved
monitoring and performance.

Brendan Robson
Brendan Robson is a project engineer at TÜV SÜD National Engineering Laboratory.

31
 Innovative,
hygienic, precise
and easy
to install:
weighing module
Novego®
Strong features for food and pharmaceutical
processes

Introduction
With the new Novego® weighing module, Minebea In-
tec offers an innovative, hygienic and precise solution for
weighing vessels. 5 load levels (275lb - 2.2 US ton) in one
design makes life easy for the tank designer. Furthermore,
the focus of the development was on easy installation.

Hygienic Design has become the reference for the food

and pharmaceutical industries. Novego® is particularly
Innovative, hygienic, precise and easyto install: weighing module Novego®

convincing in terms of overall performance. Let yourself be surprised by what is really  Back to TOC
new about the product.

What does German Quality stand for?

Products with the German Quality seal receive the highest recog-
nition worldwide. This applies both in the consumer sector and in
the industrial environment. According to international studies, the
seal enjoys a high international reputation and ranks first out of 52
countries in the Made-in-Country index. Our knowledgeable local
US team are on hand for all your weighing and application needs.

Applications:
For whom is Novego®
suitable?
The Novego® weighing module has
been specially developed to meet the
increasing demands of the food and
pharmaceutical industries, while its com-
paratively low price makes it suitable for
other branches of industry as well.

Use for content determination

The Novego® weighing module is pre-
destined for the precise weighing of
vessels used in the food and pharmaceu-
33
Innovative, hygienic, precise and easyto install: weighing module Novego®

tical industries. It is therefore ideal for weighing storage  Back to TOC

vessels to determine their contents. Furthermore, the
module can also be used with mixers to either dose or
determine the current contents. In both applications, it
scores with its immunity to lateral forces.

Novego® during
dosage
When it comes to dos-
ing individual compo-
nents from intermediate vessels into a continuing
container, Novego® is recommended as a precise
solution for component dosing. In addition to the
food and pharmaceutical industries, the product is
equally interesting for the cosmetics industry.

Filling of finished products

You want to fill finished products accurately? Novego®
offers high measuring accuracy and process reliabili-
ty for your production. Thanks to its hygienic design,
the weighing module is suitable for industries where a
germfree environment is important, such as the food
or pharmaceutical industries.

34
Innovative, hygienic, precise and easyto install: weighing module Novego®

The shape: Load cell or vessel foot?  Back to TOC

Although vessels, pipes and fittings with improved hygienic properties are used in
food, pharmaceutical and cosmetics production, for the first time a weighing mod-
ule has been added that looks like a hygienically
designed container base.

Small details that save big costs

The Novego® weighing module was developed in
accordance with the EHEDG guidelines for hygien-
ic design: A large number of design details based
on the Hygienic Design Guidelines minimize con-
tamination and ensure efficient cleaning processes.

Particularly noteworthy here are, for example, the minimi- The container base of the
Novego® is ideally suited for
zation of horizontal surfaces, low surface roughness and simple and effective cleaning.
the use of FDA-compliant silicone.

Cleaning requires less time and fewer cleaning agents and in addition to greater
safety, savings are also achieved here.

The surface: Optimised for easy cleaning

In hygiene-sensitive production areas today, a lower surface rough-
ness is required. Novego® meets this trend with an Ra value of 0.8
μm and thus meets the requirements of the EHEDG. The Novego®
weighing module scores points with many small details that have a
positive effect on cleaning.
35
Innovative, hygienic, precise and easyto install: weighing module Novego®

Strict minimization of folds, edges and screw connections  Back to TOC

FDA compliant silicone is approved for use in the food industry. Falling surfaces:
Sloping surfaces allow the cleaning water to run off more easily.

No damming depressions: This is an important

point, especially in hygiene-sensitive areas, as
substances settle in depressions or corners and
edges and lead to contamination.

Minimization of screw connections in the visible

area: screw connections leave unnecessary gaps
in which residues can settle.

Easy to clean: By strictly adhering to hygienic

design guidelines, the Novego ® weighing module
ensures that cleaning can be performed quickly and effectively.

The steel: more resistant than ever

Many load cells are currently made of the alloyed steel AISI630/17-4PH/DIN1.4542.
This is highly valued for its good metrological weighing properties. However, its cor-
rosion resistance is limited.

New stainless steel scores with special durability

The AISI S165M/1.4418 stainless steel used for the first time for Novego® is partic-
ularly corrosion-resistant and durable. The proof: the pitting corrosion potential of
AISI630/17-4PH/DIN1.4542 stainless steel of conventional load cells and Novego®.
36
Innovative, hygienic, precise and easyto install: weighing module Novego®

This means that the cell can easily  Back to TOC

withstand frequent cleaning cycles
with aggressive media, some of which
are used in the food industry.

The accuracy: precise, even

when things get rough
During operation, mixers sometimes
exert lateral forces on the weighing
equipment. This can result in fluc-
tuations in the dosed quantities. The less the weighing technology is influenced by
lateral forces, the higher the reproducibility.

Unwavering: precise results despite strong lateral forces

Unique on the market, Novego ® maintains the specified measuring accuracy even
with high lateral forces of up to 20
percent of the load. The integrated
360 degree restraint always causes
the load cell to return to the center
position and from any direction.
The load cell’s six strain gauges
guarantee a measuring accuracy of
C3 according to OIML R60. In real
applications, system accuracies
of better than 0.05% have already
been documented.
37
Innovative, hygienic, precise and easyto install: weighing module Novego®

The installation: A round thing  Back to TOC

A simple installation is included with Novego®. The
installation kit allows the system to be set up in any
orientation. All components can be individually se-
lected from a range to suit the installation situation.

Classical installation kits are predominantly rectan-

gular in design and must be aligned exactly with
the tank wall. In case of errors, mechanical block-
ages and implausible measured values can occur.

Thanks to its rotationally symmetrical design, No-

vego ® enables plant manufacturers and end cus-
tomers to carry out simple, error-free installation.
The circular floor plan eliminates the question of
correct alignment.

A positioning collar is included in the scope of delivery for cen-

tred alignment of the load cell to the pendulum base.

Height compensation: the innovative turn!

Vessels with more than three legs must be levelled otherwise
they can rock, this means not all of the load cells are in contact
with the vessel, this can cause substantial errors.

38
Innovative, hygienic, precise and easyto install: weighing module Novego®

Compensation of up to 8 centimeters –  Back to TOC

in no time at all
Novego ® offers an innovative solution here. A
height adapter allows height differences of up
to 8 cm to be compensated for by simply turning
the device. For example, differences in length of
a container with 4 legs can be easily compensat-
ed with two adapters.

Always in the horizontal position

In the food and pharmaceutical industries, floors
are often constructed with a slope to allow
cleaning water to drain off. This makes normal load cells optimal installation difficult.

Leaning? No problem for Novego®!

The Novego® concept offers a unique solution for this. The pendulum base is also
available with integrated tilt correction for installation on sloping floors. This allows
cleaning water to run off while the weighing module is installed exactly in the hori-
zontal plane. This ensures precise measurement results where other load cells pro-
duce errors.

Always fits: The installation parts

Conventional installation kits require the structural adaptation of the container leg.

This requires a great deal of time and, above all, financial effort. The weighing mod-
ule consists of three components: Adapter plate, load cell and pendulum base.
39
Innovative, hygienic, precise and easyto install: weighing module Novego®

Novego®: The weighing module that can be adapted to the environment  Back to TOC
In contrast, the installation parts available for Novego® adapt to the conditions of the
container. Each load cell has a matching pendulum foot for mounting on a frame or one
for floor mounting. We have also minimized the number of screw connections required.

For example, three threaded screws are sufficient for mounting on the floor. For
mounting on the tank leg, we offer an adapter plate that can be attached with a single
screw connection.

Everything from a single source

Minebea Intec provides products, solutions and services to improve the reliability,
safety and efficiency of production and packaging lines in virtually all industries. From
goods receipt to goods issue – our portfolio comprises a variety of automatic and
manual weighing and inspection solutions, software and services for a wide range of
applications and industries.

40
 Process Instrumentation
& Sensors
Content Archive Thank you for visiting the Process Instrumentation
& Sensors eBook!
2023 Fall Edition

2023 Summer Edition If you have any questions or feedback about the contents
in this eBook, please contact CFE Media at
customerservice@cfemedia.com

We would love to hear from you!