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Contents A4

A4 Not all PID controllers are the same

Variations in the proportional-integral-derivative (PID) algorithm from one
controller to the next can be confusing. Here are considerations when
applying PID to your next implementation.

A8 Powering gas distribution SCADA

with the sun
A multi-phase project led to a customized, cost-effective, reliable solar-
powered automated gas distribution regulator monitoring system from Huffman
Engineering, which improved the safety of Nebraska’s Metropolitan Utilities
District (MUD) gas system.

A12 Getting focused: Using 80 GHz radar

sensors for liquid level measurement
The introduction of 80-GHz radar sensors represents a paradigm shift in liquid-level
measurement. High-frequency devices have ushered in an era of new possibilities
for the process control industry, and it’s because of signal focusing. This article
looks at things an 80-GHz radar sensor can do that its predecessors cannot.
A8
C OMMENT
Looking back; looking ahead

D
uring 2017, including this issue, many of the original monitoring stations with a
AppliedAutomation ran 18 articles; 10 of pole-mounted, solar-powered remote terminal
them were case studies—almost 56%. unit, supported by a modem, charge controller,
That’s not bad for our first year of run- battery, and a pressure transmitter.
ning primarily case studies and application stories The cover story in this issue of
because they’re harder to come by. The April AppliedAutomation revisits a topic that never
2017 issue stood out because it had five articles, gets old: proportional-integral-derivative (PID)
all of them either case studies or technical articles control. However, this article examines different
Jack Smith that included application stories. Moving forward, types of PID algorithms, their applicability, and
Editor I encourage you to contribute more studies. the potential for confusion among them.
The case study in this issue focuses on a The third article in this issue looks at using
natural gas utility in the U.S. Midwest that was 80-GHz radar sensors for liquid level measure-
facing the challenge of dealing with aging infra- ment. According to the authors, “Using 80-GHz
structure. The original system of pole-mounted transmission frequency liquid-level measurement
mechanical paper chart recorders that monitored can improve signal focusing to allow accurate,
gas inlet and outlet pressures was antiquated reliable measurement in tanks with agitators,
and labor-intensive. The solution was to replace heating coils, and other internal obstructions.”

ON THE COVER The beauty of the proportional-integral-derivative (PID) algorithm for feedback control is its simplicity, which has made it a
fundamental building block of refineries, chemical plants, and many other process industry facilities for many decades, regardless
of the specific PID algorithm variation. Courtesy: Emerson

Applied Automation December 2017 • A3

 C o v e r s t o ry

Not all PID controllers

are the same
variations in the proportional-integral-derivative (PID) algorithm from one
controller to the next can be confusing. Here are considerations when applying
PID to your next implementation.

By Control Engineering compute the error signal, its integral, and its derivative,

T
but they typically combine those three quantities using a
slightly rearranged formula with a different set of tuning
he beauty of the proportional-integral-derivative parameters: controller gain (Kp), integral time (Ti), and
(PID) algorithm for feedback control is its sim- derivative time (Td), as shown in Figure 2.
plicity. The controller needs to only compute the
current error between the measured process Advantages of the standard algorithm
variable and the desired setpoint, then calcu- The weighting factors for the proportional, integral,
late how much and how fast that difference has and derivative terms in the standard PID algorithm are
been changing over time. The controller then can combine Kp, Kp/Ti and Kp x Td respectively. That may seem com-
the resulting proportional, integral, and derivative terms to plicated unnecessarily, but there is a method to that
generate a suitable control effort. madness. Configuring K p to affect all three terms equally
The trick is in deciding how to best combine those three gives the control engineer a single knob to turn to make
terms or modes to achieve the most efficient regulation of the overall controller more aggressive or more conser-
the process variable. The most obvious way is to use a sim- vative.
ple weighted sum where each term is multiplied by a tuning The format of the standard PID algorithm gives physi-
constant or gain, and the results then are added together cal significance to Ti and T d that can be illustrated best
(see Figure 1). The relative contributions of each term can by a conceptual experiment. Imagine opening the feed-
be adjusted by choosing appropriate values for the propor- back loop, resetting the controller to a zero output, and
tional gain (P), integral gain (I) and derivative gain (D). inputting a constant error into the controller. The output
But that’s not how most PID controllers actually work of the proportional term (the proportional action) imme-
in industrial applications. Commercial PID controllers do diately will assume a constant value while the output of

Figure 1: The theoretical Disturbances

proportiona-integral-
P
derivative (PID) algorithm
computes the next control Setpoint Error + +
effort by adding the error + I + Process +
- +
(setpoint minus process
variable), the integral of the d
D
error, and the derivative of dt
the error with weighting
factors P, I, and D, respec- Controller
tively. Although this is
arguably the most intuitive
form of the PID algorithm, it
can lead to confusion when Process Variable
tuning the loop. A control
engineer attempting to make the controller less aggressive by decreasing the proportional gain P might actually make the closed loop
unstable for reasons that are not at all obvious. All graphics courtesy: Control Engineering

A4 • December 2017 Applied Automation

Figure 2: The standard Disturbances
or noninteracting PID 1
algorithm first adds the
integral of the error and Setpoint Error 1 + +
+ Kp + Process +
the derivative of the - Ti +
error using weighting
d
factors 1/Ti and Td. That Td
sum then is increased
dt
by 1, and the results
Controller
are multiplied by the
controller gain Kp to
compute the next con-
Process Variable
trol effort.

the integral term (the integral action) will start ramping P=3
up from zero. The magnitude of the integral action will
catch up to the proportional action in exactly Ti seconds. I = 3/2 = 1.5
The integral time describes the relative strengths of
the proportional and integral actions in terms of the time D=3x1=3
each requires to achieve the same contribution to the
overall control effort. A relatively weak integral action The controller would end up with the desired degree
corresponds to a longer value of Ti and vice-versa. of proportional action but 25% less integral action (with a
Similarly, a relatively weak derivative action corresponds gain of 1.5 rather than 2) and three times as much deriva-
to a longer value of T d and vice-versa (though the con- tive action as the engineer had intended.
ceptual experiment that demonstrates this correlation
involves inputting a ramp into the offline controller rather Which is which?
than a constant error.) A third PID algorithm adds to the confusion. Some
commercial controllers use the series or serial form as
Potential for confusion shown in Figure 3. A control engineer trying to tune three
Fortunately, it’s easy enough to compare the theoretical controllers in otherwise identical loops will get different
and standard PID algorithms and relate P, I, and D to Kp, results if one controller happens to use the theoretical
Ti, and Td as follows: algorithm, the second uses the standard algorithm, and
the third uses the series algorithm.
P = Kp Worse still, both the theoretical and standard algo-
rithms sometimes are described as the ideal algorithm,
I = K p / Ti even though they’re different. Consequently, some tech-
niques for tuning ideal controllers won’t work on some
D = Kp x Td ideal controllers.
On the other hand, the phrases parallel, ideal paral-
The proportional gain P is the same as the controller lel, and independent seem to refer exclusively to the
gain Kp, so a control engineer unaware of the difference theoretical algorithm in which the proportional, integral,
between the theoretical and standard PID algorithms and derivative terms operate independently and in paral-
might also assume that “integral gain” is synonymous lel rather than in series. Ironically, the three terms in the
with “integral time,” and “derivative gain” is synonymous standard algorithm also operate in parallel, but standard
with “derivative time.” Unfortunately, that mistake makes and parallel are almost never used synonymously.
tuning the loop virtually impossible.
Suppose, for example, an inexperienced control engi- Tuning terminology
neer has determined that a particular feedback loop The tuning parameters also have different labels
requires a theoretical controller with a proportional gain depending on who’s describing them. When PID control-
of 3, an integral gain of 2, and a derivative gain of 1. lers were first developed, the derivative term was known
Entering those three values into a standard commercial as the pre-act mode because it seemed to act preemptive-
controller under the headings of controller gain, integral ly, accelerating the controller’s corrective efforts beyond
time, and derivative time would be akin to setting: what the proportional term could manage on its own.

Applied Automation December 2017 • A5

 C o v e r s t o ry

Disturbances

1 1

Setpoint Error + + +
+ Kp Process +
- + +

1 d
Td
Ti dt

Controller

Process Variable

Figure 3: The series or interacting PID algorithm first computes the integral and derivative of the error signal, increases each by 1, then
multiplies their product by Kp to compute the next control effort. This convoluted form of the PID algorithm doesn’t have any practical
advantages in the age of digital computing, but it was easier to construct out of pneumatic or passive electronic components back in the
days of analog controllers.

Early control engineers increased or decreased the More variations

degree of preemptive (derivative) action by selecting a Compounding the confusion are the various ad hoc
larger or smaller pre-act time. Today’s PID vendors typi- enhancements that have been developed over the years
cally describe a controller’s derivative action as its rate. to improve a PID controller’s performance (see “Fixing
Integral action was originally known as automatic reset PID,” Control Engineering, November 2012, May 2014,
because the integral term seemed to automatically adjust December 2015).
the setpoint to the exact value required to eliminate the Fortunately, all these fixes work no matter which PID
steady-state offset caused by the proportional term (see algorithm a particular controller uses, and most are avail-
“The Three Faces of PID,” Control able as options on most commercial
Engineering, March 2007). Some controllers. On the other hand, it’s
control engineers still specify the The first step when retuning not always obvious which options
reset time when tuning a controller’s have been selected for a particular
integral term, but a higher reset time or otherwise modifying an controller already in operation.
corresponds to less integral action, For example, the process variable
not more. existing controller has to be signal often is filtered before it enters
Alternately, the degree of inte- the PID calculation so as to remove
gral action is sometimes specified determining exactly which measurement noise that would oth-
in terms of the reset rate, which is erwise cause the control effort to
the inverse of the reset time and kind of PID controller it is. fluctuate unnecessarily
entirely unrelated to the derivative (see “The Basics of Numerical
rate. Confusing “reset” and “reset rate” leads to increased Filtering,” Control Engineering, October 2008).
integral action when the control engineer wants less, and Unfortunately, filtering the process variable also tends
vice-versa. to make the controller look sluggish. A control engineer,
Likewise, the proportional gain in some PID control- unaware that a filter is in place, might try to make the con-
lers is specified in terms of its inverse known as the pro- troller more responsive by turning up the controller’s gains.
portional band. More precisely, the proportional band is The desired closed-loop performance might be achievable,
100 divided by the proportional gain so it represents the but the filter and the PID algorithm will end up working
percent change in the error signal necessary to cause against each other.
a full-scale change in the proportional action. Confusing With so many variations on the PID algorithm in use
“proportional band” with “proportional gain” leads to today, the first step when retuning or otherwise modifying
decreased proportional action when the control engineer an existing controller has to be determining exactly which
wants more, and vice-versa. kind of PID controller it is.

A6 • December 2017 Applied Automation

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 C a s e s t u d y: s o l a r sC a d a

Powering gas distribution

SCADA with the sun
a multi-phase project led to a customized, cost-effective, reliable solar-powered
automated gas distribution regulator monitoring system from Huffman engineering, which
improved the safety of Nebraska’s Metropolitan utilities district (Mud) gas system.

By Craig Malesker, PE outlet pressures (see Figure 1). The

and Sean Creager chart recorders could record three to
Huffman Engineering Inc. seven days of the regulator pressure

A
reading data. Every 48 hours—or
on a weekly basis—the charts were
merica’s natural gas changed manually and examined by
utilities operate 2.5 MUD employees solely dedicated to
million miles of distribu- this responsibility.
tion and transmission
pipelines that span Figure 1: Original mechanical paper chart
the country to provide
recorders at gas regulator stations. All
service to more than 177 million
graphics courtesy: Huffman Engineering Inc.
Americans. Natural gas utilities are
part of the communities in which they
operate. Their mission of keeping Not only was this antiquated and
customers safe, secure, and informed labor-intensive, the fact that data was
is paramount. not analyzed for up to a week was
Like other utilities across the a major concern for MUD in terms
country, Nebraska’s Metropolitan of emergency response time to cor-
Utilities District (MUD) is tasked rect abnormal operating conditions.
with the challenge of addressing the MUD wanted to be able to monitor
sustainability of aging infrastructure. the remote stations in real time and
MUD is the fifth-largest public gas have the information display on the
utility in the U.S., providing natu- supervisory control and data acquisi-
ral gas to more than a quarter of a tion (SCADA) system at their system
million customers in the cities of control headquarters.
Omaha, Bennington, Fort Calhoun,
Springfield, Yutan, and Bellevue. The journey to the solution
Huffman Engineering has been a Replacing the paper chart recorders
trusted advisor to MUD for more than 20 years. “We count began in 2005 with just five pilot locations. MUD relied on
on Huffman Engineering’s expertise in control systems Huffman Engineering as a partner and advisor during the
and technology to guide our infrastructure upgrades. The five-phase project with automation of the final set of regu-
reliability and responsive willingness to answer our calls lator stations taking place in 2017. Huffman Engineering’s
any time of the day or night has contributed to a partner- role included design of the control panels and installa-
ship that keeps the communities we serve safe,” said Jim tion of the new hardware to transmit the pressure read-
Bewley, MUD gas distribution foreman. ings to MUD’s system control SCADA system. Huffman
Engineering programmed the SCADA system software to
The problem integrate the new centralized data collection with display,
In 2005, each of MUD’s 280 remote gas regulator alarm, trend, historical logging, and report capabilities.
stations had a pole-mounted enclosure containing a Bewley summarized the benefits of automation gas
mechanical paper chart recorder to monitor inlet and distribution sites, “The cost savings has been substantial.

A8 • December 2017 Applied Automation

More importantly, the safety and security of the com-
munities we serve has improved through a reliable auto-
mated monitoring system where problems are reported
within 15 minutes rather than potentially taking up to
seven days.”

Challenges along the way

n Cost: With the pilot sites, the major cost was for the
electrical contractor. The local electric utility company
connected power to the site free of charge. However,
when researching the conversion for the next set of
sites, electric power was not readily available, so the
costs were higher. The cost to have the electric utility
and electrical contractor bring in electricity ranged from
$10,000 to $20,000 per site, depending on distance and
difficulty in reaching the site. This made it cost-prohibitive
for MUD. These locations required an off-grid solution to
power the equipment.
n Alternative power—poor fit: After several initial
solar installations, MUD continued to search for the
optimal solution. For the monitoring sites located in
publicly-accessible areas, the solar arrays (panels)
stand out because of their size. One alternative solution
tested was a thermoelectric battery charger, which is a
small device that does not stand out like a solar array.
The thermoelectric battery charger uses natural gas to
create a temperature differential that is then converted
to electricity. Because natural gas is available at each of
the regulator sites, it made sense to try it. However, the Figure 2: New pole-mounted enclosure and solar-powered site hardware.
thermoelectric device failed after a couple months due
to internal corrosion. MUD determined the thermoelec- by a system-control operator 24 hours a day. The RTUs
tric battery charger was not a good long-term solution are programmed to collect pressure data every 15 min-
for this application. utes and under normal conditions, they report pressure
n A lengthy process: The plan to replace all the readings every four hours to the SCADA system. If the
manual chart recorders was scheduled to take place in pressure goes out of range, the RTUs report the pressure
phases, with one phase installed per year. Six or seven readings within 15 minutes to the SCADA system. The
months are needed to complete each phase, which com- pressure is alarmed on the SCADA screen to alert the
prises a set of 50 to 60 sites. The process included site operator with a Hi, Hi/Hi, Low, and Low/Low status. The
prep work and gas line piping to connect the transmitters, operator can report the problem to a supervisor to take
a lengthy bidding and selection procedure, parts procure- immediate action.
ment, panel building, installation, and testing.
Solution benefits
Solution highlights n Safety: According to MUD, the real-time monitoring
n Solar-powered site hardware: The hardware consisted already has alerted MUD personnel to abnormal operating
of a pole with a mounted enclosure for a remote terminal conditions (pressures above or below alarm setpoints).
unit (RTU), modem, charge controller, battery, mounted n Daily reports: Technicians are emailed reports daily
enclosure containing the pressure transmitter(s), and solar to streamline work for the day. These reports, and the abil-
panel mounted on the top of the pole (see Figure 2). The ity to access historical data to see trends, allow for predic-
RTU input/output points include pressure readings, battery tive maintenance to keep the gas regulator stations up and
voltage, and heartbeat data. running (see Figure 3). The reports include:
n SCADA system at MUD’s system control: By remov- -Site pressure alarms.
ing nearby or redundant sites, the scope of the project was -Communication failures.
reduced to upgrading 225 monitoring locations. All stations -Number of call-ins by site.
are monitored at MUD’s system control, which is manned -Battery voltage in solar panel.

Applied Automation December 2017 • A9

 C a s e s t u d y: s o l a r sC a d a

Figure 3: Regulator station data monitoring with the new SCADA system.

n Consistency and ease of maintenance through system. Huffman Engineering is proud to have contrib-
standardization uted to the improved safety and efficiency of MUD’s gas
-The panels are all built the same. There are only three system. Innovative, low-cost solutions such as these
drawing sets: one for a 1-transmitter site, 2-transmitter can be implemented throughout the U.S. to increase the
site, and 3-transmitter site. sustainability of aging infrastructure.
-All panels have the same parts, reducing the number
of spare parts to keep on-hand.
-There is no individual complex setup for the RTU pro- Craig Malesker is a senior electrical engineer and
grams; there are only three variations, again based on project manager at Huffman Engineering Inc., in Lincoln,
the number of transmitters. Neb., where he has worked since 1993. Specializing
n Labor savings in programming control systems for a variety of indus-
-Elimination of chart technician positions (previously tries, Malesker is trained in nine leading-edge platforms
two employees). and has experience with all the major brands. Malesker
-SCADA reports emailed in the morning to gas distribu- graduated from the University of Nebraska-Lincoln with a
tion personnel give direction for how to organize their bachelor of science in electrical engineering.
day.
-Standardization of the panels allows for employees to Sean Creager is a senior electrical engineer at
have the right spare parts on-hand and resolve mainte- Huffman Engineering Inc., where he has worked for
nance issues quickly. nearly eight years. His specialty is human-machine inter-
n Other cost savings face (HMI) configuration, and he has completed training
-Reduction in cellular data usage and power cost by on five popular platforms. His HMI configuration skills
programming the cellular modem to only power on include operator interface design, database design and
when transmitting data (every four hours except in the maintenance, and web-based reporting. Creager received
event of an alarm condition). his bachelor of science in electrical engineering from the
-The 12-V solar charging system uses minimal power. University of Nebraska-Lincoln, where he was part of the
J.D. Edwards Honors Program.
This project led to a cost-effective, reliable solar- Huffman Engineering Inc., is a CSIA certified control
powered automated gas distribution regulator monitoring system integrator.

A10 • December 2017 Applied Automation

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 R a d aR l e v e l m e a s uR e m e n t

Getting focused: Using 80-GHz radar

sensors for liquid level measurement
the introduction of 80-GHz radar sensors represents a paradigm shift in liquid-level
measurement. High-frequency devices have ushered in an era of new possibilities for the
process control industry, and it’s because of signal focusing. this article looks at things
an 80-GHz radar sensor can do that its predecessors cannot.

By Gregory Tischler and Tom Brewer With an antenna of the same size,
VEGA Americas 80-GHz gauges emit a beam angle

U
of only 3 deg. This allows them to be
used in vessels with internal installa-
sing 80-GHz transmis- tions or heavy buildup on the walls.
sion frequency liquid-level The focused microwave beam simply
measurement can improve avoids these obstacles as if they
signal focusing to allow aren’t even there. This is welcome
accurate, reliable mea-
surement in tanks with agi- Figure 1: The focused beam (yellow) of
tators, heating coils, and other inter-
80-GHz radar sensors avoids internal agita-
nal obstructions. That’s because a
tors that contact the 26-GHz radar beam
narrower emitted beam makes radar a
realistic option for use on ball valves, (gray). All graphics courtesy: VEGA Americas
and increased transmission frequency
correlates to a smaller antenna mak- news in chemical and food produc-
ing it ideal for retrofitting and use on tion, where obtrusive internals are the
smaller tanks. norm and space is at a premium (see
Figure 1).
Focused beam avoids An exciting benefit of increased
obstructions signal focusing is the performance of
Increased focus of the beam angle 80-GHz radar sensors when mounted
is the principal benefit of 80-GHz radar on ball valves. Historically, attaching
instruments—the one improvement a 26-GHz radar gauge to a ball valve
that makes the rest possible. In every and receiving an accurate level mea-
process, focus is crucial to accurate surement has been a significant chal-
level measurement, and these new lenge. Ball valves contain many interior
instruments emit the most focused signals on the market. surfaces that reflect radar signals. To make matters worse,
Plant operators have struggled with unfocused radar they often are used in combination with a bleed ring that
for decades—particularly in liquid-level applications. The can create even more signal noise. These reflections
wide beam angle of 26-GHz sensors (and 6-GHz sensors make it difficult to discern which signals are generated by
before them) made it difficult for radar signals to miss the valve and which are from the product. This confusion
agitators, heating coils, and other vessel internals. For forces operators to turn to instrumentation manufacturers
example, a radar sensor with a transmission frequency of for help, but the best solutions often are difficult to imple-
26-GHz and an 80 mm-diameter antenna was limited to a ment and may require periods of trial and error despite the
beam angle of approximately 10 deg. These instruments best efforts of plant technicians. Before long, the manufac-
picked up reflections from vessel installations that dis- turer’s tech is onsite servicing the 26-GHz radar.
torted the returning signal, forcing users to make adjust- The increased focus of high-frequency gauges
ments to monitor the true liquid level. means fewer signals are reflected by the valve’s inte-

A12 • December 2017 Applied Automation

rior. This minimized noise creates a clear picture of video, knowing that one of the pixelated figures on the
the level inside a tank. Users across the world have screen is a criminal mastermind. The computer whiz
experienced consistent level measurement mounting punches a few keys and the word “enhance” appears in
an 80-GHz radar gauge on garden-variety 3-in. and green letters on the computer screen. The blurry face
4-in. ball valves. The bigger the valve, the clearer the gets a little clearer. The computer whiz clacks away at
signal, but 80-GHz sensors also are performing well the keyboard and enhances the footage once more,
on 2-in. ball valves. This is a big break for users who revealing a crystal-clear image of the villain’s face. This
need ball valves to separate their equipment from their might be an example of lazy screenwriting, but it’s a
product but have avoided installing a radar-level device good analogy of the difference in resolution one would
because the degree of measurement difficulty was too experience when switching from low-frequency
great. Radar’s accuracy and low-maintenance reliabil- to high-frequency radar sensors.
ity is now a viable option. When the level of liquid in a ves-
Superior focus makes for accurate measurement sel gets low enough, 26-GHz radar is
without adjustment even when mounted on a ball
valve, but the increased focus of 80-GHz radar
sensors creates other benefits for users. Figure 2: Small process fittings make 80-GHz
radar sensors ideal for retrofitting onto
Small antennas take radar where existing tanks.
radar has never gone before
Amping up a radar sensor’s focus
has an opposite effect on its anten- unable to distinguish the signal
na—its size decreases as trans- returned by the remaining product
mission frequency increases. from that of the tank bottom, and the
An 80-GHz sensor, therefore, user rightly thinks the vessel is empty
does not require a large when it isn’t. This is the same as the action-
horn to focus its beam at movie computer whiz being unable to enhance
the measured material. surveillance footage. Limited resolution presents a
The signals take a narrow natural handicap to process efficiency. Ultra-focused
beam all on their own. The saved 80-GHz devices measure liquid down to the last mil-
space makes a huge impact, particularly as limeter in the tank, giving users accurate data that
it applies to retrofitting. Plants can integrate the most can help optimize their processes. It won’t thwart a
advanced radar devices into an existing process without terrorist attack or prevent an elaborate heist, but the
shelling out thousands of dollars for vessel modifica- enhanced resolution of 80-GHz radar sensors helps
tions. For users who have longed for radar but could users avoid waste.
not afford a retrofit, this news is tantamount to a budget
increase. Smaller instruments, however, aren’t just good Limitations of high transmission frequency
for old vessels; they also can help manufacturers stay There are certain scenarios where 80-GHz sensors
nimble and market-responsive. are limited. In liquid applications where foam is ram-
There’s a trend in the pharmaceutical and chemical pant, a guided wave radar (GWR) sensor is usually
industries toward batch production. Batching allows a more appropriate solution than an 80-GHz sensor
operators to produce seasonal and low-volume prod- because a GWR transmitter emits a concentrated radar
ucts with less financial investment. Small batches are pulse conducted via a probe that will not be absorbed
produced in small vessels, where conventional wisdom into the foam. That’s not to say 80-GHz radar won’t
says using radar is impossible due to small process work in applications with foam, just that guided wave
connections. Thanks to the compact antenna of 80-GHz sensors typically work better.
radar sensors, that is no longer true, and operators no Additionally, high-frequency instruments are not
longer have to sacrifice accurate measurement in the recommended for use on stilling wells or on stand-
name of space (see Figure 2). pipes. This is an instance where high frequency works
against the application. Note that 80-GHz beams have
Enhanced resolution measures to the last drop more modes (think, pathways) to the product, and in
Any fan of cliché action films is familiar with this the confined space of a stilling well, signals from those
scene: An investigator stands behind a computer whiz in modes create a confusing level reading. Again, 80-GHz
a laboratory full of expensive-looking surveillance equip- radar sensors will work, but 6-GHz sensors are going
ment. They are watching a grainy piece of closed-circuit to output a measurement that is easier to read.

Applied Automation December 2017 • A13

 R a d aR l e v e l m e a s uR e m e n t

Looking ahead beam makes radar a realistic option for use on ball
This cannot be overstated: 80-GHz transmission fre- valves. The increased transmission frequency correlates
quency changes everything as it concerns liquid-level to a smaller antenna that is ideal for retrofitting and use
measurement. Superior signal focusing allows for accu- on smaller tanks, and enhanced resolution lets users
rate, reliable measurement in tanks with agitators, heat- make the most of every vessel. The future of radar level
ing coils, and other internals. Plus, the narrower emitted sensors is here. That future is 80-GHz.

Amping up a radar sensor’s focus has Gregory Tischler is a product manager at VEGA
Americas and is responsible for radar and guided wave
radar sensors. He has almost 20 years of experience
an opposite effect on its antenna— in the industrial automation industry, all with VEGA
Americas. He is a voting member of the American Society
its size decreases as transmission of Mechanical Engineers Bioprocessing Equipment
Process Instrumentation subcommittee, which is respon-
sible for writing instrumentation standards for bioprocess-
frequency increases. An 80-GHz sensor, ing equipment, and he was also an active member of the
Measurement, Control & Automation Association commit-
therefore, does not require a large tee responsible for shaping new Federal Communications
Commission rules for tank level probing radars (Section
horn to focus its beam at the mea- 15.256), which were released in 2014.
Tom Brewer is marketing content specialist at VEGA
Americas. Edited by Jack Smith, content manager,
sured material. CFE Media, Control Engineering, [email protected].

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A14 • December 2017 Applied Automation

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