100% Employee Owned, Founded 1954

100% Employee Owned, Founded 1954

Process Solutions Group Resources

Articles and Whitepapers

Industrial control valves are constantly moving and therefore will wear faster than an on/off block valve. They require more maintenance than block valves and can be very expensive to replace. Proper material selection, sizing and maintenance are crucial to extending the life of control valves. Pneumatic Control Valves Pneumatic Control…

As an integrator we are often brought into new projects later than what would be ideal, which results in the creation of additional work for the integrator and additional cost for the customer. If the OEM or custom equipment has already been spec’ed and ordered before engaging an integrator, there…

Commissioning For Process Controls: The Pursuit of Excellence Commissioning is a team effort to document the continuity of a project as it moves from one project phase to the next. To achieve commissioning excellence requires that the testing documents be accurate and written in an orderly fashion. The Documentation Gatekeeper,…

Technical Bulletins and Guides

Achieving High Availability with Redundant Rockwell ControlLogix Systems Rockwell’s Allen Bradley ControlLogix line supports enhanced redundancy with processors, communications, and power supplies to achieve high availability of your control system. Here are some of our recommendations, plus some pitfalls to avoid when implementing such a system. 1. Make sure you…

Advanced Methods for Tuning a PID Loop A PID loop adjusts its OP to maintain its PV at its SP. Some PID loops cannot be satisfactorily tuned by adjusting the three primary constants. When combined with good basic tuning, advanced methods can improve stability, responsiveness, and limit overshooting. See The…

How to Tune a PID Loop The art of tuning a PID loop is to have it adjust its output (OP) to move the process variable (PV) as quickly as possible to the set point  (responsive), minimize overshoot, and then hold the variable steady at the set point without excessive…

Hazardous Area Classification Guide The National Electrical Code (NEC) defines hazardous locations as those areas “where fire or explosion hazards may exist due to flammable gases or vapors, flammable liquids, combustible dust, or ignitable fibers or flyings.” Hazardous locations are classified in three ways by the NEC: type, condition, and…

Oval Gear Flow Meter Installation & Troubleshooting Knowing the do’s and don’ts of oval gear flow meter installations is just as important to the life of your meter as was the selection criteria for choosing  an oval gear flow meter. To avoid any unintentional damage to your new oval gear…

Draeger Tube Accuro Pump Best Practices & Maintenance Guide What is the Draeger-Tube System? In order to optimize your gas detection results, you need a clear understanding of the Draeger Tube System. So, exactly what is a Draeger Tube System? The system contains two key parts that work in tandem.…

Case Studies and Application Notes

Cross Helps HRSD Measure Flow Ultrasonically in Concrete Pipe Application Hampton Roads Sanitation District (HRSD) is responsible for wastewater treatment in Southeast Virginia. They have nine large treatment plants and eight small plants in Southeastern Virginia and the Eastern Shore. They also have over 100 pump stations, and many remote…

Cross Process Solutions Helps Paper Mill Reduce Risk with Draeger Gas Detectors A Virginia paper mill was struggling with their chlorine dioxide fixed gas monitors. The devices were regularly breaking down and the maintenance team at the facility was, in turn, having to dedicate significant time to repairing the gas…

Cross Helps Pharmaceutical Manufacturer Improve pH Measurement Process A pharmaceutical manufacturer located in North Carolina’s Research Triangle Park was experiencing some issues with their automated pH measurement system. The existing systems were used for monitoring pH in their critical utilities wastewater treatment area. The existing systems were obsolete and required…

Cross Helps Kemira Migrate Safety System While Keeping their Facility Operational Kemira, a specialty chemical manufacturer, located in Marietta, GA made the decision to migrate their existing Triconex safety control system to a Siemens PCS7 system. The Triconex system had been in place since 1993 and was starting to cause…

Cross Process Solutions Group Helps Carlstar Get Back Up and Running Quickly After Fire Carlstar, a tire manufacturer in Clinton, TN, experienced a fire that destroyed several of their control panels. They immediately reached out to Cross Process Solutions for help. The Process Solutions experts at Cross involved a team…

Cross Helps Major Pharmaceutical Company Reduce Risk with Custom Engineered Gas Detectors When a pharmaceutical manufacturer decided to take a closer look at their safety procedures, they reached out to Cross Process Solutions for help. Their most specialized need was in their solvent recovery room where they were using both…

Application Note: Secure Smart Valves for Military Base Cross Helps Military Base Install Secure Smart Valves A military base was in need of smart valves for their high-pressure air service to a wind tunnel test stand. The application required ANSI 2500# Class valves with modern electric actuators. For security reasons,…

Case Study: Jack Daniel’s Distillery Flexible Batch Processing and Systems Integration Jack Daniel’s is a storied distillery with a popular and well known history and their product is widely appreciated as a reliable and quality whiskey. The company’s traditional distilling process – known as “Jack’s Way” – is a critical…

Case Study: DTE Calvert City The following case study written by our very own Josh Dalzell appears in the Applied Automation supplement for Control Engineering and Plant Engineering. DTE Calvert City (DTECC) made the decision three years ago to upgrade their obsolete Process Suite HMI to APACS OS. For 15 years, APACS DCS had been a reliable…

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