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 valves utilize a positioner and …

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Top 10 Low Hanging Fruits to Pick for Process Improvement Before or After a Lean Audit This article was featured in Valve World Americas and was written to help any plant manager, maintenance supervisor, process engineer, or mechanical team shine. These may not be everyday ideas for you, but they are simple and absolutely impact …

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The Preventative Maintenance Mindset: How to quantify the True Cost of Inaction Many of us have heard of lean initiatives such as predictive maintenance. Possibly in the past, you focused upon preventative maintenance, or even use to failure. Each of these have their good points and bad points. Today we’re going to discuss the value …

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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 include the right parts Use …

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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 Basics of Tuning PID Loops for …

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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 OP changes (stable). Definitions PID = …

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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 nature. Hazardous Location Types – …

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Case Studies and Application Notes

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 frequent maintenance due to operational …

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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 problems. The issue was the …

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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 of more than ten associates …

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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 acetone and isopropyl alcohol. These …

Application Note: Custom Engineered Gas Detectors for Major Pharmaceutical Company Read More »

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 component to their business success. …

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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 and comfortable system that was …

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Biomass Cogeneration Project for Nippon Paper Industries Cross Helps Nippon Paper Industries Implement New Biomass Cogeneration Project Cross Company worked closely with Nippon Paper Industries’ Port Angeles, WA plant as they built a new biomass cogeneration facility. The process solutions group at Cross implemented all of the programming, startup and checkout services for the biomass …

Case Study: Nippon Paper Read More »

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