Minimizing variability and maximizing production

Posted on by Trident

What if you could fine-tune your control system to minimize variability and maximize production? There are hundreds of process loops in an ethanol plant that can be a significant source of variability. Taking the time to identify variability and determining if control loops are a contributor is often complex and time consuming.

Until now.

Trident Automation is offering a software module that works in conjunction with our Trident Workbench called LoopPAC©, Control Loop Performance Monitoring. LoopPAC© is a software program that quickly and accurately identifies control loops that are operating at less than optimal performance.

“Plant operations is often adjusting for variability, but it is typically hard to track down root cause in a system as complex as a biofuels refinery.” Jerry Wenzel, Chief Knowledge Officer for Trident said. “Control loops can be a significant contributor to that variability.  LoopPAC© is the tool to shine a light on that variability and help you resolve it.”

There are typically a lot of issues that LoopPAC© finds when you first run it.  The package helps you prioritize what it reports, and the first run results often are eye opening.  There is often “low hanging fruit”, opportunities for significant improvement without a huge effort or cost.  Long-term, because control loop performance often degrades over time due to things like control valve wear, LoopPAC© is able to significantly contribute to your preventative maintenance efforts.

LoopPAC© uses your plant’s existing data and automatically configures its database by identifying loops in your control system configuration. The package analyzes PV/SP deviation, valve travel and numerous other key indications of control loop health.  When one of those factors degrades LoopPAC© flags the loop as needing attention and reports it according to the priority level you place on that loop.

The benefits of LoopPAC© are:

  • Records and aggregates deviation between PV & set point, so you can control the ranges of your plant’s optimal operation.
  • Records the cumulative change in controller output. Excessive output changes are an indication of poor control loop performance and a major case of control valve failure. This allows operators to better monitor the wear and tear on plant hardware..
  • Tracks the time loops spend in manual. If operators are consistently putting a loop in manual, that is an indication the loop needs attention.
  • Organizes and reports loop problems in an easy to understand prioritized format. .

Control loops are a significant source of variability and keeping your plant at peak performance means increased profitability. LoopPAC© is the valuable tool needed to manage the production details that may be affecting your bottom line.

LoopPAC© is available as a module to Trident Workbench© Suite of products.

Contact Trident Automation for more information or a demonstration at [email protected].

Trident’s innovative e-store for previously used DCS hardware

Posted on by Trident

In order to better support customers, Trident Automation is providing a service—an online e-store featuring previously used hardware. The Trident e-store has been open as of Oct. 3, 2017 and provides hundreds of replacement parts for businesses currently running APACS, Foxboro and other control systems.

Siemens announced it will discontinue support for the APACS system in 2020; as an independent integrator and Siemens solution partner, Trident will continue to offer replacement parts and system service. Foxboro announced the FCP270 Field Control Processor will no longer be sold and the manufacturer will no longer support this product.

As one of the largest independent integrators in the nation, Trident has been upgrading customer systems, re-purchasing the old APACS systems and Foxboro products, and keeping them in inventory. “We’ve been working with the APACS system since before we were founded in 2002 and have replaced or upgraded more than 30 systems,” said Jason Hurst, CEO of Trident Automation. As a result, Trident has a healthy inventory of IEMs, ACMs, cables, IO cards, controllers, cables, termination boards, chassis, and more.

The APACS system is widely used in paper industry, ethanol industry, wastewater treatment plants and many more industries. The Foxboro FCP270 Field Control Processor is used chemical, petroleum, power generation and other industries that use continuous process automation.

Trident leaders created the e-store due to the large number of industries still using the product. “This will give customers a little more time to make a decision about system upgrading,” Hurst said. “If you’re trying to go an extra couple years using an APACS system, we’re here to help.”

Trident currently has many items listed for sale and current promotions for the remainder of the year. To use the Trident e-store, visit  to search the product database and place online orders via credit card. Parts will be shipped within two business days.

According to Hurst, Trident will continue to service the APACS product and Foxboro products indefinitely. “We actually have the experience to maintain the product instead of just selling parts,” Hurst said. For more information from Trident Automation, please visit

Why upgrade?

Jason Hurst, Founder

The distributed control system (DCS) is the brain of any manufacturing plant, providing the intricate knowledge and responsiveness needed to keep production running smoothly. For many plants, the decision to upgrade a DCS is often made well beyond the life of the system, when operations are starting to fail or falling behind current technology.

So how do plant managers know when it’s time to upgrade?

Check out the article, DCS Upgrade Detailed, written by our very own Jason Hurst. This article is featured in Ethanol Producer’s October 2018 issue.

Advanced and Enhanced

Trident Automation has been featured in an article by Ethanol Producer Magazine.

Check out the article, Advanced and Enhanced written by Susanne Retka Schill.

Trident’s Focus: Customer Confidence and Trust

Posted on by Trident

Trident Automation has been featured in an article by AutomationWorld Magazine.
Learn how Trident found a solution for ways to limit downtime during a control system migration for our customers in the continuous process industries.

Check out the article, Using Simulation to Reduce Commissioning Time and Increase Customer Confidence.

Join Trident at the TEAM M3 conference

Posted on by Trident

Stay on top of the ethanol industry with networking and best practices at the Team M3 conference! Join Trident to learn from industry insiders about how to improve your ethanol operations. The association of ethanol maintenance professionals meets twice a year for networking; breakout sessions, presentations and a vendor exposition. Trident will be on hand to share the most updated solutions to plant efficiency.

“This is a remarkable open forum between ethanol producers where plants share ideas and best practices to problem solve challenges,” said Jason Hurst, Trident’s CEO.

Trident representatives will be on hand to review the latest hardware and software to maximize DCS functionality. Top for the industry, replacing APACS systems by 2020 with upgrades and other DCS solutions. According to Hurst, Trident will continue to service the APACS product indefinitely, but system upgrades are in high demand. “Because we’re a Siemens Solution Partner, we actually have the experience to maintain the product instead of just selling parts,” Hurst said. “However we have several Siemens certified engineers that can replace an aging APACS DCS with the latest Siemens platform,” he said.

Trident has also experienced increase demand for the BMS First Out system—a module that identifies alarms and allows operators to quickly identify the source of an alarm, solve the issue, and get production back up and running.

To learn more about these Trident products and other industry issues, consider attending the Team M3 conference, August 14-16, 2018 held at the Westin Hotel in Westminster, Colorado. For more information, please visit:

Meet us at the Siemens Summit

Posted on by Trident

Join Trident Automation at the annual Siemens Summit, June 25-18 at Marco Island, Florida.  Leaders from Trident will present case studies pulled from real-life experiences showing how the latest control system technology at work. Trident will host two of 50 user-led presentations—we are a Siemens Solution Partner and have designed and integrated Siemens products for a wide range of customers.

SIMIT: Factory acceptance test, change management and training tool

Jeff Meneau, Controls Designer II

Jeff Meneau, Trident Automation Controls Designer II and certified PCS 7 engineer, will present a case study on how Trident used SMIT to reduce risk and increase efficiency. Trident projects often involve a full rip-and-replace of the legacy IO to PCS 7, new configuration, and subsequent training. In all situations, customers need to minimize production outage time, so SMIT has been used to test the system during factory acceptance testing, onboarding operators to the new system, and speeding up system commissioning.

“By running these sequences in a virtual ethanol plant environment, we are able to simulate flow, valve and pump operations, and test the system without ever leaving Trident’s offices,” Meneau said.

SIMIT has also been used as a troubleshooting tool. Learn how one customer called with a question about interlocks/sequencing, assuming they had a configuration error. By using SIMIT, Trident teams were able to show the configuration logic was working and, instead, isolated a problem in the field.

Design Considerations When Migrating to PCS 7 V9 with ET200SPHA

Nathan Nutter, Controls Designer II

Nathan Nutter, Trident Automation Controls Designer II and certified PCS 7 engineer, will present a case study on the design considerations, configuration approach and migrating a Trident customer from APACS+ to PCS 7 V9 with a distributed ET 200SP HA PROFINET architecture.

We will share best practices on our approach to the new IO series, IO card selection, termination and cabinetry design. We will also discuss the PROFINET network that includes both copper and fiber segments utilizing Scalance Switches for network communications.

“Newer doesn’t always mean better, but in the world of control system technology, even a few years of innovation can provide enhancements and improvements for plant operation,” Trident CEO Jason Hurst said.

During this session, Trident will discuss the role of the service bridge, considerations for network security, the use of software tools such as SIMATIC Topology Editor for the PROFINET network, and SIMIT for testing the configuration to help reduce project risk.

In addition to learning from Trident, attendees at the Siemens Summit will also be able to consult with Siemens representatives, technical experts, access free training, and review the latest products in the control systems marketplace. For more information, please visit

Reduce installation time and enhance maintenance with Trident’s newest innovation.

Posted on by Trident

Constant innovation—it’s the hallmark of working with Trident. The latest innovation for Trident customers is the result of perfecting a solution to a problem faced in many DCS environments—ripping out an old system and replacing it with a new one in a short timeframe.  The challenges of moving thousands  of field wires to the new DCS is a painstaking process.

Jerry Wenzel, Founder

“We are always looking for more ways to optimize a rip and replace,” said Jerry Wenzel, Chief Knowledge Officer, Trident automation. “I wanted to streamline the process of re-landing field wiring to the new DCS along with providing additional features and on-going value for the customer.

Wenzel’s solution was to create a product called TermPAC© — a compact, feature-rich solution to connecting field wiring to a new or existing DCS. He had first-hand experience with the time-consuming process of attaching cables from the endpoint to the control system, then hooking up meters and testing fuses. “There had to be an easier way,” Wenzel said.

After several prototypes, input from field personnel and months of testing, Trident developed and tested the TermPAC© design. Hundreds of TermPAC© termination assemblies are currently installed in 4 plants. “We looked long and hard for an existing solution that incorporates the features we were looking for. No product had even half of the features we feel are important in a termination system optimized for process control.” Wenzel said.

“We strive to use existing solutions when they exist and create solid, easily supportable solutions where none exist. I believe this termination system has more features that any other termination system in the world.”

The system is built with modular components and works with all major DCS platforms on the market. The TermPAC© technology board consolidates features on an easily replaceable board that secures to a base containing field IO terminals, DCS & power connectors. This allows users to replace technology boards for repair or additional features and upgrade their control system without having to re-terminate any field wiring.

In creating the system, Trident designed features that bring long-term benefits:

  • Components are modular, allowing for fast and easy replacement or maintenance.
  • One termination assembly handles loop powered, field powered and analog outputs.
  • Provides per-channel test points to connect a milliamp meter or HART handheld without breaking the loop.
  • Has a solid state fuse for each channel that resets automatically when a wiring short is repaired and an LED that will indicate a field wiring short.
  • End users can quickly connect TermPAC to their DCS with a prebuilt cable solution or use more traditional hand wiring.
  • A terminating resistor can be switched in if a field instrument is disconnected. This prevents unwanted diagnostic errors on that channel.
  • A bypass feature turns the base board into a pure terminal block if there is a need to run without the technology board.
  • Works with Siemens PCS7 & APACS, Rockwell PlantPAX, Foxboro IA, Honeywell PKX & LX, Emerson Delta V.

The system will make field wiring easier and faster, it will also make maintenance and troubleshooting easier for customers.

TermPAC© is available for purchase and will be debuted at the FEW Workshop and Expo June 11-3 held in Omaha, Nebraska. For information on FEW, please visit To schedule an in-person demonstration from Trident, please contact [email protected] and ask about TermPAC©.

Posted in General | Comments Off on Reduce installation time and enhance maintenance with Trident’s newest innovation.

Trident Automation’s philosophy that keeps customers happy

Posted on by Trident

We’ve all been there: after a meeting with a vendor, you don’t remember a thing because you didn’t understand the layers of technology. If that ever happens here at Trident, we have failed. Our primary goal is to build a control system our customers understand—a system that is easy to maintain and grow with each business.

Our three founders grew up in the controls industry and have seen your business from the inside out. Our customers trust our boots on the ground approach to keep their plants running. This means we get to know each individual ethanol customer and the quirks with every operating system. Our goal is to integrate the best products on the market, and to customize solutions for each plant.

It all starts at the top and we’d like to share the philosophy that keeps our customers happy.

Owner Jerry Wenzel founded Trident Automation in 2002 after working in a variety of engineering positions. He is a degreed engineer and a recognized expert in distributed control systems, process design, configuration, and startup. Here’s what he has to say about building transparency into our control systems:


Owner Jason Hurst joined Jerry as the second partner in Trident. While working with Moore Products, he integrated DCS products into more than 40 companies and has a thorough understanding of working with our customers. Listen to what he says about creating a culture of customer service:


Owner Don Jolly is retired, but his impact on Trident is still active. He joined Jerry and Jason as a partner after a career as a process controls and instrumentation engineer. Under his leadership, Trident team members developed a high level of expertise to solve problems for our customers. Here’s what he says about innovation:


As you consider upgrading or replacing your control system, contact us to learn more about how Trident can solve your control system problems.

Contact us at [email protected] or call 920-759-7477.


Empowerment. Direct customer contact. Professional growth.

Posted on by Trident

No, it’s not a self-help course; it’s what team members at Trident Automation say is great about working for the company. The systems integrator employs 41 engineers, technical staff, and support staff that service customers across the nation. Trident supports multiple industries, and customers depend on them to keep plants and production running smoothly.

Dave McCabe, Controls Engineer

“I like the fact that I get to work directly with system operators, engineering teams, and plant managers at our customer locations,” said Dave McCabe, controls engineer at Trident. “Having direct access to the decision-makers and end-users makes it easier to do my job to design systems that meet the plants’ needs.”

McCabe has been working at Trident for six years and bypassed the big company experience in favor of a more entrepreneurial environment. “The experience I receive on the job is fast-tracked here. I’m not in some corporate training department or sitting in a cube. At Trident I’m on the job learning every day.”

That sentiment is echoed by Angy Millan, a project coordinator who has been working at Trident for two years. “I come from big corporate America, I worked for the same company for 17 years,” she said. “I look at growth in in a different way now; it’s not about being on a two-year management track. At Trident it’s about developmental growth and learning as much as you can.” In her role as a project coordinator, Millan says she’s the “air traffic controller” for the engineering teams.

Angy Millan, Project Coordinator

“I love that no day is ever the same,” Millan said. “For me there is always a new challenge or a new customer situation—I feel empowered, appreciated, and work with great people who help you be the best person you can be.”

That sentiment is echoed by Whitney Washington who joined Trident in June of 2017. She served four years in the Marines in the aviation electronics field where she discovered her technical aptitude. Following military service, she enrolled at Northeast Wisconsin Technical College where a friend told her about working at Trident. Even before she graduated as a controls designer, she was employed by Trident.

Whitney Washington, Controls Designer I

She is proud to be a woman working in a male-dominated technical field and encourages more women to follow this career path. “It’s challenging in a way that I haven’t been challenged before.” Washington said. “It’s huge to me that I work for people that respect your ability to learn and have opportunity for advancement without a four-year degree.”

For her, the ability to have direct customer contact and become a member of a true team was important. “I’ve never had a job where they cared about my feelings the way they do here,” she said. “If I raise a concern, I’m encouraged to bring it to the team leaders’ attention.”

Although control engineers and designers have technical degrees, Trident employs team members in support roles of administration, finance, marketing, purchasing, and human resources. Still, employees proudly assert their tech pedigrees. As Angy Millan says, “I think you have to be a little bit of a nerd to work with a bunch of nerds. And that is nothing to be ashamed of!”


Trident is always accepting resumes for our controls engineer and controls designer positions. Please send resumes and cover letters to [email protected]


Our Partners

Siemens OpX Control Rockwell Automation Wonderware CSIA