In any industrial process, accuracy is inarguably the most critical variable of success in liquid analytics. There’s no shortage of hoops and hurdles along the road to achieving that success, however. Getting through those barriers requires the collaboration of several different departments in an industrial environment. From maintenance to operations and engineering, every division of a site must be on the same page in regards to the countless variables that factor into managing the quality of their product and the efficiency of the process. Let’s examine some of these variables while discussing some tips to navigate them in order to achieve maximum accurate uptime for your industrial process.
1. Start with the Right Equipment
The road to maximum accurate uptime for your process begins with the right equipment. We know, this one seems obvious. But there are many considerations to be made before making your selection. What classifications do you require? Would a glass or PEEK sensor be better? What kind of sensor junction will be sustainable for your process conditions? Choosing the proper sensors, holders, transmitters, and automation equipment is the baseline path to a process’ success. No two processes are identical, and the demands of each may require unique measurement ranges, installation necessities, or qualifications. To smooth out the selection process, M4 Knick creates helpful guides that aim to ease the burden of choosing the right equipment.
2. Be Mindful of Installation: Orientation and Alignment
The proper equipment requires a proper installation. Inadequate sealing or improper connections like a loose fitting or a missing O-ring can result in leaks, creating unnecessary downtime. Other process variables like pressure, temperature, and flow are also considered when installing holders, sensors, etc. Proper alignment when installing is critical. For example, a pH sensor installed at an improper angle can have severe impacts on accuracy and process efficiency.
3. Prioritize Maintenance Schedules
Measurements will not be accurate without a structured approach to proper sensor cleaning and calibration. Keeping a sensor cleaned and calibrated is the first step in ensuring your sensor is reading correctly. A cleaning and calibration schedule, whether automated or manual, can seriously boost a sensor’s long-term health and integrity. Precision and repeatability of these schedules leads to increased accuracy and consistency.
4. Utilize Sensor Diagnostics
Transmitters equipped with diagnostic capabilities are incredibly helpful in maintaining maximum accuracy as well as increasing uptime. These features enable the detection of potential issues such as sensor drift, fouling, wear, or calibration errors before they lead to significant measurement inaccuracies or equipment failures. Incorporating these diagnostic checks can help you understand when it’s time to clean, calibrate, or replace a sensor entirely before their process uptime is impacted.
Getting to Maximum Accurate Uptime
Maintaining the integrity of your equipment, structurally or electronically, is the baseline for getting to maximum accurate uptime. Of course, there are countless other variables that must be accounted for to maintain this integrity. Regular cleaning, calibration, and validation routines, along with real-time adjustments for dynamic process conditions, are just the first steps in maintaining accurate data and minimizing downtime. Following these tips can provide the reliability and peace of mind that makes managing a process feel less demanding.
