Re-evaluating process instrumentation maintenance practices

IN INDUSTRIAL operations, the seamless functioning of process instrumentation is paramount. In sectors such as food and beverage, water and wastewater, chemical, oil and gas, power and energy and life sciences, instrumentation ensures precision, safety and efficiency. However, having the correct maintenance practices in place for these critical instruments is vital to protect operational integrity and maximise plant performance.

Process instrumentation maintenance

Traditionally, process instrumentation maintenance has focused on routine procedures, such as scheduled calibration, and repairs of faulty devices. Both have disadvantages. Reactive maintenance - handling device failures when they occur unexpectedly - causes unplanned disruption and has potentially significant business implications. Preventive maintenance based on fixed schedules is better, but still runs the risk of acting too early or too late. Both methods fail to leverage the full potential of contemporary technological innovations.

In contrast, predictive maintenance, powered by Industry 4.0 technologies, offers a transformative approach. Endress+Hauser’s patented Heartbeat Technology assists engineers and technicians to make that shift. Integrated into numerous Endress+Hauser measuring devices, Heartbeat Technology provides in-depth device and process insights to increase plant performance and reduce maintenance costs. It consists of three functions: diagnostics, verification and monitoring. These provide an immediate indication of device failures or processes operating out of specification, monitoring of sensor responses and specific device parameters for maintenance planning, and verification tests in the running process. The latter not only provides an indication of device health without process interruption but can be used to optimise calibration and proof test cycles.

Digitalising maintenance

Adapting to the digital transformation of industry can feel overwhelming, particularly as process plants are under pressure to conserve resources while constantly evolving and improving. Instrumentation holds a vast amount of information beyond its primary function, and being able to tap into that wealth of data - and use it intelligently - is key. Effective asset management and digital solutions are becoming more important than ever before.

IIoT systems such as Netilion from Endress+Hauser turn instrumentation data into actionable information. From a simple smartphone application, installed instruments can be monitored and error codes can be diagnosed and resolved remotely. The first step in using the cloud-based solution Netilion is to create digital twins of your physical assets, which gives you a clear picture of your installed base and allows you to access data securely at any time from any location. Protecting sensitive data and ensuring the integrity of maintenance systems is vital, so robust cybersecurity measures are an integral part of Endress+Hauser’s systems. 

The long-term benefits of predictive maintenance - reduced downtime, enhanced safety and optimised resource allocation - are too substantial to ignore. Investing in this transformation will not only safeguard operations but also create efficiencies that would previously have been unattainable. 

Clive Poyser ​is managed services consultant at Endress+Hauser UK