Process instrumentation and measurement play a massive role in sanitary processing plants. Irrespective of the industry, this aspect needs to be closely monitored for improved product quality. Industries that fail to monitor their processes are likely to create a false economy for themselves, one that is bound to crash under the weight of production and standard practices. While some argue that process monitoring requires more equipment, thus requiring higher financial investment, others believe you have to be alert irrespective of the number of instruments installed. PPS Professional Process Systems is an ABB instrumentation and analytical supplier that has found process instrumentation to be a critical aspect of manufacturing that is not to be ignored.
In this article, the ABB instrumentation and analytical supplier addresses the common pain points of process instrumentation in the manufacturing industry. The article touches on areas like;
- What should I be monitoring?
- Why process monitoring is necessary
What Should I Be Monitoring?
As a manufacturer, you ought to understand what to keep track of to ensure proper sanitary measures in your processing plant. Below are some of the essential areas to stay on top of.
Pressure in process pipes or vessels
There is an expected pressure range across the pipes and vessels in your process plant. Changes in the pressure range often cause changes in product consistency or quality. Frequently, the pressure changes in the pipes or vessels indicate possible problems affecting the pump, agitator, or other equipment. To prevent product inconsistencies and wastage, you should monitor slight pressure changes.
Temperature
Temperature is such an essential part of equipment function. Process monitoring that does not include recording equipment temperature and temperature changes is incomplete. Temperatures that are too high or too low affect product quality. Depending on the industry, slight temperature changes can cause drastic product and product quality. Staying on top of temperature and cooling times can help understand heat loss or cooling problems.
Fluid Level
Certain fluid levels are essential for the proper functioning and lubrication of equipment in the processing system. Low fluid levels can cause massive problems that drastically affect performance and production. Low fluid levels can also create safety problems on the manufacturing floor. It is essential to stay up to date with fluid levels under and outside of process conditions to understand how processes run and equipment management.
Fluid Flow Rate or Velocity
The fluid flow rate or fluid velocities are indicators or process conditions. They affect productivity just as much as all other factors listed above. Fluid flow can be used to monitor the overall equipment processing rate. It can also be used to determine the correct conditions for manufacturing; for example, a balanced flow rate is needed when filing a pasteurizer or other continuous processing equipment. Manufacturers need accurate fluid flow rates to keep processes running for such industries.
Product Analytics
This is an essential part of process monitoring. It considers crucial factors like pH, conductivity, chemical composition, and weight. All of these could be monitored to reach the desired product quality.
Why Process Monitoring is Necessary
Efficiency
Process parameter and variations monitoring give manufacturers a clearer picture of their production tunnel and how each parameter affects their product quality. This information can be used to prevent and track problems that may arise due to varied parameters and process conditions. Knowing what could be wrong can ease the stress and rigor of walking around the plant. It also saves time on repairs and process optimizations.
Quality
Specific operation parameters and variables impact the product and product quality more than others. For example, the temperature is often a critical operating variable affecting product quality in most food and beverage processing plants. Temperature ranges that are too high or too low can destroy a batch of products by overcooking or undercooking.
Safety
Safety on the manufacturing floor is an essential consideration for all businesses. It would help if you strived hard to maintain the safety of equipment and workers by staying on top of parameters that may spike chain reactions. For example, equipment temperature plays a huge role in the safety of plants and workers. Overheating has been known to cause fires in many plants. Monitoring these parameters can help to maintain safety and reduce industrial accidents.
Preventative Maintenance
Maintenance is an integral part of process plants and manufacturing processes. Proper maintenance gives you a better chance of conducting error-free operations and keeping your equipment safe.