Industrial sensor monitoring: challenges and benefits
Sensors are the eyes of industrial operators; without these precious tools, it would be impossible to monitor and manage installations, let alone optimize their operation. However, industrial sensors, like any other equipment, wear out over time. Through this article, our instrumentation expert, Rémi Pelletier, reminds us of the importance of sensor monitoring and preventive maintenance.
Industrial Sensors: Central Components of the Installation
Generally placed within processes and utilities, industrial sensors allow for the measurement of various physical quantities: mass, distance, temperature, pressure, flow, electric current, etc.
“The use of these physical quantities allows an installation to: monitor consumption (energy, production, etc.), evaluate it, regulate it, and optimize it. Among other things, industrial sensors are the starting point for ensuring a optimal understanding of a plant’s operation. Without them, teams would not be able to effectively manage and optimize the installation.”
Rémi Pelletier, Project Manager at Dametis
Regardless of the plant’s size, all have numerous sensors, generating a considerable amount of data that needs to be made reliable.
Rémi Pelletier:
“Just because industrial operators have a significant number of measurements doesn’t mean it’s necessary to analyze them all. You only need to collect, analyze, and exploit the data that meets the industrialist’s needs to achieve their objectives.
To better understand this, a very simple parallel can be drawn with daily life. In a car, numerous data circulate, yet when driving, only essential information is displayed on our dashboard: speed, fuel level, warning lights. While the overall data triggers alerts, it’s not displayed on the dashboard, fortunately, because there would be so much of it that we wouldn’t be able to see anything.
It’s exactly the same principle in industry. And that’s why at Dametis, we developed an EMS software which allows all information to be collected thanks to industrial sensors. But this tool goes further; it validates, standardizes, and contextualizes the data. This allows the most relevant data to be displayed in a very visual way. Thus, the factory can more easily make decisions to reach its production, energy performance, and environmental goals, etc.”
However, to measure the achievement of objectives and implement effective optimization actions, the input data must be reliable.
“The reliability of data integrated into the software is essential to guarantee the accuracy of analyses, recommendations, and gain calculations.”
This is why it becomes essential to control, verify, and ensure the reliability of sensors present on site.
What method for controlling industrial sensors?
Sensor monitoring is the metrological intervention of a technician who visits sites with the means to test, evaluate, and compare the measurements present at industrial facilities. He then ensures that the values returned by the industrial sensor are accurate and consistent with the actual measured quantity. Ultimately, this technician certifies that the values are correct and therefore usable.
Rémi gives us more details on how a sensor check is carried out!
Rémi, how often should sensors be checked?
“It varies depending on several factors related to the sensors: operating conditions, technologies, equipment age, obsolescence, and the ambient environment in which they are located. But this control frequency also varies depending on the energy management system for the factory (such as ISO 50001).”
There are many criteria, so the frequency of sensor checks must be adapted to each installation.
“For example, pressure probes, temperature probes, and flow meters must be checked more regularly. Within the framework of ISO 50001 in particular, a flow meter measuring data related to an SEU (Significant Energy Use) must be subject to more frequent checks. Conversely, the measurement of an electric current is less likely to drift and does not require such regular monitoring.”
Note that it is mandatory to periodically check industrial sensors. However, it is up to each industrial operator to determine a monitoring frequency, and this can vary from one sensor to another.
Can you give a concrete example of a frequency already experienced with a client?
“Yes, we have a client in the food industry who chooses to check their temperature and pressure sensors on an annual basis. On the other hand, this client has measurement units reporting electrical data. They choose to have them checked every 3 years, as drifts related to these are less frequent.
“The more important the measurement is for our clients—both in terms of regulations and also consumption and objectives to be achieved—the more we advise them to regularly check the industrial sensors related to this data, for example every year. On the other hand, if the measured data is less critical for the client, having less impact on analyses and other factors, we recommend a more spread-out monitoring frequency (every 2, 3, or 5 years).”
How is a sensor check carried out?
“There are several methods for this.
The first consists of referring to a metrologically traced master equipment. The master sensor is then installed in parallel with the sensor to be checked. The measurements from each are recorded and the results compared. Following the first measurement, the operation is repeated by modifying the setpoint. This allows us to ensure the proper functioning of the industrial sensor across its entire operating range.
The second method consists of comparing incoming and outgoing results within the same timeframe and units. The sub-metering is then compared with the main meter. The discrepancy highlighted by this comparison either validates or invalidates the control of the sub-metered measurements.
For certain more restrictive measurements, it is possible to carry out comparisons between a master meter and an in-situ measurement in the industrial sensor’s own environment, depending on its technology. This method offers a partial comparison; however, sensor validation is still ensured.”
Sensor monitoring and ISO 50001: additional information
ISO 50001 certification introduces reinforced requirements for measuring the most energy-intensive uses, and in the absence of industrial sensor verification, data can be erroneous. This is why the standard requires guaranteeing the reliability and metrological traceability of sensors that have an impact on consumption monitoring.
Industrial operators are therefore obliged to identify these pieces of equipment, and to plan and record their periodic checks. Currently, the standard does not impose any specific frequency for sensor checks; it is up to the industrial operator to define their own verification intervals.
The importance of sensor monitoring in industry
When industrial operators regularly check their sensors, they ensure:
- Guaranteeing the reliability of their measurements and analyses for continuous performance improvement. “With sensor control, we ensure that analyses are qualitative, which then allows us to focus on optimizing performance.”
- Anticipate, detect, and correct drifts. “Frequent monitoring allows for the rapid identification of wear in an industrial sensor. If it drifts slightly, EMS software might not detect this drift (as it triggers an alarm based on configured thresholds). This monitoring therefore allows for the anticipation of any drift, acting accordingly by applying an adjustment or a replacement. Among other things, it is useful for avoiding a total loss of reliability in analyses.”
- Preventing and avoiding risks related to equipment, quality, and overall performance. “Applying too much pressure without knowing it can damage certain equipment. Similarly, a truly low temperature displayed as higher can impact production quality.”
- Optimizing the sizing of future installations. Sensors provide a reliable history of current installation data; we don’t start from a blank slate, but from a solid existing foundation. If the industrial operator decides to expand their installation by adding a new production line, for example, this can be done without over- or under-sizing the operation of existing equipment.
- Having a better vision to effectively optimize the management of the installation as a whole. An essential step in increasing your energy efficiency approach.
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