The Cost of Incorrect Measurements in Industrial Facilities: What Sensor Errors Can Lead To

The Cost of Incorrect Measurements in Industrial Facilities

In industrial facilities, the proper execution of processes relies on the accurate measurement of critical parameters such as flow, pressure, temperature, and level. However, many businesses underestimate the impact of sensor errors on their systems. Even a small measurement error can have serious consequences, ranging from production quality issues to increased energy costs. In this article, we will explore why incorrect measurements are dangerous, the cost burden they impose on operations, and actionable strategies to prevent these errors.

1. What Is an Incorrect Measurement and Why Is It Important?

An incorrect measurement occurs when a sensor reading does not reflect the true value. Measurement errors can cause control systems to make wrong decisions, reduce equipment performance, and even compromise process safety.

Accurate measurement:

• Stabilizes process control

• Increases energy efficiency

• Ensures production quality

Incorrect measurement has the opposite effect, undermining these goals.

2. Sources of Sensor Errors

Sensor errors often stem from the following:

a. Incorrect Installation and Positioning
A temperature probe placed in the wrong location cannot reflect the actual temperature. Flow sensors positioned in turbulent regions produce inaccurate flow readings.

b. Environmental Conditions
Humidity, vibration, extreme temperatures, or chemical corrosion can degrade sensor performance. These factors are often overlooked.

c. Lack of Calibration
Sensors can drift over time. If calibration is skipped, readings gradually deviate from reality.

d. Choosing the Wrong Sensor for the Application
Not every sensor is suitable for every application. For example, using a pressure sensor that isn’t rated for high-pressure systems can result in significant measurement errors.

3. Effects of Incorrect Measurements on the System

The negative impact of sensor errors is often greater than it appears:

Reduced Energy Efficiency
Incorrect pressure or flow measurements can cause control systems to consume unnecessary energy, increasing operational costs.

Fluctuating Production Quality
Errors in temperature or level sensors can result in inconsistent product quality, leading to defective products and customer dissatisfaction.

Reduced Equipment Lifespan
Pumps, valves, or compressors operating based on inaccurate readings endure higher stress, increasing maintenance costs and the likelihood of early failures.

Unplanned Downtime
Control systems receiving incorrect data may trigger unplanned stoppages, causing production losses, repair costs, and reputational damage.

4. 5 Effective Strategies to Prevent Incorrect Measurements

The good news is that most of the effects of incorrect measurements can be prevented. Effective strategies include:

1. Correct Product Selection
When choosing sensors, consider:

• Operating environment conditions

• Measurement range of the parameter
  Selecting the right sensor for the application improves system reliability.

2. Proper Installation and Placement
Sensors should be installed at the correct measurement point, not just mounted anywhere. A field analysis should be conducted before installation.

3. Periodic Calibration
Sensors should be calibrated at regular intervals to ensure continuous measurement reliability.

4. Environmentally Resistant Products
Use sensors that withstand vibration, humidity, and extreme temperatures to minimize measurement errors.

5. Automation and Data Analytics
Analyzing data from automation systems allows early detection of abnormal readings, enabling quick intervention.

5. Measurement Accuracy Is Not a Luxury, It’s a Necessity

Even small sensor errors can lead to significant long-term costs, including:

• Increased energy bills

• Reduced production quality

• Higher maintenance costs

• Operational disruptions

To prevent these outcomes, it is critical to select the right sensors, install them correctly, and maintain regular calibration.

Conclusion

Ensuring measurement accuracy in industrial facilities is not only a part of process control but also essential for improving operational efficiency, reducing costs, and maintaining quality standards. To minimize the costs of incorrect measurements, adopt the principles of choosing the right sensor, proper installation, and regular maintenance.

At Isimatik, we provide reliable measurement and control solutions for your processes, minimizing error risks and maximizing efficiency.