Getting to the Root: Solving a Multi-Instrument Mystery at a 12 Tank Production Facility

Omni was approached by a process engineer we'd previously worked with to investigate several challenges at a production facility under their management. The facility operated twelve 7,000-gallon process tanks, each equipped with double agitators, load cells, level transmitters, and temperature transmitters. The tanks handled a range of functions including mixing, heating, pasteurizing, storing, and transferring various liquid products, and the process engineer had been tasked with streamlining operations to improve overall product quality and throughout.

The trouble centered on the level transmitters, which were intermittently providing false readings or failing to function altogether. Compounding the issue, load cells were frequently indicating full tanks while the associated level transmitters read empty, a conflict that made reliable process control impossible. Omni dispatched a senior technician to examine the system and review batch trends from previous months, and it quickly became clear that the level transmitters were the source of the problem.

We contacted the manufacturer's application engineer, who recommended calibration, various tuning procedures, and additional testing. Despite following those guidelines, the issues persisted. Digging deeper, we eventually identified the root cause. When the tank level transmitters were originally specified, no one had accounted for the heavy steam blanket generated inside the tanks during operation. The existing transmitters simply weren't designed for those conditions. Omni, along with a reliable LIT (level indicating transmitter) manufacturer, recommended a GWR (guided wave radar) level transmitter, a technology capable of performing reliably in heavy steam environments.

The manufacturer provided two units on loan, which were installed on a pair of tanks, calibrated, and trend-logged over a three-week period. The results were exactly what we had hoped for. The facility moved forward with purchasing twelve new level transmitters to replace the faulty instruments across all tanks. Omni also recalibrated all load cells and the three temperature transmitters on each tank. With every instrument properly specified, installed, and calibrated, the process engineer was able to deliver on the client's goals of smoother operations, consistent product batches, and improved overall process efficiency.

Instrumentation issues don't always have an obvious cause. If your facility is dealing with unreliable readings or process control conflicts, Omni can help you track down the problem and get the right solution in place. Contact us to learn more.