Instrumentation Reliability in Process Plants

Instrumentation Reliability in Process Plants

BiC, a consulting firm with extensive experience in instrumentation, mechanical, electrical, civil projects, and IT systems, recognizes the crucial role of instrumentation in automated plants. While automation has led to manpower reduction, the reliability of instrumentation remains a key factor in ensuring process safety, profitability, and customer satisfaction. a case study on improving instrumentation reliability in power plants, chemical industries, Cement, Oil and Gas, and many more.

With the advent of Industry 4.0, large-scale plants have witnessed automation on a sophisticated level. While automation brings numerous benefits, it also introduces the risk of catastrophic failures due to instrumentation malfunctions. Many control systems heavily rely on sensors, and a failure in these sensors can lead to incorrect tripping decisions or alarms. Additionally, critical machines often lack comprehensive measurement systems, resulting in manual checks that are subjective and prone to errors.


BiC, with its focus on reliability and safety, conducted extensive studies emphasizing the critical role of instrumentation in plant safety and consistent operation. The research revealed that approximately 70% of tripping incidents could be avoided with reliable instrumentation, including quality supply and correct installation. Based on these findings, BiC proposes the following approach to improve reliability.


  • Detail study has been conducted for the mitigation plan and work out the solutions keeping in the view of cost time and return expected out of expenditure. 
  • Conclusion found that sensor failure is cable favours is the main cause of tripping thereby it is very important to go for multiple sensors and voting system to be put in place including control system whenever it required to be put is 2/ 3 triple logic , mid of three control, Cable route are different, each sensor termination in different junction box. To be executed in steps.


  • 2/3 Trip Logic: Implement a trip logic system where three sensors are installed, and any one sensor can trigger the tripping event, ensuring redundancy and accuracy.
  • Mid of 3 Critical Controls: Deploy three sensors for critical controls and use the middle value of the three as the input for controllers, enhancing reliability and reducing the chances of erroneous readings.
  • Cable Routing: Separate controllers and route cables in a manner that damage to one cable, junction box, or controller does not impact the overall plant operation, ensuring uninterrupted performance.
  • Vibration and Temperature Monitoring: Install vibration and temperature sensors on all critical rotating machines, providing centralized monitoring and alarms. This empowers the maintenance department with timely information for proactive actions.


By implementing the proposed measures, BiC has successfully improved reliability in existing plants, achieving outstanding results, including:

  • Trustworthy Indications: Plant operation teams now have three indications available, eliminating guesswork and building trust in the accuracy and reliability of the data.
  • Quick Response to Sensor Failures: Immediate action can be taken by the department in case of sensor failures, ensuring safe plant operation without any concerns.
  • Enhanced Machine Monitoring: Vibration and temperature monitoring has provided the operations department with significant control, enabling close monitoring of critical machines and offering confidence in their performance.


The implementation of Industry 4.0 concepts in plant operations, brings numerous benefits, including profitability, reliability, safety, and predictive analytics. With Industry 4.0 it becomes possible to anticipate and prescribe actions in case of potential issues. BiC's expertise in IT industries and technical abilities position them uniquely to deliver comprehensive solutions that address future challenges and facilitate better-automated decision-making processes.

What BiC Can Offer: Advantage and Differentiation

BiC's promoter possesses over three years of experience in IT industries along with 41 direct in the industry holding a position as CEO, learning AI implementation in recent years in another area. and holds a complete cycle of expertise in operations, maintenance, and IoT. This broad cross-section experience, combined with a focus on future challenges and available software, enables BiC to provide unparalleled expertise in AI-driven solutions for improved decision-making processes. Unlike other service providers, BiC combines AI implementation with grassroots technical ability, making them the ideal partner for organizations seeking comprehensive and effective solutions.

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