The Hidden Cost of Ignoring Instrument Calibration — Why It Still Matters in Modern Plants

In today’s highly automated plants, reliable instrumentation is more critical than ever.

Modern control systems rely entirely on accurate, timely data to maintain safe and efficient plant operation.

Yet in many plants we visit, instrument calibration is treated as a low priority — or worse, as a box-ticking exercise during annual shutdowns.

This mindset is a hidden source of risk.

When calibration is neglected:

• Controllers make decisions based on inaccurate data

• Process drift erodes efficiency over time

• Safety interlocks may trigger incorrectly or fail to trigger when needed

• Unnecessary maintenance actions are driven by bad readings

• Product quality suffers

All of this leads to higher operational costs — and reduced trust in the control system itself.

Real-World Impact

At BIA Engineering Ltd, we regularly see cases where poor instrument calibration has been the root cause of major plant performance issues.

In one recent project, a chemical plant was experiencing chronic process instability — with operators forced to intervene manually to maintain control.

After conducting a detailed audit, we found that several key flow and temperature sensors were significantly out of calibration — some by more than 10%.

This led to:

• Incorrect control outputs

• Oscillating process behaviour

• Increased wear and tear on control valves and equipment

By systematically restoring proper calibration across the affected systems, we helped the plant stabilise — reducing manual intervention, improving product quality, and lowering maintenance costs.

Why Calibration Is Often Overlooked

There are several reasons why calibration gets neglected in modern plants:

• Over-reliance on control system diagnostics

• Resource constraints — too few technicians, too many assets

• A false sense of security once instruments are installed and commissioned

• Pressure to minimise shutdown time

But the fact remains: no matter how modern the plant, good data in = good control out.

Calibration is not optional — it is fundamental to reliable plant operation.

Our Approach

At BIA Engineering Ltd, we treat calibration as a core component of plant reliability.

Our services include:

• Full-scope calibration of critical process instrumentation

• Verification of sensor performance under live plant conditions

• Identification and correction of process drift issues

• Support for building robust ongoing calibration and maintenance programmes

Engineering solutions beyond expectations means helping our clients build trust in their systems — and delivering the reliable data needed for safe, efficient operation.

If your plant is struggling with process instability or unexpected downtime, don’t overlook the role of calibration — it may be the key to unlocking consistent performance.