Supporting accuracy and compliance for a specialist chemicals manufacturer
Introduction
A high-profile speciality chemicals manufacturer required specialist support to review and calibrate process instrumentation across its site.
Stream had previously supported the business with flow meter calibration, but following a period of operational change, the site’s calibration programme had not been carried out for several years. The customer re-engaged Stream to help restore confidence in the accuracy and repeatability of its measurement systems.
The project covered a wide range of instrumentation, including flow, pressure, temperature and level measurement, across a complex manufacturing environment where accuracy is critical to product quality, operational efficiency and compliance.
Customer Challenge
The customer’s manufacturing process relies on accurate and repeatable measurement. Products are produced in batches, meaning the correct volume or mass of each ingredient must be delivered consistently. If a flow meter is under or over-delivering, the end product may not meet the required specification.
The site therefore needed to understand how accurately its instruments were performing, particularly as its calibration programme had not been completed for some time.
The scale and nature of the site also added complexity. The project involved around 76 instruments, with more than 70 flow meters located across different areas of the plant. These included hazardous environments and hard-to-access locations where special lifting platforms and access arrangements were required.
Work also had to be carefully planned around production. Testing was carried out at weekends during planned shutdown periods, giving the Stream team restricted windows to complete the work safely and efficiently.
Solution
Stream developed a flexible calibration approach to suit the different instruments, locations and access requirements across the site.
Rather than relying on a single method, the team used a range of technologies and techniques, including non-intrusive ultrasonic transducers, gravimetric testing using scales, pressure and temperature calibration equipment, and dry blocks for generating controlled temperatures.
For flow meter testing, Stream used ultrasonic clamp-on meters where appropriate. These allowed the team to assess performance without cutting into pipework. In other areas, gravimetric testing was used, where product is pumped through the flow meter and weighed to verify the accuracy of the measurement.
Pressure and temperature calibrations were carried out using high-quality calibration equipment, while dry blocks were used to support temperature testing. Where the customer’s instruments were found to be out of tolerance or outside specification, the Stream team supported the customer in making adjustments within their control systems to optimise output readings.
The work was delivered by Stream’s qualified, site-safe engineers, operating under strict clean room and safety protocols. This included the use of specialist PPE including overalls, footwear, gloves and hair nets, as required by the environment.
Outcome
Stream helped the customer restore confidence in the accuracy and reliability of its process instrumentation.
By calibrating equipment in line with required standards and supporting adjustments where needed, Stream helped protect product quality and improve measurement accuracy.
The work also provided a clearer path for future improvement. While on site, Stream was able to recommend ways to streamline future testing, improve isolation and control and identify where instrumentation could be upgraded to make future calibration more efficient.
For a manufacturing environment where inaccurate measurement can lead to quality issues and product waste, the value of reliable calibration is clear. Stream supported the customer’s environmental and commercial priorities by helping reduce waste, improve accuracy and maintain confidence in the systems behind its production process.
It also demonstrated one of Stream’s key strengths: the ability to provide more than one route to the right result. From ultrasonic testing and gravimetric methods to pressure, temperature and level calibration, Stream acted as a single specialist partner capable of adapting its approach to meet the demands of a complex site.