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Instrumentation & Control Services | Dhyami Industrial Solutions
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Instrumentation & Control System Services
Instrumentation & Control System Services
A boiler or thermic fluid heater is only as reliable as the instrumentation and control systems managing it. Drifted sensors, poorly tuned control loops, and untested safety interlocks are among the most common causes of nuisance trips, process instability, and — in the worst cases — undetected unsafe conditions. At Dhyami Industrial Solutions, we provide professional instrumentation calibration, control loop tuning, and safety interlock testing services — ensuring every sensor reads accurately, every control loop responds correctly, and every safety system activates when it must.
- Pressure transmitter calibration & verification,
- Temperature sensor & RTD inspection & replacement,
- Flow switch & level switch testing & calibration,
- PID control loop tuning & optimisation,
- Modulating control valve & actuator servicing,
- Safety interlock & trip system functional testing
Why Instrumentation Maintenance Is Non-Negotiable
A pressure transmitter that has drifted 5 percent from calibration does not trigger an alarm — it simply gives you a wrong reading that your control system acts on. A safety interlock that has never been functionally tested may not trip when it needs to. These are not hypothetical risks — they are among the most common findings during first-time instrumentation audits on operating plant. Structured calibration and interlock testing programmes eliminate these hidden risks before they become incidents.
Instrument Calibration & Verification
All pressure transmitters, temperature sensors, flow switches, and level switches are calibrated against traceable references and verified against their operating setpoints — ensuring every reading your control system relies on is accurate.
Safety Interlock Functional Testing
Every safety interlock — high pressure, low water level, flame failure, flow switch, and high temperature — is functionally tested to confirm it activates correctly at its setpoint and trips the system as designed.
PID Control Loop Tuning
Poorly tuned PID loops cause hunting, overshoot, and process instability. We retune pressure, temperature, and flow control loops to deliver stable, responsive, and energy-efficient process control.
How We Work
- We begin with a full instrumentation audit — listing every field instrument, transmitter, switch, and safety interlock on the system and reviewing calibration records, last test dates, and current setpoints.
- Every pressure transmitter, temperature sensor, and flow switch is calibrated against a traceable reference standard — as-found and as-left values are recorded for every instrument in the calibration report.
- Safety interlocks are functionally tested one by one — high pressure trips, low water level cutoffs, flame failure interlocks, flow switches, and high temperature trips are each verified to activate at the correct setpoint and trip the system correctly.
- Modulating control valves and actuators are inspected and serviced — checking for hysteresis, stiction, and positioner drift that cause control loop instability and process hunting.
- PID control loops are reviewed and retuned where required — pressure control, temperature control, and feed water level control loops are adjusted to deliver stable, responsive performance within the design setpoint band.
- The nitrogen blanketing pressure regulator and expansion tank level instrumentation on thermic fluid systems are verified and calibrated — ensuring the blanketing system functions correctly between maintenance visits.
- A full instrumentation service report is provided — documenting calibration results, interlock test outcomes, control loop tuning changes, and specific recommendations for the next calibration interval.
We calibrate and service pressure transmitters, temperature sensors and RTDs, flow switches, level switches, pressure gauges, modulating control valves with positioners, and all safety interlock devices on steam boiler and thermic fluid heater systems.
Calibration frequency depends on instrument type, criticality, and statutory requirements — typically annually for safety-critical instruments and every 6 to 12 months for process control instruments. Safety interlocks should be functionally tested at least annually or per the applicable statutory schedule.
Functional testing verifies that each safety interlock — high pressure trip, low water level cutoff, flame failure, flow switch — actually activates at its correct setpoint and correctly trips the burner or system as designed. Calibration alone does not confirm this — a separate functional test is required.
The most common causes are incorrect PID tuning parameters, a faulty or drifted transmitter feeding wrong values to the controller, a worn or sticky modulating control valve that cannot respond accurately, or a process load change that has moved the system outside the original tuning range.
Yes. We inspect and service pneumatic and electric modulating control valves — checking for stiction, hysteresis, positioner calibration, and actuator condition. A sticky or poorly calibrated control valve is one of the most common causes of pressure and temperature hunting on boiler and heater systems.
Yes. Every instrument calibration is documented with as-found and as-left values referenced against a traceable calibration standard — providing a complete calibration certificate for every instrument serviced, suitable for your quality management system and statutory compliance records.
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