What does it mean to be out of tolerance?
An instrument is out of tolerance when its measurement error exceeds the specified limit, thus losing reliability and precision in its readings.
Main operational risks
1. Incorrect process decisions
This scenario can lead responsible people to make process decisions based on erroneous data, which directly affects the operation. Decisions made with inaccurate information can trigger inappropriate adjustments to critical parameters, cause deviations in production, and increase the likelihood of errors in later stages of the workflow.
2. Security risks
When a pressure instrument is out of tolerance, it creates a significant risk to operational safety. This type of instrument, by losing precision, can cause incorrect readings that lead to the exposure of people, equipment and processes to unsafe conditions, which increases the probability of accidents, technical failures and dangerous situations within the plant or facility.
3. Loss of product quality
This situation can cause the process parameters to not be maintained within the appropriate ranges, which directly impacts the final quality of the product. If instrument readings do not reflect actual conditions, defective or inconsistent batches may occur, affecting uniformity and expected characteristics. As a result, loss of quality can lead to complaints, rework or even the inability to market the product.
4. Increase in operating costs
Using an out-of-tolerance pressure instrument can result in a significant increase in operating costs. This occurs because decisions made with inaccurate data can trigger unnecessary or incorrect process adjustments, resulting in rework, wasted materials, and additional resource consumption.
5. Non-conformities in audits
The use of instruments out of tolerance can lead to negative findings during internal or external audits. Since the measurements made with this equipment lack the required precision and reliability, there is a risk of failing to comply with quality, environmental or safety regulations and standards.
Technical recommendation
It is recommended to implement a periodic calibration program for pressure instruments, guaranteeing metrological traceability through standardized standards and procedures.
It is key to define criteria according to the criticality of the process, prioritizing the most important equipment to reduce operational risks and non-conformities.