Overcoming Challenges in Harsh Environments: Robust Design in Gas & Liquid Analysers
29 October 2025
Working in tough industrial environments is part of the job for many of our clients. Whether it’s extreme temperatures, high humidity, corrosive chemicals or potentially explosive atmospheres, these conditions demand more from every part of your process.
At Process Instrument Solutions, we’ve spent years helping businesses maintain measurement accuracy and compliance in some of the most challenging settings. One of the key ways we do this is by focusing on robust design in both gas and liquid analysers.
It’s not just about durability. It’s about safety, reliability and ensuring consistent performance when conditions are anything but ideal.
What Makes an Analyser Fit for Harsh Conditions?
In environments where standard equipment fails, specially designed analysers can make the difference between smooth operation and constant downtime. Here are a few features we look for when specifying instruments for these conditions:
- Corrosion-resistant materials
Housing, fittings and wetted parts often need to be made from stainless steel, PTFE, or other chemically resistant materials. This helps avoid deterioration from exposure to aggressive media or salty air. - ATEX or IECEx approvals
In areas where flammable gases, vapours or dust are present, safety is paramount. We supply analysers that are fully certified for use in hazardous zones, giving peace of mind and meeting regulatory obligations. - Weatherproof and rugged housings
Instruments used outdoors or in unheated buildings need protection from the elements. IP-rated enclosures, temperature controls and vibration resistance all play a role in long-term reliability. - Low-maintenance design
In many cases, harsh environments are also hard to access. Reducing the need for manual intervention is essential. We work with manufacturers who offer self-cleaning sensors, auto-calibration features and remote diagnostics to reduce the strain on maintenance teams.
Real-World Applications
From offshore energy installations to chemical processing plants and wastewater treatment sites, we’ve helped deliver rugged analyser systems across the UK and beyond.
For example, in coastal facilities, salt-laden air can eat through standard equipment in months. Using marine-grade stainless steel and protected cabling, we’ve extended system lifespans and improved uptime.
In ATEX-rated areas, we’ve installed gas analysers within certified enclosures, ensuring both safety and easy access for inspection.
Support Beyond the Specification
Choosing the right instrument is just the start. We also help clients with proper installation, commissioning and long-term servicing. That means you’re not only getting a rugged analyser — you’re getting a reliable solution that is supported for the long haul.
Our team works with you to understand the risks, assess your site, and recommend solutions that are practical, compliant and future-proof. To find out more please visit our dedicated Process Instrument Services page.
Final Thoughts
Harsh environments demand more from equipment, and cutting corners often leads to costlier problems down the line. With the right design, materials and certifications, gas and liquid analysers can thrive in even the most demanding conditions.
If you’re working in an aggressive or hazardous environment and want guidance on building a more robust analytics setup, we’d be happy to help.
