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"Usually, controllers have software that detects sensor failure." Perhaps for some failures, but not all. In some processes, multiple sensors from different suppliers are mandated, with Quintuple CPU and memory redundancies to avoid catastropic control failures. "What is a problem is coarse...

In parallel with what?

Least we forget, all these strategies, presume a linear system, 100% realiability of all sensors, control devices, and a stable process response to all changes large or small.

They are coupled, as part of a closed loop, though the dynamic response of your sensor, the dynamic response of your controlled device, and the dynamic response of the process you are aiming to control!

Are they independent? No! Ki (Integration) increases the control adjustment the longer the process variable deviated from your set point. Kd (differentiation) immediately bumps the control command intended to reduce the time needed to achive the set point. Both can lead to instability depending...

You'll nesd to contact the manufacturer "Setra"

Just do an internet search for "Plug-In O-Ring Quick Connects "

Oil leaks suggest worn bearing seals

45 mA circuits havent been used in 50+ years, but it is a simple matter to translate the current to commonly used voltage inputs

Laser light curtains are commonly used to reduce hazard.

A photograph and a supplier drawing of the reed switch location is a good start

Consult the IEEE standards

Given the variety of control panels, working in a panel shop or in engineering construction is a good start.

Even the calibration gas can be off spec, too

There are plenty of data loggers on the market for trouble shooting, PLC's are mainly used for control, inless the data logging feature is part of it menu choices. Drop-in programming would need to be documented and confirmed as not interfering with the control algorithms oftem used for safe...

You can expect a reduction in HHV with reduction of you ethane component

evolves from a process or a piece of machinery that you need to control or monitor. It began with water mills, clocks, steam engines, and countless others

what is the controller model number and its input details.

Check the vendors https://sps-support.honeywell.com/s/article/Ex-certification-for-explosive-atmospheres-Ex-ia-Ex-d-and-Zone-Area-Classification-explained

Unfortunately, it is not an issue that AI can solve in thin air, so specifc details are required