slide Endress+Hauser CT554_Calibration_Basics_and_Why.pdf

Calibration basic

1. Products Solutions Services
3/11/2015
Calibration
•What is Calibration?
•Why Calibrate?
•Calibration Management
Slide 1

2. 3/11/2015
What is Calibration?
UUT Measuring
Instrument
Standard
Determine relationship
Indicate
deviation
Calibration= quality assurance
•Comparison of the Unit Under Test against a traceable
reference standard. Adjustment= error correction
•Reduction of deviation to the
smallest possible value
•Calibration is Not:
•Adjustment
•Configuration
•Functional Check
•Loop check
•Defines the Accuracy, Tolerance,
Deviation, Error
Slide 2
What is Calibration?

3. 3/11/2015
Other Calibration Definitions & Terms
• Measurement Uncertainty -Influences in the measurement causing
uncertainty (%). Examples: temp., pressure., humidity, fittings etc.
•MPE– Maximum Permissible Error --Tolerance allowed in process by the
customer for determining whether or not an instrument passes or fails
(instrument & process tolerance)
• As Found – Calibration result (before adjustment)
•As Left – Calibration result after adjustment
• Verification–Typically referring to a functional check or performing a
comparison with an instrument not classifi ed as a reference standard for the full
measurement.
Slide 3
What is Calibration?

4. 3/11/2015
Calibration Basics
Calibrator
System of
conduits
Measurement
results
Instrument Under Test
Transmitter
Sensor
Temperature
Air density
Local acceleration
due to the gravity
Level
difference
Level
position
Temperature
Density
Level
position
Temperature
Power supply
Positioning
Resolution
Drift
Interpolation
drift
Conversion
Round-
ness
Error sources creating “Uncertainty”
Variables creating
a measurement
uncertainty
of the standard
Diaphragm Pipes Connection Valves Media
Characteristics : Null drift Repeatability Hysteresis Drift
Variables creating
a measurement
uncertainty
of the Transmitter
Slide 4

5. 3/11/2015
Calibration Basics
Conformity statement
(measurement result + uncertainties)
3
1
4
5
2
U
Maximum Permissible Error
Why combine uncertainties and measurement result?
The UNCERTAINTY qualifies the RELIABILITY of a measurement RESULT
Difference UUT/ reference Difference + Uncertainty Conformity
Point 1 Inside MPE Inside MPE Yes
Point 2 Inside MPE Inside MPE Yes
Point 3 Inside MPE Outside MPE No
Point 4 Outside MPE Outside MPE No
Point 5 Outside MPE Outside MPE No
Slide 5
??

6. 3/11/2015
Why Calibrate? Importance of Calibration •Why Calibration?
•To gain confidence that the instrument measurement is accurate and within the
limits you need to produce a Safe Quality Product
•Reduce overall businesscosts; Profit/Loss
•Minimize Quantityfluctuations; Feedstock
•Keep your Qualitylevel constant; Product
to meet Quality-relevant requirements
•Avoid Energy losses
•Avoid Human and Environmental changes & damages
Slide 6
Why Calibrate?

7. 3/11/2015
Why Calibrate? Importance of Calibration •To meet external Regulatory Requirements
•FDA – EPA – ATF - State requirements
•To comply with Industry Standards
•ISO9000/9001
•API
•IFS 5.0 (International Food Standard)
•SOP’s (internal
procedures)
ISO 9001:2000Chapter 7.6 Control of monitoring and measuring devices
…where necessary to ensure valid results measuring equipment shall be
calibrated …”
ATFATF
Slide 7
Why Calibrate?

8. 3/11/2015
ROI Example 1: Flowmeter Example
Assumption: 6,000lbs/h -Flow meter deviation: 0.7%
What is the savings in $$$, if 1 critical flowmeter is calibrated?
Top 4 products used in the Chemical industry and 1 in the F&B industry:
SAVINGS
Price/lbs2080h 6240h
•Sulfuric Acid $ 0.10 $ 8,736 $ 26,208
•Ethylene $ 0.25 $ 21,840$ 65,520
•HFCS55 $ 0.20$17,472 $ 52,416
•Phosphoric Acid
$ 0.35 $ 30,576$ 91,728
•Ammonia $ 0.10 $ 8,736 $ 26,208
5d/8h 5d/24h 12/2010
Why Calibrate?
Slide 8

9. 3/11/2015
ROI example 2: Flowmeter Example •Milk processing plant with 2,000,000 gallons/year capacity
•Raw milk truck unload metering with flow meter deviation of 0.7%
•$1.46/gallon standard raw milk price
(August 2011)
Potential savings of $20,440 /year per loop (meter)
Slide 9
Why Calibrate?

10. 3/11/2015
ROI example 3: Temperature Example Aseptic VTIS UHT-treatment module
•5000 hours production per year
•Temperature transmitter indicates 284°F
•Reality: 286°F
2°Ftemperature difference = 44lbs steam per hour wasted
44lbs × 5000 h × $0.046/lbs =
Very few $
$10,120 per year
Calibration will save you:
Direct Cost
Indirect Cost (Hidden Costs)
Slide 10
Why Calibrate?

11. 3/11/2015
•Laboratory Calibration
•Best Accuracy
•Days to weeks turnaround
•Larger size meters – 12” and larger
•Usually higher cost than on-site
•On-site Calibration
•Good Accuracy, but not as good as Laboratory
•Fastest Turnaround - Hours
•2” and smaller on rig – can do 3” to 4” in line
•Usually lower cost than Laboratory
Where can Calibrations be Performed?
ISO 17025
Accredited
ISO 17025
Accredited
Slide 11

12. 3/11/2015
Calibration Program
Calibration Program •People
•Program Management for Quality and Technical Aspects
•Performing & Executing calibrations
•Training
•How to execute calibrations and create appropriate certificates
•Assessing Instruments for classification/categorization/cal. intervals
•Equipment
•Hardware: Calibrators and printers
•Labeling / tagging
•Computers with storage
•Software: Calibration Management, Life Cycle Management
•Set-up Intervals / Scheduling calibrations / Create calibration work schedule (alerted)
•Calibration Documents & Creating the certificates
•Rules (repeatability)
•Standard Operating Procedures
•Ensure Measurement Traceability
(Safeguarding of calibration references)
Slide 12
ISO 17025 Accredited

13. 3/11/2015
International Accreditation to ISO 17025 Go to www.a2la.org> Search Accredited Organizations tab > Search for: Endress
Not just documentation and processes, but competence, proven to an independent auditing body , to provide calibrations to the Scope specified.
Slide 13

14. 3/11/2015
Local Support
Key Fact Endress+Hauser
Mix of Representatives/Authorized Service Providers and direct Sales/Service
•All have access to same training and databases.
•USA HQ in Indianapolis, IN (Greenwood)
Slide 14

15. 3/11/2015
Thank You! Any Questions?
Slide 16