Products Solutions Services

3/11/2015

Calibration • What is Calibration?

• Why Calibrate?

• Calibration Management

Slide 1

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?

3/11/2015

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 classified as a reference standard for the full measurement.

Slide 3

What is Calibration?

3/11/2015

Calibration Basics

Calibrator System of conduits

Measurement results

Instrument Under Test

Transmitter Sensor

TemperatureAir density

Local accelerationdue to the gravity

Level difference

Level position

TemperatureDensity Level

position

Temperature

Power supply

Positioning

Resolution

Drift

Interpolationdrift

ConversionRound-

ness

Error sources creating “Uncertainty”

Variables creatinga measurement uncertaintyof the standard

DiaphragmPipesConnectionValvesMedia

Characteristics :Null driftRepeatabilityHysteresisDrift

Variables creatinga measurement

uncertaintyof the Transmitter

Slide 4

3/11/2015

Calibration Basics

Conformity statement (measurement result + uncertainties)

3 1

4

52U

Maximum Permissible Error

Why combine uncertainties and measurement result?

The UNCERTAINTY qualifies the RELIABILITY of a measurement RESULT

Difference UUT/ reference Difference + Uncertainty ConformityPoint 1 Inside MPE Inside MPE YesPoint 2 Inside MPE Inside MPE YesPoint 3 Inside MPE Outside MPE NoPoint 4 Outside MPE Outside MPE NoPoint 5 Outside MPE Outside MPE No

Slide 5

??

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 business costs; Profit/Loss

• Minimize Quantity fluctuations; Feedstock

• Keep your Quality level constant; Productto meet Quality-relevant requirements

• Avoid Energy losses

• Avoid Human and Environmental changes & damages

Slide 6

Why Calibrate?

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 9001:2000 Chapter 7.6 Control of monitoring and measuring devices

…where necessary to ensure valid results measuring equipment shall be calibrated …”

ATFATF

Slide 7

Why Calibrate?

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/24h12/2010

Why Calibrate?

Slide 8

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?

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°F temperature 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?

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 17025Accredited

ISO 17025Accredited

Slide 11

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

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

3/11/2015

Local SupportKey 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

3/11/2015

Thank You! Any Questions?

Slide 16