Calibration Management

Matthias Schuetzeberg

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10/07/2009

Calibration ManagementIn Food & Beverage

Utilities and Calibration Management


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10/07/2009

Calibration Management

Calibration Service

Calibration definitions

Calibration refers to the process of verification that an instrument is within its designated accuracy.

This is usually accomplished by formal comparison with a standard which is traceable to national standards and certified reference materials

upper +lowertolerance




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10/07/2009


Calibration Service

Should you adjust after calibration?

Instruments are calibrated to ensure accuracy

After adjustment is not automatically a part of the procedure, but a conformity statement always is required

Adjusting a defective instrument is a mistake

Calibration after adjustment is a must to confirm

Standard(Traceable to thenational standard)

MeasuringInstrumente.g. pressure,

flow, temperature

Output value

Determine relationship

Input value

Information aboutvalue Indicate deviation




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10/07/2009


Calibration Service

Why and when do you calibrate?

For a new instrument

To ensure compliancy

At a specific frequency

when a specified usage (operating hours) has passed

when an instrument has had a shock or vibration which potentially may have put it out of calibration

whenever observations appear questionable




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10/07/2009


Calibration Service

Reasons for Calibration

What can be a reason for calibration?

- Lining is deformed- pollution/scaling on the lining- Electronics defect- Coil current is changed- Combination of factors- Legislation demands- …

What could be the consequences when there is a deviation discovered?

- Production loss cost loss?- Environmental impact?- Personal impact?- Lost of enegy - money lost...




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10/07/2009


Calibration Service

What do you do when…?

…there is deviation found?

Adjusting the K-factor? Replace instrument? ….

- How do you record this?- Who manages this?- When is this done?- Which departments are involved?- What is the history of the instrument?- …?




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Calibration Service

Tell me, how do I find the calibration certificates when the auditor wants to see them?

Tell me, how do I find the calibration certificates when the auditor wants to see them?

I need information about your results …

Tell me which assets where reported with a deviation last year and how this is solved.

Tell me which assets where reported with a deviation last year and how this is solved.

..... I need help, please tell me how to reduce costs on maintenance and calibration over the life cycle.

..... I need help, please tell me how to reduce costs on maintenance and calibration over the life cycle.




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10/07/2009


Calibration Service

Hyperlink Integration

W@M Life Cycle Management

“I need more information!”

PC= Product CenterSC= Service & Sales Center

CER

“We know more!”

Serial#

Work order / Calibrationinformation

Endress+Hauser Product center• Serial number• Order code• Manuals• Certificates• Purchase infoEvents:• Production info• Calibration info• Repair info

Flow

Pressure

Level

Temperature

Analysis

Endress+HauserSales center• Maintenance reports• Calibration reports• Service reports• Repair reports• Inspection reports within maintenance or calibration contracts

Dynamic hyperlink / Web Services

Calibration Management System

Your application

Our information




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10/07/2009


Calibration Service

Accredited and traceable calibration

Diameter 1 mm up to 2000mm

Total Accuracy 0f 0.05%

Economical for single devices

Requirements

Delivery to the factory

Flowmeter must be cleaned

Recalibration in the factory




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10/07/2009


Calibration Service

Short shut down time only during the calibration

No mounting or demounting of the sensor

Recalibration on traceable international standards

Advantage for a recalibration in field




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10/07/2009


Calibration Service

Inline calibration in field

SCS-calibration in Reinach / Cernay

Calibration rig accredited according to ISO/IEC17025

Mobile calibration rig

By the customer

Traceable recalibration




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Calibration Service

Calibration in field Movable calibration riggs

Temperature

Pressure

pH Instruments




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Calibration Service

100 %

50 %

0 %

25 %

75 %

TotalOperation

Costs

Project Costs

Time

Perc

en

t to

tal

cost

Sta

rt u

p

Source:Automation Research Corporation

…. Most operating costs relate to equipment maintenance

Where to save the most money or time ?

Total Cost of Operation is much larger than initial project cost!




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10/07/2009


Calibration Service

40%

20%

0

Source: ARC

Processimprovements

Unplanned Breakdowns

Inventory Costs

Downtime

Defects

Equipment Life

Workforce Efficiency

Equipment Productivity

40%

20%

Cost Reductions

60%

What are the areas in terms of cost savings …


Calibration in Food Industry

Matthias Schützeberg

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10/07/2009


Calibration Service

Calibration of instruments

TPPC/MEG, No. 18

But there is still more to safe your money



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Calibration Service

Consider the total cost

Direct cost

Indirect cost



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Calibration Service

Example: 2 temperature transmitters not calibrated

Alrox Lacta deaeration module

Differential temperature transmitters indicates ΔT 4°C

1. Reality: 2°CNot sufficient deaeration. Effects the product quality

2. Reality: 6°COvertreatment. Increased energy consumption and product losses.

40.000 € per yearVery few €

100 kg/h × 5000h x 0.08 €/kg =

0,08 € = steam and cooling water cost/kg



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10/07/2009


Calibration Service

Calibration

Aseptic VTIS UHT-treatment module

Temperature transmitter indicates 140 °C

Reality: 142 °C

5000 hours production per year

2 °C temperature difference = 30 kg steam per hour

30 kg × 5000 h × 0.04 €/kg = 6000 € per year

Very few €



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10/07/2009


Calibration Service

Just some Questions - general

Did you ever ask yourself…

…how can I ensure the quality of my product?

…how can I fulfill my calibration and maintenance obligations of my critical instruments?

…are my calibration cycles set correctly?

…are there more efficient calibration procedures than my current ones?

…how can I optimize my maintenance cost.

…is it possible to work with one supplier for all my calibration needs?


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10/07/2009

Thank you very muchfor your attention!

Documents

Calibration Management