ct554 calibration basics and why - rockwell automation · pdf fileiso 9001:2000 chapter 7.6...
Post on 17-Mar-2018
213 Views
Preview:
TRANSCRIPT
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
top related