Calibration or Quality Assurance

Calibration or Quality Assurance
03/29/2010
Marco van Veen
Slide 1
Follow the Signal from Product to Vision
Process Value
Quality Value
: Quality Assurance/Metrology
: CMS (Calibration)
: Not real time (week/month)
: 4-20mA, Fieldbus (digital)
Driver
: Quality
Quality Management
: Efficiency
Energy Management
CMMS
System
CMS
DCS
EMS
ERP
03/29/2010
MES
Marco
PAM van Veen
PLC
SCADA2
Slide
SiS
aM&T
: Computerized Maintenance Management

: Calibration Management System
: Distributed Control System
: Energy Monitoring System
: Enterprise Resource Planning
: Manufacturing Execution System
: Plant Asset Management
: Programmable Logic Controller
: Supervisory Control And Data Acquisition
: Safety Instrumented System
Driver
al u
lV
: Process Manager
: MES, EMS (Energy)
: Not real time (hour/day)
yV
al u
e
User
System
Data
Signal
: Operator
: DCS, PLC/SCADA
: Real time (second)
Driver
: Process, Accuracy
Process Management
a
tic
g is
User
System
Data
Signal
fet
Lo
d
ie l
Sa
lu e
a
V
Diagnostics Value
User
System
Data
Signal
User
System
Data
Signal
: Safety
: SiS (Safety)
: Real time (second)
: 4-20mA, Fieldbus (SiS,
PROFIsafe)
Driver
: Safety, Reliability
Safety Management
User
Systems
Data
Signal
: Maintenance
: PAM, CMMS (Asset)
: Not real time (hour)
: Status (digital)
User
System
Data
Signal
: Logistics
: ERP (Material Management)
: Not real time (hour/day)
Driver
: Reliability, Availability
Driver
: Delivery, Flexibility
Asset and Life Cycle Mngt.
Inventory Management
TankVision
Why is maintenance important?

ARC Best Maintenance Practices survey
03/29/2010
Marco van Veen
Slide 3
Source: ARC Advisory Group
Reasons for Calibration

What can be a reason for calibration?
Lining is deformed
Pollution/scaling on the lining
Electronics defect
nd s
a
m
e
nd
o
i
t
a
l
Coil current is changed
Legis
5. 0
S
F
Combination of factors
I
CP
C
A
Process optimization - H
-
What could be the consequences when there is a

deviation discovered?
Production loss?
Environmental impact?
Personal impact?
03/29/2010
Marco van Veen
Energy loss?
Slide 4
Example: Calibration at Tetra Pak

Therm Aseptic
UHT-treatment module
Temperature transmitter
indicates 140C
Reality 142C
5000 hours production per year
Consequences
2C temperature difference = 30kg steam per hour
30kg x 5000h x 0.08 /kg = 12,000 per year
Calibration costs:
Indirect cost: 12,000 per year

03/29/2010
Marco van Veen
Slide 5
We thank TetraPak for providing this case study
Picture to be
added
What do you do when?

deviation is found?
Adjusting the K-factor?
Replace instrument?
Inform Quality
.
How do you record this?
Who to manage this?
When is this done?
03/29/2010
Marco van Veen
Slide 6
What is the history of the instrument?

?
Is your calibration information always up to date?
Calibration Certificates
Who performed the calibration
Calibration frequency / calibration plans
SOPs
Deviations on which instruments
Specification sheets
Product Status
Supplier specific information
Traceability
03/29/2010
Marco van Veen
Slide 7
How can I be Compliant?

The cornerstones of valid plant instrument calibrations are:
Defined Criticality
Classification
and Tolerance
Technically Valid
Calibration
Procedures
Calibration
Management and
Notification
Traceable
Reference Standards
03/29/2010
Marco van Veen
Slide 8
Competent
Calibration
Personnel
Calibration along the life cycle

Calibration Management
Software
Logbook
Standard Operating
Procedures (SOP)
Master-SOP
Cal.Record
Calibration
Label
Calibration
SOP
Key Elements of
Calibration from
Owner Operator
viewpoint
Calibration
Work
Traceable
equipment
03/29/2010
Marco van Veen
Slide 9
Calibration
Protocol
Cal.Plan
Trained
Employees
Calibration rigs are

traceable to
international standards
Standard
calibration
certificate
System Integration
Calibration Management System
Your application
Work order /
Calibration
information
I need more information!
Dynamic hyperlink / Web Services
W@M Life Cycle Management

We know more!
Endress+Hauser
Product center
Flow
Serial number
Order code
Pressure Manuals
Certificates
Purchase info
Level
Events:
Production info
Temperature
Calibration info
Repair info
Serial#
Endress+Hauser
Sales center
Maintenance reports
Calibration reports
Service reports
Repair reports
Inspection reports
within maintenance or
calibration contracts
Our information
PC= Product Center

SC= Service & Sales Center
03/29/2010
Marco van Veen
Slide 10
Analysis
CER
W@M
All data is stored in the W@M Life Cycle Management Portal
Data is dynamic and all actions taken in the future, (like

calibrations and repairs) are stored in the logbook
03/29/2010
Marco van Veen
Slide 11
Additionally the product status per instrument is kept up-to-date
On-site Calibration
Temperature measurements : RTD, TC, Infra Red
Conductivity measurements
pH measurements
Pressure measurements : Process, Differential
pressure
Flow measurements
Open channel flow measurements
Dataloggers, recorders and displays
Date calibrated:
Du e da te:
03/29/2010
Marco van Veen
Slide 12
Reference:
ISO9001:2000
Workshop + Factory Calibrations

Calibration laboratories
ISO17025 (EN45001)
Flow
EA (European Cooperation for Accreditation)
Flow
DN1 DN2000, 0-1666 l/s
Pressure
Relative, absolute and vacuum
Temperature
RTD, TC and transmitters
03/29/2010
Marco van Veen
Slide 13
EMC/RFI
System & Gauging
Pressure
Temperature
Practice: Premiumcal calibration lab.

The most accurate, accredited production calibration
installation in the world!
Deviation on 1000 liter = 1 glas of Champagne (0.015%)
PremiumCal rigs are located in Reinach and Greenwood
Uncertainty +/- 0.015%
accredited according to ISO 17025
1-gram weight on
a 400-kg tank
during calibration
03/29/2010
Marco van Veen
Slide 14
High-tech installation (0.015%)

Polished certified weights,
accuracy class F2 with 0.8 g/50
kg 0.0016%
Class F2 weights : Normally
used for weight measurement of
precious metals
Load cells: OIML class C6
Installation is automatically
calibrated every two week.
03/29/2010
Marco van Veen
Slide 15
Calibration services to ensure product quality & safety

Fulfill regulatory requirements
and optimize quality efforts
Need to comply to ?
Benefits of calibration services:

Measurement reliability is
proven and documented for
audits
Process costs are reduced by
ensuring optimal instrument
performance
Calibration intervals are
adapted to the application
03/29/2010
Marco van Veen
Slide 16
Take advantage of Endress+Hausers

calibration management solution:
CompuCal
Example: Quality assurance

Installation availability and product quality is the common
concern of a QA department, Maintenance Management and
Plant Management.
Delivering a high quality end product is your core-business,
Maintenance and calibration of process-instrumentation is
(often) no core-business
But maybe necessary due to assure quality
03/29/2010
Marco van Veen
Slide 17
We have to balance necessary maintenance to cost

Its not about how much a service provider can charge
More about how much can be saved
03/29/2010
Marco van Veen
Slide 18
A good service provider should always

have this picture in mind
Questions?
03/29/2010
Marco van Veen
Slide 19

Calibration or Quality Assurance - Endress+Hauser

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