Products Solutions Services

Calibration • What is Calibration?

• Why Calibrate?
• Calibration Management

Slide 1 3/11/2015
 What is Calibration?
What is Calibration?
Calibration = quality assurance
• Comparison of the Unit Under Test against a traceable
reference standard.
• Defines the Accuracy, Tolerance,
Deviation, Error
Standard
Adjustment = error correction UUT Measuring
• Reduction of deviation to the Instrument
smallest possible value
Determine
• Calibration is Not: relationship
• Adjustment
• Configuration Indicate
• Functional Check deviation
• Loop check

Slide 2 3/11/2015
 What is Calibration?
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 3/11/2015
Calibration Basics
Error sources creating “Uncertainty”

Level Resolution
Local acceleration difference Power supply Interpolation
due to the gravity Temperature drift
Temperature Conversion
Air density Level Positioning Drift
Density Round-
Temperature Level position ness
position

System of Measurement
Calibrator Sensor Transmitter
conduits results

Instrument Under Test

Variables creating Diaphragm Characteristics : Variables creating

a measurement Pipes Null drift a measurement
uncertainty Connection Repeatability uncertainty
of the standard Valves Hysteresis of the Transmitter
Media Drift

Slide 4 3/11/2015
 Calibration Basics
Conformity statement (measurement result + uncertainties)
Why combine uncertainties and measurement result?

??

3 1 2 5
U

Maximum Permissible Error

4

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

The UNCERTAINTY qualifies the RELIABILITY of a measurement RESULT

Slide 5 3/11/2015
Why Calibrate?
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; Product

to meet Quality-relevant requirements

• Avoid Energy losses

• Avoid Human and Environmental changes & damages

Slide 6 3/11/2015
Why Calibrate?
Why Calibrate? Importance of Calibration

• To meet external Regulatory Requirements

• FDA – EPA – ATF - State requirements
ATF

• 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 …”

Slide 7 3/11/2015
 Why Calibrate?
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/lbs 2080h 6240h
12/2010 5d/8h 5d/24h

• 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

Slide 8 3/11/2015
Why Calibrate?
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 3/11/2015
Why Calibrate?
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

Very few $
Direct Cost
Calibration will save you:
44lbs × 5000 h × $0.046/lbs =
$10,120 per year
Indirect Cost (Hidden Costs)

Slide 10 3/11/2015
Where can Calibrations be Performed?

ISO 17025 • Laboratory Calibration

Accredited
• Best Accuracy
• Days to weeks turnaround
• Larger size meters – 12” and larger
• Usually higher cost than on-site

ISO 17025 • On-site Calibration

Accredited
• 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

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 ofISO 17025 Accredited
calibration references)

Slide 12 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
Key Fact Endress+Hauser
Local Support

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 3/11/2015