Calibration Management

1. Calibration Management In Food & Beverage Matthias Schuetzeberg

2. Calibration definitions Calibration Management • 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 + lower tolerance Matthias Schuetzeberg

3. Should you adjust after calibration? Calibration Management • 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 the national standard) Measuring Instrument Input value e.g. pressure, flow, temperature Output value Information about value Indicate deviation Determine relationship Matthias Schuetzeberg

4. Why and when do you calibrate? Calibration Management • 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 Matthias Schuetzeberg

5. Reasons for Calibration Calibration Management • 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 à cost loss? • Environmental impact? • Personal impact? • Lost of enegy • money lost... Matthias Schuetzeberg

6. What do you do when…? Calibration Management …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? - …? Matthias Schuetzeberg

7. I need information about your results … Calibration Management ..... I need help, please tell me how to reduce costs on maintenance and calibration over the life cycle. Tell me which assets where reported with a deviation last year and how this is solved. Tell me, how do I find the calibration certificates when the auditor wants to see them? Matthias Schuetzeberg

8. Temperature Pressure Analysis Flow Level Calibration Management System Your application Our information Hyperlink Integration Calibration Management Work order / Calibrationinformation Dynamic hyperlink / Web Services “I need more information!” W@M Life Cycle Management “We know more!” • Endress+Hauser Product center • Serial number • Order code • Manuals • Certificates • Purchase info • Events: • Production info • Calibration info • Repair info Serial# CER • Endress+HauserSales center • Maintenance reports • Calibration reports • Service reports • Repair reports • Inspection reports within maintenance or calibration contracts PC= Product Center SC= Service & Sales Center Matthias Schuetzeberg

9. Recalibration in the factory Calibration Management Requirements Delivery to the factory Flowmeter must be cleaned • Accredited and traceable calibration • Diameter 1 mm up to 2000mm • Total Accuracy 0f 0.05% • Economical for single devices Matthias Schuetzeberg

10. Advantage for a recalibration in field Calibration Management • Short shut down time only during the calibration • No mounting or demounting of the sensor • Recalibration on traceable international standards Matthias Schuetzeberg

11. Traceable recalibration Inline calibration in field Calibration Management Mobile calibration rig By the customer SCS-calibration in Reinach / Cernay Calibration rig accredited according to ISO/IEC17025 Matthias Schuetzeberg

12. Calibration in field Movable calibration riggs Calibration Management • Temperature • Pressure • pH Instruments Matthias Schuetzeberg

13. Where to save the most money or time ? Calibration Management Total Cost of Operation is much larger than initial project cost! 100 % 75 % 50 % Total Operation Costs Start up Percent total cost 25 % Project Costs 0 % Source: Automation Research Corporation Time …. Most operating costs relate to equipment maintenance Matthias Schuetzeberg

14. What are the areas in terms of cost savings … 40% Calibration Management Equipment Productivity Process improvements 20% Workforce Efficiency Equipment Life 0 Defects 20% Downtime Cost Reductions Inventory Costs 40% Unplanned Breakdowns Matthias Schuetzeberg Source: ARC 60%

15. Calibration of instruments But there is still more to safe your money Matthias Schützeberg  TPPC/MEG, No. 18

16. Consider the total cost Direct cost Indirect cost Matthias Schützeberg

17. 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. 100 kg/h × 5000h x 0.08 €/kg = 40.000 € per year Very few € 0,08 € = steam and cooling water cost/kg Matthias Schützeberg

18. 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 Very few € 30 kg × 5000 h × 0.04 €/kg = 6000 € per year Matthias Schützeberg

19. 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? Matthias Schützeberg

20. Thank you very muchfor your attention! Matthias Schützeberg