UNIT-V FMM.HYDRAULIC TURBINE - Construction and working
Transcat and Fluke Webinar: Streamlining Instrument Calibration
1. Streamlining Instrument Calibration with
Calibration Management Software and
Documenting Field Calibrators
Documenting tools and calibration management
software combine for a paperless calibration
solution
1
Host: Transcat
Presenters:
Jim Shields and Bob Crepps
Fluke Process Calibration Group
2. Agenda
• Instrument calibration, challenges and elements
– Reasons to calibrate
• Establishing a process calibration maintenance management
program
– Using Calibration Management Software (CMS) to:
• Manage process instruments and calibration records
• Interface with Field Documenting Process Calibrators
• Predict instrument performance, minimize maintenance costs
– Using Documenting Process Calibrators to :
• Manage procedures or tasks downloaded from CMS
• Perform field calibrations and adjustments
• Record field calibration results
• Upload field calibration results to CMS
• Paperless calibration management program benefits
3. Why Calibrate?
• Regulations, standards and trade
• Custody Transfer
• Internal/External Quality Programs (like ISO-9000)
• Plant Safety and Uptime
• EPA, FDA, NRC, OSHA and other mandated
regulations
4. Why Calibrate?
• All instruments change with
– Time, temperature, humidity, environmental
exposure, vibration, wear and tear
– No two instruments change exactly the same
• Scheduled calibrations reduce process
downtime risk
– Improves the performance and reliability of critical
assets
• Product Quality / Yield
– Calibration helps processes comparable to traceable
calibration standards
• Helps minimize process deviations
– Helps drive process optimization and cost savings
5. Industry changes
• Regulatory forces increasing
• The plant isn’t getting smaller but shrinking budgets are reducing
the maintenance staff
– Driving efficiencies and the need to “Do more with less”
• Experienced instrumentation professionals retiring
– Technical and Vocational Schools working to fill voids
• Plant modernizations lead to control system changes
• Competitive pressure offshore push the need for plant
optimization, streamlined operations and maintenance practices
6. Process Calibration
Elements:
• Calibration equipment, procedures, instrument documentation,
calibration management software (CMS), trained personnel
Benefits:
• Consistent process performance and efficiency, improved product
quality, reduced downtime, safety, regulatory compliance,
maximized use of skilled maintenance personnel
7. Calibration, definitions…
Calibration: Comparison of a measured value to a traceable
measurement standard
– Adjust to agree with the standard if necessary
• Accuracy: The closeness of agreement between an observed
value and that of a traceable measurement standard
• Adjustment: Manual or digital compensation of the output signal
of device with a known input value applied
– Necessary if a device is not performing as required
• Need to understand adjustment tolerance
• Need communication tool for digital adjustment
Adjustment is part of a calibration process, it is not calibration by
itself.
8. Fluke Petrochemical Corporation By Tag ID
RESULTS FROM FLUKE 702 CALIBRATIONS
2-Feb-96
Fluke Petrochemical Corp.
By:
Title:
Cert. No.: 1
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As found 25-Jan-96 4:46
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025 Input Value: Units Output value: Units Error % Status MeasUEV
3.906 mA 40.0 °C -0.59 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
19.923 mA 70.0 °C -0.48 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
3.907 mA 40.0 °C -0.58 Failed Disabled
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As left 25-Jan-96 4:53
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025 Input Value: Units Output value: Units Error % Status MeasUEV
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
20.018 mA 70.0 °C 0.12 Passed Disabled
12.016 mA 55.0 °C 0.10 Passed Disabled
4.003 mA 40.0 °C 0.02 Passed Disabled
Fluke Petrochemical Corporation By Tag ID
RESULTS FROM FLUKE 702 CALIBRATIONS
2-Feb-96
Fluke Petrochemical Corp.
By:
Title:
Cert. No.: 1
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As found 25-Jan-96 4:46
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025 Input Value: Units Output value: Units Error % Status MeasUEV
3.906 mA 40.0 °C -0.59 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
19.923 mA 70.0 °C -0.48 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
3.907 mA 40.0 °C -0.58 Failed Disabled
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As left 25-Jan-96 4:53
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025 Input Value: Units Output value: Units Error % Status MeasUEV
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
20.018 mA 70.0 °C 0.12 Passed Disabled
12.016 mA 55.0 °C 0.10 Passed Disabled
4.003 mA 40.0 °C 0.02 Passed Disabled
Fluke Petrochemical Corporation By Tag ID
RESULTS FROM FLUKE 702 CALIBRATIONS
2-Feb-96
Fluke Petrochemical Corp.
By:
Title:
Cert. No.: 1
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As found 25-Jan-96 4:46
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025 Input Value: Units Output value: Units Error % Status MeasUEV
3.906 mA 40.0 °C -0.59 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
19.923 mA 70.0 °C -0.48 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
3.907 mA 40.0 °C -0.58 Failed Disabled
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As left 25-Jan-96 4:53
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025 Input Value: Units Output value: Units Error % Status MeasUEV
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
20.018 mA 70.0 °C 0.12 Passed Disabled
12.016 mA 55.0 °C 0.10 Passed Disabled
4.003 mA 40.0 °C 0.02 Passed Disabled
Fluke Petrochemical Corporation By Tag ID
RESULTS FROM FLUKE 702 CALIBRATIONS
2-Feb-96
Fluke Petrochemical Corp.
By:
Title:
Cert. No.: 1
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As found 25-Jan-96 4:46
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
3.906 mA 40.0 °C -0.59 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
19.923 mA 70.0 °C -0.48 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
3.907 mA 40.0 °C -0.58 Failed Disabled
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As left 25-Jan-96 4:53
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
20.018 mA 70.0 °C 0.12 Passed Disabled
12.016 mA 55.0 °C 0.10 Passed Disabled
4.003 mA 40.0 °C 0.02 Passed Disabled
Fluke Petrochemical Corporation By Tag ID
RESULTS FROM FLUKE 702 CALIBRATIONS
2-Feb-96
Fluke Petrochemical Corp.
By:
Title:
Cert. No.: 1
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As found 25-Jan-96 4:46
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
3.906 mA 40.0 °C -0.59 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
19.923 mA 70.0 °C -0.48 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
3.907 mA 40.0 °C -0.58 Failed Disabled
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As left 25-Jan-96 4:53
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
20.018 mA 70.0 °C 0.12 Passed Disabled
12.016 mA 55.0 °C 0.10 Passed Disabled
4.003 mA 40.0 °C 0.02 Passed Disabled
Fluke Petrochemical Corporation By Tag ID
RESULTS FROM FLUKE 702 CALIBRATIONS
2-Feb-96
Fluke Petrochemical Corp.
By:
Title:
Cert. No.: 1
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As found 25-Jan-96 4:46
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
3.906 mA 40.0 °C -0.59 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
19.923 mA 70.0 °C -0.48 Failed Disabled
11.918 mA 55.0 °C -0.51 Failed Disabled
3.907 mA 40.0 °C -0.58 Failed Disabled
Model: FLUKE 702 Serial:6150203 User ID: JSmith 010
Cal. Status: 14 Loop Power: 24V
As left 25-Jan-96 4:53
Measure: 4.000 to 20.000 mA
Source: 40.0 to 70.0 °C Type: Pt100(3916) 2W RTD ITS-90
Test Tolerance: 0.25% Tag ID:TT451 Serial: 987654321
Test Strategy: 3 ^v Task Name: Temp Transmitter RTD1234
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
20.018 mA 70.0 °C 0.12 Passed Disabled
12.016 mA 55.0 °C 0.10 Passed Disabled
4.003 mA 40.0 °C 0.02 Passed Disabled
National
Standards
Traceability
• Unbroken chain of
calibration.
• Documented
proof.
9. Process Calibration requires:
Traceable calibration tools, source functions:
– Temperature, electronic simulation of thermocouples or RTDs
• Does not test the sensor installed in a process
– Temperature, dry block or temperature bath calibrator
• Tests the temperature sensor and transmitter electronics
– Pressure, hand pump, or other means to apply pressure to the unit under
test
– Pressure measurement reference to measure the pressure generated (by a
pressure source) and applied to the UUT
• Transfer standard approach
– Other Electronic signals
• Frequency for flow, speed and rotation
• Current for I/P and analog I/O
• Voltage for signal conditioners and analog I/O
10. Process Calibration requires:
Traceable calibration tools, measurement functions:
– Temperature, thermocouple or RTD thermometer
• Measure the process temperature with a reference probe directly
and compare with control system
– Pressure, measure the pressure output from an I/P or other
pneumatic control signals
– Other Electronic signals
• Frequency for flow, speed and rotation
• Current for all transmitter mA loop signal outputs
• Voltage for signal conditioners other voltage output devices
– Many transmitters have voltage output instead of mA output.
11. Why document calibration, how?
Calibration Records may be:
– required for regulations
– required for quality standards
– required by your customers
Calibration records can:
– assist in understanding the performance of a process
– be used to determine a devices suitability for a process
– help assess if a device needs repair
– be used to help adjust maintenance intervals
• Calibration records can:
– be manually recorded on a paper form
– be recorded on a palm device or portable computer
– be recorded using a calibrator with documenting capabilities
Calibration management software + documenting calibrators enables easy
documenting and analysis of field calibrations
12. Calibration process, setup
• Identify critical instruments
– Safety instrumented systems
– Environmental critical (water and air outflow)
– Quality critical: directly effect product quality and value
– Revenue critical instruments:
• Custody transfer, trade related measurements
• Define the interval to maintain desired accuracy
– Instrument should perform in tolerance when tested
• Specifications and test tolerances need careful consideration
– Manufacturers claimed accuracies can be misleading
– Test tolerances should be specified by process engineer
– The accuracy of both the instrument being tested and the calibrator need to
be considered
• Define the procedures for the identified tags
13. Calibration process; execution
• Identify the tags that need calibration
• Organize the work into logical routes
• Collect the necessary procedures, documentation and tools
• Isolate the device from the process
– Lock-out, Tag-out procedure if warranted
• Connect the calibrator, begin to calibrate
– Perform the As-Found test, document the results
– Adjust the transmitter if the measured errors are greater than the
adjustment threshold defined by the procedure.
– Perform the As-Left test, document the results
– Complete the documented record with Tag#, time, date, Serial numbers of
the TAG, the test equipment used and its’ calibration data
14. Documented Calibration Requires – As Found Data
• Testing the instrument to
determine “As-Found” performance
• Accurate knowledge of the source
value is required
– The sourced value and measured values
need to be traceable
– The total uncertainty of the source should
be 3 to 4 times better than the device
under test
• Pass-fail assessment (fail)
• Adjustment required!
Graph of Percent Error
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0
10
20
30
40
50
60
70
30
90
100
Input % of Span
%Error
+Tolerance
-Tolerance
15. Graph of Percent Error
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0
10
20
30
40
50
60
70
30
90
100
Input % of Span
%Error
+Tolerance
-Tolerance
Documented Calibration Requires – As Found Data
• Re-test to verify adjustments.
• “As Left” test documents the
condition of the transmitter after
adjustment
• Time and date of the test need to be
documented
• Instrument tag, serial number and
technician data need to be
documented
17. Why use a documenting calibrator?
• Multifunction source and measure
• Automatically capture results, date/time
user and tag information
• Eliminates manual transcription and
legibility errors
• Eliminates “pencil whipped” results
• Ensures calibrations performed per
documented procedures
• Coupled with CMS complete a paperless
documenting field calibration system
• Assists to comply with regulations and
audits
• Many have HART communication
capability built in
18. Why use a documenting calibrator?
• Multifunction source and measure
• Automatically capture results, date/time
user and tag information
• Eliminates manual transcription and
legibility errors
• Eliminates “pencil whipped” results
• Ensures calibrations performed per
documented procedures
• Coupled with CMS complete a paperless
documenting field calibration system
• Assists to comply with regulations and
audits
• Many have HART communication
capability built in
19. Why use a documenting calibrator?
• Multifunction source and measure
• Automatically capture results, date/time
user and tag information
• Eliminates manual transcription and
legibility errors
• Eliminates “pencil whipped” results
• Ensures calibrations performed per
documented procedures
• Coupled with CMS complete a paperless
documenting field calibration system
• Assists to comply with regulations and
audits
• Many have HART communication
capability built in
20. • Manage calibration records for field process instrumentation
• Print reports or run queries for instruments due for calibration to
help assess, schedule and manage
• Connect to Documenting Process Calibrators (DPCs)
– Load instrument procedures and upload documented calibrations
• Documented results enable analysis for drift, reliability or
maintenance costs
• Many CMS applications have connectivity to CMMS packages like
SAP, Oracle and Maximo
Why use Calibration Management Software (CMS)?
21. Examples:
• Fluke DPCTrack2
• Prime Technologies
ProCalV5
• Emerson AMS
• Yokogawa PRM
• Meridium
• Intergraph SmartPlant
Why use Calibration Management Software (CMS)?
• CMS completes the documenting
solution when coupled with a
documenting calibrator
• Many different solutions from fully
integrated CMMS to stand alone CMS
• Vary in complexity and price, $4K to
$100K
22. CMS Software Example, DPCTrack2
Modern calibration management software packages are
easy to use and deliver good reasons to adopt.
• Example entry level
single user CMS
application.
• Upgradeable to
ProCalV5 Enterprise
CMS software
23. What should a CMS package do?
• Manage and document process instrumentation performance
• Create custom procedures for download to DPCs
• Upload results from DPCs and store for later retrieval or analysis
• Print a variety of reports that support ISO 9000 or other
documentation needs
• Search for particular tags and report their history
• Search for tags due for calibration in the past or future
• Keep track of all Tags “touched” by a particular piece of test
equipment (reverse traceability)
24. Instrument View Search Queries
• Search queries can be customized to find populations of tags
differentiated by:
>Cal Due Date
>Tag Id
>S/N
>Location
>Device type
>Location
>Other fields
27. Upload and download information to DPCs
• Tags identified in the date based search are loaded into the
calibrator
28. Live DPCTrack2 demo
• Creating tags using example templates
• Error% calculation explanation
• Sorting the database for calibrations using database query tools
• Loading tags for a calibration route into the Fluke-729
29. Task Selection, (DPC)
• Tags downloaded to the DPC
available for selection
• Supervisor can assign as a
route to a technician
• Usage count indicates whether
a task has been completed
using the downloaded task
• Tasks must be performed for
usage count to increment
Tag
Number
Task Usage
& completion
Count
30. Downloaded transmitter test parameters
Predefined procedures
automatically fill in test
parameters:
• Source and measure end
points,
• Test tolerance,
• Test strategy (number of tests)
• Leak test available on 729 to
verify test setup for leakage
31. Pressure documenting made easy
• On the test screen:
– Applied pressure (top)
– Measured mA value (4.000 mA would be
the ideal value for this device)
– Error % of Range/Span
• Green for in tolerance
• Red for out of tolerance
– AutoTest and the 729 will automatically
apply the test pressures, measure mA
signals calculate Error % and document
• Out of tolerance tests flagged in Red
• Tag number, serial number and technician
name recorded.
32. Transmitter Adjustment, HART
PV zero trim
– Zero out transmitter offset
Output Trim
– Fetch retrieves the current value being
measured
– Trim 4 mA and Trim 20 mA performs mA
adjustment
Trim to applied Values
– Apply Expected 0 and 100% range values
– Adjust 4 and 20 mA outputs to match applied
pressures.
33. Transmitter calibration As-Left measurement
The As-Left test will repeat the initial
tests to verify and document the “As
Left”, post adjustment condition of
the transmitter
• Press “As Left”
• This As-Left result is successful as
noted by Pass
• The documented test is now ready
for upload
If the test fails As Left, additional
adjustment and additional As-Left
test(s) may be necessary.
34. Live DPCTrack2 demo
• Uploading documented calibration results
• Review and authorize the uploaded results
• Viewing the calibration certificate
• View other reporting capabilities
37. Takeaways
• Efficiency of route based calibrations can save up to 50% on
calibration maintenance labor making technicians more efficient
• Multifunction documenting calibrators minimize returning to the
shop to get additional tools
• The efficiency of performing pressure tests with the 729
Automatic Pressure Calibrator both saves time making the
technician efficient but also improves the quality of the
calibration result.
• Documented calibration results can assist in passing audits or
other requirements where calibration records are required
38. Summary
• Calibration is a critical practice to remove variability and maintain
safety in a process
• Documentation of calibration history enables advanced analysis
techniques
• Field documentation with a documenting calibrator eliminates
transcription errors and enables data to be uploaded to
Calibration Management Software (CMS)
• CMS can be used to sort the calibrations due into routes for
download, maximizes use of skilled personnel
• CMS assists in managing and interpreting documented calibration
records and day to day workload assignments
41. Fluke Corporation
• 3000 employees worldwide
• Presence in more than 100 countries
• Products include:
• Process Calibration Tools
• DMMs
• Calibration Standards
• High Performance Oscilloscopes
• Power Quality Analyzers
• Electrical Testers
• Thermal imaging
• Condition monitoring
• More!
42. Current Offer
• Now through June 30th
– Free Fluke tools with purchases $250+
– www.transcat.com
42
43. Questions or Comments?
Email Nicole VanWert-Quinzi
nicole.vanwert@Transcat.com
Transcat: 800-800-5001
www.Transcat.com
For related product information, go to:
www.Transcat.com/Fluke