Transcat and Fluke Webinar: Streamlining Instrument Calibration

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

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

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

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

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

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

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.

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
As left 25-Jan-96 4:53
3.998 mA 40.0 °C -0.01 Passed Disabled
12.011 mA 55.0 °C 0.07 Passed Disabled
2-Feb-96
By:
Title:
Cert. No.: 1
2-Feb-96
By:
Title:
Cert. No.: 1
2-Feb-96
By:
Title:
Cert. No.: 1
1,996.001.0025Input Value: Units Output value: Units Error % Status MeasUEV
2-Feb-96
By:
Title:
Cert. No.: 1
2-Feb-96
By:
Title:
Cert. No.: 1
National
Standards
Traceability
• Unbroken chain of
calibration.
• Documented
proof.

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

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.

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

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

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

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

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

Paperless Instrument Calibration management

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

• 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)?

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

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

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)

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

Tag Instrument Data
• Input the data describing the tag

Transmitter Data
• Describe the input, output and expected tolerance of the
transmitter

Upload and download information to DPCs
• Tags identified in the date based search are loaded into the
calibrator

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

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

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

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.

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.

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.

Live DPCTrack2 demo
• Uploading documented calibration results
• Review and authorize the uploaded results
• Viewing the calibration certificate
• View other reporting capabilities

Uploaded Test Results
As-Found, As-Left results uploaded and authorized to
add to the database for analysis and printing

Calibration record
• Documented
calibration stored
for recall and
printing as
needed.
• Calibration date
updated in
database and
next calibration
due date is set.

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

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

Fluke Corporation
Fluke Headquarters, Everett
Washington, USA
From John Fluke’s basement to an industry
leader

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!

Current Offer
• Now through June 30th
– Free Fluke tools with purchases $250+
– www.transcat.com
42

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

Transcat and Fluke Webinar: Streamlining Instrument Calibration

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