10/09/2018
Products Solutions Services
Services supporting your audits
Installed base analysis, calibration services
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10/09/2018
Services supporting your audits
The customer’s challenges
• Reduce business costs
• Ensure constant quality
of the final product
• Minimize emissions of
greenhouse gases
• Improve plant safety
• Improve energy efficiency
• Compliance with quality standards and regulations
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10/09/2018
Services supporting your audits
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10/09/2018
A service fully meeting your needs!
Services supporting your audits
Assessment includes:
• Identification of safety, quality & environmental critical devices
• Identification of obsolescence risks and migration priorities
• Recommendations for quick device replacement and optimized spares storage
• Recommendations for improved preventive maintenance / calibration
• Full reporting with an implementation plan
For plant users who need detailed insights of their installed base to:
• Improve process availability and minimize downtime risks
• Reduce complexity and operational costs
• Meet quality and compliance demands
• Increase safety.
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10/09/2018
How do we work with you?
Services supporting your audits
Step 1 – Data collection
On-site data is collected bya Endress+Hauser qualitied Field Service Engineer. During a site visit, we work with you to gather all key asset information, which can include first identification of asset improvement. Focus on the instruments in place and on stock, providing further analysis in the context of your most critical facility performance.
Step 2 – Criticality & maintainability assessment
According to a defined & agreed methodology, we work with you to establish the relative importance of one asset to another. We assess the criticality based on the likelihood and consequence of the asset malfunction on the process. In addition, we evaluate the asset maintainability to ensure maintenance tasks can be performed easily and
effectively.
Step 3 – Detailed insights
Using software for analysis, our Maintenance Management Consultants start to identify potential risks based on current asset life cycle situation. Furthermore, they develop To Be recommendations needed to help you make decisions regarding the maintenance and obsolescence management of your installed base process instruments.
Step 4 – Analysis delivery
Our consultants deliver the analysis to you, along with recommendations and work with you to develop an implementation plan. The reports detail on one side what’s installed, what’s missing and what equipment is obsolete. Our presentation to you discusses solutions that are going to be most effective in helping you improve maintenance performance.
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10/09/2018
A detailed report with To Be Recommendations for improved maintenance
Services supporting your audits
Management summary with action plan
Standardization report
Corrective maintenance report
Obsolescence and migration report
Preventative maintenance report
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10/09/2018
Services supporting your audits
Access to online database with complete installed base transparency
• Access to all assets registered during the
Installed Base Analysis on the web application
“Analytics” and find simple KPIs and dashboard
functions. Continue to enhance your database
and keep it here up-to-date.
• Reach another step with additional tools:
Scanner app: a smartphone app for a
quick asset registration, data collection
and RFID chip writing.
Edge device: a smart gateway for an easy
connectivity and an automatic registration
of the assets.
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10/09/2018
Services supporting your audits
The Endress+Hauser Industrial Internet of Things (IIoT) eco-system
Ad
de
d V
alu
e
3rd party
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10/09/2018
Products Solutions Services
Importance of calibration
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10/09/2018
Why to measure?
Services supporting your audits
Input Process Output
Process Control SystemProcess Control System
MeasurementsMeasurements ControlsControls
En
erg
y
WaterAirGasElectricitySteam
WaterAirGasElectricitySteam
Em
issi
on
s$
$
$
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10/09/2018
Why to calibrate?
Services supporting your audits
Minimizes quantityfluctuations
Keeps the quality level constant
Avoids
energy losses
Avoids humanand environmentaldamages
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10/09/2018
Energy Efficiency
• Tetra Pak Ultra-High Temperature (UHT) treatment module
• 5000 hours / year in operation
• Temperature transmitter
Services supporting your audits
• The temperature deviation of 2°C results in an additionalsteam consumption of 150tons / year !
• This corresponds to approximately 20 kg CO2 emissions !
• Costs could have been reduced by performing calibration !
• The temperature deviation of 2°C results in an additionalsteam consumption of 150tons / year !
• This corresponds to approximately 20 kg CO2 emissions !
• Costs could have been reduced by performing calibration !
30 kg × 5000 h × 0.04 €/kg = 6000 € per year
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10/09/2018
Services supporting your audits
Some organizations that define the rules
• API – American Petroleum Institute
• EI – Energy Institute (formerly Institute of
Petroleum – UK)
• ISPE – International Society for
Pharmaceutical Engineering
• FDA – Food and Drug Administration (USA)
• EMA – European Medicines Agency
(European Union)
• OIML - International Organization of Legal
Metrology
• …
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10/09/2018
Services supporting your audits
Industry standards
• ISO 14001
• ISO 22000
• …
Quality management systems -- Requirements
Environmental management systems -- Requirements
with guidance for use
Food safety management systems -- Requirements for
any organization in the food chain
• ISO 9001
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10/09/2018
Services supporting your audits
ISO 9001
7.6 Control of monitoring and measuring devices
…
Where necessary to ensure valid results, measuring equipment shall
• be calibrated or verified, or both, at specified intervals or prior to use,
against measurement standards traceable to international or
national measurement standards; where no such standards exist, the
basis used for calibration or verification shall be recorded (see 4.2.4);
• be adjusted or re-adjusted as necessary;
• have identification in order to determine its calibration status;
• be safeguarded from adjustments that would invalidate the
measurement result;
• be protected from damage and deterioration during handling,
maintenance and storage.
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10/09/2018
Products Solutions Services
Calibration basics
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10/09/2018
Services supporting your audits
What a calibration is… and what it isn´t
• Calibration is the comparison of an
instrument to a known standard.
• Calibration is attempting to determine
measurement errors coming from the
calibrated instruments.
• Calibration is not an adjustment, only a
comparison.
• After a calibration a device could be
adjusted, the device must be recalibrated.
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10/09/2018
Calibration at Endress+Hauser
Services supporting your audits
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10/09/2018
Services supporting your audits
The calibration concept (pressure calibration)
Reference standard Unit Under Test (UUT)
Input value (pressure)
Beamex MC6 calibrator
Information about “true value”
Output value
“Quantitative outcome”
Calibration certificate
Calibration procedure (SOP)
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10/09/2018
Products Solutions Services
Endress+Hauser calibration competence
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10/09/2018
Worldwide calibration capabilities
• Calibration in 60 countries
• > 250 qualified calibration technicians
Services supporting your audits
Ranking criteria:• Ratio: calibration net sales vs. Total SC net sales • Number of trained field service engineers,
parameters and calibration tools• Accreditations in place
• > 50’000 on-site calibrations
• > 1500 calibration tools in the operations
• Various ISO 17025 accreditation in 6 countries
• Unified Calibration certificate in 16 languages
Core calibration parameters• Flow• Pressure• Temperature• pH• Conductivity
Additional parameters• Volume• Level• Electrical parameters• Density• Rotational Speed• Energy transfer• Other liquid analysis
High
Medium
Low
Status: April 2014
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10/09/2018
E+H Calibration capability breakdown
Factory Calibration
Wide measuring rangeDistance, turnaround time-
Workshop Calibration
Faster turnaround, less costSmaller ranges-
On-site Calibration
Fastest turnaround On-site preconditions, know-how Direct communication, least
down-time
Services supporting your audits
Co
st o
f ca
lib
rati
on
(€
)
Measurement Uncertainty (%)
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10/09/2018
Pillar 1: Quality Management System
• Standard Operating Procedure (SOP)
• Generic instructions which have to be
followed
• Work Instructions (WI)
• Detailed instructions which
have to be followed
Services supporting your audits
SOP’s and WI’s ensure that calibrations can be repeated anywhere and at any time !SOP’s and WI’s ensure that calibrations can be repeated anywhere and at any time !
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10/09/2018
Pillar 2: Validation & Traceability
Standardized calibration equipment (reference standards) for various
parameters:
Services supporting your audits
Flow Pressure Temperature
Flow Calibration Rigwith Promass 83F
Beamex MC6with different pressure modules
Beamex MC6 + FB150with PT100 reference probe
• Measuring range*:0 … 70000 kg/h
*with Promass 83F DN50 2”Different ranges available
• Measuring range*:- 1 … +20 bar
*Different ranges available
• Measuring range*:- 25 … + 150 °C
*Different ranges available
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10/09/2018
Pillar 2: Validation & Traceability
Services supporting your audits
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10/09/2018
Advanced
Expert
Basic
Fundamentals
E+H Service Training Steps
Fundamentals – ServiceObjectives:
Ten standardpoints/technologie
Relevant service tools
Basic Training – ServiceObjectives:
Commissioning, repair, basic diagnosis, maintenance, instrument update/upgrade
Practical Experience
Time in field gaining experience on topics from Basic Training
Advanced Training – ServiceObjectives:Advanced application commissioning, repair, maintenance and diagnosis, experience exchange
Practical Experience
Time in field gaining experience on topics from Advanced Training
Expert Training Objective:
Involvement & input into group activities related to technology, peer recognition, expert diagnosis. Experience exchange with presentation of experience mandatory
Train the Trainer Objective:
Train the trainer program, learn how to teach
Min. 5 years of field experience or specialized
Product Update Training:New enhancements, updates, releases to existing products
Pass of Theoretical &Practical Assessment
Pass of Theoretical Assessment
Prerequisite
Prerequisite
Prerequisite
Pass of Theoretical &Practical Assessment
Stan
dar
diz
ed E
+H Q
ual
ific
atio
n L
evel
Services supporting your audits
Pillar 3: Competence
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10/09/2018
Products Solutions Services
Flow Calibration Service
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10/09/2018
The verification and calibration of flowmeters
Flow Calibration Service
On-site calibration
Factory calibration
Workshop calibration
On-site control measurement
• Heartbeat Verification on demand
• Control measurement from the outside
• Mobile test rigs
• Stationary calibration facilities
Effort
Qu
ali
ty o
f te
stin
g
Calibration:
Flow performance
confirmationFlowmeter functionality
verification
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10/09/2018
Flow Calibration Service
Calibration methods – secondary calibration method
Unit Under Test
Water Reservoir
Ma
ste
r U
nit
s
D = 3 dm 3
2503 dm3
2500 dm3
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10/09/2018
Reference Master Meter
Flow Calibration Service
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Reference Meter•Proline Promass F 300 DN 08 (3/8”)•Proline Promass Q 300 DN 25 (1”)•Proline Promass Q 300 DN 50 (2”)
10/09/2018
Our Service at Glance – Flow Calibration Rig at E+H MY
Flow Calibration Service
Calibration Method
• Comparison with in series master meter
• Mobile calibration with Coriolis flowmeter as reference
Calibration Range and Flowmeter Size
• Pump module: 0.20 to 60 m3/h (depend on UUT pressure loss)
• DN8 to DN80
Calibration Points
• 5 points (default)
• Others on request
Time required (per device)
• 2 to 3 hours (depending on calibration points, process condition/connection, etc)
• Cleaning has to be performed before calibration
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10/09/2018
Flow Calibration Rig in Endress+Hauser Malaysia
Flow Calibration Service
You are all welcome to see the live demo!
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10/09/2018
Products Solutions Services
Any questions?
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