02 services supporting your audits - endress+hauser · 2018-10-23 · “analytics” and find...

10/09/2018

Products Solutions Services

Services supporting your audits

Installed base analysis, calibration services

Slide 1 JG

10/09/2018


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


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10/09/2018

A service fully meeting your needs!


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?


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


Management summary with action plan

Standardization report

Corrective maintenance report

Obsolescence and migration report

Preventative maintenance report

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10/09/2018


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


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


Importance of calibration

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10/09/2018

Why to measure?


Input Process Output

Process Control SystemProcess Control System

MeasurementsMeasurements ControlsControls

En

erg

y

WaterAirGasElectricitySteam

WaterAirGasElectricitySteam

Em

issi

on

s$

$

$

Slide 10 JG

10/09/2018

Why to calibrate?


Minimizes quantityfluctuations

Keeps the quality level constant

Avoids

energy losses

Avoids humanand environmentaldamages

Slide 11 Slide 11 JG

10/09/2018

Energy Efficiency

• Tetra Pak Ultra-High Temperature (UHT) treatment module

• 5000 hours / year in operation

• Temperature transmitter


• 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


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


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


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


Calibration basics

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10/09/2018


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


Slide 18 JG

10/09/2018


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


Endress+Hauser calibration competence

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10/09/2018

Worldwide calibration capabilities

• Calibration in 60 countries

• > 250 qualified calibration technicians


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


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


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:


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


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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


Pillar 3: Competence

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10/09/2018


Flow Calibration Service

Slide 27 Yang FF

10/09/2018

The verification and calibration of flowmeters


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


Calibration methods – secondary calibration method

Unit Under Test

Water Reservoir

Ma

ste

r U

nit

s

D = 3 dm 3

2503 dm3

2500 dm3

Slide 29 Yang FF

10/09/2018

Reference Master Meter


Slide 30 Yang FF

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


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

Slide 31 Yang FF

10/09/2018

Flow Calibration Rig in Endress+Hauser Malaysia


You are all welcome to see the live demo!

Slide 32 Yang FF

10/09/2018


Any questions?

Slide 33 JG

02 services supporting your audits - endress+hauser · 2018-10-23 · “analytics” and find...

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