inline quality monitoring - my.endress.com to monitor any validate inline systems: ... what’s...
TRANSCRIPT
01/04/2016
Products Solutions Services
Inline Quality Monitoring
Ensuring and Improving Quality and production costs
Slide 1
02/02/2016
Process variables and impact
• The raw material, • Seasonal• Supplier
• The operator• The utilities
• Energy supply• Plant conditions
• The equipment• Cleaning/Fouling status• Maintenance• Calibration
Is all that covered by the recipe in your control system?
Digital Inline Quality Control
Slide 2 Holger Schmidt
02/02/2016
Why consider digital with quality control?
• 4-20 mA: the working global analogue standard
• 4-20mA HART: only global digital standard (available in all sensors)
• Ethernet IP: the future of plug and play installations that supply all available information from a sensor. Flow and analytical are equipped with it. Strong joint development with Rockwell Automation.
• Profibus PA /DP: looked like the future in the past. Was too complex and difficult to find good support.
• Modbus: look today like a niche, as well as IO Link and Profi Net
Digital Inline Quality Control
Slide 3 Holger Schmidt
02/02/2016
Digital communication, Ethernet IP, Profibus…
The digital communication allows to access the full set of information the sensors creates. All data can be seen on the control screen. All settings can be done in the control room.
Digital Inline Quality Control
Flow(mass and volume), density, viscosity, temperature, totalizer, concentration, calculations, system status like dumping for maintenance, frequencies, e.g. to detect entrained air and improve the process
Slide 4 Holger Schmidt
02/02/2016
How to monitor any validate inline systems:
• All quality relevant systems need reported checks. Sensors have to be calibrated frequently, but what happens in the mean time?
• Digital systems allow to transfer all sensor data, showing inconsistencies in it performance right away.
• Other systems run checks on demand, initiated manually like with Memocheck
• For complete system checks in Endress+Hauser flow and level sensors have another technology on board, it is called:
Digital Inline Quality Control
Slide 5 Holger Schmidt
02/02/2016
MonitoringVerificationDiagnostics
What’s Heartbeat TechnologyTM can achieve?
Digital Inline Quality Control
Reliable self-monitoring• Continuous, built-in
diagnostic functionality• Broadest test coverage• Quick, concise guidance
in case of errors (NE 107)
Compliant testing• On-demand, effortless
procedure• Easy handling,
no process interruption• Electronic quality reporting
Condition-based maintenance• Permanent reading of
process-related variables• Impact assessment• External trend analysis
Slide 6 Holger Schmidt
02/02/2016
Supply chain support based on inline data
• Production planning process based on inventory
• Production panning based on plant availability considering visible repair and maintenance needs
• Spare part handling and trouble shooting supported online with integrated asset management.
Digital Inline Quality Control
Slide 7 Holger Schmidt
02/02/2016
Digital Inline Quality monitoring can…
• Helps to improve the overall quality of product and production.
• Is the basis for steady process optimization, compensating variables in raw material, utilities supplies, plant conditions and training status of the operator.
• Supplies the data for efficient traceability.
• Improves the data base for quality improvement.
• Helps to improve the cleaning and maintenance regime, neither to late nor to often.
• Supplies the necessary data to improve the process long term.
• Makes all operations and quality relevant actions transparent.
Digital Inline Quality Control
Slide 8 Holger Schmidt
01/04/2016
Lab Measurements
F&B Industry Strategic Directions 2016
The accuracy always depends on certain parameters and is measured against known values. The result needs to be absolute and valid anywhere under any circumstances.• Lab Measurements are highly accurate and should take into account things
like sample temperature variations.• Lab Measurements will still be important with installation of inline quality
monitoring instruments, as they validate inline measurements and provide the highest possible accuracy.
High AccuracyHigh Repeatability
Slide 9
01/04/2016
Lab Measurements
F&B Industry Strategic Directions 2016
We are not trying to “replace lab measurements”
Why? 1. Different levels of accuracy compared to inline instruments
2. We will always need verify inline instruments
3. Inline process measurements bridge the gap between lab measurements
4. Together they facilitate higher consistency and quality
Slide 10
01/04/2016
Inline Measurements
F&B Industry Strategic Directions 2016
Repeatability shows, what variances will be expected under production circumstances. • Inline meters are more robust, but less accurate then lab sensors, however
their high repeatability facilitates process improvements. • If different readings are detected every time measurements are taken,
quality cannot be improved. One could argue that it is better to be repeatable, rather than accurate for quality improvements
Instruments lose their calibration, and hence their accuracy, over time, therefore it is necessary to recalibrate to guarantee that an instrument is capable of measuring to the specifications for which it is rated.
Good AccuracyHigh Repeatability
Low AccuracyLow Repeatability
Slide 11
02/02/2016
Inline Quality Monitoring and Quality controls
F&B Industry Strategic Directions 2016
RSG45 Data Recorder
• Quick commissioning via integrated webserver• Seamless data exchange between field level and control level• Encrypted email notification for off-limit conditions and
alarms• Fulfillment of IT security requirements for FDA 21 part 11
conformity
Data TransparencyData recorders facilitate easy visualization of trends and capture historical data for analysis and reporting.
Safe data storage and email alerts keep you informed of developing process trends.
Slide 12
02/02/2016
Inline Quality Monitoring and Quality controls
F&B Industry Strategic Directions 2016
Fast-responding instruments can help increase quality directly.
Inline measurements enable faster response to changes in raw material quality or process drifts.
Blind spots between lab samples are eliminated
This allows operators to react quickly to prevent batch loss
Avoid Product LossesResponse Time Makes the Difference
Slide 13
02/02/2016
Inline Quality Monitoring and Quality controls
F&B Industry Strategic Directions 2016
Promag H 100
• Built-in conductivity measurement• Onboard meter verification with Heartbeat Technology,
HistoROM data management, built-in webserver, and Ethernet IP communication option
Contamination AlertsA Magmeter with integrated Conductivity measurement can provide early detection of contamination from improperly flushed lines or leaking valves.
This facilitates early identification of the source of the issue and prevents contaminated product from being used in downstream processes.
Slide 14
02/02/2016
Inline Quality Monitoring and Quality controls
F&B Industry Strategic Directions 2016
Promass I 100 Coriolis Meter
• Single straight measuring tube with full-bore design
• Real-time process information about corrosion, abrasion, and build-up
• Onboard meter verification with Heartbeat Technology, HistoROM data management, built-in webserver, and Ethernet IP communication option
Inline Density MeasurementSugar content, concentration or viscosity are parameters that are oftencritical to product quality.
Coriolis offers accurate and repeatable mass flow, density or viscosity determination.
Slide 15
02/02/2016
Inline Quality Monitoring and Quality controls
F&B Industry Strategic Directions 2016
FMD71 Electronic DP measurement
• High purity ceramic membrane for resistance against vacuum and abrasion
• Fast and easy installation
• 10 times faster response than capillary systems
• Eliminates up to 95% of errors due to ambient temperature effects
Filter MonitoringProactively monitoring the pressure build up across the filter to facilitatecleaning before a breakthrough happens.
Prevent product quality issues and eliminate rework of product that is over turbidity specification.
Slide 16
02/02/2016
Inline Quality Monitoring and Quality controls
F&B Industry Strategic Directions 2016
CPA875 Retractable + CYC25 Autocleaning
• No process shutdowns for calibrations or cleaning
• Memosens sensors can be hot swapped with the process running
• Reduces potential contamination of process from dirty sensors
• Regular cleaning increases sensor life and measurement reliability
Retractable Assemblies and Automated Sensor CleaningRetractable assemblies allow for easy removal of pH, ORP, or DO sensorsfor cleaning or calibrations without process shutdowns.
Automated cleaning systems facilitate increased process uptime by eliminating the need to shutdown or remove the probe manually for routine cleaning.
Slide 17
02/02/2016
Pasteurization of Beer, Milk, Juice, Sauce etc.
In a pasteurizer overshooting the temperature by even a few degrees affects taste, while undershooting can means unsafe products.
F&B Industry Strategic Directions 2016
QuickSens technologyT/°C
t/min
< min-min. Temperature biological risk
To hot Energy wasted and loss of quality
Fast response ensures the tightest control window possible for improvement of quality and energy
consumption
iTHERM TM411
Customer Benefit: • Higher Quality –Taste consistency
• Improved Product Safety
• Energy Savings
• 9x faster compared to standard RTDs (t90: 0.75s Quicksens insert; 2.5s in thinwall thermowell)
Slide 18
02/02/2016
Product monitoring for contamination
F&B Industry Strategic Directions 2016
Promag H 100 Early detection of contamination from improperly flushed lines or leaking valves for identification of the source of issues and to prevent contaminated product from being used in downstream processes.
Promag H 100 Product Features:
• Integrated conductivity measurement allows for continuous contamination monitoring for product safety.
• Reliability and long service life from IP69K ingress protection,
• easy and time saving set up with webserver.
Customer Benefit: • Improved Product Safety
• Early identification of quality issues
Slide 19
02/02/2016
pH monitoring in Sauces, Condiments, Jam, etc.
CPS471D + CM44x + CPA875
Critical Control point for product safety/quality ‐ Detection of trace CIP fluid contamination.
• CPS471D offers a glass free ISFET design to prevent glass contamination and ensure product safety.
• CPS71D offers high accuracy and resistance to clogging with a pressurized reference junction
• Retractable assembly is used to extend probe life under CIP Conditions
F&B Industry Strategic Directions 2016
Final pH monitoring—Quality control point Correct pH is needed for flavour and shelf life.
CPS71D-7TP****+ CM44x + CPA875
Customer Benefit: • Higher product quality
and safety
• Early identification of quality issues
Slide 20
02/02/2016
Dissolved Oxygen monitoring prior to packaging COS22D + CM44x
Monitoring for DO before heat process can prevent taste issues created by the increased oxidation rates seen at higher temperatures
F&B Industry Strategic Directions 2016
In almost any packaged sauce or liquid picking up entrained air can cause early product spoilage and reduced shelf life.
Customer Benefit: • Reliability of product “best before
dates“
• To ensure taste consistency
• Protection of brand image
• Amperometric Dissolved Oxygen measurement with long-term stability
• Plug and Play, Pre-calibration
• 12 mm Sensor design for use in all retractable and sanitary assemblies
• Memosens Sensor Technology
Slide 21
02/02/2016
F&B Industry Strategic Directions 2016
Beer pH monitoring Prior to Packaging
In Beer production a critical point for product safety is enabling detection of trace CIP fluid contamination before packaging.
Trace amounts of 40ppm NaOH or higher can be detected (pH change of 0.3 pH) –
• Regular calibration and cleaning is required for optimal performance to accurately detect such a small change in pH
CPS441D
with retractable CPA875 +
CYC25 Auto Cleaning
CPS71D-7TP****
with retractable CPA875 +
CYC25 Auto Cleaning
Customer Benefit: • Highest possible product safety and quality
Slide 22
02/02/2016
F&B Industry Strategic Directions 2016
pH monitoring in milk reception, butter and yogurt production
CPS441D
with retractable CPA875,
CYC25 auto cleaning
pH of milk used for butter manufacturing must be closely monitored. In yogurt the finished product pH is a final quality control point.
Customer Benefit: • Improved product quality
• Assurance of reliability of best before dates
• Brand protection
Product Features: • Glass free ISFET design to prevent glass contamination,
• Flowing KCL prevents clogging of reference junction.
• Retractable allows easy removal for cleaning or calibrations without process shutdowns.
• CYC25 can automate the cleaning process.
Slide 23
02/02/2016
F&B Industry Strategic Directions 2016
Mass Flow and Viscosity in Batters, Gravies and Sauces
Promass I 100
Correct viscosity is important quality control point to ensure the final product has the correct consistency.
• Straight tub design ensures low pressure drop and gentle product handling. Ethernet IP allows for easy setup and communication of all parameters simultaneously.
• IP69 K water ingress Protection
Customer Benefit: • Improved final product
Quality
Slide 24
02/02/2016
F&B Industry Strategic Directions 2016
Colour monitoring of fruit juice, soft drinks, etc
OUSAF22 + CM44PFinal product quality control of colour and purity.
• Monitoring for colour changes from overheating, incorrect dilutions, or incorrect colour dosing.
Customer Benefit: • Improved colour
consistency
• Identification of changes over time
• Dual wave length absorbance sensor. The second wave length ensures compensation of variations in turbidity.
• Color and absorbance sensor measures even the slightest change of color in products to determine product concentration or quality.
• High quality design, long service life and stable measurement
Slide 25
12/02/2015
Products Solutions Services
Calibration Services
Cost-effective, reliable calibration as and when needed
Slide 27 Service Office
02/02/2016
Welcome – Introduction
• Yang Feh Fan• Senior Engineer –
(Service and Solution)Marketing Dept.
• 3 years in E+H
• Contacts :
• 03 – 7843 3872
• 012 – 661 0219
F&B and Life Science Training
Slide 28 Service Office
02/02/2016
Calibration
Agenda
• Calibration basics• Importance of calibration• Endress+Hauser calibration competence• Flow calibration in Endress+Hauser Malaysia• Best practice for flow calibration management• Q&A
Slide 29 AS
02/02/2016
Calibration
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.
• Don’t confuse with verification
Slide 31 AS
02/02/2016
The verification and calibration of flowmeters
Calibration and Verification
On-site calibration
Factory calibrationWorkshop calibration
On-site control measurement
• Heartbeat Verification on demand
• Control measurement from the outside
• Mobile test rigs
• Stationary calibration facilities
Effort
Qua
lity
of te
stin
g
Calibration:Flow performance
confirmation
Slide 32 ED / MVA
Flowmeter functionality verification
02/02/2016
Heartbeat Technology - Verification
• Heartbeat Technology verifies the correct function of the measuring device according to the specifications and generates a verification report without process interruption
• The automatic generated protocol supports the documentation requested by internal and external formalities, laws and standards
Slide 33 Seou Wei
02/02/2016
Oil & Gas Flow - precise and efficient
Calibration methods – secondary calibration method
Unit Under Test
Water Reservoir
Mas
ter U
nits
= 3 dm 3
2503 dm3
2500 dm3
Slide 35 Ngo
02/02/2016
Calibration
The customer’s challenges
• Reduce business costs
• Ensure constant qualityof the final product
• Minimize emissions ofgreenhouse gases
• Improve plant safety
• Improve energy efficiency
• Compliance with quality standards and regulations
Slide 37 AS
02/02/2016
ROI example – Cost savings• Flow measurement with the rate
20 t/hour
• Increase in accuracy of 0.1% gained by regular calibration
RM/ton
Reduce of waste when operating 8x5 (Per year)
Reduce of waste when operating 24x7(Per year)
Fresh Milk 7000 RM 291,200 RM 1,223,040
Fanta 2000 RM 83,200 RM 349,440
Sunflower Oil 10000 RM 416,000 RM 1,747,200
Red Bull 20000 RM 832,000 RM 3,494,400
Red Wine 50000 RM 2,080,000 RM 8,736,000
Microsoft Excel Worksheet
Try putting your data in !
F&B and Life Science Training
Slide 38 Service Office
02/02/2016
Calibration is required by regulators§7.6: Control of monitoring and measuring equipment
… Where necessary to ensure valid results, measuring equipment shall:
a) 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);
b) be adjusted or re-adjusted as necessary;
c) have identification in order to determine its calibration status;
F&B and Life Science Training
§5.4: Calibration, adjustment an checking of measuring and monitoring devices
5.4.2 All measuring devices shall be checked, adjusted and calibrated, under a monitoring system, at specified intervals and in accordance with defined recognisedstandard/ methods. The results of the checks, adjustments and calibrations shall be documented. Where necessary, corrective actions on devices and, if necessary, on process and products shall be carried out.
Slide 39 Service Office
02/02/2016
Worldwide calibration capabilities• Calibration in 60 countries• > 250 qualified calibration
technicians
Calibration
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
Slide 42 AS
02/02/2016
Accreditation by Swiss Accreditation Service (SAS)
Since 1994, Endress+Hauser has been accredited as a calibration provider for flowmeters by the Swiss Accreditation Service (SAS) in accordance with ISO/IEC 17025. The very good results of the comparative verification measurements carried out by both the Swiss Federal Institute of Metrology (METAS) and Endress+Hauser confirm the high reliability of the flow calibration rigs accredited by SAS at Endress+ Hauser.
Xperience The Future
Yang FFSlide 43
02/02/2016
100% Traceability
Xperience The Future
Yang FFSlide 45
• The Endress+Hauser approach is accredited calibration rigs based on ISO/IEC 17025 as the traceability foundation.
• This means full traceability with an uninterrupted chain of proof regarding the test equipment, from the test device to the hierarchically highest standard in each country “national standard”, confirmed by an accreditation.
Calibration rig
Testing equipment
National standard
Global reference
±0.000001% ±0.0001% ±0.0016% ±0.015%
Example: Promass F is calibrated with a measurement uncertainty of ±0.025% as a master meter and Maximum Permissible Error (MPE) of ±0.05% (in customer’s production plant).
The calibration rig (Endress+Hauser)• PremiumCal calibration rig for testing Promass83F/84F (as an example)• Measuring uncertainty: ±0.015%• Accredited to ISO/IEC 17025 by the Swiss Accreditation Service (SAS)• Annual SAS audits of the facility
The gravimetric scales (Endress+Hauser)• Gravimetric scales of the PremiumCal calibration rig for measuring the referenceflow values• Regular verification of the scales every 2 weeks with calibrated reference weights(= internal reference standard)• Measuring uncertainty of the reference weights (class F2): ±0.0016%
The national standard (national institute of metrology)• Verification of the reference weights used by Endress+Hauser every 5 years bythe Swiss Federal Institute of Metrology METAS using a mass comparator andnational reference weights (national reference standards)• Measuring uncertainty of the METAS 500 kg reference weight (set 502, class E2):±0.0001% (0.5 gram to 500 kg)• Periodic comparison of the reference weights to Switzerland’s replica No. 38 of the IPK every 10 years
The International Prototype Kilogram (at BIPM, France)• International Prototype Kilogram (IPK) = global reference and basic unit of mass.The Bureau International des Poids et Mesures (BIPM), founded in 1875, keepsthe IPK under lock and key in a vault on its premises in Sèvres near Paris (France).• In 1950, 1991 and 2003 comparison measurements for verification took placebetween the IPK and Switzerland’s replica No. 38.• Measuring uncertainty: ±0.000001% (±10 micrograms)
02/02/2016
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
Calibration
Cost
of c
alib
rati
on (R
M)
Measurement Uncertainty (%)Slide 47 AS
02/02/2016
What is On-Site Calibration Service from Endress+Hauser
• Arrival of trained calibration technician(s) on your site with high accuracy mobile calibration tools
• Performing calibration of measurement devices with shortest possible out-of-operation time
• Producing and handing over standardized calibration reports
F&B and Life Science Training
Slide 48 Service Office
02/02/2016
Example of calibration certificate
F&B and Life Science Training
• Available in 16 languages• Contains all fields required by
ISO 17025• Contains graph for better
visualization• Can be provided in paper, PDF-
files or uploaded directly to your assets management system
Slide 49 Service Office
02/02/2016
Pillars of our Quality
F&B and Life Science Training
1. Comprehensive SOPs and Working Instructions
2. Certified Trainings for staff
3. Corporate Standard on Calibrations and Corporate Quality Management System
4. State-of-art software and tools
Slide 50 Service Office
02/02/2016
Our calibration portfolio - MY
F&B and Life Science Training
Core Calibration Parameters• Flow (Liquid)-NEW• Pressure• Temperature• pH• Conductivity• Level
Additional Parameters• Recorder• Other liquid analysis
Slide 51 Service Office
02/02/2016
Benefits at a glanceWe help to save extra• Define optimal calibration intervals• Shorten your replacement stock with fast
onsite calibrations• Get a expert analysis of calibration results• Establish and track KPIs to enable
improvements
You get it from one hands• Audit, Calibration, Consulting, Maintenance,
Repairs, Replacements from one supplier
Instant access to calibration results• All calibration results could be put directly
your Installed Base Management system
F&B and Life Science Training
Slide 52 Service Office
02/02/2016
Flow Calibration in Endress+Hauser Malaysia (NEW!)
F&B and Life Science Training
COMING SOON!
Slide 53 Service Office
02/02/2016
Video – Mobile Flow Calibration Rig
F&B and Life Science Training
Slide 54 Service Office
02/02/2016
Flow Calibration Rig (Coming Soon to Malaysia)
F&B and Life Science Training
Flow Calibration Rig Diagram
• Flow rate:
• Best uncertainty:
Small pump: 0.20 to 30 m3/h (depend on UUT pressure loss)Big pump: 0.20 to 60 m3/h (depend on UUT pressure loss)0.12%
Slide 55 Service Office
02/02/2016
Our Service at Glance – Flow Calibration Rig at E+H MY
F&B and Life Science Training
Calibration Method• Comparison with in series master meter• Mobile calibration with Coriolis flowmeter as reference
Calibration Range and Flowmeter Size• Small pump: 0.20 to 30 m3/h (depend on UUT pressure loss)• Big pump: 0.20 to 60 m3/h (depend on UUT pressure loss)• DN8 to DN100
Calibration Points• 3 or 5 points• 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 56 Service Office
02/02/2016
Our Service at Glance – Flow Calibration Rig at E+H MY
F&B and Life Science Training
Equipment Concerned• Electromagnetic• Vortex• Coriolis• Thermal• Ultrasonic• Mechanical• Others upon request
Documents Issued• Calibration Certificate• On request, copy of the proof of conformity to the
national/international standard
Benefits• Calibration can be conducted on-site or in E+H Malaysia workshop• Reduce downtime• Save cost
Slide 57 Service Office
02/02/2016
Best Practice for Flow Calibration ManagementCommon myth: My flowmeter needs to be calibrated annually because.... (you are not so sure)
Calibrate at an optimum frequency and save cost!
Fail to plan for flow calibration? Fail to save cost...
What we recommend:Yearly calibrations are not necessary, as some flowmeters require calibration only once every 3 or 4 years depending on the process fluid, operation, and criticality. In other cases, a flowmeter may require calibration much more frequently, to maintain a safe, efficient, or regulatory compliant operation. It’s also important to realize that calibration intervals are not always fixed, meaning that they might fluctuate based on usage or historical performance.
Xperience The Future
Yang FFSlide 58