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Instrument Calibration
Program Implementation
Guide
Foreword Operational Excellence through line optimization while maintaining product quality
and ensuring safety has been the driving force in our factories these days. This has
triggered the definition of tough operational requirements that are established based
on measurable benchmarks.
In our manufacturing lines, some of these benchmarks are based on measurable
physical quantities. And to make sure that the benchmarks are realistic, the
accuracy of the instruments used must be regularly checked and maintained.
To support this, installing an effective instrument calibration program is essential.
This program ensures that calibratable instrument or measuring systems used in
factories are compared and adjusted to metrology standards of higher accuracy.
Purpose and This document should serve as a reference for those who are responsible for putting
content of the in place and maintaining an instrument calibration program. This will help them to:
document
Better understand the meaning and purpose of instrument calibration.
Have an idea how to set-up, implement, and maintain an instrument
calibration program
Know how to ensure instrument calibration traceability in accordance with
the requirements of the Nestle Quality System.
Target This document is addressed to: Market Chief Engineers, PTC and R&D Engineering
Audience Heads, Factory Engineers, Factory Electricity & Automation Heads, and Project
Engineers.
Instrument Instrument calibration is the 4.8th element in the Nestl Quality System (NQS), and is
Calibration as part of the requirements for achieving the First Priority Level. It has been given
an NQS priority among others, because the reliability of a manufacturing process is largely
Element dependent on the accuracy of the instrument used for the application.
For this reason, an effective calibration program has to be put in place in compliance
with the NQS.
Basic Elements In implementing an instrument calibration program, the following basic elements
have to be complied with:
Measuring Loop Inventory and Calibration Quality Requirements
Calibration procedures and calibration-related forms
Scheduling system
Labeling/tagging system
Measurement traceability
Adequacy of calibration equipment (test and reference instruments or
working standards)
Personnel Training
Calibration certificates
Documentation/Instrument calibration filing system and/or calibration
software
Periodic Review of Calibration Program
Factory The Factory Engineer takes overall responsibility for ensuring that an effective and
Engineer sustainable instrument calibration program is implemented in their plant.
Factory The factory Electricity & Automation (E&A) group is responsible for the following:
Electricity &
Management and maintenance of the instrument calibration program
Automation
Creation and maintenance of the measuring loop inventory
Creation, update, and safekeeping of instrument calibration historical
records and certificates
Compliance of Calibration Program Quality Requirements
Planning, scheduling and performing instrument calibrations
Define the Calibration Program Quality Requirements together with Quality,
Manufacturing and Safety
Safeguarding of test and reference instruments
Purpose The various elements for the instrument calibration program must be defined
properly before starting the actual calibration. This is important to ensure that:
The prioritization of instruments or measuring loops is well defined
Calibration intervals and calibration quality requirements are set
Instrument calibration schedule is well established
Calibration procedures and forms are well defined
Procedure In the preparation of Calibration Quality Requirements, the following procedure may
be followed:
1. Measuring Loop Inventory the list of measuring loops (or chains) in the
manufacturing process (including test and reference instruments) has to
be prepared, complete with all the relevant information relating to the
instrument(s) in the measuring loop.
2. Assignment of Calibration Class together with the responsible persons,
the measuring loops (or instruments) will then have to be classified
according to their calibration class. The calibration class is dependent
on the various requirements from quality, operational, and safety
perspectives
3. Definition of calibration interval. Taking into consideration the calibration
class, degree of utilization, environmental factors and manufacturers
recommendations, the calibration interval has to be set.
4. Maximum Permissible Error in Measurement This has to be defined
taking into consideration the following: Uncertainty Budget + the
allowable tolerance (or margin) in operational requirements (based on
the criticality or risk involved in the measurement)
5. Definition of other calibration requirements. Other calibration criteria
must also be defined such as number of calibration points, reference
standard, maximum number of adjustments allowed, etc.
Measuring The Measuring Loop Inventory must include all calibratable instruments or
Loop Inventory measuring systems. This must include the following:
1. Field installed measuring instruments (installed in the process lines)
2. Test and reference measuring instruments (reference standards)
Calibration The calibration interval is defined during the identification of critical instruments. This
Interval is defined in collaboration with the manufacturing group, QA, safety officer, and
manufacturing specialist.
Measuring loops falling under calibration classes A & B must be strictly defined.
Compliance to the defined intervals must also be strongly enforced.
Instruments under classification class C may take the recommended interval by the
manufacturer or may be calibrated on an upon request basis. The cost of
calibration is a major factor to consider for the instruments in this calibration class.
However, in any situation, the local legal requirements for calibration interval, if
existing, must be strictly complied with. Example for this is the legal requirements for
Thermal Processing operations.
The definition and revision of calibration interval has to be approved by the
Approving Technical Authority.
Please refer to Appendix II for the guide in defining Calibration Intervals
Maximum The total accuracy of a measurement in industrial applications means the accuracy
Permissible of the final reading, i.e., the accuracy of the whole measuring loop. The final
Error in measured value is often the digital value in the automation system used for process
Measurement control, process reports, energy and material balance calculations, etc.
In determining the maximum permissible error (uncertainty budget) for industrial
applications, it is important to identify the uncertainty contributors. Here are the most
common uncertainty contributors:
Reference
Standard
Measuring
Environment Equipment
Uncertainty of Installation
Metrologist the Measured
Characteristic
Calculation or
Definition of
reading errors
Measurand
Calibration
Procedure
The maximum permissible error has to be defined collectively by the groups involved
in the program. This must also be approved by the Approving Technical
Authority. It is not practical to enforce very tight accuracy requirements on all
measuring loops. The maximum permissible error has to be defined taking into
consideration the following criteria:
Measurement error determined considering the uncertainty contributors.
Calibration Class
Allowable tolerance (or margin) in manufacturing requirements for measuring
loops under Categories B and C, a wider permissible error may be tolerated.
Accuracy requirements will have a direct impact on the calibration cost since they will
directly affect the calibration interval and the choice of instruments.
Where,
ETot = the combined error
E1-n = the uncertainty factory for each uncertainty contributor
This means that the contributor with the biggest uncertainty factor will have a
significant impact on the combined uncertainty, while the contributors with
small uncertainty factor will have insignificant impact on the combined error.
For industrial applications, we could simplify the model by considering only the major
uncertainty contributors.
Let ES be the error due to the sensor or measuring equipment,
Let EL be the uncertainty in reading the indicator (or the display in the HMI)
of the system to be checked or calibrated; this value is given by the
manufacturer.
Let ET be the uncertainty of the test and reference instrument or standard,
as shown in the last calibration report for this system.
Let EC be the uncertainty of any intermediate signal conversion device you
may put in between the measuring equipment and the indicating device such
as analog/digital converters, PLC cards, etc.
Let EG be the overall measurement error (or uncertainty budget).
For industrial applications, we could simplify the model by considering only the major
uncertainty contributors.
The Maximum Permissible Measurement Error in Measurement is then calculated
using this overall measurement error EG as a reference plus a certain margin
depending on the criticality (Calibration Class) of the measurement loop. As an
example, the accuracy required for a temperature measurement for a sterilization
process may not be as stringent as the temperature measurement of the
temperature of the hot air for the Egron.
The Manufacturing Group in collaboration with Engineering, Quality Assurance and
Safety must define this margin. This margin normally can be in the range from 1.1x
to 2.0 x EG.
Calibration The calibration procedure defines the process of performing the actual calibration. It
Procedure provides the following information:
The equipment required
The physical medium to be used for calibration
The type, number and settings for input signals
The required accuracy
The test and reference instruments needed
The number of tests required
Other information related to the instrument
The calibration procedure for each type of measuring loop or instrument must be
defined.
Procedures must be clearly and effectively documented in Standard Operating
Procedure (SOP) or Quality Monitoring Scheme (QMS) format.
Please refer to Appendix V for an example of a calibration procedure.
Adjustment If a measurement or the result of the calibration exceeds the maximum permissible
error, an adjustment or correction has to be made. The appropriate adjustment
procedure must be followed. After any adjustment, a re-calibration has to be made.
Multiple adjustments or re-calibrations may be needed until the instrument can be
restored to the desired accuracy. If the desired accuracy is never attained after
several adjustments, the instrument has to be replaced. The maximum number of
adjustments or re-calibration must also be defined.
In-Line In-line validation is a quick process of checking the reliability of some key
Validation instruments at the point of measurement. This can be made in the process through
simple comparison between the measuring instrument and a working standard. The
comparison could be on either instantaneous value or accumulated value of the
parameter. The operator could then request calibration of the instrument if the
measuring error is unacceptable.
Examples of this are: checking temperature sensors with a reference thermometer;
or checking load cells with known test weights. This, however, is not applicable for
some measuring loops.
A separate procedure can also be established in the factory for this purpose.
Maximum Permissible Error 1.5 x the Global Error of the Measuring Loop
The Global Error of the Measuring Loop, being the quadratic sum of the errors of the
instrument that compose it.
However, if the Maximum Permissible Error is below the error allowance stated
above, it is recommended to perform the calibration of the measuring loop as a
whole.
Measuring Loop Calibration
For a measuring loop consisting of multiple components, such as an instrument, a
transmitter and a display, this set of measuring devices will have to be jointly
calibrated as one measuring system.
A test will be made in normal conditions of work and with all the instruments correctly
installed. The calibration can be done by using a reference standard measuring in
parallel with the instrument under test, or by using a signal generator at the point of
measurement. The reading in the reference standard is then compared to that of the
display in the visualization software, indicator, or stand-alone controller, as the case
may be.
The calibration has to demonstrate that the measuring loop has the accuracy
superior or equal to the required accuracy of the manufacturing process.
Measuring If an instrument inventory is readily available, the same inventory can be used in
Loop Inventory preparing the Measuring Loop Inventory. From the instrument inventory, the
Form measuring loop number (if it is different from the instrument tag number) and the
calibration class have to be added.
You may use the form in Appendix VI as an example in completing the Measuring
Loop Inventory. This form indicates the detailed specification of the measuring
loop or instrument concerned
Calibration The calibration report has to be prepared by the technicians after conducting the
Report calibration in the field. This report is used as a reference in preparing the calibration
certificate or as an input to the calibration software. This must also be put on file.
Please refer to document in Appendix VII as an example.
Electronic records may be allowed as long as it complies with the local regulations
and with the agreement of the Approving Technical Authority.
Purpose To sustain the effectiveness of the calibration program, a scheduling system has to
be put in place. The scheduling system will provide the information on which
measuring loop has to be calibrated and at which date. The system must also be
designed so as to properly distribute the calibration activities within one calibration
cycle, taking into consideration the calibration intervals, shutdown schedules,
working standards, and manpower resources.
Manual The calibration schedule can also be planned manually through the preparation of an
Scheduling Instrument Calibration Schedule. This is a spreadsheet containing the list of
measuring loops with their corresponding schedule for calibration, spread over a 6
month or one year period.
As an example, refer to the Appendix VIII
Tagging The following rules should be followed in tagging measuring loops or instruments:
Convention
Each measuring loop should have a unique tag number. A measuring loop
may contain one or more instruments.
The tag number should be linked to the asset number where the measuring
loop belongs.
All instruments belonging to one loop must have the same numeric tag (the
letter prefix may vary depending on the function. This is important because
the calibration will be done on a per loop basis, and the recording system (in
either manual or electronic) is also on a per loop basis.
For more details on the tagging convention please refer to TM 221.18
Instrument Tag Each instrument should be provided with an instrument tag in accordance with the
tagging convention mentioned above. The tag can be of stick-on or hook-up type.
This are usually mounted on the instrument, if conditions permit. Otherwise, these
tags can also be placed on the wall or on the support next to the instrument.
The type of material and printing method has to be specified that it can withstand the
environmental condition where the instrument is installed.
Here is an example of the stick-on instrument tag made of Gravoply (2-layer plastic
material for engraving), with engraved characters:
Loop No.
Calibration date
Calibrated by
Calibration
due
Calibration The calibration date refers to the date of actual calibration. This is dependent on the
Date instrument calibration plan, which is based on the calibration interval defined for
each instrument. This has to be indicated in the calibration tag after the actual
calibration has been made. This must also be indicated in the corresponding
calibration report and must be entered in the calibration software. The next
calibration due is calculated from this last calibration date.
Calibration Due The calibration due refers to the next calibration schedule, the maximum of which is
defined by the calibration interval. This must also be indicated in the calibration tag
after the actual calibration. This must also be reflected in the calibration report. If
calibration software is used, the next calibration schedule is calculated automatically
provided the calibration interval has been properly defined and entered into the
system.
Definition & According to the internationally recognized VIM definition, traceability is defined as
Purpose the property of the result of a measurement or the value of a standard whereby it can
be related to stated references, usually national or international standards, through
an unbroken chain of comparisons all having stated uncertainties.
This is also an important element in the Nestl Quality System. The proof of
measurement traceability is important to guarantee the quality of our products and
processes and to ensure the safety of our work place and environment
Traceability The calibration program must be designed such that it provides a way to relate the
results of a measurement or value of a reference standard to higher-level standards.
The program must ensure that the measuring loops (particularly those in Calibration
Classes A&B) must be traceable to a national or international standard.
Calibration certificates and/or reports must state the traceability to a national or
international standard of measurement and must provide the measurement results
and associated uncertainty of measurement and/or a statement of compliance.
Reference instruments should be regularly sent for calibration to external bodies
capable of providing traceability to national or international reference standards.
Reference materials should, where possible, be traceable to national or international
standards of measurement or reference material.
It is important to note that traceability is the property of the result of a measurement,
not of an instrument or calibration report or laboratory. The measuring loop by which
values are transferred must be clearly understood and under control.
Working
Standards Factory
Test Weights
Process
Instruments
Load Cell
Purpose Test and reference measuring devices (working standards) are essential to facilitate
the calibration of field instruments. These devices must be periodically sent to
certified external bodies for calibration. These test and measuring devices that are
used for field calibration, guarantee the traceability of the calibration of our
measuring systems.
Types of The most common type of test and reference measuring devices are as follows:
Instruments
Thermometers
Pressure calibrators
Signal generators (current, voltage, interval, etc.)
Resistance boxes
Multi-function calibrators or meters
Reference weights or masses
You may use the following form in Appendix IX to list the test and reference
measuring devices. This form indicates the detailed specification of these
instruments.
Calibration These test and reference instruments and standards must be sent periodically for
Certificates calibration to legally recognized external certifying bodies. They will determine if an
instrument or standard is still valid for its intended use, and they will also specify the
next calibration due. They must also issue a certificate, duly signed by the person
responsible, specifying the accuracy level of the instrument calibrated. The
certificate is valid until the next calibration due indicated in the certificate.
This certificate must be properly kept in the corresponding folders of the test and
reference measuring device.
Purpose Instrument calibration involves complicated and highly technical systems and
procedures. In order to have an effective instrument calibration program, it is
imperative to have competent technical staff to manage and implement the program.
Competent It is required to have at least 1 highly skilled staff in the factory to manage the
Staff instrument calibration program. The person(s) implementing the calibration program
must be proficient in performing the required tasks. He must also be knowledgeable
in the requirements of traceability as mandated in the Nestl Quality System. He
must also be knowledgeable of the safety-related measurements in the plant.
The personnel performing the calibration must have the necessary education,
training, background, and experience.
Training The person(s) managing the calibration program and doing the actual measurement
and calibration must have undergone the appropriate training on metrology and
calibration. The level of competency and the kind of training required will have to be
adopted locally according to legal requirements and available training programs.
The qualifications and training must be documented. On a periodic basis, the
calibration personnel must be updated with the current technology and procedures.
Purpose Calibration certificates provide the proof of calibration. It will also be used as a
reference for the current accuracy of the instrument and the error corrections made.
Also, it will be used as the basis for the determination of the next calibration
schedule.
Calibration This certificate must be provided by the authorized external calibration bodies or by
Certificate for the instrument or device supplier. The calibration certificate must always be
test and traceable to national or international reference standards.
reference
This document certifies that the instrument performs within the acceptable error
standards
tolerance limits. The certificate must also indicate the expiration date of the
calibration. This expiration date should be the latest date for the next calibration
schedule for the reference standard concerned.
These certificates must be kept in their corresponding folder in the calibration files.
Calibration This certificate is prepared by the technician conducting the actual calibration and to
Certificate for be duly signed by the person responsible for calibration. The certificate maybe
other prepared manually using a calibration certificate form or it may also be automatically
measuring generated using the calibration software.
systems
For the measuring loops, which are usually sent to the manufacturers or their
authorized representatives for calibration, they must issue a calibration certificate
indicating that the instrument is working within the tolerable limits and the
corresponding expiration date.
Signed copies of these certificates must be put on file, for traceability purposes.
Please refer to Appendix IV for an example of the calibration certificate.
Purpose To facilitate traceability, it is important to have an efficient filing system. The fast and
accurate retrieval of calibration information must be ensured. The use of calibration
software facilitates this task. The filing system consists of two parts.
Measuring Loop Inventory database. A calibration software is very useful for
this purpose
Calibration certificates this is mandatory and each instrument must have on
file a valid calibration certificate.
Instrument An inventory database of all field instruments and all test and reference instruments
inventory must be put in place. The database contains the following information for each
database measuring loop
Tag number
Description of instrument
Location (area where installed)
Operating value or range
Maximum Permissible Error in Measurement
Instrument brand and model
Calibration Class
Calibration Interval
Process Medium
The database should also contain the following information:
Calibration schedule
Maintenance History of the measuring loop or instrument.
Calibration Calibration records must be loop independent. Although we have a common loop
Records number for all instruments belonging to one measuring loop, each instrument
belonging to that loop should have a unique identifier (by adding a suffix to the loop
number, or using the instrument serial number as a reference as examples).
Each measuring loop record then should contain all the data about the loop as well
as the calibration history of each instrument belonging to the loop. If an instrument is
transferred from one measuring loop to another, its calibration history should also go
with it, and that the change must be reflected in the measuring loop record.
Filing of Calibration certificates have to be properly put on file. Two separate calibration
calibration certificate-filing systems have to be setup: one for the field instruments and one for
certificates the test and reference instruments.
Filing has to be done by loop number. Past calibration certificates must be kept
together with the succeeding ones. Retention period may be defined as needed.
Purpose As the number of instruments in the inventory increases, the more difficult it is to
manage the calibration program. The calibration software helps the user in the
following tasks:
Management of the Measuring Loop Inventory database. Ensures fast and
efficient storage and retrieval of information
Planning of instrument calibration schedule by automatically tracking
calibration dates and calibration interval.
Traceability
Prints reports including calibration certificate.
Purpose The periodic review is needed to fine tune and re-validate the following:
Measuring Loop Inventory
Calibration Class
Maximum Permissible Error in Measurement
Calibration Interval
Instrument Calibration Schedule
The Measuring Loop Inventory and the corresponding Calibration Class have to be
reviewed in relation to the changes in the manufacturing requirement or process.
With the use of historical calibration information it is practical to adjust accordingly
the calibration interval and calibration schedule.
Review of The Measuring Loop Inventory and the Calibration Class have to be reviewed
Measuring annually. This is to ensure that changes to existing manufacturing operations are
Loop Inventory taken into account, that no critical measurement is left out, and that retired
instruments are removed from the inventory. It is also important to review the
Calibration Class and Maximum Permissible Error in Measurement in order to
update the prioritization of the instruments.
Calibration The calibration interval must also be reviewed annually. With the help of historical
Interval Review calibration data, we can fine-tune the calibration interval. If the calibration history
shows no drift in the accuracy, it may be economical to lengthen the interval between
calibrations. On the other hand, if the drift is significant, it maybe practical to shorten
the calibration interval, to ensure reliability of measurement.
This review of calibration interval can also help in identifying the reliability of the
instrument used in the processing lines.
APPENDICES
Table of contents
Calibration Class
A High Priority
Category Function
B Medium Priority
C Low Priority
Quality
CCP (Critical Control Point) refers to measuring
loops identified to be critical in ensuring Food
Safety, based on the HACCP studies. The proper
calibration of this measuring loop is mandatory to
comply with Food Safety (First Priority Level of the
Nestl Quality System). A
Examples:
Temperature measurement used in
sterilization process
Metal detectors classified as CCP
Thermal Processing Measuring Loops refers to
processes involving sterilization and
pasteurization. This is also considered as a
CCP, but is highlighted here due to some specific
applications and strict government requirements
1 in traceability.
Examples: A
Temperature measurement and
recording in cookers and sterilizers.
Sterilization process involved in retorts
and UHT where the temperature and
flow measurements are critical to
ensure the minimum time required.
CP (Control Point) refers to the measuring loops
that have direct influence on the quality of the
product but do not necessarily affect food safety.
Examples:
Roaster drum temperature B
measurement
Weigh scales batching systems
Pressure and temperature measuring
loops on evaporators
Calibration Class
A - High Priority
Category Function
B - Medium Priority
C - Low Priority
Operational
Legal Operational Requirements refers to
measuring loops installed in the lines that are
periodically inspected or used by legal authorities.
Examples: A
BOD (Biological Oxygen Demand)
monitors on effluents
Flowmeter for Waste Water Effluents
Production/Usage Monitors, KPI Benchmarks
refers to measuring loops used in monitoring
production output, material usages, line efficiency
and performance, or those used as benchmarks
for Key Performance Indicators (KPI)
B
2 Examples:
Batch weighers
Level transmitters used for Inventory
Energy consumption meters
Process Control refers to all measuring loops
used in controlling or for monitoring the process.
There performance may not have a significant
impact on the finished product quality, and they
are not used for legal requirements and for
production/usage report or KPIs. C
Examples:
Steam flow measurement
Process tank level measurement
Process temperature measurement
Calibration Class
A - High Priority
Category Function
B - Medium Priority
C - Low Priority
Safety & Environment
Primary Element - refers to all measuring loops,
which directly triggers the actuation of a safety
interlock, such as valve closure, motor stoppage
or plant shutdown. This also includes all
measuring loops triggering alarms that signal the
drastic and immediate human intervention due to
safety reasons, such as room evacuation, manual
shower triggering, etc.
A
Examples:
Egron CO Detection System
Egron Exhaust air temperature used for
Egron Safety Interlocks
Extraction cell pressure measurement
Oxygen level detectors
Secondary Element - refers to all measuring
loops, which triggers pre-alarm levels, or warning
3 signals (if they are separate from the primary
element).
Examples:
B
High-pressure alarm triggers for pressure
vessels such as boiler drums.
High level alarm triggers for tanks
containing sensitive media, such as acids,
caustic solutions, etc.
Monitoring instrument refers to all measuring
loops installed for environmental protection
purposes, but only for monitoring trends.
Examples:
C
DO (Dissolved Oxygen) and pH meters for
waste water treatment plant
Differential Pressure Measurement for Bag
Filters
Factors to Here are the key factors to consider in the initial definition of the calibration interval.
consider 1. Calibration Class
2. Degree of Utilization
3. Environmental Consideration
4. Manufacturers Recommendation
5. Legal Requirements
However, one must remember that the optimum calibration interval is always based
on experience and historical calibration data. It is recommended to have a periodic
review of the defined intervals, when sufficient calibration data have been gathered.
The simplified table below can be used as a quick guide for the initial definition of
calibration interval. It provides recommendations on calibration intervals taking into
consideration the above-mentioned factors.
Calibration This is the classification defined during the preparation of the Measuring Loop
Class Inventory. The measuring loops can be prioritized as follows:
Class A - High Priority
Class B - Medium Priority
Class C - Low Priority
The interval has to be adopted based on the criticality of the instrument. The greater
the risk involved the more frequent the calibration of this measuring loop should be.
Degree of The utilization of the instruments is also a factor that affects their performance. All
Utilization instruments do drift over time even if they are not used, but the frequency of and the
duration of usage can speed up the drift.
We can classify the degree of utilization of instruments into two main groups:
High when the instrument is used (or powered up) 50% or more of the time within
one calibration cycle (time between 2 calibration).
Low when the instrument is used (or powered up) less than 50% of the time. This
is typically applicable to factories with single-shift operation (provided they cut-
off the power supply to instruments after the shift). This is also applicable for
factories or lines with seasonal operation (used only for a few weeks or months
in a given year).
Environmental The environment where the instruments are installed can also have an effect on how
Consideration they behave over time. Examples are temperature, vibration, dust, etc.
We can classify the environmental consideration into two main groups:
Severe when the instruments are subjected to severe vibrations or high ambient
temperature.
Normal for normal environmental conditions (within the manufacturers
recommended operating conditions).
There is no clear and strict rule as to these groupings, it will be up to the judgment of
the responsible individuals to decide which conditions are considered severe and
which ones are considered normal for the instrument under consideration.
Manufacturers The starting point for defining the calibration interval would be the recommendation
Recommendati from the manufacturer, particularly those instruments where we dont have so much
on experience working with. These are normally conservative estimates if the
instruments are used within the process and environmental conditions specified for
the instrument concerned.
In the absence of the manufacturers recommendation, this value will then be based
on the best judgment of the calibration technicians, using relevant historical
information and experience.
Legal Some countries may have existing laws that regulate calibration requirements for
Requirements certain measuring loops involved in high-risk food manufacturing applications such
as in Thermal Processing. In any case, the calibration interval mandated by these
regulations must be strictly complied with.
1 Monthly
3 Every 3 months
6 Every 6 months
9 Every 9 months
12 Every 12 months
24 Every 24 months
R Upon Request (Calibration Class C instruments with intervals beyond 24
months)
THERMOSTATIC OVEN
Operational 1. Set the switch on the AMETEK oven, located above the supply connector, to I.
Procedure
2. Check that "Read C" is lit.
3. Press the "Set / Read" button.
4. Check that "Set" is lit.
5. Press the "Temp. set" button and set the first value to be simulated.
6. Press the "Set / Read" button and check that "Read" is lit.
7. Wait until the temperature shown on the indicators is stable within + / - 0,1 C.
8. Note the temperature readings on all indicators.
9. Repeat the adjustments and readings at all calibration points.
10. Set the switch to 0.
11. Update the calibration tag.
12. Prepare the calibration report.
NCPP
LP-W17 Balance Ktron 160 to 240 Kg/h 2 kg/h B 12 Operational 130495-01
ZLT Line Ktron Dry mix
NCPP
LP-F1A15 Hot Water Flowmeter 140 to 200 Kg/h 2 kg/h B 12 Operational 0880088197
ZLT Line Emerson Water
LP- NCPP
Enzyme BAN Flowmeter 4 to 6 Kg/h 50 g/h B 12 Quality 383387 Enzyme
FM1B12 ZLT Line Emerson
LP- NCPP
Enzyme Cereflo Flowmeter 4 to 6 Kg/h 50 g/h B 12 Quality 381747 Enzyme
FM1B16 ZLT Line Emerson
LP- NCPP
Enzyme AMG Flowmeter 4 to 6 Kg/h 50 g/h B 12 Quality 363512 Enzyme
FM1B27 ZLT Line Emerson
NCPP
LP-T1B37 Temp. tubular Heater 80 to 100 C 1C A 6 Quality 12A8241
CHE Line Fortex Water
LP-P1121 Pressure in reactor NCPP 40 to 50 Bar 1 Bar A 6 Safety Emerson 5TE 21W25
Nitrogen
LP-FI1B15 Flowmeter out of reactor NCPP 130 to 180 Kg/h 2 kg/h B 12 Operational Labom GA2200 436234G Slurry
A - IDENTIFICATION
Apparatus description: TEMPERATURE MEASURING LOOP Tag:
Sensor Manufacturer Supplier Type / Model Serial No. Error Tolerance
Other:
B - DESCRIPTION OF OPERATION
Method used: Calibration with physical quantity generator: Thermostatic oven
Procedure used:
Range checked:
Values simulated:
Material used:
Weather station Hygrometer, Barometer, Thermometer
Working Manufacturer Type No. Accuracy class Calibration Date
standards: Last Next
Sensor
Indicator
C - MEASUREMENTS
Environmental conditions: Influential Readings Uncertainties
parameters
Humidity % RH +/- % RH
Atmospheric pressure hPa +/- hPa
Temperature C +/- C
SIMULATED
READINGS (C) FROM INDICATORS
VALUES, C
AS FOUND AS LEFT
Units: Reference Stand. Control Room Other: Reference Stand. Control Room Other:
X. Definitions
Accuracy (of From VIM: closeness of the agreement between the result of a measurement and a
measurement) true value of the measurand.
Note: accuracy is a qualitative concept. (A 'true' value can never be perfectly known
or indeed defined.). The term precision should not be used for "accuracy".
Accuracy (of a From VIM: ability of a measuring instrument to give responses close to a true value.
measuring
instrument)
Accuracy class From VIM: class of measuring instruments that meet certain metrological
requirements that are intended to keep errors within specified limits
Note: A number usually denotes an accuracy class or symbol adopted by convention
and called the class index.
Adjustment From VIM: operation of bringing a measuring instrument into a state of performance
suitable for its use
Note: Adjustment may be automatic, semiautomatic or manual.
As found The result of the measurement before any correction or adjustment is made on an
calibration instrument or measuring loop. This is normally the result of the first calibration.
The definition provided by the International Vocabulary of Basic and General Terms
in Metrology (VIM; 1993).
Calibration is a set of operations that establish, under specified conditions, the
relationship between values of quantities indicated by a measuring instrument or
measuring loop, or values represented by a material measure or reference material,
and the corresponding values realized by standards.
Calibration and The result of a calibration may be recorded in a document, sometimes called a
measurement calibration certificate or a calibration report. Also can refer to a document
certificates accompanying a certified reference material stating one or more property values and
their uncertainties, and confirming that the necessary procedures have been carried
out to ensure their validity and traceability.
(VIM and ISO Guide 30: Terms and definitions used in connection with reference
materials. See also ISO Guide 31: Contents of certificates of reference materials)
Calibration The calibration procedure defines the actions and materials or devices needed to
Procedure compares an "unknown" or test item(s) or instrument with reference standards
according to a specific algorithm.
Correction From VIM: the value added algebraically to the uncorrected result of a measurement
to compensate for systematic error.
Notes:
1. The correction is equal to the negative of the estimated systematic error.
2. Since the systematic error cannot be known perfectly, the compensation cannot
be complete.
Corrected Result of a measurement after a correction or adjustment has been made for a
result measurement error. This is commonly referred to as the result of the second or third
calibration after an adjustment or modification
Deviation The difference between the measured value and its reference value
Dead band From VIM: maximum interval through which a stimulus may be changed in both
directions without producing a change in response of a measuring instrument
Error (of From VIM: result of a measurement minus the true value of the measurand.
measurement) Error is numerically equal to correction but opposite in sign.
Error (of From VIM: indication of a measuring instrument minus a true value of the
measuring corresponding input quantity
instrument) Notes:
1. Since a true value cannot be determined, in practice a conventional true value is
used
2. This concept applies mainly where the instrument is compared to a reference
standard.
3. For a material measure, the indication is the value assigned to it.
Error, random From VIM: result of a measurement minus the mean that would result from an
infinite number of measurements of the same measurand carried out under
repeatability conditions
Error, From VIM: mean that would result from an infinite number of measurements of the
systematic same measurand carried out under repeatability conditions minus a true value of the
measurand
Measurement From VIM: set of operations having the object of determining a value of a quantity
Measuring or From VIM: set of values of measurands for which the error of a measuring
working range instrument is intended to lie within specified limits
Measuring loop Series of elements of a measurement system that constitutes the path of the
or measurement signal from the input to the output.
measurement
chain
Measuring From VIM: complete set of measuring instruments and other equipment assembled
system to carry out specified measurements
Nominal range Range of indications obtained through a particular setting in the configuration of a
measuring instrument. In most measuring instruments, this can be adjustable
relative to the application or use.
Note: Nominal range is normally stated in terms of its lower and upper limits, for
example, "6 bars to 10 bars".
Reference From VIM: conditions of use prescribed for testing the performance of a measuring
conditions instrument or for intercomparison of results of measurements
Reference From VIM: material or substance one or more of whose property values are
material sufficiently homogeneous and well established to be used for the calibration of an
apparatus, the assessment of a measurement method, or for assigning values to
materials.
Repeatability From VIM: ability of a measuring instrument to provide closely similar indications for
(of a measuring repeated applications of the same measurand under the same conditions of
instrument) measurement
Notes:
1. These conditions include:
reduction to a minimum of the variations due to the observer
the same measurement procedure
the same observer
the same measuring equipment, used under the same conditions
the same location
repetition over a short period of time.
2. Repeatability may be expressed quantitatively in terms of the dispersion
characteristics of the indications.
Repeatability From VIM: closeness of the agreement between the results of successive
(of results of measurements of the same measurand carried out under the same conditions of
measurements) measurement
Notes:
1. These conditions are called repeatability conditions.
2. Repeatability conditions include:
the same measurement procedure
the same observer
the same measuring instrument, used under the same conditions
the same location
repetition over a short period of time.
3. Repeatability may be expressed quantitatively in terms of the dispersion
characteristics of the results.
Reproducibility From VIM: closeness of the agreement between the results of measurements of the
(of results of same measurand carried out under changed conditions of measurement
measurements) Notes:
1. A valid statement of reproducibility requires specification of the conditions
changed.
2. The changed conditions may include:
principle of measurement
method of measurement
observer
measuring instrument
reference standard
location
conditions of use
time.
3. Reproducibility may be expressed quantitatively in terms of the dispersion
characteristics of the results.
4. Results are here usually understood to be corrected results.
Resolution (of a From VIM: smallest difference between indications of a displaying device that can be
displaying meaningfully distinguished
device) Notes:
1. For a digital displaying device, this is the change in the indication when the least
significant digit changes by one step.
2. This concept applies also to a recording device.
3. It is important not to confuse the resolution of a display alone with the resolution
of a force-measuring system which incorporates a display; the system will have
less (poorer) resolution than the display alone
Response time From VIM: time interval between the instant when a stimulus is subjected to a
specified abrupt change and the instant when the response reaches and remains
within specified limits around its final steady value.
Span The difference between the upper and lower limits of a nominal range.
Example for a nominal range of -40 mbar to +40 mbar, the span is 80 mbar.
This is sometimes commonly referred to simply as range.
Stability From VIM: ability of a measuring instrument to maintain constant its metrological
characteristics with time.
Standard, From VIM: a standard recognized by a national decision to serve in a country as the
National basis for assigning values to other standards of the quantity concerned.
Standard, From VIM: standard that is designated or widely acknowledged as having the highest
Primary metrological qualities and whose value is accepted without reference to other
standards of the same quantity
Standard, From VIM: standard whose value is assigned by comparison with a primary standard
Secondary of the same quantity
Standard, From VIM: standard, generally having the highest metrological quality available at a
Reference given location or in a given organization, from which measurements made there are
derived
Standard, From VIM: standard that is used routinely to calibrate or check material measures,
Working measuring instruments or reference materials
Notes:
1. A working standard is usually calibrated against a reference standard.
2. A working standard used routinely to ensure that measurements are being
carried out correctly is called a check standard.
Transparency From VIM: ability of a measuring instrument not to alter the measurand
Examples:
mass balance is transparent;
a resistance thermometer that heats the medium whose temperature it is
intended to measure is not transparent.
Uncertainty of Parameter, associated with the result of a measurement that characterizes the
measurement dispersion of values that could reasonably be attributed to the measurand.