Instruments Maintenance Management System PDF

Maintenance Policy
Production Policy & Control
Zoeterwoude,
Issue 01 / April 2000
Final
Principal : Steering Committee BDM and Maintenance Policy – Mr. A.W. Govaert
Author : Mr. H. van Vianen, Mr. M. Vrugteveen, Mr. A. Nijhof
Project Manager :
Keywords :
Issue : 01 / Apr. 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Status : Final INSTRUMENTS Page : 1 of 43
PP&C POLICIES & STANDARDS QUALITY MANAGEMENT
CONDITIONS OF USE
CONFIDENTIAL INFORMATION
1. The standardised information contained in this manual is the sole property of Heineken Internationaal
Beheer B.V. It reflects the Heineken knowledge and experience, which contents should not be revealed
to 3rd parties.
2. Eligibility for use of the manual is determined by function and geographical location of the user and
issue is authorised by the Production Policy and Control Director.
3. Designated users of this manual are personally responsible for ensuring the security and confidentiality
of its contents. This manual is for personal use only; no part of this manual may be copied or
distributed without the prior written consent of Heineken.
4. In some cases, more than one copy of the manual may be issued to a single user for onward
distribution to other functionaries. In these circumstances the main user remains responsible for the
proper use of all copies.
5. When a designated user's function or location is changed, he/she is responsible for ensuring that the
manual is either officially handed over to the successor or returned to the document manager at the
address shown below.
Heineken Technical Services

PO Box 510
2380 BB Zoeterwoude
The Netherlands
Attn.: W.P. Vergunst, room 4.159
6. Users should ensure that only the latest issue is in use by replacing amended sections with the new
versions provided by the document manager.
THE MANAGEMENT
HEINEKEN INTERNATIONAAL BEHEER B.V.
Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Status : Final for INSTRUMENTS Page : 2 of 43
MODIFICATION REQUEST FORM

INTRODUCTION.
This form is a means of communication to indicate your suggestions for improvement of PP&C
Engineering Policy Instructions & Procedures, such as “Production Automation & Information Technology
Instructions”, “BDM Manuals”, etc.
SUGGESTIONS FOR IMPROVEMENT

Document type :
HMESC Code :
Issue date :
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Suggestion(s) :
Please return this form to the Document Manager, who will forward it to the secretary of the BDM Steering Committee.
Address:
Heineken Technical Services B.V.
W.P. Vergunst
Room: 4.159
PO Box 510
2380 BB Zoeterwoude
The Netherlands
Tel. : (31)715456406
Fax.: (31)715457188
E-mail: W.P._Vergunst@Heineken.nl
“MAINTENANCE MANAGEMENT SYSTEM FOR

INSTRUMENTS”
CONTENTS
Page:
1. INTRODUCTION 6
1.1 Procedures for improvement of this manual 6
2. QUALITY MANAGEMENT AND INSTRUMENT MAINTENANCE 7
3. PRACTICAL IMPLEMENTATION OF INSTRUMENT MAINTENANCE 8

3.1 Inventory of instruments to be included in the maintenance system. 8
3.2 Selection of instruments critical for product quality and/or critical for process control 8
3.3 Required accuracy of instruments critical for product quality 9
3.4 Required accuracy of instruments critical for process control 10
3.5 Practical calibration set-up 11
3.6 Reference instruments 11
3.7 When to adjust an instrument 11
3.8 Planned maintenance system for instrumentation. 12
3.9 Optimisation of calibration frequency 13
4. GENERAL REMARKS 14
APPENDIX 1 - CALIBRATION PROCEDURES AND SPECIFIC EXAMPLES 15

1 General calibration Procedure 15
2 Specific calibration procedure 16
2.1 Calibration of pressure measurement 16
2.2 Calibration temperature measurement 18
2.3 Calibration of flow meters for liquid 21
2.4 Calibration of flow meters for gas 21
2.5 Calibration of mass measurement (weighing scales, tanks, bins and weighing bridges) 23
2.6 Calibration procedure for laboratory instruments for conductivity and pH 23
2.7 Calibration procedure for process conductivity meters 23
2.8 Calibration procedure for process pH meters 25
2.9 Calibration procedure for CO2 concentration meters 26
2.10 Calibration procedure for oxygen (O2) meters 27
2.11 Calibration procedure for turbidity meters 28
2.12 Calibration procedure for original wort monitors 30
2.13 Calibration procedure of NH3, CO2, CH4 and H2S atmospheric detection systems 31
2.14 Electrical quantities 32
2.15 Concentrations and other chemical properties 32

APPENDIX 2 - WORK INSTRUCTION FOR CALIBRATION OF WORKSHOP INSTRUMENTS (EXAMPLE) 33
APPENDIX 3 - LIST OF CRITICAL INSTRUMENTS (EXAMPLE) 37
APPENDIX 4 - TEST CERTIFICATES OF REFERENCE INSTRUMENTS (EXAMPLES) 39
APPENDIX 5 - ISO 9001:1994 (E) 41

1. INTRODUCTION
Instruments play a more and more important role in quality management in breweries. Instruments are used
to assure the quality of the product but also play a key role in the (automated) control of the production
process. Because of this, the requirements on instrument maintenance become more and more strict. Also
the introduction of the ISO9000 quality assurance system and HACCP (Hazard Analysis Critical Control
Points) require a structural approach of instrument maintenance.
In this manual a guideline for efficient implementation of maintenance management is described for
instruments critical for product quality as well as instruments critical for process control. Consequently
this manual can also be used to comply with the requirements of ISO9000.
As appendix example procedures are given for calibration of instruments. These procedures can serve as
starting point for breweries to set up their own procedures.
Instruments as described in this document can be single instruments or can be part of a measuring loop
connected to a controller or control system (e.g. PID).
The specified accuracy’s must be considered as “loop accuracy”, i.e. this means that the accuracy of input
cards has to be taken in account.
The Maintenance Management System for Instruments is part of the Maintenance Policy for breweries,
and is subject to the following rule is issued by PP&C:
Rule: Every brewery needs to implement a Maintenance Management System for Instruments in
general and critical instruments in particular to assure a constant quality of product and a proper
production process. A proper production process is measured in terms of reliability,
reproducibility, efficiency, losses and integrity & quality of the product.
1.1 PROCEDURES FOR IMPROVEMENT OF THIS MANUAL
It is of great importance to continuously improve the manual Maintenance Management System for
Instruments. If breweries or their consultants (HTS, Chief Engineer, Technological Controller…) come to
the conclusion that a change or addition to the manual is recommendable, they should summarise and
argue their proposal on the “Modification Request Form” and submit it to the Document Manager (Wim
Vergunst at HTS PS). The Steering Committee BDM / Engineering will evaluate the proposal according
to ISO 9000 procedures of PP&C (03.11.04.402). If the proposed change or addition to the BDM is
accepted by the Steering Committee, the Document Manager will adapt the manual and issue it for
approval to the Director of PP&C. Consequently this procedure will ensure that a critical view of the
applicability of the manual will be maintained.

2. QUALITY MANAGEMENT AND INSTRUMENT MAINTENANCE

In general breweries require a quality management system to assure the quality of the produced beer. An
example of a quality assurance system that is now adopted by many breweries within Heineken is
ISO9002. The brewery has to describe in work procedures and work instructions how actions critical for
the production of beer are carried out. One of these actions is instrument maintenance. In this report the
requirements of ISO 9002 are used as a guideline for a Maintenance Management System for
Instrumentation.
Although ISO9002 only requires procedures for instruments critical for product quality, the described
Maintenance Management System also includes instruments critical for process control.
The system focuses on assurance of product quality, efficient process control and a reduction of cost of
ownership.
Requirements of ISO9002 on instrument maintenance
In the ISO 9002 document the requirements are described for a quality assurance system for installation,
production, and servicing. The objective is that a manufacturer (the brewery) is able to ensure a constant
(specified) quality of his product by means of this system. The ISO document is divided into four chapters.
The first three chapters describe the scope of the document, the normative reference and the definitions.
The fourth chapter describes the quality system requirements and is subdivided into 20 sub paragraphs.
Each paragraph describes the specific requirements of, for instance; management responsibility, contract
review, purchasing, process control, control of non-conforming products etc. Of special interest for
maintenance of instrumentation are the paragraphs 4.9 (process control) and 4.11 (control of inspection,
measuring and test equipment).
The contents of paragraph 4.9 (process control) can be characterised as follows: The brewery shall monitor
and control suitable process parameters and product characteristics to ensure the product quality.
Paragraph 4.11 (control of inspection, measuring and test equipment) can be summarised as follows: The
brewery shall establish and maintain documented procedures to control, maintain and calibrate inspection,
measuring and test equipment to demonstrate the conformance of the product to the specified
requirements.
In the paragraphs the requirements are described in more detail and it is strongly advised that the
paragraphs 4.9 up to 4.11 be thoroughly studied. See Appendix 5
The ISO 9000 series document is a publication of International Organisation for Standardisation, title
“Quality systems - Model for quality assurance in production, installation and servicing” Reference
number ISO 9002:1994(E), Second edition 1994-07-01.

3. PRACTICAL IMPLEMENTATION OF INSTRUMENT MAINTENANCE
To ensure a successful implementation of an instrument maintenance system following steps are important
• Make an inventory of all instruments to be included in the maintenance system

• Determine which instruments are critical for product quality or process control
• Determine the required accuracy for the instruments
• Describe the calibration and maintenance procedures & frequencies
• Determine the required test equipment
• Maintain calibration records
• Validate the calibration records
• Optimise maintenance frequency
• Set up of communication procedures when critical instruments are out of range.
• Incorporate the Maintenance Management System for instrumentation in the CMMS
The steps outlined above will be discussed in more detail in the following paragraphs.
3.1 INVENTORY OF INSTRUMENTS TO BE INCLUDED IN THE MAINTENANCE SYSTEM.

Instruments play a more and more critical role in breweries to be able to produce beer. The following
instruments are used in breweries;
• Laboratory instruments, which in general are used to check throughout production process the quality
of the product.
• Process instruments for process control and monitoring.
• Workshop instruments, which are used for calibration of process instruments.
This report typically describes maintenance procedures for process and workshop instruments. Procedures
for maintenance of laboratory instruments are not included.
A practical approach to make an inventory is to make a list of all instruments to be included in the
maintenance system. From this list, the instruments are selected that are critical for the product quality or
for process control. The required accuracy for the critical instruments has to be indicated. Guidelines for
determination of the required accuracy will be given in the following chapters. Based on the classification
and required accuracy of an instrument the type of maintenance is chosen. Basically, maintenance of
critical instruments is carried out periodically. It is advised to make an overview or inventory as a table. In
this table are columns reserved for Tagnumber, description of the measurement, critical for product or
process, required accuracy, maintenance interval, maintenance procedure etc.
3.2 SELECTION OF INSTRUMENTS CRITICAL FOR PRODUCT QUALITY AND/OR CRITICAL FOR PROCESS
CONTROL
See APPENDIX 3 List of critical instruments as used in Zoeterwoude (example)
In breweries we classify the instruments in three categories;
1. Instruments critical for product quality

Instruments are considered critical for product quality when they are used to control and ensure a constant
product quality. This means that the quality of the product is completely depending on this instrument. The
final approval of the product quality is done with only this instrument. A guideline for selection can be the
basic recipe of the product in which product quality is described. Important criteria when selecting is
whether or not a laboratory instrument is used to check the final product quality. In that case the laboratory
instrument is critical for product quality and not the process instrument.

2. Instruments critical for process control.

All instruments essential for the control of the production processes in the brewery are within this
category. If these instruments fail a proper control of the processes is not possible.
3. Indicative instruments
These are the remaining instruments like for instance local indicators which don’t play a major role in
process control.
To clarify the way instruments can be categorised, the following examples are given.
Example 1
The dissolved CO2 content is a critical quality parameter of beer (one of the product specifications). By
means of the in-line CO2 meter the CO2 dosing is controlled and is thus a very important instrument.
However, the final result of the CO2 dosing is checked by means of a portable CO2 meter and also the
approval of the beer is based on the portable meter. Because of this, the portable meter is the critical in-
strument for product quality and the in-line meter is critical for process control.
Example 2
The fermentation temperature is one of the process parameters decisive for the quality and taste of beer.
There is no laboratory test to check if the fermentation is carried out at the proper temperature. Because of
this, the temperature measurement on the fermenter is considered as critical for product quality.
Example 3
A potential hazard for product integrity is that (return) bottles are filled which contain foreign parts. As
preventive measure an empty bottle inspector (EBI) is installed to check the condition of the bottles. In this
case the EBI can be considered as critical for product quality.
Critical instruments for product quality could be: weight cells on malt bins, temperature measurements in
various brew vessels, wort cooler, fermenters, pasteuriser temperatures etc. and f.e. additive dosing-and
product flow meters.
3.3 REQUIRED ACCURACY OF INSTRUMENTS CRITICAL FOR PRODUCT QUALITY

Apart from the selection of a category for the instruments, also the required accuracy has to be determined
to assure the required product quality.
The object of an installed instrument in general is to assure that a quantity (like for instance temperature,
flow, pH etc.) is controlled within certain limits. These limits are described as the control accuracy. To be
able to control a temperature in any circumstance within a range of +/- 0.4°C an instrument accuracy is
required of for instance at least +/- 0.2°C. When a control loop is in operation on a certain set-point, there
will always be small deviations from the set-point caused by the response of the process.
The required accuracy for the instruments critical for product quality primarily depends on the required
quality of the product.
The required accuracy of instruments critical for process control primary depends on the process.
Example 1
The product for instance, requires that the fermentation temperature is controlled within a range of +/-
0.4°C. Or in other words the quality of the beer becomes uncertain when the temperature is controlled at
an uncertainty higher than +/- 0.4°C. To be able to assure this, an instrument accuracy is required of for
instance at least +/- 0.2°C. In general the instrument has to be at least twice as accurate as the required
control accuracy.

3.4 REQUIRED ACCURACY OF INSTRUMENTS CRITICAL FOR PROCESS CONTROL

When determining the required accuracy of these instruments the requirements of the control of the
process has to be considered. In general instruments are used to control quantities within a certain range.
To determine this range, the process has to be analysed and a choice has to be made how big this range can
be before the control of the process become uncertain.
To explain this some examples will be given.
Example 1
For control of the steam pressure by the boilers a pressure transmitter is installed. The steam pressure
should be controlled for instance within a range of 10 bar +/- 0.2 bar.
(10 bar ± 2%). In this case the required accuracy of the pressure transmitter is +/- 1 %
Example 2
For temperature control of hot caustic a temperature transmitter is installed. This temperature should be
controlled within a range of the 85 +/- 2 degrees. The required instrument accuracy can be for instance +/-
1 degree.
Example 3
For control of the standardisation of beer an original gravity monitor is installed. To ensure that the
original gravity of the beer is controlled within a range of +/- 0.2 degree. the instrument accuracy should
be at least +/- 0.1 degree. and preferably better. Depending on the installed instrument and the used
reference to calibrate the instrument this +/- 0.1 degree. is a practical good value.
Example 4
For control of the level in a CIP tank or a water tank a level transmitter is installed. It is sufficient when
this level is controlled within a range of +/- 5%. The required accuracy of the installed instrument can be
for instance +/- 2%
General remarks on required instrument accuracy
To determine the required accuracy, every application of an instrument has to be reviewed. Important to
note are the consequences of a too high-required accuracy. The costs of installed instruments, maintenance
costs and costs for reference instruments will increase exponential with an increase in required accuracy.
In general when determining the required instrument accuracy, two situations can occur.
1) The installed instrument is able to meet the required accuracy. If, for instance the required control
accuracy is +/- 0.6% and the specified accuracy of the instrument is +/- 0.25%, the installed
instrument is able to meet the required accuracy.
2) In case the installed instrument is not accurate enough alternatives must be looked for, such as
installation of more accurate instruments. If this is not possible because the most accurate
instruments do not meet the required accuracy, then the instrument accuracy is leading and the
accepted accuracy is fixed at twice the instrument accuracy.
When the instrument accuracy is considered, the whole instrument loop has to be analysed, including the
accuracy of the process control system and the accuracy of the reference or calibration instrument used. As
an example the list of instruments critical for product quality with control accuracy for the Zoeterwoude
brewery is shown in appendix 3.
It is advised to review the list with critical instruments and required accuracy’s every year.
Guideline
An instrument should be at least twice as accurate as the required control accuracy.
A reference instrument should be at least twice as accurate as the instrument to be calibrated.

3.5 PRACTICAL CALIBRATION SET-UP

Basically, calibration is the comparison of the reading of an instrument with the reading of a reference. For
instance, an object with a mass of 1 kg (a mass piece) is used as reference for calibration of a weighing
scale. The reading of the scale, for instance 1.0030 kg, is compared with the reference mass piece that has
a mass according the calibration certificate of, for instance, 1.0008 kg. From this comparison the
inaccuracy of the instrument is determined.
(1.0030 - 1.0008 = +0.0022 kg) When a calibration is carried out the complete instrument loop has to be
considered. This means that not only the instrument itself but also indicating instrument like for instance
the process computer is calibrated. Because of this it is generally advised that the calibration be carried out
on the complete instrument loop in position. This means that, for instance, the temperature is measured at
the tip of the temperature probe with a reference temperature indicator, and compared with the reading on,
for instance, the process computer. If it is not possible to calibrate the complete loop the components have
to be calibrated separately. The disadvantage of separate calibration of the components is that extra
inaccuracies will be introduced. Also separate calibration is time consuming.
Practical calibration procedures and work instructions for calibration of instruments are described in
appendices 1 and 2.
3.6 REFERENCE INSTRUMENTS
The maintenance of instruments is based on regular calibration. Calibration determines the inaccuracy by
comparing the reading of the instrument with the reading of a reference instrument. A reference instrument
is an instrument with a known measuring in-accuracy. This means that the reference is traceably calibrated
against an international standard. This trace-ability is guaranteed by means of a test certificate that is
recognised by a national or international calibration institute. An example of a test certificate is enclosed
as appendix 4. Shown on this certificate is all relevant information of interest for a traceable calibration.
The accuracy of the reference instrument has to be at least twice that of the process instrument that has to
be calibrated. Based on the measuring principle and stability of the reference a calibration frequency has to
be fixed. Most references should be calibrated each year.
3.7 WHEN TO ADJUST AN INSTRUMENT

When a calibration is carried out the result is that almost always an inaccuracy is found. Depending on the
inaccuracy found, a decision has to be made on the actions to be taken.
Possible actions are

• Acceptance of the inaccuracy found (according set limits)
• Adjustment of the instrument
• Maintenance, repair or replacement of the instrument
It is advised to decide what action to take on the basis of a strict set of requirements. An example of a
requirement is to adjust an instrument only when the inaccuracy found is more then 50% of the required
accuracy.
If the inaccuracy is less then 50% of the required accuracy, the accuracy is accepted. If it is not possible to
reduce the inaccuracy within 50 % after adjustment, the instrument has to be maintained, cleaned, repaired
or replaced. If for example the required instrument accuracy is +/- 1% and the inaccuracy found after
calibration is +/- 0.6% then the instrument should be adjusted. When the inaccuracy is +/- 0.4% the
instrument is not adjusted.
In case an inaccuracy is found for critical instruments outside the required accuracy the supervisor
responsible for the product quality has to be informed immediately (copy to the Technological Controller
and Chief Engineer). Depending on the situation the supervisor has to double check the product quality
and decide on corrective actions.

3.8 PLANNED MAINTENANCE SYSTEM FOR INSTRUMENTATION.

A good planned maintenance system should include the following aspects;
A database containing an inventory of all equipment to be maintained.
Work instructions describing calibration and maintenance procedures.
Scheduling tools for planned maintenance.
Tools to store historical data of calibrations for later evaluation (calibration records).
The most simple planned maintenance systems can be based on a card deck system. For small breweries
this can be an efficient system. More sophisticated are CMMS systems (Computerised Maintenance
Management Systems) based on software programs. Advantages of CMMS systems are easy retrieval and
selection of information.
Information to be included in the inventory;

• instrument identification based on tagnumbers
• qualification of the instrument; critical for product quality or process control.
• required control accuracy
• required instrument accuracy
• calibration frequency
• references to calibration procedures to use
• references to documentation of equipment
CMMS systems also open possibilities to include the information of instrument lists in the inventory.
Instrument lists contain all relevant specifications of instruments, which can be used to order new
instruments, for spare parts management and for calibration.
Scheduling tools should generate work-orders for planned maintenance. Every week for instance an
overview should be given which instruments should be calibrated. The possibility should exist to
reschedule calibration activities because of general overhauls of parts of the installation.
Proper calibration records are essential for efficient planned maintenance.

The purpose of these records is to store all relevant calibration data in a convenient and effective way. The
records are used as proof that the instruments meet the guaranteed accuracy. The records are also used to
optimise the maintenance frequency. Important information that has to be included on a calibration record
is:
• Identification of the instrument (tag number and serial number)

• Description to the calibration procedure used
• The reference instruments used
• Who carried out the calibration
• Calibration results before and after adjustment
• Remarks such as replacement, repair, adjustment or cleaning
• Validation and authorisation. A responsible employee has to analyse the results and has to authorise
the record
• Indication when the instrument is due for the next calibration
The calibration records can be stored as cards in a card deck system. Alternatively the calibration records
can be stored in a CMMS system which opens the possibilities to make trend graphs of found accuracies. It
has to be stressed again that recording of accuracies of instruments found before adjusting is of utmost
importance. By means of this it is possible to optimise the maintenance frequencies.
In addition to the system with the calibration records instruments should be marked by means of
calibration stickers. Each time after a successful calibration a sticker is put on the instrument indicating the
following information;
• Instrument tag number and serial number

• Date of calibration
• Date for next calibration
• Who carried out the calibration
• Measuring range and output signal
The use of calibration stickers is strongly advised and dictated by the ISO9000 system, because it is a very
convenient tool to give in the field insight into the calibration status of an instrument and information
during breakdown maintenance.
3.9 OPTIMISATION OF CALIBRATION FREQUENCY
One of the objects of ISO 9002 quality assurance system is to constantly improve all kinds of quality and
efficiency aspects. An example is the optimisation of the calibration frequency. When an instrument
maintenance system is started the calibration frequency is set to an interval based on experience with a
certain instrument. After carrying out a number of calibrations information is obtained on the behaviour of
the inaccuracy of the instrument through time. Suppose when found, that an instrument that is tested every
week shows a more or less stable inaccuracy of +0.15% up to +0.25%. If this inaccuracy is reached
without any adjustment or other maintenance and the required accuracy is +/- 1.0% then the calibration
frequency can be changed into for instance every month.
On the other hand, when found that the accuracy of the instrument is regularly outside the required
accuracy, then the calibration frequency has to be increased.
The starting point for optimisation of the calibration frequency is that the calibration history of the
instrument is stored in a convenient way, enabling easy analysing. Preferably that the results of several
calibrations are displayed, for instance, in a table or in a graph.

4. GENERAL REMARKS
Implementation of a quality assurance system is time-consuming, takes a lot of effort and is, therefore, a
high investment. The benefits of implementation are multiple. First, there is the quality assurance of the
produced beer. Secondly strict agreements on the required accuracy of the instruments are of importance.
Instrument maintenance in the conventional way was carried out in such a way that the instruments always
met the instrument specifications. In most cases this meant that too much effort was put into calibration.
Because there is a strict agreement on the required accuracy it is possible to optimise the choice of
instruments when new process instruments are purchased. If, for example, it appears that for a certain
application the use of a magnetic flow meter meets the requirements instead of a much more expensive
mass flowmeter, then a saving in investment is possible. Also the choice of reference instruments for
calibration of process instruments can be optimised on the required accuracy. Successful implementation is
an action which means that for the Technical Department the following matters have to be organised;
The technical documentation, drawings, manuals etc. have to be organised. This means it has to be clear
who is responsible for certain documents, identification of documents, how revisions of documents are
carried out etc.
Procedures and working-instructions have to be made for the organisation of planned and break down
maintenance. Included in these instructions should be the corrective actions to take when a critical
instrument is found to be outside the required accuracy.
Job descriptions for all employees of the technical department have to be made.
Technicians who carry out maintenance should be well trained and experienced. Being a well-qualified
technician starts with an education with a technical background followed by practical experience in
instrument calibration and maintenance.
The workshop equipment has to be properly organised. Within HTS lists are available of recommended
test instruments, furniture and tools.

APPENDIX 1
APPENDIX 1 - CALIBRATION PROCEDURES AND SPECIFIC EXAMPLES
1 GENERAL CALIBRATION PROCEDURE
Periodic calibration of instruments is part of a planned maintenance system.

Planned maintenance is carried out by a qualified E&I technician. The results of the calibration are
recorded on the PM (Planned Maintenance) card.
Comparing the reading of a measuring instrument with the reading of a reference meter or a measurement
standard usually comprises the calibration. The deviation found in the calibration is compared with the
required instrument accuracy as recorded in the list of process instruments. If this accuracy is out of
specification then the responsible department supervisor - brewing, - packaging or - utilities shall receive a
written warning as quickly as possible. If the deviation is more than 50% of the required accuracy then the
instrument shall be adjusted and where relevant be serviced and cleaned. After correction the instrument
shall be calibrated once again. It is assumed that after correction the greatest deviation will be brought to
within 50% of the required instrument accuracy. If this is not possible then the instrument has to be
replaced.
The PM card contains records including the following: instrument tag number and serial number location,
PM frequency, work instruction number, workshop number, working range, required accuracy and history
of previous calibrations.
After a calibration has been performed then the following will be entered in PM system. Date, the
deviation before and after correction, the instruments used for the calibration, and comments, if any.
Breakdowns shall be entered under comments. After calibration the instrument is labelled with a
calibration instrument sticker, which includes the tag number, calibration date, the name of the employee
who made the calibration, the working range and the output signal. Calibration may only be carried out
using instruments of which the accuracy has been properly indicated.
The actions necessary to correct an instrument are explained in the user's manual for the instrument
concerned. The user's manuals for all instruments in use in the brewery should be properly filed.
The following paragraphs describe the basic calibration procedures and reference instruments to be used in
breweries. The required accuracy of reference instruments fully depends on the accuracy of the
instruments to be tested.

APPENDIX 1
2 SPECIFIC CALIBRATION PROCEDURE
2.1 CALIBRATION OF PRESSURE MEASUREMENT
As primary reference instrument for pressure in general a pneumatic dead-weight tester (0.1 -10 bar) is
used, with an accuracy of 0.05 or 0.025 %. This instrument is used for high-accuracy calibrations and a
means to calibrate workshop reference instruments. Calibration of the dead-weight tester has to be carried
out by a third party to assure that certification is according a national standard. Because dead-weight
testers are expensive instruments it can be considered to use a certified dead-weight tester of a third party.
For moderate-accuracy calibrations and calibrations in the field in general digital pressure indicators are
used with a lower accuracy then the dead-weight tester. The accuracy of the digital pressure indicators has
to be at least 0.1% of reading. All pressure meters in the workshop used for calibration of process meters
shall be periodically calibrated with the dead-weight tester.
The calibration of process pressure transmitters is carried out by disconnection of the pressure transmitter
from the process. A test pressure is applied to the pressure transmitter, which is measured with the
reference instrument. A test of the complete instrument loop is preferred. This means that the reading of
the process indicator has to be compared with the reading of the reference. In practice it is advised to use a
portable pressure calibrator and calibrate in the field. Because some pressure transmitters are sensitive for
the mounting position (horizontal, vertical or under an angle) it is advised to calibrate under the same
position as mounted. The pressure is varied stepwise and at each step the deviation of the output signal is
recorded. When the pressure transmitter needs adjustment it is necessary to measure the output signal of
the pressure transmitter by means of a calibrated multimeter.
If the calibration shows that the pressure measurement does not comply with the specified accuracy as
recorded on the PM card then the pressure transmitter must be corrected. The necessary actions for
maintenance and correction are described in the user's manual for the instrument concerned.

APPENDIX 1
Flowchart calibration of a pressure transmitter
Start
Disconnect transmitter and

connect to a reference
pressure indicator / generator
Record reading of transmitter

at atmospheric pressure
Increase pressure with

20 % of measuring range
Record reading of transmitter

and reference indicator
Maximum pressure
Determine absolute error

reading for each input signal
Calculate relative error

and inaccuracy
Inaccuracy <
Calibrate / adjust instrument
required accuracy
Instrument correct
Re-install transmitter
End

APPENDIX 1
2.2 CALIBRATION TEMPERATURE MEASUREMENT
As reference for temperature calibrations a digital temperature indicator with separate probe is used. The
required accuracy is at least +/- 0.10°C. Resolution of the indicator at least 0.02 °C.
To calibrate temperature instruments the reading of the instrument is compared with the digital indicator.
For calibration both instruments are submerged in, for instance, a water bath which is kept at a constant
temperature and which is well stirred.
So far, the use of dry-block temperature calibrators has not been successful and is not advised because of
unacceptable inaccuracies.
PT100 elements are checked by measuring the temperature and the resistance of the element. The accuracy
is checked by means of a PT100 table showing the relation between temperature and resistance. A
recognised PT100 table is DIN43760.
Adjustment of PT100 transmitters is in general carried out by connecting a PT100 simulator at the input
and a multimeter at the output of the transmitter. A PT100 simulator is capable of generating a resistance
signal similar with a PT100 at a certain temperature.
After the transmitter is adjusted the complete instrument loop should be calibrated including the PT100 by
means of the digital temperature indicator.
There are two alternatives when calibrating PT100 temperature measuring systems:
A) Direct calibration by immersion of the PT100 sensor in a thermostatic bath together with a reference
thermometer.
B) The alternative method is to use a twin PT100 sensor whereby one sensor is used as the calibration
reference and the other is used for the normal process measurement.
Method A is preferred.
Method B is permitted when the execution of A is not possible in practice.

APPENDIX 1
2.2.1 Calibration of temperature measurements, Method A
The PT100 sensor is removed from the process and immersed into a thermostatic bath with reference
temperature indicator. The temperature shall preferably be read from the process meter, in order to test the
entire loop. This means that either the water bath is taken into the field or the process indicator is
disconnected and taken into the workshop. Preferred is the first option because then also the influence of
cabling is included.
Flowchart of the calibration of a temperature measurement method A
Start
Disconnect PT100 and immerse

in thermostatic bath
acc. test setup
Adjust temp. of bath at lowest

calibration temperature
Increase temp. for next

Record temperature and output
calibration step
Maximum No
practical
temperature
Yes
Determine absolute errors of

PT100 for each calibration step
Calculate relative errors

and inaccuracy
No
Inaccuracy <
required accuracy
Yes
Instrument correct
Reinstall PT100 in process
End

APPENDIX 1
2.2.2 Calibration of temperature measurements method B
It is assumed that the PT100 has a double sensor. One sensor is used for the process measurement, and the
other serves as the reference for the calibration. The procedure to calibrate the temperature measurement is
as follows:
Both sensors of the PT100 are subjected to calibration in a thermostatic bath prior to installation. In this
calibration the values of the resistance’s are recorded for both sensors for at least one temperature. The
accuracy of the PT100 has to be within the manufacturers specification. After installation one sensor is
connected to the process temperature indicator and transmitter which, if necessary, has been adjusted using
a PT100 simulator. For calibration of the complete loop a portable reference temperature indicator is
connected to the second sensor. The calibration is performed by comparing the reading of the portable
indicator with the process indicator for at least one temperature. If the deviation is greater than allowable
then the individual components shall be calibrated and if necessary corrected. The necessary actions for
maintenance and correction are described in the user's manual for the instrument concerned.
Flowchart for calibration of temperature measurement (method B)
Start
Connect temp. indicator to

second Pt100 sensor
Record reading of
indicator and Pt100 during
normal process conditions.
Determine inaccuracy of Pt100

at this temperature
Inaccuracy < No
required accuracy
Yes
Instrument correct
Disconnect temp. indicator
End

APPENDIX 1
2.3 CALIBRATION OF FLOW METERS FOR LIQUID
For flow meter calibrations a master flow meter with an accuracy of 0.05% up to 0.2% of reading is
required. As master magnetic flowmeters or mechanic PD meters are used. The choice of the type of meter
depends on the required accuracy. Mechanical PD meters are the most accurate meters (0.05% up to
0.10%) but are also the most expensive and sensitive for mechanical wear. Magnetic flow meters have an
accuracy of 0.10% up to 0.20%. A calibration is in general carried out by connecting the master flow meter
in series with the meter to be calibrated. It is advised to make provisions in the pipework for connection of
the reference flow meter in series with the flow meters that has to be calibrated. Also, the use of extra
(pulse) inputs on the process computer for connection of the master flow meter is advised. During
calibration the process is run at a number of flow rates. At each flow a batch of product or water is
measured by the process meter and the master meter. It is advised to make test runs of sufficient length to
improve the accuracy of the test.
Instead of using a master flow meter a flow meter can also be calibrated using a weighing balance or a
volumetric measuring tank, of which the accuracy has been demonstrated in a suitable manner.
If the calibration shows that the flowmeter does not comply with the specified accuracy the instrument
should be checked. Critical with flowmeters are the way flowmeters are installed, enough straight pipe
before and after, properly aligned, seal properly mounted, electrodes not fouled and so on. Apart from that
there can also be electrical causes of inaccuracies like moist in the sensor, non-proper zero adjustment,
earthing problems and so on. Vortex flowmeters used for steam are calibrated by the manufacturer by
means of water. In case these flowmeters have to be re-calibrated it is advised to send them to the
manufacturer. For instructions on trouble shooting of flowmeters and adjustment see the instrument
manual.
2.4 CALIBRATION OF FLOW METERS FOR GAS
As master meter for small gas flow meters (such as used for wort aeration) a mass flow meter is advised.
The flow meter can be a thermal mass flow meter or a corriolis mass flow meter. The master flow meter is
calibrated for a specific gas by an institute capable of carrying out traceable calibrations. The selection of
the master flow meter depends on process conditions such as medium, mass flow rate, pressure and the
required accuracy. An alternative to the in-house calibration of mass flow meter for gas is to dismount the
flow meter and to send it to an institute capable of carrying out calibrations. Gas flow meters with a high
capacity such as for CO2 recuperation can be calibrated by third parties. A possibility for calibration of
high capacity flowmeters is when they are installed in the outlet pipe of the headspace of a tank (for
instance a fermenter). When the fermenter is filled with water by means of a reference water flowmeter
then a volume of the headspace is pushed out of the fermenter equal to the volume of water that is pumped
into the fermenter. This volume is used to calibrate the gas flowmeter.

APPENDIX 1
Flowchart for calibration of flowmeters for liquid and gas
Start
Connect reference flow meter

in serie with the process meter
Run process at lowest

practical flow
Record readings of reference Increase flow for next

and process flow meter calibration step
No
Max. flow ?
Yes

flowmeter for each calibr. step

and inaccuracy
Inaccuracy < No
required accuracy
Yes
Instrument correct
Disconnect reference flowmeter
End

APPENDIX 1
2.5 CALIBRATION OF MASS MEASUREMENT (WEIGHING SCALES, TANKS, BINS AND WEIGHING BRIDGES)
Small size weighing scales (< 100 kg) are calibrated by means of mass pieces. Mass pieces are metal test
weights with a test certificate. Required inaccuracy better than 0.05%. The test weights are put on the
weighing scale and the reading of the scale is compared with the weight of the mass pieces.
Weighing tanks like for instance yeast storage tanks are calibrated with a master flowmeter.
The tank is filled with water via the master flow meter. When the density of water is known then the mass
in the tank or the bin can be calculated from the volume and the water density. For direct mass calibration
with a flow meter the use of a mass flow meter can also be considered.
Calibration of weighing bins for malt is in general carried out by putting weights on top of the bin.
An alternative is to transport a known mass of malt from a malt truck into the bin. The netto mass from the
truck can be determined by means of a weighing bridge.
If the bin is watertight it is also possible to load the bin with water by means of a master flowmeter.
Calibration of weighing bridges for trucks is generally carried out by recognised institutes who have mass
pieces of sufficient size.
2.6 CALIBRATION PROCEDURE FOR LABORATORY INSTRUMENTS FOR CONDUCTIVITY AND PH
For calibration of laboratory or reference instruments for conductivity and pH, buffer solutions are used as
reference. These buffers can be made by the brewery laboratory, on the basis of a recognised procedure, or
can be purchased from a third party, which guarantees the accuracy of the buffers. In general, the pH and
the conductivity of the buffer are indicated on a test-certificate as a function of temperature.
When calibrating a pH or conductivity instrument by means of buffers, simultaneous measurement of the
temperature is of utmost importance. This is because both pH and conductivity are dependent on
temperature. The temperature is measured by means of a reference temperature indicator. Most of the time,
the pH and conductivity measuring instruments are equipped with temperature compensation (TC). In this
case, also the temperature measurement of the instrument has to be calibrated. The TC, which has to be
adjusted on the instrument is depending on the medium that is measured. This means that the TC for beer
and for instance caustic separately has to be adjusted. The accuracy of the TC is checked by measuring the
pH or conductivity of a medium at different temperatures. If the TC is properly adjusted, the pH or
conductivity readout remains stable within the tested temperature range.
2.7 CALIBRATION PROCEDURE FOR PROCESS CONDUCTIVITY METERS
The pre-adjustment of process conductivity transmitters is carried out by simulating a certain conductivity
by means of a resistance decade box. In the instrument manual is described which resistance has to be used
for a certain conductivity. When adjusting the transmitter the temperature compensation has to be switched
off.
To calibrate a process conductivity meter a sample of the product is taken and the conductivity is
determined with a portable reference meter. The deviation is determined by comparing the reading of the
reference meter with that of the process meter. If it is not possible to take a sample then the sensor must be
disconnected from the process. The sensor is then placed in a beaker of product together with a laboratory
meter. The product should preferably be at process temperature. It is important that the laboratory meter is
calibrated and temperature corrected for the product to be measured. If the conductivity meter is used for
instance to measure the transition of beer and water or CIP liquids the meter should be calibrated for all
this liquids.
If the calibration shows that the process conductivity meter does not comply with the specified accuracy
then the sensor must be cleaned and the instrument's amplifier must be adjusted. The necessary actions for
maintenance and correction are described in the user's manual of the instrument

APPENDIX 1
Flowchart for calibration of process conductivity meters
Start
Take sample of product from

a sample point and record the
reading of the process meter
Record reading of lab analysis

of sample

of output

and inaccuracy
Inaccuracy < No
required accuracy
Yes
Instrument correct
End

APPENDIX 1
2.8 CALIBRATION PROCEDURE FOR PROCESS PH METERS
To calibrate the pH meter the sensor is disconnected from the installation, and immersed in a buffer
solution with a known pH. The pH of the buffer is chosen such that it lies within the working range of the
pH meter to be calibrated. Common used buffers are of 7 and 4 pH. After rinsing the electrodes with
demin-water the electrodes are subsequently emerged in the buffers of 7 and 4 pH. If the deviation exceeds
the required accuracy, the transmitter has to be adjusted. In case the instrument responds very slow on
changes of pH when the electrodes are put into the buffers the electrodes are fouled and have to be cleaned
or replaced. When calibrating with buffers the temperature of the buffers has to be noted. The pH of the
buffers is depending on the temperature.
The necessary actions for the adjustment of the pH meter are described in the user's manual for the
instrument concerned.
Flowchart for calibration of process pH meters
Start
Disconnect pH electrodes
from process line
Imerse electrodes in a buffer

solution with low pH
Record reading of instrument
Imerse electrodes in a buffer

solution with High pH

output for each input signal

and inaccuracies
Inaccuracy < No
required accuracy
Yes
Instrument correct
Reinstall pH electrodes
in process line
End

APPENDIX 1
2.9 CALIBRATION PROCEDURE FOR CO2 CONCENTRATION METERS
Portable meters
Portable off-line CO2 meters are used as reference for the measurement of CO2 concentrations. The
portable meters are connected to the product line by means of a sample point. The meters operate on the
principle of measurement of the vapour pressure and temperature of the dissolved CO2. Calibration of the
pressure and temperature measuring elements is carried out by using the reference standards of the
workshop, such as the dead weight tester and a digital temperature indicator.
Process meters
To calibrate a process CO2 meter, a portable off-line CO2 meter is connected to the process pipeline. And
taking a reading simultaneously of the CO2 concentration as indicated by the portable meter and the
process meter. If the calibration shows that the CO2 meter does not comply with the specified accuracy as
recorded on the PM card, then the CO2 meter must be corrected and if necessary serviced. The common
used process CO2 meters are also based on the measurement of CO2 vapour pressure and temperature.
Servicing and adjusting is also based on a calibration of these two measurements The necessary actions for
maintenance and correction are described in the user's manual for the instrument concerned. At the
moment also CO2 meters are available which are based on the thermal conductivity of CO2. (Orbisphere).
The calibration and adjustment of these meters is based on the use of reference CO2 meter.
Flowchart for calibration of process CO2 meters
Start
Connect portable CO2 meter

to sample connection on
process pipeline
Record reading of processmeter

and portable meter

output
Calculate relative errors and

inaccuracy
Inaccuracy < No
required accuracy
Yes
Instrument correct
Disconnect labmeter
End

APPENDIX 1
2.10 CALIBRATION PROCEDURE FOR OXYGEN (O2) METERS
Inline and portable oxygen meters are used for the measurement of oxygen concentrations in beer and
water. Oxygen meters are based on the measurement of the vapour pressure of dissolved oxygen. The
vapour pressure is, apart from the oxygen concentration, depending on the temperature. The reference for
the calibration of oxygen meters is ambient air. The oxygen concentration in ambient air is in general
constant enough to be used for calibration and adjustment of oxygen meters. The vapour pressure of
oxygen in ambient air is also depending on the absolute atmospheric pressure. This means that during
calibration also the temperature and the atmospheric pressure has to be considered. The sensor for oxygen
consists of a membrane covering electrodes in an electrolyte. The membrane is permeable for the dissolved
oxygen. The electrodes are kept at a constant voltage. Depending on the oxygen concentration there will be
an electrical current, which is proportional with the oxygen concentration. Periodically the membrane has
to be replaced and the electrodes to be cleaned. In the instrument manual the procedure for calibration,
maintenance and adjustment of the instrument is described. The zero-point of the oxygen meters is verified
using pure nitrogen gas.
To calibrate a process oxygen meter a portable laboratory oxygen meter is connected to the process
pipeline. Calibration is carried out by reading simultaneously the oxygen concentration as indicated by the
laboratory meter and the meter being calibrated. An oxygen meter needs maintenance when adjustment of
the instrument is not possible anymore or when the meter is showing slow responses on changes in oxygen
concentration.
Flowchart for the calibration of process oxygen meters.
Start
Connect portable Oxygen

meter to sample connection on
process pipeline
Record reading of portable

and process meter
Determine absolute error of

output

and inaccuracy
Inaccuracy < No
required accuracy
Yes
Instrument correct
Disconn. Lab meter
End

APPENDIX 1
2.11 CALIBRATION PROCEDURE FOR TURBIDITY METERS
In general turbidity meters are used in the brewhouse for turbidity measurement of lautertun or mash-filter
run–off and for measurement at the brightbeer filter of brightbeer. To check the zero calibration of a
process turbidity meter the process pipeline is filled with clear process water, and the zero point is
checked. For a check of the working range of a process meter a sample is taken from the product and
analysed with a labmeter. If the calibration shows that the instrument does not comply with the required
accuracy then the system must be corrected.
For adjustment of the working range of a turbidity meter there are different methods depending on the type
of instrument. The working range can be verified by filling the measuring tube with a calibration
suspension of known turbidity. This method is not very practical.
Another procedure is based on placing a calibration glass of known turbidity in the light beam of the
instrument. Some instruments are equipped with an internal turbidity reference, which simply can be
activated by means of a switch on the instrument.
The procedures for maintenance and adjustment are described in the user's manual of the instrument
concerned. Laboratory turbidity meters are in general calibrated and adjusted by means of standard
turbidity suspension of for instance 2 EBC. These solutions can be bought ready made with a certificate or
made by the brewery laboratory according a recognised procedure like for instance for an EBC formazine
suspension.
A remark has to be made on comparison of measuring results of different turbidity meters. Turbidity is a
relative quantity depending on a number of properties of the substance that is causing the turbidity.
Especially the particle size and the light absorption characteristics cause those two turbidity meters using
different measuring systems will show different measuring results. Different measuring systems means for
instance different colour of the light beam, measuring angle, length of measuring path and so on. An
example is for instance the Haze meter in the lab for measurement of bright beer and the installed process
meter. In practice it appeared that these meters deviate systematically 0.10 up to 0.15 EBC even when
adjusted according the proper procedure.

APPENDIX 1
Flowchart for the calibration of turbidity meters
Start
Fill turbiditymeter with

clear water
Fill turbiditymeter with a

liquid with knowturbidity
or
use a calibration glass
with knowturbidity

output for each input signal

and inaccracies
Inaccuracy < No
required accuracy
Yes
Instrument correct
End

APPENDIX 1
2.12 CALIBRATION PROCEDURE FOR ORIGINAL WORT MONITORS
In line original wort monitors are based on measurement of sound velocity in beer. The sound velocity is
proportional with the original wort content. It has to be stated that the relation between original wort and
sound velocity can be different for each beer type. This means that each beer type requires its own
calibration parameters. Factors that differentiate beer types are the brew recipe (process and raw
materials), fermentation type, fermentation degree, CO2 content etc:
An in-line original wort monitor is calibrated by taking a sample of beer during production and then
determining the original wort content of the sample in the laboratory. The laboratory measurement is used
as the reference to determine the deviation of the in-line monitor. The lab determination of original gravity
can be based on measurement of density and refractive index or on determination by means of a beer
analyser like for instance the Scaba. In general the calibration and maintenance procedures of these
instruments are described in laboratory work instructions.
If the calibration shows that the in-line original wort monitor does not comply with the required accuracy
then the monitor must be corrected. The method how the monitor has to be corrected is depending on the
type of monitor used and is described in the instrument manual. In general, the first calibration with water
is carried out to set the zero. Then the monitor is run with beer from which samples are taken. The span of
the monitor is then adjusted until the reading matches the lab analysis. The monitors have proven to be
very stable. Deviations in general are caused by changes in beer type properties.
Flowchart for calibration of original gravity monitors
Start
Take sample of product from

a sample point and record the
reading of process meter
Determine original wort in the

laboratory

and inaccuracies
Inaccuracy < No
required accuracy
Yes
Instrument correct
End

APPENDIX 1
2.13 CALIBRATION PROCEDURE OF NH3, CO2, CH4 AND H2S ATMOSPHERIC DETECTION SYSTEMS
Atmospheric detection systems are calibrated by the use of calibration gases with a known certified
concentration of the gas to be detected. If the calibration shows that a system does not comply with the
specified accuracy then the system must be corrected. The necessary actions for correction are described in
the user's manual for the system concerned..
Flowchart for calibration of atmospheric detection systems
Start
Connect a cylinder with a

calibration gas to the
measuring system
Determine absolute error of

the instrument

and inaccuracies
Inaccuracy < No
required accuracy
Yes
Instrument correct
End

APPENDIX 1
2.14 ELECTRICAL QUANTITIES
Electrical quantities like voltage, current and resistance sources are measured by means of multimeters.
Institutes capable of carrying out such calibrations generally calibrate multimeters. An alternative is that
the brewery purchases a high-accuracy multimeter, which is used as reference. A certified institute
calibrates this multimeter.
In some cases electrical sources are used for adjustment of instruments. Such sources are, for instance,
decade boxes for resistance simulation and mA sources for adjustment of mA measuring loops. These
sources can be calibrated by certified institutes or checked by means of the above - mentioned reference
multimeter.
2.15 CONCENTRATIONS AND OTHER CHEMICAL PROPERTIES
In general, calibration of the instruments measuring concentration or other chemical properties is done
using reference material. Reference material is material whose composition is known with certain
accuracy. Some examples of reference materials are:
Ambient air for the calibration of oxygen measuring instruments. Ambient air generally has a constant
oxygen concentration, which can be used as reference.
Formazine suspensions for the calibration of turbidity measuring instruments. A formazine suspension is
made in the laboratory on the basis of recognised procedure, which has a known turbidity in EBC.
Several buffers for concentration measurements like Na+, Cl+ in liquids.
Test gases with a known composition for calibration of concentration measuring systems in gas like NH3,
CO2, CH4 and H2S.

APPENDIX 2
APPENDIX 2 - WORK INSTRUCTION FOR CALIBRATION OF WORKSHOP INSTRUMENTS (EXAMPLE)
(as used in Zoeterwoude)
Responsible :
Name :
Initialled :
1. PURPOSE
This work instruction describes the planned calibration of workshop instruments. The objective is to
ensure that these instruments measure in compliance with national standards, concerning the required
accuracy.
2. SCOPE
This work instruction applies to all instruments in the workshop used to calibrate and adjust process
instruments throughout the brewery.
3. REFERENCES
DOC. NO. DOC. TITLE
4. DEFINITIONS
Calibration The determination of the value of the deviation of the measurement of an

instrument in comparison with the applicable standard.
Correction The actions carried out to allow the instrument to function with an
accuracy sufficient for the purpose for which it was intended.
Instrument A piece of equipment used to do measurements.

APPENDIX 2
5. PROCEDURES
5.1 GENERAL PROCEDURE
All workshop instruments used to calibrate and correct instruments performing measurements critical to
the process are recorded in a document named the List of Workshop Instruments.
The workshop instrument is calibrated periodically. The frequency of the calibration is recorded in the List
of Workshop Instruments. The member of the Technical Department responsible for the workshop
instruments sends a calibration instruction to the users of the instruments before the expiry date. The users
have to hand over their instruments to the responsible person in the workshop for calibration.
The following gives the specific calibration procedure for each type of instrument. In this a differentiation
can be made between those instruments which are calibrated against internal standards in the possession of
the workshop and those instruments which are calibrated by third parties.
After calibration the instrument is labelled with a calibration sticker on which the calibration date is
recorded.
The results of the calibration are recorded and filed.
A calibration certificate will, when applicable, enable the calibration to be traced to a national standard.
The starting point with calibration is that an instrument will comply with the specification as given by the
supplier of the instrument. This specification is, when possible in practice, stated on the calibration
certificate. All calibration certificates of the workshop instruments are to be filed in alphabetical order in a
file cabinet in the E&I workshop.
5.2 SPECIFIC PROCEDURE
5.2.1 Pressure instruments
In the workshop pressure balances are used as the internal standard, which are periodically calibrated by a
certified third party in a way, which certification will be according national standard. All pressure meters
in the workshop used for the calibration and correction of process pressure measurements shall be
calibrated periodically with a pressure balance. Pressure meters who cannot be calibrated with the pressure
balances in the workshop, such as barometers, vacuum gauges, and high-pressure manometers, are
periodically and traceably calibrated by third parties.
5.2.2 Electrical current, voltage and resistance instruments
A calibrator is used as the internal standard in the workshop for the electrical units of current, voltage and
resistance. A properly certified authority calibrates this calibrator. The calibrator generates a voltage
potential, current or resistance with a certified accuracy.
All workshop instruments used for the calibration and correction of process instruments shall be
periodically calibrated with the use of the calibrator.
5.2.3 Electrical current, voltage and resistance simulation equipment
This simulation equipment is used to generate signals to calibrate and correct components of
instrumentation systems. This simulation equipment is calibrated by the use of a reference current, voltage
and resistance meter. This reference meter is in turn periodically calibrated with the above-mentioned
workshop standard (5.2.2)
5.2.4 Thermometers
A thermostatic bath with temperature indicator is used as the internal standard in the workshop. The
indicator is periodic calibrated by a properly certified authority. The calibration shall be traceable to a

APPENDIX 2
national standard. The thermometers that are critical to the process are periodically calibrated using the
thermostatic bath with display.
5.2.5 Flow meters
A reference flow meter is used as the internal standard in the workshop. The flow meter is periodically
calibrated by a properly certified authority. The calibration shall be traceable to a national standard. The
reference flow meter is used to calibrate flow meters that are critical to the process.
5.2.6 pH meters
Buffers, which are purchased with a specified pH, are used as the internal standards in the workshop for
the calibration and correction of process pH meters. The pH of the buffer is recorded on a certificate. The
pH shall be traceable to a national standard. The buffers are for one-off use and are discarded after use.
The shelf life (date) is shown on the packaging of the buffers.
5.2.7. Conductivity instruments
A portable laboratory conductivity meter is used as the internal standard in the workshop to calibrate and
correct process conductivity meters. This laboratory meter is calibrated using buffers. Specifications are
supplied of the conductivity of these buffers as a function of the temperature. The calibration of the
laboratory meter is performed with the internal temperature compensation switched off. As every product
to be measured has its own Temperature Coefficient (TC) then the TC of the laboratory meter shall be
adjusted to this specific product before measurements are made. The TC for a specific product is verified
by varying the temperature of the product, during which time the reading of the laboratory meter must
remain constant.
Common products are for example water, beer, alkali, acid, etc.
The buffers are for one-off use and are discarded after use. The buffers can be purchased as such or be
prepared by the quality control laboratory.
5.2.8 CO2 (carbon dioxide) concentration meters
Portable off-line CO2 meters are used as standards for the measurement of CO2 concentrations. These are
used to measure the CO2 concentration in beer, and operate on the principle of measurement of the vapour
pressure of the dissolved CO2 together with the temperature. Calibration is performed by calibration of the
pressure and temperature measurement using the standards in the workshop, such as the pressure balance
and the thermostatic bath.
5.2.9 O2 (oxygen) concentration meters
Portable off-line O2 meters are used as standards for the measurement of O2 concentrations. The reference
for the calibration of O2 meters is saturated ambient air. An O2 concentration is simulated, depending on
the temperature and the absolute atmospheric pressure, which is used as a calibration point. The zero-point
of the meters is verified using pure nitrogen gas. The necessary actions for the calibration, and if needs be,
correction of the off-line O2 meters are described in the user's manual for the instrument.
5.2.10 Na+ (sodium ion) concentration meters
Buffers are used as internal standards in the workshop for the calibration and correction of process Na+
concentrations. The buffers are prepared by the quality control laboratory with a specified Na+
concentration. The buffers are for one-off use and are discarded after use. The shelf life (date) of the
buffers is indicated.
5.2.11 Gas concentration equipment for atmospheric detection.

APPENDIX 2
Calibration gases containing a certified concentration of the gas to be detected are used to calibrate the
atmospheric detection systems. The following gases are used:
NH3 in nitrogen, CO2 in nitrogen, H2S in nitrogen and CH4 in nitrogen. The gases are for one-off use.
5.2.12 Turbidity meters
Solutions with a known turbidity are used as internal standards in the workshop to calibrate and correct
process turbidity meters. These solutions are purchased with a turbidity as specified on a certificate. The
solutions are for one-off use.
5.2.13 Weights
Weighing systems are calibrated using calibration weights (mass pieces), which are periodically calibrated
by a properly certified authority.
5.2.14 Cl- (chloride ion) in water concentration meters
A portable laboratory Cl- meter is used as an internal standard in the workshop for the calibration and
correction of process Cl- in water meters. This instrument is calibrated using buffers containing a known
chloride concentration. These buffers are purchased with a Cl- content as specified on the certificate. The
solutions are for one-off use.

APPENDIX 3
APPENDIX 3 - LIST OF CRITICAL INSTRUMENTS (EXAMPLE)
(as used in Zoeterwoude)
As an example the instruments found to be critical in the Zoeterwoude brewery (which is brewery specific)
are summarised below. Indicated are the required control accuracy’s to ensure the product quality. The
instruments have to be preferable twice as accurate to guarantee the required accuracy.
Brewhouse
Control accuracy Instrument accuracy
Malt weighing bins 0.2 % 0.1%
Temperature mash tun, mash copper 0.5 °C 0.3 °C
Water flowmeter mash copper 0.5 % 0.3 %
Temperature hot water 0.5 °C 0.3 °C
Wort level lautertun 3 cm WC 1.5 cm WC
Pressure difference lautertun 3 cm WC 1.5 cm WC
Wort level whirlpool 0.5 % 0.3 %
Flowmeter hop dosing 2.0 % 1.0 %
Service block and fermentation

Temperature measurement wort after wortcooler 0.4 °C 0.2 °C
Wort flowmeter 0.5 % 0.3 %
Air flowmeter for wort aeration 5.0 % 2.0 %
Temperature measurement fermenters 0.4 °C 0.2 °C
Brightbeer filtration and stabilisation

Beer flowmeters before and after the filter 0.5 % 0.3 %
Beer flowmeters for dosing of additives 1.0 % 0.5%
Flowmeters for additive dosing 1.0 % 0.5%
Flowmeter isohop dosing 3.0 % 1.0 %
Yeast storage and dosing

Temperature yeast storage tanks 0.4 °C 0.2°C
Flowmeter yeast dosing 2.0 % 1.0%
Flowmeter brew salt dosing 2.0 % 1.0 %
Bottling hall
Brightbeer interface detection (conductivity measurement) 5 % (conc.) 2.0%
Beer pressure to filler 3% 1.0%
Vacuum pressure filler 0.1 Bar 0.05 Bar
CO2 pressure on filler 3% 1.0%
Keg weigher before and after keg filler 20 gr. <20 gr.

APPENDIX 3
Bottle washer and pasteuriser Control accuracy Instrument accuracy
Pressure rinsing water bottle washer 3% 1%
Caustic concentration cleaning bath bottle washer 2% 1%
Temperature pasteurisation zones bottle pasteuriser 0.5 °C 0.3
Beer flow tube pasteuriser 1% 0.5 %
Temperature tube pasteuriser 0.5 °C 0.3
Utilities
H2S concentration in CO2 before treatment plant 5% 3%
Sulphur detection in CO2 after treatment plant 5% 3%
H2S concentration in CO2 after treatment 5% 3%
Dew point CO2 4 °C 2 °C
Oxygen concentration in CO2 after treatment plant 1 ppm 0.5 ppm
Dew point compressed air 4 °C 2 °C
Remarks:
This selection is typical for a highly automated brewery.
For less automated breweries this selection has to be modified.

APPENDIX 4
APPENDIX 4 - TEST CERTIFICATES OF REFERENCE INSTRUMENTS (EXAMPLES)

APPENDIX 4

APPENDIX 5
APPENDIX 5 - ISO 9001:1994 (E)
4.8 Product identification and traceability

The required inspection and testing, and the records to be established,
Where appropriate, the supplier shall establish and maintain shall be detailed in the quality plan or documented procedures.
documented procedures for identifying the product by suitable
means from receipt and during all stages of production, delivery 4.10.2 Receiving inspection and testing
and installation.
4.10.2.1 The supplier shall ensure that incoming product is not
Where and to the extent that traceability is a specified used or processed (except in the mcircumstances described in
requirement, the supplier shall establish and maintain 4.10.2.3) until it has been minspected or otherwise verified as
documented procedures for unique identification of individual conforming to specified requirements. Verification of
product or batches. This identification shall be recorded (see conformance to the specified requirements shall be in
4.16). accordance with the quality plan and/or documented
procedures.
4.9 Process control
4.10.2.2 In determining the amount and nature of receiving
The supplier shall identify and plan the production, installation inspection, consideration shall be given to the amount of
and servicing processes which directly affect quality and shall control exercised at the subcontractor’s premises and the
ensure that these processes are carried out under controlled recorded evidence of conformance provided.
conditions. Controlled conditions shall include the following:
4.10.2.3 Where incoming product is released for urgent
a) documented procedures defining the manner of production, production purposes prior to verification, it shall be positively
installation and servicing, where the absence of such identified and recorded (see 4.16) in order to permit immediate
procedures could adversely affectquality; recall and replacement in the event of nonconformity to
specified requirements.
b) use of suitable production, installation and servicing
equipment, -and a suitable working environment; 4.10.3 In-process inspection and testing
c) compliance with reference standards/codes, quality plans The supplier shall:
and/or documented procedures;
a) inspect and test the product as required by the quality plan
d) monitoring and control of suitable process parameters and and/or documented procedures;
product characteristics; b) hold product until the required inspection and tests have
been completed or necessary reports have been received
e) the approval of processes and equipment, as appropriate; and verified, except when product is released under
positive-recall procedures (see 4.10.2.3). Release under
f ) criteria for workmanship, which shall be stipulated in the positive-recall procedures shall not preclude the activities
clearest practical manner (e.g. written standards, outlined in 4.10.3 a).
representative samples or illustrations);
4.10.4 Final inspection and testing
g) suitable maintenance of equipment to ensure continuing
process capability.
The supplier shall carry out all final inspection and testing in
accordance with the quality plan and/or documented
Where the results of processes cannot be fully verified by
procedures to complete the evidence of conformance of the
subsequent inspection and testing of the product and where, for
finished product to the specified requirements.
example, processing deficiencies may become apparent only
after the product is in use, the processes shall be carried out by
The quality plan and/or documented procedures for final
qualified operators and/or shall require continuous monitoring
inspection and testing shall require that all specified inspection
and control of process parameters to ensure that the specified
and tests, including those specified either on receipt of product
requirements are met.
or in-process, have been carried out and that the results meet
specified requirements.
The requirements for any qualification of process operations,
including associated equipment and personnel (see 4.18), shall
No product shall be dispatched until all the activities specified
be specified.
in the quality plan and/or documented procedures have been
satisfactorily completed and the associated data and
NOTE 16 Such processes requiring prequalification of their
documentation are available and authorized.
process capability are frequently referred to as
special processes.
4.10.5 Inspection and test records
Records shall be maintained for qualified processes, equipment
The supplier shall establish and maintain records which provide
and personnel, as appropriate (see 4.16).
evidence that the product has been inspected and/or tested.
These records shall show clearly whether the product has
4.10 Inspection and testing
passed or failed the inspections and/or tests according to
defined acceptance criteria. Where the product fails to pass
4.10.1 General
any inspection and/or test, the procedures for control
ofnonconforming product shall apply (see 4.13).
The supplier shall establish and maintain documented procedures for
inspection and testing activities in order to verify that the specified Records shall identify the inspection authority responsiblefor
requirements for the product are met. the release of product (see 4.16).
4.11 Control of inspection, measuring and test equipment
4.11.1 General

APPENDIX 5
NOTE 18 The metrological confirmation system for
The supplier shall establish and maintain documented measuring equipment given in IS0 10012 may be
procedures to control, calibrate and maintain inspection, used for guidance.
measuring and test equipment (including test software) used by
the supplier to demonstrate the conformance of product to the 4.12 Inspection and test status
specified requirements. Inspection, measuring and test
equipment shall be used in a manner which ensures that the The inspection and test status of product shall be identified by
measurement uncertainty is known and is consistent with the suitable means, which indicate the conformance or
required measurement capability. nonconformance of product with regard to inspection and tests
performed. The identification of inspection and test status shall
Where test software or comparative references such as test be maintained, as defined in the quality plan and/or
hardware are used as suitable forms of inspection, they shall documented procedures, throughout production, installation
be checked to prove that they are capable of verifying the and servicing of the product to ensure that only product that
acceptability of product, prior to release for use during has passed the required inspections and tests [or released
production, installation or servicing, and shall be rechecked at under an authorized concession (see 4.13.2)] is dispatched,
prescribed intervals. The supplier shall establish the extent and used or installed.
frequency of such checks and shall maintain records as
evidence of control (see 4.16). 4.13 Control of nonconforming product
Where the availability of technical data pertaining to the 4.13.1 General

inspection, measuring and test equipment is aspecified
requirement, such data shall be made available, when required The supplier shall establish and maintain documented
by the customer or customer’s representative, for verification procedures to ensure that product that does not conform to
that the inspection, measuring and test equipment is specified requirements is prevented from unintended use or
functionally adequate. installation. This control shall provide for identification,
documentation, evaluation, segregation (when practical),
NOTE 17 For the purposes of this International Standard, the disposition of nonconforming product, and for notification to the
term “measuring equipment” includes functions concerned.
measurement devices.
4.13.2 Review and disposition of nonconforming product
4.11.2 Control procedure
The responsibility for review and authority for the disposition of
The supplier shall: nonconforming product shall be defined.
a) determine the measurements to be made and the accuracy Nonconforming product shall be reviewed in accordance with
required, and select the appropriate inspection, measuring documented procedures. It may be
and test equipment that is capable of the necessary
accuracy and precision; a) reworked to meet the specified requirements,
b) identify all inspection, measuring and test equipment that b) accepted with or without repair by concession,
can affect product quality, and calibrate and adjust them at
prescribed intervals, or prior to use, against certified c) regraded for alternative applications, or
equipment having a known valid relationship to
internationally or nationally recognized standards. Where d) rejected or scrapped.
no such standards exist, the basis used for calibration shall
be documented; Where required by the contract, the proposed use or repair of
product [see 4.13.2 b)] which does not conform to specified
c) define the process employed for the calibration of requirements shall be reported for concession to the customer
inspection, measuring and test equipment, including details or customer’s representative. The description of the
of equipment type, unique identification, location, frequency nonconformity that has been accepted, and of repairs, shall be
of checks, check method, acceptance criteria and the recorded to denote the actual condition (see 4.16).
action to be taken when results are unsatisfactory;
Repaired and/or reworked product shall be reinspected in
d) identify inspection, measuring and test equipment with a accordance with the quality plan and/or documented
suitable indicator or approved identification record to show procedures.
the calibration status;
4.14 Corrective and preventive action
e) maintain calibration records for inspection, measuring and
test equipment (see 4.16); 4.14.1 General
f) assess and document the validity of previous inspection The supplier shall establish and maintain documented
and test results when inspection, measuring or test procedures for implementing corrective and preventive action.
equipment is found to be out of calibration;
Any corrective or preventive action taken to eliminate, the
g) ensure that the environmental conditions are suitable for causes of actual or potential nonconformities shall be to a
the calibrations, inspections,measurements and tests being degree appropriate to the magnitude of problems and
carried out; commensurate with the risks encountered.
h) ensure that the handling, preservation and storage of The supplier shall implement and record any changesto the
inspection, measuring and test equipment is such that the documented procedures resulting from correctiveand
accuracy and fitness for use are maintained; preventive action.
i) safeguard inspection, measuring and test facilities, 4.14.2 Corrective action

including both test hardware and test software, from
adjustments which would invalidate the calibration setting. The procedures for corrective action shall include:

APPENDIX 5
a) the effective handling of customer complaints and reports
of product nonconformities;
b) investigation of the cause of nonconformities relating to
product, process and quality system, and recording the
results of the investigation (see 4.16);
c) determination of the corrective action needed to eliminate
the cause of nonconformities;
d) application of controls to ensure that corrective action is
taken and that it is effective.
4.14.3 Preventive action
The procedures for preventive action shall include:
a) the use of appropriate sources of information such as

processes and work operations which affect product quality,
concessions, audit results, quality records, service reports
and customer complaints to detect, analyse and eliminate
potential causes of nonconformities;
b) determination of the steps needed to deal with any

problems requiring preventive action;
c) initiation of preventive action and application of controls to

ensure that it is effective;
d) ensuring that relevant information on actions taken is

submitted for management review (see 4.1.3).


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Maintenance Policy

Production Policy & Control

Issue : 01 / Apr. 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Heineken Technical Services

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

MODIFICATION REQUEST FORM

SUGGESTIONS FOR IMPROVEMENT

“MAINTENANCE MANAGEMENT SYSTEM FOR

3. PRACTICAL IMPLEMENTATION OF INSTRUMENT MAINTENANCE 8

APPENDIX 1 - CALIBRATION PROCEDURES AND SPECIFIC EXAMPLES 15

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

APPENDIX 2 - WORK INSTRUCTION FOR CALIBRATION OF WORKSHOP INSTRUMENTS (EXAMPLE) 33

APPENDIX 3 - LIST OF CRITICAL INSTRUMENTS (EXAMPLE) 37

APPENDIX 4 - TEST CERTIFICATES OF REFERENCE INSTRUMENTS (EXAMPLES) 39

APPENDIX 5 - ISO 9001:1994 (E) 41

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

1.1 PROCEDURES FOR IMPROVEMENT OF THIS MANUAL

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

2. QUALITY MANAGEMENT AND INSTRUMENT MAINTENANCE

Requirements of ISO9002 on instrument maintenance

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

3. PRACTICAL IMPLEMENTATION OF INSTRUMENT MAINTENANCE

• Make an inventory of all instruments to be included in the maintenance system

3.1 INVENTORY OF INSTRUMENTS TO BE INCLUDED IN THE MAINTENANCE SYSTEM.

See APPENDIX 3 List of critical instruments as used in Zoeterwoude (example)

In breweries we classify the instruments in three categories;

1. Instruments critical for product quality

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

2. Instruments critical for process control.

3.3 REQUIRED ACCURACY OF INSTRUMENTS CRITICAL FOR PRODUCT QUALITY

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

3.4 REQUIRED ACCURACY OF INSTRUMENTS CRITICAL FOR PROCESS CONTROL

General remarks on required instrument accuracy

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

3.5 PRACTICAL CALIBRATION SET-UP

3.7 WHEN TO ADJUST AN INSTRUMENT

Possible actions are

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

3.8 PLANNED MAINTENANCE SYSTEM FOR INSTRUMENTATION.

Information to be included in the inventory;

Proper calibration records are essential for efficient planned maintenance.

• Identification of the instrument (tag number and serial number)

• Instrument tag number and serial number

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

1 GENERAL CALIBRATION PROCEDURE

Periodic calibration of instruments is part of a planned maintenance system.

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

2.1 CALIBRATION OF PRESSURE MEASUREMENT

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Flowchart calibration of a pressure transmitter

Disconnect transmitter and

Record reading of transmitter

Increase pressure with

Record reading of transmitter

Determine absolute error

Calculate relative error

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Issue : 01 April 2000 MAINTENANCE MANAGEMENT SYSTEM HMESC : 01.21.10.001

Disconnect PT100 and immerse

Adjust temp. of bath at lowest

Increase temp. for next