Inline Quality Monitoring - my.endress.com to monitor any validate inline systems: ... What’s...

01/04/2016

Products Solutions Services

Inline Quality Monitoring

Ensuring and Improving Quality and production costs

Slide 1

02/02/2016

Process variables and impact

• The raw material, • Seasonal• Supplier

• The operator• The utilities

• Energy supply• Plant conditions

• The equipment• Cleaning/Fouling status• Maintenance• Calibration

Is all that covered by the recipe in your control system?

Digital Inline Quality Control

Slide 2 Holger Schmidt

02/02/2016

Why consider digital with quality control?

• 4-20 mA: the working global analogue standard

• 4-20mA HART: only global digital standard (available in all sensors)

• Ethernet IP: the future of plug and play installations that supply all available information from a sensor. Flow and analytical are equipped with it. Strong joint development with Rockwell Automation.

• Profibus PA /DP: looked like the future in the past. Was too complex and difficult to find good support.

• Modbus: look today like a niche, as well as IO Link and Profi Net



02/02/2016

Digital communication, Ethernet IP, Profibus…

The digital communication allows to access the full set of information the sensors creates. All data can be seen on the control screen. All settings can be done in the control room.


Flow(mass and volume), density, viscosity, temperature, totalizer, concentration, calculations, system status like dumping for maintenance, frequencies, e.g. to detect entrained air and improve the process


02/02/2016

How to monitor any validate inline systems:

• All quality relevant systems need reported checks. Sensors have to be calibrated frequently, but what happens in the mean time?

• Digital systems allow to transfer all sensor data, showing inconsistencies in it performance right away.

• Other systems run checks on demand, initiated manually like with Memocheck

• For complete system checks in Endress+Hauser flow and level sensors have another technology on board, it is called:



02/02/2016

MonitoringVerificationDiagnostics

What’s Heartbeat TechnologyTM can achieve?


Reliable self-monitoring• Continuous, built-in

diagnostic functionality• Broadest test coverage• Quick, concise guidance

in case of errors (NE 107)

Compliant testing• On-demand, effortless

procedure• Easy handling,

no process interruption• Electronic quality reporting

Condition-based maintenance• Permanent reading of

process-related variables• Impact assessment• External trend analysis


02/02/2016

Supply chain support based on inline data

• Production planning process based on inventory

• Production panning based on plant availability considering visible repair and maintenance needs

• Spare part handling and trouble shooting supported online with integrated asset management.



02/02/2016

Digital Inline Quality monitoring can…

• Helps to improve the overall quality of product and production.

• Is the basis for steady process optimization, compensating variables in raw material, utilities supplies, plant conditions and training status of the operator.

• Supplies the data for efficient traceability.

• Improves the data base for quality improvement.

• Helps to improve the cleaning and maintenance regime, neither to late nor to often.

• Supplies the necessary data to improve the process long term.

• Makes all operations and quality relevant actions transparent.



01/04/2016

Lab Measurements

F&B Industry Strategic Directions 2016

The accuracy always depends on certain parameters and is measured against known values. The result needs to be absolute and valid anywhere under any circumstances.• Lab Measurements are highly accurate and should take into account things

like sample temperature variations.• Lab Measurements will still be important with installation of inline quality

monitoring instruments, as they validate inline measurements and provide the highest possible accuracy.

High AccuracyHigh Repeatability

Slide 9

01/04/2016

Lab Measurements


We are not trying to “replace lab measurements”

Why? 1. Different levels of accuracy compared to inline instruments

2. We will always need verify inline instruments

3. Inline process measurements bridge the gap between lab measurements

4. Together they facilitate higher consistency and quality

Slide 10

01/04/2016

Inline Measurements


Repeatability shows, what variances will be expected under production circumstances. • Inline meters are more robust, but less accurate then lab sensors, however

their high repeatability facilitates process improvements. • If different readings are detected every time measurements are taken,

quality cannot be improved. One could argue that it is better to be repeatable, rather than accurate for quality improvements

Instruments lose their calibration, and hence their accuracy, over time, therefore it is necessary to recalibrate to guarantee that an instrument is capable of measuring to the specifications for which it is rated.

Good AccuracyHigh Repeatability

Low AccuracyLow Repeatability

Slide 11

02/02/2016

Inline Quality Monitoring and Quality controls


RSG45 Data Recorder

• Quick commissioning via integrated webserver• Seamless data exchange between field level and control level• Encrypted email notification for off-limit conditions and

alarms• Fulfillment of IT security requirements for FDA 21 part 11

conformity

Data TransparencyData recorders facilitate easy visualization of trends and capture historical data for analysis and reporting.

Safe data storage and email alerts keep you informed of developing process trends.

Slide 12

02/02/2016



Fast-responding instruments can help increase quality directly.

Inline measurements enable faster response to changes in raw material quality or process drifts.

Blind spots between lab samples are eliminated

This allows operators to react quickly to prevent batch loss

Avoid Product LossesResponse Time Makes the Difference

Slide 13

02/02/2016



Promag H 100

• Built-in conductivity measurement• Onboard meter verification with Heartbeat Technology,

HistoROM data management, built-in webserver, and Ethernet IP communication option

Contamination AlertsA Magmeter with integrated Conductivity measurement can provide early detection of contamination from improperly flushed lines or leaking valves.

This facilitates early identification of the source of the issue and prevents contaminated product from being used in downstream processes.

Slide 14

02/02/2016



Promass I 100 Coriolis Meter

• Single straight measuring tube with full-bore design

• Real-time process information about corrosion, abrasion, and build-up

• Onboard meter verification with Heartbeat Technology, HistoROM data management, built-in webserver, and Ethernet IP communication option

Inline Density MeasurementSugar content, concentration or viscosity are parameters that are oftencritical to product quality.

Coriolis offers accurate and repeatable mass flow, density or viscosity determination.

Slide 15

02/02/2016



FMD71 Electronic DP measurement

• High purity ceramic membrane for resistance against vacuum and abrasion

• Fast and easy installation

• 10 times faster response than capillary systems

• Eliminates up to 95% of errors due to ambient temperature effects

Filter MonitoringProactively monitoring the pressure build up across the filter to facilitatecleaning before a breakthrough happens.

Prevent product quality issues and eliminate rework of product that is over turbidity specification.

Slide 16

02/02/2016



CPA875 Retractable + CYC25 Autocleaning

• No process shutdowns for calibrations or cleaning

• Memosens sensors can be hot swapped with the process running

• Reduces potential contamination of process from dirty sensors

• Regular cleaning increases sensor life and measurement reliability

Retractable Assemblies and Automated Sensor CleaningRetractable assemblies allow for easy removal of pH, ORP, or DO sensorsfor cleaning or calibrations without process shutdowns.

Automated cleaning systems facilitate increased process uptime by eliminating the need to shutdown or remove the probe manually for routine cleaning.

Slide 17

02/02/2016

Pasteurization of Beer, Milk, Juice, Sauce etc.

In a pasteurizer overshooting the temperature by even a few degrees affects taste, while undershooting can means unsafe products.


QuickSens technologyT/°C

t/min

< min-min. Temperature biological risk

To hot Energy wasted and loss of quality

Fast response ensures the tightest control window possible for improvement of quality and energy

consumption

iTHERM TM411

Customer Benefit: • Higher Quality –Taste consistency

• Improved Product Safety

• Energy Savings

• 9x faster compared to standard RTDs (t90: 0.75s Quicksens insert; 2.5s in thinwall thermowell)

Slide 18

02/02/2016

Product monitoring for contamination


Promag H 100 Early detection of contamination from improperly flushed lines or leaking valves for identification of the source of issues and to prevent contaminated product from being used in downstream processes.

Promag H 100 Product Features:

• Integrated conductivity measurement allows for continuous contamination monitoring for product safety.

• Reliability and long service life from IP69K ingress protection,

• easy and time saving set up with webserver.

Customer Benefit: • Improved Product Safety

• Early identification of quality issues

Slide 19

02/02/2016

pH monitoring in Sauces, Condiments, Jam, etc.

CPS471D + CM44x + CPA875

Critical Control point for product safety/quality ‐ Detection of trace CIP fluid contamination.

• CPS471D offers a glass free ISFET design to prevent glass contamination and ensure product safety.

• CPS71D offers high accuracy and resistance to clogging with a pressurized reference junction

• Retractable assembly is used to extend probe life under CIP Conditions


Final pH monitoring—Quality control point Correct pH is needed for flavour and shelf life.

CPS71D-7TP****+ CM44x + CPA875

Customer Benefit: • Higher product quality

and safety

• Early identification of quality issues

Slide 20

02/02/2016

Dissolved Oxygen monitoring prior to packaging COS22D + CM44x

Monitoring for DO before heat process can prevent taste issues created by the increased oxidation rates seen at higher temperatures


In almost any packaged sauce or liquid picking up entrained air can cause early product spoilage and reduced shelf life.

Customer Benefit: • Reliability of product “best before

dates“

• To ensure taste consistency

• Protection of brand image

• Amperometric Dissolved Oxygen measurement with long-term stability

• Plug and Play, Pre-calibration

• 12 mm Sensor design for use in all retractable and sanitary assemblies

• Memosens Sensor Technology

Slide 21

02/02/2016


Beer pH monitoring Prior to Packaging

In Beer production a critical point for product safety is enabling detection of trace CIP fluid contamination before packaging.

Trace amounts of 40ppm NaOH or higher can be detected (pH change of 0.3 pH) –

• Regular calibration and cleaning is required for optimal performance to accurately detect such a small change in pH

CPS441D

with retractable CPA875 +

CYC25 Auto Cleaning

CPS71D-7TP****

with retractable CPA875 +

CYC25 Auto Cleaning

Customer Benefit: • Highest possible product safety and quality

Slide 22

02/02/2016


pH monitoring in milk reception, butter and yogurt production

CPS441D

with retractable CPA875,

CYC25 auto cleaning

pH of milk used for butter manufacturing must be closely monitored. In yogurt the finished product pH is a final quality control point.

Customer Benefit: • Improved product quality

• Assurance of reliability of best before dates

• Brand protection

Product Features: • Glass free ISFET design to prevent glass contamination,

• Flowing KCL prevents clogging of reference junction.

• Retractable allows easy removal for cleaning or calibrations without process shutdowns.

• CYC25 can automate the cleaning process.

Slide 23

02/02/2016


Mass Flow and Viscosity in Batters, Gravies and Sauces

Promass I 100

Correct viscosity is important quality control point to ensure the final product has the correct consistency.

• Straight tub design ensures low pressure drop and gentle product handling. Ethernet IP allows for easy setup and communication of all parameters simultaneously.

• IP69 K water ingress Protection

Customer Benefit: • Improved final product

Quality

Slide 24

02/02/2016


Colour monitoring of fruit juice, soft drinks, etc

OUSAF22 + CM44PFinal product quality control of colour and purity.

• Monitoring for colour changes from overheating, incorrect dilutions, or incorrect colour dosing.

Customer Benefit: • Improved colour

consistency

• Identification of changes over time

• Dual wave length absorbance sensor. The second wave length ensures compensation of variations in turbidity.

• Color and absorbance sensor measures even the slightest change of color in products to determine product concentration or quality.

• High quality design, long service life and stable measurement

Slide 25

02/02/2016

Any questions?

12/02/2015


Calibration Services

Cost-effective, reliable calibration as and when needed

Slide 27 Service Office

02/02/2016

Welcome – Introduction

• Yang Feh Fan• Senior Engineer –

(Service and Solution)Marketing Dept.

• 3 years in E+H

• Contacts :

• [email protected]

• 03 – 7843 3872

• 012 – 661 0219

F&B and Life Science Training


02/02/2016

Calibration

Agenda

• Calibration basics• Importance of calibration• Endress+Hauser calibration competence• Flow calibration in Endress+Hauser Malaysia• Best practice for flow calibration management• Q&A

Slide 29 AS


12/02/2015

Calibration basics

Slide 30 AS

02/02/2016

Calibration

What a calibration is… and what it isn´t

• Calibration is the comparison of an instrument to a known standard.

• Calibration is attempting to determine measurement errors coming from the calibrated instruments.

• Calibration is not an adjustment, only a comparison.

• After a calibration a device could be adjusted, the device must be recalibrated.

• Don’t confuse with verification

Slide 31 AS

02/02/2016

The verification and calibration of flowmeters

Calibration and Verification

On-site calibration

Factory calibrationWorkshop calibration

On-site control measurement

• Heartbeat Verification on demand

• Control measurement from the outside

• Mobile test rigs

• Stationary calibration facilities

Effort

Qua

lity

of te

stin

g

Calibration:Flow performance

confirmation

Slide 32 ED / MVA

Flowmeter functionality verification

02/02/2016

Heartbeat Technology - Verification

• Heartbeat Technology verifies the correct function of the measuring device according to the specifications and generates a verification report without process interruption

• The automatic generated protocol supports the documentation requested by internal and external formalities, laws and standards

Slide 33 Seou Wei

02/02/2016

Primary Calibration Method - Gravimetric

Slide 34 Ngo

02/02/2016

Oil & Gas Flow - precise and efficient

Calibration methods – secondary calibration method

Unit Under Test

Water Reservoir

Mas

ter U

nits

= 3 dm 3

2503 dm3

2500 dm3

Slide 35 Ngo


12/02/2015

Importance of calibration

Slide 36 AS

02/02/2016

Calibration

The customer’s challenges

• Reduce business costs

• Ensure constant qualityof the final product

• Minimize emissions ofgreenhouse gases

• Improve plant safety

• Improve energy efficiency

• Compliance with quality standards and regulations

Slide 37 AS

02/02/2016

ROI example – Cost savings• Flow measurement with the rate

20 t/hour

• Increase in accuracy of 0.1% gained by regular calibration

RM/ton

Reduce of waste when operating 8x5 (Per year)

Reduce of waste when operating 24x7(Per year)

Fresh Milk 7000 RM 291,200 RM 1,223,040

Fanta 2000 RM 83,200 RM 349,440

Sunflower Oil 10000 RM 416,000 RM 1,747,200

Red Bull 20000 RM 832,000 RM 3,494,400

Red Wine 50000 RM 2,080,000 RM 8,736,000

Microsoft Excel Worksheet

Try putting your data in !



02/02/2016

Calibration is required by regulators§7.6: Control of monitoring and measuring equipment

… Where necessary to ensure valid results, measuring equipment shall:

a) be calibrated or verified, or both, at specified intervals or prior to use, against measurement standards traceable to international or national measurement standards; where no such standards exist, the basis used for calibration or verification shall be recorded (see 4.2.4);

b) be adjusted or re-adjusted as necessary;

c) have identification in order to determine its calibration status;


§5.4: Calibration, adjustment an checking of measuring and monitoring devices

5.4.2 All measuring devices shall be checked, adjusted and calibrated, under a monitoring system, at specified intervals and in accordance with defined recognisedstandard/ methods. The results of the checks, adjustments and calibrations shall be documented. Where necessary, corrective actions on devices and, if necessary, on process and products shall be carried out.



12/02/2015

Endress+Hauser calibration competence

Slide 41 AS

02/02/2016

Worldwide calibration capabilities• Calibration in 60 countries• > 250 qualified calibration

technicians

Calibration

Ranking criteria:• Ratio: calibration net sales vs. Total SC net sales • Number of trained field service engineers,

parameters and calibration tools• Accreditations in place

• > 50’000 on-site calibrations

• > 1500 calibration tools in the operations

• Various ISO 17025 accreditation in 6 countries

• Unified Calibration certificate in 16 languages

Core calibration parameters• Flow• Pressure• Temperature• pH• Conductivity

Additional parameters• Volume• Level• Electrical parameters• Density• Rotational Speed• Energy transfer• Other liquid analysis

High

Medium

Low

Status: April 2014

Slide 42 AS

02/02/2016

Accreditation by Swiss Accreditation Service (SAS)

Since 1994, Endress+Hauser has been accredited as a calibration provider for flowmeters by the Swiss Accreditation Service (SAS) in accordance with ISO/IEC 17025. The very good results of the comparative verification measurements carried out by both the Swiss Federal Institute of Metrology (METAS) and Endress+Hauser confirm the high reliability of the flow calibration rigs accredited by SAS at Endress+ Hauser.

Xperience The Future

Yang FFSlide 43

02/02/2016

ISO 9001, ISO 14001, OHSAS 18001


Yang FFSlide 44

02/02/2016

100% Traceability


Yang FFSlide 45

• The Endress+Hauser approach is accredited calibration rigs based on ISO/IEC 17025 as the traceability foundation.

• This means full traceability with an uninterrupted chain of proof regarding the test equipment, from the test device to the hierarchically highest standard in each country “national standard”, confirmed by an accreditation.

Calibration rig

Testing equipment

National standard

Global reference

±0.000001% ±0.0001% ±0.0016% ±0.015%

Example: Promass F is calibrated with a measurement uncertainty of ±0.025% as a master meter and Maximum Permissible Error (MPE) of ±0.05% (in customer’s production plant).

The calibration rig (Endress+Hauser)• PremiumCal calibration rig for testing Promass83F/84F (as an example)• Measuring uncertainty: ±0.015%• Accredited to ISO/IEC 17025 by the Swiss Accreditation Service (SAS)• Annual SAS audits of the facility

The gravimetric scales (Endress+Hauser)• Gravimetric scales of the PremiumCal calibration rig for measuring the referenceflow values• Regular verification of the scales every 2 weeks with calibrated reference weights(= internal reference standard)• Measuring uncertainty of the reference weights (class F2): ±0.0016%

The national standard (national institute of metrology)• Verification of the reference weights used by Endress+Hauser every 5 years bythe Swiss Federal Institute of Metrology METAS using a mass comparator andnational reference weights (national reference standards)• Measuring uncertainty of the METAS 500 kg reference weight (set 502, class E2):±0.0001% (0.5 gram to 500 kg)• Periodic comparison of the reference weights to Switzerland’s replica No. 38 of the IPK every 10 years

The International Prototype Kilogram (at BIPM, France)• International Prototype Kilogram (IPK) = global reference and basic unit of mass.The Bureau International des Poids et Mesures (BIPM), founded in 1875, keepsthe IPK under lock and key in a vault on its premises in Sèvres near Paris (France).• In 1950, 1991 and 2003 comparison measurements for verification took placebetween the IPK and Switzerland’s replica No. 38.• Measuring uncertainty: ±0.000001% (±10 micrograms)

02/02/2016

E+H Calibration capability breakdown

Factory Calibration

Wide measuring rangeDistance, turnaround time-

Workshop Calibration

Faster turnaround, less costSmaller ranges-

On-site Calibration

Fastest turnaround On-site preconditions, know-how Direct communication, least

down-time

Calibration

Cost

of c

alib

rati

on (R

M)

Measurement Uncertainty (%)Slide 47 AS

02/02/2016

What is On-Site Calibration Service from Endress+Hauser

• Arrival of trained calibration technician(s) on your site with high accuracy mobile calibration tools

• Performing calibration of measurement devices with shortest possible out-of-operation time

• Producing and handing over standardized calibration reports



02/02/2016

Example of calibration certificate


• Available in 16 languages• Contains all fields required by

ISO 17025• Contains graph for better

visualization• Can be provided in paper, PDF-

files or uploaded directly to your assets management system


02/02/2016

Pillars of our Quality


1. Comprehensive SOPs and Working Instructions

2. Certified Trainings for staff

3. Corporate Standard on Calibrations and Corporate Quality Management System

4. State-of-art software and tools


02/02/2016

Our calibration portfolio - MY


Core Calibration Parameters• Flow (Liquid)-NEW• Pressure• Temperature• pH• Conductivity• Level

Additional Parameters• Recorder• Other liquid analysis


02/02/2016

Benefits at a glanceWe help to save extra• Define optimal calibration intervals• Shorten your replacement stock with fast

onsite calibrations• Get a expert analysis of calibration results• Establish and track KPIs to enable

improvements

You get it from one hands• Audit, Calibration, Consulting, Maintenance,

Repairs, Replacements from one supplier

Instant access to calibration results• All calibration results could be put directly

your Installed Base Management system



02/02/2016

Flow Calibration in Endress+Hauser Malaysia (NEW!)


COMING SOON!


02/02/2016

Video – Mobile Flow Calibration Rig



02/02/2016

Flow Calibration Rig (Coming Soon to Malaysia)


Flow Calibration Rig Diagram

• Flow rate:

• Best uncertainty:

Small pump: 0.20 to 30 m3/h (depend on UUT pressure loss)Big pump: 0.20 to 60 m3/h (depend on UUT pressure loss)0.12%


02/02/2016

Our Service at Glance – Flow Calibration Rig at E+H MY


Calibration Method• Comparison with in series master meter• Mobile calibration with Coriolis flowmeter as reference

Calibration Range and Flowmeter Size• Small pump: 0.20 to 30 m3/h (depend on UUT pressure loss)• Big pump: 0.20 to 60 m3/h (depend on UUT pressure loss)• DN8 to DN100

Calibration Points• 3 or 5 points• Others on request

Time required (per device)• 2 to 3 hours (depending on calibration points, process

condition/connection, etc)• Cleaning has to be performed before calibration


02/02/2016

Our Service at Glance – Flow Calibration Rig at E+H MY


Equipment Concerned• Electromagnetic• Vortex• Coriolis• Thermal• Ultrasonic• Mechanical• Others upon request

Documents Issued• Calibration Certificate• On request, copy of the proof of conformity to the

national/international standard

Benefits• Calibration can be conducted on-site or in E+H Malaysia workshop• Reduce downtime• Save cost


02/02/2016

Best Practice for Flow Calibration ManagementCommon myth: My flowmeter needs to be calibrated annually because.... (you are not so sure)

Calibrate at an optimum frequency and save cost!

Fail to plan for flow calibration? Fail to save cost...

What we recommend:Yearly calibrations are not necessary, as some flowmeters require calibration only once every 3 or 4 years depending on the process fluid, operation, and criticality. In other cases, a flowmeter may require calibration much more frequently, to maintain a safe, efficient, or regulatory compliant operation. It’s also important to realize that calibration intervals are not always fixed, meaning that they might fluctuate based on usage or historical performance.


Yang FFSlide 58

12/02/2015


Any questions?

Slide 59 AS

02/02/2016

Thank You

Coming soon 2018 in Endress+Hauser Malaysia! See you there!



Inline Quality Monitoring - my.endress.com to monitor any validate inline systems: ... What’s...

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