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maintenance

the magazine for all instrument users

Monitoring
and measuring
energy efficiency

today

Cost-effective
calibration
solutions

Optimized solutions for


maintenance and calibration
Fewer headaches with your installed base

Issue 5 07/2010

Save time
for a coffee break

Maintenance publications
recently issued
The Maintenance Guide - new release: this manual is the reference
text for your production, metrology and maintenance teams. Its
content has been updated and the new issue has been available
since 07/2009. Keep a copy on your desk all year round!
Maintenance Actions is a handy collection of information sheets
dealing with a specific subject of direct relevance to your dayto-day operations. Each sheet offers you options for immediate
action. We publish several sheets each year.

Recent issues:
Easy Access to Spare Parts (11/2009)
Memosens Welcome to the digital age! (11/2009)
Tailor-made training programs (11/2009)
Overcome differential pressure issues (1) (04/10)

the magazine for all instrument users

In this issue:
uide

Cost-effective calibration solutions


Save time for a coffee break

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Instru

Trends, solutions, shared experiences


Everything you need to get the best
out of your installed base!

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Endress+Ha Internationa
Instruments se 2
Kaegenstras ch
4153 Reina
81 00
Switzerland
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Tel. +41 61 715 25 00
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Fax +41
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info@ii.end

+Hauser

Maintenance analysis to stop fire fighting

p. 10

Endress

Plant documentation: your system and W@M

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Maintenance Today - Issue 5 - 07/10

Monitoring and measuring energy efficiency


according to the new EN 16001 standard
In an effort to achieve short-term energy-saving
opportunities or to minimize its long-term indirect
greenhouse gas footprint, your company is
implementing the EN 16001 standard. Has your
metering capability been adapted accordingly?
European Standard, EN 16001 Energy management
systems - Requirements with guidance for use was
published on 31 July, 2009. This standard specifies
the requirements for an energy management system,
which requires the development of an energy policy,
identification of an organizations past, present, and
future energy consumption as well as the development
of an energy performance-monitoring plan.

Utilities
measurement

Optimization

Long-term action
Energy counting plan
Follow-up plan

Data analysis

Many organizations in the European Union are


adopting EN 16001 to meet local regulatory
obligations and to improve bottom line energy
performance. Concurrently, the American National
Standard Institute (ANSI) is leading the effort in the
development of ISO 50001, an international standard
on energy management largely modeled after ANSI/
MSE 2000 and following the established EN 16001
framework. International standard ISO 50001 is
expected to be finalized by the end of 2010.

These recommendations lead to three essential questions:


Has the organization planned what will be measured,
where and when it should be measured, and what
methods should be used with respect to energy use?
Is the energy consumption of most relevant energy
consuming processes, machines and/or products
being measured, monitored, recorded, analyzed and
reported on a regular basis?
Are other parameters affecting energy consumption
being measured and monitored on a regular basis?

With regard to monitoring and measurement, the


standard states: The organization shall identify and
describe the measuring and monitoring requirements
of its energy management programs. On a regular
basis, the organization shall measure, monitor and
record significant energy consumption and the factors
that affect it.

To answer these questions Endress+Hauser can


help you perform an audit of your existing metering
capability and evaluate the additional points for
measurement required by the energy management
system. In a second step, you will need to adequately
maintain and periodically calibrate these measuring and
monitoring devices. Here again Endress+Hauser is the
ideal partner to help avoid any future drift of the system
and thus ensure durable performance.

Maintenance Today - Issue 5 - 07/10

Acquisition of
energy data

Up to 15% savings
through efficient
energy monitoring
Need to think about the
complete solution for
you to take control of
your energy costs? Our
experts are keen to share
their expertise and build
the appropriate solution
combining measuring
instrumentation, IT
network and software.

Cost-effective
calibration solutions

In this new article


covering our
serial story about
metrology and
calibration we
compare mutual
benefits of on-site
and laboratory
calibration.
Lets dive into
a world where
uncertainty and
traceability are
key words.

The performance of a measuring instrument


and its ability to work accurately and
repeatably within a process environment
is crucial and directly linked to the
control, safety, quality and yield of a
production plant. For this reason the need
to periodically check, prove, calibrate and
adjust instruments in service is often a
critical but specialized activity within a
quality controlled organization.
One of the most time consuming aspects
of an instrument technicians work is
to routinely check and calibrate quality
critical instrumentation, proving optimum
performance and traceability within the
production process. In the past such checks
were considered to be good practice,
and carried out on an ad hoc basis, but
today for many industries periodic testing
of quality critical instruments has become
mandatory. Typical drivers to this situation
include the Food and Drug Administration
(FDA) who license and audit the operating
facilities of the pharmaceutical companies,
to ensure that all products are produced to
the strictest quality. This activity is also a
fundament in ISO 9001 quality accredited
manufacturing facilities that process food or
produce chemicals.
There are two sides to the on-site activity
which are prevalent, first is the actual
activity of calibration itself. This requires
skilled personnel, the right tools and
standard operating procedures (SOPs) that
everybody follows to ensure consistency of
the work.
The second activity is the whole
management of the activity, scheduling
the appropriate time for re-calibration,
arranging access to the process plant,
allocating the resources, documenting the
results, producing compliant calibration
certificates and archiving the records.

Calibration of a
temperature sensor

Maintenance Today - Issue 5 - 07/10

This can be more demanding than the role


of calibration itself. The quality of which
is fundamental to ensuring traceability
within the process plant for quality control
purposes. If you are visited by an FDA
or ISO 9000 auditor, it is within the
management and control of the scheduling
process and retrieval of the records that
he will likely focus. In the past this was
a mainly manual process and complex
paperwork systems were evolved to satisfy
the regulatory requirements. A recent
trend is that today, software tools, which
are fully auditable and compliant to the
necessary standards now, exist. These tools
simplify the tasks of not just calibrating the
instruments but also the process around it.
The most desirable method
In many instances, on-site calibration can
be relatively easy to achieve. Portable
calibration equipment offers the possibility
to usually check in situ the uncertainty of
pressure transmitters, temperature systems
and level sensors. However, flowmeters are
more difficult and the options open to users
to prove their device in the application
are limited and the necessary tools can be
expensive for the average production plant
to own and operate. In these instances and
also where it makes no sense to employ
and train staff the activity of calibration and
maintenance of critical instruments is often
outsourced. This article focuses on the
subject of flow calibration.
In situ flow meter calibration is
undoubtedly the most desirable method as
it is performed with the field device in its
operating location, therefore indicating the
installed performance of the instrument,
which could differ from the original
manufacturer specification due to installed
effects such as asymmetrical flow profile or
swirl caused by upstream bends and fittings.
When considering which devices require
calibration you also need to take into
account the costs involved from two angles.

National levels
National standard

DKD/SCS/SIT/COFRAC/NAMAS

Calibration laboratory
Reference standard

Internal calibration laboratory


Factory standard

Test equipment for manufacturing process


Product
Measuring accuracy

Traceability

The calibration traceability chain

Maintenance Today - Issue 5 - 07/10

Using portable calibrators to calibrate pressure devices is


practical but the measuring accuracy is limited.

1. Major influences on calibration cost include:


The number of devices
The type of devices
The method of calibration
The frequency of calibration
The tolerance bandwidth for a good
calibration result
2. Major influences on operational cost are:
Quality problems
Production stops
Regulatory problems
(shutdown = cost interruption)
Safety, environmental and
other hazard related costs
Cost for repair of affected equipment
Balancing the two above cost factors yields
optimized (best practice) total cost. Other
considerations involve where to calibrate
and whilst on site is always desirable it
might not be practical and hence the meter
might need to be removed and sent back
to an independent facility for testing and
calibration.
Off-site Calibration
These facilities should ideally be traceable
and accredited. An accredited calibration
rig provides full traceability to national
standards. Additionally, comparison
measurements against other accredited rigs
are often made, to ensure good agreement.
Calibration rigs whose measuring uncertainty
calculations are based on internationally
accepted standards and which have been
awarded an accreditation according to
ISO17025 are usually regarded by qualified
auditors as fully credible.

Most rigs use water as the primary test


medium and it needs to be assessed if this
is representative for the meter under test;
other specialized rigs exist for testing meters
in hydrocarbons and gas for example but
such facilities are not so common and the
associated calibration cost can be high. The
measuring uncertainty of a calibration rig is
usually the best quality indicator to compare
calibration laboratories against each other.
The facilities with the lowest measuring
uncertainty are usually regarded as the rigs
with the highest quality potential but the
lower the measuring uncertainty the higher
the cost of the rigs.
On-site Calibration
If a flow measuring instrument is
calibrated right at the point of the actual
measurement, all installation related
influences are also considered in the result.
Unfortunately an on-site calibration is not
always easy to accomplish and quite often
during the design stage of a production
plant the calibration aspects are neglected.
When critical measuring points are
planned, the installation of fittings, or a
bypass downstream of the flow meter
should be foreseen. The process fluid can
thus be redirected through a master meter,
or for a Coriolis mass flowmeter, fed into
a vessel and its weight determined by a
scale. At the bypass points care should
be taken that no leaks occur, particularly
during calibration. The scope within which
an on-site calibration is possible depends
largely on the process fluid and on the flow
meters used in that process. Limitations
must be expected if the process fluid is

Method of calibration

Typical uncertainty

Primary ISO 17025 calibration rig

0.05 - 0.2%

Traceable calibration rig

0.2 - 0.5%

Mobile Master/Slave

0.5 - 1%

Ultrasonic clamp-on comparison

2 - 5%

Electronic meter verification + sensor inspection

3 - 5%

The acceptable uncertainty is a key criterion for choosing the right method.

corrosive, very expensive, or dangerous, or


is under high temperature, or pressure. For
meters with sizes above 250 mm, on-site
calibration becomes increasingly difficult
and is perhaps not economically favorable.
Good experiences have been made
with mobile calibration skids which are
temporarily fixed into a place in the plant,
close to the measuring point and on which
one or more master flow meters, including
all the necessary transmitting and recording
equipment is installed. Before such a system
is ready for use, a calibration of the mobile
master unit, in a traceable calibration
laboratory has to be performed and a
calibration certificate issued. One additional
way to check the functionality of measuring
instruments on site could be the use of an
electronic test and verification instrument
to check most of the important parameters
of a measuring point and monitor possible
drifts in the measuring instrument also
over longer periods of time. By using this
method the ideal time of maintenance for
the instrument, or the time for recalibration
could possibly be established.

Another common method to check a


flowmeter in situ is by installing non
intrusive ultrasonic clamp-on sensors to
the outside of a pipe and measure the flow
velocity of the liquid in the pipe. The inside
diameter of the pipe, as well as the wall
thickness must be known and the liquid
must be acoustically transparent. These two
latter methods are quite practical and useful
for simple checks, but the limitations in
measuring accuracy must be considered.
Obviously the decision regarding the
method to be used will influence cost
and degree of involvement, which will
ideally include a team of responsible site
personnel, involving Engineering, Quality
and Management who should review such
methods and also how often to calibrate.
This subject will be explored in the next
edition of Maintenance Today.
To be continued in the next issue

On-site calibration using a mobile flow rig


(Coriolis mass flowmeter)

Maintenance Today - Issue 5 - 07/10

Save time for a coffee break


The installation of
differential pressure
instruments can
often be quite
challenging for
technicians.
Consider some of
these easy steps
when planning a
new installation
or replacing old
instruments and you
might actually find
you have time to
take a coffee break!

Maintenance Today - Issue 5 - 07/10

Technicians in charge of maintaining


differential pressure instruments have
reported that they constantly face some
common issues. Trapped gas is one of the
most frequent issues with these devices.
The presence of gas in the impulse lines
causes an unstable zero point especially
with changing ambient temperature. The
reason is that being compressible, the air
acts like a spring, which leads to an unstable
measurement. Simple to understand but
often its not so easy to vent and solve.
To simply install a DP instrument is
sometimes not as straightforward as you
would think... if the impulse lines have
been installed by the pipe fitter without
consideration of the DP cell orientation
then it may well prove impossible to fit the
instrument without rerouting the pipes,
which can be a nightmare, especially
when the lines have already been lagged
and heat traced.
Do you recognize some of these
challenges? Youll be glad to know
that these issues (and several others)
now definitely belong in the past. At
Endress+Hauser, we strive to think of
everything to make your life easier.

New range of pressure devices


- a real opportunity
Whilst working on the design of the new
Deltabar M differential pressure device,
we put ourselves in your shoes, and
considered all challenges you are likely to
face... We hope you like the result. Please
check out on the following pages to see
how you can overcome DP issues easier
than ever with Deltabar M.
From now on we hope that replacing
older generations of DP instruments
(whatever the make) is a real opportunity
for you to save time and benefit from
devices that offer universal connectivity,
combined with the latest technology... and
Endress+Hausers proverbial instrument
reliability. Last but not least, through special
selection and ordering tools we guarantee
that the device will totally match your
application, thus making installation and
commissioning easier than ever.
The result, we hope, will be a perfect
installation with fewer headaches
and more time for coffee - what more
could you want?

Our on-site technician reports


on how he overcame some of the
most frequently reported DP issues
Venting solutions
quickly removing air bubbles
An unstable measurement is usually
due to the presence of air bubbles in the

system and should normally be vented


via the side flange drain vents. On older
transmitters when operating the venting
system, it didnt always appear suitable for
every mounting position and was difficult
to remove the air.
Today with Deltabar M Ive got the right
venting system whatever the installation
(vertical or horizontal impulse lines). One
or two drain vents enable to easily get the
air out of the device.
Note: this system may also work for getting liquid out
of air or gas filled impulse lines.

Easy re-assignment of pressure entries


When arriving at the location of the
DP instrument I planned to install and
commission, I realized that the impulse lines
were connected the wrong way: the HP (+)
side of the transmitter was connected to the
low pressure line and vise versa. In the past
Ihad to disconnect and re-install the impulse
lines - this was a nightmare if the lines are
already lagged and heat traced.

pressure entry either to the High or to the


Low pressure side. This HP / LP change is
also possible via software (display, handheld
or HART communication).

Today with Deltabar M, no mechanical


re-work is necessary. The electronic insert
is equipped with a simple DIP switch,
which allows easy assignment of the

Cost-effective calibration
Once the transmitter is installed on a tank
then its calibration needs to be checked.

If the tank is already in service, then its


necessary to wait until the tank is full to do
the wet calibration.
Today with Deltabar M if the tank has a
linear shape I dont need to wait until its
full; I can even do it during the production
process. In fact I can do a wet calibration
with a tank only partially filled e.g. 20%
and 25%.
For other tank shapes the tank linearization
can be fully performed in the instrument.

Maintenance Today - Issue 5 - 07/10

Quick verification via test pins


with 420 mA simulation

I need to check the DP transmitter is


correctly connected via the 420 mA loop
to the PLC or DCS and ensure the loop
calibration is correct. Usually I have to check
first if the cabling is OK then check if the
scaling in the system has been set up correctly.
With the Deltabar M, I can access the
420mA output of the transmitter via test
pins, plus the current output of the transmitter
can be directly simulated, which allows me to
simply verify the cables and their connection
as well as the check the PLC or DCS.

Optimized cost of the measuring point


In order to simplify the management of
spare parts, weve standardized on the
use of DP transmitters also for relative
(gauge) pressure and absolute pressure
measurement. This has a strong impact on
the cost of each measuring point.
Today we use Cerabar M for relative
(gauge) and absolute pressure and
DeltabarM for differential pressure
applications. These devices all have the
same electronics, display and software;
furthermore, with Cerabar M, we can save

Minimize mistakes
We have many different vendors
transmitters installed in our plant. If I need
to replace one of these old DP transmitters
and Ive found the right Endress+Hauser
replacement product, how can I be sure not
to forget anything when ordering and get
the right pre-configured product?

up to 30% of the cost of the measuring


point compared to the DP transmitter.
Note: Endress+Hauser proposes 1 to 1 replacement
solutions for each existing pressure transmitter.

Endress+Hauser checks the data ensuring


that right range and selected product fit
together for example. Once validated, the
transmitter is produced to order arriving
ready to fit to your application.

Deltabar M can be ordered pre-calibrated


and set-up for pressure, level or flow
measurement. If you use the Configuration
Data Sheet included in the product Data
Sheet then all the necessary information
is captured and the processing system of

A cost-effective solution
We have been testing the Deltabar M for one year and
can state that this DP instrument is exactly what we
needed. The Deltabar M fits many applications where the
higher accuracy and functionality of the Deltabar S is not
required. Furthermore, the technician who replaced the
old instrument with the new Deltabar M confirmed this
was really easy and quick to do.
Rudolf Eichin, Engineering and Production Manager,
HeidelbergCement AG (Germany)

Maintenance Today - Issue 5 - 07/10

Plant documentation: your system and W@M


Plant documentation with all its components is a time
consuming task, especially considering all the legal
provisions and specifications. Endress+Hausers W@M
portal provides full service support for preparation,
production and updates on plant documentation right
from the start. How does W@M interact with your
existing management system?
Electronic plant documentation offers considerable advantages,
particularly in process industries with complex plants and their
often extensive documentation. Access to up-to-date product
information, documentation, spare part lists, order references and
the history of realized maintenance work of individual components
during the plant life cycle considerably lowers operating costs.
The Endress+Hauser W@M portal provides ready access to
valuable information during the entire plant life cycle, whereby
the fast and simple retrieval of product data and documentation
saves valuable time and costs. The life cycle of the individual
components is centrally monitored, updated and clearly indicated
for all users. Events such as production, commissioning,
maintenance and troubleshooting or repair work are contained in
the logbook with all details.

second language in case the documents are not available in the


desired one. The system now searches for suitable information
and provides lists from which users make a selection and start
downloading. The data is not only downloaded but directly
integrated into the product. The components are unambiguously
identified via a serial or TAG number. All downloaded documents
are assigned versions. Users enjoy full transparency of the product
life cycle without having to update. The data integration into
existing systems of users automates the information availability
process and provides maximum benefit.
We asked Stefan Besmehn, Head of Electrical Engineering at
Wolfsburger Entwsserungsbetriebe (Germany), which of the
portal functions he found most helpful in his day-to-day work.
His response was: The automatic availability of information
on Endress+Hauser instruments in the database. If required,
we can easily find the needed documentation. The availability
of instruments, spare parts and accessories is immediately
recognized. If needed, we can put these straight into the shopping
cart of the online shop. This saves precious time.

If a breakdown of the plant occurs, it is quickly and precisely


rectified with the automatically generated information and spare
parts can be immediately identified and procured all of which
reduces down time and associated costs.
Automatic transfer of information to existing systems
Do you need to update and manage another database? No! The
integrated interfaces provide a connection to existing software
tools for engineering, procurement and upkeep. Information and
documentation may be automatically exchanged between the
existing system and the W@M portal on the basis of web services.
This is illustrated by the following example.
With the Prodok PLT CAE system of Rsberg Engineering GmbH
(Germany), users may select the part of the plant for which
information is to be downloaded. They input the type of
documentation and the respective language and define a

10

Stefan Besmehn, Head of Electrical Engineering


at Wolfsburger Entwsserungsbetriebe (Germany)

Maintenance Today - Issue 5 - 07/10

Maintenance analysis
to stop fire fighting
Tired of constantly having to put out fires? You can
avoid these problems with an appropriate analysis
of your maintenance activity. Dont worry, it has
been tried and tested by numerous clients
Consider the paradox: performing less maintenance
than necessary does not generate any savings. This is
because any reduction of maintenance costs is more
than counter-balanced by higher operation costs due to
reduced process availability. Moreover the maintenance
department looks like a firemens barracks with people
constantly facing emergencies. The other consequences
could be a negative impact on product quality or
problems in the spare parts supply and the like.
On the other hand, excessive maintenance - especially
unnecessary actions lead to increased labor costs and
probably also the cost for storing unnecessary spare parts.
This is where Endress+Hauser can help. Our
service consultants perform an audit of the installed
instrumentation and give guidelines to turn reactive
maintenance to proactive maintenance, thus preventing
fire-fighting issues from occurring. They also help find
the right balance to avoid excess maintenance.
Experience in mid-size and large process plants suggests
that equipment and plant availability is improved whilst
maintenance efforts are redirected to improve plant
productivity. In some instances the result is an increase
in preventive activities, in other cases a reduction and
redirection of the efforts for more productivity. In most
cases, the spare parts stock is consistently reduced.

Joop, what frame of mind are customers in when


starting the analysis?
People we meet on site are driven by the necessity to
improve the production process and to lower the costs.
Many of them also face increasingly high regulatory
demands aimed at proving the products quality.
Everybody would like to optimize the whole system
and thus be able to perform maintenance in a balanced
way. But in most cases they just do not know where to
start! Totally focused on production, they dont have
time to identify the instruments that need maintenance
and/or calibration. Furthermore, they generally dont
have the competence to find out how to optimize and
balance maintenance. Hence I can say they are looking
for help!

Joop Pels
Service Consultant
Endress+Hauser
Netherlands

What are the most common situations


you face on site?
Customers who already have a maintenance
system use it on the application level but not on the
instrumentation one. Therefore they often dont know
how many instruments are on their processes and
cannot be sure they have the right spare parts. This is
why we need to make an inventory prior to any analysis
of the installed base.

As Service Consultant at Endress+Hauser


Netherlands, Joop Pels has conducted a
number of maintenance analysis
projects in process plants
in recent years. Read
here to discover some
of his tips for easing
life in maintenance
departments.

Maintenance Today - Issue 5 - 07/10

11

How do you proceed to reach the objectives?


As projects differ from one to the other, we first find
out our customers biggest pain - even though our
contacts would spontaneously list many concerns and
wishes, we cannot start solving everything at once.
By focusing on the biggest pain we can ask the right
questions and start building a specific approach.
For one such customer we found out that they
essentially needed advice on how to optimize
maintenance and to identify the right method for the
instruments calibration on site. Because of the quality
systems, they had to calibrate but didnt know how.
Another customer already had a maintenance plan but
needed help to improve his SOPs in order to be able to
prove quality to the Food and Drug Administration etc.

During the inventory, instrumentation and process data is easily collected on-site and
stored in Endress+Hausers FieldXpert tool. Data is then uploaded into W@M Life
Cycle management in order to allow the analysis and the production of a report.

What are the most important outcomes that allow


customers to stop fire fighting?
With a balanced maintenance plan, an overview of the
installed base places focus on critical instrumentation,
appropriate SOPs, optimized spare parts stock and
a training program; customers who follow the
conclusions of our Installed Base Audit are well armed
to meet regulatory requirements and face future
events. And with such information available 24/7, they
definitely have peace of mind at least regarding these
topics... Last but not least, in most cases our approach
leads to lower costs at the end.
The collaborative effort between manufacturer and
end-user to carry out maintenance analysis and define
a well-balanced maintenance strategy has proven to be
an effective approach. The focus on process-critical and
difficultto-maintain instruments and the anticipation of
failures leads to a visible reduction of downtime while
keeping maintenance efforts focused.

W@M is available either as a web portal or as part of the enterprise local


network, thus enabling 24/7 availability of instrument information.

One outstanding outcome is the reduction of the


spare parts stock through standardization and focus on
critical instruments. There are numerous other benefits,
though: the traceability simplifies budgeting and cost
control; and plant reliability is enhanced through better
control of maintenance risks.
Standardization allows consistent spare parts stock reduction. Here is a typical stock of
spare parts before (left) and after (right) Endress+Hausers maintenance analysis.

12.06/I.I.

Instruments International
Endress+Hauser
Instruments International AG
Kaegenstrasse 2
4153 Reinach
Switzerland
Tel. +41 61 715 81 00
Fax +41 61 715 25 00
http://www.endress.com
info@ii.endress.com

CM 005H/29/ae/07.10
PF/INDD CS2