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Calibration White Paper www.beamex.com

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How often should

instruments be
calibrated
BEAMEX Calibration White Paper
How often should
instruments be calibrated
P
lants can improve their efficiency and reduce costs by
performing calibration history trend analysis. By doing
it, a plant is able to define which instruments can be
calibrated less frequently and which should be calibrated more
frequently. Calibration history trend analysis is only possible
with calibration software that provides this functionality.
Adjusting calibration intervals based on history trend
analysis
Manufacturing plants need to be absolutely confident that
their instrumentation products temperature sensors, pressure
transducers, flow meters and the like are performing and
measuring to specified tolerances. If sensors drift out of their
specification range, the consequences can be disastrous for a
plant, resulting in costly production downtime, safety issues
or possibly leading to batches of inferior quality goods being
produced, which then have to be scrapped.
Most process manufacturing plants will have some sort
of maintenance plan or schedule in place, which ensures
that all instruments used across the site are calibrated at the
appropriate times. However, with increasing demands and
cost issues being placed on manufacturers these days, the time
and resources required to carry out these calibration checks
are often scarce. This can sometimes lead to instruments being
prioritised for calibration, with those deemed critical enough
receiving the required regular checks, but for other sensors
that are deemed less critical to production, being calibrated
less frequently or not at all.
But plants can improve their efficiencies and reduce costs by
using calibration history trend analysis, a function available
within Beamex CMX calibration software. With this function,
the plant can analyze whether it should increase or decrease
the calibration frequency for all its instruments.
Cost savings can be achieved in several ways. First, by
calibrating less frequently where instruments appear to be
highly stable according to their calibration history. Second,
by calibrating instruments more often when they are located
in critical areas of the plant, ensuring that instruments are
checked and corrected before they drift out of tolerance.
This type of practise is common in companies that employ
an effective Preventive Maintenance regime. The analyses
of historical trends and how a pressure sensor, for example,
drifts in and out of tolerance over a given time period, is only
possible with calibration software that provides this type of
functionality.
www.beamex.com How often should instruments be calibrated
Plants can improve their efficiencies
and reduce costs by using
calibration history trend analysis,
a function available within Beamex
CMX calibration software.
Current practices in process plants
But in reality, how often do process plants actually calibrate
their instruments and how does a maintenance manager or
engineer know how often to calibrate a particular sensor?
In March 2010, Beamex conducted a survey that asked
process manufacturing companies how many instruments in
their plant required calibrating and the frequency with which
these instruments had to be calibrated. The survey covered all
industry sectors, including pharmaceuticals, chemicals, power
and energy, manufacturing, service, food and beverage, oil
and gas, paper and pulp.
Interestingly, the survey showed that from all industry
sectors, 56% of the respondents said they calibrated their
instruments no more than once a year.
However, in the pharmaceuticals sector, 59% said they
calibrated once a year and 30% said they calibrated twice a
year.
Perhaps unsurprisingly, due to it being a highly regulated
industry, the study proved also that the pharmaceuticals
sector typically possesses a significantly higher number of
instruments per plant that require calibrating. In addition,
these plants also calibrate their instruments more frequently
than other industry sectors.
Sensors that are found to be
highly stable do not need to be
re-calibrated as often as sensors
that tend to drift.
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BEAMEX Calibration White Paper
The benefits of analyzing calibration history trends
But regardless of the industry sector, by analysing an
instruments drift over time (ie. the historical trend)
companies can reduce costs and improve their efficiencies.
Pertti Mki is Area Sales Manager at Beamex. He specialises
in selling the Beamex CMX to different customers across all
industry sectors. He comments: The largest savings from
using the History Trend Option are in the pharmaceuticals
sector, without doubt, but all industry sectors can benefit
from using the software tool, which helps companies identify
the optimal calibration intervals for instruments.
The trick, says Mki, is determining which sensors should
be re-calibrated after a few days, weeks, or even years of
operation and which can be left for longer periods, without
of course sacrificing the quality of the product or process or
the safety of the plant and its employees. Doing this, he says,
enables maintenance staff to concentrate their efforts only
where they are needed, therefore eliminating unnecessary
calibration effort and time.
But there are other, perhaps less obvious benefits of looking
at the historical drift over time of a particular sensor or set of
measuring instruments. As Mki explains: When an engineer
buys a particular sensor, the supplier provides a technical
specification that includes details on what the maximum
drift of that sensor should be over a given time period. With
CMXs History Trend Option, the engineer can now verify
that the sensor he or she has purchased, actually performed
within the specified tolerance over a certain time period. If it
hasnt, the engineer now has data to present to the supplier to
support his findings.
The function enables users to plan
the optimal calibration intervals for
their instruments.
But thats not all. The History Trend function also means
that a plant can now compare the quality or performance
of different sensors from multiple manufacturers in a given
location or set of process conditions. This makes it an
invaluable tool for maintenance or quality personnel who,
in setting up a new process line for example, can use the
functionality to compare different sensor types to see which
one best suits the new process.
www.beamex.com How often should instruments be calibrated
Calibration software such as CMX can also help with the
planning of calibration operations. Calibration schedules take
into account the accuracy required for a particular sensor and
the length of time during which it has previously been able
to maintain that degree of accuracy. Sensors that are found
to be highly stable do not need to be re-calibrated as often as
sensors that tend to drift.
History Trend displays the
instruments drift over a given period
both numerically and graphically.
The History Trend function enables users to plan the
optimal calibration intervals for their instruments. Once
implemented, maintenance personnel, for example, can
analyze an instruments drift over a certain time period.
History Trend displays the instruments drift over a given
period both numerically and graphically. Based on this
information, it is then possible to make decisions and
conclusions regarding the optimal calibration interval and
the quality of the instruments with respect to measurement
performance.
The History Trend window enables users to view key
figures of several calibration events simultaneously, allowing
to evaluate the calibrations of a position or a device for a
longer time period compared to the normal calibration result
view.
For example, the user can get an overview of how a
particular device drifts between calibrations and also whether
the drift increases with time. Also, the engineer can analyze
how different devices are suited for use in a particular area of
the plant or process.
Reporting is straightforward and the user can even tailor the
reports to suit his or her individual needs, using the Report
Design tool option.
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BEAMEX Calibration White Paper

CALIBRATION HISTORY TREND ANALYSIS SUMMARY

Calibration history trend analysis allows you to The benefits of calibration history
analyze the instruments drift over a certain time
period.
trend analysis:
Analyzing and determining the optimal calibration
The Beamex CMX stores every calibration event into
interval for instruments
the database; the history trend is made automatically
without any extra manual work. Conclusions can be made regarding the quality of a
particular measuring instrument
The Beamex CMX also indicates when new devices
have been installed and calibrated. This helps in Time savings: faster analyses is possible when
comparing differences between devices. compared to traditional, manual methods

The graphical display of the history trend helps in Enables engineers to check that the instruments they
visualizing and optimizing the calibration interval for have purchased for the plant are performing to their
the instruments. technical specifications and are not drifting out of
tolerance regularly

Supplier evaluation: the performance and quality of

HISTORY TREND USER-INTERFACE

different sensors from different manufacturers can be

compared quickly and easily.

When calibration frequency can be decreased:

If the instrument has performed to specification
and the drift has been insignificant compared to its
specified tolerance

If the instrument is deemed to be non-critical or in a

low priority location

When calibration frequency should be increased:

History Trend Page 1 / 1
Printed: 10/5/2012 12:53:14 PM
Printed by : ajn
History Trend
Position ID: 101DR-PT0002
Page 1 / 1
Printed: 10/5/2012 12:53:56 PM
Printed by : ajn
CMX Version : 2.7.424.0 (2.7)
If the sensor has drifted outside of its specified
Position ID: 101DR-PT0002 CMX Version: 2.7.424.0 (2.7)

Position
Name
Location
Dryer pressure to controller
0025 Room
Device
Device ID
Serial Number
PT0005
54.618
Position
Name
Location
Dryer pressure to controller
0025 Room
Device
Device ID
Serial Number
PT0005
54.618 tolerances during a given time period
HISTORY TREND REPORT

Plant Pharmaceutical Plant/Plant 1, Finland ( BPF )/Block 1/101 DR Manufacturer Model Fisher-Rosemount 3051 Plant Pharmaceutical Plant/Plant 1, Finland ( BPF )/Block 1/101 DR Manufacturer Model Fisher-Rosemount 3051
(Dryer 1)/ (Dryer 1)/
Function
Calibration Procedure Name Pressure Transmitter (pt) Calibration Procedure Function
Interval 365 days Transfer Function Linear Interval 365 days Name Pressure Transmitter (pt)
Reject If Error > 0.5 % of span Input Range 0 ... 10 bar (G) Reject If Error > 0.5 % of span Transfer Function Linear
Adjust To Error < 40 % of Reject If Error Input Range 0 ... 10 bar (G)

If the sensor is located in a critical process or area of

Adjust To Error < 40 % of Reject If Error Output Range 4 ... 20 mA
Output Range 4 ... 20 mA

Max. Error Error Limit

0.86
Max. Error Error Limit

the plant and has drifted significantly compared to its

Max. Error [% of span]

0.32 0.86
Max. Error [% of span]

-0.21
0.32

-0.75
-0.21
-1.28

specified tolerance over a given time period

2/19/2000 8/21/2000 2/20/2001 8/23/2001 2/23/2002 8/26/2002 2/25/2003 8/28/2003 2/28/2004 8/29/2004 3/1/2005 -0.75
Calibration Date
Max. Hysteresis Max. Nonlinearity
-1.28
0.28

2/19/2000 8/21/2000 2/20/2001 8/23/2001 2/23/2002 8/26/2002 2/25/2003 8/28/2003 2/28/2004 8/29/2004 3/1/2005
0.17
Calibration Date
[% of span]

0.06

-0.05 Position ID Device ID Serial Manufacturer Model Calibration As Found Reject If Error > Maximum Passed
Number time As Left Error Failed

When measuring a sensor that is located in an area of

[% of span]
-0.16
101DR-PT0002 PT0002 94876 Fisher-Rosemount 3051 2/19/2000 As Found 0.5 % of span -0.928 Failed
2/19/2000 8/21/2000 2/20/2001 8/23/2001 2/23/2002 8/26/2002 2/25/2003 8/28/2003 2/28/2004 8/29/2004 3/1/2005
101DR-PT0002 PT0002 94876 Fisher-Rosemount 3051 2/19/2000 As Left 0.5 % of span -0.340 Passed
Calibration Date
101DR-PT0002 PT0002 94876 Fisher-Rosemount 3051 8/16/2000 As Found 0.5 % of span -0.403 Passed
Avg. Zero Error Avg. Span Error
0.51
101DR-PT0002 PT0002 94876 Fisher-Rosemount 3051 2/19/2001 As Found 0.5 % of span -0.465 Passed
101DR-PT0002 PT0002 94876 Fisher-Rosemount 3051 8/20/2001 As Found 0.5 % of span -0.570 Failed

the plant that has high economic importance for the

0.11 101DR-PT0002 PT0002 94876 Fisher-Rosemount 3051 8/20/2001 As Left 0.5 % of span -0.643 Failed
[% of span]

101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 8/20/2001 As Found 0.5 % of span -0.095 Passed
-0.29
101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 2/19/2002 As Found 0.5 % of span 0.085 Passed
101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 8/15/2002 As Found 0.5 % of span 0.150 Passed
-0.69
101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 2/17/2003 As Found 0.5 % of span 0.195 Passed
-1.08 101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 8/17/2003 As Found 0.5 % of span 0.188 Passed
101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 2/23/2004 As Found 0.5 % of span 0.200 Passed

plant
2/19/2000 8/21/2000 2/20/2001 8/23/2001 2/23/2002 8/26/2002 2/25/2003 8/28/2003 2/28/2004 8/29/2004 3/1/2005

Calibration Date 101DR-PT0002 PT0005 54.618 Fisher-Rosemount 3051 3/1/2005 As Found 0.5 % of span 0.285 Passed

Position ID Device ID Calibration As Found Reject If Error > Maximum Maximum Maximum Average Zero Average Span
time As Left Error Hysteresis Nonlinearity Error Error
[% of span] [% of span] [% of span] [% of span] [% of span]
101DR-PT0002 PT0002 2/19/2000 As Found 0.5 % of span -0.928 0.098 0.163 -0.819 0.246
101DR-PT0002 PT0002 2/19/2000 As Left 0.5 % of span -0.340 0.092 0.108 -0.263 0.205
101DR-PT0002 PT0002 8/16/2000 As Found 0.5 % of span -0.403 0.092 0.108 -0.326 0.205
101DR-PT0002 PT0002 2/19/2001 As Found 0.5 % of span -0.465 0.154 0.139 -0.377 0.142

Where costly production downtime may occur as a

101DR-PT0002 PT0002 8/20/2001 As Found 0.5 % of span -0.570 0.154 0.139 -0.482 0.142
101DR-PT0002 PT0002 8/20/2001 As Left 0.5 % of span -0.643 -0.084 0.203 -0.393 -0.112
101DR-PT0002 PT0005 8/20/2001 As Found 0.5 % of span -0.095 -0.083 0.096 -0.018 0.075
101DR-PT0002 PT0005 2/19/2002 As Found 0.5 % of span 0.085 0.022 0.041 0.032 0.052
101DR-PT0002 PT0005 8/15/2002 As Found 0.5 % of span 0.150 0.028 0.046 0.105 0.045
101DR-PT0002 PT0005 2/17/2003 As Found 0.5 % of span 0.195 -0.018 0.065 0.125 0.070

result of a faulty sensor

101DR-PT0002 PT0005 8/17/2003 As Found 0.5 % of span 0.188 0.063 0.051 0.188 -0.017
101DR-PT0002 PT0005 2/23/2004 As Found 0.5 % of span 0.200 -0.025 0.049 0.188 0.012
101DR-PT0002 PT0005 3/1/2005 As Found 0.5 % of span 0.285 -0.040 0.084 0.240 0.045

Where a false measurement from a sensor could lead

to inferior quality batches or a safety issue

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BEAMEX Calibration White Paper

ISO 9001:2008 quality management requirements

7.6 Control of monitoring and measuring devices
The organization shall determine the monitoring and
measurement to be undertaken and the monitoring
and measuring devices needed to provide evidence of
conformity of product to determined requirements.
The organization shall establish processes to ensure
that monitoring and measurement can be carried out
and are carried out in a manner that is consistent with
the monitoring and measurement requirements.
Where necessary to ensure valid results, measuring
equipment shall
a) be calibrated or verified 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;
In addition, the organization shall assess and record
the validity of the previous measuring results when the
equipment is found not to conform to requirements.
The organization shall take appropriate action on the
equipment and any product affected. Records of the
results of calibration and verification shall be maintained
(see 4.2.4).
When used in the monitoring and measurement of
specified requirements, the ability of computer software
to satisfy the intended application shall be confirmed.
This shall be undertaken prior to initial use and
reconfirmed as necessary.

b be adjusted or re-adjusted as necessary;

c) be identified to enable the calibration status to be

determined;

d) be safeguarded from adjustments that would

invalidate the measurement result;

e) be protected from damage and deterioration during

handling, maintenance and storage.

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