Real Life Examples of how Calibration helps Companies

The National Center for Quality Calibration is a part of Punyam Management Services Pvt. Ltd. (Leading ISO Consultancy Firm) during our ISO 9001 implementation we had gone across few experiences of our clients which are listed below;

Case Study –1 (Fire caused major damages to property and Human)

Chemical Process Plant

Critical reactions were carried out in the pressure vessel – steam jacketed. Process was going on the reaction was exothermic in nature.

Controlling – Monitoring Points

• Pressure Gauge – Steam pressure monitoring – inside jacket
• Temperature Controller – Temperature monitoring inside the vessel
• Pressure Gauge – Vessel inside pressure monitoring

Status of Instruments

• Non calibrated
• In operation since 5 years

Incidence

Due to increase in steam pressure and exothermic reaction, pressure and temperature inside the vessel increased more than safe working capacity of pressure vessel. Pressure goes to above 10 Kg/cm2 and temperature goes to above 700°C (above flesh point of 690°C). But actually on monitor it Temperature Controller (Shows only 620°C) was not calibrated.

Reason
Indication inside the vessel reaction and temperature, were showing as within the process control limit.

Results - Vessel Blast

Damages to

• Major damages to plant, collapsed structure huge loss in terms of money.
• 2 operators working near by affected seriously and got permanent disability.

Could be controlled

• If instruments were calibrated periodically,
• Knowledge of calibration amongst employees

Conclusion - Rs. 1000/- per annum can serve loss of lacs of rupees and happy human life.

Case Study –2 (Saves Product Quality)

CNC Machine for preparation of mould

Very costly dies of plastic processing machines were produced in CNC machine in various sequence of operation.

Controlling – Monitoring Points 

Programme is entered in PLC through IOP as per the relevant design / drawings submitted also same can be monitored through IOP.

Status of Instruments Calibration

• PLC, IOP not validated / calibrated with respected to actual travel / traverse / feed / axial / radial play.
• In operation since 10 years

Incidence

Due to increased radial and axial play about 0.5 mm, the critical dimensions on the die could not controlled. Two nearest holes comes near each other due to higher play and crossed each other by 0.1 mm.

Reason
Indication on IOP guided by PLC was showing dimensional movement of machine as per programme.

Results - Loss of quality in dies. Die rejected due to crossing of holes with each other.

Damages to

• End product quality   
• Product rejection rate high
• Loss of image in the eyes of customer   

Could be controlled

• By periodic calibration of traverse / feed / play
• Knowledge and requirements of calibration amongst employee, even through highly accurate machines

Conclusion - Loss of product quality worth in lacs of rupees.

Case Study –3 (Higher Consumption in Energy)

Material Transfer Pump With Motor

Material transfer pump with motor was engaged in transferring of materials from reaction vessel to holding vessel and it tooks about 12 hours a day. Pump working daily 12 hours.

Controlling – Monitoring Points
Ampere Meter – Showing load taken by motor during pumping

Status of Instruments

• Non calibrated
• In service since 4 years

Incidence

Due to long working duration, pump was jammed and rotating with too much friction. Due to same the motor was working always in overload condition. However ampere shown on Ampere meter were indicating, that the motor is working in safe rating. However motor was taking 10 ampere overload than the specified current rating. The same caused higher energy consumption.

Reason - Indication in Ampere were showing safe current limit.

Results - Higher electricity bills. I.e. 125% of total required consumption of motor.

Damages to

• Company’s financial stability, increase in manufacturing cost of product.
• Could be controlled
• If Ampere meter was calibrated periodically
• Knowledge of calibration amongst employees

Conclusion - 25% higher energy consumption due to extra 10 ampere on specified rating.

Case Study –4 (Less Productivity)

Length of Material measure by Mtr/Min Meter
In textile process unit length of material measured by Mtr./Min Meter.

Controlling – Monitoring Points
Mtr./Min Meter – Showing length of material

Status of Instruments

• Non calibrated
• In service since 3 years

Incidence

Due to long working duration, Mtr/Min Meter was showing wrong reading. However Mtr/Min Meter was showing 100 meters instead of 110 meters.

Reason - Mtr/Min Meter was showing wrong reading.

Results - Less productivity. i.e. 10% more material consumption.

Damages to
Company’s financial stability, increase in manufacturing cost of product.

Could be controlled

• If Mtr/Min Meter was calibrated periodically
• Knowledge of calibration amongst employees

Conclusion

• 10% less productivity due to Mtr/Min Meter was showing 10% less reading
• The electronic  equipment in the actual humid / chemical work environment may show error over a period of life span (after 2 to 3 years). It is therefore advisable to check and calibrated once in a year.
• Actually calibrated equipment with more precise masters will save your lacs of rupees due to safety, save energy consumption, increase product quality
• Also prefer to carry out actual calibration of instrument from reputed calibration laboratory rather then taking report of calibration.

Calibration of test equipment
Calibration for pressure gauges