Welcome to the Industrial Technology Lounge

Beware of Fake.......

2009-08-19T06:41:00.003-08:00

A few job slots available and an outburst of too many job seekers is a common situation that applicants and employers encounter during hiring sessions through out the world especially in third world countries around the globe.

A great feat it is if one of the tens or hundreds of applicants would be able to pass through the rigid written tests and interviews. A congratulation to that person indeed. And it should be if such person is 'legitimate'.

Too many nowadays where documents can easily be copied and tampered. Fake diplomas, job experience and skill trainings or competency certificates abound and readily available for just a mere amount. Many people who 'cheat' like this are ironically the ones that get the 'job' for they have awesome experiences and superb education.

This is the sad reality that workers face especially the one that take real schooling and they even started from the lowest position available in a certain industry. They meet the newly hired 'empty' superiors with great compensation and be laughed at.

It is a pain for those who strived hard to get something in the end but with dreams shattered because of the 'fake' reality.

Standards Certification... The Need... The Lies...

2008-08-22T01:13:00.002-08:00

Almost everyone make a lie or two in their lifetime. Even at certain times that you aren't conscious of it, and before you even know it, you are already lying to to someone. But I have recently seen the ultimate liars (aside from our government) right before my very eyes.

I am part of that agenda actually though not directly. If you are wondering what the heck I am talking about here, continue to read through this article. Have you heard of TPM or ISO even? The so-called Standards Certification thing?

When the company management starts to say something like:

"Hey, we will be applying for this international standards thing. We need your help. When someone from external auditing team for this ISO or TPM or JIPM team would ask you something blah blah blah, you should say blah blah blah. Don't ever say that we are blah this and blah that. Help the company, it will be for everyone here."

You are part of the lying thing. When the company does not really follow the Company Corporate Policy and it is just a mere sort of poster there in your office wall, then all of you are lying. It is the cheat and lying fever.

Fixed the major non-conformance temporarily while this auditors would do their thing next day or week or month. Be prepared to lie, I mean be prepared to answer what you have studied for that event. Even if just for that day. You are greatly needed.

You need to lie to be one of the Heroes. hehehehe.

Risk taking in the field... Is it worth it?

2008-07-30T08:21:00.003-08:00

I have known some risk-takers in the field of industrial technology. It usually happens during troubleshooting or system modification and I admit that in some in instances, i have been one of those risk-takers. But i tell, i usually do that when i have no experience in a particular area of the industry but got a backing up theory learned somewhere while reading technicals and adding all industrial concepts related to that situation. Gladly to tell anyone reading this article that i have been quite successful most of the time. It is some sort of a first and final thing to do in a real life situation where less time spent and analysis applied equals money saved by the company and your increase in ranking in terms of the view from others as what you are capable of.

There are sureballers that i knew of that wouldn't contribute even just a little action towards a certain industrial activity because they have no specific experience or training on that certain equipment or system. They need to be sure on what they are doing and are afraid to make and accept mistakes if ever that would happen. In short, they lacked confidence and refuse to let their minds do their work, and sad to say that I know some people who are like that personally. They cannot share anything out of the box. They need to have stored knowledge of a certain thing to be able to take part confidently.

In the field of industrial instrumentation, where I currently venturing into, the fact that most if not all are just following the basic principles of sensorics and signal manipulation and its just the brands, models, and data syntaxing and commands are what that is different. If you know basic industrial instrumentation principles, then there is no need to be afraid of what is new.You got me?

4-20 mA Current Loop Primer

2008-07-16T02:28:00.003-08:00

This application note’s primary goal is to provide an easy-tounderstand primer for users who are not familiar with 4-20mA current-loops and their applications. Some of the many topics discussed include: why, and where, 4-20mA current loops are used; the functions of the four components found in a typical application; the electrical terminology and basic theory needed to understand current loop operation. Users looking for product-specific information and/or typical wiring diagrams for DATEL’s 4-20mA loop- and locallypowered process monitors are referred to DMS Application Note 21, titled “Transmitter Types and Loop Configurations.”

Despite the fact that the currents (4-20mA) and voltages (+12 to +24V) present in a typical current loop application are relatively low, please keep in mind that all local and national wiring codes, along with any applicable safety regulations, must be observed. Also, this application note is intended to be used as a supplement to all pertinent equipment-manufacturers’ published data sheets, including the sensor/transducer, the transmitter, the loop power supply, and the display instrumentation.

Read more...

Download now at this page Download Section below!

Lessons in Electric Circuit Ebook Download

2008-07-12T07:34:00.002-08:00

Just added a new ebook free at the download section entitled Lessons in Electric Circuits Reference. From useful equations to conversion factors to various trigonometric and calculus references to circuit codes and symbols, all are available here in this awesome free ebook.

With 161 pages of pure electrical references and information, you could ask nothing more in this field.

In portable document format (format) for compatibility and ease of printing to a hard copy.

Download now at this page's download section!

What are Pressure Transmitters

2008-07-10T09:20:00.001-08:00

Pressure transducers are devices that convert the mechanical force of applied pressure into electrical energy. This electrical energy becomes a signal output that is linear and proportional to the applied pressure. Pressure transducers are very similar to pressure sensors and transmitters. In fact, transducers and transmitters are nearly synonymous. The difference between them is the kind of electrical signal each sends. A transducer sends a signal in volts (V) or millivolt per volt (mV/V), and a transmitter sends signals in milliamps (mA).

Both transmitters and transducers convert energy from one form to another and give an output signal. This signal goes to any device that interprets and uses it to display, record or alter the pressure in the system. These receiving devices include computers, digital panel meters, chart recorders and programmable logic controllers. There are a wide variety of industries that use pressure transducers and transmitters for various applications. These include, but are not limited to, medical, air flow management, factory automation, HVAC and refrigeration, compressors and hydraulics, aerospace and automotive.

There are important things to consider when deciding what kind of pressure transducer to choose. The first consideration is the kind of connector needed to physically connect the transducer to a system. There are many kinds of connectors for different uses, including bulletnose and submersible connectors, which have unique applications. Another important part is the internal circuitry of the transducer unit, which is housed by a "can" that provides protection and isolates the electronics. This can be made of stainless steel or a blend of composite materials and stainless steel. The various degrees of protection extend from nearly no protection (an open circuit board) to a can that is completely submersible in water. Other kinds of enclosures safeguard the unit in hazardous areas from explosions and other dangers.

The next thing to consider is the sensor, which is the actual component that does the work of converting the physical energy to electrical energy. The component that alters the signal from the sensor and makes it suitable for output is called the signal conditioning circuitry. The internal circuitry must be resistant to harmful external energy like radio frequency interference, electromagnetic interference and electrostatic discharge. These kinds of interferences can cause incorrect readings, and are generally to be avoided when doing readings. Overall, pressure transducers are well-performing and high-accuracy devices that make life easier for many industries.

New Download Section...

2008-07-09T19:26:00.002-08:00

Hi!

Just recently added a download section of this site for free items related to Industrial Technology. I will be offering free ebooks and references as well as applications and other software. You can also request items by either contacting me through the chat box or through my email for more privacy. I am a research junkie and had already at my hand hundreds of softwares and ebooks related to this field. Enjoy!

d4rkhowl

What is OPC Server Development?

2008-07-09T17:49:00.001-08:00

An OPC Sever is a software application that acts as an API (Application Programming Interface) or protocol converter. An OPC Server will connect to a device such as a PLC, DCS, RTU, etc or a data source such as a database, HMI, etc and translate the data into a standard-based OPC format. OPC compliant applications such as an HMI, historian, spreadsheet, trending application, etc can connect to the OPC Server and use it to read and write device data. An OPC Server is analogous to the roll a printer driver plays to enable a computer to communicate with an ink jet printer. An OPC Server is based on a Server/Client architecture.

There are many OPC Server Development toolkits available for developing your own OPC Server; MatrikonOPC's Rapid OPC Creation Kit (ROCKit) is one of it and enables quick OPC Server development. ROCKit offers a flexible and affordable solution that enables programmers to fully control their own product.

OPC ROCKit packages the complete OPC interface into a single DLL, eliminating the need to learn the complexities of Microsoft COM, DCOM or ATL. A developer simply writes the communication protocol routines for the underlying device and ROCKit takes care of the OPC issues.

Features include:

- Fully compliant with OPC DA 1.0a, 2.05 and 3.0 specifications.
- Free threading model on Windows NT, 2000 and XP platforms.
- Supports self-registration, browsing, data quality reporting, and timestamps.
- Can be used as a stand-alone server or as a service.
- In-proc server design for high-performance communication.
- Sample application code and comprehensive documentation illustrating how to use the ROCKit.
- OPC Explorer client that exercises the OPC COM interface for testing and debugging your server.
- The interface to the Device Specific Plug-in application code is separate from the OPC COM interface code. This means that future OPC source code updates are simply plugged in, while your own protocol code remains untouched, resulting in minimal engineering effort.

OPC (OLE for Process Control) Overview

2008-07-09T17:44:00.001-08:00

OPC is a series of standards specifications. The first standard (originally called simply the OPC Specification and now called the Data Access Specification) resulted from the collaboration of a number of leading worldwide automation suppliers working in cooperation with Microsoft. Originally based on Microsoft's OLE COM (component object model) and DCOM (distributed component object model) technologies, the specification defined a standard set of objects, interfaces and methods for use in process control and manufacturing automation applications to facilitate interoperability. The COM/DCOM technologies provided the framework for software products to be developed. There are now hundreds of OPC Data Access servers and clients available.

Adding the OPC specification to Microsoft's OLE technology in Windows allowed standardization. Now the industrial devices' manufacturers could write the OPC DA Servers and the software (like Human Machine Interfaces HMI ) could become OPC Clients.

The benefit to the software suppliers was the ability to reduce their expenditures for connectivity and focus them on the core features of the software. For the users, the benefit was flexibility. They don't have to create and pay for a custom interface. OPC interface products are built once and reused many times, therefore, they undergo continuous quality control and improvement.

The user's project cycle is shorter using standardized software components. And their cost is lower. These benefits are real and tangible. Because the OPC standards are based in turn upon computer industry standards, technical reliability is assured.

The original specification standardized the acquisition of process data. It was quickly realized that communicating other types of data could benefit from standardization. Standards for Alarms & Events, Historical Data, and Batch data were launched.

Current and emerging OPC Specifications include:

Specification	Description
*OPC Data Access*	The originals! Used to move real-time data from PLCs, DCSs, and other control devices to HMIs and other display clients. The Data Access 3 specification is now a Release Candidate. It leverages earlier versions while improving the browsing capabilities and incorporating XML-DA Schema.
*OPC Alarms & Events*	Provides alarm and event notifications on demand (in contrast to the continuous data flow of Data Access). These include process alarms, operator actions, informational messages, and tracking/auditing messages.
*OPC Batch*	This specification carries the OPC philosophy to the specialized needs of batch processes. It provides interfaces for the exchange of equipment capabilities (corresponding to the S88.01 Physical Model) and current operating conditions.
*OPC Data eXchange*	This specification takes us from client/server to server-to-server with communication across Ethernet fieldbus networks. This provides multi-vendor interoperability! And adds remote configuration, diagnostic and monitoring/management services.
*OPC Historical Data Access*	Where OPC Data Access provides access to real-time, continually changing data, OPC Historical Data Access provides access to data already stored. From a simple serial data logging system to a complex SCADA system, historical archives can be retrieved in a uniform manner.
*OPC Security*	All the OPC servers provide information that is valuable to the enterprise and if improperly updated, could have significant consequences to plant processes. OPC Security specifies how to control client access to these servers in order to protect this sensitive information and to guard against unauthorized modification of process parameters.
*OPC XML-DA*	Provides flexible, consistent rules and formats for exposing plant floor data using XML, leveraging the work done by Microsoft and others on SOAP and Web Services.
*OPC Complex Data*	A companion specification to Data Access and XML-DA that allows servers to expose and describe more complicated data types such as binary structures and XML documents.
*OPC Commands*	A Working Group has been formed to develop a new set of interfaces that allow OPC clients and servers to identify, send and monitor control commands which execute on a device.

What are Temperature Transmitters

2008-07-08T23:50:00.000-08:00

Temperature measurement using modern scientific thermometers and temperature scales goes back at least as far as the early 18th century, when Gabriel Fahrenheit adapted a thermometer (switching to mercury) and a scale both developed by Ole Christensen Røemer. Fahrenheit's scale is still in use, alongside the Celsius scale and the Kelvin scale.Many methods have been developed for measuring temperature. Most of these rely on measuring some physical property of a working material that varies with temperature. One of the most common devices for measuring temperature is the glass thermometer. This consists of a glass tube filled with mercury or some other liquid, which acts as the working fluid. Temperature increases cause the fluid to expand, so the temperature can be determined by measuring the volume of the fluid. Such thermometers are usually calibrated, so that one can read the temperature, simply by observing the level of the fluid in the thermometer. Another type of thermometer that is not really used much in practice, but is important from a theoretical standpoint is the gas thermometer.

Temperature transmitters, RTD, convert the RTD resistance measurement to a current signal, eliminating the problems inherent in RTD signal transmission via lead resistance. Errors in RTD circuits (especially two and three wire RTDs) are often caused by the added resistance of the leadwire between the sensor and the instrument. Transmitter input, specifications, user interfaces, features, sensor connections, and environment are all important parameters to consider when searching for temperature transmitters, RTD.Transmitter input specifications to take into consideration when selecting temperature transmitters, RTD include reference materials, reference resistance, other inputs, and sensed temperature. Choices for reference material include platinum, nickel or nickel alloys, and copper. Platinum is the most common metal used for RTDs - for measurement integrity platinum is the element of choice. Nickel and nickel alloys are very commonly used metal. They are economical but not as accurate as platinum. Copper is occasionally used as an RTD element. Its low resistivity forces the element to be longer than a platinum element. Good linearity and economical. Upper temperature range typically less than 150 degrees Celsius. Gold and Silver are other options available for RTD probes - however their low resistivity and higher costs make them fairly rare, Tungsten has high resistivity but is usually reserved for high temperature work. When matching probes with instruments - the reference resistance of the RTD probe must be known. The most standard options available include 10 ohms, 100 ohms, 120 ohms, 200 ohms, 400 ohms, 500 ohms, and 1000 ohms. Other inputs include analog voltage, analog current, and resistance input. The temperature range to be sensed and transmitted is important to consider.Important transmitter specifications to consider when searching for temperature transmitters, RTD, include mounting and output. Mounting styles include thermohead or thermowell mounting, DIN rail mounting, and board or cabinet mounting. Common outputs include analog current, analog voltage, and relay or switch output. User interface choices include analog front panel, digital front panel, and computer interface. Computer communications choices include serial and parallel interfaces. Common features for temperature transmitters, RTD, include intrinsically safe, digital or analog display, and waterproof or sealed. Sensor connections include terminal blocks, lead wires, screw clamps or lugs, and plug or quick connect. An important environmental parameter to consider when selecting temperature transmitters, RTD, is the operating temperature.

What is a Control System?

2008-07-04T07:34:00.001-08:00

In the case of linear feedback systems, a control loop, including sensors, control algorithms and actuators, is arranged in such a fashion as to try to regulate a variable at a setpoint or reference value. An example of this may increase the fuel supply to a furnace when a measured temperature drops. PID controllers are common and effective in cases such as this . Control systems that include some sensing of the results they are trying to achieve are making use of feedback and so can, to some extent, adapt to varying circumstances. Open-loop control systems do not directly make use of feedback, but run only in pre-arranged ways.

Pure logic controls were historically implemented by electricians with networks of relays, and designed with a notation called ladder logic. Nowadays, most such systems are constructed with programmable logic controllers.

Logic controllers may respond to switches, light sensors, pressure switches etc and cause the machinery to perform some operation. Logic systems are used to sequence mechanical operations in many applications. Examples include elevators, washing machines and other systems with interrelated stop-go operations.

Logic systems are quite easy to design, and can handle very complex operations. Some aspects of logic system design make use of Boolean logic.

Controller System for Industrial Automation

2008-07-04T07:29:00.002-08:00

The element linking the measurement and the final control element is the controller. Before the advent of computers, the controllers are usually single-loop PID controllers. These are manufactured to execute PID control functions. These days, the controllers can do a lot more, however, easily 80 to 90% of the controllers are still PID controllers.

Analogue vs Digital Controllers

It is indeed difficult to say that analogue controllers are definitely better than digital controllers. The point is, they both work. Analogue controllers are based on mechanical parts that cause changes to the process via the final control element. Again like final control elements, these moving parts are subjected to wear and tear over time and that causes the response of the process to be somewhat different with time. Analogue controllers control continuously.

Digital controllers do not have mechanical moving parts. Instead, they use processors to calculate the output based on the measured values. Since they do not have moving parts, they are not susceptible to deterioration with time. Digital controllers are not continuous. They execute at very high frequencies, usually 2-3 times a second.

Analogue controllers should not be confused with pneumatic controllers. Just because a controller is analogue does not mean it is pneumatic. Pneumatic controllers are those that use instrument air to pass measurement and controller signals instead of electronic signals. An analogue controller can use electronic signals. Compared to pneumatic controllers, electronic controllers (can be analogue or digital) have the advantage of not having the same amount of deadtime and lag due to the compressibility of the instrument air.

Measurements

2008-07-02T07:52:00.004-08:00

Measurement

Measurements have got to be one of the most important equipment in any processing plant. Any decision made on what the plant should do is based on what the measurements tell us. In the context of process control, all controller decisions are similarly based on measurements.

With the advent of computers, it is now possible to do inferential measurements, meaning telling the value of a parameter without actually measuring it physically. It should however, be remembered that inferential measurement algorithms are also based on physical measurements. Therefore, rather than rendering measurements redundant, they have made measurements all the more important.

Pressure Measurement

The measurement of pressure is considered the basic process variable in that it is utilized for measurement of flow (difference of two pressures), level (head or back pressure), and even temperature (fluid pressure in a filled thermal system).

All pressure measurement systems consist of two basic parts: a primary element, which is in contact, directly or indirectly, with the pressure medium and interacts with pressure changes; and a secondary element, which translates this interaction into appropriate values for use in indicating, recording and/or controlling.

An electronic-type transmitter is shown in the figure above. This particular type utilizes a two-wire capacitance technique.

Process pressure is transmitted through isolating diaphragms and silicone oil fill fluid to a sensing diaphragm in the center of the cell. The sensing diaphragm is a stretched spring element that deflects in response to differential pressure across it. The displacement of the sensing diaphragm is proportional to the differential pressure. The position of the sensing diaphragm is detected by capacitor plates on both sides of the sensing diaphragm. The differential capacitance between the sensing diaphragm and the capacitor plates is converted electronically to a 4-20 mA dc signal.

Flow Measurement

Numerous types of flowmeters are available for closed-piping systems. In general, the equipment can be classified as differential pressure, positive displacement, velocity and mass meters.

Differential pressure devices include orifices, venturi tubes, flow tubes, flow nozzles, pitot tubes, elbow-tap meters, target meters, and variable-area meters.

Positive displacement meters include piston, oval-gear, nutating-disk, and rotary-vane types. Velocity meters consist of turbine, vortex shedding, electromagnetic, and sonic designs.

Mass meters include Coriolis and thermal types. The measurement of liquid flows in open channels generally involves weirs and flumes.

Temperature Measurement

How can I measure temperature?

Temperature can be measured via a diverse array of sensors. All of them infer temperature by sensing some change in a physical characteristic. Six types with which the engineer is likely to come into contact are: thermocouples, resistive temperature devices (RTDs and thermistors), infrared radiators, bimetallic devices, liquid expansion devices, and change-of-state devices.

Why Calibrate ? Or "Calibration? How does that help me?"

2008-06-29T07:13:00.001-08:00

British scientist Lord Kelvin (William Thomson 1824-1907) is quoted from his lecture to the Institution of Civil Engineers, 3 May 1883...
"I often say that when you can measure what you are speaking about and express it in numbers you know something about it; but when you cannot express it in numbers your knowledge is a meager and unsatisfactory kind; it may be the beginning of knowledge but you have scarcely, in your thoughts, advanced to the stage of science, whatever the matter may be."

This famous remark emphasizes the importance that measurement has in science, industry and commerce. We all use and depend upon it every day in even the most mundane aspects of life -- from setting your wristwatch against the radio or telephone time signal, to filling the car fuel-tank or checking the weather forecast. For success, all depend upon proper calibration and traceability to national standards.

As components age and equipment undergoes changes in temperature or sustains mechanical stress, critical performance gradually degrades. This is called drift. When this happens your test results become unreliable and both design and production quality suffer. Whilst drift cannot be eliminated, it can be detected and contained through the process of calibration.

Calibration is simply the comparison of instrument performance to a standard of known accuracy. It may simply involve this determination of deviation from nominal or include correction (adjustment) to minimize the errors. Properly calibrated equipment provides confidence that your products/services meet their specifications. Calibration:

* increases production yields,
* optimizes resources,
* assures consistency and
* ensures measurements (and perhaps products) are compatible with those made elsewhere.

By making sure that your measurements are based on international standards, you promote customer acceptance of your products around the world. But if you're still looking to justify that the cost of calibration does add value, check-out some of the calibration horror stories that have been reported.

Paperless Calibration

2008-06-28T02:44:00.002-08:00

Bulging filing cabinets or over-full hanging files are a common office scene. But as far as calibration records are concerned, is the "paperless office" taboo ?

What do You Keep in Your Drawers ?

Most quality managers keep calibration results and certificates in their drawers! From discussions that have taken place with many people in industry whose responsibility includes the control of test instruments, a filing cabinet full of paper calibration ‘evidence’ is an integral part of the quality system -- without which audits would fail and the business would crumble. But when pressed for a rationale for such belief, three main reasons to maintain paper records emerge:

They believe that auditors would not accept any alternative
They believe that ISO9000 or accreditation agencies demand it
It is historical; they have always done it and it is a comfort factor.

Alternative Feared

During these discussions a potential alternative option based around electronic records being retained by the calibration supplier, to be provided electronically on demand, was met with a mixed reaction.

On one hand, the positive aspects of fewer papers to handle, file, retain, refresh, retrieve, etc. were enthusiastically supported. However, the conflicting dilemma that such a change might have an impact on audit success tempered that initial enthusiasm. Equipment managers' fundamental belief is that both ISO/IEC Guide 25 or EN45001 (ISO17025) and ISO9000 audit bodies would not recognize or be comfortable with such a ‘virtual’ record system. This fear alone would deter them from seriously considering any such change.

This collective feedback formed the basis of a discussion between Hewlett-Packard in Britain and senior officials from the United Kingdom Accreditation Service, the agency responsible for both accrediting calibration/test labs and overseeing quality management system registrars. The goal was to establish, for the record, whether UKAS would endorse a paperless system. The outcome of this meeting is summarized in a letter to Agilent Technologies from Brian Thomas, Technical Director of UKAS, in which he summarizes that the responsibility of the user of calibration services (the customer)

"....is to be able to demonstrate to the assessor that it can, and does when needed, obtain evidence of calibration and that it has an effective records system enabling tracking back of full calibration data and certification for the defined period."

This doesn’t mean that records are necessarily kept locally by the equipment-user in paper form but that they could, indeed, be retained by the supplier of the service and provided when needed at any time in the future. In most cases, the only data a company needs in real-time relates to parameters found to be outside the instrument’s specification when initially tested (on-receipt status) so that a potential product-recall process may be invoked. But even this doesn’t need to be provided on paper -- it could be made available to the customer via the Internet (e.g. e-mail or a secure web server) or through a variety of other electronic means (fax, floppy disk, etc.).

Control is Crucial not Mechanism

Whichever medium is most appropriate, it is the evidence of control that is imperative, not the evidence of paperwork. In Brian’s words:

"In principle, your customers would be able to contract you to retain their calibration records; this arrangement would then become part of their system for retention of records. UKAS assessment of such a customer would address whether this system provided access that was easy, quick and reliable and controlled from the point of view of security, confidentiality and accuracy. Assuming this to be so in practice then the system would be acceptable to UKAS."

This alternative solution is, therefore, one which UKAS would support provided that the customer and the supplier met some key requirements. Those requirements are concisely detailed by Brian as:

"The documentation of such records and certification is acceptable in any form of medium, hard copy, electronic, etc. provided that it is legible, dated, readily identifiable, retrievable, secure and maintained in facilities that provide a suitable environment to minimize deterioration or damage and to prevent loss."

Dispelling Reluctance

So, the voice of industry is clear. It would like to take advantage of contemporary technology by contracting-out its data and certificate storage requirements and, provided that their suppliers could satisfy their needs (echoed by the needs of UKAS above), they are willing to forego historical practices by trusting virtual documentation. But the most significant reason that they are reluctant to take this step is fear of audit failure.

Agilent Technologies believe that a major step forward would be made if quality system and accreditation consultants and assessors could advise their clients that, far from impeding audit success, such a move could enhance it -- whilst at the same time saving space, time and ultimately money for both the equipment owner and calibration provider.

Calibration, Verification or Conformance?

2008-06-28T02:41:00.002-08:00

When discussing calibration requirements with a potential supplier it's obviously important to understand what's being offered. Other articles in this section should help you to establish your requirements and distinguish the differences between available services. But one of the variations has, sometimes, even confused calibration laboratories and quality auditor. It's a matter of the difference between calibration, verification and even conformance.

Similar to the often confused specification terms accuracy and precision, a myth became "established wisdom" that calibration and verification are differentiated on the basis of quality or integrity.

* Specification terminology

Popular opinion being that verification is a quick-check of performance perhaps made without any real traceability, whereas calibration provides genuine assurance that the product really meets its specification. In fact, the US national standard ANSI/NCSL-Z540 defines "verification" as being calibration and evaluation of conformity against a specification. This definition originated with the now obsolete ISO/IEC Guide 25 but neither its replacement (ISO/IEC 17025) or the International Vocabulary of Measurement (VIM) currently have it or any alternative. The only relevant international standard that includes terminology covering the process of both calibrating and evaluating a measuring instrument's performance against established criteria is ISO10012 which uses the rather cumbersome term "metrological confirmation".

Calibration is simply the process of comparing the unknown with a reference standard and reporting the results. For example:
Applied= 1.30V, Indicated= 1.26V (or Error= -0.04V)
Calibration may include adjustment to correct any deviation from the value of the standard.

Verification, as it relates to calibration, is the comparison of the results against a specification, usually the manufacturer's published performance figures for the product. (e.g. Error= -0.04V, Spec= �0.03V, "FAIL"). Some cal labs include a spec status statement on their Certificate of Calibration. (i.e. the item did/did not comply with a particular spec).

Where no judgment is made about compliance, or correction has not been made to minimize error, it has been suggested that Certificate of Measurement would be a more descriptive title to aid recognition of the service actually performed. Some suppliers also use Certificate of Verification where no measurements are involved in the performance testing (such as for certain datacomm/protocol analyzers), rather than Certificate of Functional Test as this latter term is often perceived as simply being brief, informal checks as might be performed following a repair (often termed "operational verification").

Verification can also relate to a similar evaluation process carried out by the equipment user/owner where the calibration data are compared to allowances made in the user's uncertainty budget (e.g. for drift/stability between cals) or other criteria such as a regulation or standard peculiar to the user's own test application.

Verification is not intermediate self-checking between calibrations. Such checks are better termed confidence checks, which may also be part of a Statistical Process Control regime. The results of confidence checks may be used to redefine when a "proper" calibration is required or may prompt modification of the item's working spec as assigned by the user.

But what about conformance, especially regarding the meaning of a Certificate of Conformance ? Typically available when an instrument is purchased, it is now generally recognized that such a document has little value as an assurance of product performance. Of course, the manufacturer expects that the product conforms to its spec but, in this sense, the document simply affirms that the customer's purchase order/contract requirement has been duly fulfilled.

Uncertainty Myths

2008-06-26T07:24:00.006-08:00

MYTH	TRUTH
—Uncertainty—
ISO17025 requires that measured values and measurement uncertainty is reported on a certificate.	This is true if the certificate does not include a statement concerning the equipment's compliance to a stated specification. In this case, section 5-10-4 says that the results and uncertainty must be maintained by the lab.
We need to determine our own measurement uncertainty so need to know the calibration lab's uncertainty.	If the calibration confirmed that the instrument met the manufacturer's specification, the effect of uncertainty on that status decision has already been taken into account (as required by ISO17025, para.5-10-4-2). In this case, the user's own uncertainty budget starts with the product specification and the calibration uncertainty is not included again. If the calibrated item does not have a specification (i.e. the certificate provides only measured values) then the cal lab's uncertainty will need to be included in the user's own uncertainty analysis.
The need to know "uncertainty" is new. We've been certified against ISO9001:1994 for years and have never been asked before.	You've just been lucky or were satisfactorily meeting the requirement without realizing it ! Look again at clause 4-11-1; it clearly states that "...equipment shall be used in a manner which ensures that the measurement uncertainty is known and is consistent with the required measurement capability." For the majority of instrument users, the requirement is readily satisfied by referring to the equipment specifications. In general terms, the specification is the user's uncertainty.
The uncertainties that an accredited lab will report on a certificate are published in their Scope/Schedule.	The published capability represents the best (smallest possible) measurement uncertainties, perhaps applicable to particular characteristics and types of tested equipment. It's very unlikely that those figures would be assigned to all calibrations made assuming a wide variety of models are seen. Until measurements are made, it may not be possible for the cal lab to estimate the uncertainty that will be assigned because the unit-under-test contributes to the uncertainty.
Published "best measurement uncertainty" can never be achieved because it assumes an ideal unit-under-test.	In the past there have been different practices allowed by the various conformity assessment schemes. However, the European co-operation for Accreditation publication EA-4/02 (refer to Uncertainty Resources in this Basics section) recognizes that harmonization was required and, in Appendix A, establishes definitions. This means that, certainly within Europe, best measurement uncertainty (BMC) must include contributions associated with the normal characteristics of equipment they expect to calibrate. For example, it's not acceptable to base the uncertainty of an attenuation measurement on a device having an assumed perfect match. Some BMC's are qualified with the phrase "nearly ideal" regarding the test item but this means that the capability does not depend upon the item's characteristics and that such perfect items are available and routinely seen by the lab.
Calibrations without uncertainty are not traceable.	It is true that the internationally agreed definition of traceability includes a need for the uncertainty of the comparisons to be stated. However, it doesn't mean that a calibration certificate must include uncertainty (or measured values), as is allowed by ISO17025 and other standards if a specification compliance statement is used, although this information must be maintained by the lab.
By using a correction based on the instrument's error as determined by calibration, the working specification can be tightened. This effectively minimizes the user's own measurement uncertainty to that of the calibrating lab.	The equipment manufacturer specifications cannot be ignored. For instance, they include allowances for drift over time and environmental conditions. In contrast, the calibration represents a performance assessment at that time and in particular conditions. Yet the myth dangerously assumes that the "error" is constant despite these variables.

Calibration Myths

2008-06-26T07:24:00.004-08:00

MYTH	TRUTH
—Calibration—
A Certificate of Calibration means that the instrument met its specification, at least when it was tested. ALSO Calibration means that the equipment was adjusted back to nominal.	Whether this is correct or not depends on the calibration laboratory's service definitions or what was agreed between the supplier and customer. The international meaning of "calibration" does not require that errors detected by the measurement comparison process are corrected. It means that adjustment to return an item to specification compliance may, or may not, be performed. Unless the Certificate contains a statement affirming that the item met the published specification it is merely a report of the measurements made. In this case it is left to the equipment user to review the data against requirements. The equipment may have been found and returned to the user out-of-tolerance!
Some equipment is more expensive to have calibrated than to purchase a new one each year. Just scrap the old item which was probably worn anyway.	The first part of this assertion is TRUE but.... It could be that a calibration certificate is not provided with the new purchase. Some users are not concerned, perhaps relying upon the manufacturer's reputation to deliver new products that are specification-compliant which may be a justifiable risk. Less justifiable is the suggested practice to dispose of the old item without first getting it calibrated. How would you know if it had been used in an out-of-tolerance condition? If it had been out-of-spec, would it affect the integrity or quality of the process or end-product? If so, the proposal is a false economy !
Only measuring equipment with the possibility of adjustment needs periodic calibration. As an example, liquid-in-glass thermometers only need certification when first put into service; they either work or are broken.	Just because an item is not adjustable doesn't mean that it's perfectly stable. Some standards may be subject to wear which changes their value (e.g. a gauge block) or they may be invisibly damaged leading to non-linear or odd behavior (e.g. a cracked glass thermometer). Or the material from which they are constructed may also not be stable. For example a quartz crystal oscillator changes its resonant frequency because mechanical stress in the crystalline structure is released over time.
If an item needs routine calibration, the manufacturer states what is necessary in the equipment's handbook; otherwise calibration isn't required.	It is true that some manufacturers provide such advice (Agilent Service Manuals spring to mind ! ). But many, typically smaller, companies do not make this investment. It's unsafe to make the assumption that no advice means no calibration. Also be aware that industry practices change over time and a manufacturer's recommendations as published thirty years ago may not be as metrologically rigorous as those produced to match today's market expectations.
The original manufacturer or the calibration lab defines the appropriate calibration interval for the product or item. The user is bound by that periodicity.	It's often unrecognized that a product's specification is generally linked to a time period. Simplistically, the manufacturer may establish the specification having assessed the accuracy and drift of prototype units. It may well be statistically justified for a particular confidence level that a certain percentage of the product population (all those produced) are likely to still comply with the spec after the stated period. Whatever the mechanism used, the calibration interval is only a recommendation. Some cal labs offer a service to manage the periodicity of customers' equipment based on the accumulated cal history. Otherwise, this risk management responsibility remains with the user.
Safety regulations stipulate the legal maximum period allowed between cals to be one year.	The problem with such a policy is that it may be implemented differently to what is intended. Maybe all items will be assigned a one year interval without any regard for its justification or applicability to the use of a particular piece of equipment? The assignment of a suitable interval should be recognized as part of an equipment user's risk management strategy. One must consider the knock-on effects if the item is later found to have been used in an out-of-tolerance condition (e.g. product recall costs). So, there's a balance to be achieved between the inconvenience and cost of excessive calibration and impact of unreliable kit. In safety-critical applications any degree of risk may be unacceptable but this would probably be implemented by parallel and back-up systems. Total reliance upon a single piece of equipment, even if tested every day, would be unusual.

Standards Myths

2008-06-26T07:19:00.002-08:00

MYTH	TRUTH
—Standards—
ISO17025 states that it's equivalent to ISO9000 so ISO9000 must be equivalent to ISO17025.	ISO17025 does indeed state, in its Introduction and in paragraph 1-6, that compliance with the standard means that the laboratory's quality system for their calibration or testing activities also meets the criteria of ISO9001/2. Two points to emphasize though: The activities of many service providers extends beyond just calibration or testing (e.g. repair, supply of parts, training, etc.) where 17025 does not apply. The equivalence is to the 1994 version of the ISO9000 standards which was superseded in late 2000.
My factory's quality system complies with ISO9000 so all my equipment must be calibrated "Before & After"adjustment.	A calibration service that provides assessment of the product's performance on-receipt and, if necessary, after adjustment or repair has been completed has two purposes. It enables analysis of the equipment's stability over time. More significantly, if the on-receipt performance did not meet the user's accuracy requirements, an investigation of its impact can be triggered that may result in product or work recall. These possibilities need only apply to equipment affecting the quality of the factory's product or service, for example that used for alignment or end-of-line inspection. Understanding the distinction can save a lot of money !
Accreditation agencies define the extent of testing for various products so that users can have confidence in their equipment's overall performance.	In some countries there are national and regulatory standards that are applicable to some measuring equipment. These usually relate to legal metrology (i.e. measurements made in the course of consumer trade) or statutory codes (e.g. safety) or certain sectors of industry. However, accreditation bodies do not stipulate that these must be used although labs would generally do so where applicable. Also, there are no standards concerning the typical general purpose instruments that may be used in the electronics industry, for example. Although accreditation criteria includes a need for calibration certificates to draw attention to limitations in the scope of testing performed versus the product's capability, it is left to the client and supplier to agree the content of the service. Whether the calibration utilizes any recommendations of the equipment's manufacturer is part of this negotiation.
My calibration supplier is ISO17025 accredited so all the calibrations they undertake meet that standard.	The results of a calibration performed under the scope of the accreditation are reported on a certificate bearing the authorized brand-mark of the accreditation program. For commercial reasons, most accredited laboratories offer at least two calibration service levels -- a certificate with the accreditation logo or a company-proprietary certificate. The processes used to undertake the calibration and the extent of testing may be the same in both cases, or may differ. Some accreditation programs allow the inclusion of (a minority of) measurements which are not within the lab's accredited capability, providing they are clearly identified as non-accredited.
Results which are simply reported as "Pass" or "Fail" are not acceptable.	Recording of numerical measurement data is not relevant for some tests. This may be because it's of the "go, no go" type (e.g. checking a bore using a plug gauge) or because the test procedure establishes known test conditions and looks for satisfactory response in the unit-under-test (e.g. checking input sensitivity of a frequency counter by applying a signal whose amplitude equals the specified sensitivity and noting whether stable triggering is observed). To summarize, pass/fail is valid where the decision criteria is defined (i.e. specification limits).
A supplier that has an ISO9000 certificate is good enough.	This may be reasonable but questions concerning the scope of the certification should be asked. If the quality system that was assessed related to a company's pressure sensor manufacturing operation in Chicago, how much assurance does that endow on micrometer service at their Dallas repair office? Possibly none! The scope of registration is explicit in coverage.
Only accredited calibrations are traceable to national standards.	Traceable measurements are those supported by records that can demonstrate an unbroken series of calibrations or comparisons against successive standards of increasing accuracy (reducing uncertainty) culminating in a recognized national metrology institute. Measurement traceability is, of course, also reviewed as part of an ISO9000 quality system certification.
My own testing laboratory is accredited against ISO17025 so our instruments must be calibrated at an accredited lab.	This may depend upon the interpretation of the standard by the particular accreditation body. Clause 5-6-2-1-1 of ISO17025 does not actually stipulate that traceability must only be obtained from an accredited facility only that the supplier "can demonstrate competence, measurement capability and traceability". The British accreditation agency has confirmed that it will not add supplementary requirements to the 17025 criteria. It also accepts the possibility of traceability to a non-accredited source provided that sufficient evidence is available to UKAS to confirm that the supplier complies with the standard and that the lab being audited by UKAS has the critical technical competence to make such an assessment.

Uncertainty Made Easy

2008-06-26T07:16:00.001-08:00

About this Article
This paper by Ian Instone was first presented at the Institution of Electrical Engineers, London in October 1996 at their Colloquium entitled "Uncertainties made easy".
Note: Details of the current versions of recommended uncertainty guidance publications can be found on the Uncertainty Resources page in this section.

Simplified Method for Assessing Uncertainties in a Commercial, Production Environment

Introduction

With the introduction of Edition 8 of NAMAS document NIS3003 ⁽¹⁾ and the inclusion of the principles outlined in the ISO Guide to the Expression of Uncertainty in Measurement ⁽²⁾ the assessment of uncertainties of measurement has become a task more suited to a mathematician rather than the average calibration engineer. In some companies with small calibration departments it might be possible for all of the engineers to be re-educated in assessment of uncertainties, however, in larger laboratories it is more usual for various engineers to become specialist in certain aspects of the calibration process. This paper aims to demonstrate a simplified approach to uncertainty assessment which falls broadly within the guidelines set out in both NIS3003 and the ISO Guide.

One of the first stumbling blocks in NIS3003 is the necessity to derive a measurement equation. Whilst it is agreed that this is a useful skill which might demonstrate a more thorough understanding of the measurement principles, it seems only to serve as an additional step in the uncertainty assessment process, steps which were not thought necessary in previous 7 editions of NIS3003. The next step, deriving sensitivity coefficients by the use of partial differentiation will cause most calibration engineers to reach for the mathematics text book. Fortunately, in many cases these two steps can be replaced using a more practical approach. A list of contributions to the uncertainty budget can be used in place of the measurement equation and each term may be partially differentiated by varying the quantity over its range and measuring its influence on the measurand. For instance, it may have been determined that temperature variations have an influence upon the quantity being measured then, rather than produce a measurement equation which includes temperature and partially differentiate it, one can simply perform the measurement, change the temperature by the specified amount and re-measure. The resultant change in the measurand becomes a contribution to the uncertainty budget. There are also cases where the same approach may be used but where there may be no necessity to perform the measurements to obtain the data. For instance, many resistors have a temperature coefficient specification, in the form of ±N parts per million per degree Celsius. Assuming the temperature is controlled to within ±2°C the change in the value of the resistor due to temperature fluctuations will be given by:-

N parts per million x 2°C

Most contributions to an uncertainty budget can be assessed using either method. The practical method described will often yield smaller values because they are based on measurements performed on only a small quantity of items, where as the latter method is based upon the equipment specification which should cover the entire population of that instrument and so will normally produce larger contributions to the uncertainty budget.

Type-A Uncertainties

In a commercial calibration laboratory often it is not economical to perform several sets of measurements on a particular instrument solely to produce a value for the random (Type-A) uncertainty contribution. The alternative method shown in NIS3003 is preferred and usually employed where possible. In cases where multiple measurements are performed it is usual practice to calculate the standard deviation of the population. The estimated standard deviation of the uncorrected mean of the measurand is then calculated using:

E_sd = P_sd / sqrt(N)

Where:
E_sd is the estimated standard deviation of the uncorrected mean of the measurand
P_sd is the standard deviation of the population of values
N is the quantity of repeated measurements

When the quantity of measurements to be performed on the equipment being calibrated is limited to one set of measurements then N in the equation above will be 1. The standard deviation of the population P_sd will previously have been determined from an earlier Type-A evaluation based upon a large number of repeated measurements. In an ideal world the measurements would be repeated on several instruments within the family and the worst case standard deviation used in the Type-A assessment. In practice however, providing the assessment techniques outlined in this paper are employed, the Type-A contribution to the uncertainty budget can often be shown to be negligible so the need to make a very large number of repeated measurements is reduced.

In the ideal world where customers are willing to pay unlimited amounts of money for their calibrations, or where we have very large quantities of similar instruments to calibrate it is a fairly simple matter to measure several instruments many times and obtain a good reliable estimate for the standard deviation. In reality, customers have limited budgets and calibration laboratories rarely have even small quantities of particular instruments which can be used for extensive testing to provide a good and reliable estimate of the standard deviation. Another simpler, and more cost effective method is required.

Before embarking upon the assessment of uncertainties we need to understand exactly what our customer is expecting of their calibration report and what use they will make of it. For the majority of simple reference standards such as resistors, standard cells, capacitors etc. it is likely that the measured values will be used by the customer so an uncertainty assessment as defined by NIS3003 will be required. For the great majority of instruments it is often not possible to make any use of the values obtained during its calibration so it is usually only necessary to provide a calibration which demonstrates that the instrument is operating within its specifications. In these cases it is usually not necessary to provide measurements with the lowest measurement uncertainties, which allows some compromises to be made.

ISO 10012-1 ⁽³⁾ suggests that we should aim for an accuracy ratio between uncertainty and the instrument being calibrated of greater than 3:1. The American interpretation of ISO Guide 25 ⁽⁴⁾, ANSI Z540-1 ⁽⁵⁾suggests that uncertainties become significant when the accuracy ratio is less than 4:1. If we assume that the instrument specification has the same coverage factor as the uncertainty the following expression would describe the resultant combination of the uncertainty and specification which should be used when the instrument is used to make measurements:

§ = sqrt [ S ² + U ² ]

Where:
§ is the resultant expanded specification resulting from the calibration
S is the specification of the parameter being measured
U is the uncertainty of measurement when performing the calibration

In the cases where S >= 4U the effect of the uncertainty upon the specification is shown to be negligible, for instance assume that S = 8 and U = 2 then:

§ = sqrt [ 8 ² + 2 ² ]
= sqrt [ 64 + 4 ]
= sqrt [ 68 ]
= 8.25

Therefore, with an accuracy ratio of 4:1 the effective specification expands by 3.1%. As most uncertainties are only quoted using two figures it is unlikely that this small increase would have any effect. Repeating the same with an accuracy ratio of 3:1 produces an increase of only 5.2%.

The same analogy can be used when assessing the significance of a particular uncertainty contribution. Type-A uncertainties are those assessed using statistical methods usually based on many sets of measurements, thereby making them the most expensive to assess. Using the model above we can show that Type-A uncertainties are insignificant when they are less than 30% of the magnitude of the Type-B uncertainties:

Total Uncertainty = Type-B uncertainties where Type-A <>

and:

Effective Specification = Specification where Total Uncert <>

From above we can show that Type-A uncertainties can be regarded as insignificant when they are less than 0.09 of the specification being tested, or in approximate terms Type-A uncertainties can be regarded as negligible when they are less than 10% of the specification.

Verifying that an uncertainty contribution is less than a given value is usually much easier than assessing the precise magnitude of it. One method described in an earlier paper ⁽⁶⁾normally requires only two complete sets of measurements to be made on the same instrument. One set of measurements are then subtracted, one measurement at a time from the other set. The largest difference is then assumed to be a conservative estimate of the Type-A uncertainty contribution. This technique has been verified many times against uncertainties assessed in the traditional way and has always produced an acceptable conservative estimate of the Type-A contribution, providing that an adequate quantity of measurements are compared across the range. Assuming that the comparison produces no values that are outside the limits defined earlier (10% of the DUT specification or 30% of the Type-B uncertainty estimate) it can be assumed that the Type-A uncertainties are not significant. To provide good confidence and consistency in the assessment process the value defined as insignificant should always be included in the assessment.

It is also possible to use values for the Type-A assessment gained from other, related instruments providing some knowledge of the construction of the instrument under test is available. For instance, it may be that a laboratory has already assessed a certain 50MHz to 18GHz signal generator and verified that the Type-A uncertainty contribution meets the criteria outlined above. A 12GHz signal generator from the same family is then submitted for assessment. In this case, providing the two signal generators share similar designs, and use similar hardware and layouts, and the same test methods and equipment are used it would be reasonable to employ the 18GHz Type-A assessment on both generators. In other cases it might be possible to refer to published data for certain Type-A contributions.

In cases where these techniques reveal that the Type-A contributions are significant (as defined above) the uncertainty assessment should be performed in the usual way using many repeated measurements.

Sensitivity Coefficient

In most cases sensitivity coefficients can be assumed to be 1. However there are some notable exceptions where other values will be used. One of these relates to the measurement of resolution bandwidth on a spectrum analyzer. In this case we have measurement uncertainties expressed in two different units; measurements of amplitude are expressed as an amplitude ratio (usually in dB units) and measurements of frequency (in Hz.). The bandwidth measurement is often performed by applying a "pure" signal to the analyzer's input and setting the controls so that the signal shown below is visible. The envelope describes the shape of the filter and normally we would measure the 3dB or 30% (below the reference) point of it (shown on the left of the figure below). To assess the sensitivity coefficient we need to determine the gradient of the graph at the measurement point. Spectrum analyzers often have an amplitude specification of 0.1dB per 1dB, therefore the amplitude uncertainty at 3dB will be ±0.3dB or ±7%. We then move ±7% from the 70% point and read off the resultant change in frequency.

The resultant change in frequency due to amplitude uncertainty is: ±3.8 frequency units. Since this value has been found for an amplitude specification of ±0.3dB it will have a sensitivity coefficient of 1.

On the right of the figure is a similar construction for assessing the frequency uncertainty due to the amplitude uncertainty when the 6dB (50%) point is measured. In this case the amplitude uncertainty increases to ±0.6dB (0.1x6). As a linear ratio this equates to ±13%.

Reading from the graph this represents a frequency uncertainty of ±6 frequency units.

Assessing the uncertainty contributions in this way greatly reduces the possibility of errors as might occur if following the theory using partial differentiation. In addition a practical technique such as this is preferred by most calibration engineers.

Other empirical means of obtaining values for the uncertainty budget may also be employed. For instance it might be possible to establish a value for temperature coefficient by changing the environmental temperature by a few degrees. In this case we could derive a sensitivity coefficient for the output signal in terms of temperature change.

Total Uncertainty Budget

One of the principle benefits of the latest revision of NIS3003 is the strong suggestion that all of the uncertainty contributions should be listed in a table along with their probability distribution. Whilst at first sight this seems a tedious task, it pays dividends in the future because it makes the contributors to the budget absolutely clear. The table below shows a typical example of an uncertainty assessment for a microwave power measurement at 18GHz using a thermocouple power sensor. These types of power sensor measure power levels relative to a known power so a 1mW, 50MHz power reference is included on the power meter for this purpose. In most cases it is simpler and more correct to use a measuring instruments specification rather than try to apply corrections and assess the resultant uncertainty. For the majority of measurements it is not possible to make corrections based upon a calibration report as that report only indicates the instruments calibration status at the time it was measured and only when operated in that particular mode described on the certificate. It is not possible to predict the errors at any other points.

Symbol	Source of Uncertainty	Value ± %	Probability Distribution	Divisor	C_i	U_i± %
K	Calibration factor at 18 GHz	2.5	normal	2	1	1.25
D	Drift since last calibration	0.5	rectangular	sqrt(3)	1	0.29
I	Instrumentation Uncertainty	0.5	normal	2	1	0.25
R	50 MHz Reference spec.	1.2	rectangular	sqrt(3)	1	0.69
Mismatch loss uncertainties:
M₁	Sensor to 50 MHz Reference	0.2	U-shaped	sqrt(2)	1	0.14
M₂	Sensor to 18 GHz Generator	5.9	U-shaped	sqrt(2)	1	4.17

A	Type-A Uncertainties	2.1	normal	2	1	1.05

U_C	Combined Standard Uncertainty		normal			4.55
U	Expanded Uncertainty		normal (k=2)			9.10

Where:

C_i is the sensitivity coefficient used to multiply the input quantities to express them in terms of the output quantity.

U_i is the standard uncertainty resulting from the input quantity.

The standard uncertainties are combined using the usual root-sum-squares method and then multiplied be the appropriate coverage factor (in this case k=2). In some cases it will be appropriate to use a different coverage factor, perhaps when a 95% confidence level is not adequate, or sometimes when the input quantities are shown to be "unreliable". The V_i (degrees of freedom of the standard uncertainty) or V_eff (effective degrees of freedom) column has not been included in the table above in order to simplify the assessment process.

Degrees of Freedom

Degrees of freedom is a term used to indicate confidence in the quality of the estimate of a particular input quantity to the uncertainty budget. For the majority of calibrations performed under controlled conditions there will be no need to consider degrees of freedom and a coverage factor of k=2 will be used. In cases where the Type-A uncertainty has been assessed using very few measurements a different coverage factor, using the degrees of freedom, would normally be calculated. However, whilst the assessment method proposed in this paper is based on only two sets of measurements being performed experimental data confirms that this treatment (taking the worst case difference) produces a reliable, conservative estimate of the Type-A uncertainties. In most cases the degrees of freedom can be assumed to be infinite and the evaluation of the t factor using the Welch-Satterwaite equation would not be necessary. NIS3003 provides some guidance on using these methods but does stress that normally it is not necessary to employ them.

Conclusion

The uncertainty assessment method described in this paper have been employed at Hewlett-Packard's UK Service Center for several years. External, internal and informal measurement audits have in every case provided confirmation that the uncertainties are being estimated with the expected level of confidence. This simplified approach is easier to understand and use which enables more calibration engineers to contribute fully to the uncertainty assessments.

References

The expression of Uncertainty and Confidence in Measurement for Calibrations, NIS3003 Edition 8 May 1995.
Guide to the Expression of Uncertainty in Measurement. BIPM, IEC, IFCC, ISO, IUPAC, OIML. International Organization for Standardization. ISBN 92-67-10188-9. BSI Equivalent: "Vocabulary for Metrology, Part 3. Guide to the Expression of Uncertainty in Measurement", BSI PD 6461: 1995.
Quality assurance requirements for measuring equipment, Part 1. Metrological confirmation system for measuring equipment, ISO 10012-1:1992.
Calibration Laboratories and Measuring and Test Equipment - General Requirements ANSI/NCSL Z540-1-1994.
General requirements for the competence of calibration and testing laboratories, International Organization for Standardization, ISO Guide 25:1990.
Calculating the Uncertainty of a Single Measurement from IEE Colloquium on "Uncertainties in Electrical Measurements", 11 May 1993, Author Ian Instone, Hewlett-Packard.

Measuring Language

2008-06-26T07:15:00.000-08:00

Metrologists spend so much time numerically quantifying physical phenomena, that the opportunity to consider the language used to actually quantify may be a welcome diversion. We start by assigning values to some comparative terms.

But how many is some ? Perhaps six or seven ? Well, it's probably more than several, so let us assume that several is four or five. And how many is a few ? Most consider it to be less than several and therefore certainly less than some. But it's more than two, since two is definitely a couple. By these terms a few must be three or four.

Reference to a handy Oxford English Dictionary reveals that some is "an appreciable or considerable number". Surprising since, conversely, sometimes isn't generally felt to be very often. Indeed, the OED defines the frequency of sometimes as "at one time or other". Seemingly, some has a serious lack of stability, having the duality of being both a large and small quantity at once. Given this, you'd need to be quite an optimist to ask for some apple pie.

Which leads us to wonder about that quite qualifier. Quite, when relating to a lot (many) diminishes the lot; quite a lot clearly being less than a lot. Similarly, quite big is smaller than simply big and also, quite good being rather poorer than good.

However, quite when used to qualify virtue, increases the degree of trueness; quite correct being more right than just correct. Likewise, probably is more probable when it is quite probably. And on the subject of confidence, just right attributes a higher degree of perfection than something that is only right. By reversing the phrase and with only an additional pause, as in "right... just", it's possible to convey a sense of barely satisfying the requirement.

A more interesting observation concerns opposites which we came upon quite by chance and which is, evidently, more extraordinary than doing so by chance. Consider valid. Quite valid is marginally less valid than valid but quite invalid is far more invalid than invalid. At the same time, quite true is truer than true; quite untrue more untrue than untrue.

By combining the foregoing propositions we can address the question of how many is quite a few? It seems to be more than a few and, alarmingly, this may then encroach on the ground occupied by several. Since quite several is nonsensical whereas quite some is more than some (albeit colloquially for emphasis, as in "That is quite some building"), it stands to reason that several misses out a bit (a bit being less than quite a lot but more than nothing).

The entire discussion serves to illustrate the imprecision of language; it has uncertainty. But to what degree? Well, certain suggests definite (=100%) but uncertain doesn't mean impossible (>0%), so maybe tends towards 50%. If certain equates to 100% and uncertain lies in the range 30-70%, might risky reflect 5-30%? But what is something having higher confidence than uncertain but not the absolute assurance of certain? Hmmm... language guardbands are required. Some metrologists are quite certain of that, surely?

And you thought the language of measurement was difficult !

A History Lesson

2008-06-26T07:12:00.000-08:00

IN THE BEGINNING was created the Imperial Ton
= 2240 pounds (lbs.)
= 20 Hundredweight (cwt) i.e. 1 cwt = 112 lbs.
AND YEA, when the Pilgrim Fathers landed on Plymouth Rock, they said
VERILY: One Hundredweight should be one hundred pounds and one Ton should be 2000 lbs.
THUS WAS CREATED the US Ton.
BUT SORELY DISPLEASED were the merchants and traders when they became aware that the colonials were making 10% on the side.
THUS IT CAME TO PASS that the British traders did declare that their galleons would, in future, also use measures of 2000 lbs, and declared that this measure should be named the Short Ton.
MANY MOONS PASSED, and the tribes of Europe did send their high priests to council one with the other, whereupon they begat the EEC (EU).
THE TRIBES OF THE CONTINENT did pour scorn upon the Ton and the Short Ton, and being more in number than the Britons did ordain that all nations should obey The New Commandment: Thou shalt worship the Tonne which equates to 1000 kilograms (kg).
THIS DID SORELY DISPLEASE THE BRITONS, since this new measure did contain 2205 lbs., but it came to pass that more tribes came to join the EEC and the Britons were obliged to pay homage to the Tonne.
THE EEC DID COMMAND that tablets of stone be carved, on which was writ:
1 IMPERIAL TON = 2240 lbs.
1 SHORT TON=1 US TON = 2000 lbs.
1 TONNE = 1000 kg = 2205 lbs.
THUS WAS THE CONFUSION CREATED.

Amen

Factors Influencing Automation Projects

2008-06-21T07:38:00.004-08:00

Here's a good powerpoint presentation about Factors Influencing Automation Projects. It tackles matters on DCS, PLC, SCADA, Industrial Local Area Networking, Standards and others. Greats for basic discussions!

Download Now!

Calibration Basics!

2008-06-20T08:32:00.005-08:00

The following is a presentation from National Instrument’s Test Equipment Summit that serves as a good primer on calibration. It explains all the basic concepts and terms in respect to incorporating calibration in best practices and ensuring product quality

What is Calibration?

Definition: Calibration is the comparing of a measurement device (an unknown) against an equal or better standard. A standard in a measurement is considered the reference; it is the one in the comparison taken to be the more correct of the two. One calibrates to find out how far the unknown is from the standard.

Typical Calibration: A “typical” commercial calibration references a manufactures calibration procedure and is performed with a reference standard at least four times more accurate than the instrument under test.

Why Calibrate?
Calibration is an Insurance Policy.

Some people consider calibration a necessary annoyance to keep the auditor off their back. In fact, out of tolerance (OOT) instruments may give false information leading to unreliable product, customer dissatisfaction and increased warranty costs. In addition, OOT conditions may cause good products to fail tests, which ultimately results in unnecessary rework costs and production delays.

Calibration Terms
Common calibration terms

Out of Tolerance Conditions: If the results are outside of the instrument's performance specifications it is considered an OOT (Out of Tolerance) condition and will result in the need to adjust the instrument back into specification.

Optimization: Adjusting a measuring instrument to make it more accurate is NOT part of a “Typical” calibration and is frequently referred to as “Optimizing” or “Nominalizing” an instrument. (this is a common misconception) Only reputable and experienced calibration providers should be trusted to make adjustments on critical test equipment.

As Found Data: The reading of the instrument before it is adjusted.
delays.

As Left Data: The reading of the instrument after adjustment or “Same As Found” if no adjustment was made.

Without Data: Most calibration labs charge more to provide the certificate with data and will offer a “No-Data” option. In any case “As-Found” data must be provided for any OOT condition.

Limited Calibration: Sometimes certain functions of an instrument may not be needed by the user. It may be more cost effective to have a limited calibration performed (This can even include a reduced accuracy calibration).

TUR - Test Uncertainty Ratio: The ratio of the accuracy of the instrument under test compared to the accuracy of the reference standard.

ISO 9000 Calibration
ISO 9000 calibrations are crucial for many industries. The following is required for ISO 9000 Compliant Calibrations.

An Accredited Calibration Lab Performing the Work: The calibration laboratory employed to perform the calibration must be an ISO 9001:2000 accredited lab or be the original equipment manufacture.

Documented Calibration Procedures: It is critical that a valid calibration procedure be used based on the manufacture’s recommendations and covering all aspects of the instrument under test.

Trained Technicians: Proper Training must be documented for each discipline involved in performing the calibration.

Traceable Assets: The calibration provider must be able to demonstrate an unbroken chain of traceability back to NIST.

Proper Documentation: All critical aspects of the calibration must be properly documented for the certificate to be recognized by an ISO auditor.

A Comprehensive Equipment List: For any manufacture to pass an ISO audit regarding calibration they must demonstrate that they have a comprehensive equipment list with controls in place for additions, subtractions and custodianship of equipment.

Calibrated and NCR Items Properly Identified: The equipment list must identify any units that do not require calibration and controls must be in place to ensure that these units are not used in an application that will require calibration.

A Proper Recall System: A procedure should be established with timeframes for recall notification, an escalation procedure, and provisions for due-date extension.

Equipment Custodianship: responsibilities for ensuring the equipment is returned to the cal lab should be assigned and delegated.

An OOT Investigation Log: Any instrument found out of tolerance requires that an investigation be performed to determine the impact on manufacturing. Records and reports need to be maintained.

ISO/IEC 17025 Calibration
ISO/IEC 17025 Calibration: As a general rule 17025 calibrations are required by anyone supplying the automotive industry and it has also been voluntarily adopted by numerous companies in FDA regulated industries.

ISO/IEC 17025 is an international standard that assesses the technical competency of calibration laboratories. ISO/IEC 17025 covers every aspect of laboratory management, ranging from testing proficiency to record keeping and reports. It goes several steps beyond a ISO 9001:2000 certification.

A “17025” calibration is a premium option that provides additional information about the quality of each measurement made during the calibration process by individually stating the uncertainty calculation of each test point.

Calibration Intervals
How Calibration Intervals are Determined

Calibration intervals are to be determined by the instrument “owner” based on manufacture recommendations. Commercial calibration laboratories can suggest intervals but in most cases they are not familiar with the details of the instrument’s application.

The OEM intervals are typically based on parameters like mean drift rates for the various components within the instrument. However, when determining calibration intervals as an instrument “owner” several other factors should be taken into consideration such as: the required accuracy vs. the instrument’s accuracy, the impact an OOT will have on the process, and the performance history of the particular instrument in your application.

How to Implement or Improve a Calibration Program
Any successful calibration program must begin with an accurate recall list of your test, measurement and diagnostic equipment.

The recall list should contain a unique identifier which can be used to track the instrument, the location, and the instrument’s custodian (Often asset management software, bar-coding systems, and physical inventories are used to help establish accurate recall lists).
It is important when assembling a recall list that modules, plug-ins, and small handheld tools are not overlooked. Also, you may have several “home-made” measuring devices (e.g. Test Fixtures) which will also need to be captured on your equipment list for a reliable calibration program.
The next step is to identify all of the instruments on your recall list which may not require calibration due to redundancies in your testing process (A commercial calibration laboratory should be able to aid you in identifying these instruments).
After creating an accurate recall list procedures must be established for adding new instruments, removing old or disposed instruments, or making changes in instrument custodianship. Recall reports should be run with sufficient time for both the end user and the service provider to have the unit calibrated with a minimal impact on production.
A late report identifying any units about to expire or already expired will ensure 100% conformity. A full service calibration laboratory will supply these recall reports and will provide special escalation reporting when equipment is not returned for service.
(Some calibration labs offer the choice of web-based equipment management systems that allow their customer to perform recall reports, late reports and keep electronic versions of their calibration certificates.)

Avoiding Production Delays
Obtain timely equipment calibrations without shutting down a line for days.

Look for a calibration service provider that can perform onsite (or in-place) calibrations at your facility. Often when your volume is more than 20 calibrations, scheduling onsite calibration saves time and lowers cost.
Make sure you find a “one-source” calibration provider that has sufficient capabilities to calibrate nearly all of your equipment during the onsite, reducing the delays and the expense of using an additional subcontractor.
Other options for reducing downtime include mobile Calibration lab services, scheduled depot calibrations, calibrations during shutdowns, scheduled pick-up and delivery, and weekend or nightshift calibrations.

Should We Calibrate Ourselves?
Most companies discover they cannot effectively perform their own calibrations for many reasons. The most frequent issues with internal calibrations are:

Cost of standards: Often, the cost of the assets with the required accuracy to perform the calibration is prohibitive (It could take years of calibrations to pay for one standard).

Developing Procedures: Many manufacture’s procedures are not readily available. Sometimes they require research and development. This can cost hundreds of hours of labor.

Productivity of Technicians: Often a non-commercial calibration laboratory’s productivity per employee is only a fraction of what can be obtained through an external commercial calibration laboratory who specializes in automation, efficient procedures and experienced management.

Cost of Management: Managing the employees, assets, maintenance and processes of a calibration lab can be burdensome on existing management staff.

Not a core competency: The overall management burden of the operation distracts from the core competency of the company.

HOW TO RECRUIT THE RIGHT PERSON FOR THE JOB?

2008-06-18T02:34:00.001-08:00

Put about 100 bricks in some
Particular order in a closed
Room with an Open window.

Then send 2 or 3 candidates in
The room and close the door.

Leave them alone and come back
After 6 hours and then analyze
The situation.

If they are counting the Bricks.
Put them in the accounts Department.

If they are recounting them..
Put them in auditing.

If they have messed up the
Whole place with the bricks.
Put them in engineering.

If they are arranging the
Bricks in some strange order.
Put them in planning.

If they are throwing the
Bricks at each other.
Put them in operations.

If they are sleeping.
Put them in security.

If they have broken the bricks Into pieces.
Put them in information Technology.

If they are sitting idle.
Put them in human resources.

If they say they have tried Different combinations, yet
Not a brick has Been moved. Put them in sales.

If they have already left for The day.
Put them in marketing.

If they are staring out of the Window.
Put them on strategic Planning.

And then last but not least.
If they are talking to each
Other and not a single brick
Has been Moved.

Congratulate them and put them
In top management

The Supervisor

2008-06-15T01:15:00.003-08:00

Any one working for any industry who started in a low ranking position have experienced under the management of its supervisor/s. These people are one of the key personnel in the life of its subordinates' career path. They are the one who unconsciously mold the thinking and actions of the people under him or her. They are the link between the upper management and the rank and file workers of a said organization. The supervisor can upgrade and inspire a rank and file personnel in terms of working attitude and views towards life or degrade it and demoralize that person or even still would pose as a nothing and stagnant to the working environment.

There are different kinds of supervisor that I have encountered now and in the past several years as a member of the working industry. The following are the different supervisor and their relationship towards its subordinates.

The Technical Supervisors - This type utilizes their skills particularly in the field that they manage in view of his team. These supervisors possesses skills and knowledge more than his or her men acquired abilities. He can do more almost most of the time what his subordinates can and can effortlessly explain technical theories regarding work. He leads by setting himself as an example. He can do work as part of the working team and rely mainly on his team somewhat for their manpower. This type of supervisor can inspire his team. He is very-well known towards other technical guys and operators but not so in the higher management for he is usually always on the work and can be barely make detailed reports with his name on it. This is one indispensable guy in terms of industry's operations.

The Signatory Supervisors - Yes, that's what they do. They just sign documents. These people are the major demoralizers of the department they are in to. These type of supervisors have lots of 'friends' from the upper management because they do it on paper. And paper can last for several years. They are almost always untechnical and rely mostly on the output of its subordinates. They cannot withstand being alone in the work area for fear that a job order might come in an emergency status and he is the only there to attend work to and has no-how of the job. These type of supervisors usually get the merit for their men's output. Are you one of them?
The Seminarian - Yeah, you heard it right. This one attends seminars for most of the time of his work schedule. This type is barely in his office and is always attending conferences and seminars either on technical or work enhancement programs. He is 'securing' his future if you know what I mean. The workers on the other hand are now practicing "Can work without supervision". It's up to the supervisor to apply what he learned during those times.

The Call Center Agent - This person answers calls and almost most of the time! He is always by the phone and be the first one to grab it when it rings. He stays by his table and just chatter away the time. I wonder what in the phone?

The Be One of Us - This guy has strategy. And his strategy could be his rise or fall. He is willing to be with his guys through thick and not so thin. He tolerates mistakes and allow it within his premises for fear that his men would go on sit down strike. What I mean is that type of supervisor would allow his men to do anything as long as they do their work very well when ordered to and be not caught by the higher management. Once one of his would get caught though, he always comes out clean and would never know anything about it once questioned. Do you know some who is like this? Let me know!

I am In-Command, do you HEAR? - This guy shows power! He can shout and point a finger at you for a job not well done. His men are always in fear that he might report something to the higher management which can either put disciplinary actions toward someone. He cannot expect to put to action the full potential of his team though. This usually happens when the age gap between the supervisor and its rank and file personnel are a bit wide.

These are the types of supervisors that I have encountered with yet either directly or indirectly. Each has its own advantage and disadvantage. One can be a mix of two or three or four of these qualities. Do you have other kinds as well? Or are you one of them? Smile...

Pulse Generator Model M938

2008-06-13T04:12:00.005-08:00

Pulse Generator
Model M938 IR-600PPR
12-15VDC, 140mA

PINOUTS

A = VDC Ground
B = +VDC
D = Channel 1
E = /Channel 1
G = Channel 2
H = /Channel 2

Encoder inside Pulse Gen. made by:
Data Technology, Inc.
Made in USA
Model: RS23-600-40/15-L203
S/N: 8911421

Wirings:
Color Function
Red +VDC
Black DC Gnd
White A Output
Green B Output
Brown/Orange Z Out/NC

Printed Circuit Board Card inside Pulse Gen.
(Part Numbers)
Q1~Q4 = 2N660
VR1 = LM340K-80
U1 = CD4041UBE
R1~R4 = BR/BK/RED = 1K ohms
CR1~Cr4 = 1N4003
C1, C2 = 244M

Industrial Views!!!

2008-06-10T10:53:00.008-08:00

Got here some pictures while on duty in the steel company I'm currently connected with. I was going to the control room via the path where those big transformers are situated around the area where it would provide power to 5000hp DC motors. I usually take this short cut than to go around the building where it would take 10 minutes to walk to the said control room from my office. Here, it would just cut offed the time to 3 to 5 minutes. So here are the pictures...

more will be posted soon!

the LVDT

2008-06-09T00:36:00.002-08:00

LVDT

The Linear Variable Differential Transformer is a position sensing device that provides an AC output voltage proportional to the displacement of its core passing through its windings. LVDTs provide linear output for small displacements where the core remains within the primary coils. The exact distance is a function of the geometry of the LVDT.

Theory of Operation

An LVDT is much like any other transformer in that it consists of a primary coil, secondary coils, and a magnetic core. An alternating current, known as the carrier signal, is produced in the primary coil. The changing current in the primary coil produces a varying magnetic field around the core. This magnetic field induces an alternating (AC) voltage in the secondary coils that are in proximity to the core. As with any transformer, the voltage of the induced signal in the secondary coil is linearly related to the number of coils. The basic transformer relation is:

(1)

where:: Vout is the voltage at the output,; Vin is the voltage at the input,; Nout is the number of windings of the output coil, and; Nin is the number of windings of the input coil.

As the core is displaced, the number of coils in the secondary coil exposed to the coil changes linearly. Therefore the amplitude of the induced signal varies linearly with displacement.

The LVDT indicates direction of displacement by having the two secondary coils whose outputs are balanced against one another. The secondary coils in an LVDT are connected in the opposite sense (one clockwise, the other counter clockwise). Thus when the same varying magnetic field is applied to both secondary coils, their output voltages have the same amplitude but differ in sign. The outputs from the two secondary coils are summed together, usually by simply connecting the secondary coils together at a common center point. At an equilibrium position (generally zero displacement) a zero output signal is produced.

The induced AC signal is then demodulated so that a DC voltage that is sensitive to the amplitude and phase of the AC signal is produced.

Carrier Demodulator

In practice, LVDTs are used with carrier demodulator modules that provide the carrier signal (the AC signal to the primary coil) and converts (or demodulates) the induced AC signal to a DC signal.

The phase sensitive demodulator is an AC to DC converter that produces a DC voltage (typically between 0 and 10 volts) proportional to the magnitude of the LVDT output and sensitive to the phase of the output signal relative to the input (carrier) signal.

When the core is displaced to one side of the primary, the LVDT output is in phase with the input and the demodulator produces a positive signal. When the core is displaced to the other side, the LVDT output is 180 degrees out of phase with the signal to the primary. The demodulator output is then a negative voltage proportional to the displacement. (from university of california, berkeley)

What is Fuzzy Logic?

2008-06-05T06:12:00.003-08:00

Fuzzy logic is a powerful problem-solving methodology with a myriad of applications in embedded control and information processing. Fuzzy provides a remarkably simple way to draw definite conclusions from vague, ambiguous or imprecise information. In a sense, fuzzy logic resembles human decision making with its ability to work from approximate data and find precise solutions.

Unlike classical logic which requires a deep understanding of a system, exact equations, and precise numeric values, Fuzzy logic incorporates an alternative way of thinking, which allows modeling complex systems using a higher level of abstraction originating from our knowledge and experience. Fuzzy Logic allows expressing this knowledge with subjective concepts such as very hot, bright red, and a long time which are mapped into exact numeric ranges.

Fuzzy Logic has been gaining increasing acceptance during the past few years. There are over two thousand commercially available products using Fuzzy Logic, ranging from washing machines to high speed trains. Nearly every application can potentially realize some of the benefits of Fuzzy Logic, such as performance, simplicity, lower cost, and productivity.

Fuzzy Logic has been found to be very suitable for embedded control applications. Several manufacturers in the automotive industry are using fuzzy technology to improve quality and reduce development time. In aerospace, fuzzy enables very complex real time problems to be tackled using a simple approach. In consumer electronics, fuzzy improves time to market and helps reduce costs. In manufacturing, fuzzy is proven to be invaluable in increasing equipment efficiency and diagnosing malfunctions. (from aptronix)

Here is a ebook tutorial on Fuzzy Logic free available for you! Just click on the link below

Tutorial_On_Fuzzy_Logic.pdf

Enjoy!!!

Job Openings for Almarai Co. Ltd. Dairy Foods Company

2008-06-04T22:36:00.002-08:00

Almarai Co. Ltd.

ALMARAI is the world's largest vertically integrated dairy food company with a 2007 sales turnovr of $1 Billion and a workforce f 10,000 employees. Operating throughout in GCC, our highly successful product range is freshly delivered from over 40 depots to some 34,000 retail outlets serving numerous happy costumers.

To build on the brand's dominance and to support and strengthen the company's market supremacy, we now wish to appoint the following for posting in Riyadh, KSA:

Plant Maintenance Team Managers
for the following disciplines:

Production (Food/Beverage process/filling)
Electronics PLC (Process Automation)
Mechanical
Electrical
Plastic Production (Injection/Blow Molding)

Applicants must be graduates of engineering or related course with at least 3 years supervisory experience in plant maintenance gained from continuous process industries. Experience gained from dairy, food, and beverages companies desired.

Production Team Managers (Blow Molding)
Applicants must be male graduate of Mechanical or Electrical Engineering course with at least 3 years experience on production supervision gained from plastic manufacturing company.

Plant Maintenance Technicians
for the following equipment:

Electronics PLC (Process Automation)
Mechanical
Electrical (Production/Filling/Packing)

Applicants must be male graduate of engineering or related technical course with at least 3 years experience in plant maintenance from continuous process industries. Experience gained from dairy, food, and beverages companies desired.

Initial Interview on June 3-6, 2008 at DE LUXE HOTEL - Cogon. Cagayan de Oro City, Philippines.
Look for Ms. Blesie

Employer's Final Interview on the 3rd week of June 2008
No Placement Fee * No Processing Fee * No Salary Deductions * Free Medical/Physical Exam

Interested applicants are advised to send 2 sets of the following through courier: Resume with detailed job description, Employment and Training Certificates, Two 2x2 photo at the address given below c/o Blessie Tayam or may send their resumes b y email to blesie@staffhouse.com and indicate position applied in Subject line/

Suite 402 Public Safety Mutual Benefit Fund Inc. Bldg.
318 Boni Serrano Ave. (Santolan Road) cor. 1st St.
West Crame, San Juan, Metro Manila 1500
Republic of the Philippines
Tel. No. (632) 410-1234
www.staffhouse.com

POEA License No. 224-LB-070501-R
For manpower pooling only. No Fees to be collected. Beware of Illegal Recruiters

For Infos, contact
+63978202929
Look for Ms. Blesie

Suggested Wiring for Reed Switches

2008-06-02T04:55:00.008-08:00

A. AC Circuits: Install a varistor or a resistor capacitor (RC) network:

This circuit will protect the switch. Use a 100 ohms 1/4 watt resistor and 0.1 microfarad non- polarized capacitor or values within that range.

B. For DC circuits, install a diode.
You can use a general purpose diode of the number 1N4004 or equivalent diode.

Additional Notes:
* Don't be mislead by the resistive ratings of the switches. Most applications involve inductive loads.
* Don't be mislead by the wattage ratings of the loads. Low wattage loads are often high inductive devices making contact protection very important.

Total Blackout...

2008-06-02T03:55:00.007-08:00

What the heck! The plant power supply is totally dead! As in "totally" dead! The supplier of our manufacturing plant electricity cutoff our mains supply because the company wasn't able to pay their electric bill for several months now. The company I'm connected with is one of the largest steel manufacturing company in South East Asia, and I just can't believe that the plug was pulled. It was even boasted of of being no.1 steel manufacturing in the region. Some sort of mismanagement here or maybe funds where just sent else where? Maybe....
Even our phonelines are dead. The backup power of our PABX system just drained out after 2 hours. So silent. I can even hear the taps of my keyboard where I usually can't hear it due to the very noisy environment. I'll just wait for now for future infos.

Just a Robot...

2008-06-02T03:34:00.005-08:00

I was just browsing through the image gallery of my cellular phone and saw the picture of this "industry"-made miniature robot sculpture. I remembered that have I made this when I was waiting for the company to install its newly acquired network server. I was researching for some integrated circuits datasheets when I saw this test clips of ICs of various DIP sizes. With my 'artistic' skills (ahem), i have made this immobile little robot replica. Reminds me of the movie Transformers...

Siemens S7-200 PLC Tips and Tricks

2008-06-01T07:36:00.004-08:00

I have found this great tips and tricks for Siemens S7-200 PLC.

Click here to download----> http://rapidshare.com/files/119338801/all_tips_s7200.zip.html

Industrial Automation and Mechatronics

2008-06-01T07:11:00.004-08:00

Tomorrow will be enrollment day of Mindanao State University - Iligan Institute of Technology for the school year 2008-2009 and one more subject to go, specifically the field of Industrial Statistics, then I will be a full pledged graduate of Bachelor of Science Major in Industrial Automation and Mechatronics which will be my second course after Industrial Automation and Controls. The department of Industrial Automation and Controls of the said university is offering these two courses which will be a stepping stone towards industrial automation expertise.

I am pursuing this second course of mine while working in a steel manufacturing company. One of the largest in South East Asia. Working in the morning for 8 regular hours and continuing in the afternoon for my formal education.

But I do enjoy the wonders of technology and taking courses like these, it helps me garner new insights and knowledge which will be a great help to make tasks and job orders during work easier.

It even make me competitive in various fields like electronics, industrial instrumentation, electromechanical, mechatronic technology, pneumatic and hydraulic systems and in the automation and control expertise.

So when i would finish this Industrial Statistics subject which is the only requirement i have left to graduate the BSIAM course, i am planning to take various National Competencies exam especially in industrial automation and mechatronics to further enhance knowledge and skills.

I know this field is wide and there are various competencies in terms of employment and expertise but i will be making out the best for my passion.

Feedback loops control discrete, continuous processes

2008-05-24T15:57:00.003-08:00

Back to Basics
Vance J. VanDoren

Arguably, the most basic tool of the control engineering profession is the feedback loop, shown below. It consists of five fundamental elements:

The process to be controlled.
A sensor (or instrument) that measures the condition of the process.
A transmitter that converts the measurement into an electronic signal.
A controller that decides whether or not the process condition is acceptable.
An actuator (or final control element) that applies a corrective action to the process according to the controller's instructions.

This measure-decide-actuate sequence repeats as often as necessary until the desired process condition is achieved.

For a continuous process, a feedback loop attempts to maintain a process variable at a desired setpoint.

For a continuous process, a feedback loop attempts to maintain a process variable (or manipulated variable) at a desired value known as the setpoint. The controller subtracts the latest process variable measurement from the setpoint to generate an error signal. The magnitude and duration of the error signal then determine the value of the controller's output or controlled variable, which in turn dictates the corrective efforts applied by the actuator.

Cruising

For example, a car equipped with a cruise controller uses a speedometer to measure and maintain the car's speed. If the car is traveling too slowly, the controller instructs the accelerator to feed more fuel to the engine. If the car is traveling too quickly, the controller lets up on the accelerator. The car is the process, the speedometer is the sensor, and the accelerator is the actuator.

The car's speed is the process variable. Other common process variables include temperatures, pressures, flow rates, and tank levels. These are all quantities that can vary constantly and can be measured at any time. Common actuators for manipulating such conditions include heating elements, valves, pumps, and dampers.

For a discrete process, the variable of interest is measured only when a triggering event occurs, and the measure-decide-actuate sequence is typically executed just once for each event. There's really no "loop" involved. For example, the eyes of the human controller driving the car measure ambient light levels at the beginning of each trip. If it's too dark to see well, the driver decides to turn on the car's lights. No further adjustment is required until the next triggering event, such as the end of the trip.

Feedback loops for discrete processes are generally much simpler than continuous control loops, since discrete processes do not involve as much inertia. The driver controlling the car gets instantaneous results after turning on the lights, whereas the cruise controller sees much more gradual results as the car slowly speeds up or slows down.

Inertia tends to complicate the design of a continuous control loop, since a continuous controller typically needs to make a series of decisions before the results of its earlier efforts are completely evident. It has to anticipate the cumulative effects of its recent corrective efforts and plan future action accordingly. Waiting to see how each one turns out before trying another simply takes too long.

The ubiquitous proportional-integral-derivative (PID) control algorithm can foresee the future if it is configured or tuned to complement the behavior of the process. A fast-acting PID controller that makes aggressive control decisions works well on a slow process and vice-versa.

Adjustable / Variable Frequency Drives

2008-05-24T14:39:00.018-08:00

Drives 101
Adjustable / Variable Frequency Drives

This lesson covers the basic functions of an Adjustable Frequency Drives (AFD).
Functions of an Adjustable Frequency Drive (AFD)

Outline:
3-phase AC Motor

1. Bi-Directional Operation
2. Change Speed
3. Constant Speed
4. Limits
5. Ramping
6. Braking
7. Save Energy

This lesson covers the basic functions of an Adjustable Frequency Drive (AFD) on a 3-phase AC (alternating current) motor. Pictured below is an AC motor.

The one pictured above is for industrial or commercial use, but in your home, AC Motors are used as well. A vacuum cleaner uses an AC motor to clean the carpet; a blender uses an AC motor to process food; and the clothes dryer uses an AC motor to dry clothes. In each of these examples, how is the AC motor controlled?

When controlling motors in the home we control them by applying AC power, and removing it usually through a switch. Obviously when power, 120 or 220 VAC, is applied to the motor it runs. With no power, the motor stops.

With the use of an Adjustable Frequency Drive not only can the AC motor be started and stopped as in the home but more sophisticated controls are accomplished. An AFD can send a modulating signal to the motor, which allows a variety of speeds to be delivered not just an ON/OFF signal. This variety can be used to match a motor speed to a particular process. There are a number of functions that the AFD accomplishes with commercial 3-phase AC motors, which are covered in the pages that follow.

To understand the functions of an AFD better, an example of a conveyor at a Package Delivery Company is used.

A Package Delivery Service uses a conveyor to deliver packages from the shipping area to the sorting area. Once sorted, the conveyor is used to return the boxes backto shipping.

Looking at the example above, see if you can identify some of the functions that must be performed by the AFD and AC motor? In other words, what must the conveyor do? Take a couple of minutes to jot down the functions of the conveyor.

The conveyor must …
_______________________________ __________________________
_______________________________ __________________________

A few of the basic functions of an AFD in controlling the AC motor and conveyor are covered here.

1. Bi-Directional Operation

FORWARD
One function of the AFD is to operate the motor in a forward direction, to move the packages from the shipping area to the sorting area.

REVERSE
Power going to the motor must be changed to move the packages backward (Reverse) from the sorting area back to the shipping area. If there were no AFD, 2 of the 3 leads of the 3-phase motor would be switched in order for the motor to change its direction and go backwards.

2. Change Speed
The speed of the conveyor must be adjustable to allow for a slower speed when fewer packages and employees are present and a faster speed for large volumes. This allows the operator to match the speed of the conveyor to a particular process. The setting of this speed is known as the Reference. Commonly reference refers to speed in Hertz (Hz), maximum reference of 60Hz, and minimum reference of 0Hz. It could also be used in regards to a pressure setting, maximum reference of 100psi, minimum reference of 40psi, if a transmitter were attached to the AFD.

In the picture below, the display of an AFD, a Danfoss VLT 5000, is shown. Speed in Hz is the reference. The plus (+) key is used to increase the reference making the conveyor go faster and the minus (-) is used to decrease the reference point.

3. Constant Speed
Another function of the AFD is to maintain the speed of the conveyor regardless of the number of packages. The AFD automatically compensates the current and torque to accommodate changes in the load, from hundreds of boxes to a few.

4. Limits
It is important that limits be placed on an AFD. Speed limits can be placed in the program of the AFD so an operator can not go beyond a maximum speed or less than a minimum speed. If a package gets stuck, there are torque limits that the AFD monitors stopping the motor if they are exceeded.

Current limits are also important for protection of the drive and motor. In the picture below the maximum reference is set to 50 Hz. Notice that in the diagram there is a minimum speed or reference of 10Hz.

5. Ramping
The AFD also ramps the conveyor up and ramps it down. When the conveyor starts, acceleration, it is important that there is no sudden lurch to the reference speed, or packages can go rolling backward. In the example below, a ramp-up slowly increases the speed from stopped or 0 Hz up to the reference, 34 Hz, over a certain amount of seconds perhaps 10 seconds. If this ramp is too short, the drive can trip on an over current alarm or torque limit.

A ramp is also present on the stop side. This is referred to as a ramp down or deceleration. It is important that packages are not jerked to a halt. A ramp-down of 10 seconds might be entered into the program for this application. If the ramp is too short, the drive can trip on over voltage.

6. Braking
There are special challenges when the conveyor is stopping. With many packages on the conveyor there is a great deal of momentum, inertia, so that the motor continues to spin when it is trying to stop. The continued spinning causes the motor to generate energy instead of using it. This extra energy must be handled in the drive or it will trip. If the drive trips, the drive releases control of the motor and the conveyor would then coast to a stop, which might take some time. A special drive is used which has external brake resistors added to dissipate this extra energy as heat as pictured below.

Other ways of braking can also be used. DC Braking is an example that places a DC signal onto the AC motor, which can produce a certain amount of braking. DC braking works best at very slow speeds. Other arrangements have been engineered to handle this extra power, such as DC
Load sharing, but will be discussed later. Only certain applications require special arrangements for braking.

7. Saving Energy
The major function of the AFD is to save energy and equipment. In the example below a drive is used on a screw compressor. Before drives, shown on the left, the motor was cycled On at full power 60Hz until the pressure setting (80psi) was reached. When 80 psi was reached the motor
was turned OFF coming back ON when the pressure dropped to perhaps 60psi. This arrangement used a great deal of energy and the frequent cycling caused a great deal of wear on equipment.

A drive is placed on the screw compressor, shown below, which slows the screw compressor down to perhaps 45Hz to constantly maintain the required pressure. The motor speeds up or slows down following load changes. This saves approximately 35% in energy costs and greatly reduces the wear on equipment.

How to produce 440V ac from 110V ac Source

2008-05-21T05:19:00.006-08:00

By using 2 pieces 110V ac to 220V ac step up transformers, one can produce 440V ac to power up certain industrial equipment for testing by following the setup above (parallel input, series output). Low power transformer can be used to power up variable frequency drives and similar equipment at no load to test programming and simulation. High power transformers should be used if used to power up with loads such as motor. At the place where I work, I usually use two variable transformers of high power rating that weighs about 10kgs for each to be be able to produce output voltages from 220 to 600Vac. It is such a big help for me instead of laying out power cables from to the 440V ac source towards the area where I usually do my work. But be be careful when doing this for one mistake could be hazardous. I mean high voltages here and that is fatal. Watch out for shorts and grounds.

Cleaning and Maintaining the Magnetic Contactor

2008-05-20T18:36:00.015-08:00

Cleaning and maintaining magnetic contactors (MC) are fairly easy and fast. Tools needed are usually screwdrivers, brush, rubber eraser (use the plastic rubber type, not the powdery rubber one). You can also spread a light colored material usually bond paper to contrast small items that comes from the magnetic contactor itself and small tools.

Start off by cleaning the outside of the MC with a brush. You can also use a high percentage ethanol solution to clear out contacts. (Ethanol is highly volatile and flammable so keep it away from flames and sparks!)

Unscrew the screw that holds the upper and lower parts together of the MC. Sometimes a locking notch at the opposite side from which the screw was found helps keep the upper and lower parts be together. This can be easily be disengaged using a flat screw driver.

Once the upper and lower parts are separated, the coil can be removed, the spring and the upper and lower cores. Check for corrosion and rust. You can use a rubber eraser to clean out minor surface problems on the cores or use an abrasive if rust has already settled. Check the resistance of the coil. It must be from a few tens of an ohms to more or less a hundred but should never be below or beyond by means of another hundred or more. Ohmic values of the core varies with the corresponding operating voltage of the coil.

Also check the resistance between the line side and load side of the terminal contacts of the MC. L1 and T1, L2 and T2, L3 and T3 should each have a resistance of less than an ohm, otherwise clean with a contact cleaner available in most of the industrial and electrical supply in your neighborhood.

After cleaning and making the necessary checks, put back the magnetic contactor ensuring that screws and locking notches are securely in place. Power up the said contactor with the correct operating voltage and check again the resistance. When power upped, always be careful of live voltages and ensure your safety first.

Our Deadwieght Tester

2008-05-20T09:52:00.004-08:00

Our Budenberg brand hydraulic deadweight tester is used to calibrate various pressure gauges ranging up to thousands of Psi of pressure. Standard weights are used with graduation on how much they are lifted up by the hydraulic medium to indicate great amount of pressure. Two gauges are on the said tester. One is the standard and the is the one to be tested and calibrated. Other hydraulic equipment or instrument can be attached aside from the said gauges to indicate and test their accuracy and capability. Many digital deadweight testers are now available in the market which can indicate pressures with very high accuracy unlike our obsolete pure analog tester. But it does show how the principle of deadweight testing and hydraulic systems work.

Multimeter Safety by Fluke

2008-05-20T03:30:00.005-08:00

As an industrial instrumentation and electronics technician, i am sharing to you these safety notes and practices shared by Fluke (maker of my issued digital multimeter). Here it goes...

Three levels of electrical reaction:

You should be aware of the electrical shock levels at which you are likely to have a mild reaction. Higher levels may be accident-provoking or even fatal. (Current rather than voltage is used below because the reaction to voltage varies more from person to person (body impedance changes with contact condition - wet or dry, extent of bodily contact, etc).)

Perception Level. This refers to the ability of the operator to sense an electrical shock. Levels as low as 1 mA current with a 1-second contact can be detected as a slight warm in the palm of the hand (dc) and a mild tingling sensation (ac).

Surprise Level. The reaction caused by the surprise level current is sudden, involuntary and totally without warning. It will trigger an unexpected reaction such as suddenly pulling one's hand away from the source of shock with enough force to cause an accident. The reaction becomes more violent with higher levels of current and voltage. Specific surprise levels vary from person to person.

Freeze Level. As voltage and amperage levels increase, the "freeze level" is reached. The hand muscles contract to the point where the victim has no control. Inability to let go of the conductor could "freeze" the victim to the electrical source long enough to cause lung and heart stoppage.

Electrical circuits can cause burns, heart fibrillation and eye injuries.
The DMM user working with or near high voltage, high-current electricity is exposed to potential danger from both actual contact and from exposure to flash hazards. Electrical contact may cause burns either two ways: (1) by touching a high voltage supply, when the resulting arc causes sudden tremendous heat and a burn; or (2) by touching a high frequency current, causing a burn under the skin.
The heart can go into fibrillation when sufficient current passes through it; it seldom recovers spontaneously.
Flash hazards occur when a short circuit creates an arc. Shorts in high-energy circuits can cause the equivalent of welding arcs, which can flash-burn the eyes or cause injury from flying molten metal.

Electrical shock danger varies by wet or dry contact.
Dry skin has a resistance perhaps 10 times greater than wet skin. (Typical impedance of a wet gripping contact is 1500 ohms in parallel with 0.22 uF. Internal body resistance between hands is about 400 ohms.) Perspiration greatly decreases the meter's users skin resistance. The same voltage that would be safe with dry skin may put the user at the "surprise level" with wet skin.

Industrial high energy circuits (>220V ac).
The dividing line between high and low energy circuits is often given as 3,600 volt-amps (such as 240V ac, 15A circuit). Above this, a poorly designed DMM (digital multimeter), or one designed for light duty, could break down, resulting in damage and possible operator injuries. Only meters having special built-in protection such 600V fusing, ohms overload capability and transient protection should be used in these conditions.

Fault Conditions. These can occur when a circuit is accidentally shorted, or the DMM itself is overloaded. Faults cause arcing, sparks, fire explosions or other immediate hazards. (A simple overload is not a fault.) Common situations that lead to faults are:

Accidental contact with a 480V ac power line while in the current mode.
Accidental contact with power lines while in the resistance mode.
High voltage transients from motor switching, load change, or indirect lightning surges.

Unsheltered locations. Any locations allowing wet conditions, including condensation, could lower the insulation value of the DMM and its accessories by creating a current path. This could present a danger to the user, or cause errors in the measurement which could lead to indirectly to hazardous decisions by the user. Take precautions to shield your meter from moisture.

Hazardous locations (potentially explosive atmospheres). A DMM may be safe by itself under normal operating conditions. But if it were to fault, it potentially could cause a spark or overheat a component to cause an explosion. Only specially designed and approved (and clearly labeled as such) meters should be used in hazardous locations. Even simply disconnecting test leads from live circuits on explosive environments, especially while measuring current with inductive loads, may create a dangerous spark.

Proper procedures for using DMMs

Always:
1) Inspect the test leads for insulation damage or exposed metal. Damaged leads should be replaced.
2) Reduce the risk of accidental contact by using leads with shrouded connectors and finger guards, and meters with recessed jacks.
3) Check continuity of the test leads.
4) Be certain the DMM itself is in good condition. During the continuity test, a meter reading that goes from overload to 0 generally means the circuitry is working properly.
5) Select the proper function and range for your measurement.
6) Electrically disconnect "hot" end first.

Safe Practices:
1) Insulate yourself from earth ground, using an insulating floor mat. If possible, employ one hand operation, keeping the other hand in your pocket to avoid accidentally allowing current to travel through your body to earth ground.
2) Follow all equipment safety procedures, disconnecting the power and discharging high-voltage capacitors prior to testing with the DMM. (This applies to dc power supplies, tube circuit transmitters, motor control circuits and x-ray machines.)
3) Working with a CRT? wear safety glasses and protective clothing to avoid injuries should an implosion cause flying glass.
4) Avoid working alone.
5) Using a current shunt? Turn the power off before connecting into the circuit. Overloading a current shunt will cause excessive heating.
6) Current greater than 2 Amps? Use clamp-on probes for maximum protection.
7) Measuring current transformer output or motor winding current? Check the fuse first. An open fuse will allow high voltage buildup, potentially damaging to equipment and operator.
8) Measuring automotive circuits? Be aware of potential danger from high voltage (up to 30,000V dc) and fire hazard from gasoline fumes/leakage.