Last month, we began this series by describing some of the most common reasons to implement a modern calibration process in power plants and the typical issues of an outdated calibration process. Now, we’d like to go over the most important reasons to implement a modern calibration and address the typical challenges faced by today’s power plants as they seek to bring their calibration process into the future. 

WHAT IS A MODERN CALIBRATION PROCESS?

If we look at the most modern calibration processes available today, we can find the following key components: First, the management, monitoring and scheduling of all calibrations is automated with the help of dedicated calibration management software. The calibration management software can be linked to the CMMS for a fully automated and paperless flow of work orders. The calibration management software also communicates with portable documenting process calibrators, meaning that the work orders can be downloaded directly into the calibrators with all the required instructions for the technicians to go into the field. 

During calibration, an intelligent calibrator performs an automatic pass/fail calculation, complicated calculations do not have to be performed. Also, the results will be stored in the calibrator’s memory, and can be directly uploaded to the calibration management software. 

Finally, the calibration management software can automatically send an update to the maintenance management software that the work has been completed. As such, the whole process is fully paperless and more can be done with fewer resources as the process is highly automated, thus reducing costs and improving the quality of calibration data. A modern calibration process is also far more efficient, allowing more calibrations to be performed in the limited time during an outage.

HOW TO IMPLEMENT A NEW CALIBRATION PROCESS

The most important reasons to implement a modern calibration process are to improve calibration efficiency, save costs, obtain higher quality calibrations and be compliant with related regulations. But how can a new calibration process be implemented? Briefly, here are a few words on implementing a new calibration process: 

First, it is vital to remember that implementing a new calibration process is a process itself, with many interrelated tasks that need to be performed in the appropriate sequence. A proven project supply implementation model is recommended, managed by a dedicated project manager and supported by experts in the subject matter. Without a proven implementation model, typical risks of implementing a new process are usually encountered, such as unclear expectations, budget and schedule overruns, scope creep, and a lack of expected benefits.

Although implementing a new calibration process is far smaller in scope than implementing, for example, a new ERP system, there are still many similarities. The implementation should start with establishing the project framework in order to have a common understanding of the project targets, specify the roles of the parties in the project team and steering group, establish management rules, determine testing and acceptance criteria. 

This blueprinting process is an important phase where the documentation of the current process (as it is) and the target process (how it should be). During specification, you will need to document all the relevant requirements and make sure all parties have a common understanding. If all previous steps have been performed correctly, the next phase is the actual execution according to plans. 

Finally, the new process is put to use with secure support when in production use. Using a supplier that has a proven implementation model and which can take responsibility for the required actions is recommended.

CASE STUDY: INCREASING ANNUAL PRODUCTION WITH HIGH-ACCURACY CALIBRATORS 

In the Central Nuclear de Almaraz (CNA) plant in Spain, an enhanced calibration system with high-accuracy calibration equipment makes it possible to perform calibration operations with better uncertainty levels, thus enabling us to improve production results. This was achieved by using the Beamex MC6 high-accuracy multifunction calibrators in the power plant.

By improving the parameter measurement from 2 to 0.4 percent (parameters associated to determining reactor power), enabled power in each unit to be increased by 1.6 percent. This has a very significant effect on annual production.

SUMMARY

In conclusion, modern state-of-the-art calibration process can help a power plant to improve the plant performance and efficiency, ensure safety and emissions control, and improve accuracy of invoicing related measurements. Making the calibration work more effective, automated, and paperless saves calibration related efforts and costs as well as improves the quality of calibration and regulation compliance.

FOR MORE INFORMATION

Beamex is a trusted partner for calibration excellence, providing accurate measurements, reliable data, and traceability for a safer and less uncertain world. Beamex helps improve efficiency, ensure compliance, and increase safety with its comprehensive ecosystem of calibration solutions–from field calibration to workshop calibration, calibration management, and services. Through the company’s global reach, Beamex products and services are available in over ninety countries. For more information, visit www.beamex.com.

MODERN PUMPING TODAY, February 2024
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