Instrument calibration exists as an essential process to maintain the accuracy of instrumentation. Whether the instrument in question is used in the field, in the laboratory or in a manufacturing facility - accurate readings provide a firmer sounding board for decision-making.
Each environment will require different levels of accuracy and deciding what is an acceptable range to configure an instrument to will be balanced between corporate policy and legal requirements. Goods manufacturers and product testers will be well-versed with the complexity of such legal requirements. It is for this reason that companies which do not employ in-house calibration specialists will often seek out calibration experts with a specific knowledge of their sector or instrumentation type.
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A variety of situations typify the need for calibration: new instrument manufacture/installation, routine maintenance, emergency maintenance, changes in external conditions and in any situation where the operator might find the reading/results questionable. Changes in external conditions can include climate changes, excessive shock damage, corrosion, water damage or gas leaks, for example. Routine calibrations occur over certain periods of time or over a specific usage/operating period (for example: 6 months usage over 5 days per week at 12 hours a day).
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Generally speaking the procedure involves the use of test equipment which is often more delicate but more accurate than industrial instrumentation. Some instrumentation manufacturers will provide individual test kits for branded instruments but ideally industrial companies would call in a calibration expert that can assess the accuracy of multiple components while drawing from their strong backgrounds in process control and safety compliance. Such an expert would be able to present decision makers not only with reports but also with recommendations. Often such an individual would identify potential for improvement; provide cost projections for implementation; as well as earmarking potential performance issues.
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Calibration is not just about reading results but also about adjusting the output of instrumentation to line up with known values - also known as "real values". For example: compensating for pressure or temperature fluctuations or dispersion. The emphasis of accuracy will depend on how critical each instrument is to the goal activities of an operation. If a manufacturer utilises volatile organic compounds then they may emphasis calibrating their safety and gas detection systems. If delicate materials are involved then the company may emphasis the accuracy of their temperature and relative humidity sensors. Instrumentation often comes with a recommended accuracy range; recommended environmental conditions for use and storage as well as recommended servicing intervals.
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The mathematics of calibration can be quite complex and even a small miscalculation could result in the incorrect usage of instrumentation with potentially dangerous outcomes. A specific knowledge of components needs to come into play because the connection between the device and the display that could affect the calibration. This is common in electronic instrumentation with analog connections as the cabling itself can call calibration results into question.
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Lastly it is important to note that the documentation is an important part of the calibration process. Ensuring that there is a post-dated audit trail available with recording in recognised standards will help to more accurately maintain the standards of production.
PJ Boner offers an expert onsite calibration service as well as bench calibrations in Ireland. http://www.pjboner.com
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