ISA RP105 00 01-2017 Management of a Calibration Program for Industrial Automation and Control Systems.pdf

1、 ISA-RP105.00.01-2017, Management of a Calibration Program for Industrial Automation and Control Systems ISBN: 978-1-945541-63-6 Copyright 2017 by the International Society of Automation (ISA). Not for resale. Printed in the United States of America. No part of this publication may be reproduced, st

2、ored in a retrieval system, or transmitted in any form or by any means (electronic mechanical, photocopying, recording, or otherwise), without the prior written permission of the Publisher. ISA 67 T.W. Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709 - 3 - ISA-RP105.00.01-

3、2017 Copyright 2017 ISA. All rights reserved. Preface This preface, as well as all footnotes and annexes, is included for information purposes and is not part of ISA-RP105.00.01-2017. This document has been prepared as part of the service of ISA toward a goal of uniformity in the field of instrument

4、ation. To be of real value, this document should not be static but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 T.W. Alexander Drive; P. O. Box 12277; R

5、esearch Triangle Park, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail: standardsisa.org. The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the pr

6、eparation of instrumentation standards. The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric system) in their business and professional dealings with other countries. Toward this end, this Department will endeavo

7、r to introduce SI-acceptable metric units in all new and revised standards, recommended practices, and technical reports to the greatest extent possible. Standard for Use of the International System of Units (SI): The Modern Metric System, published by the American Society for Testing certifies indu

8、stry professionals; provides education and training; publishes books and technical articles; hosts conferences and exhibits; and provides networking and career development programs for its 40,000 members and 400,000 customers around the world. ISA owns A, a leading online publisher of automation-rel

9、ated content, and is the founding sponsor of The Automation Federation (www.automationfederation.org), an association of non-profit organizations serving as “The Voice of Automation.“ Through a wholly owned subsidiary, ISA bridges the gap between standards and their implementation with the ISA Secur

10、ity Compliance Institute (www.isasecure.org) and the ISA Wireless Compliance Institute (www.isa100wci.org). The following served as voting members on the ISA105 committee: NAME COMPANY J. Federlein, Chair Federlein avoids acting on incorrect information; ensures the desired results of the calibratio

11、n efforts; and promotes the correct operation of an IACS. In an IACS, more hardware faults occur in the measuring instrumentation, and control valve components than in the control components of the IACS. A calibration program can aid in early detection of these failures. Inadequate calibration and m

12、aintenance of an IACS may increase the likelihood of system problems, including: Inaccuracy of measurements and control; System not responding correctly or as desired; Reduced awareness of instrument performance and actual need for calibration and maintenance; and Potential for reporting of incorrec

13、t environmental or other data. However, targeted reduction, or increase, in calibration activities based upon the assessment of data derived from an instrument asset management calibration program can both reduce maintenance costs and improve reliability and safety. Various definitions of the term c

14、alibration can be found: The formal definition of calibration by the International Bureau of Weights and Measures is: “Operation that, under specified conditions, in a first step, establishes a relation between the quantity values with measurement uncertainties provided by measurement standards and

15、corresponding indications with associated measurement uncertainties (of the calibrated instrument or secondary standard) and, in a second step, uses this information to establish a relation for obtaining a measurement result from an indication.“ (from International vocabulary of metrology - Basic an

16、d general concepts and associated terms (VIM) (JCGM 200:2012, 3rd edition). A definition found in the NIST Handbook 150:2001 is: “1.5.8 Calibration: Set of operations that establish, under specified conditions, the relationship between values of quantities indicated by a measuring instrument or meas

17、uring system, or values represented by a material measure or a reference material, and the corresponding values realized by standards. ISA-RP105.00.01-2017 - 10 - Copyright 2017 ISA. All rights reserved. NOTE 1 The result of a calibration permits either the assignment of values measured to the indic

18、ations or the determination of corrections with respect to indications. NOTE 2 A calibration may also determine other metrological properties such as the effect of influence quantities. NOTE 3 The result of a calibration may be recorded in a document, sometimes called a calibration certificate or a

19、calibration report.” According to standards ISO 9001:2008 7.6 and ANSI/NCSL Z540.3-2006, calibration is a comparison of the device being tested against a traceable reference instrument (calibrator) and documentation of this comparison. Although calibration does not formally include any adjustments,

20、in practice, adjustments are possible and often included in the calibration process. In the absence of a calibration program, maintenance practices for line, vessel or equipment-mounted devices such as pressure, temperature and level indicators, unfortunately, may occur only when the error in readin

21、g becomes large enough to be obvious to the operator or technician. Maintenance personnel routinely make decisions based on these devices. A faulty indication on such a device could lead to the release of energy or other unsafe action. A well-considered calibration program that periodically measures

22、 actual loop accuracy can provide confidence in the indications and drive the calibration intervals for these devices. Instrumentation based on newer technology, e.g., “smart” devices, is more accurate than older technology devices and more stable, requiring less frequent calibration monitoring. A c

23、alibration program should also accommodate these device types appropriately, such as calibration check frequency and accuracy of calibration equipment required. Instrumentation worth purchasing and installing is worth calibrating and maintaining. All instrumentation, including the highest quality de

24、vices, will drift over time and provide less accurat e measurements. Calibration corrects for that drift. Thus, it is critical that all instruments are calibrated on their appropriate intervals. Companies striving to maintain a safe working environment while ensuring the reliability of their facilit

25、ies may use calibration as a means of verifying the functionality and accuracy of their equipment. Like other aspects of maintenance, there are many things to consider when establishing a company calibration program. Certainly, this is the case with the calibration of monitoring and control loops in

26、 a facility IACS. This document presents a recommended approach to developing, implementing and maintaining a calibration program that is intended to increase accuracy and reliability of an IACS, decrease maintenance costs, and improve quality control. More importantly, this approach is also intende

27、d to increase safety of operation as the result of increased accuracy and reliability of the instrumentation. This approach to calibration has proven successful when companies have adhered to the concepts set forth in these guidelines, enabling those companies to realize the full benefits from a sta

28、ndardized approach to calibration. The intended audience for this document is any company or industry that utilizes instrumentatio n in the monitoring and control of a process or facility. Organization This recommended practice is organized to provide recommendations on: Establishing a calibration p

29、rogram; Calibration program activities; and Calibration program management. - 11 - ISA-RP105.00.01-2017 Copyright 2017 ISA. All rights reserved. 1 Scope 1.1 General applicability The recommended practice detailed in this document defines a baseline definition and model of a quality management system

30、 that can be utilized to implement and maintain a calibration program for industrial automation and control systems. It is applicable to all IACSs. 1.2 Inclusions and exclusions 1.2.1 Manufacturer specific calibration procedures This document does not provide or recommend manufacturer-specific calib

31、ration procedures for specific instruments as these are established by the instrument manufacturer and are outside the scope of this document. 1.2.2 BPCS and SIS functionality This document does not include any consideration for how instrumentation and control signals are handled within the BPCS or

32、SIS other than including indication of the s ignal in loop accuracy calculations. 1.2.3 Control valve and other final control devices calibration This document does not cover the essential maintenance of the mechanical aspects of these and other mechanical devices. 1.2.4 Regulatory requirements Regu

33、latory requirements related to loop/instrument accuracies are not included in this recommended practice. 1.2.5 SIS instrument calibration The calibration of monitoring and control loops that are part of safety instrumented systems is included in the scope of this recommended practice. The documentat

34、ion and management of these instruments as part of safety instrumented systems is excluded. For more information, see ISA -84.00.01 (IEC 61511 Mod) and all its parts. 1.2.6 Instrument criticality This document mentions criticality as it applies to a calibration program. This document does not modify

35、 any guidelines for establishing criticality provided in ISA-TR91.00.02. 1.2.7 Control loop performance The performance of final control elements and the tuning of control loops are excluded from th e scope of this recommended practice. 1.2.8 Hazardous areas Instruments can be located in hazardous l

36、ocations. These instruments are to be installed, operated and maintained in accordance with requirements for those hazardous locations. The precautions for working on these instruments are outside the scope of this document. Refer to other codes and standards addressing electrical equipment in hazar

37、dous locations for applicable requirements, such as ANSI/ISA-12.01.01-2013, Definitions and Information Pertaining to Electrical Equipment in Hazardous (Classified) Locations. 2 References ISA-TR91.00.02-2003, Criticality Classification Guideline for Instrumentation ANSI/ISA-5.1-2009, Instrumentatio

38、n Symbols and Identification ISA-RP105.00.01-2017 - 12 - Copyright 2017 ISA. All rights reserved. ISA-5.4-1991, Instrument Loop Diagrams ANSI/ISA-12.01.01-2013, Definitions and Information Pertaining to Electrical Equipment in Hazardous (Classified) Locations ISA-84.00.01 Parts 1-3 (IEC 61511 Mod),

39、Functional Safety: Safety Instrumented Systems for the Process Industry Sector NIST Handbook 150 Checklist:2001, National Voluntary Laboratory Accreditation Program (NVLAP) Liptak, Bela G., Editor. Instrument Engineers Handbook, Process Measurement and Analysis, Fourth Edition, International Society

40、 of Automation, 2003 Ultimate Calibration, 2nd Edition, Beamex, 2009 Cable, Mike. Calibration: A Technicians Guide, International Society of Automation, 2005 ISO 9001:2015, Quality management systems, Clause “Control of monitoring and measuring equipment”, International Organization for Standardizat

41、ion ANSI/NCSL Z540.3-2006 (R2013), Requirements for the Calibration of Measuring and Test Equipment, NCSL International ANSI/NCSL RP-1-2010, Establishment and Adjustment of Calibration Intervals, NCSL International JCGM 200:2012, 3rd edition. International vocabulary of metrology - Basic and general

42、 concepts and associated terms (VIM) 3 Definition of terms and acronyms 3.1 Terms 3.1.1 accuracy as part of the calibration activity, the degree of conformity of a devices output to its actual input value, typically expressed in terms of the measured variable, for example percent of full scale value

43、 or percent of actual reading; usually measured as an inaccuracy and expressed as accuracy Note 1 to entry: The difference between these expressions can be great. The only way to com pare accuracy expressed in different ways is to calculate the total error at certain points in engineering units. 3.1

44、.2 adjustment as part of a calibration activity, the act of adjusting a device to meet a known standard 3.1.3 calibration procedure (3.1.18) of checking or adjusting (by comparison with a reference standard) the accuracy of a measuring instrument SOURCE: ISO 15378, modified “process” was replaced wi

45、th “procedure” 3.1.4 calibration work instructions step by step instructions for performing a calibration on a specific device or loop 3.1.5 criticality criticality ranking or classification of items or events based upon relative significance, importance, or severity. - 13 - ISA-RP105.00.01-2017 Cop

46、yright 2017 ISA. All rights reserved. 3.1.6 device a piece of instrument hardware designed to perform a specific action or function 3.1.7 device calibration a calibration performed on only one device 3.1.8 error the difference between an indicated value and the actual value expressed as either a) pe

47、rcent of full scale difference between the indicated value and the actual value, expressed as a percentage of the devices full scale (minimum-to-span) range of values or b) percent of reading difference between the indicated value and the actual value, expressed as a percentage of the actual value 3

48、.1.9 hysteresis the deviation in output at any point within the instruments sensing range, when first approaching this point with increasing input values, and then with decreasing input values (in other words, when a device produces a different output at the same input point based on whether the inp

49、ut is increasing or decreasing) 3.1.10 industrial automation and control system collection of personnel, hardware, software and policies involved in the operation of the industrial process and that can affect or influence its safe, secure and reliable operation ANSI/ISA-62443-3-3 Note 1 to entry: This system includes sensors and final elements and may be either a BPCS or an SIS or a combination of the two. 3.1.11 instrument asset management coordinated work processes of an organization to ensure the intended capability of assets is available 3.1.1