Ron Cash, Senior Combined Cycle Tech at the Lawrenceburg Energy Facility, was the visionary that led the maintenance department to streamline their calibration processes, automate documentation and standardize tools. Thus far, the results have included the retirement of 80 measurement standards which saves them $18,000 annually in recertification costs, implementation of a paperless system that is intuitive and easy to learn, improved data integrity and reliability, exposure of shortfalls in calibration of mission-critical instrumentation, and time savings of up to 50% on calibration work.

Ron explains, “I took over the instrument calibration duties without any instrument calibration experience.  Our program was a mess to say the least.  We were still using paper and pen for our calibration reports.  I started looking at calibration reports and talking to others who performed calibrations in the past and realized that everyone completed the phases of the process differently.  I found all these issues to be a huge problem that could end up costing the company money.  With the permission of the Plant Manager, I purchased two Beamex MC6 documenting calibrators, two external modules and the CMX software.  And the rest is how legends begin.”

Achievements at Peñoles Quimica del Rey

Versatility

Helps in the planning, management, analysis and documentation stages, ensuring that working is safe and efficient.

With the Beamex CMX

Functionality

Performing field calibrations with just a single piece of equipment required.

Using the MC6

Digitalization

Streamlining the process helps to achieve business principals.

Integrated Calibration Solution

Summary

Peñoles Quimica del Rey, the Latin-American based intermediary, operates within the metallurgical-mining and chemical industries and are part of the Peñoles Group, the second largest Mexican mining company and the first Mexican producer of gold, zinc, lead and silver.

Peñoles Quimica del Rey maintain their domestic leadership by supplying 56% of the national magnesium sulphate market and are the largest Sodium Sulfate plant in the Western Hemisphere. Despite strong competition, the company are ranked third in the world in terms of their installed capacity of sodium sulphate which is used for the production of detergents, glass and paper.

Quality-Controlled Production Process

“Calibration plays a fundamental role in ensuring that our business objectives are fulfilled, measurements are accurate and controlled
processes are in place. The precision of the measurements in the different stages of production determines the quality; if we have inaccurate measurements we will have low quality products, but if the measurements remain accurate and correct, we will continue to supply high quality products.” Roberto Lopez, the Supervisor of Instrumentation Department at Peñoles Quimica del Rey, says.

Enhancing Processes with Documenting Capabilities

One of the core principals in the decision-making process for Peñoles Quimica del Rey was inevitably to find an accurate calibrator, but one which also featured documenting functionality and a supporting software solution to aid the process. The Beamex MC6 calibrator was rendered an appropriate choice of equipment for the company along with CMX, the Calibration Management Software, to help compliment and streamline the process. Lopez commented on the deployment:

“Due to the great versatility of the CMX Calibration Software, it helps us in the planning, management, analysis and documentation stages, ensuring that we work in a safe and efficient way. The Beamex MC6 is a truly functional piece of equipment that helps us to perform calibrations with just a single piece of equipment required. Being a field communicator with great precision makes it a great tool for our technicians.”

The Expectations

Accuracy and precision during the production stages aligns the company view that “a better decision can be made at any time” and “if you cannot measure it, you cannot improve it!” Roberto Lopez, the Supervisor of Instrumentation Department at Peñoles Quimica del Rey, goes on to say.

Real Enviroment

With a dedicated instrumentation department consisting of 26 people and a mission statement dedicated to providing high quality products, the production process at the plant is ensured to remain in optimal conditions with precise readings at all times.

Commitment

One of the core principals in the decision-making process for Peñoles Quimica del Rey was inevitably to find an accurate calibrator, but one which also featured documenting functionality and a supporting software solution to aid the process.

Digitalisation and Software Integration

Prior to rolling out with the Beamex product solution, Peñoles Quimica del Rey trialled the equipment and discovered that the time taken to complete the calibration was reduced by two hours. Automatic calibrations using the Beamex POCs and Temperature Blocks, in addition to the automatically generated documentation produced through CMX and the MC6, has made huge time savings for the company and has significantly enhanced efficiency and productivity within the department.

CMX is now an integral part of Peñoles Quimica del Rey calibration process. Calibrations are performed in accordance to their annual maintenance plan CMMS, Maximo, and Performance Management software, Meridium. The Work Orders raised in Maximo are integrated into CMX which provides necessary information on the instrument and process required for calibration. Guidance is provided throughout the procedure indicated by the MC6 and once complete, measurements are uploaded into their CMX software for reference.

The Benefits

The accurate measurements provided with the MC6 in parallel with the integrated software solution continues to help Peñoles Quimica del Rey produce a high-quality product, it reduces the waste of raw materials, cuts costs and reduces their carbon footprint.

The Results

Streamlining the process has made huge time savings, enhanced efficiency, maintenance, improved productivity, but fundamentally, it has helped us to achieve our business principals and continue with the delivery of our high-quality products.” Lopez comments.

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