VS-3000E Sensor System Standard Operation Procedure

Field Service Procedure 200018 VS3000E

Standard Operating Procedure V9 for Beer

BevSense VS3000E SOP Beer Field Service Procedure 200018 December 2018

1

VS-3000E Sensor System

Standard Operation Procedure

This VS-3000E Standard Operating Procedure involves two programs:

The VS-3000E Sensor Monitor

CalFAST 3000E ™ Calibration Software

Both programs must be properly installed prior to using this procedure. The

programs are provided with each system by VitalSensors

A Lab Reference Instrument and Lab Reference Data Must be Available so that

the VS-3000E ™ Calibration Software can be used to align and maintain the

sensors.

For Questions

Contact: BevSense LLC Tel: +1 978-758-3308

29 Glenwood Avenue

Newton, MA 02459 Web: http://vitalsensorstech.com

USA

First Revision: January 2014

Revision 9: December 2019

http://vitalsensorstech.com/




2

General Notes for Calibration and Sampling - SOP:

Startup:

o When first running a brand and it is in equilibrium near to target concentration press “Set to Target”

button. This will offset the sensor to the target concentration values.

For a brand/product to be considered calibrated, the following criteria must be fulfilled:

o Samples on 3 different tanks/batches of the same product must be tested o At least 3 samples per tank/batch must be taken o Process the results in CalFAST-3000E Software Application. (Automatically done if robot is enabled) o Best practice to perform calibration activities on consecutive tanks/batches o 3 additional samples should be entered monthly thereafter to minimize offsetting o If BevSense Validation/Verification services are purchased, quarterly a qualified BevSense engineer will

remote in and optimize sensor performance. Remote access is required for this service. TeamViewer is the recommended remote access software Sampling across 3 tanks provides concentration variability and temperature variability. Encompassing these varying factors during the calibration process ensures stable readings moving forward.

After Calibration, periodic lab sampling must be done according to the Plant schedule. The following are rules of thumb that may change with production and plant experience

o Take lab sample 10 minutes after startup of the line o For CO2 if the difference between the CarboQC or Gehaltameter and the VS3000E sensor is less than 0.1

grams/liter or .05 v/v % no offset should be entered. The measurement is within specification. o For Alcohol if the difference between the density and sound velocity lab instrument is less than .025

ABW or .03 ABV no offset should be entered. o For Real Extract if the difference between the density/sound velocity lab instrument is less then .1 then

no offset should be entered o For Original Extract if the difference between the density lab instrument is greater then .15 then no

offset should be entered




3

Entering Lab Data on the Sensor Monitor Using “GO” Button

Click Enter Lab Data

Click “Go”

Take sample

Enter value into correct column

Click “OK”

Enter Lab Reference Data for Product in Production Tips:

o The lab sample timer is the time it takes to grab the sample, measure and enter it into the Sensor

Monitor. This will ensure that the lab sample time is correct. o The lab sample measurement should be as precise as possible. If there is a large deviation in the lab

sample versus product target and limits consider retaking the sample to confirm the data.




4

o If satisfied with Lab value, click

Save. Only the concentrations that have been tested need to be filled out. Leave other concentrations blank. Sample 1, Sample 2, Sample 3 are a higher accuracy way to take a sample if three measurements of the same sample (bottle) are taken accuracy improves.

Sensor Monitor Display with CO2 only after Lab data entry.




5

If entering an offset does not yield linear response, use CalFAST to calibrate

Stop Logging

Run CalFAST

CalFAST-3000Emain screen.

Select a Product to CAL




6

Click LOAD DATA o Graph will be shown

on screen

o Graph shown

o LOGGED DATA in

BLUE

o LAB DATA points in RED

o TEMPERATURE in PINK

CalFAST 3000E Load Data Tips:

o This step loads sensor log data, sensor temperature data (for reference) and lab data entered into via

the Sensor Monitor. o This is the actual historical data as recorded by the sensor. o If you point a click on the CalFAST 3000E application lab and log data will be shown at any point in time

from the graph (see vertical black line on graph and corresponding data in the boxes)




7

Click CAL o New CAL model is

shown in BLACK

CalFAST-3000E Cal Tips:

o By clicking on the CAL button, CalFAST 3000E will align the sensor log data with the corresponding lab

data point generating a new Product calibration. o The new predicted CAL measurement is shown by the black line o If the new CAL is acceptable go to the next step. o The new CAL is enabled and stored only if the SAVE button is clicked o If the new CAL is not better than what is already on the sensor click the EXIT button o Note also that there are tabs for each measurement enabled on the sensor. All the tabs and

measurements function the same. o You can try different products to calibrate with and as long as you don’t SAVE, you can reload

repeatedly for each different scenario. o Refer to the complete CalFAST-3000E user manual for more complete instructions.




8

Click SAVE

Confirm the correct product(s) are selected

Click SAVE CAL




9

Part IV: Refresh CAL(s) on VS-300 Sensor Management Station

Start Logging

Refresh SMS

The new Calbration is now in effect. Without hitting the Refresh SMS button the new Calibration would be

ubdated the next time the current brand runs




10

Notes on Calibration for Blending Beer

For High Gravity beer blending the following needs to be done to make the sensor work:

1. Data points need to be taken at the highest concentration of Ethanol and Sugar at least

three point when the sensor is in equilibrium. All concentrations that are going to be

used have to be taken at this level. If it is only a CO2 sensor only CO2 needs to be taken

2. Data points need to be taken at the middle range of concentration at least three data

points for at least three different tanks. All concentrations that are going to be used have

to be taken at this level.

3. Data points need to be taken at the lowest concentration that a blender will use. At least

three data points need to be taken at least 15 minutes apart. All concentrations that are

going to be used have to be taken at this level.

4. The data needs to be run through CALFAST to get a Product Calibration and once

similar products are identified a group calibration.

5. One data point needs to be taken once tanks get into equilibrium and entered into the

sensor monitor as part of SOP for each tank. This can be lessened once the process and

sensor are repeatable. This offsets the sensor to the lab concentrations automatically and

insures that the concentration is correct.

Over time Beers should be done in groups with similar ingredients and concentrations. Light

beers, Lagers, Ales, Stouts... This strengthens the calibration for all of the beverages in the

group because with fewer data points per brand you get more concentration range and

temperature range.

After the first six months the calibration should be updated for at least one product in each group

Once a month a data point should be taken on each beverage and should be processed through

CalFAST to insure that the sensor always gets more stable over time. If before the one month

maintenance any product offset becomes greater than .2% CalFAST should be run to increase

the accuracy of the sensor.

Laboratory data must be carefully taken with accepted, consistent

procedure using laboratory instrumentation that is maintained and

regularly calibrated. Failure to adhere to good lab procedure will

not yield good inline sensor results!

VS-3000E Sensor System Standard Operation Procedure

Documents

Transcript of VS-3000E Sensor System Standard Operation Procedure