CALIBRATION TECHNIQUES

AND PROCESS
ABDUL LATIF, PE
H(NI)
 What is calibration?
According to ISAs, the word calibration is defined
as
a test during which known values of measurand
are applied to the transducer and corresponding
output readings are recorded under specified
conditions
The definition includes the capability to adjust the
instrument to zero and to set the desired span.
What is calibration? (cont)
An interpretation of the definition would say
that a calibration is a comparison of measuring
equipment against a standard instrument of higher
accuracy to detect, correlate, adjust, rectify and
document the accuracy of the instrument being
measured.
Calibration range
Calibration of an instrument is checked at several
points through out the calibration range of the
instrument.
Calibration range is defined as The region
between the limits within which a quantity is
measured, received or transmitted, expressed by
stating lower and upper range values.
Limits
The limits are defined by the zero and span values.
The zero value is the lower end of the range.
Span is defined as the algebraic difference
between the upper and lower range values.
The calibration range may differ from instrument
range, which refers to the capability of the
instrument.
Example
An electronic pressure transmitter may have a
nameplate instrument range of 0~750pounds per
square inch gauge(psig) and output of 4~20mA.
However, the engineer has determined the
instrument will be calibrated for
0~300psig=4~20mA. Therefore the range would
be specified as 0~300psig=4~20mA. In this
example, the zero input value is 0psig and
Example (cont.)
and zero output value is 4mA. The input span is
300psig and output span is16mA.
Characteristics of a Calibration
Calibration Tolerance:
Every calibration should be performed to a
specified tolerance. The terms tolerance and
accuracy are often used incorrectly.
In the ISAs the automation, systems and
instrumentation dictionary, the definitions for each
are as follows:
Characteristics of a Calibration(cont)

Accuracy
The ratio of the error to the full scale output or the
ratio of the error to the output.
Expressed in percent span or percent reading,
respectively.
For example: the accuracy of pressure transmitter is
0.25%FS. Its error will be
0.25/100*16=0.04mA
Characteristics of a Calibration(cont)

Tolerance
Permissible deviation from a specified value;
May be expressed in measurement units, percent of
span, or percent of reading.
Example

For example: you are assigned to perform the

calibration of the previously mentioned 0 to
300psig pressure transmitter with a specified
calibration tolerance of 2psig. The o/p tolerance
would be
2psig/300psig*16mA=0.1067mA
The calculated tolerance is rounded down to 0.10mA,
because rounding to 0.11mA would exceed the
tolerance.
Traceability
All the calibrations should be performed traceable to
a nationally or internationally recognized standard.
For example: in the US, The national institute of
standard and technology (NIST),maintains the
nationally recognized standard.
Traceability(cont.)
Definition: traceability is defined by ANSI as the
property of a result of a measurement whereby it
can be related to appropriate standards, generally
national or international standards, through an
unbroken chain of comparisons.
Traceability is accomplished by ensuring the test
standards we use are routinely calibrated by
higher level reference standard.
Traceability pyramid(cont.)
Combined accuracy
Why is calibration required?
It makes sense that calibration is required for a new
instrument. We want to make sure the instrument is
providing accurate indication or output signal when
it is installed. But why cant we just leave it alone as
long as the instrument is operating properly and
continuous to provide the indication we expect?.
Why is calibration required?(cont.)
Instrument error can occur due to a variety of
factors: drift, environment, electrical supply,
addition of components to the output loop, process
changes, etc. since a calibration is performed by
comparing or applying a known signal to the
instrument under test, errors are detected by
performing a calibration.
Error
An error is the algebraic difference between the
indication and actual value of the measured value.
Typical errors that occur include:
Span Error
Span Error
Zero Error
Combined Zero & Span Error
Linearization Error
Adjustments
Zero and span errors are corrected by performing a
calibration. Most instruments are provided with
means of adjusting zero and span of instrument.
Zero adjustment is used to produce a parallel shift of
the input and output curve.
Span adjustment is to change the slope of the input-
output curve.
Adjustments
Linearization error may be corrected if the
instrument has a linearization adjustment. If the
magnitude of the instrument has a un-acceptable
and it cannot be adjusted, the instrument must be
replaced.
why perform calibrations?
To detect and correct instrument error, periodic
calibrations are performed.
Who performs calibration?
A control system technician (CST) is a skilled
craftsperson who knows pneumatic, mechanical, and
electrical instrumentation. He understands process
control loops and process control systems, including
those that are computer based. Typically, he has
received training in such specialized subjects as
theory of control, analog and digital electronics,
microcomputers/computers etc.
CST
A CST performs calibration, documentation, loop
checks, troubleshooting, and repair or replacement
of instrumentation. These tasks relate to systems that
measure and control level, temperature, pressure,
flow, force, power, position, motion, physical
properties, chemical composition and other process
variables.
Xtics of CST
1. Honesty and Integrity
2. Attention to Detail
3. Excellent Documentation Practices
4. Understanding of Process
 Calibration practices
Calibrations are generally performed the same, some
different practices are;
1. Loop calibration VS individual instrument
calibration
2. Bench calibration VS field calibration
3. Classification of instruments as critical, non critical,
for reference only.
Loop calibration vs. individual
instrument calibration
Disadvantage of Advantages of individual
individual calibration calibration
1. Entire loop is not 1. Correct instrument
verified with will be adjusted.
tolerance. 2. More compatible
2. Mistakes on re- with multifunction
connect. calibrators.
3. Less efficient use of
time for one
calibration.
CNPGS CALIBRATION

General

Calibration Sheet
 Calibration of RTDs
Model of Resistance Temp. range Calibration Tolerance t(C)
thermometer (C)

Class B (-200~+800C)
Tolerance (0.3+0.005ltl)
WZP
-200~+420 Pt100 Class A (-200~+650C)
Pt Resistance
Tolerance
(0.15+0.002ltl)

WZC -50~+100C)
-50~+100 Cu-50
Cu-Resistance Tolerance(0.30+6x103t)
 RTD (PT100)

INSULATION
RESISTANCE
OF RTD
SHOULD BE IN
THIS RANGE.
Calibration steps of RTD
1. Measure the insulation resistance.
2. Connect the RTD with process calibrator.
3. First measure the room temperature with standard
thermometer and record the RTD reading on
process calibrator.
4. Place the RTD in temp. bath and give four suitable
temperature values from temp. bath on increasing.
Calibration steps of RTD(Cont.)
5. Repeat these 4 steps on decreasing temperatures.
6. Record all the values in calibration sheet.
7. Calculate the error.
8. If error is more than the acceptance criteria then
use new RTD.
Appearance of RTDs

RTD without head RTD with head

Surface mounted RTD

SURFACE MOUNTED RTD SURFACE MOUNTED RTD

Surface mounted RTDs
Pressure Transmitters
Two type of pressure transmitters are used in
CHASHMA NUCLEAR POWER PLANTS.
1. CECY (GP)
2. CECA (AP)
These pressure transmitter are Chinese make.
SHANGHAI GUANGHUA INSTRUMENT FACTORY
Pressure Transmitters

Conventional pressure transmitter Safety Class pressure transmitter

Transmitters Selection Guide
Applications of GP/AP
These transmitters can be used for measurement of
liquid density, gauge pressure, absolute pressure of
liquid, gases and vapors, and level of liquid in open
vessel.
Input pressure ranges 0~1KPa to 0~40MPa
Output 4~20mA, two wire system
Power supply 12~45VDC
ZERO Suppression /Elevation
Zero Suppression
Calibration of pressure transmitter
Prior to calibration of transmitter, connect the multi-
meter at test point of the transmitter to read output
current.
Suppose initial calibration of transmitter is at
0~40kpa.
The desired calibration is at 0~10kpa.
Zero adjustment; with 0kpa pressure to transmitter,
turn zero screw until output reads 4maA DC.
Calibration of pressure transmitter
Span adjustment; To reduce the span, turn the span
potentiometer clockwise until the output with 0kpa
pressure at input, equals
4mA x existing span/desired span
=4max40/10=16mA
Re-zero; with 0kpa pressure input, turn the zero screw
until the output equals 4mA. Now the calibration of
transmitter is close to 0~10kpa.
Calibration of pressure transmitter
Check the full span output;
Fine tune the span and zero adjustment if required.
This way the transmitter is calibrated to new range
0~10kpa.
Figures of pressure transmitter
regarding calibration
Zero and Span Adjustment External circuit connections
Figures of pressure transmitter
regarding calibration
Zero elevation/suppression
Zero/span potentiometer jumper
R/V Module
Calibration of R/V Module
Termination of R/V Module
Isolator Module
Termination Module of isolator
Calibration of I/V Module
Calibration of 2 nd O/P
MV/V Module
Termination of MV/V Module
Calibration of MV/V Module
Monitor Switch Module
Termination of monitor switch module
Calibration of monitor switch module
MCR Indicators

KMF indicator XZZ Indicators

XZZ Indicator Termination
XZZ Indicator calibration (PV1)
XZZ Indicator calibration (PV2)
KMF Termination
KMF Calibration(PV1)
KMF Calibration(PV2)
THANKS