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REVISI0N HISTORY

Revision Number Date Comments

Rev: 0 15-09-04
Signed off by Iain Adamson 15-12-04
Rev: 1 02-11-04
ISSUE 1

REV 1: Test Equipment (ID-006) Page 2 of 57

AIMS AND OBJECTIVES

Duty: Instrumentation
Course Title: Test Equipment (ID-006)
Duration: 2 Days

To identify and understand the safety requirements of

Aims
the following items of test equipment

OBJECTIVES

The delegate will be able to:

 Identify the following types of test equipment

 Understand the safety requirements in regard to the use of the following

test equipment

 Perform measurements and calibrations competently using any necessary

support documentation and the equipment listed below

TOPICS COVERED INCLUDE

 Comparator

 Digital multimeter

 Druck Pressure Source

 Decade Box

 Millivolt source

 Jofra Temperature Calibrator

 Unimat Instrument Calibrator

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  Dead Weight Testers

 Smart calibrator

 Milliamp source

 Workshop exercises – Calibration of pressure gauge, dp cell, pressure

switches, thermocouple and RTD check calibrations

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CONTENTS

TEST EQUIPMENT (ID-006)

1. CALIBRATION & DOCUMENTATION

1.1. INTRODUCTION

1.2. ACCURACY & REPEATABILITY

1.3. SENSITIVITY

1.4. TRANSMISSION

1.5. STABILITY

1.6. RELIABILITY

1.7. GENERAL PROBLEMS OF MEASUREMENT

1.8. CALIBRATION ERRORS

1.9. HYSTERESIS ERROR

1.9.1. PRESSURE STANDARDS

1.9.2. PRIMARY STANDARD INSTRUMENTS

1.9.3. EXAMPLES OF PRIMARY STANDARD INSTRUMENTS

1.9.4. THE DEAD WEIGHT TESTER (DWT)

1.9.5. THE MANOMETER

1.9.6. TRACEABILITY & CALIBRATION OF TEST EQUIPMENT

1.9.7. CALIBRATION SHEET

2. MULTIMETER

2.1. ANALYSING A CIRCUIT

2.2. OVERVIEW OF ELECTRICAL TERMS

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 2.3. USING A MULTIMETER

2.4. MEASURING IN PARALLEL

2.5. MEASURING CURRENT

2.6. MEASURING CONTINUITY

2.7. MEASURING RESISTANCE

2.8. MULTIMETER SAFETY

3. DRUCK PRESSURE SOURCE

4. COMPARATOR

4.1. USE OF COMPARATOR

4.2. COMPARATOR OPERATION INSTRUCTIONS

5. DEAD WEIGHT TESTER

6. DECADE BOX

7. MV SOURCE

8. SMART CALIBRATOR

9. MA SOURCE

9.1. GENERATE MILLIAMP

9.2. LOOP POWER

9.3. CHECKING THE OPERATION OF A CONTROL VALVE

9.4. FIXED WORKSHOP MILLIAMP SOURCES

10. TEMPERATURE BATH

10.1. PLACING AN INSTRUMENT INTO THE BATH

10.2. TYPICAL TEMPERATURE RANGERS COVERED

10.3. LIQUID TEMPERATURE BATHS

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 TEST EQUIPMENT (ID-006)

1. CALIBRATION & DOCUMENTATION

1.1. INTRODUCTION

Before anything can be controlled, it must be possible to measure it. The

more precisely it can be measured, the more precisely it can be controlled.
This chapter is about measurement and calibration – what is meant by
calibration, and how the measurement is transmitted.

1.2. ACCURACY & REPEATABILITY

As can be seen from figure 1 it is possible to have repeatability without

accuracy. However, it is not possible to have an accurate measurement
without repeatability.

Repeatability is a measure of the instrument’s ability to produce the same

answer each time. Accuracy is a measure of the instrument’s ability to give
the correct answer. If it does give the correct answer each time, it must have
good repeatability.

Poor Repeatability Good Accuracy Means Good Repeatability

Means Poor Accuracy Good Repeatability Does Not Mean
Good Accuracy

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 Figure 1

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 1.3. SENSITIVITY

Another important attribute of a good measuring instrument is discrimination

or sensitivity. All instruments have some limitation to the precision with which
the measurement is displayed, the markings on the scale of an analog
instrument (see figure 2) or the number of figures displayed by a digital
instrument. Take a digital thermometer, for example, displaying in whole
numbers. If it is indicating in degrees Fahrenheit then it will have a better
sensitivity than if it were indicating in degrees Celsius.

150 160

150 160

Figure 2

Notice that the accuracy of an instrument cannot be better than its

repeatability and its repeatability cannot be better than its sensitivity.

In most cases improvements can be made by concentrating on a narrow

range of measurements. A three digit display can indicate over the range 0 to
999 or 0 to 0.999. In each case the sensitivity is 0.1% of the range of the
instrument, but in absolute terms, the sensitivity is either unity or 0.001. In
the same way, a level installation covering the range 75% to 85% of a vessel
will give ten times better sensitivity than if it were measuring the level over the
whole vessel.

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 Vessel wall

Level Transmitter

Figure 3

A balance always has to be sought between the sensitivity required (and

hence the measurement accuracy limitation in absolute terms), the range to
be covered and the cost.

If the accuracy specification is made tight, the cost will increase greatly. It
must not be forgotten that the maintenance of an instrument of high accuracy
will also increase if the accuracy is to be retained. Frequent and careful
calibration will be required. Thus greater accuracy than is really required
must not be specified. Equally, the narrowest practical range should be used,
increasing accuracy without any cost penalty.

1.4. TRANSMISSION

The importance of setting the narrowest practical range to cover the

measurement of interest can also be seen when considering transmission.

It will be found that some of the measurements made on process plants

involve delicate equipment and small currents or voltages. Such signals are

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 subject to invasion by unwanted electrical voltages, known as “pick-up” or
“noise”. There is considerable advantage in using relatively high powered
signals which are less susceptible to these unwanted voltages to transmit
these measurements over any distance greater than a few feet. From this
concept comes the idea of the transmitter, the transmission signal and the
receiver.

The earliest forms of transmission signal were pneumatic, historically

because the oil industry was in the forefront of development and electrical
signals could have provided incentive sparks if faults had occurred. There is
no such risk with pneumatic signals. The standard until recently has been to
use 3 psi to represent 0% of range of 15 psi to represent 100% or full scale.
Now, with the advent of metrication, that has been converted to 0.2 to 1.0
barg.

Electrical signals are now most common, largely because of the advent of
solid state electronics, hand in hand with development of intrinsic safety
techniques. The common transmission signal is 4 to 20 mA, but 0 – 10 volts
and 1 – 5 volts are used for short distances, that is behind control room
panels.

1.5. STABILITY

Another quality of an instrument sometimes quoted is its stability. This is, of

course, the ability of the instrument to maintain its accuracy of calibration over
a period of time, and is generally quoted in terms of a drift of so many per
cent of full scale over a year.

1.6. RELIABILITY

Care has to be taken in choice and maintenance of instruments and due

regard must be paid to the environment and the process conditions.

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 Transmitters will work better and will be easier to maintain if the Plant
Environmental Conditions are clean and dry and the temperature is not high
or low or variable.

Instruments that stand up to dust, explosive atmospheres, vibration, humidity

(or even splashing), heat or cold must be chosen where appropriate.

Good IP Rating as taught on the Hazardous Awareness module

The instruments will also be better maintained if the environment is congenial,

with good lighting and a bit of space for the technician to work in.

1.7. GENERAL PROBLEMS OF MEASUREMENT

It should be appreciated that it is difficult to make accurate measurements of

certain materials.

Slurries are a prime example.

Impulse lines will block up, samples will be unrepresentative, separation will
occur causing the variations and so on.

Precautions can be taken in most cases such as purges for impulse lines,
short sample lines, heat tracing and so on. This makes the installation and
maintenance more expensive and less reliable.

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 1.8. CALIBRATION ERRORS

We known that there are three types of error from which a pressure
instrument may suffer. They are illustrated by the graphs shown in figure 4.

Graph (a) zero error Graph (b) span error

Indicated Pressure Indicated Pressure

Actual Calibration Actual Calibration

Correct Calibration Correct Calibration

True Pressure True Pressure

Graph (c) angularity or linearity error

Indicated Pressure

Correct Calibration

Actual Calibration

True Pressure

Figure 4

Graph (a) shows a zero error, which is a constant error over the whole span
of the instrument. In the case of the C-type Bourdon tube gauge this could be
corrected by removing the gauge pointer and replacing it in the correct
position (normally with 50% pressure applied).

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 Graph (b) shows a span error, which is a progressively increasing error. In a
C-type gauge this is corrected by adjusting the position of the span
adjustment screw as shown in figure 5

Graph (c) shows an angularity or linearity error. This means that the
calibration is correct at zero and full-scale but out at mid-scale. Correcting
this type of error involves a process called squaring the links. This is done
by applying 50% pressure to the gauge and adjusting the length of the link
until the angle between the link and the quadrant is 90° as shown in figure 5.

Angularity or Linearity Adjustment

Figure 5

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 1.9. HYSTERESIS ERROR

This is an error that is seen when progressive rising and falling pressures are
applied to the instrument. If we take the example of the C-type gauge again,
hysteresis error is caused by wear of the teeth on the quadrant or pinion.

Hysteresis error can be graphed as follows:

C B

Indicated Pressure

True Pressure (Applied to Gauge)

Figure 6

Referring to figure 6, A to B shows an increase in the pressure applied to the

gauge from zero up to the scale maximum value (fsd). A to B in fact, looks
like a good calibration! However, when the applied pressure is reduced the
indicated pressure does not fall until point C is reached. The indicated
pressure now falls to D giving the appearance of a zero error (B to C is called
a dead zone). Where the rising and falling readings do not agree, then the
gauge under test suffers from hysteresis. A common cause of hysteresis is
worn quadrant and pinion teeth giving rise to lost motion in the gauge
mechanism. Correction of hysteresis error normally requires the replacement
of the worn parts.

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 A hysteresis test is a useful check to perform on a gauge that has been in
service for some time.

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 1.9.1. PRESSURE STANDARDS

To perform a calibration we first require a very accurate means of measuring

the input pressure applied to the gauge under test.

The devices used to provide such accurate measurements are called

pressure standards.

These may be divided into two groups:

 Primary standard instruments

 Substitute standard instruments

We deal with each group in detail.

1.9.2. PRIMARY STANDARD INSTRUMENTS

Primary standard instruments are the more accurate of the two groups, been
accurate to within plus or minus 0.05% (written ± 0.05%).

With a primary standard the value of accuracy is expressed as a percentage

of the pressure been measured.

For example, if a pressure of 100 bar is indicated, the true value of pressure
is within the range of 100 bar ± 0.05%.

This means the true value of the applied pressure lies between 100 + 0.05%
and 100 – 0.05%.

1.9.3. EXAMPLES OF PRIMARY STANDARD INSTRUMENTS

A primary standard device is normally of reasonably simple construction, the

accuracy of the instrument depending upon accurately machined parts. Two
examples of devices used as primary standards are the Dead Weight Tester
(DWT) and the Manometer.

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 1.9.4. THE DEAD WEIGHT TESTER (DWT)

A DWT is illustrated below in figure 7.

Figure 7

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 In this device, the calibrating pressure is provided by an oil-filled system, the
main components of which are shown in figure 8.

Figure 8

Before fitting the gauge the DWT must be primed to ensure there is no air in
the system. With the isolation valve closed, the screw press is turned until the
oil rises up the gauge mounting connection. Fit gauge and apply a little
pressure by turning the screw press. Open the oil reservoir valve and check
for the release of any air bubbles.

When the isolation value is closed and the screw press wound in, the oil
pressure increases.

To accurately measure the input oil pressure applied to the gauge under test,
a finely machined piston and cylinder unit is fitted to the system.

The applied oil pressure is compared to the pressure exerted by the piston
inside the cylinder. When these two pressures are equal a point of balance is
reached. When this occurs the piston lifts in the cylinder and is supported by
the oil pressure. This is illustrated in figure 8 above, where the exposure of a
coloured band indicates that the balance point has been achieved and that
the pressure of the oil equals the pressure exerted by the piston inside the
cylinder.

When the calibration is complete, wind the screw press right out and open the
isolation value before removing the weights from the DWT table.

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 1.9.5. THE MANOMETER

A manometer is a primary standard at its simplest involving only mass and

gravity, in this case a head of liquid balancing the applied pressure.

Well type manometers and U-tube manometers are often used for calibration
purpose.

A typical arrangement using a well type manometer is shown in figure 9.

Figure 9

In this case the gauge is calibrated using air pressure from the regulator. The
pressure to the connecting pipework is increased in increments and the
manometer reading (the true value) and the pressure gauge reading (the
indicated value) are noted at each stage.

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 A typical gauge is shown in figure 10.

Figure 10

This is a C-type Bourdon tube gauge manufactured to a greater accuracy

than the C-type gauge intended for normal plant use.

Gauges for normal plant use have an accuracy of around ± 1% of fsd,

compared to ± 0.25% of fsd for a standard test gauge.

Also standard test gauges are often of large format, having a scale of
between 200mm and 250mm as opposed to 150mm for a plant gauge.

A typical calibration arrangement using a substitute standard is shown in

figure 11.

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 Figure 11

The readings on the gauge been tested are compared with those on the
standard test gauge. They are recorded and any error identified.

1.9.6. TRACEABILITY & CALIBRATION OF TEST EQUIPMENT

Calibration is the periodical comparison of measuring instruments with

national recognised standards, which are known to be constant and accurate.

Traceability is documentation of the existence of a calibration chain between

an instrument and an ultimate standard.

When we calibrate an instrument, adjustments are made for errors at

standard reference points such as:

1. Zero. (0% Input)

2. Span or Range (100% input)

A typical Traceability tree is shown below for the calibration of a pressure

transmitter

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 Ultimate Standard National Standard
e.g. Pressure Balance

T Transfer
TransferStandard
Standard Dead Weight Tester
ransfer Standard e.g.

Laboratory Standard Standard Pressure Gauge

e.g.

Instrument To be Calibrated Pressure Transmitter

e.g.
Increasing Accuracy

Figure 12

The transmitter is calibrated using the laboratory standard pressure gauge,

which itself should be calibrated using the transfer standard (the dead weight
tester). This is turn should be calibrated using the ultimate standard.

Each element in the ladder should be significantly more accurate than the
element below it.

Test equipment such as multi-meters, pressure sources, temperature sources

etc, requires a third party calibration at regular intervals to comply with
specific company legislation.

The calibration interval is generally determined by the organisation. A

common calibration interval for a multi-meter would be 24 months.

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 Temperature and pressure sources are commonly a 12-month calibration
cycle.

If the test equipment is out of calibration, it must not used until a valid
calibration has been carried out.

The third party calibrations use a transfer standard that is traceable against a
national ultimate standard. When the test equipment has been calibrated, a
calibration certificate is issued to that piece of equipment.

As a security measure, tamper-proof seals are usually applied at the time of

third party calibration. These seals are applied to the test equipment and must
not be removed. Any piece of equipment that has a calibration seal removed
must not be used.

1.9.7. CALIBRATION SHEET

% PSI / Bar ma
0

25

50

75

100

75

50

25

Figure 13

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 2. MULTIMETER

Figure 14 – Multimeter

A multimeter is a piece of test equipment that is capable of measuring:

 Voltage

 Current

 Resistance

 Frequency sometimes

A multimeter can be useful to verify voltage and current for faultfinding or as a

safety aid.

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 2.1. ANALYSING A CIRCUIT

If you are checking a circuit, you must know whether the circuit is:

 AC (alternating current)

 DC (direct current)

You also need to know how much current and voltage you’re potentially
measuring.

2.2. OVERVIEW OF ELECTRICAL TERMS

AC volts (VAC) - Alternating Current

Most pieces of plant and equipment operate on AC voltage (240v or 110v).

DC volts (VDC)- Direct Current

The normal source of DC current is a battery. DC voltage is polarized,

meaning that there is a positive (+) and a negative (-). The negative is
sometimes referred to as ground. Generally the red lead is (+), and the black
lead is (-)

Resistance (ohms W)

A measurement of how difficult it is for the current to flow through the

electrical system.

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 2.3. USING A MULTIMETER

Multimeters have a dial allowing you to select various modes of

measurement. As shown in the next slide, the different settings have to be
selected. These settings are designated by:

 V DC (volts DC)

 V AC (volts AC)

 A DC (amps DC)

 Resistance (W)

Display

Voltage DC Voltage AC

Current
Resistance
Meter Lead Terminals

Figure 15

The next step in the process is to select an appropriate range. There are a
variety of ranges available for volts, amps and resistance. For example, you
would not use a two-volt setting to measure 600 volts.

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 Figure 16

The previous slide shows the multimeter measuring a voltage of 1.999V. The
2v range is selected. If a voltage of 10v was to be measured, the next range
(20v) would have to be selected. If the voltage exceeded 20v, then the 200v
scale would be required etc. If you’re unsure of the approximate voltage
range, a good technique is to start with the maximum range and work your
way down. If you are not sure if you were measuring two volts or 200 volts,
you should initially measure the voltage with the highest possible range (in
this case 1000 volts)

2.4. MEASURING IN PARALLEL

The following measurements are made in parallel:

 Voltage

 Resistance

This means the meter probes are placed directly across the circuit to be
measured.

Note

When measuring resistance the circuit under test must be de-energised

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 Figure 17

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 2.5. MEASURING CURRENT

Multimeters have the ability to measure current directly. This portion of the
meter is usually fused to protect against excessive current loads. If high
current measurements are required, such as starting or charging circuit tests,
current clamps are available.

Figure 18

The only quantity measured with a multimeter in series with the circuit. Circuit
must be modified in the following way:

 Create a gap in the circuit where you want to measure the

current

 Reconnect the circuit with the multimeter connected across

the gap as shown on the next slide

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 Multimeter Measuring Current (A)

Circuit being measured

Figure 19

2.6. MEASURING CONTINUITY

Sometimes, you just need to find out if power is able to get from point A to
point B. This is called a continuity test. A continuity test involves using the
Ohms section of your Multimeter. Make sure power to wire is off. Place one
probe at one end of the wire that you’re testing and place the other probe on
the other end. This involves the multimeter sending a tiny amount of current
into the circuit to be measured. If the resistance level is very low, then the
current can get through the wire. The circuit is then ‘closed circuit’. If the
resistance level is infinite, then the circuit is ‘open’. The circuit being
measured has a break in it from point A to point B. Many meters produce an
audible signal when continuity is present. If the circuit is continuous, you will
hear the tone.

2.7. MEASURING RESISTANCE

You can also use the Ohm section of your multimeter to test resistance. First,
make sure that there’s no power going through the circuit. Place the red
probe on one side of the object to be measured for resistance. Place the

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 black probe on the other end of the object. Select the correct resistance scale
on the multimeter. If the scale is unknown, start at the highest scale and
move down accordingly. The resistance of the object being measured will
indicate on the meter display.

2.8. MULTIMETER SAFETY

When measuring AC, it doesn’t matter which probe goes to which wire.
When measuring DC, you should always observe polarity by attaching the red
probe to the positive and the black probe to the negative. Measuring current
and voltage are the only operations that should be performed with the power
on. All other measurements should be taken with the power off.

 Prove meter before and after use on known source to check

that meter is operating properly.

 Make sure to touch only the plastic on the multimeter’s probes

and never the metal.

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 3. DRUCK PRESSURE SOURCE

A pressure source is a pressure standard which is used as a reference to

check pressure instruments. The source is accurate enough to be used in a
laboratory, and portable enough to be used on site. The portable pressure
source has a small internal hand operated pressure pump. The pressure is
increased or decreased manually using the hand pump. The instrument to be
tested is connected to the pressure source outlet.

Pressure Outlet
Keypad and Display

Pressure Adjustment Valve

Pressure Vent Valve

Hand Pump

Figure 20

The pressure source is capable of both generating and measuring pressure.

The source is also capable of generating vacuum pressure. Maximum
pressure ranges covered can be up to 80MPa with the use of special
pressure cell attachments. Typical accuracy achieved is 0.025% of reading.
Various types of pressure source are available depending on application:

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 Membrane Keypad

Instrument Connection

Pressure Vent Valve

Fine Adjustment Screw Pressure Pump

Figure 21 – Typical Modern Pressure Calibrator (Druck DPI 601)

The pressure input or pressure output from the calibrator is made through the
instrument connection.

The function, generate signal, measure signal, range of measurement

etc. is selected by pressing the relevant keys on the membrane pad.

To inject a pressure to calibrate an instrument close the pressure vent valve,

then use the pressure pump to produce a pressure which can be read on the
digital display.

Use the fine adjustment screw to give small increases or decreases in

pressure, especially when the trip point of a switch is being set or checked.

To measure pressure simply connect the signal line to the calibrator through
the instrument connector, select the correct range and monitor the reading on
the digital display.

Do not use source to measure pressure of systems containing liquid

otherwise the calibrator will be filled with liquid.

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 The modern calibrator normally offers both pressure generation and pressure
measurement.

Modern pressure transducers as used in pressure calibrators have excellent

linearity and hysteresis characteristics, that do not significantly change
calibration, some even when subjected to four times the full scale pressure of
higher. The transduction principle used in modern calibrators is the integrated
silicon strain gauge bridge.

In modern calibrators controls are normally via a sealed membrane key-pad

ensuring reliable operation even under adverse weather conditions.

Parameter selection, zero adjustment and all other operating commands via
the key-pad and the powerful microprocessor provide a wide range of display
capabilities.

Intrinsically Safe (IS) versions of the modern instruments, are freely

available for use where required. See figure 22

For example the Druck DPI 601 Series model can measure pressures to an
accuracy of + 0.05% and can supply 10v to energise transducers or
transmitters under test and measure the output response (except IS version).
A 2 volt analogue output is also provided for use with chart recorders or other
data recording systems. The microprocessor controlled circuit provides many
advanced features such as peak reading, signal filtering, square root and 0 to
100% readout.

Safety

Ensure correct selection of tubing and fittings.

Permit required to use test equipment on plant (unless IS rated)

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 Figure 22 - Applications

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 4. COMPARATOR

Oil reservoir

Gauge ports

Hand pump

Figure 23 – Comparator Buldenberg Model 106

4.1. USE OF COMPARATOR

The comparator is used to check and calibrate the following instruments

against a laboratory certified standard test gauge.

 Gauges

 Pressure switches

 Pressure Transmitters

4.2. COMPARATOR OPERATION INSTRUCTIONS

1. Check for oil in reservoir.

2. Close oil reservoir isolation valve.

3. Adjust hand pump to raise oil to top of pressure gauge connections, to

avoid trapping air.

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 4. Apply thread tape to both the gauge connection to be calibrated and to
the reference standard gauge connection and screw gauges into the
left and right comparator ports.

5. Apply a small pressure ( rotate hand pump clockwise)

6. Open oil reservoir slowly and observe pressure release for any air
bubbles.

7. Rotate hand pump anti-clockwise to fully retracted position, drawing oil

from reservoir, maintaining oil level to prevent ingress of air, topping up
if necessary.

8. Close oil reservoir isolation valve and repeat steps 6 to 8 until no air is
released.

9. Proceed as per calibration instructions.

Safety

Ensure that the correct fittings and sealing washers are used.

Ensure that the comparator is depressurised before disconnecting

the gauges

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 5. DEAD WEIGHT TESTER

A very accurate primary pressure standard used for calibration of pressure

instruments. The dead weight tester can generate known pressures based on
the precise knowledge of applied weight and piston area. The mass of the
weights is known and equal to a known pressure.

Weights
Instrument under test

Piston

Oil Reservoir
Adjustable feet
Piston Handle

Figure 24

The pressure in an oil reservoir is increased by a hand pump and piston. As

the pump handle is turned, the piston compresses the oil in the reservoir,
increasing its pressure. There are only two outlets for the pressure:

1. The piston and weights outlet

2. The test pressure outlet (shown connected to a gauge below

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 Gauge under test

Piston

Hand Pump

Oil
Figure 25

When these pressures are the same and balance:

 The total pressure due to the weights and piston is equal to

the pressure exerted at the test pressure outlet

 At this point, the piston and weights lift to indicate pressure

equilibrium

 The instrument under test is then compared to the known test

pressure exerted by the weights.

 Any adjustments are then made to the instrument

As previously stated, the mass off the weights is known and equal to a known
pressure:

 A 1KG weight is equal to 100 kPa (gauge) pressure

To take readings or calibrate a pressure instrument using a dead weight

tester, the pressure range of the instrument must be known. This information
will confirm which weights are required for the calibration. The hand pump
must be turned so that the pressure in the piston chamber is equal to the
applied weights. When the pressures are equal, the piston and weights lift.
The example in the following slides shows a 0 to 2000 kPa pressure gauge
being tested. The calibrated weights used are:

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  0 kPa = No weights applied

 1000 kPa = 1 x 10 KG Weight

 2000 kPa = 1 x 20 KG Weight

No Pressure applied:

Figure 26

With no weights applied, there is no pressure at the gauge connection, the

gauge indicates zero pressure.

10 KG Weight added:

Figure 27

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 With a 10 KG weight balanced by the piston pressure, the pressure at the
gauge is 1000 kPa.

2x10 KG Weights added.

Figure 28

With a 20 KG weight balanced by the piston pressure, the pressure at the

gauge is 2000 kPa. Calibration Adjustments

The instrument under test has now been checked against a known pressure
reference source. If the instrument indication does not match the pressure
applied to the dead weight tester, zero or span adjustments must be made to
the instrument under test.

Safety

Ensure that the DWT table is level by checking the spirit level on the DWT
and adjusting the feet on the DWT to bring the table into the horizontal plane.

Ensure there is sufficient oil in the reservoir before carrying out test

Ensure connections, fittings and seals are used before carrying out test.

Ensure DWT is depressurised before removing the weights.

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 6. DECADE BOX

Is a piece of test equipment used to simulate electrical resistance. Internal

coils of known resistance are housed in a box as shown:

Output Lead Connections

Range Selector Switches

Figure 29

Each decade box houses a number of coils of different resistance. A

resistance can be simulated using different variations in coils used. For
example:

 Coil 1 = increments of 1 W

 Coil 2 = increments of 10 W

 Coil 3 = increments of 100 W

 Up to increments of 100,000 W

Resistance boxes come in a variety of different shapes and forms. Different

models are used for different resistance range requirements.

 1 ohm is shown as ‘000001’ (Top left to bottom right)

 10 ohms is shown as ‘000010’

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  100 ohms is shown as ‘000100’

 1k ohms is shown as ‘001000’ (1000 ohms)

 10k ohms is shown as ‘010000’

 100k ohms is shown as ‘100000’

For example, 73598 ohms is shown as ‘073598’

3
7
0

8
9
5

Figure 30

Uses

For calibrating or simulating RTD inputs to temperature transmitters.

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 7. MV SOURCE

Output terminals

Thumbwheel switches

Range switches

Figure 31 - mV Source Time Electronics Model 404S

 3 Ranges up to 1V

0-999.9mV in 3 ranges

0-99.99mV in 10µV steps

0-9.999mV in 1µV steps

 0.05% Accuracy

 20 mA Output Current

 Short circuit and overload protected

 Portable

The 404S is an accurate low cost millivolt source suitable for voltage injection
applications.

Three output ranges are provided to give adjustable output values from 1µV
to 1V with a basic 0.05% accuracy.

 0-999.9mV in 3 ranges

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  0-999.9mV in 0.1mV steps

 0-99.99mV in 10µV steps

 0-9.999mV in 1µV steps

For signal injection, the operator needs only to switch on, check the battery
condition, select the range and set the required voltage using the thumbwheel
switches.

The 404S uses a precision reference diode and low temperature co-efficient
resistors to give a highly stable output.

Power is provided by 6-AA (penlight size) batteries. Battery life is several

months, depending on usage. The battery condition is monitored by an
indicator which is mounted on the end of the unit.

The 404S has up to 20 mA drive current and is short circuit and overload
protected. A normal /off / reverse output polarity switch is provided.

Uses

 As an accurate millivolt source

 Thermocouple simulation using appropriate lookup table

 Chart recorder calibration

 A/D converter

 DMM calibration and as a stable voltage for backing off DC

offsets.

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 8. SMART CALIBRATOR

SMART pressure transmitters are a microprocessor based instrument. The

smart electronics and sophisticated communication make the unit extremely
versatile to interface with modern control systems. SMART transmitters are
compatible with the HART/SMART hand held communicator. This allows the
user to communicate with the smart transmitter from a control room, or from
any wiring point within the loop. This saves the Technician the need to
access the transmitter from its actual plant location.

Technicians can communicate with modern digital SMART transmitters by

using hand held communication devices. These devices can digitally access
the SMART transmitter configuration data banks and can be used for the
following maintenance functions

1. Displaying Process Variables

2. Displaying Transmitter Tag Number

3. Re-Ranging the instrument.

4. Assigning new operating units

5. Transmitter Sensor Calibration

Figure 32

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 The hand held communicators used in the oil and gas industry would normally
be of intrinsically safe construction and type.

SMART Transmitter

HART Communicator

Figure 33

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 9. MA SOURCE

The majority of transmitted instrument signals are measured in milli-amps

(mA). mA signals can be measured and generated using a variety of
workshop test equipment. The equipment can be bench mounted for test and
calibration or portable to be used on site. A typical mA calibrator can be seen
below:
Output or Read Selector switch

Loop power external or internal selector switch

Digital display

Test leads Pushbuttons to increase or decrease the mA input signal

Figure 34

The calibrator is small is size and weight so it is portable

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 Figure 35

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 A typical mA calibrator has the following functions:

 Measure mA – output from a transmitter (4-20mA)

 Generate mA – input 4-20mA to calibrate an I/P converter

( current to pressure converter)

 Power Instrument loops

 ‘Stroke’ valves via an I/P

As with any measurement of current, the mA calibrator requires placing ‘in

series’ with the circuit. The calibrator measures the current within the loop
generated by the instrument under test. The calibrator can be programmed to
display actual current or a percentage.

Figure 36

9.1. GENERATE MILLIAMP

mA can be generated to test a variety of instruments and functions:

 Substitute for transmitters for loop testing

 ‘Stroke’ valves via I/P converter

4mA = 0% (e.g. valve fully closed)

8mA = 25%

12mA = 50%

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 16mA = 75%

20mA =100% (e.g. valve fully open)

 Alarms via trip amplifiers

 Trip amplifiers

 Indicators

 Loop power

The calibrator varies the current within the instrument loop. Current of up to
24mA can be generated. The current can be generated in ‘steps’. This is
useful for checking at set intervals:

 e.g. 0%, 25%, 50%, 75%, 100%

9.2. LOOP POWER

The mA calibrator can be used to supply 24v power to an instrument loop.

This is useful when a designated power supply is unavailable. The calibrator
powers the instrument and fixes the current level within the loop
simultaneously.

9.3. CHECKING THE OPERATION OF A CONTROL VALVE

A valve can be checked for operation (or ‘stroked’) using the mA calibrator.
The position of the valve can be controlled by varying the mA signal to the
control valve. Valves are commonly checked at fixed intervals to ensure they
are fully opening and closing. See figure 37

 4mA = 0% (e.g. valve fully closed)

 8mA = 25%

 12mA = 50%

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  16mA = 75%

 20mA =100% (e.g. valve fully open)

I/P converter
Input 4-20mA Control valve
Output 0.2-1.0 Bar 0.2-1.0 Bar input

mA source injecting 4-20mA

Figure 37 Typical hook-up using a mA source to calibrate I/P converter

stroking a valve (4-20mA)

9.4. FIXED WORKSHOP MILLIAMP SOURCES

Bench test equipment is also available to carry out calibrations in the

workshop. Bench test equipment is capable of the same functions as the
portable equipment. Due to the bench equipment being non portable, plant
mounted equipment must be removed from site and tested in the workshop.

Safety

Permit required to use on site (non IS)

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 10. TEMPERATURE BATH

A temperature bath is a temperature standard which is used as a reference to

check temperature instruments. The bath is accurate enough to be used in a
laboratory, and portable enough to be used on site. The bath has an internal
heating block which is electrically heated. The bath is accurately heated to
the required temperature. The temperature of the bath is measured internally
and displayed on the bath’s interface display.

Internal Heating Block

Temperature Display

Temperature input interface

Figure 38

A sleeve is placed into the bath’s internal temperature block. As the

temperature of the block changes, the heat is transferred to the sleeve.
Instruments to be checked are placed inside the sleeve as shown.

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 10.1.PLACING AN INSTRUMENT INTO THE BATH

Instrument Under Test

Temperature sleeve

Temperature Bath

Figure 39

The temperature sleeve is a metal block which is finely machined to different

size diameter holes. The diameter of the probe is measured so it can be
placed in the correct diameter sleeve hole.

The instrument should be a tight fit in the sleeve to ensure good heat transfer

A typical sleeve arrangement is shown:

Figure 40

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 10.2.TYPICAL TEMPERATURE RANGERS COVERED

A dry block bath typically covers temperature ranges:

 -10 to 600 Deg C

10.3.LIQUID TEMPERATURE BATHS

Liquid temperature baths are another temperature standard also used. They
are similar in principle to the dry block temperature bath, except liquid is
heated as the reference. The instrument to be tested is inserted into the
liquid at known temperature.

Liquid Reservoir
Temperature Display and Controller

Figure 41

Liquid bath’s can achieve much lower temperatures than a dry block bath. A
typical liquid bath can control at temperatures as low as –80 DegC. Care
must be taken not to come into contact with liquid at low temperatures.

When operating a temperature bath the following PPE is recommended:

 Heat resistant Gloves

 Tongs

 Temperature resistant apron

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  Full face mask (when using liquid bath)

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