Instruments Calibration Procedures

Instrumentation Tools
Learn Instrumentation and Control Engineering. Inst Tools covers topics of Industrial
Instrumentation, PLC, DCS, SCADA, Field Instruments, Analyzers and so on.
https://instrumentationtools.com
Author: Instrumentation Tools
Categories: Calibration
Instruments Calibration Procedures
om
s .c
ol
To
i on
at
nt
me
ru
st
In
Calibration refers to the adjustment of an instrument so its output accurately corresponds to its
input throughout a specified range. The only way we can know that an instrument’s output
accurately corresponds to its input over a continuous range is to subject that instrument to
known input values while measuring the corresponding output signal values. This means we
must use trusted standards to establish known input conditions and to measure output signals.
The following examples show both input and output standards used in the calibration of
pressure and temperature transmitters:
InstrumentationTools.com
om
s .c
ol
To
i on
at
nt
A noteworthy exception is the case of digital instruments, which output digital rather than analog
me
signals. In this case, there is no need to compare the digital output signal against a standard, as
ru
digital numbers are not liable to calibration drift. However, the calibration of a digital instrument
still requires comparison against a trusted standard in order to validate an analog quantity.
st
For example, a digital pressure transmitter must still have its input calibration values validated
In
by a pressure standard, even if the transmitter’s digital output signal cannot drift or be
misinterpreted.
om
s .c
ol
To
i on
at
nt
me
ru
st
It is the purpose of this section to describe procedures for efficiently calibrating different types of
In
instruments.
Linear Instruments
The simplest calibration procedure for an analog, linear instrument is the so-called zero-and-
span method. The method is as follows:
1. Apply the lower-range value stimulus to the instrument, wait for it to stabilize
2. Move the “zero” adjustment until the instrument registers accurately at this point
3. Apply the upper-range value stimulus to the instrument, wait for it to stabilize
4. Move the “span” adjustment until the instrument registers accurately at this point
5. Repeat steps 1 through 4 as necessary to achieve good accuracy at both ends of the
range
An improvement over this crude procedure is to check the instrument’s response at several
points between the lower- and upper-range values. A common example of this is the so-called
five-point calibration where the instrument is checked at 0% (LRV), 25%, 50%, 75%, and 100%
(URV) of range.
A variation on this theme is to check at the five points of 10%, 25%, 50%, 75%, and 90%, while
still making zero and span adjustments at 0% and 100%. Regardless of the specific percentage
points chosen for checking, the goal is to ensure that we achieve (at least) the minimum
necessary accuracy at all points along the scale, so the instrument’s response may be trusted
when placed into service.
Yet another improvement over the basic five-point test is to check the instrument’s response at
five calibration points decreasing as well as increasing. Such tests are often referred to as Up-
down calibrations. The purpose of such a test is to determine if the instrument has any
significant hysteresis: a lack of responsiveness to a change in direction.
om
Some analog instruments provide a means to adjust linearity. This adjustment should be moved
.c
only if absolutely necessary! Quite often, these linearity adjustments are very sensitive, and
prone to over-adjustment by zealous fingers. The linearity adjustment of an instrument should
s
be changed only if the required accuracy cannot be achieved across the full range of the
ol
instrument. Otherwise, it is advisable to adjust the zero and span controls to “split” the error
between the highest and lowest points on the scale, and leave linearity alone.
To
on
The procedure for calibrating a “smart” digital transmitter – also known as trimming – is a bit
different. Unlike the zero and span adjustments of an analog instrument, the “low” and “high”
i
trim functions of a digital instrument are typically non-interactive. This means you should only
at
have to apply the low- and high-level stimuli once during a calibration procedure. Trimming the
sensor of a “smart” instrument consists of these four general steps:
nt
me
1. Apply the lower-range value stimulus to the instrument, wait for it to stabilize
2. Execute the “low” sensor trim function
ru
3. Apply the upper-range value stimulus to the instrument, wait for it to stabilize
4. Execute the “high” sensor trim function
st
In
Likewise, trimming the output (Digital-to-Analog Converter, or DAC) of a “smart” instrument

consists of these six general steps:
1. Execute the “low” output trim test function

2. Measure the output signal with a precision milliammeter, noting the value after it
stabilizes
3. Enter this measured current value when prompted by the instrument
4. Execute the “high” output trim test function
5. Measure the output signal with a precision milliammeter, noting the value after it
stabilizes
6. Enter this measured current value when prompted by the instrument
After both the input and output (ADC and DAC) of a smart transmitter have been trimmed (i.e.
calibrated against standard references known to be accurate), the lower- and upper-range
values may be set. In fact, once the trim procedures are complete, the transmitter may be
ranged and ranged again as many times as desired. The only reason for re-trimming a smart
transmitter is to ensure accuracy over long periods of time where the sensor and/or the
converter circuitry may have drifted out of acceptable limits. This stands in stark contrast to
analog transmitter technology, where re-ranging necessitates re-calibration every time.
Non-linear Instruments
The calibration of inherently nonlinear instruments is much more challenging than for linear
instruments. No longer are two adjustments (zero and span) sufficient, because more than two
points are necessary to define a curve.
Examples of nonlinear instruments include expanded-scale electrical meters, square root

characterizers, and position-characterized control valves.
Every nonlinear instrument will have its own recommended calibration procedure, so I will defer
you to the manufacturer’s literature for your specific instrument. I will, however, offer one piece
om
of advice: when calibrating a nonlinear instrument, document all the adjustments you make (e.g.
.c
how many turns on each calibration screw) just in case you find the need to “re-set” the
instrument back to its original condition. More than once I have struggled to calibrate a
s
nonlinear instrument only to find myself further away from good calibration than where I
ol
originally started. In times like these, it is good to know you can always reverse your steps and
start over! To
on
Discrete Instruments
i
The word “discrete” means individual or distinct. In engineering, a “discrete” variable or

at
measurement refers to a true-or-false condition. Thus, a discrete sensor is one that is only able
to indicate whether the measured variable is above or below a specified setpoint.
nt
me
Examples of discrete instruments are process switches designed to turn on and off at certain
values. A pressure switch, for example, used to turn an air compressor on if the air pressure
ru
ever falls below 85 PSI, is an example of a discrete instrument.

st
Discrete instruments require periodic calibration just like continuous instruments. Most discrete
In
instruments have just one calibration adjustment: the set-point or trip-point. Some process
switches have two adjustments: the set-point as well as a deadband adjustment. The purpose
of a deadband adjustment is to provide an adjustable buffer range that must be traversed before
the switch changes state. To use our 85 PSI low air pressure switch as an example, the set-
point would be 85 PSI, but if the deadband were 5 PSI it would mean the switch would not
change state until the pressure rose above 90 PSI (85 PSI + 5 PSI).
When calibrating a discrete instrument, you must be sure to check the accuracy of the set-point
in the proper direction of stimulus change. For our air pressure switch example, this would mean
checking to see that the switch changes states at 85 PSI falling, not 85 PSI rising. If it were not
for the existence of deadband, it would not matter which way the applied pressure changed
during the calibration test. However, deadband will always be present in a discrete instrument,
whether that deadband is adjustable or not.
For example, a pressure switch with a deadband of 5 PSI set to trip at 85 PSI falling would re-
set at 90 PSI rising. Conversely, a pressure switch (with the same deadband of 5 PSI) set to trip
at 85 PSI rising would re-set at 80 PSI falling. In both cases, the switch “trips” at 85 PSI, but the
direction of pressure change specified for that trip point defines which side of 85 PSI the re-set
pressure will be found.
A procedure to efficiently calibrate a discrete instrument without too many trial-and-error

attempts is to set the stimulus at the desired value (e.g. 85 PSI for our hypothetical low-pressure
switch) and then move the set-point adjustment in the opposite direction as the intended
direction of the stimulus (in this case, increasing the set-point value until the switch changes
states).
The basis for this technique is the realization that most comparison mechanisms cannot tell the
difference between a rising process variable and a falling setpoint (or vice-versa). Thus, a falling
pressure may be simulated by a rising set-point adjustment. You should still perform an actual
changing-stimulus test to ensure the instrument responds properly under realistic
circumstances, but this “trick” will help you achieve good calibration in less time.
om
.c
Also Read : SMART Transmitter Calibration
s
ol
To
i on
at
nt
me
ru
st
In
Powered by TCPDF (www.tcpdf.org)

Instruments Calibration Procedures

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instruments Calibration Procedures

Uploaded by

Copyright:

Available Formats

Instrumentation Tools

Author: Instrumentation Tools

Instruments Calibration Procedures

Likewise, trimming the output (Digital-to-Analog Converter, or DAC) of a “smart” instrument

1. Execute the “low” output trim test function

Examples of nonlinear instruments include expanded-scale electrical meters, square root

The word “discrete” means individual or distinct. In engineering, a “discrete” variable or

ever falls below 85 PSI, is an example of a discrete instrument.

A procedure to efficiently calibrate a discrete instrument without too many trial-and-error

You might also like