Field Pressure Calibration and Equipment Maintenance

Copyright © Yokogawa Corporation of America
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Pressure Transmitter Calibration
Simplified - Webinar
Ronit Mukerji
Product Manager – Calibration Instruments

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Event Logistics

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 Host: Elizabeth Perdue
Marketing Specialist
elizabeth.perdue@us.yokogawa.com
 Presenter:
Ronit Mukerji
ronit.mukerji@us.yokogawa.com
Host & Presenters

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Topics

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Topics
 Introduction to Pressure
 Pressure Sensor Types
 Transmitters
 Verification & Calibration Basics
 FieldMate Basics
 Unique Solutions
 Applications

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Pressure Introduction

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Basic Physics of Pressure
 It is a measure of force
 One of four common plant measurements
 Mathematically, pressure is expressed:
P = F / A
P = Pressure F = Force A = Area
What is Pressure?

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Pressure Reference
0 psig
+14.7 psia
-14.7 psig
0 psia
Reference
NegativeGauge
Pressure
Reference
PositiveGauge
Pressure
Vacuum
PositiveAbsolute
Pressure
Vacuum
Reference
Reference
Gauge Absolute Vacuum Differential
Atmospheric
Pressure
(Sea Level)
Absolute Zero
Pressure
(Perfect Vacuum)

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Pressure Transmitters
Absolute DP Gauge

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Pressure Sensor
Technologies

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Pressure Sensor Types
Capacitance Silicon Resonant
Piezoresistive
15-50 pf differential
Two ‘H’ shaped
bridges resonating
@ 90 kHz are located
in a silicon substrate
Typical Capacitance
Pressure Sensor
Isolating
Diaphragm
Capacitor
Plates
Fill Fluid
Sensor
Plates
Wheatstone Bridge
Diaphragm
Silicon
Pyrex Glass
Piezoresistor
(4x)

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Silicon Resonant Sensor

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Silicon Resonant Sensor
When a D.P. is applied
 The outer sensor goes into tension (freq )
 While the inner sensor goes into compression (freq )
The resultant D.P. is linear with
the difference in frequency
Low Pressure Side
High Pressure Side
Tension
Compression

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Advantages of Resonant Sensor
Inherently Digital Output
 Frequency Signal
 No A/D Conversion Errors
 Re-ranging Errors Eliminated
Large Change in Output
 Excellent Resolution
 Frequency Shift 40K Hz
Silicon Resonator
 Minimal Hysteresis
 Minimal Temperature Coefficient

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Transmitter Overview

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Transmitter Overview
Sensor
Convert to analog
or digital signal
Transmit
signal
Controller or
monitor
Process
variable
Quckly, Accurately, Reliably

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Transmitter Terminology
Lower Range Limit (LRL): Minimum value that a sensor can measure.
Upper Range Limit (URL): Maximum value that a sensor can measure.
Range: Total pressure that the sensor can measure. (Range = URL + │LRL│)
Lower Range Value (LRV):
The lowest value that the transmitter has been adjusted to measure. This
value corresponds to the 4 mA analog signal.
Upper Range Value (URV):
The highest value that the transmitter has been adjusted to measure. This
value corresponds to the 20 mA analog signal.
Span:
The difference between the URV and LRV (Span = URV – LRV). Sensor
have a minimum span requirement that must be considered while assigning
the 4 to 20 mA analog output.
SPAN
LRV URV
N >N
URLLRL
4 mA 20 mA
RANGE

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Verification and
Calibration Overview

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Calibration Basics
 Sensors convert pressure, current, voltage,
temperature, humidity, light, sound, etc to a
quantity that can be measured by a process
controller (voltage, current, or resistance)
 Various types of field sensors include:
 Thermocouples/RTD’s –
Temperature measurement
 Current Transformers –
Current (mA,A) measurement
 Strain Gauges – Force (applied pressure)
 Photodiodes – Light
 Manometers – Pressure
 Microphones – Sound

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Characterization of Sensor
Each sensor is unique;
therefore it yields a unique output for a give input.
Unique
Output
Input
Pressure
Unique
Sensor
Characterization Curve
Input
Pressure
Unique
Sensor
Characterization
Curve
Unique

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Calibration Basics
 Most, if not all, transmitters have default factory settings that may or may not
be matched accurately with the quantities they are measuring
 The idea is to linearize the process variable measurement range of the
transmitter across its full span
 For example, if a pressure sensor is rated for 2000 PSI, we’d want it to output
maximum current (20 mA) when we apply that pressure to the input
 For this discussion, we will focus exclusively on pressure sensors, due to their
ubiquitous nature
 Temperature, flow and level can all be derived from pressure
Sensor Readings and Scaling

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Calibration Basics
 These calibrators are best designed for
in field usage and combine accuracy
with portability.
 They are mostly battery operated,
although some may have connections
for a wall socket
 They can support some of the most
commonly used industrial protocols
such as HART, BRAIN, ProfiBus,
Modbus, and Ethernet/IP
 Other features include data logging to
internal memory or and external drive
for offline analysis
Portable Calibrators
CA150 Multifunction
Calibrator
CA450 Process
Multimeter

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Calibration Basics
 A calibrator is a type of instrument that functions both as a sourcing and a
sinking device. Some of the most commonly encountered types of
calibrators measure:
 Temperature
 Voltage/Current
 Power
 Pressure
 Resistance
 Their function is to verify sensor output by producing a stimulus (either
current or voltage) and verify the reading of the transducer under test
When and Why to Use a Calibrator

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Calibration Basics
 For example, A technician may want to verify that his or her temperature
controller is displaying the proper output (in degrees C or F) based on
thermocouple type
 A Temperature calibrator, which, at its core, is a highly precise DC voltage
source that can output a wide range of voltages for different thermocouple
types can be used for this purpose
 The calibrator’s output would then be used to adjust the sensitivity or verify
the accuracy of a controller

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Calibration Basics
 All test and measurement devices come with a certain accuracy as per
specifications
 Over time, these instruments degrade due to normal wear and tear, as well as
due to exposure to hazardous environments
 Periodic maintenance (anywhere from monthly to annually) is thus essential to
making sure these instruments maintain their reliability
 At its core, calibration involves adjusting the tolerance levels of a measuring
device against a known reference, so the two are in sync
Calibration – Why it is important

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Calibration Basics
 There are two commonly used types of calibration data available to
manufacturers and end users of field instruments
 As Found data refers to the performance of the instrument in its latest state.
 For example, a company may have a pressure transmitter in a refinery for a
year, and would like to know if the device is out of tolerance.
 He would then run through his calibration procedures to verify proper functionality.
 As Left data refers to the performance of the instrument after adjustment.
 If the As Found tests passed successfully, this step would not be necessary, or
would only need minor adjustment
As Found vs As Left Calibration

| Presentation Name | Date |
© Yokogawa Corporation of America
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Calibration vs Verification
 Although the terms are sometimes used interchangeably, it is important to note
that they are two different processes
 Calibration is used to determine what correction is needed for an instrument to
meet its rated settings
 Verification determines the percentage error of the instrument’s readings
relative to a maximum percentage error the end user is willing to accept
 I.e., a 2% error on a verification test with a maximum tolerance of 1% would
be a “NO-PASS”

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Verification
 This need not necessarily be the maximum specifications of the
unit, and often times is not
 As mentioned earlier, this is the
(URV – LRV)
 Linearization involves the transmitter outputting maximum current
(20mA) at the URV and 4mA at the LRV, with 12mA corresponding
the average of the URV and LRV
Pressure transmitter verification involves
1 Choosing a span around which to linearize
the transmitter

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Verification
 The rule of thumb is to have a calibrator which is at least four times
as accurate as the unit under test
 For example, if our transmitter is rated for 0.04% of reading, we would
want a pressure calibrator that has at least 0.01% accuracy
 First an As Found calibration is performed at predetermined
tolerance levels
 Tolerance levels are specified in percentages, which then correlate to a
mA deviation limit
 Yokogawa calculates this as ±((100% value of the measurement function
– 0% value of the measurement function) × tolerance setting / 100)
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Comparing the measured value of the
transmitter against a known reference point –
A pressure calibrator

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Verification
 So if we use 4mA as our low range, 20 mA as the upper range, with a
1% tolerance, our threshold for pass/fail would be ±(20 mA – 4
mA)×0.01/100 = ±0.0016 mA
 Thus, if we are calibrating the URV at 1% tolerance, we should
expect to get a reading from the transmitter between 19.9984 mA and
20.0016 mA
 If the unit passes the As Found test, no further calibration is
necessary

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Verification
 We then perform an adjustment
 This involves changing the URV and LRV parameters on the transmitter to match
what is being read on the calibrator
 I.E., if our span is 0-2000 PSI, we’d want the transmitter to output 20mA when the
calibrator is reading 2000 PSI, and 4 mA when it is reading 0 PSI
 We then do an As Left Calibration in a similar fashion as the As Found
 If adjustments were done properly in the previous step, we should see the
transmitter reacting more similarly to the calibrator
If the unit does not pass the As Found test

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Verification
 All tests performed on the unit
 The results (Pass/Fail) of each test and the margin by which the test
results differed from the expected results
 The model and serial number of the UUT
 The date/time the tests occurred
 The pressure ranges and response times of each test
Once the As Left calibration process is
finished, it is typical to generate a
calibration report which details

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Verification
DEVICE TAG
MODEL EJX110A
SERIAL NO 91H336726
PRODUCT DATE 1900/00/00
LOOP NAME Pressure Test
PRESS. RANGE 0.00 – 100.00 kPa
OUTPUT RANGE 4.00 – 20.00 mA
DSPLAY RANGE 0.0 – 100.0%
TOLERANCE ±1%
CALLIBRATION DATE 2017.10.02
CALLIBRATION MODEL CA700
CALLIBRATION SERIAL 91PA10134
Device Information
As Found:
TARGET DATA MEASURED DATA
INPUT OUTPUT INPUT OUTPUT ERROR JUDGE
kPa mA kPa mA %
0.000 4.000 -0.080 4.400 2.58% FAIL
50.000 12.000 49.440 11.886 -0.16% PASS
100.000 20.000 100.030 19.955 -0.32% PASS
COMMENT
As Left:
TARGET DATA MEASURED DATA
INPUT OUTPUT INPUT OUTPUT ERROR JUDGE
kPa mA kPa mA %
0.000 4.000 0.040 4.010 0.02% PASS
50.000 12.000 50.990 12.174 0.09% PASS
100.000 20.000 100.760 20.142 0.12% PASS
COMMENT
Callibration Information:
Generated by FieldMate Yokogawa Electric Corporation

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CA700
The Yokogawa Portable
Pressure Calibrator (CA700)
uses the same technology as
our DPHarp series pressure
transmitters (EJA-E and EJX-
A). It provides an accurate and
efficient calibration and
verification tool for any
pressure transmitter or other
type of field device.

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PM100 2300 PSI Module
 Due to high demand in the US
market to calibrate larger pressure
ranges, Yokogawa released the
PM100 2300 PSI (16 MPa)
module
 Effectively extends the calibration
range of the CA700, while still
maintaining the same basic
accuracy of 0.01% of reading
 This unit plugs into the top of the
 CA700 via a connection cable
that converts the measured
pressure to digital data. CA700’s
with firmware version earlier than
1.10 will need to be updated to
1.10 to communicate with this unit
112 (W) × 75 (H) × 148 (D) mm
Approx.1.2Kg

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FieldMate Overview

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What is FieldMate??
 Field Device Configuration and Management Tool
 Portable PC Based
 One Tool for All Instruments (Regardless of Comm.
Protocol or Manufacturer)

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Differences in FieldMate versions
Functionality
FieldMate
Remark
Lite Edition Full Function Edition
FieldMate recording the
information of the device
connected in the past
(Number of Device
Maintenance Information)
7 Devices 500 Devices
FieldMate Lite Edition
does not support
importing/exporting
function.
FieldMate showing 10 Typical
parameters on Home Screen
(Segment Viewer)
Not Selectable Selectable
FieldMate conducting “Input
Loop Check” based on its test
pattern
Unable to edit its test pattern Editable test pattern
Report function is
limited (Max. only 7
devices)
FieldMate generating the report
of parameter comparison
between past and current one
No support Support
Lite Edition vs Full Function Edition

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FieldMate Communication
FieldMate is a single tool which supports device
configuration of multiple vendors and leading
industry standard communication protocols.

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FieldMate Maintenance Features
Home screen (New Interface of Segment Viewer)
Conduct frequently used functions from Home Screen
Device Icon
Yokogawa Device only
Device Status
Color coded status of
online device
Typical Parameters
10 frequently used
parameters can be
selected by user
Memo, Photo,
Configuration Tool
Latest device appearance
Device Configuration from
Action button
Device Info.
Tag, Vendor, etc.
Frequently used function
Last conducted data is also
shown
1
2
3 4
6
5
1
2
3
4
6
5

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Home screen (New Interface of Segment Viewer)
Conduct frequently used functions from Home Screen
Multi protocol
support
Users do not
usually change the
communication
protocol, hence this
function is not
shown as default.
From this button,
show and change
the communication
protocol.

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Example: User’s work flow for Device Installation
Zero Adjustment
Zero Adjustment
Loop Check
Work Report
Installation of Devices
Calibration Check
(if users want)
Configuration & Parameter Check
HOME SCREEN

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New Features for R3.03 c
FieldMate
 CA700 with PM100 Calibration
Procedure
 Link with Pressure calibrator
expands device maintenance
and management capability
 Trend Data and Alarm List
History
 Selected data are displayed
and stored every time on its
connection
 BT200 displayed
 New look and feel

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PC/FieldMate
EJA
24VDC
Power Unit
SUPPLY CHECK
+ -
Load
Resistor
USB
USB FieldMate MODEM
No porlarity
FieldMate HART Hardware Setup
 HART/BRAIN EJA/EJX Pressure Transmitter
 24 VDC Power Supply
 Load Resistor (250Ω)
 USB Modem (HART/BRAIN)

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USB cable
FieldMate
modem
Pressure transmitter
Air tube
Pressure pump
Measurement
Leads
Field Equipment Maintenance
New Features for R3.03 c

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BACKGROUND
 Configure the Field Device
parameters to fit a users’
process and to bring out the
Field Device performance, which
in turn will help to optimize
facilities operations.
FIELD MATE CORE
FEATURES
 Provide onscreen configuration
guides to ensure the efficient
device configuration. Field Mate
supports a dedicated
configuration tool for Yokogawa
devices.
 Support device configuration of
multiple vendors and leading
industry standard communication
protocols.
FIELD MATE ADDITIONAL
FEATURES
 Generate the reports by only one
click
 Save the additional information
about a device condition
 Share Maintenance info with
PRM for Total Asset
Management
Review of FieldMate

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Applications

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Applications
Maintenance Recalibration Flow
Measurement
Filter
Measurement

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Summary
 Pressure transmitters come in four varieties
Gauge
Absolute
Differential
Vacuum
 Sensors used to measure pressure come in three major
groups:
Capacitive
Piezoelectric
Silicon Resonant

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Summary
 Sensors and Calibrators
Sensor
Calibrator
Calibration vs Verification
 Pressure Calibration involves checking the linearity of a
pressure transmitter against a known reference. The
stages involve:
As FOUND Testing
Adjustment/Sensor Trimming
AS LEFT Testing
Report Generation

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Summary
 Yokogawa Tools to facilitate pressure transmitter
calibration involve:
CA700
PM100
FieldMate

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Disclaimer
 Images within this presentation are from various
sources unless otherwise noted

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Thank you for
your attention!

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