ISA Calibration A Technician S Guide Cable 2005 PDF

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CALIBRAT'ION
. A TECHNICIAN'S GUIDE
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C·ALIBRA TION·,
A TECHNICIAN'S. GUIDE
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MikeCable
ISA TECHNICIANSERIES
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Copyright © 2005 by ISA
67 Alexander Drive
P.O. Box 12277
Research Triangle Park, NC 27709
All rights reserved.
Printed in the United States of America.

10 9
August 2011 Printing
ISBN-10: 1-55617-912-X
ISBN-I3: 978-1-55617-912-9
No part of this work may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise,
without the prior written permission of the publisher.
Notice
The information presented in this publication is for the general education of the
reader. Because neither the author nor the publisher has "anycontrol over the use of the
information by the reader, both the author and the publisher disclaim any and all liability
of any kind arising out of such use. The reader is expected to exercise sound professional
judgment in using any of the information presented in a particular application.
Additionally, neither the author nor the publisher have investigated or considered the
effect of any patents on the ability of the reader to use any of the information in a particular
application. The reader is responsible for reviewing any possible patents that may affect
any particular use of the information presented.
Any references to commercial products in the work are cited as examples only.
Neither the author nor the publisher endorses any referenced commercial product. Any
trademarks or tradenames referenced belong to the respective owner of the mark or name.
Neither the author nor the publisher makes any representation regarding the availability of
any referenced commercial product at any time. The manufacturer's instructions on use of
any commercial product must be followed at all times, even if inconflict with the
information in this publication.
Library of Congress Cataloging-in-Publication Data inprocess.

TABLE OF CONTENTS
About the Author . . . . . . . . • . . . . . . . ..' • . . . , , , , , , , , , . . • . ix
Acknowledgements, . , . , .. : , .. , .. , .... " , , , , , , , . , , , . , , xi
Introduction ... , . , . , ... , , . , , . , .. , , .. , , , , . , , , , , , , , : xiii
Chapter 1 Calibration Principles .. ,.: :; , . , .'1 i

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1.1 - What Is Calibration? , ,, ,,.,, 1 I
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1.2 What Are the
.. Characteristics of a Calibrationli
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1.3 Why lsCalibration Required?" ,., .. " ... ··:··"~·'.·6 , ·~·i
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1.4 Who Performs Calibrations? - The Control
System Technician 8
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1.5 Characteristics of a Control System Technlclan-. 9
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1.6 Loop Calibration vs. Individual Instrument ;~

Calibration .. ' ..... '... '.' . ; .' ' ,~ 10.
1.} Bench Calibration vs. Field Calibration '.. 11
1.8 Classiflcatlon of Instruments , 12
Chapter ?ummary '.' . 13
Review.Questions -.. . . . . . . . . .. 14·
Chapter 2 Documentation . . . , , . . . . . . , , . , . . , , , . . . , ., 17
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2,1 Calibration Procedure'Content, .... , , , , . .. 19
2.2 Calibration Data Sheets
(See Examples in .Appendix A-4) , . , 21
2.3 P&IDs (See Example in Appendix A-1 l ' .. . . . 23
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2.4 . Loop Diagrams (See Examples.in

Appendix A-2l .' ' 25
v
vi Table of Contents
2.5 Instrument Specification Forms

(See Examples in Appendix A-3) . . . . . . . . . . 26
2.6 Project Specifications 27
2.7 Manufacturer's Specifications 27
2.8 Calibration Intervals 28
2.9 Safety Considerations 29
2.10 Calibration Status Labels. . . . . . . . . . . . . . . . 30
Review Questions . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 3 Temperature Instrument Calibration 33

3.1 What is Temperature? 33
3.2 Temperature Sensors 34
3.3 Signal Conversion 35
Chapter 4 Pressure Instrument Calibration. . . . . . . . . . . . . • . 49

4.1 What is Pressure'? ................................ 49
4.2 Challenges When Calibrating Pressure .......... 50
4.3 Calibrating Pressure Gauges ........ , ....... 52
4.4 Calibrating Pressure Transmitters .......... 55
4.5 Calibrating Pressure Switches ............ 55
Review Questions 56
Chapter 5 level Instrument Calibration 61

5.1 Types of Level Instruments .............. 61
5.2 Special Considerations with Level Calibration 64
5.3 Calibrating a Differential Pressure Level
Transmitter ......................... 67
5.4 Calibrating a Capacitance Level Instrument ... 71
5.5 Ca1ibratingan Ultrasonic Level Instrument. ... 72
Chapter 6 Flow Instrument Calibration . . . . 77

6.1 Types of Flow Instruments : 77
Calibration vii
6.2 Calibration of Flowmeters ' 82

6.3 DIP Transmitter Calibration 83,
6.4 Example: Magnetic Flowmeter Calibration 84
6.5 Flowmeter Calibration Using a Master
Meter (Prover). . . . . . . . . . . . . . . . . . . . . . . 86
6.6 Gravimetric Method for Flowmeter
Calibration (Measurement by Weight) . . . . . . . 87
Chapter 7 Final Control Devices Calibration . . . . . . .'. . . . . . . 89

7.1' Calibration of an l/P Transducer '. . 95
7.2 Calibration of a ValvePositioner " 96
7.3 Calibration of a Control Valve ~ ', .. 97 j
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Review Questions :0';:' 9<7 " , .: I

Chapter 8, ProcessAnalytical Instrument Calibration. . . . . .. 101 ;1
8.1 pH Calibration Procedure ' ~105 :~
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8.2 Diagnostic Test for pH Electrodes 106
8.3 Measuring Conductivity '·'107
8.4 Calibration Procedurewith Explanations. . .. 109
Review Questions . . . . . . . . . . . . . . . . . . . . . .. 111
Bibliography ........•............... " . . • . . . . . . . .. 113
, Appendix A-1. Piping & Instrument Diagrams(P~IDs) . . . . . . .. 117
,Appendix A-2. loop Diagrams..... : . . . . . . . . . . . . . . . . . . . 119
Appendix A-3. Instrument Specifications . . . . . . . . . . . . . . . .. 123

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Appendix A-4. Calibration Procedures ; '. . . 145
Appendix A-5. Test Equipment ......•.............•.•• 227
Appendix A-G. RTD and Thermocouple Tables 229
Appendix A-7. ConversionTables .....•............... ~ 245
Appendix B. Answers to Chapter Review Questions... '. . . • • . 249
Index ....•. ~ 271

ABOUT THE AUTHOR
Michael Cable is a Level 3 Certified Control System Technician. He is

currently the Validation Manager at Argos Therapeutics illDurham, NC
where his responsibilities include managing the Calibration Progr~.
Michael started his career as an Electronics Technician in the Navy
Nuclear Power Program, serving as a Reactor Operator ~d" Engineering""' ""
Watch Supervisor aboard the USSLos Angeles submarine"and then at .the
AIW prototype in Idaho Falls. After leaving the Navy, he started his ". ,
civilian career at Performance Solutions performing technical services for
the pharmaceutical industry. His 11 years there was highlighted by an, '",
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assignment to Eli Lilly Corporate Process Automation managing .' "
Instrument Qualification projects and-then starting up a Calibration

Services division within Performance Solutions. His practical expertise in
instrumentation and, controls led him to his current career path ill
Validation, which has been his main focus'for the last 7 years.
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ACKNOWLEDGEMENTS
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I'd like to thank Tom Stevens for running a company where people are
allowed to pursue their interests, but more importantly because of the
support and encouragement he has given me over the years. I'd also like
i to thank those professionals that I have worked with over the years who
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have contributed in so many ways to my development and the
development of those throughout industry. I need to thank those that
helped me early on with performing calibrations in an industrial '
environment: Billand Randy at the Eli Lilly (Greenfield) Instrument Shop.
Also to my last supervisor in the Navy, Master Chief Lane Phillips, who
taught me many things technically; but most importantly, character. I alsO" .
appreciate Chip Lee and the staff at ISAwho have been very patient,
gently nudging me along, as I struggled through this project. .
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INTRODUCTION
ISA's Certified Control System Technician (CCST)program

requirements were developed based on a Job Analysis Report initiated by
ISA- The Instrumentation, Systems, and Automation Society and
. Instrument Technicians Labor-Management Cooperation Fund, Response
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to the survey used to validate the Job Analysis Report indicated that
calibration was the most important, most critical, and most frequently
performed of all seven domains for each of the three levels of certification:
This is'not to minimize the importance of the other six domains, because
each is important to'alltechnicians:.How.ever;itis:ob.vious,that;calibIatiorF~::: ..
is what most of us do eyery day. The purpose 'ofthis book is to serve as a:'
• Study guide for the Calibrationdomain in CCSTcertification. ,!!

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..I • Reference for technicians who perform process instrument :

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calibrations, ~;.,
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• Reference in the classroom for students pursuing studies related to »:

,instrumentation. :"
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This text is applicable for control system technicians performing
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maintenance and calibrations within the process industry. Although most
of the principles would apply, this is not meant for metrologists
performing calibrations of lest standards in a standards laboratory.
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Mike Cable I
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CALIBRATION PRINCIPLES
,After completing this chapter, you should be able to:

Define key terms 'relating to calibration and interpret the
meaning of each.
Understand traceability requirements and how they are
.meimsined.
Describe characteristics of a good control system technician.
Describe differences between bench calibration and field
calibration. List the advantages and disadvantages of each.
Describe the differences between Ioop calibration .end-r-:
individual instrument calibration. List the advantages and
disadvantages of each.
List the advantages and disadvantages of classifying
I] instruments according to process.importance -"-for example, ,

'critical, non-crittoel, reference only, OSHA, EPA, etc.
1.1 WHAT IS CALIBRATION?

There are as many definitions of calibration as there are methods,
According to ISA's The Automation, Systems, and Instrumentation Dictionary,
'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 toset the desired span.
An interpretation of the definition would say that a calibration is a
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comparison of measuring equipment against a standard instrument of
_ higher accuracy to detect, correlate, adjust, rectifyand document the
accuracy of the instrument being compared.
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Typically, calibration of an instrument is checked at several points
thr~ughout the calibration range of the instrument. The calibration range is,
defined as "t~eregion between the limits within which a quantity is
measured, received or transmitted, expressed by stating the lower and
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2 Calibration Principles
upper range values. The limits are defined by the zero and span values.
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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 the instrument range, which refers to the
capability of the instrument. For example, an electronic pressure
transmitter may have a nameplate instrument range of 0-750 pounds per
square inch, gauge (psig) and output of 4-to-20 milliamps (rnA). However,
the engineer has determined the instrument will be calibrated for 0-to-300
psig = 4-to-20 rnA. Therefore, the calibration range would be specified as
=
O-to-300 psig 4-to-20 rnA. In this example, the zero input value is 0 psig
~nd zero output value is 4 rnA. The input span is 300 psig and the output
span is 16 mAo
Different terms may be used at your facility. Just be careful not to
confuse the range the instrument is capable of with the range for which
the instrument has been calibrated.
1.2 WHAT ARE THE CHARACTERISTICS OF A

CALI BRATION?
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Calibration Tolerance: Every calibration should be performed to a specified
tolerance. The terms tolerance and accuracy are often used incorrectly. In
ISA's The Automation, Systems, and Instrumentation Dictionary, the
definitions for each are as follows:
Accuracu: 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.
Tolerance: Permissible deviation from a specified value; may be expressed

in measurement units, percent of span, or percent of reading.
As you can see from the definitions, there are subtle differences
between the terms. It is recommended that the tolerance, specified in
measurement units, is used for the calibration requirements performed at
your facility. By specifying an actual value, mistakes caused by calculating
percentages of span or reading are eliminated. Also; tolerances should be
specified in the units measured for the calibration.
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Calibration 3
For example, you are assigned to perform the calibration of the

previously mentioned O-to-300psig pressure transmitter with a specified
calibration tolerance of ±2 psig. The output tolerance would be:
2 psig
+ 300 psig
X 16mA
0.1067 rnA-
The calculated tolerance is rounded down to 0.10 mA, because

rounding to 0.11rnA would exceed the calculated tolerance. It is
recommended that both ±2 psig and ±O.10 rnA tolerances appear on the
calibration data sheet if the remote indications and output milliamp signal
are recorded. .
Note.the manufacturer's specified accuracy for this instrument may
be 0.25%full scale (FS).Calibration tolerances should not be assigned i
based on the manufacturer's specification only. Calibration tolerances -I
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should be determined from a combination of factors. These factors I
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include: I
• - Requirements of the process I

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• Capabilityof available test equipment
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• Consistency with similar instruments at your facility
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• Manufacturer's specified tolerance.
, Example: The process requires ±soC; available test equipment is capable

of ±O.25°Ci and manufacturer's stated accuracy is ±O:25°C. The specified j
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calibration tolerance must be between the process requirement and
manufacturer's specified tole:rance.Additionally the test equipment must
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be capable of the tolerance needed. A calibration tolerance of ±i °C might
be assigned for consistency with similar instruments and to meet the !
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recommended accuracy ratio of 4:1. . "J
AccuraCY Ratio: This term was used in the past to describe the relationship i
between the accuracy of the test.standard and the accuracy of the
instrument under test. The term is still used by those that do not
understand uncertainty calculations (uncertainty is described below). A .
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good rule of thumb is to ensure 'an accuracy ratio of 4:1when performing r

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calibrations. This means the instrument or standard used should be four
times more .accuratethan the instrument being checked. Therefore, the test
equipment (such as a field standard) used to calibrate the process

instrument should be four times more accurate than the process
instrument, the laboratory standard used to calibrate the field standard
should be four times more accurate than the field standard, and so on.
With today's technology, an accuracy ratio of 4:1is becoming more
difficult to achieve. Why is a 4:1ratio recommended? Ensuring a 4:1 ratio
will minimize the effect of the accuracy of the standard on the overall
calibration accuracy. If a higher level standard is found to be out of
tolerance by a factor of two, for example, the calibrations performed using
that standard are less likely to be compromised.
Suppose we use our previous example of the test equipment with a
tolerance of ±O.2S°Cand it is found to be O.soCout of tolerance during a
scheduled calibration. Since we took into consideration an accuracy ratio .
of 4:1 and assigned a calibration tolerance of ±1DCto the process
instrument, it is less likely that our calibration performed using that
standard is compromised.
The out-of-tolerance standard still needs to be investigated by reverse
traceability of all calibrations performed using the test standard.
However, our assurance is high that the process instrument is within
tolerance. Ifwe had arbitrarily assigned a calibration tolerance of ±O.2SDC
to the process instrument, or used test equipment with a calibration II
tolerance of ±1DC,we would not have the assurance that our process
instrument is within calibration tolerance. This leads us to traceability.
Traceability: All calibrations should be performed traceable to a nationally

or internationally recognized standard. For example, in the United States,
the National Institute of Standards and Technology (NIST),formerly
National Bureau of Standards (NBS),maintains the nationally recognized
. standards. Traceability is defined by ANSI/NCSL 2540-1-1994(which
replaced MIL-STD-4S662A)- as lithe 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."
Note this does not mean a calibration shop needs to have its standards
calibrated with a primary standard. It means that the calibrations
performed are traceable to NIST through all the standards used to
calibrate the standards, no matter how many levels exist between the shop
andNIST.
Traceability is accomplished by ensuring the test standards we use
are routinely calibrated by "higher level" reference standards. Typically
the standards we use from the shop are sent out periodically to a
standards lab which has more accurate test equipment. The standards
Calibration' 5
from the calibration lab.are periodically checked for cali~ration by "higher

level" standards, and so on until.eventually the standards are tested
against Primary Standards maintained by NIST or another internationally
recognized standard. .
The calibration technician's ~olein maintaining traceability is to
ensure the test standard is within its calibration interval and the unique
identifier is recorded on the applicable calibration data sheet when the
instrument calibration is performed. Additionally, when test standards .
are calibrated, .the calibration documentation must be reviewed for ,
accuracy and to ensure it was performed using NIST traceable equipment.
FIGURE 1-1.
Traceability Pyramid
National
Measurement
Standard
(e.g, NIST)
I. Primary Standards
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Secondary Standards
Working Standards
("norma'" shop instruments)
Process Instrument
Uncertaintu: Parameter, associated with the result of a measurement that

characterizes the dispersion of the values that could reasonably be
attributed to the measurand. Uncertainty analysis is required for
calibration labs conforming to ISO 17025requirements. Uncertainty
analysis is performed to evaluate and identify factors associated with the
calibration equipment and process instrument that affect the calibration
accuracy. Calibration technicians should be aware of basic uncertainty
analysis factors, such as environmental effects and how to combine
multiple calibration equipment accuracies to arrive at a single calibration

equipment accuracy. Combining multiple calibration equipment or
process instrument accuracies is done by calculating the square root of the
sum of the squares, illustrated below:
Calibration equipment combined accuracy
J(calibrator 1 errol) 2 + (calibrator2 erroj 2 + (etc. erroj 2

Process instrument combined accuracy
(sensor erroj 2 + (transmitter erroj 2 + (indicator errol) 2 + (etc. errol) 2
1.3 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 can't we just leave it alone as
long as the instrument is operating properly and continues to provide the
indication we expect?
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. An error is the algebraic difference
between the indication and the actual value of the measured variable.
Typical errors that occur include:
FIGURE 1"2.
Span Error
100%
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a. SPAN ERRORS
5o
<f.
"/0 INPUT
Calibration 7
FIGURE 1-3.
Zero Error
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0..
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% INPUT
FIGURE 1-4.·
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Combined Zero and Span Error
100%
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0..
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{~OMBINED ZERO AND
SPAN ERRORS·
o .. % INPUT
FIGURE 1-5.
Linearization Error
100%
f-
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0..
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% INPUT
Zero and span errors are corrected by performing a calibration. Most

instruments are provided with a means of adjusting the zero and span of
the instrument along with instructions for performing this adjustment.
The zero adjustment is used to produce a parallel shift of the input-output
curve. The span adjustment is used to change the slope of the input-output
curve. Linearization error may be corrected if the instrument has a
linearization adjustment. If the magnitude of the nonlinear error is
unacceptable and it cannot be adjusted, the instrument must be replaced.
To detect and correct instrument error, periodic calibrations are
performed. Even if a periodic calibration reveals the instrument is perfect
and no adjustment is required, we would not have known that unless we
performed the calibration. And even if adjustments are not required for
several consecutive calibrations, we will still perform the calibration check
at the next scheduled due date. Periodic calibrations to specified
tolerances using approved procedures are an important element of any
quality system.
1.4 WHO PERFORMS CALIBRATIONS? - THE

CONTROL SYSTEM TECHNICIAN
A control system technician (CST)is a skilled craftsperson who
knows pneumatic, mechanical, and electrical instrumentation. He or she
understands process control loops and process control systems, including
Calibration 9
those that are computer-based. Typically, he or she has received training

in such specialized subjects as theory of control, analog and/ or digital
electronics, microprocessors and/ or comput~rs, and the operation and
maintenance of particular lines of field instrumentatio~. .
A CSTperforms 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.
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1.5 CHARACTERISTICS OF A CONTROL SYSTEM
TECHNICIAN ..
Honesty and Integrity: A CSTmust possess honesty and integrity above all
else. Most technicians work independently much of the time. Calibrations. __ :,
must be performed in accordance with procedures and must be properly
documented. Additionally, the calibr~tion department may-be : ~;J
understaffed and production schedules.may demand unrealistic ,;(:;.
completion requirements. These factors can have a real impact on proper' ..
performance and documentation of calibrations: Remember: Nobody-can
take away your integrity; only you can give it away. _'.'
.' . Attention to Detail: Calibrations should be performed ~ accordance with .\-
detailed instructions. Each different make/model instrument is adjusted

differently. Each instrument is installed in a different physical and loop
configuration. Because of these and many other differences, attention to
detail is very important. The minute a technician is not paying attention to .
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detail, safety and proper performance are jeopardized ..
Excellent Documentation Practices: In many facilities, the impression of

quality is, determined by the 'content and appearance of documentation.
,Many technicians complain the paperwork is 90% of the work. In today's
world of 1509000, cGMPs,A2LA and other quality standards,
documentation is essential. If it isn't documented; it wasn't done.
Calibration Data Sheets must be neat, complete, signed and, if required,
~eviewed in a timely manner. When changes occur, all related .
documentation, such as drawings, manuals, specifications and databases
_must also be updated.
Understanding of Processes: One thing that sets technicians apart is an

understanding of the' process, particularly how the instruments monitor
and control the process. There is a difference between calibrating an
individual component and calibrating an instrument as part of the bigger
process control loop. For example, knowing when a controller can be
placed in manual without affecting the process and what to do while that
controller is in manual, requires an understanding of the process.
Additionally, when an operator says there is a problem with his
indication, a technician who knows the instrument loop and process will
be more capable of identifying the cause of the problem.
Some basic concepts on how calibrations should be performed need
to be discussed before we go on. Some of these may be new concepts not
used in your facility, but you should be familiar with them. Some of these
practices are industry dependent. Although calibrations are generally
performed the same, some different practices have developed. These
practices are:
• Loop Calibration vs. Individual Instrument Calibration
• Bench Calibration vs. Field Calibration
,
• Classification of Instruments as Critical, Non-Critical, For
Reference Only, etc.
1.6 LOOP CALIBRATION VS. INDIVIDUAL

INSTRUMENT CALIBRATION
An individual instrument calibration is a calibration performed only on
one instrument. The input and output are disconnected. A known source
is applied to the input, and the output is measured at various data points
throughout the calibration range. The instrument is adjusted, if necessary,
and calibration is checked.
DISADVANTAGES OF INDIVIDUAL ADVANTAGES OF INDIVIDUAL

CALIBRATION CALIBRATION
1. Entire loop is not verified within 1. Correct instrument will be adjusted

tolerance 2. More compatible with multifunction
2. Mistakes on re-connect calibrators
3. Less efficient use of time to do.one
calibration for each loop instrument as
opposed to one calibration for the
loop I
Calibration 11
A loop calibration is performed from the sensor to ali loop indications

with all the loop componentsconnected, FOf example, a temperature
sensor connected to a temperature transmitter would be inserted in a .
temperature bath/block. (Note: Either the bath/block would be calibrated
0; a temperature standard ~ould be used in the bath/block for '
traceability.) The temperature of the bath/block would be adjusted to each
data point required to perform the calibration. All local and remote
indications would be recorded. It is also recommended to record the
transmitter output, If all indications and transmitter output are within
tolerance, the loop is within tolerance. If any loop component is not within "
tolerance, then a calibration is performed on that instrument. Do not
adjust a transmitter to correct a remote indication.
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ADVANTAGE;S OF LOOP DISADVANTAGES OF LOOP
1. Entire loop, including sensor, is 1. Wrong instrument may be adjusted to

verified within tolerance bring the loop within calibration, ,_
2. Mistakes on re-connectmlnlmlzed 2. Not as cornpatiblewith multifunction
3. More efficient use of time to do one calibrators used-for "paperless" d~~a,
calibration for, loop as-opposed to one
calibration for each loop,instrument,
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1.7 BENCH CALIBRATION VS. FIELD

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CALIBRATION (i
A bench calibration is performed in the shop on the bench with power I

, supplied from an external source, if required. Bench calibrations may be
performed upon receipt of new instruments prior to installation. This
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provides assurance the instrument is received undamaged. This also I
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allows configuration and calibration in a more favorable environment. l

Some companies perform-the periodic calibrations on the bench. In this
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case the process instrument is removed from service, disconnected and "
taken to the shop for calibration. In some instances, a spare is installed in

its place so the process downtime is minimized. For example, critical flow
sensors might be sent out to a certified flow calibration facility. To prevent
shutting the process down for several weeks, a replacement flow sensor
would be installed.
Field calibrations are performed "in-situ," or in place, as installed. The
instrument being calibrated is not removed from the installed location.
Field calibrations may be performed after installation to ensl!re proper
connections and configuration. Periodic calibrations are more likely to be

performed in the field. Field calibrations are performed in the
envirorunent in which the instrument operates. If the instrument is
installed in a harsh environment it is calibrated for that envirorunent. If
the instrument is removed for a bench calibration and then returned, some
error may be introduced due to the ambient conditions and orientation.
ADVANTAGES OF BENCH ADVANTAGES OF FIELD

1. Removed, cleaned, inspected 1. May save time

2. Better work environment 2. May identify and allow trouble-
3. Fixed calibration setup and utilities shooting of installation problems
(electrical, air, vacuum) available 3. Performed in actual ambient
environment
1 .8 CLASSIFICATION OF INSTRUMENTS
In some industries or even within individual companies it may be
advantageous to classify your instruments in a way that indicates the
instruments' "importance." There are two schools of thought here. Some
say that no instrument is more important than any other instrument.
However, in some processes, the undetected error in an instrument may
result in product rejections or even product recalls. Additionally, some
instruments have calibration requirements specified by outside agencies.
For these reasons, it is recommended that each instrument is assigned a
classification. ISA-TR91.00.02-2003,Criticality Classification Guideline for
Instrumentation, is an excellent resource to assist with establishing
classification of instrumentation. One example used for classifying
instruments is outlined below.
Critical: An instrument which, if notconforming to specification, could

potentially compromise product or process quality.
Non-critical: An instrument whose function is not critical to product or

process quality, but whose function is more of an operational significance.
Example: An instrument that is not classified as critical, but the reading
obtained from the instrument is recorded in operating logs.
Reference Only: An instrument whose function is not critical to product

quality, not significant to equipment operation, and not used for making
Calibration 13
quality decisions. Routine calibration may be less frequent and

verification of proper operation will be performed if suspect of error.
O~HA; Calibration of the instrument is mandated by the Occupational

Safety and Health Administration. . '
EPA: Calibration of the instrument is mandated by the EPA. Example:

Calibration of the flow totalizer for the wastewater treatment system may
be required by EPA.
. The above classifications may be helpful in assigning calibration

frequencies. For example,' you might assign a calibration frequency of six
months to a "Critical" pressure transmitter. The same pressure transmitter
assigned as "Non-critical" might be calibrated every 12 months.
Another advantage to assigning classifications is to inves~gate out-
.of-tolerance' calibrations 'more' efficiently:'In-many-industries) -out-bf= '.'-
tolerance calibrations are formally reported to.the Quality Department. If
classification of instruments is not used, all out-of-tolerance calibrations
must be investigated for the effect-on product. Ifthe instruments are 'i~:
r
cIassified~and classifications are approved-by the Quality Departmentcthe. ..
ij investigation is performed only for Critical instruments·. Of course, the
Calibration Department should investigate all out-of-tolerance conditions, Ii
but the release
, . of product would not be held up due to an unnecessary
. . "'I!
I'
investigation. , ,
CHAPTER SUMMARY
In this chapter we covered the What, Why, Who, and How as an
introduction to Calibration. We've covered some definitions and concepts
. that calibration technicians need to be familiar with. It should be
emphasized that not all of these concepts are applicable to your facility.
Although it would be convenient if we all ran our calibration programs
exactly the same way, it just isn't so. Most of what will be presented in this
book are examples that do not fit every situation.
REVIEW QUESTIONS
1. Match the term on the left with the definition on the right.
Calibration A. permissible deviation from specified
value
_ Instrument Range B. upper and lower values specified for
facility
_ Calibration Range C. algebraic difference between the upper
and lower range value
_ Accuracy D. adjustment used to produce a parallel
shift of the input-output curve
_ Tolerance E. comparison of instrument to a known
value
_ Traceability F. percent error
Zero G. characterizes the dispersion of the

values that could reasonably be
attributed to the measurand
_Span H. upper and lower values specified by
manufacturer
_ Uncertainty 1. measurement related to standards
through an unbroken chain of
comparisons
2. Which of the following errors is typically not correctable?

A. Zero
B. Span
C. Linearity
D. Zero, span, and linearity errors are always correctable
3. Why should a calibration technician have:
A. Honesty and Integrity?
B. Attention to detail?
C. Excellent documentation practices?
D. Understanding of processes?
Calibration 15
4. What are the advantages of performing a field calibration?

Disadvantages?
5. What are the advantages of performing a bench calibration?

Disadvantages?
6. What are the advantages of performing a loop calibration?

Disadvantages?
7. What are the advantages of performing an .individual instrument

calibration?Disadvantages?
I
i I
,[
8. Wha:tare the advantages of classifyinginstruments by their
J. . "importance I criticality".to .aprocess? ,.
I· ~
'J
d
IJ
9. Arrange the traceability hierarchy below, beginning with lowest
level and ending with the highest, ~ __, -J ......-J _
".
A. Priinary Standards
B. Working'Standards I
C. Process Instrument j
D. NIST (or recognized national standard)
E. Secondary Standards
I
I
I
I
-e-
. i
2
DOCUMENT ATION
. .
After complet/ng this chapter, you should be able to:
List the fundamental elements of a calibration procedure.
List the fundamental elements of a calibration data sheet.

I
Define the relevant calibration information contained in the .j
I
• following resource documents: P&ID, Loop Diagram;
Instrument Specification Sheet, Project Specifications, and J
. Manufacturer's Specifications.
I) List the resources for determination of initial calibration
frequency.for an instrument.
I
i
Identify safety considerations relating to cslibrstion.
Describe the use of calibration status labels and What

,I
.!
I information is required on each.
1
I Because of quality system requirements throughout industry, .
documentation has become as important as the actual performance of a
calibration. This chapter will summarize documentation that all
calibration technicians should be familiar with. Another ISA text,
Instrumentation and Control Systems Documentation, details the
documentation mentioned in this chapter, and more.
i The accuracy and reliability of instrumentation in a facility is .
1I maintained through the development and implementation of a quality
i ..calibration program. Iri addition to inventorying instruments, determining
I calibration parameters and intervals, and purchasing appropriate .test
! ...
i
standard's, a calibration program includes written procedures for
performing calibrations. The level of detail contained in calibration.
procedures can vary considerably-from a generic procedure used to
calibrate an instrument type to a very specific procedure used to calibrate
one particular instrument. Different types of calibration procedures are
discussed below and examples of each are included in Appendix A-4.
17
18 Documentation
Technical Manual procedure: Typically, a manufacturer's technical manual is

provided for each similar model of instrument. Calibration instructions
for the instrument are usually given in the technical manual. These
instructions can be adopted or adapted as the calibration procedure for the
applicable instruments. Most often, the manufacturer's calibration
procedure is used to develop a comp,my calibration procedure approved
by management and the quality department. However, the actual
technical manual procedure may be used or referenced as the calibration
procedure if this practice is approved.
TABLE 2-1.
Using Calibration Procedures from a Technical Manual
ADVANTAGES DISADVANTAGES
Very little time/resources required to Does not contain all necessary elements
develop procedures of a calibration procedure
Technically accurate and detailed Applies to instrument only, not taking
instructions for the specific instrument into account application/process
Generic procedure: Generic calibration procedures can be developed for

each instrument type. For example, one procedure could be developed for
Electronic Pressure/Vacuum Transmitters and another procedure for
Pneumatic Temperature Controllers. You could even go more generic and
develop a procedure for Pressure Instrument Calibration, which would
include gauges, transmitters, etc. for pressure, differential pressure, and
vacUl~m.Generic procedures should recommend using the
manufacturer's technical manual to perform any necessary adjustments.
TABLE 2-2.
Generic Calibration Procedures
ADVANTAGES DISADVANTAGES
limits number of procedures to a Inconsistent methods by different

manageable level technicians using same procedure
Can be a good first step for new facility Inexperienced technicians need more
start-up until more effort can be devoted detail
to procedure development
Specific procedure for an instrument or a manufacturer/model: In most facilities,

some calibration procedures will have to be very specific to particular
instruments. In some cases, specific detailed procedures are required for
each instrument. Analytical instruments for such parameters as
Calibration 19
conductivity (resistivity), oxygen, and lab instrumentation typically

require specific procedures for each type due to the unique differences in
the way each is calibrated. Also, if your generic procedure for a particular
pressure instrument does not adequately address the proper method, a
specific procedure should be developed. Obviously, if safety could be
compromised by using an inadequate generic procedure, a new procedure
, !
addressing the specific safety issues must be developed.
: r
I
TABLE 2-3.
Specific Calibration Procedures
ADVANTAGES DISADVANTAGES r
I
I
Calibrations are performed the same way
~.
by all technicians
Increases resources required to develop,
maintain, and track procedures
. i
I
May take into account the effect on
process
Technicaliy accurate and detailed
I
i
lnstructions for the specific instrument
Some "old school" technicians initially dislike theuse of calibration

'I procedures. They say, "We've always done it this way and neverhad any
problems. Now we've got all this paperwork, it's a wonder We can get any
actual work done." Well, in today's regulated environment,you'll be out
of business if you don't have a documented' calibration program in place,
Your customers must be assured of a certain quality product based on
parameters you said you could maintain. Most of those assurances are
provided from.accurate process instrumentation. It h~s been
demonstrated that instrument accuracy deteriorates during use. The only
way to keep track of accuracy at any given time is to verify, adjust, and
document the calibration data. .J
2. 1 CALIBRATION PROCEDURE CONTENT

What information should be included in a calibration procedure?
First, the format should follow the f6~mat required by yOUI'company
., .-.~-
procedures. Als~ any governing documents, such as the Calibration
Policy, and any applicable procedures subordinate to'the Calibration
Policy must be followed.
20 Documentation
The calibration procedure typically includes most or all of the

following sections:
• Purpose: Clearly states the reason for the procedure such as: "The
purpose of this procedure is to provide standardized instructions
for the calibration of temperature instruments."
• Scope: Clearly states to what and to whom the procedure applies
such as "This procedure applies to the calibration of all analog
pressure gauges at the ABC Company calibrated by employee and
contract teclmicians."
Note: The purpose and scope can be combined into one section of
the procedure. The information in these sections is typically
obvious to those of us who perform calibrations, but the managers
need this so they know what they're approving.
• Definitions: Contains brief descriptions of key terms, as applicable,
for clarity. Acronyms and abbreviations used in the procedure are
noted in this section to document their meaning throughout the
text.
• References/Attachments: Identifies other documents, including
attachments, that are required to be used in conjunction with the
procedure, or allow the user to gain further information regarding
the procedural content.
• Test Equipment/Materials Required: Identifies the test equipment and
materials required to perform the procedure. Listing specific test
equipment in this section helps to ensure uncertainty requirements
are met and/ or the desired accuracy ratio is achieved, particularly
if the minimum tolerance achievable is specified in the Scope or
Title of the procedure. Note that if the specified test equipment is
not available, the technician must notify the supervisor prior to
performing the calibration.
• Safety: Provide information on potential human health hazards
and po~ential hazards to the facility, equipment, or process. All
Safety Work Permit requirements and Material Safety Data Sheet
(MSDS)references are included in this section.
• Prerequisites/Initial Conditions (optional): Provides any conditions
that should be met prior to performing the calibration, such as tank
drained, controller in manual, or system shutdown. Alternatively,
Calibration 21
these conditions can be included in the test procedure and/or

notes printed on the calibration data sheet.
• Test Procedure: This is the meat of the procedure which outlines the
procedure in-a clear, concise,step-by-step manner. If any steps of "
J
the calibration procedure cannot be performed as specified, the
technician must return the instrument to a 'safe condition and
..notify the supervisor.
• Acceptance Criteria: The pass/fail criteria may be included in the
Test Procedure section or as a separate step at completion,
evaluating the results obtained against the tolerances specified.
• Approvals: The author and approval Signatures or approval
authority should be included on ea0 calibration procedure.
As you can see there is a lot of flexibility in what information is

included in the calibration procedure and where the.information is lou'ated'.
in the procedure. Much of this depends on the culture at your facility-and
experience level of the technicians. Personally, Ilike to develop good:":
generic procedures with the instrument specifics printed on the
calibration data sheet used to record calibration data. There are some;~:
·11
. example procedures in the reference section, Some comply with whathas
been described above, some do not. :~:~.
2.2 CALIBRATION DATA SHEETS

(See Examples in Appendix A-4)
You may refer to this as something else, put.what we're talking about
here is the form where the as-found and as-left calibration data is recorded
when a calibration is performed. As of now, most calibration data sheets
.are still hardcopy, usually printed out from a calibration software
package ..Some are still totally manual with no pre-pri.l;ted information,
and that's OK, it works.Weare seeing increased use of paperless
calibrations where the datais either automatically collected by a
documenting calibrator or manually entered into a handheld device as an
electronic record, In any case, the following information should be
I
included as part of a calibration data sheet: I
i
I
• Instrument Tag Number/Instrument Identification Number: This is a
unique identifier or unique combination used as the main tracking
number for each instrument. In most cases the tag number is the
I
f
I
22 Documentation
P&ID tag number if applicable (P&IDs are discussed later in this

chapter). If the instrument is not associated with a P&ID, there
should be some consistent tag number system at your facility that
utilizes the ISA-S.I-I984-(Rl992)standard.
Several facilities use an additional identification number which is
sequentially assigned as an additional tracking number. The tag
number references the instrument location within a system, and
the instrument identification number stays with the instrument.
This way the history of any instrument installed in the instrument
location (Tag Number) is traceable and the history of any
instrument is traceable. Many instruments stay in the same
location for the life of the equipment, in which case this is not as
important. But, failures occur and instruments need to be replaced.
In other instances, spares are installed temporarily to keep a
\ . process running when an instrument is removed for calibration.
This traceability is important, for example, in a pharmaceutical
facility that produces penicillin. Any instrument removed from a
penicillin manufacturing area cannot be used in any other
manufacturing area. The instrument identification number used to
track where an instrument has been is a useful tool in ensuring that
instrument is not installed where it shouldn't be. Even if you don't
have similar needs, it's good practice to use both types of
identification numbers.
• Nameplate Data: The manufacturer, model number, and serial number
should be listed on the Calibration Data Sheet.
• Calibration Range and Calibration Tolerance: This defines the upper
and lower limit used for calibration. Ideally, this is the input and
output range, if applicable. For example, a good format for the
calibration range of a temperah.1r€transmitter would be O-to-IOO°C
= 4-to-20 rnA with a calibration tolerance of ±l.O°Cj±O.I6 mAo As
we saw in Chapter I, the calibration range is not always the same
as the instrument range or capability of the instrument.
• Location: Be as specific as possible about location of the instrument.
You don't want your new technician wasting hours searching.
• Calibration Procedure Number: This is the calibration procedure that
is used to perform the calibration. In some facilities, the entire
calibration procedure is printed on the calibration data sheet.
Calibration 23
• Last Calibration Date, Calibration Due Date, and Calibration Interval:

This information should be included to ensure the calibration is .[
being performed periodically as required. .
• As-found data and As-left data: Relates the test points specified with
the corresponding test standard value. If all as-found data is
. within tolerance and no adjustments are made, the as-left data
would be N / A or the same as the as-found data. Note: Everyeffort
should be made to record as-found data for failed instruments
prior to making any adjustments, in order to provide the most data
for evaluation.
• Test Standards: Record the unique identification of any test
standards used to perform the calibration and, if required by . '..
procedure, record the calibration due' date of the standardfsj.It .
would be best to record this prior to beginning the calibration to
ensure each standard is within its calibration
.
periodicity (butt.of..':.
.:;,..g.. ~:..
"t,
. course you checked this when you obtained the standard froru'the- .
shop). The most important reason for documenting the test. '~.
standards is for reverse traceability in.case a 'standard is foundito
II , be out of tolerance. If a test standard is found out of tolerance on its
. I!, next calibration, it is critical that any calibration performed using
that standard since its last calibration is known and evaluated-to
determine a course of action.
• Comments: The technician needs someplace to record any
comments or observations.
• Technician Signature and Date of Calibration
• Supervisor or Reviewer Signature and Date .
. Example Calibration Data Sheets are included in Appendix A-4. In )
;'.
, addition, some example calibration procedures include a data sheet as an
attachment. I
I
2.3 P&IDs (See Example in Appendix' A-1)
Process/Piping and Instrument Diagrams/Drawings (p&lDs) are I
drawings that provide a detailed overview of a process system They'
include major components, utilities, flowpaths, supporting equipment,
I
and instrumentation. Although P&IDs are' commonly used throughout
industry, there is not yet a "standard'" P&ID. Process Industry Practices
24 Documentation
(www.pip.org) has developed a P&ID practice; however PIP is not a

developer of standards. Draft-Standard-for-Trial-Use, JSA-DSTU-S.07.01,
Piping and Instrumentation Diagram Documentation Criteria, was issued
in May 2002. ISA-DSTU-S.07.01is the result of a cooperative effort
between ISA (SPS.7)and Process Industries Practices (PIP) by which ISA
will develop an American National Standard covering the requirements,
design, and graphic elements of that class of engineering drawings called
a P&ID, or Piping & Instrumentation Diagram. ISA-DSTU-S.07.01is based
on existing PIP Practice PICOOL
ISA standards ISA-S.l-1984-(R1992),Instrumentation Symbols and
Identification, and ISA-S.3-I983,Graphic Symbols for Distributed Control
Shared Display Instrumentation, Logic, and Computer Systems, are the most
generally accepted guides for developing symbolism for instrumentation
and control systems.
From the P&ID of a particular system, a technician can determine
pertinent information about the instrumentation and controls applicable
to performing calibrations and understanding the system operation. The
most important of these include:
• Components of an instrument loop
• Functional identification
• Methods of signal transmission (pneumatic, electronic, hydraulic,
software link, etc.)
• Controller input(s) and output(s)
• Control valve characteristics (fail position, direct! reverse acting)
• Flow sensor types
P&IDs are also used to organize project documentation. Using P&IDs

as the base for all information in a large project provides a single reference
point for data provided on other documents. This makes sense since
P&IDs are used to define system boundaries. It is very important that
P&IDs are controlled and maintained up to date. During start-ups the
"master" P&IDs are marked up and highlighted to reflect the state of a
system at any time. If the technician discovers any discrepancy at any
time, the technician must take the responsibility to ensure the controlled
drawing is properly revised.
An example of a P&ID is in Appendix A-I. Let's look at the P&ID and
see what we can determine about the temperature loop for this process.
We can see from the P&ID that the temperature loop i{lcludesTE-300,
TI-300, TIC-300,TY-300,and TV-300.Using ISA-S.l as a reference, we
Calibration 25
know that the TE is a temperature sensor. We do not know if the

temperature sensor is an RTD or thermocouple. That would be
determined from the specification or physical inspection. The TT is a
temperature transmitter that provides the only input to TIC-300. The TIC
is a shared display, shared control temperature-indicating controller, The
TY is not as obvious if you're not familiar with the use of this symbol. If
you think about it though, you see that the TY is between the electronic
output of the TIC and the pneumatic input of the valve, TV. Since the "Y"
in TY refers to relay, compute, or convert, according. to Table 1 of ISA-5.1,
the TY must be a conversion device in the temperature loop. Most likely
the device is an l /P transducer which converts a 4-to-20 rnA signal from
the TIC to a 3-to-15 psig signal for the valve. The TW inthe loop is a
temperature well, or thermowell, that provides a physical boundary
.between the temperature sensor and the process.
Side note: The thermowell is not a necessary component in the signal

conversion of the temperature signal or control. However, because th~ --"
thermowell consists of a specified thickness of metal it wip slow do~±: the
response time of the temperature signal. Itis also very important to eri.'Sure
'I the temperature sensor is the correct length to make contact with the end
Ii' of the well. Otherwise the air gap will cause an inaccurate reading oJthe
actual process temperature.
2.4 LOOP DIAGRAMS (See Examples in Appendix A·2)

A loop is a combination of interc~nnected instruni..ents that measures
and/ or controls a process variable. An instrument loop diagram is a ..
composite representation of instrument loop information containing all
associated electrical and piping connections. Instrument loop diagrams
are developed in accordance with standard ISA~5.4-1991, Instrument Loop
Diagrams. Example loop diagrams are included in the Reference Section,
Appendix A-2_The minimum content requirements include:
• Identification: of the loop and loop components

• Point -to-point interconnections with identifying numbers or colors
of electrical and/ or pneumatic wires and tubing, including
junction boxes, terminals, bulkheads, ports, and grounding
connections
• General location of devices such as field, panel, I/O cabinet, •
control room, etc ..
26 Documentation
• Energy sources of devices

• Control action or fail-safe conditions
Additional content requirements, format, and examples are included

in ISA-S.4-1991.
A formalized loop check should be documented prior to placing any
loop in service. Tl..is formalized program should include verification of
installation against the loop diagram and simulation of signals to verify
output responses andindications throughout the range. Why is this
important? A significant percentage of instrument loops have some
problem, which may result in hidden failures. For example, a temperature
transmitter output wired to a programmable logic controller (PLC) analog
input provides a temperature display on an operator interface. The
transmitter is calibrated from O-lOO°Cto provide a proportional 4-20 rnA
output. If the PLC programmer writes the code for this input as 0-lS0°C
for a 4-20 rnA input and a loop check is not performed, an inaccurate
displayed value will go undetected. Other typical problems found and
corrected by performing loop checks include wiring connected to the
wrong points, ground loops, and broken wires. Loop checking is another
of the CCST domains and is covered in more detail in another ISA
Technician Guide.
2.5 INSTRUMENT SPECIFICATION FORMS

(See Examples in Appendix A-3)
Instrument specification forms contain the information necessary to
obtain vendor quotes and purchase instrument devices. ISA-TR20
Specification Forms include device specifications for many temperature,
pressure, level, flow instruments in Microsoft Word format. The
information included on each form is specific to the instrument type but
typically includes dimensions, materials of construction, design
temperature/pressure, connection sizes, ambient conditions, indicator
detail, instrument ranges/tolerances, etc. Examples of instrument
specifications are included in the reference section, Appendix A-3. When
instruments are received from the vendor, each should be verified against
the specification to the maximum extent practicable. This should be
documented using a formalized receipt verification process.
For facilities that do not have instrument specification forms from the
system design, these forms can be developed using ISA-T~O or in
accordance with company procedure. Some calibration departments
Calibration 27
develop 'their own forms to specify the information needed to perform

calibrations. These specifications should be approved by users and the
Quality Department to ensure process and quality requirements are
considered. An example of this form is included at the end of
Appendix A-3.
2.6 PROJECT SPECIFICATIONS

Any new manufacturing facility or large expansion project willhave
a set of project specifications. They include architectural, plumbing,
mechanical, electrical, and instrumentation specifications, etc. For J
instrumentation, the project specifications are usually general, but include

content the technician should be aware of, such as:
I
• Instrument tagging requirements
• Size and type of pneumatic tubing .
:'~~. .~.
• Approved methods of mounting instruments
• Wire labeling conventions
·)1 • Intrinsic safety standards "·.1
For some facilities, the project specifications may include detailed

instrument specification forms and an original master instrument list:
Although the calibration technician is not usually installing the devices,
any discrepancies observed should be brought to the attention of a
supervisor ..
2.7 MANUFACTURER'S S'PECIFICATIONS

illthe manufacturer's technical manual or product literature, there is
almost always a specification section. Although most manufacturers
provide very good specifications, they can vary from inadequate to overly
complex. Understanding
.,
what the manufacturer's specifications
. .
mean is
important to purchasing an instrument acceptable for the process
requirements and the technician maintaining the instrument. The most
.important specification for the calibration technician is the instrument
range and accuracy. The range capability of the instrument is usually
understandable; accuracy is another matter. For example, accuracy may be
specified as 0.25%. What does this mean? Is it{).25% of the range or the
reading?For the calibration ofa 0-100 psig pressure transmitter at 20 psig,
28 Documentation
this can mean the difference between 0.25 psig and 0.05 psig. In addition,
the specified accuracy is usually different at different ranges of the
instrument, varying ambient conditions, and may not even be referred to
as accuracy. The lesson is, if you're not sure, ask a technical resource from
the manufacturer what the specification means.
2.8 CALIBRATION INTERVALS

Probably the #1 question asked at calibration seminars is "How do I
determine the initial calibration intervals?" The answer to this question is
difficult at first for someone new to developing a calibration program. It
ends up being pretty simple. Initially we try to use a variety of resources
which include:
• Manufacturer recommendation
• National Conference of Standards Laboratories Recommended
Practice RP-l
• Past experience
• Intervals of similar existing instruments
~!
In reality, it is a combination of all the above, but mostly past
experience. As an example, in my experience, electronic transmitters have
a calibration interval of 6 months and analog gauges have an interval of a
year. Many manufacturers' specifications contain a 6-month stability
specification. This stability specification, in effect, only guarantees the
accuracy specification for 6 months. Also, electronic transmitters are
typically installed in applications that are "more important" to the
process. Even though these instruments are more reliable than analog
gauges and fail calibration less often, we check the calibration on a more
frequent basis. This means we set our calibration intervals based on how
much risk we are willing to take. If we wanted an almost 100% assurance
that our instruments were within calibration tolerance, we'd have to check
the calibration almost every day. Obviously, that would be impracticable.
So we assume some risk that every once in a while a calibration is not
going to pass. Of course our managers and quality department don't want
to hear that, but it happens and we need to educate other disciplines that it
does happen.
Don't be alarmed if you calibrate more or less often than described
above. It simply means you're willing to take more or less risk based on
the process and quality standards at your facility or you have more history
Calibration 29
to base your calibration intervals on. Of course not all instruments fit into
the same category. Some instruments, particularly analytical
instrumentation, are calibrated more frequently, even to the point that the
user performs a calibration check prior toeach use. On the other hand,
some instruments may have an interval of two years or more.
i
, i Calibration intervals may be adjusted over time. Once several
calibrations have been performed, the calibration history of the device
·1 I
may be used to adjust the calibration interval, If the as-found calibration
data of a particular instrument does not meet the calibration tolerance, the ,
calibration interval may be shortened. If several instruments with a
particular manufacturer / model number are always well within the
calibration tolerance, the interval is increased.
./
2.9 SAFETY CONSIDERATIONS I

Obviously, performing calibrations safely is very important. One .. j
.r lapse on safety could cost you or your co-worker your lives. Even if itis not :~~
',:1
a life lost, minor injuries caused by unsafe work practices are preventable. ":':
; ..,
Safety of the product is also of concern when performing calibrationsin a
manufacturing environment. There are.many resources available frd~ ISA
on the topic of safety, including Chapter 1 of Troubleshooting: A ri': ·ij
Technician's Guide, by William L. Mostia. Here are a few things' we, a§i ~.;
calibration technicians, can do to i,mprove safety in our day-to-day work ;.' -,.1...j
activities. '.; I••
";
.-':..........
• Jnclude specific safety considerations. in each calibration

procedure. For example, if we know there is a tank that does not
have a thermowell installed for the resistance temperature detector
(RID), highlight this fact. Better yet, ifpossible, get a thermowell
installed,
• Keep the shop arid work areas clean and free of trip hazards .:
I • • • .
• Work with a partner or at least make sure someone knows where

you are working at all times.
• Some instruments are always installed at difficult places to reach ..
If it's possible to install some permanent platform, have it done.
Otherwise use safety harnesses, ladders, and lifts properly.
• Technicians may be exposed to lethal electrical voltages. Know
what the high voltage areas are, de-energize electrical circuits that
. are not required.and use proper electrical safety practices
30 Documentation
(insulated floor mat, rubber electrical safety gloves, roped off area,
safety man outside the area with a rope tied around you).
• Ensure electrical power cords are properly insulated. Ensure
equipment is properly grounded.
2.10 CALIBRATION STATUS LABELS

Calibration status labels are used to provide a visual indication of the
calibration status of an instrument. Many different label styles are in use
throughout industry. The main information that must be displayed
showing the calibration status are the Instrument Identification (such as
Tag Number, Instrument 10 number, or serial number), date of
calibration, next calibration due date, and the technician who performed
the calibration (initials, employee ID, etc.). An example is illustrated
below.
ABC Company - Calibration Status

ID:
--------------------
Cal Date: _
Cal Due: ---------------- ~I
Technician: --------------
Other amplifying information may be included on the label or a

separate label. Examples include:
• Customized labels with company name and color coded for
classification as described in Chapter l.
• Limited Calibration Label for instruments that are not calibrated
throughout the range of the indication. An example of this would
be a compound gauge that is not calibrated for the vacuum range
because the process does not operate under a vacuum at any time.
• Another example would be an instrument that does not meet
tolerance requirements at the extremes, but the process would
never operate at these extremes.
• Other labels such as "Do Not Use" or "Calibration Not Required"
can be used, if applicable.
• Sometimes tamper-proof seals are used to cover e:;_<posed
adjustments so that any unauthorized adjustments are detected.
Calibration 31
This chapter has summarized the most common documentation

required or utilized by the calibration technician. These subjects were not.
discussed in excruciating detail, because other resources are available.
However, it is important to expose technicians to the concepts and
provide some examples to help put the big picture together before we start
with the actual performance of the calibrations.
REVIEW QUESTIONS
1. List the advantages of each procedure development method below.
A. Straight from technical manual
B. Generic procedure for an instrument type
i
._.....~
:;;
.<:
..
C. Procedure developed for a specific manufacturer/model or :~
specific instrument in the plant
"'I1
2. If test equipment with the specified. accuracy is not available to ":.

perform the calibration, wha~ should you do?
3. If a step of a calibration proced11!e cannot be followed as specified or

a procedure does not exist, w~at actions would you take?
II
J
I
4. What elements of a calibration data sheet reflect that the calibration is I
NIST-traceable?
I
5. F~r an established facility, what is the most likely resource for
determining the calibration frequency of a new instrument?
I
I
32 Documentation
6. For a new facility,what is the most likely resource for determining

initial calibrationfrequency?
7. What justificationcan be used to increase the calibration interval

(performing calibration less often) of all instruments of the same
type?
8. What event(s)can lead to decreasing the calibration interval

(performing calibration more often)?
9. Match the resources on the left with content on the right.
P&ID A. Includes general instrument

specificationsfor the facility
_ Instrument Specification B. Includes instrument range
Sheet capability and instrument
accuracy !I
_ Loop diagram C. Detailed overview of a process
system
_ Projectspecifications D. Detailed device requirements
Manufacturer's E. Includes all associated electrical

Specifications and piping connections
10. What is the purpose of a calibration seal?
11. What is the minimum information required on a calibration status

label?
12. When should a Limited Calibration status label be used?
13. What criteria must be met for test equipment to be used for
calibration?
3 .:
lEMPERATURE INSTRU'MENT
CALIBRATION
After completing this chapter, you should be eble to:

Describe the different types' of temperature sensors, including
important advantages and disar;!vantagesof each. '
Calibrate the following temperature-instrument types (to ISA
standards, where applicable) and determine acceptability:
• Glass and Dial Thermometers

• Temperaturesensors.(RTDs,thermocouples, and.
thermistors)
t -
:
I
; • Temperaturetransmitters
I
I
• Digital temperature indicators and controllers
. • Temperatureswitches
,
:, I Select proper calibration procedure and calibration data sheet
I
Select appropriate certified test equipment.
Properly setup/connect test equipment to the Device Under
Test (DUT) for calibration.
Properly isolate temperature devices and/or remove from
service for field calibration.
Return equipment to service follo.wing calibration. I-
Complete and properly maintain calibration documentetlon.
I
3.1 WHAT IS TEMPERATURE? /'
Anything that moves.has kinetic energy, the energy of motion. Atoms I
I
and molecules have kinetic energy because they are always moving. The
faster a molecule moves, the greater its'kinetic energy. Heat is the measure
of the total quantity of kinetic energy due to molecular motion in a body of !
matter. Temperature measures the intensity of heat due to the average
kinetic energy of the molecules. . .
33
34 Temperature Instrument Calibration
3.2 lEMPERATURE SENSORS

There are several different types of sensors used to measure
temperature. Some of the more common sensor types are summarized in
this section.
Thermocouples
Thermocouples are very common due to the ruggedness, low cost,
response time, and relatively good accuracy, but mostly because of the
versatility. Thermocouples can be used over a wide range of temperatures,
whereas RTDs are useful only over a certain temperature range.
Thermocouples are based on the principle that joining two dissimilar
metals will produce a voltage signal proportional to temperature.
Although very commonly used, thermocouples are least understood due
to the complexity of different metals used, reference junction, and
methods of compensation. The Reference Section of the Omega Temperature
Handbook provides a very good explanation of the details.
There are several types of thermocouples, based on the types of
metals that make up the thermocouple. For example, a Type T
thermocouple is made from copper and constantan wires, whereas
Type K is made from chrome! and alumel. Each type is color coded and,
per U.S. standards, the red lead is always negative. Due to the many
thermocouple types, a technician must verify the thermocouple type used
and ensure the correct reference table and/ or test equipment setup is used
for that thermocouple type. (For examples, see the reference tables in
Appendix A-6.)
Resistance Temperature Detectors (RTDs)

RTDs are most commonly made from platinum, due to its stability
and linearity throughout the range of use. However, RTDs exhibit a
slower response time to temperature changes than thermocouples. All
RTDs have a positive temperature coefficient, which means the resistance
increases as temperature increases. The most widely accepted type of RTD
conforms to DIN 43760.This RTD has a resistance of 100 ohms at O°Cwith
a temperature coefficient (n) of 0.00385(spoken as three-eighty-five
alpha).
The alpha coefficient is determined from the slope of the line between
o degrees C and 100degrees C and also the resistance of the RID at 0
degrees C. The alpha is expressed in units of ohms per ohm per degree C
where the second "ohms" refers to the resistance at 0 degrees C. For the
DIN 43760RTD, the ohms for a degrees C is 100 and the ohms for 100
Calibration 35
degrees C is 138.50.The change-in ohms for 100 degrees is 38.50. The

change for i degree is 0.385ohms. The alpha is 0.385ohms per degree C
divided by the resistance at 0 degrees (100 ohms) which equals 0.003850
ohms per ohm per degree C. The resistance output for an RID is not
perfectly linear, and the ohms for a given temperature cannot be
determined from the alpha coefficient alone. The complete equation for
_I
the RTD output also includes other coefficients that define the non-
linearity. .
, RTDs are connected electrically in a bridge configuration to offset the
effects of lead length resistance. RTDs are purchased as 2-wire, 3-wire, or I
4-wire RTDs.Again, the Omega, Handbook provides a good explanation of I
the details. The most important thing for a technician to understand is the
RIDs must be connected correctly during initial installation and upon ,
1
completion of calibration. Also the technician must be careful to use 'the
correct RTD table as a reference whenperforming calibrations. lI
Thermistors j
Thermistors are based on'a resistance change in a ceramic i
semiconductor. Thermistors are much more temperature sensitive that

thermocouples or RIDs. This allows thermistors to detect very small
I
'1
changes in temperature which would not be detected by RIDs or
thermocouples. Most thermistors have a negative temperature coefficient,
which means the resistance decreases as the temperature increases.
However, thermistors are very non-linear and therefore must be used over
a small range to provide a linear response. Thermistors are also
susceptible to drift and are very fragile.
Filled Bulb
Filled-bulb sensors are a closed system filled with a liquid that,
expands as the temperature increases and contracts when temperature
decreases, producing a proportional changein temperature indication or a
control valve response.
'3.3 SIGNAL CONVERSION'

Signal conversion is used to convert the voltage of a thermocouple or
resistance of an RTD/thermistor to a Signal usable.by an instrument
system. For exampl~ a temperature transmitter may convert the RID
resistance to a 4-20mA signal for a PLe input or a recording device (or
both). A separate signal conversion device is not 'always used since many
devices (controllers, indicators, PLC inputs) can be configured for direct

sensor input.
Now that we have some idea of how temperature is sensed, let's look
at some examples.
Example Temperature Calibration #1 - Calibration of a Dial

Thermometer
A dial thermometer consists of a sensing probe connected to a dial
indicator. The temperature sensed causes movement of the dial pointer
across a graduated scale. The graduated scale provides an indication over
a range of temperatures. The goal of the calibration is to verify that the
pointer "points" to the correct value over the range of the instrument, Our
example thermometer has a range of 0 to 100°C,and we'll be checking the
calibration at 5 points: DoC,25°C, 50°C, 75°C, and ioo-c,
The test equipment we'll use is a refrigerated temperature bath and a
temperature standard. An ice bath could be used to check the DOCpoint if
a refrigerated bath is not available. An ice bath is prepared by using
crushed ice made from distilled water and adding distilled water to make
a "slush." It is best to make the ice bath in an insulated container. The ice
bath should be adequately mixed just prior to placing the sensor in the ice
bath and, if possible, while the sensor is in the ice bath.
Insome cases, the temperature bath may have a temperature
indication which could be used as the temperature standard. The
temperature indication on the temperature bath can only be used as a
standard if it has been calibrated itself. It is still not the best practice to use
the bath temperature indication as a reference since the location of the
sensor is not the same as the device being calibrated. Inmost cases, a
separate temperature standard must be used to obtain the required
accuracy ratio (accuracy ratio is discussed in Chapter 1).
To perform the calibration, the thermometer is removed from the
system and placed in the temperature bath (or ice bath) at the minimum
test point of Doe.Our temperature standard is also placed in the
temperature bath (or ice bath) at the same depth such that the tips of the
thermometer and standard are as close together as possible. Once the
readings have stabilized, the "as-found" readings are recorded for the
temperature standard and the unit under test. No adjustments are made
until all "as-found" readings are recorded for all test points. Now we
change the temperature bath setpoint to 25°C. (If an ice bath was used at
aoc, move the thermometer and standard to the bath.) Once readings have
stabilized, record the "as-found" values for the thermometer and standard
on the calibration form. Note that we do not need to record the bath
Calibration 37
temperature indication, if provided, since this is not our standard and has
no bearing on the calibration; Obtain the "as-found" readings for the
thermometer and the standard at 50°Cbath setpoint; then 75°C setpoint
and finally 100°Csetpoint.
Now that the "as-found data has been collected, let's evaluate the
data. The table below shows our as-found results.
AS-FOUND DATA
TEST POINT TEST UNIT UNDER' ERROR

STANDARD TEST READING
READING
.I DOC 0.12°C 1°C + 0.88
25°C 25.08"C 26°C + 0.92 t.
- 50°C 50. 17°C 51.5°C + 1.33
75"C 74.99"C 76.5°C + 1.51
100°C 100.02°C 102°C + . 1.98. '''::'.ii~~~
.•" _,. ,. i
is
. Let's say our calibration tolerance 2°C and we find the thermometer
is adjustable. Some are not adjustable, in which case the thermometer= ..~
'
'I
would need to be replaced if the "as-found" data was not within the ,2
II acceptable tolerance. Since this thermometer has one adjustment using'an .
external screw( how much should we adjust the thermometer? If the ;'::
process, monitored by the thermometer, normally operates at a specific
setpoint, it. is recommended to adjust the thermometer to read correctly
.
at . '. ~'I'
' ....
that value. If the process operates over the r!ffigeof the instrument, adjust ,'..1:: ,
the thermometer based on the average error such that all readings are as
.. close as possible, In any case, the thermometer should be adjusted such
that when you've completed the adjustments all r'as-left" data is within
the specified tolerance.
We find the process operates at 50°C.Therefore, adjust the .
temperature bath setpoint to 50°C. Once readings have stabilized, adjust
the thermometer to read the same as the temperature standard. Once the I
adjustment is complete, record the stabilized thermometer and standard I
I
reading' at each test point as the "as-left" readings. Verify all values are
within tolerance and the desired results were achieved. Below is a table of ~
our results.
I
AS-FOUND DATA AS-LEFT DATA

lEST POINT TEST UNIT UNDER ERROR TEST UNIT UNDER ERROR
STANDARD TEST STANDARD lEST
READING READING READING READING
O°C O.12°C 1°C + 0.88 O.10·C - 0.5°C -0.60
26°e zs.os-c 26°C + 0.92 25.05°e 24.5 C
Q - 0.55
so-c OO.17°C si.s-c + 1.33 50. 13°C 50°C - 0.13
76°C 74.SSoC 76.5°C + 1.51 74.91°C 75°C + 0.09
100°C 100.02°C 102°C + 1.98 99.97°e 100.5°C + 0.53
Note: A Calibration Seal should be affixed to the external adjustment to

detect any unauthorized adjustment to the thermometer.
Once you actually perform a calibration as described above, you'll see

it can be very time consuming to wait for the temperature bath to stabilize
at each of the five points (depending on the type of bath used). It may take
all day to perform this one calibration. There are several things you can do
to increase productivity.
1. Have several thermometers scheduled for calibration at the same
time. It is typically the supervisor's job to properly schedule the
work, but you can look to see if there are other thermometers due the
same month and obtain authorization to calibrate them.
2. If there are other temperature baths available, set up the baths at
different temperature setpoints, It is recommended to use the same
temperature standard for all test points, but it does not take as long
for the standard to stabilize as it does for the baths.
3. Use your spare time waiting during setpoint changes to perform
other work.
Example Temperature Calibration #2 - RTD Calibration Check

Although temperature sensors are usually checked as part of a
calibration of the connected device, it may be necessary to check a suspect
temperature sensor or to verify the accuracy of a new RTD. The principles
of this RID calibration check would apply to any sensor type. The only
exception would be a thermocouple calibration check if the test equipment
used to read the thermocouple does not have automatic reference junction
temperature compensation. All modern test equipment performs the
temperature compensation, but it is important to verify. If you perform a
thermocouple calibration check and do not have temperature
compensation, you'll need a second temperature standard to measure the
reference junction ambient temperature and compensate manually.
Calibration 39
Por this example,let's say we need to check the RTD at five points,
from soap to 250 P. Just like the thermometer in example #1, we'll need a
0
temperature bath capable of achieving the desired range of soep to 250oP, a

temperature standard, and a test instrument capable of reading resistance
(such as a multimeter or multi-function calibrator). Will we need a
refrigerated "bath(or an ice bath) like we needed for the thermometer
calibration in example #1? Yes,since the' minimum test point of Soop is
below normal ambient temperature, we will need a refrigerated bath. I
We'll also need the correct RTD table to determine our expected
resistance at 50oP, 100°F,150oP,200oP, and 250°F.Typically, we would use
.i
. i
the applicable RID table. However it is not unusual for the manufacturer
to provide an RTD table specific to an individual RTO; If the manufacturer
provides a specific RID table, it should be added to the documentation file
.ij
for this device, used for the calibration check of this RTD, and used for the
: calibration of any device connected to this RID. Par our example, we will
.:I
I
use the standard RID table for our RTD, whlchis a 100 ohm, platinum, :
385 alpha RTD. (Refer to the correct RTD table in Appendix A-6.) . I
To perform the calibration check, place the temperature standard-and .
RTDin the temperature bath. Adjust the bath temperature to each of the .
test points. Record the temperature standard reading and RID resistance ..
II at each ~estpoint. Fill in the expected resistance readings for the five-point .
calibration check from the applicable table in Appendix A-6. If you h'i_ve
difficulty, an explanation follows the table. ."
lEST TEMPERATURE CONVERSION ~XPECTED RTD ACTUAL ATD ERROR

POINT STANDARD TO °C RESISTANCE RESISTANCE (OHMS)
(OF) READING (OF) (OHMS) (OHMS)
50 50.0 103.88
100 100.0 114.70
150 150.0 125.40 f
200 200.0 136.00 I'!
,. 250 250.0 '146.50·
J
First of all, we base our expected resistance yalues on the actual
temperature standard reading obtained, not-the test point. We made this
easier by using nice even temperature standard readings, which will not
be the case in reality. However, since the RID tablesreference
temperature in degrees Celsius, we did add a degree of difficulty
specifying the test points in degrees Fahrenheit. For the.first data point of
50.0°Fwe must first convert to °C using the conversion °C = (OP - 32) X 5/9,
which results in an answer of 10.0°C.The remaining conversions are

37.78°C, 65.56°C,93.33°C,and 121.11°C, respectively.
For the expected resistances, we can obtain the value for lOoCdirectly
from the RTDtable. You should have 103.90ohms for the expected
resistance at 50°F(10°C).The remaining test points are not as simple. They
require interpolation. For the 37.78°Cdata point you must first find the
resistances for 37°Cand 38°C, which are 114.38ohms and 114.77ohms,
respectively. Next, find the difference between these resistance values,
which is'0.39ohms in this case. To perform this interpolation, understand
that we are basically finding the resistance value, which is 78/100ths of
the way between 114.38and 114.77.This is simply done by multiplying
0.78 x 0.39,and adding the result to 114.38.The expected resistance for
37.78°C is 114.68ohms,
To find the expected resistance for 6S.56°C(100.0°F),multiply 0.56 x
0.38 and add the result to 125.17ohms. The value for the expected
resistance at the lOO°Fis 125.38ohms. For 93.33°C,multiply 0.33x 0.38and
add the result to 135.85ohms for an expected resistance of 135.98ohms.
For 121.11"C,multiply 0.11x 0.37 and add the result to 146.45ohms, for an
expected resistance of 146.49ohms. .
Complete the table. Assuming our allowable tolerance is 0.1% of
reading, did our calibration check pass? At the expected resistance of
103.90,the allowable tolerance is 103.90x 0.001,or 0.1 ohms. The
remaining acceptable tolerances are calculated by multiplying 0.001by
expected resistance.
Example 'Iemperature Calibration #3 - TemperatureTransmitter

There are two basic methods to calibrate a temperature transmitter in-
situ. The first is to calibrate the sensor and transmitter together by placing
the sensor in a temperature bath/block and measuring the transmitter
output. TI1esecond basic method is to disconnect the sensor from the
transmitter and use a simulator in place of the sensor. If the sensor is an
RTD, a decade box or RTD simulator would be connected to the
transmitter input in place of the RTD. If the sensor is a thermocouple, a
thermocouple simulator of the correct type would be connected to the
transmitter input. Any local or remote indications connected to the
transmitter output could be calibrated along with the transmitter as a
loop.
It is recommended that, if a loop calibration is performed, the
transmitter output should still be measured and recorded. The reason for
measuring the transmitter output for a loop calibration is-to determine
which device, transmitter or indicator, would require adjustment if an
Calibration 41
.
. adjustment were necessary. Either method, individual instrument
.
calibration or loop.calibration, is acceptable depending on your industry
practices and procedures. The advantages and disadvantages of each
method are discussed in Chapter 1.
FIGURE 3-1.
Temperature Transmitter Calibration Setup (Courtesy Rosemount, Inc.) .
DMM
TRANSMITTER
POWER
SUPPLY
READOUT RESISTOR
.. :",.-.
..
~-.
'
:~~. .. I
CALTERNATE READOUT)
.
-,.::
"--- LEAD'~/MULAT/ON RESISTORS' .

II
For our example let's perform a calibration of TT-300 using a d~~ade
box per the' calibration procedure SOP-CAL-08,Method B in Appendix A-
4. The specification for TI-300 is included in Appendix A-3. Use the
information from procedure SOP-CAL-08,TI-300 specification; and RTD
Table in Appendix A-6 f?r 385-alpha to complete the tables below.
TABLE3-1.
Preliminary Operating Point Check .
TEST . TEMPERATURE ACTUAL CONVERTED ERROR
POINT STANDARD lRANSMITTER TEMPERATURE
OUTPUT
70°C 70. 12°C 11.35 mA 68.90°C -1.22·C
TEST SIMULATED INPUT EXPECTED ACTUAL

POINT TEMPERATURE RESISTANCE lRANSMITTER "TRANSMITTER ERROR
(OC) (OHMS) OUTPUT (mA) OUTPUT (rnA)
10% 15.0 '.

105.85 5.60 5.50 -0.10 mA
50% 75.0 128.98 12.00 11.88 -0.12 rnA
90% 135.0 157.31 18.40 18.27 -0.13 rnA
Given the actual transmitter output above, does the transmitter

require calibration? If the manufacturer's specification of 0.2% is used, the
transmitter requires calibration. If the calibration tolerance is ±1%, which
would equate to 1.5°Cand 0.16 mA, the instrument is within tolerance,
but should be adjusted since it is close. A good rule of thumb is to adjust if
the instrument is> Ihthe specified tolerance. You should not get in the
practice of always performing adjustments to get the instrument
calibration "right on," because even performing adjustments can lead to
deteriorated performance.
You maybe asking yourself why the procedure requires test points of
10%,50%, and 90%.Zero percent, 50%,and 100%may be the normal test
points that you are used to and that is fine. For loops that include an
operator interface, the reading may not go below the minimum or above
the maximum. Therefore, if the 0% and 100%test points were used, you
would not know if the reading was actually below the 0% reading or
above the 100%reading.
Example Temperature Calibration #4 - Temperature Controller

loop
A temperature controller can be a stand-alone device or a function of
the computer control system, such as a programmable logic controller 'I
'I
(PLC) or distributed control system (DeS). Ifthe temperature controller is
a function of a computer control system, it is typically not calibrated
because it is not really a device subject to going out of calibration. A stand-
alone controller usually has many capabilities such as multi-function
configuration, alarm setpoints, analog and on/ off outputs. For our
example, we'll assume we have a Moore 352controller configured for
4-20 rnA input with a corresponding display do to 100°C.The controller
is also configured for a low alarm of 30°Cand a high alarm of 40°C. The
4-20 rnA output is supplied to an l/P (current-to-pneumatic) transducer
for control of a steam valve.
For our calibration we only need to concern ourselves with the
controller itself. The temperature transmitter that supplies the rnA input is
calibrated separately. The I/P transducer is also calibrated separately. It's
a good idea to have the calibration of all loop components scheduled
together. You could also perform a calibration for the entire loop as
previously discussed, if desired. However, to start with it is very
important that the control system technician understands how the
controller interfaces with the process. First of all, the system must be in a
state which will allow the safe performance of the calibration. The system
controlled by this controller should be shut down and the controller
Calibration 43
placed in manual operation. If the controller remained in automatic

during the calibration, the simulated signals would cause output
responses which could be detrimental to equipment and process.
FIGURE3~2.
Control Loop on P&I Drawings
I
i
I
j
STEAM J
..".j
~J
FROM REACTOR
FEED PREp·
. II E -107 CONDENSATE,.· ',i
"II:
~-:.
Once the system is in a safe condition and the controller is placed' in
manual,.we can disconnect the controller input leads and connect a . ...? »<
J
I
..••.•, I
.•, "'i
milliamp simulator to the input. To perform the calibration, adjust the
milliamp simulator to the desired setpoints and record the controller
display. Ifthe display requires calibration, follow the manufacturer's
procedures for calibration. For rnicropro~essor based instruments, the
calibration is usually not performed by turning a potentioineter, but rather I
adjusting the input to a pre-determined value and pushing buttons so the
microprocessor can make the adjustments.
I
Once the display is properly calibrated, it's a good idea to verify
i
. alarm setpoints and control output action. This is not required and many
calibration procedures would not include it. To perform the alarm checks,
I
the milliamp simulator is adjusted as necessary to determine the
temperature at which the low and high alarms trip and reset. To check the
controller output for proper operation; adjust the milliamp simulator
. above and below the setpoint safely to verify the proper output action is
occurring.
Example Temperature Calibration #5 - Temperature Switch

A temperature switch is a device that senses temperature and
changes state at the programmed or adjusted setpoint. A temperature
switch usually has at least one set of normally open (NO) and one set of
normally closed (NC) contacts, but may have only a NC contact, a NO
contact, or more than one set of each. NO and NC refer to the state of that
contact with the switch de-energized. The tricky part of calibrating a
temperature switch is to know whether the switch should "trip" with
increasing or decreasing temperature. Typically, a high temperature
switch would "trip" with increasing temperature, and vice versa.
Basically the calibration of the switch is checked by placing the sensor
in a bath and measuring across the applicable contact with a multimeter.
The bath temperature is increased/decreased to the setpoint. The
multimeter will read the change of voltage or resistance when the switch
changes stqte. In other words, the multimeter will read 0 volts with the
switch closed and supply voltage with the switch open. If the contact is a
"dry" contact (no voltage), the multimeter will read close to 0 ohms with
the contact closed and infinite ohms with the switch open. (Hint: You may
want to disconnect and electrically insulate the leads to check the switch
by itself. This removes any parallel resistances and external circuits from
interfering. As an alternative, use the remote indication as confirmation of
proper switch operation. Be cautious of circuit and display time delays.)
REVIEW QUESTIONS
Situation for Questions 1-10:TT-300is installed in a process tank, which

is currently in production. This is the first calibration after initial startup.
Use the references in Appendix-A to answer the following questions.
1. What is the correct calibration range and manufacturer's specified
accuracy for TT-300?(Appendix A-3)
2. Select the correct procedure(s) that could be used for this calibration
of TT-300?(Appendix A-4)
3. What local! remote indications should be recorded during calibration

of TT-300?(Appendix A-l)
Calibration 45
4. What must be done prior to removing RTDfor calibration of TT-300?

(initial conditions of standard op~ratfug procedure, SOP)
5. what are the correct resistance values to input for 10%,50%, and
90%? (refer to the correct RTD table in Appendix A-6)
6. What are the expected transmitter output values for the resistance
inputs from step 5? '
7, Indicate the correct test equipment ho,?kup for calibration of TT-300.
Meter (mA) ",

Decade Box.
oilier
(if
Resistance
Simulator
6"J~ .'1:.
IT-300
'
Temperalure--Transmitter
+
-
.j~'
,
'iI
ill -
. I
_',I
I
8. Assume a calibration tolerance of ± O.soC/O,OS m.A. With the results

indicated, what instrument(s) in the loop require(s) adjustment?
% INPUT rnA OUTPUT TIC-300 INDICA nON
10% 5.70 15.9

50% 12.10 75.9
90% 18.50 .. 135'.9
9, What type of error is indicated by the results of question 8?

A. Zero error
B. Span error
C. Zero and Span error
D. Linearity error
10. Following adjustment, all r'as-Ieft" data is within tolerance. What
must be performed to place the instrument loop back in service?
Situation for questions 11-15: You will be performing an initial

calibration of TI-200 on the bench, prior to installation. Use the references
in Appendix A to answer the following questions.
11. What are the correct reference temperatures and corresponding
millivolt values to input for a calibration check at the following test
points?
% INPUT lEMPERATURE MILLIVOLTS
0%
25%
50%
75%
100%
12. What are the expected transmitter outputs for the following
simulated inputs?
% INPUT OUTPUT (rnA)
0%
25%
50%
75%
100%
Calibration 47
13. Indicate the correct test equipment hookup for calibration of TI-200.
Meter (mA) .
Thermocouple
Simullltof
Temperature Transmitter
moo
24VDC .
Power
Supply
!.
14. Assume a calibration tolerance' ofe l.oop10.08 mAo ·Withthe results
indicated, what must be done to bring the instrument to within
tolerance?
0% 4.00
25%' 7.98 I
.... JI
50% c 11.96 ..
75% 15.94
100% 19.92
I
15. Following adjustment(all"as-Ieft" data is within tolerance. What
steps remain to complete the bench calibration?
I
Situation for questions 16 - 20:The operator suspects that TI-302is not
. reading the correct temperature of Reactor 300. You will be performing a
calibration of TI-302.Use the references in Appendix A to answer the
following questions .'
16. What test equipment will be used for calibration of TI-302?
17. What must be performed to safely remove TI-302from the process?
18. What important consideration must be taken into account for a

proper calibration using a temperature block?
19. The thermometer has one external adjustment. With the results
tolerance?
% INPUT THERMOMETER INDICATION

(OF)
0% 2
25% 34
50% 66
75% 99
100% >130
:1
20. What would you do if the thermometer was out of tolerance and the
thermometer does not have an adjustment available?
For questions 21- 23you will be performing a bench calibration of a

temperature switch, TSH-20S.
21. What is the specified trip point and reset point of TS-20S?
Trip Reset _
22. What type of sensor does TS-20Suse?
23. When performing an initial calibration on the bench, is it important

to know what function TS-20Swill perform once installed? Why or
why not?
4 i
I
PRESSURE .INSTR.UMENT· I
CALIBRATION
I
After completing this chapter, you should be eble to:
Calibrate the fol/owing pressure instrument types (to ISA

standards, where applicable) and determine ecceptebititv:
• Gauges
• 'Transmitters
• Switches
Select proper calibration procedure and calibration d_atasheet.

Properly set up/connect test equipment to DUT for celibratton.
/1 Properly isolate pressure devices and/or remove from service "
for field calibration. d

Return equipment to service foljowing calibration.
Complete and properly maintain calibration documentation.
4. 1 WHAT IS PRESSURE?
Air pressure is the force exerted on you by the weight of tiny particles
of air (air molecules). Although air molecules are invisible, they still have
r
weight and. take up space. Atmospheric presstITeis approximately 14.7 l
pounds per square inch (psi) at sea leveL This means that if we could put . 'I
one square inch of air from the ground to the 1.1pperatmosphere on a scale,
it would weigh 14.7pounds. We do not feel this pressure because it also
I
acts internally and is thus balanc~d. Since there's a lot of "empty" space
between air molecules, air can be compressed to fit in a smaller volume.
When it's compressed, air is said to be "under high pressure."
There are two ways to look at pressure: (1) the small-scale action of .
Individualair molecules, or (2)the large-scale action of a large number of
50 Pressure Instrument Calibration
molecules. Starting with the small-scale action, a gas is composed of a

large number of molecules that are very small relative to the distance
between molecules. The molecules are in constant, random motion and
frequently collide with each other and with the walls of any container. The
molecules possess the physical properties of mass, momentum, and
energy. As the gas molecules collide with the walls of a container, the
molecules impart momentum to the walls, producing a force
perpendicular to the wall. The sum of the forces of all the molecules
striking the wall divided by the area of the wall is defined to be the
pressure. The pressure of a gas is then a measure of the linear momentum
of the molecules of a gas.
4.2 CHALLENGES WHEN CALIBRATING

PRESSURE
The first thing we have to deal with when calibrating a pressure
instrument is the unit of measure we're dealing with. There seems to be
dozens of units. In the U.S. we usually deal with pounds per square inch
(psi), but even with that we need to know if it's absolute or gauge pressure
(psia or psig). And although we usually deal with psig, we'll routinely
deal with inches of water (H20 or "w.c.") for low pressure applications.
Other units of measure we will be exposed to are: bars (1 bar = 1
atmosphere), inches of mercury (Hg), millimeters of mercury (mm of Hg),
millimeters of water (mm of H20), microns, ton', pascals (Pa), and
dynes/ cm2. Some conversion factors for pressure units are included in
Appendix A-7.
Many of the modern pressure calibrators allow us to select the
desired units of measure, but we still need to understand the relative
pressure we're dealing with to ensure the correct test equipment, pressure
module, and tubing/fittings rated for the maximum test pressure are
used.
When I first started calibrating, I had a pressure gauge that read
about 15 psi high at all test points. I went through a tremendous amount
of effort to drain the glycerin from the gauge, remove the cover, and
attempt to adjust the gauge needle. When I couldn't get the gauge to
calibrate properly, I took it to my supervisor to order a new replacement
gauge. My supervisor informed-me that the gauge read in psia, my "as-
found" data was acceptable, and I ruined a perfectly good gauge. The
gauge was ruined because the vacuum that had existed in the gauge case
was eliminated when the gauge was opened. This vacuum was present to
Calibration 51
provide the gauge with a reference to absolute zero pressure. So, if you
calibrate a gauge and it reads about 15psi with no pressure applied, take it
from me, the gauge reading is probably in psia, not psig. Know the unit of
measure for the device you are calibrating!
Another challenge with pressure calibrations is having the correct
fittings to connect the pressure source, pressure standard, and the unit
under test. Even with a few drawers full of fittings in the shop and access
to more adapters in the mechanical shop and spare parts stock, we never
seem to have the right fittings. To minimize this problem, enter the fittings
needed in the calibration notes that print out with the calibration data
sheet or work order. The important thing is to minimize the number of
connections in the test setup in order to minimize the potential for
leakage.
Leakage is another problem we have to deal with.when performing
pressure calibrations. This problem is amplified when Weuse a hand
pump as our pressure/vacuum source. Small leaks in the test setup can be
compensated for by using a constant pressure source such as a N2 bottle, a
spare plan~air connection, or vacuum pump. However, leakage should be
eliminated or minimized for allpressure calibrations even when using a
constant pressure source. Even the smallest leak is frustrating when using
II a hand pump, so those connections have to be minimized and tight.
I
i
Hysteresis is the measure of the difference in response of a device as I
I
the input signal increases from minimum value to a maximum value, and, I
subsequently decreases from maximum to minimum over the same range.
Hysteresis is expressed in percent of full scale (% FS).)nstruments with
I
mechanical movements such as pressure gauges and current-to- II
pneumatic (l/P) transducers develop hysteresis error. Often this is caused
by friction and wear of the mechanical components.There is no way to ·1
. I
adjust for hysteresis error during calibration. Hysteresis can be evaluated
. by-obtaining calibration data with the input applied in both the increasing l
and decreasing direction as illustrated below. '
i
r
. APPLIED INPUT AS-FOUND ·AS-FO·UNQ· HYSTERESIS·
[PSIG)
10
VALUES (1)
9
VALUES
10
(il (%FS)
1%
I
25
50
24
49
25
51
1%
2%
I
75
90
74
90·
76
91
2%
1%
I
When evaluating hysteresis, it is important to approach the target

value without overshooting the applied input. If the input value exceeds
the increasing target value, decrease the applied input to the previous test
point and retry. If the input value exceeds the decreasing target value,
increase the applied input above the previous test point and retry.
Special sajeh) considerations must be considered when calibrating
pressure instruments. First of all, ensure the system pressure has been
released prior to attempting to remove any pressure devices. Also, you
must know what potential hazards exist with the process material Some
process material may be toxic or may cause harm to the environment if
exposed. Verify with the supervisor of the area before removing any
device for calibration.
FIGURE 4-1.
Typical Pressure Calibration Test Setup
Power
Input Supply
Standard (if needed)
Pressure/ Unit Output

Vacuum Under Standard
Source* Test (if needed)
• Including regulator and vent, if necessary
4.3 CALIBRATING PRESSURE GAUGES

Pressure gauges are often used as local indicators of process pressure.
An analog pressure gauge, because of its links, levers, and elastic pressure
sensing element, requires periodic calibration checks. Pressure changes
applied to the gauge cause the elastic element to expand and contract. The
movement of the element is translated into movement of the pointer
through links, levers, and gears. The measurement values of the gauge are
read directly on the gauge scale from the position of the pointer.
Calibration 53
FIGURE 4-2.
Bourdon Pressure Gauge
I,
i
!
:'1"1 Calibrating a pressure gauge includes 'adjustment of these components

until the gauge accurately represents the input. The power supply ami
output standard illustrated above are not used for calibrating a pressure
gauge. <
The instrument under test determines the calibration standards. First,
you n~ed a source 'of pressure such as a hand pump or regula ted pressure
source (vacuum hand pump or regulated vacuum source if calibrating a
vacuum gauge). A regulator with the smallest'range available that exceeds
the gauge's range is most appropriate. 'Urisallows the gauge's full range
to be tested as accurately as possible as well as precise adjustment of the '
pressure input. Select the proper input standard for the pressure range r
tested. The pressure standard may be a precision gauge or digital test t
standard with the correct pressure module, manometer, or dead weight
~,
tester.
Use a tee to connect the input test standard to the pressure source and
the gauge und~r test. Besure the gauge under test is mounted in the same
I
I
orientation as in the process. Positioning a gauge vertically for calibration
and then reinstalling the gauge in its horizontal configuration in the
pr~cess will introduce error. I
Determine the five test points used for the upscale and downscale
checks of the gauge under test. As discussed earlier in this chapter, with I
j
I
any mechanical instrument, it is important to accurately determine

whether hysteresis is present in the instrument. This means that you will
begin your upscale check from 0% and approach the first test point, 10%,
from below. Approach each increasing test point from below and do not
overshoot. If you overshoot, reduce pressure to the previous test point and
repeat. Similarly, start the downscale check by increasing the input to
100%,then approach 90%from above. Now that the "as-found" data for
our 0-200psig gauge has been collected, let's evaluate the data. The table
below shows our lias-found" results.
AS-FOUND DATA
TEST TEST UNIT ERROR UNIT UNDER ERROR HYSTERESIS

POINT STANDARD UNDER {il lEST (!I ERROR
READING lEST (PSIG) READING (!) (PSIG) (Ll
(PSIG) READING (PSIG)
Ii PSIG)
10% 20.0 19 -1. 19 -1 0%

25% 50.0 49 -1 50 0 0.5%
50% 100.0 99 -1 100 0 0.5%
75% 150.0 149 -1 151 +1 1%
90% 180.0 179 -1 180 0 0.5%
The test results are then checked against the allowable tolerance. If
the results are outside the allowable tolerance, determine the type of
errors present (linearity, zero, span, and hysteresis), and adjust per the
manufacturer's instructions or use the general instructions, as applicable,
that follow.
On most motion balance instruments, adjust linearity first. The
movement of the elastic element in a pressure gauge causes a proportional
movement in the linkage. On a properly calibrated gauge, the linkage
angle will be exactly 90° when the input to the gauge is at 50% of total
range. Therefore, apply 50%input and use a template to check the 90 0,
angle.
With linearity adjusted, position the pointer so the gauge reads mid-
scale. You may need to remove the pointer and reposition it on the shaft. If
removing the pointer is necessary, be sure to use the proper tool. Now
lower the input to 10%and adjust the zero so the gauge reading equals the
applied input.
Calibration 55
Now correct the span error. Increase the-input pressure to 90% and
adjust the gauge to read the input value. For span adjustments, loosen the
screws and rotate the entire adjustment mechanism.
Repeat the zero and span adjustment until the readings at 10% and
90% are accurate. Zero and span interact in the mechanical device, so
rechecking them is necessary. When zero and span require no further
adjustments, rech~ck the linearity to make sure it is still properly adjusted.
There are no adjustments for hysteresis. After adjusting linearity, zero and
span, perform another full scale check and record.as-Ieft calibration data.
,. 4.4 CALIBRATING PRESSURE lRANSMITTERS

Calibrating a pressure transmitter-is similar to calibrating a pressure
gauge, except we must measure the-output signal using an appropriate
measuring standard. For example, we would use a milliammeter to .;..:__ .... ,
measure a 4-to-20 rnA transmitter output Signal. If necessary, we ma~'also
have to provide the transmitter output power source, such as 24 volts-.
direct current (VDC). Most modern calibration standards provide the~:
ability to supply the transmitter power so a separate power source is not
.j jl. required. .
Adjust the input values to the required test points arid record "a~~.
found'; values for' the milliamp output If the transmitter includes a local .·~:~;1
.,.;oj
.~I
readout, record the display. Typically,
, it is not necessary to check a
transmitter in both the upscale and downscale directions (follow your ..:.l
company procedures). Once the lias-found" data has been recorded,
evaluate the error against the acceptable tolerance to determine if
adjustment is' required. If adjustment is required, perform the zero and
span adjustments per the manufacturer's procedures. Sometimes this is
I
I
adjustment of a zero and span potentiometer, sometimes it's a pushbutton
adjustment, while other transmitters require th~ use of a handheld
I
J
r
interface., Because some zero and span adjustments interact, it is important
J
to recheck the zero and span until no further adjustment is required.
Once no further adjustments are required, repeat the five point check I
t
and record lias-left" values.
4.5' CALIBRATING PRESSURE SWITCHES

A pressure switch is a device that senses _pressure and changes state
at the programmed or adjusted setpoint. A Single pole double throw
(SPOT)pressure switch has one set of normally open (NO) and one set of
normally dosed (NC) contacts. A double pole double throw pressure
switch is furnished with two SPDT switches. NO and NC refer to the state
of that contact with the switch de-energized. The tricky part of calibrating
a pressure switch is to know whether the switch should "trip" with
increasing or decreasing pressure and which contact is used for the circuit.
Typically a high pressure switch would "trip" with increasing pressure,
and would use the NO contact. This means at normal pressure the switch
would be dosed and would open when the high pressure setpoint is
reached. Using the NO contact provides a fail-safe condition if the circuit
failed (power failure or broken wire). However the requirements of the
alarm circuit must be considered.
The calibration setup of a pressure switch is similar to a pressure
gauge and pressure transmitter, except a multimeter set to measure
voltage or resistance, as applicable, is connected to the applicable set of
contacts (such as the common and NO terminals). The applied input
pressure is increased to the setpoint. The multimeter will read the change
of voltage or resistance when the switch changes state. In other words, the
multimeter will read 0 volts with the switch closed and supply voltage
with the switch open. If the contact is a "dry" contact (no voltage), the
multimeter will read close to 0 ohms with the contact closed and infinite
ohms with the switch open. (Hint: You may want to disconnect and
electrically insulate the leads to check the switch by itself. This removes
any parallel resistances and external circuits from interfering. As an
alternative, use the remote indication as confirmation of proper switch
operation. Be cautious of circuit and display time delays.)
REVIEW QUESTIONS
Use the information in Chapter 4 and the references in Appendix A to
answer the following questions.
1. Arrange the following in order from lowest to highest pressure:
---' _, ---'-I _,_
A. 14.7psia
B. 14,7psig
C. 500 millitorr
D. 30 "Hg
E. 500 "H20
F. 500mmHG
Calibration 57

accuracy for PIT-303?
3. Select the correct procedure to be used for this calibration of PIT -303.
i
4. What local! remote indications should be recorded during calibration
ofPIT-303? I
i
I
5. What must be done prior to removing pressure sensor for calib~~tion , I
ofPIT-303? .·~1~
,
.;l~
~i
:[" ~
:;.:
6. What pressure values will be applied to perform calibration of PIT- .,~
~~~,
'-::J
~~.~~
OO~ ~ '.~.,~
.1
.~.,
'-1
7. ,What are the expected transmitter output values for the pressures I
applied in the previous step?
58 PressureInstrument Calibration
8. Indicate the correct test equipment hookup for calibration ofPIT-303

by inserting the correct item from the list below into the appropriate
box:
Power supply
Referencestandard pressure indicator
Milliammeter
Pressure source
Unit
Under
Test
~ ~
9. What safety considerations must be taken into account when

performing a pressure instrument calibration?
10. Assume a calibration tolerance of ± 0.3psig/0.l0 rnA. With the

results indicated, what instrurnent(s) in the loop requires
adjustment?
% INPUT rnA OUTPUT PIC-303 INDICATION
10% 5.50 5.0

50% 11.90 25.0
90% 18.30 45.0
11. How would the calibration required in the previous step be

performed?
,I
Calibration 59
12. Following adjustment, all "as-left" data is within tolerance. What

must be performed to place the instrument loop back in service?
13. What is the importance of checking the calibration of a pressure

gauge while increasing and decreasing pressure applied?
14. PI-304 is a compound pressure gauge which measures /Indicates

both vacuum and positive pressure. What test equipment will be
required to perform this calibration?
15. What safety considerations must be taken into account when

removing a pressure gauge for calibration?
16. PI-304 is out of tolerance on the vacuum portion andwithin tolerance

on the pressure portion. With no available replacements, under-what
. conditions could this gauge be used? • I
17. What are the specified trip points of PDIS-405? Is the output of the
switch connected to the normally open or-normally closed contacts?
I
.1
I
I
5
LEVEL INSTRUMENT
CALIBRATION.
After completing this chapter, you should be able to:

Calibrate the following levelinstrument types (to ISA
standards, where applicable)and determine acceptability:
• Differential pressure
• Capacitanceprobe
• Ultrasonic
. Select the proper calibration procedure and calibration.dets .
sheet.
Select appropriatecertified test equipment.
Properly set up/connect test equipment to device under test

(DUT) for calibration.
Properly isolate level devices and/or remove from service for

field calibration.
.
Return equipment to service following calibration.
.
5.1 lYPES"OF LEVEL INSTRUMENTS

There are numerous types of level sensors and instrumentation. The
sensor type used in a particular application depends on many factors
including the process fluid measured, density, vented/pressurized, direct
or indirect detection, agitated, continuous or point measurement,
accessibility, maintenance requirements, etc. We will briefly overview a
few of the major sensor types:
Differential Pressure
Differential pressure sensors have a high pressure side and a low
pressure side with a sensing element, such as a bellows, separating the
two sides. The high pressure side of the sensor is usually connected to the
61
62 Level Instrument Calibration
FIGURE 5-1.
Differential Pressure Sensor
HIGH PRESSURE LOW PRESSURE
II
bottom portion of the vessel and, therefore, senses the pressure exerted by
the weight of the process fluid in the vessel plus the tank pressure (if
pressurized). The low pressure side is usually connected to the vapor
space at the top of a pressurized vessel or is open to atmosphere if the
vessel is vented or open to atmosphere. The low pressure side only senses
the vessel pressure (or atmospheric pressure) and not the weight of the
process fluid. Differential pressure (dip) measurement is based on the
principle that the difference between the two pressures is equal to the
height of liquid, multiplied by the specific gravity of the fluid.
Capacitance/Radio Frequency (RF)

A capacitor consists of two plates electrically isolated from each other
by a dielectric (nonconductor). The plates have an area (A) and are
separated by a distance (D).Different mediums have a specific dielectric
constant (K). Capacitance (C) :;:KA/D. Therefore, if the plate area and gap
distance remain constant, capacitance varies as a function of the dielectric
constant of the substance filling the gap.
For capacitance level measurement, a capacitor is formed when a
level-sensing electrode is installed in a vessel. The metal rod of the
electrode acts as one plate of the capacitor, and the tank wall acts as the
Calibration. 63
other plate. If the tank wall is not metallic, a reference electrode is used.
Referring to Figure 5-2,you can see that, as the liquid level rises; the air or
gas around the electrode is displaced by the process material, which has a
different dielectric constant. Therefore, there is a corresponding change in
capacitance between the probe and the vessel wall. The measured
capacitance is proportional to liquid level. The unit of capacitance is the .
farad. Capacitance level probes typically measure in the pico-farad range
(10-12farads).
FIGURE 5-2.
Capacitance Probe
r----
PROBE:
ONE PLATE
OF CAPACITOR
I
I
METAl.: WALL: I
r OTHER PLATE
OF CAPACITOR·
II 'I
Ultrasonic
Level is measured using the ultrasonic method by transmitting a
sound pulse from the instrument to the surface of a material. The sound ..
pulse is reflected off the surface, and the echo returns to the instrument
where it is detected. A shorter time for the transmitted signal to return
means the level is closer to the Sensor and, therefore, the level is higher in
.the tank. The amount of time for the return signal is inversely proportional
to the level.
FIGURE 5~3.
Ultrasonic Measurement
GENERATOR AND
TRANSMITIER ~---I
TIMING
GENERATOR 1-----.1 lOGIC AND
DISPLAY
n
\.U
'------.----'
I I I 10
WAVE
SHAPING
__fI TRANSMITTED BURST
RECEIVED BURST (ECHO)
ELAPSED TIME PROPORTIONAL

TO DISTANCE
-
5.2 SPECIAL CONSIDERATIONS WITH LEVEL
CALIBRATION
Suppressed/Elevated Zero
If the dip cell is not located at an elevation that corresponds to 0%
level in the tank, it must be calibrated to account for the difference in
elevation. This calibration adjustment is called zero elevation when the
cell is located above the lower tap; it is called zero suppression when the
cell is located below the lower tap.
To calculate the amount of elevation or suppression, the distance
between the zero reference level and the high pressure port of the dip
cell must be accurately measured. Taking into account that 27.72:' H20 =
1 psig, calibrate the transmitter for the distance measured in direction
necessary to result in an accurate output.
Specific Gravity
Specific gravity is ratio of density of a process material to the density
of water or air. It is particularly important to consider the specific gravity
of the process material when performing calibrations of differential
pressure level devices. If specific gravity is assumed to be 1.0, or not
Calibration 65
considered at all.signlficant error will be introduced if the process

a
material is not water or specific gravity of 1.0.Water has a density of
62.4Ibs/cu. ft.'
FIGURE 5-4.
Liquid Head Measurement
WEIGHS.62.4 LBS.
DENS)TY'" 62.4 LBS.lCU. FT.i

···
-~
1 SO. INCH
PRESSUREAT BOTTOM
'.
=m
AREA
= 62.4tes.·
144SQ. INCH
= 0433
.
PSI PER 12' WATERCOLUMN ;-'
.:
OR 0433 PSI = 0.03609 PSI PER INCHWATER COLUMN
,-
12'
,H
~.
'..
-,
FIGURE 5-5.
Effect of Specific Gravity on Liquid Head Measurement
• As specific gravity changes (& density changes) "h", or
head must be multiplied by the specific gravity of the
.liquid to convert to inches H20
This gives the pressure at the bottom of the tank-in inches Hp
" -.--
SPECIFIC
GRAVITY =?
-_
.--r
"h" (INCHES)
_l
To determine the specific gravity of a process material, simply divide

the density of the process material by the density of water. For example,
the density of petroleum is 54.81bsl cu. ft. Therefore the specific gravity of
petroleum is 54.8 -;.62.4, or 0.88. To properly calibrate a dip transmitter
for a sensor monitoring the level of petroleum, the nominal test points for
input pressure must be multiplied by 0.88. Specifically, if the transmitter is
calibrated for a to 100" = 4-to-20 rnA output, you would use the following
to properly adjust the transmitter for the process fluid specific gravity of
0.88:
NOMINAL ACTUAL lEST EXPECTED

(IN. H2O) PRESSURE OUTPUT
(IN. H2O) (MA)
NOM. x 0.88
10 8.8 5.60
25 22.0 8.00
50 44.0 12.00
75 66.0 16.00
100 88.0 20.00
I!
Dry and Wet Legs
For differential pressure measurements, the pressure of the vapor
space in pressurized vessels is connected to the low pressure side of the
dip cell. When process vapors are non-condensing, non-corrosive, and
non-plugging, the leg external to the vessel that is connected to the dip
cell is a dry leg. If any condensate accumulates in this leg, significant error
would result in the level indication. Can you see why? If there is
condensate in the dry leg, the weight of the condensate adds pressure to
the low pressure side of the dip cell. This would reduce the dip sensed
and result in a level indication or output that is lower than the actual level.
On the other hand, if the process vapors condense, the reference leg
can be filled to form a wet leg. The specific gravity and height of the
reference column must be accurately determined and accounted for in any
calibration of the dip cell.
Interface
For purposes of level instrumentation, "interface" typically refers to
the point at which two non-mixable fluids meet, such as oil and water.
Special considerations must be made to accurately measure the level of
each fluid and/or the level of the interface.
.!
Calibration 67
5.3 CALIBRATING A DIFFERENTIAL PRESSURE

LEVEL lRANSMITTER
FIGURE 5-6.
Shop Calibration - DP Transmitter.
AUXILIARY Ct:JRRENT
READOUT
:1:0.1%
DIFFERENTIAL mAREADOUT
B. PRESSURE
TRANSMllTER
:I: 0.1% ACCURACY
OR BElTER SERIES RESISTANCE
REQUIREDWITH
SOME TRANSMITTERS
PROCESS.
SIMULATOR
INCHESH20 O'.250" Hp H
>0.1% ACCURACY r----l~..:.:.....J......::_j 24VDC
OR BElTER
POWERSUPPLY
VENT TO
ATMOSPHERE
>20 PSIG
AIRS!JPPLY 120VAC
JI The illustration above indicates a typical test setup for performing a

bench calibration of a differential pressure transmitter. Calibrating a dip
transmitter is similar to calibrating a pressure transmitter discussed in
Chapter 4. Measured pressure is applied to the high pressure port of the
.dip cell, and the low pressure side is vented to atmosphere, Be sure to
remove,any caps, cleanliness plugs, or obstructions from the low pressure
port, (This is sometimes overlooked, partic~arly for new instruments.), .
The calibrator and transmitter must be at the same elevation to prevent
inducing head which would introduce error. A milliammeter is connected .. i
in series to measure a 4-to-20 rnA transmitter output Signal. If necessary, I
we may also have to provide the transmitter output power source.euchas
24 volts direct current"(VOC).Again, most modern calibration standards ..: I
. provide the ability to supply the transmitter power so a separate power
source is not required
j~
'The dip transmitter in Figure 5-6 is calibrated for a 0-250"H20 input
;;;::
4-to-20 rnA output. On the bench, with no remote displays to over range,
we can perform the five-point check at 0%, 25%,50%, 75%,and 100%.The
calibration data table is illustrated below.
TABLE 5-1.
Calibration Data Table for 0-250 in. H20 DIP Transmitter
% SPAN ACTUAL IDEAL AS· % AS-LEFT %
INPUT OUTPUT FOUND DEVIATION OUTPUT DEVIATION
("H2O) (rnA) OUTPUT (ERROR) (rnA) (ERROR)
(rnA)
0% 0.0 4.00
25% 62.5 8.00
50% 125.0 12.00
75% 187.5 16.00
100% 250.0 20.00
Once the test setup is established, adjust the input values to the
required test points and record lias-found values for the milliamp output.
II
Typically, it is not necessary to check a transmitter in both the upscale and

downscale directions. Once the lias-found" data has been recorded,
evaluate the error against the acceptable tolerance to determine if
adjustment is required. The following "as-found" values were obtained.
The error is calculated by [(Actual Output-Ideal Output) ..;.(Ideal Output)]
x 100%.
11
TABLE 5-2.
Calibration Data Table for 0-250 in. H20 = 4-20 mA DIP Transmitter
(Note: The % error is calculated based on the reading and not % span
in this case)
% SPAN ACTUAL IDEAL AS- % RDG AS-LE'FT % RDG
(NH2O) (MA) OUTPUT (ERROR) (MA) (ERROR)
(MA)
0% 0.0 4.00 4.01 0.25%

25% 62.5 8.00 8.02 0.25%
50% 125.0 12.00 12.03 0.25%
75% 187.5 16.00 16.05 0.3125%
100% 250.0 20.00 20.08 0.40%
If adjustment is required, perform the zero and span adjustments per

the manufacturer's procedures. Sometimes this is adjustment of a zero and
span potentiometer, sometimes it's a pushbutton adjustment, while other
transmitters req.uirethe use of a handheld interface. Because some zero
and span adjustments interact, it is important to recheck the zero and span
until no further adjustment is required.
Calibration 69
vyith the "as-found" readings obtained above, what adjustments will

likely berequired? The zero is adjusted to achieve a 4.00 rnA output with
the input vented to atmospheric pressure. The span is adjusted to achieve
an output of 20.00 rnA with 250.0"H20 applied to the input. The zero and
span adjustments are repeated until no further adjustments are required.
Once no further adjustments are required, repeat the five-point check and
record "as-left" values. The "as-left" values obtained are recorded below.
TABLE 5-3.
Calibration Data Table for 0-250 in. H20 DIP Transmitter wi As-Left
Data
% SPAN ACTUAL IDEAL AS- % AS~LEFT %
(rnA)
0% 0.0 4.00 4.01 0.25% 4.00 0.0%

25% 62.5 8.00 8.02 0.25% 8.01 0.13:%;:
50% . 125.0 12.00 12.03 0.25% 12.00 0.0%

....
75% 187.5 . 16.00 16.05 0.31% 16.01 0.06%
100% 250.0 20.00 20.08 0.40% 20.00 .0.0%
.:
How would this calibration change if the process material has a ... j
. specific gravity of 1.17If we installed the above dip transmitter to .,"

measure the tank level of a material with specific gravity of 1.1,what
would the indicated level be at an actual level of 100"7Since the process
. ;
•
material is denser than water by a factor of 1.1~it will exert a pressure of
1.1times water at the same height. Therefore the indicated level would be
110"at an actual level of 100".
.' For an accurate level indication, the input press:ure must be adjusted
to compensate for the specific gravity of the process material. This
compensation is calculated by multiplying the input pressure in inches of
H20 times the specific gravity. This calculated input pressure is then
applied at the corresponding % span using the same ideal output rnA
values as before..The Calibration Data Table compensated .fora specific
gravity of 1,.1is illustrated below. I
r
I
I
TABLE 5-4.
Calibration Data Table for 0-250 in. DIP Transmitter @ Specific
Gravity = 1. 1
% SPAN ACTUAL IDEAL AS- % AS· LEFT %
(rnA)
0% 0.0 4.00
25% 68.75 8.00
50% 137.5 12.00
75% 206.25 16.00
100% 275.0 20.00
How would this calibration change if it were done in the field? There
is no change in the calibration principles. However, some of the
considerations that must be made are listed below:
• Before doing anything, the process conditions must be evaluated.
This is also true if the instrument is removed from service for a
bench calibration. Is the system shutdown with the tank drained?
Is the process operating in automatic level control? If so, the
system must be placed in manual control and an alternate means
II
of manual level control employed.
• Can the dip cell be isolated from the system? If not, the system
must be shutdown and drained. If so, isolate the dip cell properly
before making test connections. If equipped, the bypass valve is
always opened first and closed last to prevent damage to the dip
cell.
• Is the process material hazardous? If so, take appropriate
precautions.
• The test pressure input is connected to the high pressure side, and
the low pressure side is disconnected, if necessary, and vented to
atmosphere.
• Most likely, the rnA output will only need to be measured, without
the need for providing a power source. The output signal circuit
usually provides the power source.
• Record the remote display(s) if required by procedure for a loop
calibration. If the remote indication(s) does not go below the 0"
Calibration 71
value or above the 100% value, check the instrument at 10% and
. 90% instead of 0% and 100%. All other test points remain the same.
5.4 CAL1SRATING A CAPACITANCE LEVEL .j

INSTRUMENT
The initial calibration of a capacitance level instrument following .
installation "isvery vendor-specific. It usually involves adjusting the actual I
.i
tank level to one point, accurately measuring that level, and entering the
. actual level in the calibration setup (or pushing a button at the zero level). I
The tank level is then adjusted to a second point, accurately measuring I
.that level, and entering the actual level in the calibration setup (or pushing j
a button at the 100% level. The calibration points must be accurately_ 'yo
determined and should be as far apart as.possible. There may also be
I
J
linearization values to enter and other factors, depending on the tankrl,v,
)
shape and probe installation.
o\>J
.To perform a periodic calibration check of the capacitance level, it~is
~~
best to establish an independent.means of determining the level. This ~;: ",
could be by: . ;1:
/1
• Installing a temporary sight glass by connecting some tubing t9 a:
tank ,bottom connection and running up the side of the tank :'.:;, '~~:I
r,'
(externally);
-c-'
. ,~,
• Measuring the actual level using a measuring stick;
• Using a calibrated flowmeter to meter the amountof fluid added
to the tank; or
, .
• Weighing out a specified amount and transferring the entire

amount to the tank,
You'll have to use your imagination and existing resources to

determine a method that works.for your application, Once a method has
been determined, check the level at a minimum of two different points in
addition to the zero level. If the level instrument requires calibration,
perform in accordance with the manufacturer's instructions in the
instrument technical manual.
Here's what does not work, based on my experience. I've tried to
measure the probe capacitance at various levels during initial setup, I
thou:ght I could then use these values to simulate a capacitance to the
instrument. It just doesn't work out. However, some manufacturers do
provide a calibrator specific to their capacitance level meters. For example,

Drexelbrook provides a PC interface to configure and calibrate the
electronics. Smart transmitters can be configured and calibrated with
smart interface devices such as Rosemount 275. To verify the accurate
level measurement, some method indicated above would still be required.
5.5 CALIBRATING AN ULTRASONIC LEVEL

INSTRUMENT
There are two methods for calibrating an ultrasonic level transmitter.
Ideally the instrument can be removed and the cabling has enough slack
to move to an open area with an unobstructed path to a smooth surface
(such as a wall or floor). If this is the case, follow Method 1. If this is not
the case, follow Method 2.
Method 1:
1. Determine the distance from the face of the ultrasonic transducer to
the 100%level. This should already be documented as part of the
instrument setup. For this example, we are going to assume the
distance is 12~'
2. Determine the test point distances. Realize the distance from the test
surface is simulating the distance from the top of the liquid level and
take into account the distance determined in step 1 above. For
example, if the distance from the transducer face to the 100%level is
12 inches and the tank level indication is 0-100inches, the following
test points would be used.
% SPAN DESIREDLEVEL DISTANCE FROM

INDICATION lEST SURFACE
0% 0" 112"
25% 25" 87"
50% 50" 62"
75% 75" 37"
100% 100" 12"
3. Tum off the transducer.

Calibration 73
4. Use appropriate safety precautions; remove the instrument from the

top of the tank. '
5. Use a tape measure to mark off the distances from the test surface at
each desired test point determined in step 2 above.
6. .Place the instrument at a distance equal to the first test point from the
wall or floor that will be used to bounce the signal back (the test
surface simulates the top of the liquid level).
7. Tum the transducer ~mand record the level reading.
8. Move to the next distance and record the level reading. Repeat until .
all "as..-found" readings have been obtained. .. .j
I
9. If necessary, adjust the instrument in accordance with the
manufacturer's instructions in the instrumenttechnicalinanuaL
I
10. If adjustments were made, repeat steps 6 to 8 above to obtain II~;..", ;{
·1
left" readings. i
11. -Return the instrument to operational condition. .):J
'~i
i
Method 2: "
.)
1. Establish an independent method for determining the actual liquid
level in the tank (such as hooking up a temporary sight glass using
tubing from a bottom connection and running external to the top of
.,.'
.. ,
the tank).
2. Adjust the level in the tank to each of the desired setpoints
throughout the range of the instrument and record the reading from
I'
the ultrasonic instrument at each test point. . I
3. If necessary, adjust the instrument in accordance with the
manufacturer's instructions in the instrument technicalmanual,
iI
4. If adjustments were made, repeat step 2 above to obtain "as-left"
i
. readings.
·5. Return the system to operational condition.
REVIEW QUESTIONS
Use the information in Chapter 5 and the references in Appendix A to

answer the following questions.
1. What is the correct calibration range and the specified accuracy for
LIT-202?
2. Select the correct procedure(s) that could be used for this calibration
ofLIT-202.
3. The process monitored by UT-2D2is at a specific gravity of 1.0.What

are the correct input pressure values for 0%, 25%,50%, 75%,and
100%?(include units)
4. What are the expected transmitter output values for the pressure
1i
inputs of step 3?
5. Indicate the correct test equipment hookup for calibration of LIT-202.
Pressure
HP Meier (mA)
Level Indienting Transmitter
Standard LIT-202
LP
~
HP
LP 24VDC
pressure Power
Source Supply
6. If the specific gravity of the process being monitored is 0.8, what

would the pressure inputs be in step 3?
Calibration 75
7. If-a tank located on the roof has a DIP level transmitter installed
100feet below the zero reference level, what would the applied
pressures be in step S? (s.g. = 1.0)
8. What type of level instrument is LT-3~5?
I
9. What is the principle of operation for the level instrument type in
step 8? I
10. Describe the basic method fpr initial calibration of LT-305.
I
I
11. How is the capacitance probe checked for proper calibration?
I
i
:"t'
.,.I
II 12. What two basic methods can be used to perform a calibration ohm
ultrasonic type level sensor?
f
I
I
6
FLOW INSTRUMENT
CALIBRA TION
After completing this chapter- you should be able to:
Explain the principles of operation for the fol/owing tlowmeter

types:
• Differentia! pressJire
• Magnetic
• Vortex-shedding
• Turbine"
• Coriolis !
.Calibrate the following flow instrument types (to·ISA
I
standards, where eppticeblel and determine acceptability:
• Flow rate meters

.• Flow totalizers
Select proper calibration procedure and calibration data sheet.:

Properly set up and connect test equipment to device under
. test (DUT) for calibration ..
Properly isolate flow devices and/or remove from service for

field calibration.
Complete and properly maintain calibration documentation .
.. v
6.1. lYPES OF FLOW INSTRUMENTS

There are numerous sertsor technologies for flow instrumentation,
The sensor type used in a particular application depends on many factors,
induding the process fluid measured, pressure, temperature, allowable
pressure drop, density, conductivity, viscosity, pipe size and orientation,
flow rate and/or flow total required, accuracy.requirements, control
77
78 Flow Instrument Calibration
system interface, accessibility, maintenance requirements, etc. We will

consider briefly a few of the major sensor types:
Differential Pressure
FIGURE 6-1.
Differential Pressure Flowmeters
'-------'~ ------l~-----.J
Upstream tap Downstream tap

High pressure Low pressure
8 pipe diameters
upstream
5 pipe diameters
downstream
Restriction-type flow instruments are based on the principle that flow

rate is p~oportional to the square root of the differential pressure across
the restriction. An orifice plate or venturi is installed inline with the
process flow to restrict the liquid flow. This restriction creates a pxessure
drop that can be converted to flow rate. 111eupstream pressure is
connected to the high pressure port of a dip (differential-pressure) cell.
The downstream side is connected to the low pressure port of the dip celL
Calibration 79
(The dip cell was described in Chapter 5.) The square root is accounted
Jar in the transmitter signal processing or by the use of square root
'extractor springs of the dip cell. However, some older models utilize a
.separate square root extractor installed in the output signal loop. In this
case the installed square root extractor must also be calibrated for the loop
to perform within specification.
Magnetic Flowmeter
FIGURE 6-2.
Magnetic Flowmeter I
f
EI£CTRIC FIELD. E I
FIELD
.[
COILS
_. j
I
r
MAGNETIC FIELD
The magnetic flowmeter is based on Faraday's Law of

electromagnetic induction. When a liquid conductor:moves in a pipe
having diameter D and travels with an average velocity V through a
magnetic field of B intensity, it will induce a voltage (E)according to the
relationship E = BVDC,where C is the constant for units conversion.
Because the magnetic field, pipe diameter, and conversion constant are_
fixed values, they can be combined into a calibration factor and the
equation reduces to ;E = KV. Magnetic flowmeters can only be used to
measure flow of conductive liquids. As conductive liquid passes through
the magnetic field, an electrical potential is induced. The change in
. potential varies directly with the liquid velocity. This voltage is sensed by
electrodes in the walls of the flowmeter .
.'
Vortex-shedding Flowmeter
FIGURE 6-3.
Vortex Shedding Phenomenon
/" High Velocity Fluid
.. Meter
Bore
Shear
Alternate ~
Vortices J
Layer
When a flowing medium strikes an obstruction, it separates and

moves around the object. At the point of contact with the object, vortex
swirls separate from the object on separate sides. This shedding causes a
11
local increase in pressure and decrease in velocity on one side of the
object. A local decrease in pressure with corresponding increase in
velocity occurs on the other side of the object. After shedding from one
side, the process is reversed. The frequency of shedding reversal is
proportional to the velocity of the fluid passing the obstruction.
A vortex-shedding flowmeter has three basic parts: a bluff body (or
shedder bar), a sensor, and a transmitter. In the process line, flowing
liquid strikes the bluff body and vortices are shed alternately on each side
of the bluff body. The velocity of the flow determines the frequency at
which the vortices are shed. The shedding of the vortices on alternate
sides of the bluff body is detected by sensors built into the bluff body.
These sensors can be force sensors or temperature sensors (thermistors).
The sensor then converts the energy created by the vortices into electrical
pulses. These pulses are conditioned and sent to the transmitter, which
generates the output signal proportional to the flow rate. The volumetric
flow rate (Q) :::vortex-shedding frequency (f) x meter coefficient (1<).
Calibration 81
Turbine Flowmeter
FIGURE 6-4.
Turbine Flowmeter
PICK-UP COIL
I
" I
j
,I
ROTOR
I
The turbine flowmeter is a mechanical flowmeter that measures flow

I! by means of a spinning turbine or rotor using an arrangement of moving
parts. The multi-bladed rotor is mounted at right angles to the flow,:"
suspended in the process fluid stream on a free-running bearing. The
speed of rotation is proportional to the volumetric flow rate. Turbine
rotation is detected by solid state devices or mechanical sensors. As shown
in Figure 6-4, a pickup coil is used to detect the rotary speed for signal ,
processing. As each blade passes the coil, a voltage pulse is generated.
Each pulse represents a discrete volume. The number of pulses per unit
volume is the meter's K-factor. The output is a continuous sine wave with
the frequency proportional to the flow rate. " I
Corio lis Mass Flowmeter
A mass flowmeter measures flow rate in weight per unit time rather
I
than volume. This measurement compensates for temperature and,
pressure changes. Fluid moving through a vibrating tube is force? to
accelerate as it moves toward the point of peak amplitude of vibration.
...".
The fluid decelerates as it moves away from the point of peakamplitude .
The acceleration and deceleration cause twisting forces on the flowtube
which are proportional to the ~ass flow.
FIGURE 6-5.
Coriolis Mass Flowmeter
FLUID
FORCE
,
FLOW
FLUID
FORCE
VIBRATING FLOW TUBE FLUID FORCES REACTING TO
VIBRATION OF FLOW TUBE
TWIST \
ANGLE ~
~l...,-0~~i~
6.2 CALIBRATION OF FlOWMETERS
All meters with moving parts require periodic testing because wear
over time will reduce the flowmeter performance. Calibration can be
performed either in the lab or in situ (in its original place) using a prover,
also called a master meter, or by weighing the flow output. There are
several methodologies for flowmeter calibration. Anyone of them, and
.others, may be acceptable depending on the process system configuration,
compatibility, availability of test standards, and accuracy requirements.
It is sometimes difficult or impossible to remove a flowmeter from
service for calibration. Therefore, field-mounted and inline provers have
been developed. Depending on the application and system configuration,
other methods can also be developed to check the accuracy of flowmeters.
Weighing the flowmeter output collected over a specified time is a
common alternative .
. The calibration of the signal-processing portion for most flowmeter
instruments can be checked by simulating the Signal from the flowmeter.
These me~hods do not check the sensor itself. No one generic method
works for all flowmeters. Tests must be performed in accordance with the
specific manufacturer's instructions. However a few of these methods are
discussed below.
Calibration 83
GENERAL METHODOLOGY WHEN TO USE
Caiibrate only the electronics (or signal If it is impossible to perform an in-situ

processing) using a test instrument to check of the- flowmeter sensor using a
simulate the sensor. . prover or other methods discussed below
and the sensor cannot be removed from
the system.
Check the calibration of the flowmeter, If the flowmeter sensor can be checked
·1
sensor and signal processing together, in situ but test standards are not
using a prover or some other standard. available for simulating test signal input.
Calibrate the electronics first, and then If the required test instruments are
check the calibration of the flowmeter, available to simulate the flowmeter input
including the sensor. signal and the flowmeter sensor can be
checked in situ.
Remove the flowmeter and send to a If the system is not compatible with in-
flow calibration lab (intemal, situ 'flowmeter calibration. It may be .
I
.i
manufacturer, or a 3rd party flow
calibration lab).
necessary to install a calibrated spare. to
keep the process downtime to a
minimum..
6.3 DIP lRANSMITTER CALIBRATION

The principles and methods discussed in Chapter 5 for the level dip
transmitter also apply here. The only difference is that you mU:stknow
how the square root is obtained. Remember that flow rate is proportional
I
to the square root of the differential pressure. As mentioned earlier in this
chapter, the square root is usually accounted for in the transmitter signal
I
processing or by the use' of a separate square root extractor installed in the
output signal loop. Sometimes, but rarely, some models utilize square root I
I
extractor springs as partof the dip cell. I
To calibrate the square root extractor in a 4-20 rnA transmitter output J
loop, a milliamp source is '~onnected to the input. A milliammeter is
connected in series tothe output with a power supply, if necessary. The
manufacturer's instructions specify the input values and expected
;.
outputs.'
Note that this does not check the actual flow sensor. It may be desired.
or required to check the flow sensor.for wear, damage, or obstruction.
Later in this chapter we will discuss methods for calibrating the flow
I
.:
sensor in situ .
.'
6.4 EXAMPLE: MAGNETIC FLOWMETER

CALIBRATION
You must refer to the manufacturer's instructions for calibration of
each specific model of magnetic flowmeter. The manufacturer may also
supply specific calibrators for its flowmeters. Here is a typical procedure
using a magnetic flowmeter calibrator as an input standard that varies the
millivolt signal to simulate the Signal from the flowtube electrodes. We'll
assume the output is 4 to 20 mAo Therefore, a milliammeter will be used as
the output standard.
1. Determine the maximum flow rate that will be checked. This is the
100%value.
2. Obtain the mV calibration factor and the phase band factor from the
instrument data plate.
3. Calculate the upper range value (URV)as follows:
URV = (Max Flow Rate) x (mV Calibration Factor)
4. Calculate the ,maximum input signal value as follows:
Max Input Signal Value = (URV) x (Phase Band Factor)
5. Disconnect the flowtube from the transmitter and connect the
magnetic flowmeter calibrator to the transmitter input.
Magnetic Callbralor
Percent-Output
Swllch
Input Powor
Indloa\ol1
Input Power
80leolor 8'W11oh
6. Connect the milliammeter in series with the transmitter output

signal.
Callbration 85
7. Set the calibrator range knob to select the maximum output signal.
For example, with a calculated maximum input signal of 8.32mV, the
range knob would be set to 10mV.
8. Set the maximum input signai value on the dial. For this example, the
dial would be set to 8.32(outer dial set at 8, inner dial set at 0.32).
.,I 9. Use the percent output switch to perform a 5-point check at 0,25,50,
75,and 100%.At each position, record the transmitter rnA output on
, the calibration data sheet.
10. At this.point youneed to evaluate whether to adjust the flowmeter. If
,you are going to check the flowmeter sensor, it JIlaybe prudent to ,cljJ
that prior to making any adjustments. Adjustments may have been, ,
made during the.last calibration to compensate for slight flow sen~or
inaccuracy. If you make adjustments prior to checking the flow"
sensor, you may be "undoing" the correction. If a check of the :
flowmeter will be performed, use one of the methods describedslateri
inthis chapter and then proceed with step 11,below. ,';,' ' ,i :~j
( .~~
I
I'
I 11. If necessary, calibrate the transmitter by adjusting zero' at the 0%,.
input for a 4.00 rnA output. Then adjust span at ~e 100%input for a
20.00 rnA output, Since zero and span often interact, recheck and-
adjust the zero and span until no further adjustment is necessary'.:
12. If adjustments were made, repeat step 9 above to obtain as-left ':'"
readings.
. . . . . '.
Note that this does not check'the actual flow sensor. It may be desired
or required to check the flow sensor for wear or damage, The next section
of this chapter will discuss methods for calibrating the flow sensor in situ.
The calibration of a vortex-shedding or turbine flowmeter would use
the same principles as the magnetic flowmeter above. However, the input '
standard would be a frequency generator. Again, you must use the
specific dllibration instructions provided by the manufacturer. '
Once the calibration of the signal-processing portion of the flowmeter
has been checked, a check of the flowmeter in situ is performed. Note that
some industries require that all as-found readings be obtained prior to any
adjustments. Therefore you may need to evaluate whether you would
adjust the electronics prior to checking the actual flowmeter in situ. So far
we have only mentioned flow rate meters. Some flowmeters are used as
i
I flow totalizers. Some flowmeters are used to obtain both flow rate and
flow total. We will have to consider how the flowmeter is used when
performing calibrations. The two methods for in-situ flowmeter

calibrations are described below.
6.5 FLOWMETER CALIBRATION USING A

MASTER METER (PROVER)
A master meter, or prover, is a calibrated flowmeter used as a
calibration standard. The master meter is installed in series with the
flowmeter under test, and the readings are compared at various flow rates
or flow totals. It is advisable to perform this comparison for at least two
different flow rates (or flow totals). Ideally, the process was designed to
incorporate a master meter in series with the installed flowmeter. In my
experience, this is not usually the case. So you have to get creative about
how to install the master meter. It may, for example, involve
disconnecting the outlet of the installed flowmeter, adapting the master
meter to the output, connecting a discharge hose with a valve at the end of
the hose, and directing the hose to a drain or back to the process vessel for
proper waste disposal. A discharge valve is important to keep the piping
full and maintain some backpressure. Without a discharge valve you may
find error in your readings, particularly at low flow conditions.
Once the test setup is made, flow the process material (or water)
through the flowmeters and close the discharge valve in order to fill the
piping completely. With the piping and flowmeters completely filled and
no flow, the flowmeters should read zero flow. If this is a desired test
point, record the readings. Sometimes zero flow is difficult to check due to
environmental factors, vibration, air pockets, etc. Next, open the discharge
valve and establish flow at the desired test point and allow the readings to
stabilize. Record the readings and repeat for all desired test points. If
adjustment is required, perform it in accordance with manufacturer's
instructions and repeat the above procedure to obtain as-left readings.
If the master meter and the installed flowmeter are not capable of
reading in the same units, conversion of the results may be required. Some
corrunon conversion factors are listed below. Additional conversion
factors are included in Appendix A-7.
1 liter == 0.2642 gallons; 1 gallon = 3.785 liters
1 gallon water = 8.35 lbs at 25°C
(measure water temperature used for calibration if Significantly
different and calculate density for calibration data analysis)
Llb = 0.45 kg; 1 kg = 2.21b
Calibration 87
6.6 GRAVIMETRIC METHOD FOR FLOWMETER

CALIBRATION (MEASUREMENT BY WEIGHT)
This method involves weighing the amount of fluid that actually
flows through the meter into (or out of) a container, For a flow rate meter,
the fluid is collected in the container for a specified amount of time, such
as one minute. Although it may require as much creativity, the test setup
is the same as the prover method, except there is not a master meter in
series with the installed flowmeter. The hard part is figuring out how
you're going to weigh the amount of fluid. You must use a container that
is large enough for the amount of flow to be tested. Likewise, a calibrated
weigh scale with adequate capacity must be used. The container will
either sit on the weigh scale in close proximity to the flowmeter or the'
container will need to be transported to the weigh scale. Obviously you
don't wantto get your container full and then discover that you can't get
the container on the scale. S6 think through the logistics before startinJHh~
calibration.' .
Once- the logistics are figured out and the test setup is made,
-
plac~Jhe
..
--:.-
empty container on the scale and TARE (zero) the scale reading. It is. _oS'
I
important to TAREthe scale with anything that will be on the scale when
I'
weighing the contents of the container. Next, flow the process materic¥.(or
.~
water) throughthe flowmeter to a waste container or drain and closafhe
discharge valve in order to fill the piping completely. If zero is a desit;~d
test point, read and record the flowmeter reading. Then open the
discharge valve and flow to the diain or waste container to establish the
desired flow rate. Once the desired flow rate is stabilized, simultaneously
start the stopwatch and switch the discharge to the weighing container.
Ensure there is no spillage out of the container and verify that the
flowmeter reading is maintained at the desired test point. Recordthe I
flowmeter reading. Continue discharging the entire output of-the
flowmeter into the container for the specified time period, such as one I
minute. It may be desirable to use more time to obtain a measurable II
amount of fluid (at least % of the container). Once the specified time
period has elapsed, Simultaneously stop the stopwatch and switch the I
discharge to the drain or the waste container. Close the discharge valve.
Record the stopwatch reading and the weight. Convert the weight to the
desired units and divide by the time to obtain-the actual flow rate.
Compare the flow rate obtained with the flowmeter reading recorded.
I.,
Empty the weighing container, if necessary, and TARE the scale. Repeat
I
the procedure above for additional test points. If adjustment is required,
perform in accordance with the manufacturer's instructions and repeat the

above procedure to obtain as-left readings.
If the flowmeter is used as a flow totalizer, the procedure is
essentially the same. Some totalizers can be set to stop the flow when the
desired flow total is achieved. Also, instead of using a stopwatch, the
totalizer is reset to zero at the same time discharge is switched to the
weighing container. If the totalizer cannot be zeroed, record the initial
totalizer reading, at the moment the discharge is switched, and the final
totalizer reading.
REVIEW QUESTIONS
Use the information from this chapter and the references in Appendix
A to answer the following questions:
1. How is a flowmeter calibration performed when accuracy to
manufacturer specifications is required and the process system is
incompatible with performing an in-situ calibration?
2. How can most flow calibrations be categorized as flow rate or flow I

totalizer when there are so many different types of flowmeters?
3. What are the two basic calibration methods for checking flowmeters?
4. What methods are used for incorporating the square root of the dip
for venturi-type flow devices?
5. Select the correct procedure to be used for this calibration of FT-301.

(Appendix A-4)
6. What local and remote indications must be recorded during

calibration of FT-301?(Appendix A-I)
7. What test equipment is required for calibration of FT-301?

7
FINAL CONTROL DEVICES
CALI.BRATION
After completing this chapter, you should be able to:
Celibrete the following instrument types (to ISA standards,

where applicable) and determine acceptability:
r
• Current-to-pressure transducers (I/P)
I • Valvepositioners I
-I .- Control valves _/
, J
i
Select proper-cshbrstion procedure and calibration data sbeet: , I
''[ I , ~
Select appropriate certified test equip/nent:
,
•
, ' I
!
; j :..,1£, ~
, •• 1
, J ::::
: ' Properly set up and connect test equipment 'to DU;r:for '.~
, , . calibration.
Properly isolate flow devices and/or remove from service for

. field calibration .
.....:.t:.
Return equipment to service following calibrl!Jion.
'!j'l
Complete and pr(?perlymaintain calibration d_ocumentation.
, -,"
The temperature, pressure, level, and flow instruments covered inthe

previous chapters all sense a process parameter and produce a signal for
indication or controller input, If we want to control a process parameter,
the controller output must be converted to a signal that may be used to
drive a control valve. The control valve is a final control element. A final
control element is any device or element that changes the value of a
manipulated variable. Valves and heaters are common examples of final
control elements. In this chapter, we will discuss control valves and the
devices that process the signal supplied to the control valve.
89 ,
90 Final Control Devices Calibration
FIGURE 7-1.
Current Practice - Field Devices
3-15 PSI (70.7 -103.4 kPa)
TRANSMIITER
LOOP
4-20 rnA
PROCESS INPUT
INSTRUMENT
AIR 20 PSI
(137.9 kPa)
SET POINT
In the illustration above, the controller output sends an electronic

signal to the current-to-pressure transducer (I/P), which sends a
pneumatic signal to the control valve. The control valve position changes
in response to the signal to adjust flow to the setpoint. As the flow
changes, it is sensed by the flow transmitter. When the flow sensed is
equal to setpoint, the valve position is maintained. Any time there is a
disturbance to the system or a change in setpoint, the flow control loop
automatically responds to achieve the programmed setpoint. A block
diagram of this concept is illustrated below.
Calibration 91
FIGURE 7-2.
Final Control Element
Disturbances
Controller
I
1
I
i
""'___ I Process
Measurement
..
-~.~;;., .'~
I
The final control element can be proportional control; as descrlbJd ....
above, or ON-OFF control. For ON~OFF control, a controller outputrelay
changes the state of the relay contact which completes the circuit for a ..;--,
:'..!
solenoid valve to energize. The solenoid valve opens to allow air to open·
"d!I (or dose) a control valve. .
The first component in the final control subsystem is the signal ':
. .:~
conditioner. The signal conditioner amplifies and, if necessary, converts

the signal for compatibility with the actuator. Typical devices used as
Signalconditioners include current-to-pneumatic transducers, current-to-
voltage (liE) transducers, amplifiers (electronic or pneumatic), relays,
digital-to-analog converters, or analog-to-digital converters. The most
common signal conditioner in a proportional control loop is an L/P
transducer.
A typical IIP transducer is a force balance device in which a coil is .:
suspended in the field.of a magnet. Current flowing through the coil
generates axial movement of the coil which causes movement of the beam.
The beam controls the backpressure against the nozzle by controlling the
restriction of air flow through the nozzle. This backpressure acts as a pilot
pressure to control the outlet pressure. The zero adjustment causes the
. beam to move relative to the nozzle. The span adjustmentis a
potentiometer that limits the currerit through the coil. The liP transducer
must be supplied with instrument air within the range specified by the
manufacturer, usually at least 20 psig. The typical L/P transducer is
.calibrated for a 4-20 rnA input = 3-15psig output. Most liP transducers
can be configured for direct action (output pressure increases as input
92 Rnal Control Devices Calibration
FIGURE 7-3.
IfP Transducer
• Used to convert current signal to pressure

signal
- Mechanical or Electronic?
Nozzle
Pressure
Oulpul- ..
Input
GAS "~~I~~~~
Rebalanclnp _ ..
Bellows
Nozzle Beam
signal increases) or reverse action (output pressure decreases as input

signal increases).
The next component in the final control subsystem, if applicable, is
the actuator. The actuator receives the conditioned signal and changes it to
some form of mechanical energy or motion. Typical devices used as
actuators include solenoids, pneumatic valve positioners, AC and DC
motors, stepper motors, hydraulic motors, and hydraulic pistons. Many
control valves include a pneumatic valve positioner.
A valve positioner is a device used to increase or decrease the air
pressure (from the L/P) operating the control valve actuator. Positioners
are generally mounted to the control valve actuator and connected
mechanically to the valve stem for position indication. A positioner is a
type of air relay which acts to overcome hysteresis, packing box friction,
and effects of pressure drop across the valve. It assures exact positioning
of the valve stem and provides finer control.
There are many types of positioners. The basic principles of operation
are similar for all types. The instrument pressure (from an liP, for
example) acts on the input module, which controls the flapper-nozzle
system of the relay. Supply pressure is applied to the relay, and the output
pressure of the relay is supplied to the control valve actuator. Most
positioners can be configured for direct or reverse action. For a direct-
acting positioner, increasing the instrument pressure causes the input
module to pivot the beam. The beam pivots the flapper a~d restricts the
Calibration 93
FIGURE 7-4.
Typical Motion-Balance Positioner
LINKAGE
I.I nozzle. The nozzle pressure increases and causes the relay assembly.to
a
increase output pressure to the actuator. With direct-acting actuator, the
increased pressure moves the actuator stem downward. The positioner is :-;'1
mechanically connected to the stern of the valve. Stem movement is,fed [
-~--;;~.,
back to the beam by means ot"a f~edback lever and range spring, which
causes the flapper to pivot slightly away from the nozzle to prevent
further increase in relay output pressure. Note that some positioners
accept a milliamp input and include' an integral liP transducer.
~I
The last component in the final control subsystem is the final control
element. We are only going to discuss control valves. (Other final control,
elements include servo valves, heaters, conveyors, auger feeds, and
hopper gates.) There are many different types, sizes, and applications for I
control valves. Selecting the correct control valve for a specific application
is crucial to 'proper system performance. Und-ersizingand oversizing are
common problems. Valve selection is not within the scope of this book,
but many valuable resources are available to assist with proper selection,
for example,
-
a good control valve sales engineer.
-
Let's look at a typical
control valve.
FIGURE7-S.
Control Valve with Actllato1'
SIGNAL FROM
CONTROLLER
DIAPHRAGM
ACTUATOR _..
,
.... ....
-,
" -,
The pneumatic signal from the positioner (or liP if a positioner is not
used) is applied directly to the actuator. For this control valve, the air is
supplied above the diaphragm and pushes against spring pressure to
close the valve. The valve is fully closed when the plug is foullyseated
against the seat ring. Notice that as air pressure is-decreased, the spring
pressure causes the diaphragm, stem, and plug to move upward, opening
the valve. This means that a loss of pressure would cause the valve to
open. Therefore this is known as a fail-open valve, Different
configurations of air inlet, spring location, and valve seat arrangement
result in different fail positions and determine whether the valve is direct-
or reverse-acting. For example, the same valve pictured above, with the
plug below the seat ring (reverse-seated), would open with increased air
pressure and would fail closed on loss of air pressure ..
As can be seen from the discussion above, all components in the final
control subsystem must be configured correctly for the system to work
properly. The fail-safe positions must be correct for the application and
the action must produce the desired results. These configurations must be
properly documented and utilized during calibration, loop checks, or
troubleshooting,
Calibration 95
7. 1 CALIBRATION OF AN lIP lRANSDUCER

FIGURE 7-6.
Ill? TransducerCalibration
i The figure above illustrates the setup for a bench calibration of an IIP
-,I
I transducer. The air supply connected to the input must be in accordance
with manufacturer's specification (typically 20-100psig). The pressure
standard is connected to the air outlet, and a rnA simulator is connected to
the current input: It is important for the L/P transducer to be oriented the
same way as the installed position in the field.A change inorientation will
introduce error in most liP transducers,
If the calibration is performedin the field, the existing supply air
would be used. It is convenient to tee into the air outlet so the control,
valve position can be checked at the same time. Of course, you need to
ensure the system is in a safe condition before you open and close the
valve.
Once the setup is established, apply the rnA inputs for each desired
test point, such as 4.0, 8.0, 12.0,16.0, and 20.0 mAo Record the
corresponding outlet pressure at each test point. For a 4-20rnA input »
3-15psig.output L/P, the corresponding outputs would be 3.0, 6.0,9.0, 12.0
and 15.0psig. Some facilities adjust the 0% test point so a slightly higher
rnA input results in the 0% output For example,4.10 mA may result in a
3.0 psig output. This ensures that the valve is closed with a controller
output of 4.0mAo
Once the as-found readings are obtained, evaluate the results against
the required specification. If required, perform zero and span adjustments
until no further adjustment is required. Then, repeat all test points to

record as-left readings.
Many organizations do not require periodic calibration of I/f'
transducers, positioners, or control valves. The justification is that the
control signal will adjust the output until the required setpoint is achieved
based on the process measurement. This is true, but you want to make
sure the output loop is performing correctly. The best way to do that is to
check the calibration periodically.
7.2 CALIBRATION OF A VALVE POSITIONER

Calibration of-the valve positioner can be performed at the same time
as the liP in a loop calibration. Simply tee in the pressure module at the
IfP outlet as mentioned above in the I/P calibration. Record the valve
position at each test point.
If the valve positioner is calibrated separately, connect an input test
pressure regulator or hand pump and monitor the input pressure applied
with a pressure standard. If supply air is not provided, connect the
required supply air to the positioner. Apply the pressure for the desired
test points and record valve position. For example, assume our valve ,
'I
positioner is 3-15psig input = 0-100%valve position. In this case, apply

3.0,6.0,9.0, 12.0,and 15.0 psig. The expected valve positions should be 0,
25,50,75, and 100%,respectively. The valve position indicator on the stem
is usually indicated in 5% or 10%increments. Therefore a best estimate of
the valve position may be all you can obtain. In other cases, a valve
position detector provides a remote indication, to a DeS, for example. In
this case, ensure both indicators are working properly.
Many organizations do not require calibration of valve positioners for
the same reason described above. To be honest, I've calibrated very few
positioners myself. However, there is documentation that control valve
positioner performance is responsible for significant loss in system
efficiency and therefore increased costs. To provide guidance on methods
for testing positioners and control valve performance, ISA has developed
a standard, ANSI/ISA-75.25.01-2000, Test Procedure for Control Valve
Response Measurement for Step Inputs. This standard has no application to
valve positioner calibration.
Calibration 197
7.3 CALIBRATION OF A CONTROL VALVE

As in positioner calibration, a pressure signal is applied to the
actuator and the resulting valve position is recorded. This can be
performed with the positioner calibration, if applicable. It can also be
performed in conjunction with L/P calibration as describe~ above. Just"
·1 remember to ensure the system is in a safe condition if performing the
;1 calibration in the-field, Also remember that you should know the correct
~I
I
action, direct or reverse, and fail position before starting.
I,. REVIEW QUESTIONS

"
.
(:
Use the information from this chapter and the references in Appendix Aas
necessary to answer the following questions:
1. From the list below, what is the likely calibration range for TY-300? " .'
.,_
,, A. 0-20 psig 4"0_
.. :~~
B. 3~25psig = 4-20 rnA .. ,

'. '.
C. 4-20 rnA = 3-15 psig
+!, D. 20SCFM ....
2. Refer to the P&ID inAppendix A-I. If the calibration ranges ofFY-

301 and PY-301 are the same as TY-300, what if any difference i~·there
between the three IIP transducers?
3. "Select the correct procedure to be used for this calibration of TY-300.
4. From your answer to question 1 and the procedure selected in

question 3, what ate the correct input values to simulate TY-300?
5.. What are the expected output values for the inputs applied from
question 3?
.'
98' Final Control Devices Calibration
6. Which is the correct test equipment hookup for calibration of TY-

300?
Pressure
Stnndartl HI'
lIP Transducer
iY·JOO
3.00 LP
rnA
Output simulator
30 psig Supply
~
Pressure
Source
7. With the results indicated, what instrument in the loop requires

adjustment?
% INPUT OUTPUT (PSIG) VALVE POSITION

fl
I.
0 3.2 2%
50 9.5 54%
100 15.8 100%
8. How would the calibration required in the previous step be

performed?
9. If a control valve is being checked during an liP calibration and the

liP is properly calibrated, what is the most likely cause of an
improper valve position (no positioner is installed)?
10. What is the purpose of a valve positioner?

Calibration 99
11. Is the action (direct or reverse) verified during a positioner

calibration?
12. What is the basic procedure for calibration of a positioner?
j',
13. .What is the basic procedure for calibration of a control valve? i
I
I
1f. j
·1
i
j
j
I
j
i
I;
I'
f
,.
8
PROCESS A.NAl YTICAL
INSTRUMENT CALIBRATION
After completing this cbepter. you should be able to:

Calibrate the following analytical instrument types (to ISA
standards, where applicable)and determine acceptability:
·pH
• Conductivity
• ResistiVity
Select the proper calibrationprocedure and calibratiofJ;c/,?ra
'"sheet.

Properly set up/connect test equipment to device under test
(DUT) for calibration.
!I
·0
. Properlymaintain pH electrodes and prepare for field
, calibration.

We can't overlook analytical instruments used to monitor and, in

I'
some cases, control processes. There are many specialized analytical
instruments used in various processes. These instruments are less I
common than temperature, pressure,level, flow, and final control I
instrum7nts-but no less important. Analytical instrumentation is more
corrunonly used in the research or quality control lab.
I
. In the lab environment, these instruments are typically verified ,
against a refererice standard by the user. In many facilities, the calibration
techIucian is not responsible for maintaining lab instruments. However,
for those control system technicians responsible for lab instrumentation,
the same principles discussed for process instruments will apply. We'll
discuss pH, conductivity, and resistivity.
101
I
·1
102 Process Analytical Instrument Calibration
Many industrial processes-such as food processing, sewage

treatment, water purification, and pharmaceutical production-are
sensitive to pH. pH is the measure of the acidity or alkalinity of an
aqueous solution. Maintaining the proper pH is essential for living
systems. When acids are added to water, they dissociate, either completely
or partially, and release hydrogen ions (H+)into the solution. pH is equal
to the negative logarithm of the hydrogen ion concentration, written in
equation form as:
You'll have to study up on logarithms, chemistry, and molarities on

your own. To give you an idea of H+ concentrations and interpreting the
associated pH value, the following table is provided. For example, the I-r
conc~ntration of pure water is 1 x 10-7 mole/liter. The log of 1 x 10-7 is -7.
Therefore the negative log is 7, and the pH of pure water is 7. A pH of 7 is
considered neutral, neither acidic nor basic. Solutions with a pH value less
than 7 are acidic; pH values above 7 are basic (sometimes referred to as
alkaline). The nominal voltage output at each pH value is described later
in the chapter.
HYDROGEN ION CONCENTRATION NOMINAL

VOLTAGE
EXPONENTIAL DECIMAL pH
OUTPUT @ 25°C
(mV)
ACIDIC
10° 1.0 a 414.12
10-1 0.1 1 354.96
10-2 0,01 2 295.8
10-3 0.001 3 236.64
10-4 0.0001 4 177.48
10-6 0.00001 5 118.32
10-6 0.000001 6 59.16
NEUTRAL
10-7 0.0000001 7 0.0
BASIC
10-8 0.00000001 8 -59.16
10-9 0.000000001 9 -118.32
10.10 O.0000000001 10 -177.48
10-11 0.00000000001 11 -236.64
10.12 0.000000000001 12 -295.8
10.13 0.0000000000001 13 -354.96
10-14 0.00000000000001 14 -414.12
Calibration' 103
.The instrumentation used to measure pH in a process system consists

of a pH meter and electrode. The electrode is actually a combination
electrode consisting of a measuring electrode and a reference electrode.
The measuring electrode has a thin, fragile glass bulb at its tip that is
sensitive to the H+ ions in the surrounding medium. An electrical
potential develops between the inner and outer'surfaces of the glass bulb. I
I
The magnitude of this potential varies, depending on the concentration of I
hydrogen ions in the solution. The reference electrode provides a stable, .
constant voltage.
The two electrodes are connected to the pH meter. The meter .i
measures the v~ltage difference between the reference electrode and the i
measuring electrode, amplifies the signal, and converts the signal to a pH I
value.
The difference between the two millivolt signals (,:lmV) is ideally,.~
OmYat a pH of 7.0.At 25°Cthe nominal ,:lmV signal increases by
59.16mV for each.pH unit measurement below 7.0pH. For exampleg ..~
AmV
= 177.48=4.0 pH. The ilmV signal irtcreases by -59.16 mV for each pH ,
unit measurement above 7.0 pfi. For example, ,:lmV. = -177.48 = 10.0 pH.
Since the pH electrode is not a perfect device and performance .
changes with age, the pH meter contains a calibration circuit. All pH."
electrodes require calibration from time to time. Many organizations.:'"
require pH calibration prior to each use, or daily. A two point calibration
characterizes an electrode with a specific pH meter. When calibrating, the
calibration circuit will adjust the 4\m V output to read 0 mV while the
electrode is immersed in a 7.0pH buffer standardization solution. This is
referred to as the "zero point" or "standardize" adjustment.
While the electrode is immersed in a 4.0 (or 10.0)pH buffer solution,
the slope ~ontrol adjusts thezsm'Voutput to read + 177 mV (or -177mV).
This is referred to as the "slope," "span," or "efficiency" adjustment. It is
preferable to use a 4.0 pH buffer solution because pH buffer solutions
above 7.0 pH are less stable and have a limited life. These high pH buffers
will more readily absorb .CO2 from the atmosphere and typically change
to a lower pH value when left open .
.Temperature is very important when measuring. pH. The measuring
electrode's response to pH is affected by temperature. Also, the pH of the
solution that is being measured may increase or decrease as temperature
changes. Temperature compensation is accomplished in one of two ways.
Most modern pH meters have an automatic temperature compensating
(ATC)probe which measures the sample temperature and compen~ates
the pH reading. This ArC probe maybe a separate probe or it may be
built into the electrode housing. If the pH meter does not have ATC, the
temperature of the solution is determined with a calibrated temperature

indicator or thermometer and the temperature dial on the pH meter is
adjusted to this temperature.
The following chart illustrates the linear ideal pH electrode output at
25°Cand the effect of temperature on pH electrode output at aoe and
100°C.
FIGURE 8-1.
pH Eloclrodo Output
mV
600,--------------------------,
600
300·- - - - - - - . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
2S·C (59.16 mV/pH)
200
100
pH
1 2 J 4 567
-100
--------------------------------
-200 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 'I
I:
-<400·
·500· - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
~ooL---------------------------~
pH electrodes must be properly stored when not in use. If not

properly stored, the electrode will dry out and this will impair
performance or possibly destroy the electrode. The probe should be stored
in a 4.0 pH buffer solution or 3.8MKCLsolution. There are special storage
bottles for long-term secure storage to prevent damage and dehydration.
Do not store in deionized water. Prior to returning a pH meter to service
after storage, the probe should be thoroughly cleaned with deionized
water and calibrated.
Calibration 105
8.1 pH CALIBRATION PROCEDURE

Consult the manufacturer' s technical manual for the required
calibration procedure, especially for microprocessor-based pH meters
with auto-calibration features. . ·1
1. Rinse the electrode thoroughly with deioniied water and gently blot
the electrode on a soft tissue.
2. Insert the electrode (and any separate temperature compensation
probe) in a 7.00pH buffer solution. Allow 30 seconds to reach
i
equilibrium. Adjust the pH meter with t~e standardize or zero
control for a pH indication of 7.0. II
. Note: If the meter does not have automatic temperature
compensation, then place a calibrated temperature indicator in the .j
same buffer solution with the pH electrode. After 30 seconds, adjust
the temperature dial on the pH meter to correspond With the ..
temperature indicated. Then adjust the pH meter indication vv.'ith the
standardize/zero control for a pH indication of 7.0. I
3. Remove the pH electrode from the buffer solution and repeat step i. ;:1
4. Repeat step 2, except use a 4.01pH buffer solution and adjust the
slope/ span contr~l for a pH reading of 4.01. . . .
:.1
Note: As mentioned above, a 10.0pH buffer solution may be '~ . ::1
substituted for the 4.01buffer solution in step 4. However, pH buffer
solutions above 7.0 are less stable. Therefore it is preferable to use the ",'
"'r
.. ~
',j
,
I
4.0~buffer solution.
5. Repeat steps l-to-4 to maximize the precision of the calibration.
6. If desired, check the pH meter indication using a 10.0pH (or 4.01pH) .
buffer.solution. Typically, there is not. an adjustment for this third
buffer solution.
;: Note: Newer, microprocessor-based pH meters allow the use of any
two standard pH buffers that bracket the pH of the samples. Some
also allow more than two buffers to determine the slope. Refer to the
manufacturer's technical manual for procedures specific to the pH
instrument.
106 ProcessAnalytical Instrument Calibration
8.2 DIAGNOSTIC TEST FOR pH ELECTRODES

The asymmetry potential (AP) and slope (efficiency) can be used as a
guideline to judge electrode performance. To perform this test, the pH
meter must have am V readout.
1. Set the pH meter to readout in m V.
2. Connect a shorting plug to the input on the pH meter and adjust the
standardize/zero control on the pH meter for a reading of 0.0 mY.
3. Disconnect the shorting plug and connect the pH electrode that will
be tested. .
4. Rinse the electrode thoroughly with deionized water and gently blot
the electrode on a soft tissue
5. Insert the electrode (and any separate temperature compensation

probe) in a 7.00 pH buffer solution. Allow 30 seconds to reach
equilibrium. Record the mV reading. This is the asymmetry potential
(AP).
Note: If the meter does not have automatic temperature

compensation, then place a calibrated temperature indicator in the .'
same buffer solution with the pH electrode. After 30 seconds, adjust
the temperature dial on the pH meter to 'correspond with the
temperature indicated. Then record the m V reading to determine the
AP.
6. Remove the pH electrode from the buffer solution and repeat step 4.
7. Repeat step 5, except use a 4.01 pH buffer solution and record the mV
reading.
8. Determine the mathematical difference between the two mV

readings (from steps 5 and 7). This is the electrodes span.
9. Divide the electrode's span by the theoretical span of 176.9 mV and

multiply the result by 100.
Example: Reading in a 7.00 pH buffer solution: -5.8 m V

Reading in 4.01 pH buffer solution: +167.5 m V
Asymmetry Potential = -5.8 mV
Span = 167.5 - (-5.8) = 173.3 m V
Slope = (173.3 mV / 176.9 mV) X 100% = 98%
Calibration 107
Typically an electrode is replaced when the AP is greater than

± 40mV and /or the slope is '< 91%.
8.3 MEASURING CONDUCTIVITY

There are situations where it is useful to measure the combined
concentration of all ions in an aqueous solution. The total ionic '
concentration is determined by measuring the conductivity of the
solution. Conductivity is defined ,asthe ability of a material to conduct
electrical current. We are used to current flowing through copper wires.
Electric current can also flow through ionic solutions. The higher the
concentration of ions in a solution, the more conducti~e the solution.
A simple device to,measure conductivity consists of two flat
electrodes placed in a sample solution, connected to.a battery and an
ammeter. The battery generates electric current that can,flow only if Qle
sample solution is conductive and completes the current path. ~ositiv'e '
ions in the solution are attracted, to the negative electrode, and negative
, ions are attracted to the positive electrode. At the positive electrode, '
negative ions give up electrons that flow to the positive battery te~al:
I At the negative electrode, positive ions take electrori.s.This results in ;: ~::.
continuing electron flow through the circuit and continuing movement of
ions through the solution. The more ions present, the mOTecurrent ,tt',
detected by the ammeter. .
The amount of current flow that is measured by the conductivity
instrument will vary depending on the distance between the electrodes (d)
and the area of the electrodes (A). For thesame ionic concentration,
electrodes spaced farther apart or a smaller electrode area would result in
less current measured. The relationship of this distance to the surface area
is known as the cell constant (K), and is defined as:
'K=d/A
, A device with a lower K value is more sensitive than a device with a
higher K value. Conductivity probes with different cell constants are
necessary for the wide range of applications that require conductivity
measurement. A purified water system has fewer ions and therefor~
,requires a more sensitive conductivity probe with a K value of about '0.1:A ,
cell constant of up to 10 would be used for solutions with high
conductivities.
Some applications utilize resistivity instruments. Resistivity
instruments are the same as conductivity instruments, except resistivity is
simply t~e inverse of conductivity. Resistivity = 1/ conductivity. The units

of conductivity are Siemens or mho. In practice, a Siemen is too large, so
instruments typically display in microsiemens/micromhos li1S/flmho) or
milliSiemens/millimhos (mS/mmho). Resistivity is measured in ohms
with typical values in the megohm range. 1 megohm';" 1 million ohms.
The conductivities and resistivities of common solutions are listed below.
SOLUTION CONDUCTIVITY RESISTIVITY

Ultrapure Water 0.055 I1S/cm 18.2 MQ
Distilled Water 1 I1S/em 1 MQ
Deionized Water 80 I.lS/cm 12,500 ohm-em
0.05% NaCI 1000l1S/em 1000 ohm-em
Seawater 50,000 I.lS/em 20ohm·em
30% H2SO4 1,000,000 I.lS/cm 1 ohm-em
Like pH, temperature has an effect on conductivity. Conductivity

probes include a temperature sensor which measures the temperature of
the solution and automatically compensates the conductivity reading.
Standard solutions for conductivity calibrations are commercially
available. Conductivity instruments can be calibrated by disconnecting
the conductivity probe and using a decade box to simulate resistance of
the solution. After the instrument calibration is completed and the probe
is reconnected, the conductivity system is checked using a standard
conductivity solution, if available, or compared to another calibrated
conductivity instrument in the same solution, To perform a calibration of a
conductivity instrument, you'll need to know the range of the instrument,
the cell constant, terminal wiring for the conductivity cell/temperature
compensation, and the temperature compensation resistance at 25°C.
Also, if the conductivity instrument provides an output Signal,the output
signal and range must be known. The following example calibration
procedure is specific to a Leeds & Northrup 7082conductivity meter and
assumes the following:
• Calibration range: 0 -10 ~/cm = 4 - 20 rnA output.
• Cell Constant = 1 (the actual cell constant for this range would
likely be 0.1, but we will assume 1 for ease of explanation).
,
• Temperature compensation thermistor wired to terminals Band D,
conductivity probe wired to terminals A and C.
• Temperature compensation resistance at 25°C is 8550'ohms_
Calibration 109
8.4 CALIBRATION PROCEDURE WITH

EXPLANATIONS
1. Verify system is shutdown and/ or conductivity cell is isolated from
. the system pressure. Carefully rem.ove the conductivity probe from
the system ensuring syste:ffi pressure is zero.
2. Rinse the probe thoroughly using deionized water.
3. Place the probe ill a standard conductivity solution within the range
of the instrument or a sample with a calibrated analytical
conductivity meter. Record the lias-found" conductivity reading.
(This is to record the "as found" condition of the conductivity
system, probe and meter, prior to any adjustments. It is difficult to
find standard conductivity solutions in this very low conductivity
range. Therefore, it may be necessary to use purified water and ::.
I
compare the indication of.the. instrument under. test to. another. : ',i,\
i
calibrated conductivity instrument.) .
4. Disconnect the thermistor from terminals Band. D and connect

"". an Ii;
8550-ohin resistor. or decade box set to 8550. ohms. (This is done to ~I
,..:
simulate a sample resistance of 25°C during calibration. If the a~tual
II .temperature compensation sensor was used, the conductivity .,
i..
1
T.
!
readings obtained would be uncompensated readings at an J

.11
.unknown temperatur~.)
5. Disconnect the conductivityprobe leads from terminals A and C. ....

Connect a decade box or other calibrated resistance simulator, I
capable of 10.0Kohms to 10.Mohms, (We will use resistance to .
simulate the conductivity probe; Remember thaf conductivity :::;:
l/Resistivity.) .
6. Connect a milliammeterin series with the 4-20. rnA output signal,
7. Set the decade box to 10.Mohms.to simulate 0..1 J,lS/cm. Recordthe

conductivity reading and the rnA output (10. Mohms is used to
simulate 0..1 ).lS/cm because J.l (micro) = 10.-6 and 1.;- 0.1 X 1O~6=
10.,0.0.0.,0.0.0..Since 1 million is mega. (M), 10.Mohms of resistance will
simulate 0..1uS/em conductivity. Confused? The expected rnA
output would be 4.16mA.. 0.1 of 10.is 1/1Oo.th and 1/10Dth of 16rnA is
0..16rnA. Add this to the zero value of 4 IDA and the expected output
. is 4.16 mA)
8. Set the decade box to 1 Mohm to .simulate 1.0 j.lS/ em. Record the
conductivity reading and rnA output. (i .;-1.0. x 1O-~:::;:
1,00.0,00.0.The
expected rnA output would be 5.60 rnA since 1 j.lS1 em of 10 J.1S1 em is

1/loth of 4-20 rnA.)
9. Set the decade box to 100 Kohm to simulate 10 J.1S1 cm. Record the
conductivity reading and rr0
output. (1 -i- 10.0 x 10-6 ;; 100,000. The
expected rnA output would be 20.0 mA.)
10. If adjustment is required, calibrate the indication and/or mA output

in accordance with the manufacturer's instruction manual and repeat
steps 7-to-9 to obtain "as-left" readings.
11. Disconnect the test equipment and restore the instrument

connections,
12. Repeat step 3 and record the "as-left" conductivity reading. (TI1isis
to record the lias left" condition of the conductivity system, probe
and meter, following any adjustments and to verify instrument is
connected properly.)
How would the simulated conductivity readings change if the cell

constant (K) is 0.1? A cell constant of 0.1 is 10 times more sensitive than a
cell constant of 1. (This means the distance between the electrodes is
reduced by a factor of 10, the surface area of the electrodes is increased by
a factor of 10, or some combination of both.) The best way to think about
this is that if we used the same simulated values as above with a K of 0.1,
the conductivity readings would be increased by a factor of 10. Therefore,
to perform the calibration properly, we must decrease the simulated
resistances by a factor of 10. So, the simulated resistances for the same
conductivity instrument with a cell constant of 0.1 would be 1 Mohm,
100 Kohm, and 10 Kohm for conductivities of 0.1 J.1S1 em, 1 j.lS1 em, and
10 ).LSI em, respectively.
Let's do one more problem. What resistance would we have used to
simulate 5 j.lS/cm with a K ;;1? Since 5 ).LS/em;; 5 x 10-6 S/cm and 1.;- 5 X
10-6, we would use a resistance of 200,000 ohms or 200 Kohms. That makes
sense since 5 IlSI em is ~ of 10 ).LSI em and we are using twice the
resistance as we used to simulate 10 ).LS/cm. Got it!
This is all simplified if you are calibrating a resistivity instrument.
The procedure is the same, except you do not need to do the conversions
from conductivity to resistivity. You do need to account for the cell
constant, however.
Calibration 111
REVIEW QUESTIONS
Use the reference section, as necessary, to answer the following questions:

1. What are the ideal amV input values for a pH meter at 4, 7, and 10
pH at 25°C?
2. What buffer solution' is used 'to .standardlze a pH meter?
3. What buffer is preferred for calibration of the slope? Why~
4. What is the purpose of a pH diagnostic?test? " .
5. What are the basic steps of ~ pH diagnostic test?
.u,
6. What is the diagnostic test acceptance criterion that determines,

, .
whether the electrode-should be replaced? .,
7. What test equipment is used to simulate a conductivity signal to a

conductivity meter?
8. How is the resistance value input for a conductivity instrument

calibration determined?
9. How is the 25°C temperature simulated during a conductivity or

resistivity instrument calibration?
10. Why is it important to know the cell constant for a conductivity

calibration?
BIBLIOGRAPHY
ANSI/ISA-51.1-1979·(R1993).Process Instrumentation Terminology. IsA

1995..
.
ANSI/ISA-75.25.01-2000.Test Procedure for Control Valve Response
Measurement for Step Inputs. I~A, 2000.
Battikha.N'E, The Condensed Handbook of Measurement and Control. Secord

edition, ISA, 2003.
Broadley-lames Corporation. The ph Primer: A Selected Review of pH

Measurement Practice from the Perspective of the pH Sensor. Broadley-lames
Corporation, 1994.
Calibrating Flaw Instrument: User's Guide. Involve® Instrument Calibration

Series. ISA and ITC Learning (ITCAIC 04), 1990.(CD-ROMwith.
Instructor's Guide and Student Workboo~) . 1
)
Calibrating Level Instruments: User'~ Guide. Inv~lve®Instrument Calibration
Series. ISA and ITC Learning (ITCAlC05), 1990.(CD-ROMwith
I
Instructor's Guide and.Student Workbook)
Calibrating Temperature Instruments: User's Guide. Involve® Instrument'

Calibration Series. ISA and ITC Learning (ITCAIC03),'1990.(CD-ROM
. with Instructor's Guide and Student Workbook)
Calibratio~ Principles: User's G~tide.Involve®Instrument Calibration Series.

IsA and ITC Learning (ITe AlC01), 1989. (CD-ROMwith Instructor's
Guide and Student Workbook)
Capacitance Level Measurement. Technical Bulletin TB~L1,rev 4-201.GLI

International, (n.d.). Retrieved 11/09/2004 from:
http://www.gliint.com/library /fb-l l.pdf
113
114 Bibliography
Instrument Calibration Series. Volume 1:Principles of Calibration, Volume 2:

Calibrating Pressure and Temperature Instruments, Volume 3: Calibrating Flow
and Level Instruments. Instrument Society of America. ISA,1989.
(Videotapes with User's Manuals)
Cubberly, William H. ISA Handbook of Measurement Equations and Tables.

Research Triangle Park, NC: ISA, 1993.
Coettsche. L. D. Maintenance of Instruments & Systems. Second edition. ISA,

2005.
ISA-5.4-1991.Instrument Loop Diagrams. ISA, 1991.
ISA-TR20.00.01-2001.Specification Forms for Process Measurement and

Control Instruments, Part I: General Considerations. ISA, 2001. (Microsoft
Word Format on CD-ROM)
ISA-TR91.00.02-2003,Criticality Classification Guideline for Instrumentation.

ISA,2003.
ISA Training Courses -- available on topics such as CSSTreview, standard

instrumentation and control documentation, calibration, and maintaining
electronic instruments -- Retrieved 11/9/2004 from http://www.isa.org/
Template.cfm?Section=Education_and_Training&Template=1
Taggedpage I trainingintro.cfm
ISOI IEC 17025:1999.General requirements for the competence of testing and

calibration laboratories. ISOllEC, 1999.
Library Reference, Vol. MM. Omega Engineering, 2001. (CD-ROM)
Seidman, Lisa A. and Cynthia J. Moore. Basic Laboratonj Methods for

BiotechnologlJ. Prentice Hall, 2000.
Temperature and Measurement Test Devices: User's Guide. Involve®Test

Measurement and Devices Series. ISA and ITC Learning (ITCAT103),
1990. (CD-ROMwith Instructor's Guide and Student Workbook)
TPC Training Systems. Process Control Instrumentation: Final Control

Elements. Trainee's Guide. TPC Training Systems, 1992. (Training Course
Materials)
Calibration. 115
Transactions in Measurement and Control, Vol. 4: Flow Level and Measurement.

Omega Engineering, (n.d.) Retrieved 11/09/2004 from:
http://www.omega.com/literature/transactions/volume4
TWI Press, Inc. Cashco Positioners. 1998.Retrieved 11/09/2004 from:

<http://www.maintenanceresources.com/ReferenceLibrary /
ControlValves/ CashcoPositioners.htm>
Type 1000 lIP and EIP Transducers (LT 06653m). Marsh Bellofram, 2003.
(Brochure).Retrieved 11/09/2004 from:
http://www.marshbellofram.com/pdfs/type1000.pdf
Type 3660 and 3661Positioners. Product Bulletin 62,1:3660.Fisher Controls

(Emerson Process Management), 2002.
i
I
j
I
"I
I
...:.:.
Appendix A-1 . i
PIPING & INSTRUMENT

DIAGRAMS (.P&IDs)
,
. I
i
;
. I .-.:
: .
:..:. ~;
I .
j
117 .
118 Piping & Instrument Diagrams (P&IDs)
P&ID for the Reactor R-300 System
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Appendix A- 2
- LOOP DIAGRAMS
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119
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Calibration 121
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Appendix A-3
INSTRUMENT SPECIFICATIONS
;
I
! '.
:'j The following Instrument Specification Forms are examples only
,
using ISA-TR20.Use the information provided in these specification forms
to answer the chapter review questions.
The ABC Company Instrument SpecificationData Form.at the end of
this section is provided as an example for reference only. This form, ."0 .
. modified for your use, can be used to document calibration information
for each instrument and obtain approval from the user, calibration
supervisor, and quality department.
,.
.~.
123
I
I
124 Instrument Specifications
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parnIcl_ctlNnd luhn!l DO PERFORMANce CHARACTERISTICS
22~
23 dlnrMl(W 1121nd1 70 'ADX:JJr.os." at dotdQl'llflmP AI
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46 [8iisafe set aOie 93
47
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52 molcOOI
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99
estimated weio.ht
Face·lo·tace dimension
53 100 OYe""'''''ioIrt
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55 102 SIanoI conn rtorM'lcl alze 51 0
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110 CAlIllRATIONSANO TEST INPUT OR TEST OUTPUT OR SCAlE
III TAG NO/FUNCTIONAL IDENT EIIS/SIGNAllTEST LRV URV ACTlON LRV unv
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116
117
118
110
120
121 to
122 COMPONENT IDENTIFICATIONS
123 COMPONENT TYPE MhNUFACTURER M LNUMDER
R_eo_
124
125
126
127
Roy Dot<l By IAo.. t IAoov2 IAooY3 REMARl<S
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Rev - Oat.,,- ReW;ion Oesaipliol> -- - By_ App..,ll_ IAIljW3 - - - ,_. - .• : -- REMARKS - -
FQ'7l1. 20(.2111 AIVO C200"SA
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Calibration 127
1 I RESPONSIBLE
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Calibration 129
1 RESPONSIBLEORGANIZATiON PRESSURE TllANSMJTTER 6 SPECIFICATIONIDENTIFICATIONS
!~® 7 Document no
646~1m
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1------1 9 Issue status
10
11 TRANSMITTERBODY 60 PERFORMANCECHARACTERtSllCS
~~EI·n flat
12 BodvJFlanaetvoe ~leh8ild SO·C MoxA1250·C
13 Process conn norrili1af sfze 112 inch RCltlnq
14 Process conn termn type threCided SMe NPT CF) 0.1 %soan
side bracket :~= n tern ~:;
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Calibration 139
1 RESPONSIBLE ORGANIZATION BJMETAlLIC THERMOMETER ~1_-IDoaImenI==,S::.P~E.::;:=lC:.:;A,.T:.:IO::.;N,-!ID::;EN=T",IF",ICA=T:.::lotI=S,-~
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w/wo THERMOWELL
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" OPERAnNG PARAMETERS 60 THERMOWElL OR PROTECTING TUBE
12 Proiect number Sub oroiect no 61 Construction twe bar siod< lhermowelf
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16 15
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PERFORMANC CHARACTERISTICS
Max Dl8SSalde.sian temo At
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Form: Intll Roy 0 @2oo' 'SA

Calibration 141
RESPONSIBLEORGANIZATION RTDlTHERMOCOUPLETEMPERATURE
TRANSMITTER OR SWITCH
Davies specmcaUon
~~ 10
PERFORMANCECHARACTERISTICS
~~~~HO-U-SI~na~~~.~~T~RAN~S~M~I~TTTER~O~R~SW1~T~C~H~'~
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15 Min measUlementsoan F 56 ContaCls ac ratlna At max
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17 Isolallon tvoe 58
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~~r-- Transien1 Dcotection failsafe : ACCESSORIES
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29 Sianallennlnation tvue Irani screw terminals 70 /Indicator enclosure
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129
130
131
132
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*':
Form: 20T2221 Rev 0 ®2001ISA

Calibration 143
ABC Company
Instrument Specification Data Form
ired:
INSTRUMENT DATA
Manufacturer: Model Number:
Equipment/System: Serial Number:
Tag Number: *Instrument Range:
Description: Calibration Standard: DYES DNa
• Per manufacturer's specification
PROCESS DATA
..* Calibration tolerance cannot be more stringent than the manufacturer's tolerance. If
tighter tolerance is necessary, the instrument must be re-evaluated for the application .
.'{.:\\<;';' ..:::'X.; IliISTRUMEI'ITCLASSIFICATION (CheCKoili:liiix,'iirilV':';'\'c<':1·:i.";'~i;:1

o Critical Instrument - Product impact- A device that, when not performing to
specification, could Causeproduct impact. The instrument owner wil! be required to
perform an evaluation on ·all out oftolerance conditions for Critical devices. An Out
of Tolerance Evaluation form will be initiated..
D Non-Critical Instrument - Equipment Performance/Safety - A device that is
significant to equipment Iproc~ss operation, or equipmentlpersonal safety, but does -.1
I
not pose an impact to product or process quality. Out od Tolerance Evaluation
Forms, are not issued 01\ Non-Critical devices, These.mstrumenrs are calibrated 00 a -v-
routine basis.
D Reference Only Instrument - Trending or Information Only. Not used for
J.
quantitative measure, not used for quality decisions; Instruments are calibrated
initially and all subsequent calibrations are perfonned on demand only.
o This instrument does not require calibration (if this box is checked attachjustification
statement) ._.
.. ;7:,"';;."'~,;""\\""'."i"',r·"';;,""TIi=lis""''''q;.''''e'''a'''·,:i''o")~l!''')-:::·b''''m"'·o"-::11'-~"'ea"'··;-:.by""··7'"::ih7"ll'>'~C.r.Q:;·lt;;'6"'ra".i"..iiJ".·'n
"",~"",,,,,~~;-;:'>;-;: .... D::·,.,f!jjQ'7·""'7i,"'.'(J·-::ii-::~."'·t.,,"..,::~~·;"';::,,.,,;""'"·::.~',,-?:.'o-"·"'' 'l' ' f;'~'~:_.·
New Calibration ID Assigned: Calibration Frequency: months .·_·1
New Calibration SOP Required? 0 YES 0 NO
New Calibration Standard(s) Required? 0 YES 0 NO .: .. 1
Is this a Calibration Program Instrument? 0 YES 0 NO
Date:
Date:
Date:
I
I
Appendix A-4
CALIBRATION PROCEDURES
The following calibration standard operating procedures (SOPs) are

examples only. Use the information provided in these procedures to
answer the chapter review questions ..
All calibration procedures in this appendix refer to the
manufacturer's technical manual for performing the adjustments. Note i
that some companies do not allow reference to other documents in -I
calibration procedures per their interpretation of OSHA 1910and other
regulations.
I
I
Pressure I
SOP TITLE
NUMBER
SOP-CAL-01 Calibration/Calibration Check of Electronic Pressure Transmitter/
Indicator
SOP-CAL-02 Calibration/Calibration Check of Electronic Differential Pressure
'Irahsmitter
SOP-CAL-03 Calibration of Differential Pressure Transmitters
SOP-CAL-04 Calibration/Calibration Check of Pressure (Vacuum) Gauges
SOP-CAL-OS Calibration/Calibration Check of a Pressure Switch
Temperature
SOP TITLE
NUMBER
SOP-CAL~06 Calibration/Calibration Check of Temperature Indicator/Recorder
SOP-CAL-O?· Calibration/Calibration Check of Dial Thermometers -
SOP-CAL-OB
SOP-CAL-09
Calibration/Caiibration
Transmitters
Check of RTD Input Electronic Temperature
Calibration Check of Glass Thermometers I

145
.>
146 Calibration Procedures
Level (see Chapter 5 for additional Level Calibration procedures)

SOP TITLE
NUMBER
SOP-CAL-02 Calibration/Calibration Check of Electronic Differential Pressure

Transmitter
SOP-CAL-03 Calibration of Differential Pressure Transmitters
SOP-CAL-l0 Calibration/Calibration Check of Capacitance Probe Level
Transmitter
Flow (see Chapter 6 for additional Flow Calibration procedures)

SOP TITLE
NUMBER
SOP-CAL-l1 Calibration/Calibration Check of Flow Totalizers/Transmitters
Final Control Elements (See Chapter 7 for additional Final Element

Calibration Procedures)
SOP TITLE
NUMBER
SOP-CAL-12 Calibration of Current to Pressure Transducers
Analytical Instruments (See Chapter 8 for additional Analytical

Instrument Calibration Procedures)
SOP TITLE
NUMBER
SOP-CAL-13 Calibration/Calibration Check of leeds & Northrup 7082

Conductivity Analyzers .
The following example calibration data sheets could be used for a

manual system or as a template report for your database system with
fields imported for each calibration. This could be used instead of the
calibration data sheet attachments to each procedure (in which case you
would not set up your system with data sheet attachments to your
calibration SOPs). .
Calibration 147
Example Calibration Data Sheet # 1
Instrument ill: System ID:

Manufacturer: Location:
Model: Classification:
Serial Number: Owner:
Description: Calibration SOP:
, Calibration Range: Calibration Tolerance:
i
I Calibration Interval: Calibration Due Date:
! Calibration Data
1 % Input Standard As-Found Deviation As-Left
I
i
I
.!
Service: Status Change.' ( ) NI A Attachments: ( ) N/A
( ) In tolerance ' ( )New ( ) Data
( ) Out of Tolerance ( ) Active ( ) Chart
( ) Adj. to within tolerance ( ) Out of service ( ) Test Report
( ) Cal by vendor, ( ) Tolerance ( ) Certificate
( ) Repaired ( ) Classification ( ) Mfg specifications
( ) Work Order ( ) Interval ( ) Other:
Standard(s) Used ID' Cal Due Date
, I
I
I Calibration Date: I Next Calibration Due Date: I
Comments:
I
!
Performed By: Date:
Reviewed By: Date:
Example Calibration Data Sheet #2
TaR Number: Location:

Calibration 10: Owner/User:
Description: Calibration Range:
Manufacturer: Calibration Tolerance:
Model: Calibration SOP:
Serial Number: Calibration Interval:
Classification: Calibration Due Date:
Calibration Data
Measured Data (DUT / Standard)
Target (Std./ OUT) {circle one)
(circle one)
As-Found Deviation As-Left Deviation
Calibration Dale: _ Next Calibration Due Date: _
Test Standard(s) Information:

Srandardts) Used ID Calibration Due Date
Technician's comments:
Check One: Check all thai apply:

o Found In Tolerance o Left in Tolerance
o Found Our ofTolcrance o Left Out of Tolerance
[] Found Damaged o Removed from service
Performed By: Dale: _
Reviewed By: Date: _

"
Calibration 149
ABC Company Calibration/Calibration Check of

Electronic Pressure SOP-CAL-OI Rev 0
Transmltter/Indication Effective Date: 3/24/03
Work Instruction Page 1 of4 Attach.: 1.
Purpose t~perform a calibration/calibration check of a pressure control loop consisting

of sensor, transmitter, and/or digital indication(s) and to operationally check
alarms and control outputs as applicable.
Equipmcnt! These items will be needed for performance of this procedure:

materials '. Regulated air or nitrogen pressure source
nceded • Digital pressure gauge accurate to 0.1% of reading
• Multimeter accurate to 0.1% of reading
• Pressure hoses and fittings capable of withstanding applied
pressures
Prerequisites The'following prerequisites shall be completed prior to performance of th~~'>'

maintenance item:
.. :
'~~
• Determine the components of the loop to be 'checked and record
identification (P&ID tag number, bar code number, serial number, or ~_
description) in the remarks column.
Record the required information on the calibration form.
.~"
Initial Perform the following prior to testing:
conditions • Ensure associated system is shut down. Ifthis is not possible, the contioi
functions from the instrument loop under test must be placed in mamjJOr
disabled to prevent rel!ponseto test signal simulations.
~-1 J
• Isolate the pressure sensor, if practical, and bleed off pressure in
accordance with the site Lockout/Tagoutprocedure.
I!
I SOP-CAL-OI Rev 0 Page 2 of4
Procedural Follow the procedural steps shown in the table below:

steps • Do not perform any adjustments until all "as found" calibration data has
been recorded.
• Note any deviation from this procedure in the remarks section of the
calibration form.
• Procedural steps marked with a pound sign (#) either require information
found on the calibration form used for recording data (Attachment A) or
require data to be recorded on the calibration form.
• If the loop being checked does not include a component that this
procedure is checking, mark the step NI A on the calibration data form.
Step Action
I Make connections between the pressure source, pressure standard,
and the transmitter input.
2 Connect the digital multi meter to the current output of the

transmitter.
3 Ex.ercise the transmitter from zero to full scale and back to zero.
4# Adjust the pressure (vacuum) source to 10, 50, and 90% of the
calibration range and record tbe following at each data point:
• Digital pressure standard reading
• Current output
• Remote indication (if applicable)
5# Verify proper operation of all control outputs and alarms at the
proper setpoints. Record all outputs checked and actual values
obtained.
Continued on next page
For Reference Only

Calibration 151
I SOP-CAL-Or Rev 0 Page 3 of4
Procedural steps (cont.)
Step Action
6#
If... Then ...
If transmitter output is not Calibrate the transmitter in -
-within 112the specified accordance with the applicable
tolerance manufacturers technical
manual and repeat step 4.
Ifremote display is not Calibrate the display in

within 1/2 the specified accordance with the i
tolerance
manual
manufacturers technical
I
and repeat step 4.
I
.;.if
If any alarm or control Adjust the output and repea.•t

. output operates improperly
or does not actuate within
step 5. . k;;;
I
.I
112the specified tolerance'
.*~
7 Disconnect the test equipment from the unit under test and
reinstall, if necessary.
&# Complete the calibration' form and apply the appropriate

calibration label. . .'..,
9 If all checks are within tolerance, restore the instruments to

operational condition and notify appropriate personnel of work
performed. .
Continued 0" "ext page
For Reference Only

I SOP-CAL-OI Rev 0 Page 4 of4
Acceptance Personnel performing this maintenance shall use the following criteria
criteria to determine satisfactory completion, subject to review of data by
supervision.
• Final readings obtained arc within thc tolerance specified on the
calibration work order fonn.
If any readings ore found to be out of tolerance or if any step cannot be

performed:
• Notify the appropriate personnel for resolution.
• . Record name of person contacted in comments section of work
order form.
Attachments The following arc attachments to this work instruction:
No. Title' Pages

A Calibration/Calibration Check of Electronic Pressure 2
Transmitter/Indication Data Sheet
References
Manunl No. Manual TiUe
N/A Applicable manufacturer's technical manual
Approvals/ This work instruction must be approved by:

author
Manager, ABC Company Datc
Quality, ABC Company Date
Author: Mike Cable, Engineering Technician
For Reference Only

Calibration 153
I SOP-CAL-Ol Rev 0 Attachment A Page 1 of 2
CALIBRATION/CALIBRATION CHECK OF ELECTRONIC PRESSURE

TRANSMITTER/INDICATION DATA SHEET
As-Found As-Left
Step#' , Parameter Reguired Data Data
4,6 Digital Pressure standard at NA

10%
4,6 Transmitter output current 5.60:1: rnA DC __ -rnA __ rnA

all0%
4,6 Remote Indication at 10% :I:

50%
4,6 Transmitter output current 12.00± rnA DC __ mA __ rnA

at 50% --
·~.I'·
4,6 Remote Indication at 50% :I:

,I
-!~~

- 90% -.
--,
l 4,6 Transmitter output current 18.4O± mADC rnA __ rnA ~~
8t90%
~~
4,6 Remote Indication at 90% ± .:';:~
.~;
5,6 Alarm or control output -- ±

-- -
5,6 Alarm or control output ±
5,6 Alarm or control output ±
Continued on nextpage
For Reference Only

I SOP-CAL-Ol Rev 0 Attachment A Page 2 of2
Standards Used:
Description Serial number or other to. Cal Due Date
Digital pressure gauge -~---.------

2 Milliammeter
Remarks:
Performed By: _ Date: _
Reviewed By: Date:
For Reference Only

r-
Calibration 155
Calibration/Calibration Check
of Electronic Diffential Pressure SOP-CAL-02 Rev 0
ABC Company Transmitter Effective Date: DRAFT
Work Instruction Page 1 of3 Attach.: 1
Purpose To perform a calibration check and, if necessary, calibration of a

differential pressure transmitter.
I
Equipment! These items will be needed for performance of this procedure:
I
materials • Regulated air or nitrogen pressure source
I
I
needed • Digital pressure gauge accurate to 0.1% of reading
• Multimeter accurate to 0.1 % of reading
." Pressure hoses and fittings capable of withstanding applied I
pressures
Prerequisites Prior to performing this maintenance item, perform the following .... -.
I
activities:
• Record required information on the calibration form.
II
:t:
.~
Procedural Follow the procedural steps shown in the table below: -'i
steps • Do not perform any adjustmentsuntil all "as found" calibration data ..
Ii
;.
has been recorded. .
• Note any deviation from this procedure in the remarks section of the jf
calibration form.
...
<'
Procedural steps marked with a pound sign (#) either require ,·d
information found on the calibration form used for recording data :"',
(Attachment A) or req~ire data to be recorded on the calibration form.
PRESSURE TRANSMITTER CALmRATION/ .

CALIBRATION CHECK ,
Step
1
Action
Make connections between the pressure source, pressure standard,
I
and the transmitter input.
j
2 Connect the digital multimeter to the current output of the
transmitter.
'."-:;:
For Reference Only

I SOP·CAL-02 Rev 0 Page 2 of3
PRESSURE TRANSMITTER CALlBRA nONI

CALIBRATION CHECK (cont.)
Step Action
3 Exercise the transmitter from zero to full scale and back to zero.
4# Adjust the pressure (vacuum) source to 0, 25, 50, 75,and 100"10of

the calibration range and record the following at each data point:
• Digital pressure standard reading
• Current output
511
If ... Then .•.
If transmitter output is not Calibrate the transmitter in accord-
within 112 the specified ance with the applicable manufac-
tolerance turers technical manual and repeat
step 4.
6 Disconnect the test equipment from the unit under test and
7# Complete the calibration form and apply the appropriate I

calibration label. 'I
operational condition and noti fy appropriate personnel of work
performed,
For Reference Only

Calibration 157
I SOP-CAL-02 Rev Q Page 3 of3
supervision.
• Final readings obtained are within the tolerance specified on the
calibration work order form.
If any readings are found to be out of tolerance or if any step cannot be

performed:
Notify the appropriate personnel for resolution.
• Record flame of person contacted in comments section ofwark
order form.
.Attachments The following are attachments to this work instruction:
No. Title Pages'

A Calibration/Calibration Check of Differential 1
Pressure'Iransmitter Data Sheet ~..
..
References
.Manual No. Manual Title
N/A. Applicable manufacturer's technical manual -......
.,.
Approvals! This procedure must be approved by:

author
Manager, ABC Company Date
Writer: Mike Cable, Engineering Technician
For Reference Only
I
I
I
I
I SOP-CAL·02 Rev 0 Attachment A Page 1 of I
CALIBRA TION/CALmRA TION CHECK OF

ELECfRONIC DIFFERENTIAL PRESSURE TRANSMITTER
Fo,': PID Tag #
As-Found As-Left
Step II Parameter Required Data Datll
4,5 Output current at 0% 4.00 ± 0.16 mA
4,5 Output current at 25% 8.00 ± 0.16 rnA
4,5 Output current at 50% 12.00 ± 0.16 mA
Standards Used:
Description Serial number or other 1.0. Cal Due Date
Digital pressure gauge
2 Milliammeter
Remarks:
Reviewed By: D;ttc: _
For Reference Only

Calibration 159
ABC Company Sta'ndard Operating Proeedure

Document No.: I ~~vision No.: I Effective Date: IPage 1 of4
SOP-CAL-03
Title:
Calibration of Differential Pressure Transmitters
I Supersedes Document No.:
None .
Author (print Name): Author Signature: Date:
QAfCompliance Approval (Print Name): QAlCompliance Approval Signature: Date:
Table of Contents
1.0 PURPOSE 1
2.0 SCOPE : ~ 2
3.0 DEFINITIONS : 2
4.0 REFERENCES/ATTACHMENTS 2
5.0 MATERIALSIREAGENTS/EQUIPMENT : ; :.2
6.0 SAFETY : 2
7.0 PROCEDURE : 3
8.0 DOCUMENT REVISION ...: : 4,
. fl
-,
~.
For Reference Only

I
ABC Company Standard Operating Procedure

DocumentNo.:
SOP-CAL-03 1
NO.:]
loROeviSion EffectiveDate: I Page 2 of 4
Tille: Cnllbratlen of Dlfferentlnl Pressure Transmitters
1.0 PURPOSE
I. I TIle purpose of this procedure is to provide standardized instruction for the

calibration of'Differentinl Pressure Transmitters.
2.0 SCOPE
2. I This procedure applies to personnel required to calibrate and maintain differential

pressure transmitters located at ABC Company.
3.0 DEFINlTIONS
3.1 NIST - National Institute of Standards and Technology
3.2 UUT - Unit Under Test
3.3 OaT - Out of Tolerance
4.0 REFERENCES/ATTACHMENTS
4.1 Calibration System Description SOP
5.0 MATERIALSfREAGENTS/EQUIPMENT
5.1 NIST Traceable Pressure Calibrating Device
5.2 NIST Traceable Milliammeter
5.3 Pressure Source
5.4 Calibration Labels
6.0 SAFETY
6.1 All procedures will be performed in accordance with and under the constraints of
ABC Company safety procedures and applicable Federal, State, and Local safety
rules and regulations.
For Reference Only

Calibration 161

DocumentNo.: l&ooeVisionNo.: IEffe~tive
Date: I Page 3 of 4
SOP-CAL-03
Title: Calibration of Differential Pressure Transmitters
7.0 PROCEDURE
7.1 Visually inspect the UUT for damage. Notify the user group and repair or replace as
directed. .
Note: Always attempt to obtain "As Found" data prior to repair, replacement, or
adjustments. .
7.2 Wann up/Stabilization Requirement: None.
7.3 UUT Accuracy/Specification: Manufacturer's specification or approved user assigned

tolerance.
. 7.4 "As-Found" Data Acquisition
7.4.1 Differential pressure transmitters will be tested at 10"10, 50%, and 90% of span
.•! unless otherwise specified by instrument owner. Test Standards must. _ ,I
maintain a 4: 1 accuracy ratio unless otherwise specified on the applicable'
Instrument Specification. Data Form.
7.4.2 Disconnect one of the transmitter output leads and connect.the millianun~ter .
i
ro. in series with the transmitter output.
7.4.3 Connect the pressure source and NIST traceable pressure calibrator to the high
t! pressure port of the UUT. ':;",
7.4.4 Apply pressute to the high pressure side of the transmitter. Approach thetest
point as indicated by the pressure standard. Record the transmitter output'
current reading and the remote indication, if applicable, on Calibration Data
Sbeet#2.
Note: Test points must be reached within +1- 5% of targeted test point.
7.4.5 Repeat step 7.4.4 for the remaining test points.
7.4.6 Proceed to section 7.5, "As Found~ Data Interpretation
7.5 "As Found" Data Interpretation
7.5.1 Compare the "As Found" data to the tolerance specified on the Calibration
Data Sheet.
For Reference Only


DocumentNo.:
SOP-CAL-03
IROOevision I
No.: EffectiveDate: I Page 4 of 4 .
Title: Cnllbratlon of Differential Pressure Transmitters
7.5.2 Iran "As Found" value is "Out of Tolerance", a Calibration Out of Tolerance
Form must be generated per Calibration System Description SOP. Proceed to
Adjustments, section 7.6.
7.5.3 To optimize instrument performance or if adjustment is needed, proceed to

7.5.4 If all of the "As Found" data is within the specified tolerance, proceed to
section 7.7.
7.6 Adjustments
7.6.1 Adjust and repair transmitter according to manu facturcrs suggested repair
guidelines. If guidelines are unavailable, replace the transmitter.
7.6.2 If'the UUT can not be adjusted to specification, remove the device from
service
7.6.3 Proceed to section 7.8, Documentation and Labeling.
7.7 No Adjustment Necessary
7.7.1 Return UUT to service.
7.8 Documentation and Labeling
7,8.1 Complete and process the Calibration Data Sheet per the Calibration System
Description SOP.
7.8.2 Complete and affix the appropriate calibration labels per the Calibration
System Description SOP.
8.0 DOCUMENT REVISION
For Reference Only

/' Calibration 163
ABC Company Calibration/Calibration Check of SOP-CAL-04 Rev 0

Pressure (Vacuum) Gauges Effective Date: 3124/03
Purpose To perform a calibration check and; if necessary, calibration of a mechanical

pressure, vacuum, or pressure/vacuum compound gauge.

materials • Regulated air or nitrogen pressure source
needed • Vacuum source, if applicable
• Digital pressure/vacuum gauge accurate to 0.1% of reading
• Pressure hoses and fittings capable of withstanding applied
pressures
Prerequisites
I The following prerequisites shail be completed prior to performance of the
maintenance item:
• Record the required information on the calibration form.
,I Initial Perform the following prior to testing:

',1 conditions • Isolate the gauge and bleed off pressure per the site Lockout/Tagout
Procedure, '
~
fl

;[ been recorded.
" "
• Note any deviation from this procedure in tbe remarks section of the
,
'/
calibration form.
'I
•
]
I
Step Action
~J
I
!
1 • Inspect !he gauge for integrity and cleanliness .
J
.
'
• Clean as neces~ary.
Conlinlledon nextpage
For Reference Only

I SOP CAL-04 Rev 0 Page 2 of3
Step Action
2 Make connections between the pressure source, pressure standard,
and thc gauge under test.
3 If gauge has been removed, stabilize the gauge in the same

orientation as when it is installed.
4 Exercise the gauge from zero to full scale three times.
511 Record the pressure (vacuum) standard reading and gauge under
test rending at 0, 25, 50, 75, and 100% of the calibration range as
pressure (vacuum) is increased.
Note: If the pressure (vacuum) is increased above the desired

reading, decrease pressure (vacuum) to the previous
reading taken, and then increase pressure (vacuum) to
desired value.
6# Record the pressure (vacuum) standard reading and gauge under

test reading at 75, 50, 25, and 0% of the calibration range as
pressure (vacuum) is decreased.
Note: Ifthe pressure (vacuum) is decreased below the desired

reading, increase pressure (vacuum) to the previous
reading taken, then decrease pressure (vacuum) to desired
value.
711 • lfthe gauge under test indicates values greater than 1/2 the
specified tolerance and the gauge is calibratablc, adjust the
gauge until indications are less than 1/2 the specified
tolerance,
• If adjustments are made, repeat steps 5 - 6 and record final
values.
8 Disconnect the test equipment from the gauge under test and
9# Complete the calibration form and apply the applicable calibration

label.
Continuedon nextpage
For Reference Only

Calibration 165
I SOP CAL-04 Rev 0 . Page 3 of3
Step Action
10 If all checks are within tolerance, restore the gauge to operational
condition and notify appropriate personnel of work performed.
Acceptance Personnel performing this maintenance shall use the following criteria to
'~riteria determine satisfactory completion, subject to review of data by supervision.
• Final pressure.(vacuum) measurements obtained are within the tolerance
specified on the calibration work order form.

performed: .
., Notify the appropriate personnel for resolution.
• Record name of person contacted in comments section of work order
furm. .
,..
-, .•..~....-
Attacbments The following are attachments to this work instruction:

I
..... ~
No. Title Pages
A Calibration/Calibration Check of Pressure (Vacuum) 2 ;',':-;'
Gauges DataSheet
References
Manual No. Manual Title
N/A App'licable manufacturer's technical manual
Approvals! 'This work instruction must be approved by:

author
Quality, ABC Company • Date
For Reference Only
)
Calibration 167
I SOP-CAL-04 Rev 0 . Attachment A Page 1 of~
CALIBRA TlON/CALlBRA TION CHECK OF

PRESSURE (VACUUM) GAUGE DATA SHEET
As-Found As-Left
Step # Parameter Reguired Data Data
5,7 0% Increasing pressure +1-

(vacuum)

(vacuum)
5,7 50% Increasing pressure +/-

(vacuum)

. (vacuum)
I
.5,7 100% Increasing pressure
(vacuum)
+/-
I
6,7 75% Decreasing pressure +/-
(vacuum)

(vacuu~)

..~
(vacuum)

(vacuum)
Continued on next poge
For Reference Only

I SOP-CAL-04 Rev 0 Attachment A Page 2 of2
Standurds Used:
Description Serial number or other 1.0. Cal Due Date
Digital pressure/vacuum
gauge
Remarks:
PcrfurmcdBy: _ Date: _
For Reference Only

Calibration 169
ABC Company Calibration/Calibration Check of SOP-CAL-05 Rev 0

a Pressure Switch Effective Date: 3124/03
. Work Instruction Page 1 of4 Attach.: I
Purpose To perform a calibration check and, ifnecessary, calibration of a pressure

switch.

materials .Regulated air or nitrogen pressure source
nee4ed • Digital pressure gauge accurate to 0.1% of reading
Multimeter capable of reading a change of state in resistance or voltage
• Pressure hoses and fittings capable of withstanding applied pressures
Prerequlsltes The following prerequisites shall be completed prior to performance of the

maintenance item:
• Record the required information on the calibration form. ..~....
Initial Perform the following prior to testing: . '; ;

condltlons • Isolate the pressure switch and bleed off pressure per the site
Lockout/Tagout Procedure.
11
. Procedural Follow the procedural steps shown in the table below:
steps • Do not perform any adjustments until all "as found" calibration data has,
. been recorded.
calibration form. . .
.found on the calibration form used for recording data (Attachment A) or
Continued ~1I next page
For Reference Only

I SOP-CAL·OSRev 0 Page 2 of4
Step Action
I Caution: Keep powcr leads separated to prevent circuit
shorting and possible equipment damage.
lfrequired, disconnect power leads from pressure switch.
2 Cnutlon: Conflrm sensing line is depressurized.

Make connections between the pressure source, pressure standard,
and the pressure switch sensing line.
3 Connect the multimeter leads across the switch contact.

• If checking a low pressure switch, go to step 6.
• For high pressure switch continue with step 4.
4# For high pressure switch:
• Increase pressure until the switch changes state, as indicated
by a change in voltage or resistance reading.
• Record the pressure switch trip value as indicated on the
digital pressure gauge.
5# For high pressure switch:

• Slowly decrease the pressure until the switch changes state, as
indicated by a change in voltage or resistance reading.
· Record the pressure switch reset value as indicated on the

6 For low pressure switch:

• Increase pressure until the switch resets, as indicated by a
change in voltage or resistance reading.
7# For low pressure switch:

• Slowly decrease the pressure until the switch changes state, as
• Record the pressure switch trip value as indicated on the
Continuedon next page
For Reference Only

Calibration 171
I SOP-CAL-05 Rev 0 Page 3 of4
Procedural steps (cont)
Step Action
8# For low pressure switch:
• Slowly increase the pressure until the switch changes state, as
• Record the pressure switch reset value as indicated on the
9# • If the actual pressure switch trip (and ifrequired, reset) values

are greater than 112 the specified tolerance, adjust the switch
until values are less than 112 the specified tolerance. ',.
i
· Ifadjustments are made, repeat steps 4 and 5 or 6 - 8 as
applicable and record final values. ." I
J
10 Disconnect the test equipment from the switch under test.
11# Complete the calibration form and affix the applicable calibra.t!p!i. '.
j
label.' . ."".'
12 Ifall checks are within' tolerance, restore the pressure switch to .

~.. ''.J:1
operational condition and notify appropriate personnel of work ._.
performed.
...
....i
:. I,
..•.
supervision. ,
'. Final trip (and reset) values obtained are within the tolerance

performed:
• . Notify the appropriate personnel for resolution.
.• Record name of person contacted in comments section of work
order form.
"
For Reference Only
I SOP-CAL-OS Rev 0 Page4of4
Attachments The following are attachments to this work instruction:
No. Title Pages

A Calibration/Calibration Check ofa Pressure Switch Data I
Sheet
References
N/A Applicable manufacturer's technicul manual
Approvnlsl This work instruction must be approved b.y:

!luthor
For Reference Only

,;
Calibration 173
I SOP-CAL-05 Rev 0 Attachment A Page 1 of I
CALIBRATION/CALIBRATION CHECK OF A PRESSURE SWITCH DATA SHEET
As-Found As-Left
Step # Parameter Reguired' Data Data
4,9 High pressure switch trip +/-
5,9 High pressure switch reset +/-

--
7,9 Low pressure switch trip +/- --
8,9 Low pressure switch reset +/-
Standards Used:
. Description Serial number or other I.D. CaJ Due Date
Digital pressure gauge
2 Multimeter
. Remarks;
PcrfurmedBy: ~-- __ Date: _

i:'
For Reference Only

"
Calibration 175
Calibration/Calibration Check of SOP-CAL-06 Rev 0

ABC ,Company Temperature IndicatorlRecorder Effective Date: 3/24/03
Work Instruction Page 1 of4 Attach.: ,I
Purpose To perform an operational check or calibration check and, if necessary,

calibration of a temperature indicator/recorder.

materials e . Digital RID reference thermometer accurate to +/- 0.5 F (0.2 C)
. needed • Temperature reference bathlblock .

.steps Do not perform any adjustments until all "as found" calibration data.has
been recorded,
Note any deviation from this procedure in the remarks section of the
calibration form.
• .Procedural steps marked with a pound sign (#) either require information I
,;
j
require data to be recorded on the calibration form. •
If... Then perform steps •••

Performing onlythe temperature indicator/ 1-3
recorder operational check (temperature sensor and 7 -8.
not accessible)
,,~ Performing temperature indicator/recorder 4- 8.

"
calibration check
Continued on nextpage.
..
r
r
I
I
. For Reference' Only
I
I SOP·CAL·06 Rev 0 Page 20f4
PERFORMING ONLY THE TEMPERATURE

INDICATOR/RECORDER OPERATIONAL CHECK
Step Action
111 • With temperature of the system at normal operating
temperature, measure the system temperature at a point near
the system thermometer using the reference RTD
thermometer.
• Allow reading to stabilize and record this as the required value
on the calibration data form.
2# Record the temperature indication on the calibration data form.
311 • If the indicator under test indicates values greater than 1/2 the
specified tolerance, perform steps I and 2 at 10% and 90% of
full range.
• Adjust the indicator until the correct reading is obtained and
repeat steps 1 - 3.
• Go to step 7.
PERFO~NGTEMPERATUREINDICATOR1JRECORDER
CALIBRATION CHECK
Step Action
4 • Verify temperature sensor is in a well and remove from
system.
• If not in a well, coordinate with the user area and isolate the
system to allow removal.
5# • Place the temperature sensor and digital RTD reference

thermometer in the temperature bathlblock.
• Record both readings at a minimum of two points (such as ice
point and process temperature).
6# • If the indicator under test indicates values greater than 112the

specified tolerance, make adjustments at process temperature
until indications are less than 1/2 the specified tolerance.
·• If adjustments are made, repeat step 5 and record final values.

Go to step 7.
For Reference Only

Calibration 177 ,
Preceduralsteps (cont.)
COMPLETION
Step Action
label.
8 If all checks are within tolerance, restore to operational condition

and notify appropriate personnel of work performed.
Acceptance Personnel performing this maintenance shall use the following'criteria

criteria ,to determine satisfactory completion. subject to review of data by
,supervision.
• Final readings obtained are within the tolerance specified on the:'
calibration work-order form.
If any readings are found to be

out of'toleranceor if any step cannot be
performed;
• Notify the'appropriate-personnel for resolution:
• Record name of person contactedirrcomments section of work
order form.
No. . -Title Pages

A Calibration/Calibration Check of Temperature I
Indicator/Recorder Data Sheet
Continued on next page I

,I
I
,,'
~.
I
o
-e-.
For Reference Only
References
Approvalsl This work instruction must be approved by:

nuthor
Manager, AIlC Company Date
Manager, A!3~ Company Date
For Reference Only

Calibration 179
I SOP-CAL-06 Rev 0 Attachment A Page 1 of 1
CALIBRA TIONfCALIBRA nON CHECK OF TEMPERA TORE

INDICATORfRECORDER DATA SHEET
As-Found As-Left
Parameter Reauired
Normal Operating ±
1,2,3
Temperature
-- --
3 10% Range ±
-- --
(if required) orNA
90% Range -- ± --
(if required) orNA
5,6 Temperature ±
(ice point)
5,6 Temperature -- ± --
(process)
5,6 Temperature ±
(additional point if desired)
L
Standards Used: I
I
I
Description Serial number or other I.D. Cal Due Date
I
J
J--
Reference thermometer
i
2 Bath/block I
3
I
j
Remarks:
I
I
.;.-
PerrormedBy:
Reviewed By:
_ Date:
Date:
_
_
I
I ,'<;
For Reference Only
Calibration : 181
ABC Company .Calibration/Calibration Check of SOP-CAL-07 Rev 0

Dial Thermometers Effective Date: 3124/03
Work Instruction Page 1of4· Attach.: 1
Purpose To perform an operational check or calibration check and, if necessary,

calibration of a dial type thermometers,

materials • Digital RTD reference thermometer accurate to +/- 0.5 F (0.2 C)
needed • Temperature reference bathlblock
• Thermocouple reference (special type T TIC and digital thermocouple
reference standard) accurate to +1- 2 F (1 C), ifrequired
Prerequisites The following prerequisites shall be completed prior to performance of the

maintenance item: '
Procedural Follow the procedural steps shown in 'the table below:

been recorded.
• Note any deviation from this procedure in the remarks section of the < ::
.: !,
calibration form.
• Procedural steps marked·with a pound sign (#) either require information A~~.
found on the calibration formused for recording data (Attachment A) or
require data to be recorded on the-calibration form. ;fl
If... Then perform steps ... '1

Performing only the thermometer 1- 3
operational check and 7 - 8.
I
Performing thermometer calibration check 4 - 8.
r
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Continued on next page I

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For Reference Only

PERFORMING ONLY THE THERMOMETER

OPERATIONAL CHECK
Step Action
III With temperature of the system at normal operating temperature,
record the thermometer indication on the calibmtion data form.
2# • Measure the system temperature at n point ncar the system

thermometer using the reference RTD thermometer or
thermocouple.
• If the system thermometer is in a well and temperature is
constant, remove the dial thermometer and place the reference
RTD thermometer in the same well.
· Allow reading to stabilize and record on the calibration data

form.
3# • If the thermometer under test indicates values greater than 1/2

the specified tolerance, adjust the thermometer until the
correct reading is obtained and perform a complete calibration
check in accordance with steps 4 - 6.
• Continue with step 7.
PERFORMING THERMOMETER CALm RATION CHECK

Step Action
4 • Verify thermometer is in a well and remove from system.
• Ifnot in a well, coordinate with the user area and isolate thc
system to allow removal.
5#
· Place the thermometer and digital RTD reference thermometer
in the temperature bathlblock.
· Record both readings at a minimum of two points (such as ice

point and process temperature).
For Reference Only

Calibration 183
Procedural steps (con t.)
PERFORMING THERMOMETER CALIBRATION CHECK

Step Action
6# • If thermometer under test indicates values greater than li2 the
specified tolerance and is calibratable, make adjustments at
process temperature until indications are less than lJ2 the
specified tolerance.
• If adjustments are made, repeat step 5 and record final values.
• If thermometer is not calibralable but within tolerance, make a
note io the remarks section and accept as is.
• Continue with step 7. ·t
COMPLETION
Step Action
label. :~ ..
8 It all checks are within tolerance, restore the thermometer to

performed,
I. ,.'
J .";c.
crlterla to determine satisfactory completion, subject to review of data by
supervision. .
• Final thermometer indications obtained are within the tolerance

performed:
• Record name of person contacted in comments section of work
order form. .
.'
For Reference Only

Attachmcnts The following nrc attachments to this work instruction:
No. Title Pages

A Calibration/Calibration Check of Dial Thermometers 2
Data Sheet
References
Manual No. Manunl Title
N/A Applicable manufacturer's technical manuul
Approvals/ This work instruction must be approved by:

author
"-:
For Reference Only
Calibration 185
I SOP-CAL-07 Rev 0 Attachment A Page I of2
CALIBRATION/CALmRATlON CHECK OF
DIAL THERMOMETER DATA SHEET .
As-Found As-Left
. r
1,2,3 Reference thermo- NA

meter (normal
operating temperature)
I
1,2,3 Dial thermo- Reference thermometer
meter (normal
operating temperature)
reading ±__
I
5,6 Reference thermo- NA
meter (ice point) I
5,6
5,6
Dial thermo-
meter (ice point)
Reference thermo-
reading ±__
NA ._--
I
meter (process)
I
5,6 Dial thermo- Reference thermometer
meter (process) reading ±__
. :,,
5,9 Reference thermo- NA
meter (additional
point if desired)
.-:";
5,6 Dial thermo- Reference thermometer
'. meter (additional reading, ±_.__
point if desired)
For Reference Only

I SOP-CAL·07 Rev 0 Attachment A Page 2 of 2
Standards Used:
D~scrlption Serial number or other I.D. Cal Due Date
2 Bath/block
3 Thermocouple reference
(if required)
Remarks:
For Reference Only

Calibration 18i·
ABC Company Calibration/Calibration Check

ofRTD Input Electronic SOP-CAL-08 Rev 0
Temperature Controller Effective Date: 3/24/03
Work Instruction Page Iof7 Attach.: 1
Purpose To perform a calibration/calibration check of an RTD input electronic

temperature transmitter and remote indication(s), in addition to
operationally checking other control outputs and alarms.
Equipment! These items will be needed for performance of this procedure: ..,
materials • RTD simulator (or decade box) accurate to +1- 0.1 5 ohms (method
i needed B only) .
• Digital RID reference thermometer accurate to +/- 0.1 C
.1
• Multimeter accurate to 0.1% of reading ':e..
Prerequisites
• Temperature reference bathlblock
:.:.',,,,.,~
The following prerequisites shall be completed prior to performance of the
.- I
j
maintenance item: .J
Determine the method to be used from the work order:
• .Loop check (Method A) or
• Electronic check (Method B)
• Record the required setpoint on the Calibration form.
• Determine the. components of the loop to be checked and record ,"'.
ideritification (P&ID tag number, bar code number, serial number, or
description) in the remarks column.
Confirm the' correct RID alpha is being used.
• Determine the required transmitter output current (required for performing'
step 4) using the following equation: .
{(Required Reference Temperature - Instrument Zero Temperature) 1
Instrument Temperature Range} * 16 rnA + 4 rnA
Example: Required reference thermometer temperature is 60 degrees C.
Temperature transmitter range is 40 - 90 degrees C.
{ (60 deg·- 40 deg) / 50 deg } * 16 rnA + 4 rnA = 10.40 rnA
'j.
.<;"
For Reference Only
r
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I
Initial Ensure temperature and humidity conditions in the area being recorded are
condltlens stable
If... Then ...
The temperature control loop • plnce controller in manual
performs control function which OR
could produce undesirable operating
• disable controller output
results while simulating test signals
(for example, temperature signal OR
provides input for control steam to • shutdown the system being
heat exchanger) controlled (coordinate with
user area).
RTD is in a well Remove the RTD from the well
RTD is not in a well Shutdown and drain the system

been recorded.
calibration form.
• Procedural steps marked with a pound sign (If) eilher require information
procedure is checking, mark the step N/A on the calibration data form.
For perform .•. steps ...

Loop check Preliminary Operating Point Check, I - 4,
(method A) Loop Check, 5 -7,
Final Operating Point Check, and 13,and
Completion 14 - 15
Electronic check Preliminary Operating Point Check, 1 - 4,
(method B) Electronic Check, 8 - 12,
Final Operating Point Check, and 13, and
Completion 14-15
For Reference Only

,'
Calibration 189
Page 3 of7
PRELIMINARY OPERATING POINT CHECK (METHOD A AND B)

Step Action
Place RTD and reference thermometer in temperature reference
bathlblock _at or within the process setpoint,
,I 2 Disconnect an output lead from the transmitter and connect

multimeter in series to measure output current.
',·1! 3 Convert the transmitter output current to an equivalent

temperature using the following equation:
-".
(Output current - 4mA)(Inst temp range) + 0% value == X deg

16mA .a !
For example: output current for 20 - 100 C transmitter ~ 13. 62 .,
rnA. Therefore [(13.62mA - 4rnA)(80 C) / 16mAJ + 20 C = 68.1"; .;
I
C. I
I, 4# • Record the reference thermometer indication, transmitter .....~
:,.1
output value (current output and converted temperature); and

remote displayts), ~
• Verify current output and remote iridication(s) are within th~
specified tolerance. ",.
',!!
• Do not make any adjustments. "
LOOP CHECK (METHOD A)

Step' Action
5# Adjust the bathlblock temperature to 10,50, and 90% of the
transmitter span and allow temperature to stabilize for 5 minutes
at each data point.
Record the following at each data point: .

• Bath/block Temperature
• Transmitter output current
,. • Remote displaj(s), if applicable
For Reference Only
:oJ
!.
I
:; .
LOOP CHECK (METHOD A) (cont.)

Step Action
6# Verify proper actuation ofall control outputs and alarms at the
proper sctpoints, Record all outputs checked and actual values
obtained.
7#
If ... Theil ...
If transmitter output is not Adjust beth/block temperature to
within 112the speci fled 0% and 100% of transmitter span.
tolerance Adjust zero and span at each
point, respectively, until no
further adjustments are required.
Repeat step 5.
If remote display is not Calibrate the display in accordance

within 1/2 the specified with the manufacturers technical
tolerance manual and repeat step 5.
If any control output Adjust the output and repeat

operates improperly or step 6.
does not actuate within
1/2 the specified tolerance
ELECTRONIC CHECK (METHOD B)

Step Action
8 Disconnect the RTD,from transmitter input and connect the RTD
simulator (or decade box) to transmitter input.
Continued on' next page
For Reference Only

Calibration 191
I SOP-CAL-08 Rev 0 Page 50f7
'. ELECTRONIC CHECK (METHOD 8) (cont.)

Step. Action
9# Set the RTD simulator to 10, 50, 90% ofthe transmitter span.
Record the following at each data point:
• Simulated Temperature
'. Transmitter output current
• Remote display(s), if applicable
10# Verify proper actuation of all control outputs and alarms at the
proper setpoints. Record all outputs checked and actual values
obtained.
11#
If... Then ...
I
If transmitter output is not Calibrate the transmitter in accord-
within U2 the specified ance with the applicable manufac-.:
I
.:..!
tolerance turers technical manual and repeat
step 9.
..
Ifremote display is not Calibrate the display in accordance
within 112the specified, with the manufacturers technical
tolerance manual and repeat step 9.
Ifany control output Adjust the output and repeat step"

operates improper! y or 10.
does not actU~te within 1/1
the specified tolerance
,; . 12 Disconnect the RTD simulator (or decade box) from transmitter

input and reconnect the RTD to transmitter input. .
Continued on II(!XI page

:-"
For Reference Only

I SOP-CAl-OS Rev 0 Page 6 of7
Prceedurnl steps (cont.)
FINAL OPERATING POINT CHECK (METHOD A AND B)

Step Action
13# • Repeat steps I, 3, and 4.
• Ifany readings are not within 1/2 the specified tolerance,
confirm the RTD has been properly reconnected. Otherwise,
determine and correct cause.
COMPLETION
Step Action
1411 Complete the calibration form and affix the applicable calibration
label.
15 Ifall checks are within tolerance, restore the instruments to

performed.
supervision.
• Final rendings obtained are within the tolerance specified on the

performed:
order form.
For Reference Only

Calibration 193
I
I' Attachments The following are attachments to this work instruction:
!~
No. Title Pages
: : A Calibration/Calibration Check ofRTD Input Electronic 2
,
Temperature Controller Data Sheet
.I
References
N!A Applicable manufacturer's technical manual
Approvals! This procedure must be approved by:

author
Author: Mike Cable, (Engineering Technician)
.,
I
• f
;1
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For Reference Only
I
'1
I
Calibration .i95
I SOP-CAL-OS Rev 0 Attachment A Page 1 of2
CALffiRATION/CALffiRA TION CHECK OF RTD INPUT ELECTRONIC

TEMFERATURE CONTROLLER DATA SHEET
For: PID Tag #

Steps performed for method B are in parenthesis.
As-Found As-Left
4,13 Reference Themometer +/-
4,13 XMTR Output Current +/- rnA . rnA
(corresponding to
reference thermometer)
I
I'
4,13 Converted Temperature Reference thermometer
reading +.1- .
4,13 Remote Display Reference thermometer
reading +/-
I
5,7 10% Temperature
(9, 1i)
5, 7 10% Output Current 5.60 +/- inA rnA
I
(9, 11)
rnA
Li
5, 7
(~, 1I)
10% Re~ote Display +/-
I
5, 7
(9, 1I)
50% Temperature
I
I
5, 7 50% Output Current 12.00 +/- rnA rnA
(9, 11) rnA
5,7 50% Remote Display

(9, 1I)
S, 7 90% Temperature +/-
(9, 11)
5, 7 9OO/O
Output Current 18.40 +/- rnA rnA
(9, 11) rnA
5,7 90% Remote Display +/- _--

e-
(9, 11)
For Reference Only
j
!
I SOP-CAl-OS Rev 0 Attachment A Page 2 of 2
CALIBRA TION/CALIBRA TION CHECK OF RTD INPUT ELECTRONIC

TEMPERATURE CONTROLLER DATA SHEET (cont.)
As-Found As-Found
SteD # Parameter Required
6, 7 Alarm or control output +/-
(10, II)
(10, II)
(10,11 )
Standards Used:
Description Serial number or other I.D. Cal Due Date
RTD simulator
2 Referencethermometer
; ,
3 Milliammeter 'f
I"
4 BathIBlock
Remarks:
Performed By: __ Date: _
Reviewed By: " __ Date: _
For Reference Only

Calibration 197
ABC Compariy Standard Operating Procedure .
:
Document No.: I ~~viSion No.: I Effective Date: I
Page 1 of4
SOP-CAL-09
Tille:
Calibration of Glass Thermometers
I Supersedes Document No.: .
None .
QAlCompliance Approval (Print Name): QAlCompliance Approval Signature: Date:
Table of Contents
1.0 PURPOSE : , ~ ~ .. : 2
2.0 SCOPE , "".2
3.0 DEFINITIONS : 2
4.0 REFERENCESIATTACHMENTS , 2.
5.0' MATERIALSIREAGENTSIEQUIPMENT ,;.~:;.; 2
6.0 SAFETY : : 3
7.0 PROCEDURE ~ ; , 3
8.0 DOCUMENT REVISION ; 4
-~
: I
For Reference Only


Document No.:
SOP-CAL-09
I
ROOeVision I
No.: Effective Date: I
Page 2 of 4
Title: Calibration of Digital and Glass Thermometers
1.0 PURPOSE
1.1 The purpose of this procedure is to provide standardized instruction for the
calibration of digital thermometers and glass thermometers.
2.0 SCOPE
2.1 This procedure applies to personnel required to calibrate and maintain glass
thermometers and digital thermometers located at ABC Company.
3.0 DEFINITIONS
3.3 OOT - Out of Tolerance
4.0 REFERENCES/ATTACHMENTS
5.0 MATERIALSIREAGENTSIEQUIPMENT
5.1 NIST Traceable Temperature Measuring Device
5.2 Temperature Source (bath)
5.3 Ice
For Reference Only

Calibration . 199

Document No.: •
SOP-CAL-09
I n No.: I Effective Date:
ROOeViSio.
L
I Page 3 of4
6.0 SAFETY
6.1 All procedures will be performed In accordance with and under the constraints of
7.0 PROCEDURE
,
i
7.1 Visually inspect the UUT for damage. If damage is found, notify the user group and
repair or replace as directed.
.j
adjustment.
1
7.2 Warm up/Stabilization Requirement None. s-
I
7.3 . UUT Accuracy/Specification: Manufacturer's specification .orapproved user-assigned.
tolerance. ~i
•.
:.•.
7.4 "As Found" Data Acquisition
Note: Glass thermometers will be tested at 3 points across the operating range of.;he
UUT in the lower, middle and upper third of the range, unless otherwise '.'
specified by instrument owner. (JOe will be used as a test point in the '. .-
appropriate third of the thermometer.
7.4.1 Place a NIST traceable temperature indicator in appropriate bath. Run the
bath to the test point as indicated on the test standard. Both the standard'and J
the UUT must be placed at the same depth in the bath. If the UUT is a partial
immersion thermometer insert the thermometer in the bath at a depth equal to
the immersion line.
704.2 After test point is achieved, record the "as found" readings from the test
standard and UUT on the Calibration Data Sheet.
7.43 . Repeat steps 7.4.1 and 7.4.2 for the remaining test points:
7.4.4 Proceed to section 7.5, "As Found" Data Interpretation.
For Reference Only
I.j
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I
J

DocumentNo.:
SOP-CAL-09
I
ROOevision I
No.: EffectiveDate: 1 Page 4 of 4
7.5 "As Found" Data Interpretation
Data Sheet.
7.5.2 If an "As Found" value is "Out of Tolerance", a Calibration Out of Tolerance

Form must be generated per Calibration System Description SOP. Proceed
to section 7.6, Adjustments.
7.5.3 Ifall of the "As Found" data is within the specified tolerance, proceed to
section 7.7.
7.6 Adjustments
7.6. I Adjust and repair gauge according to manufacturers suggested repair

guidelines. If guidelines are unavailable, replace thermometer.
7.6.2 If the UlIT can not be adjusted to specification, remove the device from
service.
7.7.1 Return UUT to service.
7.8.1 Complete and process the calibration data sheet per the Calibration System
Description SOP.
For Reference Only

Calibration 201
ABC Company. Calibration/Calibration Check of

a Capacitance Probe Level SOP-CAL-IO Rev 0
Transmitter Effective Date: 3124/03
Work Instruction Page lof5 Attach.: 1
Purpose To perform a calibration check and, if necessary. calibration of a capacitance

probe level transmitter.
I
'1 Equipment! These items will be needed for performance of this procedure:
,! materials
needed
• Multirneter accurate to O.~% of reading
• Capacitance meter (if desired to check probe capacitance) .
• Frequency counter (ifdesired to check probe frequency)
• Capacitance Decade Box (for Method B using capacitance)
./
• Function Generator (for Method B using frequency) , J
i
Prerequisites The following prerequisites shall be completed prior to performance of t~: ,f
maintenance item: . 'jd:.
J
• Determine the method to be used from the work order: .
* Actual Tank Volume (Method A) or
,* CapacitancelFrequency Simulation (Method B).
Procedural Follow the procedural steps shown in the-table below:

steps • Do not perform any adjustments until all "as found" calibration data has'
been recorded. -
.".
• Note any deviation from this procedure in the remarks section of the ;_;:
calibration form. _• ' ,
~.
I·~
For Reference Only I

I
I SOP-CAL-tO Rev 0 Page 2 of5
If... Then perform steps ...

Using actual tank volume (method 1 -7
A) and 15 - 16
Capacitance/frequency simulation 8 - 14
(method B) and 15-16
USING ACTUAL TANK VOLUME (METHOD A)

Step Action
1 Drain the associated tank and fin to 10% capacity.
2# Record the current output from the transmitter and remote

indication. If desired, also record the probe capacitance andlor
frequency for future reference.
3# Fill to 50% total volume. Record transmitter current output and

remote indication. If desired, also record the probe capacitance
andlor frequency for future references.
4# Fill to 90% total volume. Record transmitter current output and

remote indication. If desired, also record the probe capacitance
and/or frequency for future references.
5# Verify proper operation of all alarm outputs and control functions.

Record results.
6#
IF_. THEN...
. The instrument under test Then calibrate in accordance
indicates values greater than with the manufacturers
112 the specified tolerance. technical manual until
indications are less than )/2
the specified tolerance and
repeat steps I - 4.
For Reference Only

Calibration 203
ISOP-CAL-IO Rev 0 Page 3.ofS
USING ACfUAL TANK VOLUME (METHOD A) (cont.)

step ·Action
7 Ifnecessary, drain tank and refill with proper fluid.
CAPACITANCEIFREQUENCY SIMULATION (METHOD B)

Step A~tion
8 Disconnect the probe from the transmitter input and install a
capacitance decade box or function generator to the transmitter
Input.
:;:
9# Simulate a capacitance or frequency signal equivalent to 10% .:.,.-:
level for the probe that was disconnected. Record the current .
output from the transmitter and remote indication
__
. ,.,
10#· Simulate a capacitance or frequency signal equivalent to 50%#,:(:-

level for the probe that was disconnected. Record the current
output from the transmitter and remote indication.
.-.
ll# Simulate a capacitance or frequency signal equivalent to 90% "
.~,
level for tbe probe that was disconnected. Record the current
output from the transmitter and remote indication. . , :.:
-i-
.,.
12# Verify proper operation of all alarm outputs and control functions.
13#
Record results,
7
,
~._'
':r
IF.... THEN ...
The instrument under test Then calibrate in accordance
indicates values greaterthan with the manufacturers
1/2 the specified tolerance. technical manual until
...
indications are less than 1/2
the specified tolerance and
repeat steps 9 - 11.
Continued Oil next ppge
.~
For Reference Only
I SOP-CAl-to Rev 0 Page4of5
CAPACITANCEIFREQUENCY SIMULATION (METHOD B)

Step Action
14 Disconnect capacitance decade box or function generator and
restore level transmitter to normal operation.
COMPLETION
Step I Action
15# Complete the calibration form and affix the applicable calibration
label.

performed.
supervision.
• Final readings obtained are within the tolerance specified on the
calibration work order form,

performed:
Record name of person contacted in comments section of work
order form.
No. ·Title Pages

A Calibration/Calibration Check of a Capacitance Probe 2
Level Transmitter Data Sheet
Continued 011 nextpage
For Reference Only

Calibration 205
I SOP-CAL-IO Rev 0 Page 5 of5
References
Approvalsl This work instruction must be approved by: )

author.

I
I
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I
.-. __JL
.,
!
-,J-
I
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For Reference Only
Calibration 207
I SOP-CAL-IO RevO Attachment A Page lof2 I

CALIBRATION/CALIBRA TION CHECK OF CAPACITANCE PROBE LEVEL'
TRANS MUTTER DATA SHEET
For: PID Tag #

Steps performed for method B are in parenthesis.
As-Found As-Left
Step # Parameter Required Data Data
2,6 10% Output Current 5.60 +/- rnA rnA rnA
(9, 13)
2,6 1Q%Remote Display +/-
(9, 13)
2,6 10% Frequency 1
'"
(9, 13) Capacitance

3,6 50% Output Current . 12.00 +1- -~ rnA rnA
. inA
--
(10, 13)
3,6 50% Remote Display +/. ,
(10, 13) J
1
3,6
(I0, 13)
50% Frequency /
Capacitance J
"I
,~. 4,6 90% Output Current i8.40 +/- rnA rnA rnA
(11, 13)
:!
4,6 90% Remote Display +/-
i
---" ',1
(11, 13)
4,6 90% Frequency
(11, 13)
As-Found As-Found
Step # Parameter Required Data Data
5 Alarm or control ouiput +/-
(12)
f!
5 Alarm or control output +/- I
(12)
I
;;;-
5
(12)
Alarm or control output +/-
I
Continued On next page
¢
For Reference Only
.1
I SOP-CAL-IO Rev 0 Page 2 of2
CALIBRATION/CALIBRATION CHECK OF RTD INPUT ELECTRONIC

TEMPERATURE CONTROLLER DATA SHEET (cont.)
Standards Used:
Description Serial number or other J.D. Cal Due Date
Milliammeter
2 Capacitance Meter
3 Frequency Counter
4 Capacitance Decade Box
5 Function Generator
Remarks:
PerfunnedBy: __ Date: _
For Reference Only

Calibration 209
Calibration/Calibration Check of Flow SOP-CAL-Il Rev 0

ABC Company Totalizers/Transmitters Effective Date: 3/24/03
Purpose To perform a calibration/ calibration checkof flow totalizer/transmitter.
Equipment/ These items will be needed for performance of this procedure:

materials • Digital scale accurate to 0.1% of reading
needed • Rosemount 268 interface (for Micromotion, if adjustment is required)
• Container adequate for amount to be dispensed
I
Prerequisites The following prerequisites shall be completed prior to performance of the '
maintenance item: I
• 'Determine a practical method of directing totalizer output into a container.
• Confirm fluid is in the sensor and ali air is out of the Iines.,
• Record the required information on the calibration form. , I
[
i
Procedural Follow the procedural steps shown in the table below: .i
steps • Do not perform any adjustments until all "as found" calibration data has, .'
']
been recorded. -\,
;
• Note any deviation from this procedure in the remarks section of the "'I"
calibration form, i
.)
• Procedural steps marked with a pound sign (#) either require information "
found on the calibration form used for recording data (Attachment-A) or

I
require data to be recorded on the calibration form. .;~
,__
If the loop being checked does not include a component that this' -r , '
procedure is checking, mark the step N/A on the calibration data form. '1
,'.,
Step Action
j
1 • Place the container on the scale and zero (tare) the scale.
• If a large amount of fluid will be weighed, it may be desirable
I
, to place the container on a cart. In this case, ensure the cart is
on the scale when tared. '. I
2 • If possible, reset the totalizer indication to zero.
• If not possible, note the initial indication.
For Reference Only

I SOP-CAL-II Rev 0 Page 2 of3
Stcp Action
3 • Direct all output from the flow totalizer into the container.
• Dispense as much fluid as is practical.
4# Weigh the amount dispensed and record the following:
·• Weight of amount dispensed

Indication of amount dispensed on totalizer
• Remote indication, if applicable
5# • Using the following conversions, determine the total volume

dispensed based on the weight obtained.
· Record this as the step 4 required value for totalizer indication

and remote indication, if applicable.
1 gallon = 8.35 Ib
1 Ib = 0.45 k~; 1 kg = 2.2 lb
1 liter = 0.2642 gallons; I gallon = 3.785 liters
6 If values obtained are not within the specified tolerance:

• Perform a calibration in accordance with the applicable
manufacturers technical manual.
• Repeat steps 1 - 5.
7 Complete the calibration form and apply the appropriate
calibration label.
8 If all checks are within tolerance, restore the flow totalizer to

performed.
For Reference Only

Calibration 211
ISOP-CAL-I I Rev 0 Page 3 of3
supervision.
• Final volumes agree within the tolerance specified on the

performed: .
I
order form.
I,
I,
I
No.
A
Title
Calibration/Calibration Check of Flow Totalizers/
Pages
1
I
Transmitters Data Sheet
I
,,, .
i
References
I
I
N/A Applicable manufacturer's technical manual.
I
Approvals! This work instruction must be approved by: I
Author I
I
Manager, ABC Company Date I
Quality, ABC Company Date r

I
I
For Reference Only I
!
I
1
·Calibration . 213
I SOP-CAL-l! Rev 0 Attachment A Page I of 1
CALIDRATION/CALIDRATION CHECK OF FLOW

TOT ALIZERSrrRANSMITIERS DATA SHEET
For: PID Tag #
II As-Found As-Left
i Step# Parameter Required Data Data
I
I 4,6 Weight of amount NA·
"
I 4, 6
dispensed
Totalizer Indication --- +/----
4, 6 Remote Indication ----+~---,

-------
(if applicable)
Standards Used:
Description Serial number. or other J.D. Cal Due Date
Digital SC,aIe
Rosemount 268 Interface'
2 (if applicable)
Remarks:
PerfurmedBy: _ Date: _
"{.-" Reviewed By: Date: __
For Reference Only

Calibration 215

Document No.:
SOP-CAL-12
I ~~viSion No.: I Effective Date: I Page 1 of4
Title: I Supersedes Document No.:

Calibration of Current to Pressure Transducers None
QAlCompliance Approval (Print Name): QAlCompliance Approval Signature: Date:
Table of Contents
1.0 PURPOSE 1:.
2.0 SCOPE ;.: 2
i
3.0 DEFINITIONS : :.2
J 4.0 REFERENCES/ATTACHMENTS ;.2
.!
I 5.0 MATERlALSJREAGENTSIEQUIPMENT :2
6.0 SAFETY 2
7.0
8.0 ~~~~~REViSioN·::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::j::::.:.
.. ·;ti-
-c:
.~~
J.~
"!,,~l
,~';!
I.
.: i
,-'I
I
~.
For Reference Only


Document No.:
SOP-CAL-12
1 RooeviSion
N0':lEfTective Date:· IPage 2 of 4
Title: Cnllbratlon of Current to Pressure Transducers
1.0 PURPOSE
1.1 The purpose of this procedure is to provide standardized instruction for the
calibration of Current to Pressure Transducers.
2.0 SCOPE
2.1 This procedure applies to personnel required to calibrate and maintain current to
pressure transducers located at AUC Company.
3.0 DEFINITIONS
3.3 OOT - Out of Tolerance
4.0 REFERENCES/A IT ACHMENTS
5.0 MATERIALSIREAGENTSIEQUIPMENT
5. I NIST Traceable Pressure Measuring Device
5.2 NIST Traceable Milliamp simulator
5.3 Pressure Source (if necessary)
6.0 SAFETY
6.1 All procedures will be performed in accordance with and under the constraints of
For Reference Only

/.
i
Calibration .217

Document No,:
SOP-CAL-12
I·ROOeviSiOn
1
I
No.: Effective Date: I Page 3 of 4
Title: Calibration of Current to Pressure Transducers
7.0 PROCEDURE
7.1 Visually inspect the UUT for damage. Notify the user group and repair or replace as
directed.
adjustments.
7.2 Warm up/Stabilization Requirement: None.
7.3 UUT Accuracy/Specification: Manufacturer's specification or approved user assigned.,

tolerance.
7.4 "As Found" Data Acquisition I

I. 7.4.1 Apply the appropriate air supply pressure to the UUT. Measure and document
~.'
7.4.2
the supply pressure in the comment section of the calibration Data Sheet: s~l'
.
Connect the milliamp simulator to the input of the UUT.
~'.
'ff, I
I
.' .....1
7.4.3 Connect the pressure measuring device to the output ofthe UUT. ;~--
7.4.4 Set,the milliamp simulator for 4 rnA (or the 0010
'signal) to the input and rec3Id ::~
.~
~,.i 7.4.5
the output pressure on the Calibration Data Sheet. .
Repeat step 7,4.4 for input values of 12.0 rnA and 20.0·mA.
j
't
,-!-i
$
.i..':
7.4.6 Proceed to section 7.5, "As Found" Data Interpretation
7.5 "AsFound" Data Interpretation

Data Sheet. .
7.5.2 If an "As Found" value is "Out of Tolerance", a Calibration Out of Tolerance

Form must be generated per Calibration System Description SOP. Proceed to
Adjustments, section 7.6. . .
7.5.3 To optimize instrument performance or if adjustment is needed, proceed to

y.
. .
.For Reference Only

DocumentNo.:
SOP-CAL-12
I
ROOCYision I
No.: ~tTcctiveDate: I Page 4 of 4
Title: Cnllbrntlon of Current to Pressure Transducers
7.5.4 If nil of the "As Found" data is within the specified tolerance, proceed to
section 7.7.
7.6 Adjustments
7.6. I Adjust and repair transducer according to manufacturers suggested repair

guidelines, If guidelines arc unavailable, replace the transducer.
7.6.2 If thc UUT can not be adjusted to specification, remove the device from
service
7.7.1 RetumUUTtoservice.
7.8.1 Complete and process the Calibration Data Sheet per the Calibration System
Description SOP.
For Reference Only

Calibration 219
Calibration/Calibration Check of
Leads & Northrup 7082 SOP-CAL-13 Rev 0
. ABC Company Conductivity Analyzers Effective Date: Draft
Work Instruetlon Page 1 of5 Attach.: 1
Purpose ·To perform a calibration check and, if necessary, calibration of Leeds &
Northrup 7082 conductivity analyzers.
Equipment/ These items will be needed for performance of this procedure:

materials • . Deionized water
needed
• 8550 ohm precision resistor, Leeds &Northrup PIN 233300 or equivalent
• Decade resistance box, 100 Kohm to 10 Mohm, accurate to +/- 0.1%
• Appropriate beakers for solution and conductivity probe length
o Hydrogen peroxide or other approved sanitizing solu~on
Prerequisites The following prerequisites shall be completed prior to performance of'the

maintenance item:' . :i,'
• Prepare a beaker of deionized water in a clean air environment and let ...,.
stand for one hour.
• Record the·requiredinformation on the calibration form.
Initial Perform the following prior to testing:

conditions Isolate the conductivity cell and bleed off system pressure per the site
Lockout/Tagout Procedure.
Procedural Follow the procedural steps shown in the table below;

steps Do not perform any adjustments until all "as found" calibration data has
been recorded. .
calibration form.
procedure is checking, mark the step N/A on the calibration data form ..
For Reference Only

I SOI'-CAL-13 Rev 0 Page 2 of5
Procedurnl steps (cont.)
Step Action
I Remove the conductivity cell from the system.
2 Rinse the probe thoroughly using deionized water.
311 Place the cell in the beaker ofprcpared deionized water.

• Record the conductivity indication.
· If available, place a digital conductivity standard in the
solution to verify the required indication.
4 Disconnect the temperature compensation leads from terminals B

and D of the conductivity cell and connect the 8550 ohm resistor.
5# • Record the ALARM I and ALARM2 setpoints on [he

calibration form.
6# • At the analyzer, press CELL CONST.

• Record the cell constant on the calibration form.
7# • At the analyzer, press CELL CONST then press CELL

CONST and the up arrow simultaneously.
• Record the cell calibration factor on the calibration form.
8 Note: This step will remove all stored alarm setpoints and cell
constant will default.
Usc the up and down arrows to change the cell calibration factor
to 1.000 and·~NTER.
9# • Disconnect the conductivity cell from terminals A and C and

connect the resistance decade box,
• Apply values of 10 Mohm, 1 Mohm and 100 Kohm.
• Record conductivity indications at each value.
Continued 011n('.TI page
For Reference Only

Calibration 221
Step Action
10#
If... Then ...
If the indicator under test Calibratethe indicator in
indicates values greater accordance with the manufacturer's
than 112the specified technical manual until indications
tolerance are less than 112the specified
·tolerance.
-.-.
If adjustments are made Repeat step 9 and record final
values.
If adjustments are made Repeat steps 2 and 3. 'Record final

values.
..
,.. .'
; ·i
II • Thoroughly rinse the probe with deionized water and sanitize.

with hydrogen peroxide or other solution approved by Quality
Assurance. ..
• Reinstall the conductivity probe .

.-
12 Disconnect the resistance decade box and reconnect the
_.
conductivity cell to terminals A and C.
..
13 Disconnect the 8550 ohm resistor and connect the temperature
compensation to terminals B and D.
.,
14. At the analyzer. press CELL CONST then press CELL CONST
and the up arrow simultaneously.
15# • Use the up and down arrows to change the cell calibration
factor to the value recorded on step 7.
• Press ENTER.
16# • Restore the ALARM I and ALARM2 to the values recorded

on step 5 of the calibration form.
~.
Continued 011 nextpage
For Reference Only

I SOP-CAL-13 Rev O ..:..P,:;)ag"'e:_4.:__0::..:f:...:5'--l
Prucedurnl steps (cont.)
Step Action
1711 • At the analyzer, press CELL CONST.
• Usc the up anddown arrows to change the cell constant to the
value recorded on step 6.
1811 Verify proper operation of any alarms and/or control functions

and record results.
Step Action
1911 Complete the calibration form and affix the applicable calibration
label.
20 If all checks are within tolerance, restore the conductivity
indicator to operational condition and notify appropriate
personnel of work performed.
crlterln to determine satisfactory completion, subject to review of data by
supervision.
Final conductivity indications obtained are within the tolerance

performed:
Record name ofpcrson contacted incomments section of work
order form.
Attachments The following nrc attachments to this work instruction:
No. Title Pages

A Calibration/Calibration Check of Lends & Northrup 2
7082 Conductivity Analyzers Data Sheet
Continued On next page
For Reference Only

Calibration 223
I SOP-CAL-13 Rev 0 Page 5 of5 I·
References
Manual No. ' Manual Title
N/A Applicable manufacturers. technical manual
;1"
I
Approvalsl This work instruction must be approved by:
I
.1
author
,
.: Quality. ABC Company Date
",J
------------------------------------------~-- "
:: I
t-..·· '\., ..
;:;;-
For Reference Only

.f
Calibration 225
I SOP-CAL-13 .RevO Attachment A Page I of2
CALIBRATION/CALIBRATION CHECK OF LEADS & NORTHRUP 7082

CONDUCTnnTYANALYZERSDATASHEET
For: PID Tag #
As-Found As-Left Tal

Parameter Required
3, 10 Conductivity in DI water
5, 16 Alarm I Setpoint NA NA
5, 16 Alarm 2 Setpoint NA NA
6, 17 Cell Constant NA NA·
7, 15 Cell Calibration Factor NA NA
9,10 Conductivity at 10 Mohm 0.1 ± 0.1 uMbo/cm

lIMho/cm . uMbo/em
9, 10 Conductivity at 1 Mohm 1.0 ± 0.1 uMbo/em

uMbo/em uMho/cm
9, 10 Conductivity at 100 Kohm 10.0 ± 0.1 uMho/cm

uMbo/em uMho/cm
18 Alarm/Control Functions Satisfactory Sat! Unsat NA I Sat

(circle one) (circle one)
Standards Used:
Description Serial number or other J.D. Cal Due Date

I
Decade Resistance Box
II
2 Digital Conductivity Standard .j
3
.~ . For Reference Only

I SOP-CAL-13 RcvO Attachment A Page 20f2
CALInRATION/CALIBRA TION CHECK OF LEADS & NORTHRUP 7082

CONDUCTIVITY ANALYZERS DATA SHEET (CODt.)
Worse Cnse Tolerance Code:
Remarks:
Performed By: .___________________ Date: _
For Reference Only

Appendix A- 5
TEST EQUIPMENT
Note: This list is for example purpose~ only and is not recommending a
particular manufacturer/model number.
EQUIPMENT 1YPE EXAMPLE SIMPLIFIED

I 'SPECIFICATIONS
Digital multimeter Fluke 87, or equivalent DCV ± (.05% + 1 digit)
'j DC Current ±'(,2% +2 digit)
ACV ± (.7%. + 1 ~igit)
AC Current ± (1.0% + 2 digit)
Resistance ± (.2% + 1 digit)
Analog multimeter Simpson 560 DCV± 2% 'FS
DC Current ± 2% FS
ACV± 3%.fS
Multi-function Fluke 743B with applicable

Resistance ± 20 of arc'
MUltiple
I
calibrator . pressure modules
Decade box
Thermocouple
General Radio 1432A
Altek 322
± 0.05% reading
± (0,008% rdg + 0.006 mv)
I
calibrator
Temperature bath Hart 7320 Range: -20C to 150C
Stability/Uniformity: ± .00Se
I
/
.' Temperature block
Precision RTD
Hart 9103
Hart 1521
-25C to 140C
± 0.25C
±0.025C
.
I
HART communicator
Floor scale
Rosemount 275
Mettler-Toledo
NA
0.1% reading + 1 digit
I
Hand pressure/vacuum Heise TP-l N/A /'
pump
Dead weight tester Ashcroft 1305D. ± 0.1 % of reading
12" analog test gCluge Heise CC ± 0.1 % FS
- 6 digit calibrated. Heise 910B
41J.z ± 0.035% span
meter
,.
227
Appendix A-6
RTD AND THERMOCOUPLE
-TABLES-
RTD VB. Resistance-Table for Alpha = .00385, ITS-90 (DIN 43760)
RID vs. Resistance Table for Alpha = .00392, ItS-90
Type J Thermocouple Reference Tables
Type T Thermocouple Reference Tables

II
Type K Thermocouple Reference Tables .-,-
oj
-,
.1
229
230 RTD and Thermocouple Tables
RTD Temperature
vs. Resistan'ce Table
For European Curve, Alpha::: .00385,ITS-90 1° Celsius Increments
·c Oh'III DU~ 'C Ohm. 0111. -c Ol&ml PUI. ·c Ohms PIff. ·C Ohms Dill. 'C Ohms 0111.
·200 rasa ·1~0 03'u 0.~2 -00 !l8.33 0.• ' ·20 02.16 0.39 00 100.00 0.39 -so 123.2~ 0.38
100 10.00 0 .• 4 139 4420 0.41 70 GO.73 O,otO 10 02.55 0.39 +1 100.39 0.39 61 12:1.62 0.38
190 19.39 0.43 138 ".71 0.42 70 00.13 0.40 19 02.05 0.40 2 100.78 0.39 62 124.01 0.39
197 19.82 0.43 137 4512 0.41 77 69.63 0.40 17 03.34 0.39 3 101.17 0.39 63 124.39 0.38
100 20.2$ 0.43 138 45.5:1 0.~1 70 69.03 0.40 10 03.73 0.39 4 101.so 0.39 a.I 124.77 0.38
ms 20.GO 6.43 135 45.05 0.42 75 70.33 0.40 15 94.12 0.39 5 101.95 0.39 65 125.17 0.40
194 21.11 0.43 134 40.3~ OAO 74 70.73 0.40 14 04.62 0040 8 102.34 0.30 66 125.55 038
103 21.64 0.43 133 40.70 0.41 73 71.13 0.40 13 04.01 0.30 7 102.73 0.39 fIT 125.93 0.38
102 21.D7 0.43 132 ~7.18 0.42 72 71.53 0.40 12 95.00 0.39 8 103.12 0.30 sa 1:tfl.32 0.39
OS.OO
101
100
lao
22.40
22.53
0043
0.43
2320 0.43
131
100
129
47.69
48.00
40.41
0.~1
0,41
0.41
71
70
ro
71.03
72.33
72.73
0.40
0.40
0.40
II
10
9
00.09
00.40
0.39
0.40
0.39
°
10
11
103.61
103.00
104.20
0.39
0.30
0.39
60
70
71
12!l.70
127.00
127.40
0.38
038
0.38
180 23.G9 0.43 120 46.02 041 80 73.13 0.40 a 06.67 0.39 12 104.80 0.39 72 127.85 0.39
107 24.12 9.43 127 40.23 0.41 fIT 73.63 0.40 7 97.20 0.30 13 105.07 0.30 73 121l.23 0.38
100 24,55 0.43 120 40.o-r 0.41 00 73.03 0.40 0 07.05 0.30 14 105.40 0.39 74 128.01 030
IDS 2~.97 0.42 125 50.00 0.42 55 7•. 33 0.40 5 08.Q4 0.30 15 105.05 O.:JD 76 12D.OD 0~6
164 25_39 OA2 124 60.47 0.4' 64 74.73 0.40 4 00.44 0.40 16 10024 0.39 78 121l.30 0.39
103 26.62 0.43 123 60.88 0.41 03 75.13 0.40 3 08.03 0.39 17 100.03 0.39 77 129.76 0.36
182 20.:tfl 0.03 122 5129 0,41 02 75.63 0.40 2 60.22 0.30 18 107.02 0.39 70 '38.14 0.38
161 20.07 0.42 121 5'.70 0.41 6' 75.03 0.40 1 99.61 0.39 19 107.~0 0.36 79 1:n52 0.36
160 27.10 0."3 120 52.11 0.41 60 76.33 0.40 20 lfIT.7e 0.39 80 130.90 0.38
170 27.62 0,42 110 52.62 0.41 59 76.73 0.40 21 108.18 0.39 81 131.26 0.36
170 27.55 0.03 110 52.92 0.40 58 77.13 OAO 22 108.57 0.39 82 131.67 0.39
177 28.37 0..2 117 53.33 0.41 57 77.52 0.39 23 100.00 0.39 83 1:!2.05 0.33
170 20.80 0.43 116· 53.74 0.41 58 77.02 0.40 24 109.35 0.39 84 132.43 0.36
178 20.22 0.42 liS 54.15 0.41 55 7B.32 0.40 25 109.73 0.38 65 132.81 0.36
17. 20.65 0.43 114 54.56 0.41 54 7B.72 0.40 21l 110.12 Q.39 88 133.19 0.36
173 30.07 0.42 113 54.97 0.41 53 79.11 0.39 27 110.51 0.39 87 1:1357 0.36
172 30.49 0.42 112 55.36 0.41 52 79.51 0.40 28 110.90 0.39 88 1:13.95 0.38
171 30.92 0.03 111 55.78 0.40 51 79.91 0.40 29 111.26 0.38 89 134.33 0.38
170 31.~ 0.42 110 56.'9 0.41 50 80.31 0.40 30 111.67 0.39 90 134.71 0.36
169 31.10 0.42 109 55.60 0.41 49 00.70 0.39 31 112J)6 0.39 91 135.09 0.38
108 32.16 0.42 108 57.00 0.40 48 81.10 D.40 32 112.45 0.39 92 135.47 0.39
1fIT 32.61 0.43 lfIT 57.41 0.41 47 61.50 0.40 as 112.83 0.38 93 135.65 0.38
IGO 33.03 0.42 106 57.82 0.41 48 61.89 0.39 34 113.22 0.39 04 13623 0.36
165 33.45 0.42 105 58.22 0,40 45 82.29 0.40 35 113.61 0.39 05 136.61 0.38
1114 33.00 0.41 104 58.63 0.41 0\4 62.60 040 36 113.99 0.38 06 138.09 0.38
103 ~.28 0.42 103 6O.o-r 0.41 43 03.!l8 0.39 37 114.38 0.39 97 137.37 0.36
162 34.70 0.42 102 59.44 0.40 42 83.48 0.'0 38 114.77 0.39 99 137.75 0.38
161 35.12 0.42 101 59.85 0.41 41 83.60 OAO 39 115.16 0.38 00 130.13 0.36
lGO 35.64 0.42 100 0020 0.41 40 84.27 0.39 40 116.64 0.39 100 138.51 0.38
159 35.99 0.~2 00 00.67 0.41 30 64.07 0.40 41 116.03 0.30 101 138.89 0.36
160 30.38 0.42 00 01.07 0.40 38 1lS.00 0.30 42 118.31 0.36 102 130.27 0,38
157 30.60 0.42 07 OUO 0.41 37 05.46 0.40 43 110.70 0.39 103 139.05 0.30
158 37.22 O.4~ 99 OUl7 0.41 30 05.05 0.39 0\4 117.06 0.30 104 140.03 0.36
155 37.63 0.41 os 62.20 0.42 35 00,25 0.40 45 117.47 0.39 109 140.30 0.38
164 36.05 0.42 901 02.69 0.40 34 00.04 0.30 40 117.05 0.38 100 140.77 0,39
163 3B.• 7 0.42 93 63.10 0.41 33 87.o-r 0,40 47 116.24 0.30 107 141.15 0.38
152 36.89 0.42 02 03.50 0.40 32 87.43 0.39 48 110.02 0.38 100 141.63 0.38
151 39.31 0,42 91 6391 0.41 3' 87.03 0.40 49 110.01 0.39 100 141.91 0.38
160 39.72 0.41 90 04.30 0.39 30 00.22 0.39 50 110.40 0.30 11,0 1422B 0.36
140 40.14 0.42 00 04.70 0.40 29 00.02 0.40 61 110.78 0.38 111 142.66 0.37
140 40.56 0.42 B8 GS.II 0,41 20 B9.01 0.39 52 120.16 0.30 112 '43.04 0.38
1~7 40.97 0.41 07 65.51 0.'0 27 69.40 0.39 53 120.55 0.39 113 143.42 Q,JB
140 41.39 0.42 86 05.91 0.40 20 60.80 0.40 54 120.03 0.36 II, ".3.00 0.38
145 41.110 0.41 05 66.3' 0.40 25 00.19 0.30 SS 121.32 0.39 116 IM.16 0.36
144 42.22 0.42 64 66.72 0.41 2' 90.59 0.40 56 121.70 0.36 110 144.so 0.38
143 42.(14 0,42 03 67.12 0.40 23 90.96 0.39 57 122.09 0.39 117 1"".94 0.36
142 43.05 0041 62 67.52 0.40 22 9'.37 0.39 58 122.47 0.36 118 145.32 0.36
141 43.411 0.41 61 67.02 0.40 21 91.77 0.40 59 122.86 0.39 119 \45.69 0.37
Nolo: At IOO·C.rosls'anco b 138.50 oruns. lOIN 4:1760)
Z·252
© Copyright OMEGAEngineering, Inc. All rights reserved. Reproduced

with the permission of OMEGA Engineering, Inc., Stamford, CT 06907
www.omega.com
I.
231
Calibration
RTD Temperature
vs. Resistance Table
1 Celsius Increments
For European Curve, Alpha = .00385,ITS-go
0
·c Ohms 0111. 'C Ohms 0111.

·c Ohms Dfff. 'C Ohms DIn. ·c Ohms DIn. 'C Ohms Diff.
0.34
ft12Q 146.07 0.38 +180 168.48 0.37 .+240 190.47 0.36 ~ 212.05 0.36 +36Q
0.35 361
23321
23356
0.35
0.35
+420
421
253.96
254.30 0.34
168.85 0.37 241 190.83 0.36 301 212.40
121 146.45 0.38 181 233.91 0.35 422 254.65 0.35
0.37 '242' 191.20 0.37 .302 212.76 0.36 362
122 146.82 0.37 182 169.22 0.35 423 254.99 0.34
0.36 303 213.12 0.36 363 234.26
147.20 0.38 183 169.59 0.37 .. 243 191.56 0.34
123 364 234.60 0.36 424 255.3J
124 147.58 0.38 184 169.96 0.37 .,244· 191.92 0.36 3Ii4 213.47 0.35
0.34
·305 213.83 0.36 366 234.95 0.35 425 255.67
192.28 0.30
-
125 147.95 0.37 185 170.33 0.37 245 256.01 0.34
aOO 214.19 0.36 .366 235.30 0.35. 426
148.33 0.38 170.69 0.36 246 192.66 0.38
126 .1~ ·307 214.55 0.35 ·367 235.65 0.35 427 256.35 0.34
187 171.06 0.37 247. 193.02 0.36
127 146.71 0.38 236.00 0.35 ·428· 256.70 0.35
246 193.38 0.36 ,306. 214.90 0.35 .·.368
128· 149.08 0.37 .1118 171.43 0.37 429 257.04 0.34
193.74 0.36 .. 215.26 0.36 .)69 236.35 0.35
0129 149.46 0.38 189 171.80 0.37 249
310 215.61 0.35 370 236.70 0.35 4sq 257.38 0.34
130 149.83 0.37 190 172.17 0.37 250 194.10 0.36
0.35 . 431 257.72 0.34
194.47 0.S7 311 215.97 0.36 371 237.05
150.21 0.36 191 172.54 0.37 '.251
131
0.37 '192 172.91 0.37 252 194.83 0.36 ·312 216.32 0.35 -ii2 237.40 0.35 ·432 258.06 0.34
132 150.58
150.96 0.38 193 173.27 0.36 253 195.19 0.36 313 216.68 0.36 373 237.75 0.35 "433 258.40 0.34
133 0.35 '314' 238.09 0.34 434 258.74 0.34
.194 173.64 0.37 254 195.55 0.36 314 217.03
134 151.34 0.38 238.44 0.35 435 259.08 0.34
2S5 195.90 0.35 315 217.39 0.36 375
135 151.71 0.37 195 174.01 0.37 259.42 0.34
255 196.28 0.36 316 217.73 0.34 :~6 238.79 0.35 435.
136 152.09 0.38 195 174.39 0.38 0.34
0.36 .257 196.62 0.36 .317 218.OS 0.35 ·377 239.14 0.35 ·437 259.76
137 152.46 0.37 197 174.75 260.10 0.34' .
·258 196.98 0.36 '318 218.44 0.38 . 37S· 239.48 0.34 436
·136 152.84 0.38 '.199 175.12 0.37 ;439·
319 218.79 0.35 1:379" 239.83 0.35 260.44 0.34
139 153.21 0.37 ,199 175.49
.·200
0.37
0.37
;~~.. 197.35
197.71
0.37
0.S8 ;320 219.15 0.36 ,390 240.18 0.35 "440 260.78 0.34
140 153.58 0.37 175.85 261.12 0.34
'201 176.23 0.37 261·: ·198.07 0.36 ·'321' 219.50 0.35 381 240.52 0.34 ·441
O&l
141 153.95
154.32'
0.37
0.37 202 176.59 0.36 .262· 198.43 0.36 '322 219.85 0.35 :.382 240.87 0.35 ~ 261.46
142
0.37 '.263: 198.79 0.36 '.323· 220.21 0.38 ·'383 241.22 0.35 ,"443 261.80 o~
·i43 154.71 0.39 203 176.96
·324. 220.56 0.35 :'384·. 241.56 0.34 444' 262.14 0.34
144. 155.08 0.37 204 177.33 0.37 '·:264 199.15 0.36
'325 220.91 0.35 0·385 241.91 0.35 '.445 262.48 0.34
155.46· 0.36 '·205 In.70 0.37 '"285 199.51 0.36
'446
145
206 178.06 0.36 ::266: 199.87 0.36 ;326 221.27 0.36 '386 242.25 0.34 262.63 0.:J5..
146
147
155.63 0.37
0.38 ir:n 178.43 0.37 .,.257.; 200.23 0.36 .:3'4. 221.62 0.35 '387 242.60 0.35 .0441. 263.17 0·31:
156.21
'206 176.80 0.37 '.268. 200.59 0.36 :.328,. 221.97 0.35 ·'-308'· 242.95 0.35 ·.!I48. 283.50 0.33
148 156.58 0.37 0'389 243.29 0.34 "+19 263.64 0.34
179.16 0.36 ·,:269 200.95 0.36 ·329.- 222.32 0.35
;49
..150
151
156.96
157.33
157.71
0.38
0.37
0.36
'209
210 179.53
211 179.90
0.37
0.37
·:·:270
~~271
201.31
201.67
0.36
0.36
::;: azasa
.-,'332:
223.03
223.38
0.38
0.35
0.35
':390'
~.391:'
::392
243064
243.98
244.33
0.35
0.34
0.35
.~50'
·45·"
452
2&1.18
264.52
264.80
0.34
0.34
0.34
212 18!J.26 0.36 "272' 202.03 0.36
152 15a.oS 0.37 . ':;33.: 223.73 0.35 ·:·300 244.67 0.34 453 265.20 0.34 .i·
--i53 158.45 0.37 ·'213 180.63 0.37 '·i!73· 202.36 0.35
0.36 ·.·334 224.09 0.36 ,~. 245.02 0.35 :~iS;f; 465.54 . 0.34
.~:'
180.99 0.36 '0274· 202.74
'154 '214
155
,l·M
158.83
159.20
159.56
0.36
0.37
0.36
·"215 181.36
;i16 181.73
0.37
0.37
·'275
:"216,
.'.
20310
203.46
0.36 ·'335'
0.36
224.45
224.60
225.15
0.36
0.35
0.35
···385-
f386
\311!'
245.36
245.71
246.05
0.34
0.35
0.34
,~
':455 265.67
266.21
: 457. 266.55
0.33
0.34
0:34
·'·2i"7 182.09 0.36 ·:277':· 203.62 0.36
·151
.i58
159.94
160.31
0.38
0.37 ·0218 182.46 0.37 ;.~: 204.18 0.36 225.50 0.35 ;j9( 246.40 0.35 ;·458' 266.89
~:4s9', 267.22
ri.34
0.33
i59
160
180.68
161.05
0.37
0.37
219 182.62
2~O 183.19
0.36
0.37 ;2800.
204.54
204.90
0.36 .:3:39'
0.36 '340'
22S.SS
226.21
0.35
0.36
"399
''#
246.74
247.09
0.34
0.35 .~:; 267.!i6 0.34
0.35 :34F 226.56 0.35 ·40F 247.43 0.34 :'~61,. 267.90 0.34
0.38 ··221 183.55 0.36 ;jJij: 205.25
i61
'162
161.43
161.80 0.37 7~ 183.92 0.37 ,·282
····283.
205.61 0.36 342
,,34:1'"
226.91 0.35 J~'-
,403'·
247.78
248.12
0.35
0.34
:462, 268.24
·'463 268.57
0.34
0.33
'm,
0:36 205.97 0.36 227.26 0.35
'223 184.2Il
'163
164
162.17
162.54
0.37
0.37 22.( 184.65 0.37 '2&\ 206.33 0.36 34<l. 227.61 0.35 246.46 0.34 ':1~, 268.91
··465· 269.25
0.34
0.34
0.35
.1.65 162.91 0.37 ' 225 185.01 0.36 ·'285. 206.70 0.37 345.: 227.96 0.35 248.81
0.34 ·.-'406· 269.58 0.33
166 163.28 0.37 '226· 185.38 0.37 . '2eii' 207.05 0.35 ·S'is 226.31 0.35 ;;106: 249.15
·;~si; 269.92 0.34
249.50 0.35
IIi! 163.66 0.38 ;2;;? .185.74 0.36 207.41 0.36 <'34.r;; 228.66 0.35 ,'407
':'~~,207.71 '·408 0·:468'- 270.26 Q.34
.~~:
0.36 :'348 229.01 0.35 249.84 0.34
·228 186.fl 0.37
:46"9
;~:
'166 164.03 0.37 ".jO!{ 0.34 270.59 0.33
169 164.40 0.37 ·229 166.47 0.38 208.13 0.36
~'.~' 229.36 0.35
~;'tl0
250.18
250.53 0.35 ·470' 27Q.93 0.34
:~~:
229.72 0.34
170· 164.77 0.37 ';2:lO: 186.84 0.37 '208.48 0.35
0.35 ··411 250.69 0.34 271.27 0.34
..~: 208.84 0.36 230.07

ii) 165.14 0.37 1
:,23 187.20 0.36
209.20 0.36 230,42 0.35 <412 251.21 0.34 271.60 0.33
'232 187.56 0.36
..172 165.51 0.37
·;2~ 209.55 0.35 230.n 0.35 ·413 251.55 0.34 ·4"73 271.94 0.34
17:i 0.37 ' 233 187.93 0.37 47....·
·174
185.88
166.25 0.37 ;234' 188.29 0.36 °·'294· 209.91 0.36 ..~. 231.12 0.35 '4;4 251.90 0.35 272.27
·'475 272.61
0.33
0.34
:o:~
;295; 210.27 0.36 ' 365· 231.47 0.35 .·415 252.24 0.34
fii; 165.62 0.37 235 188.55 0.36
···416 252.59 0.35 272.95 0.34
··236 189.02 0.37 296 210.62 0.35 '356. 231.81 0.36
176 167.00 .0.38 ·351 41·7 252.94 0.35 273.28 0.33
·'29j· 210.98 0.36 232.16 0.35
rTf 167.37 0.37 237 189.38 0.36
.·.298·· 211.34 0.36
0358 232.51 0.35 ::418 253.28 0.34 ·476 273.62 0.34
0.37 236 189.74 0.36
479
178
'ii9
167.74
168.11 0.37 239 190.11 0.37 0299. 211.69 0.35 .3?9 232.66 0.36 ::41~ 253.62 0.34 273.95 0.33·
lOIN 43 760)
Nota. Ar 100°C, reslsteree Is 138.50 ohms.
Z-2S3
© Copyright OMEGA Engineering, Inc. All rights reserved. Reproduced

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RTD Temperature
.
For European Curve, Alpha = .00385,ITS-gO 1· Celsius Increments
·c 01.... ow. ·c Oh .... Dill. -c orun. Dill. ·c Ohms 0111. 'C Ohm> DIll. "C Ohms DIIt.
1-400 274.29 0.34 +542 294.87 0,33 .004 315.00 0.32 +61;8 331,68 0.32 +728 353.91 0.30 +790 372.710.30
401 274,t;:!
0,33 543 295.20 0.33 005 316.32 0,32 667 334.09 0.31 729 354.22 0.31 791 373.G10.30
402 27~,OO 0.34 044 295,63 0,33 000 316.64 0.32 668 335,31 0,32 730 354.53 0.31 792 373.310.30
403 275.20 0.33 04~ 205,65 0,32 007 315.06 0,32 GQ9 335,62 0.31 731 354.63 0.30 793 373.610.30
484 276.63 0.34 G40 200.18 0.33 000 316.28 0.32 070 335.93 0.31 732 355.14 0.31 794 373.910.3D
485 275.00 0.33 641 200.51 0.33 GOO 310.00 0.32 671 33025 0.32 733 355.44 0.30 195 374.21 0.30
4SO 270.31 0,34 640 290.84 0.33 010 31M2 0,32 072 33O,G(l 0.31 ?34 355.75 0.31 796 374.51 o.aa
407 276.0.10,33 649 201.18 0.32 011 317.24 0.32 073 330.07 0,31 735 356.06 0,31 797 374.80 0.29·
400 270.07 0.33 ~50 267.40 0,33 012 317,6(1 0.32 074 337,18 0,31 738 356.37 0.31 7!lO 374.10 0.30
400 2n,31 0.34 551 207.82 0,33 013 317,00 0.32 676 337.60 0.32 737 356.68 0.31 799 375.40 0.30
400 ~n.64 0,33 Ci52 200,14 0,32 014 310,20 0.32 670 337.01 0.31 738 350,98 0.30 eoo 375.70 030
491 2n.OO 0.34 653 208.47 0.33 016 3'8.52 0.32 on 330.12 0,31 739 357,29 0.31 801 376.00 0.30
492 276.31 0,33 634 208.eo 0.33 DID 31M!; 0,33 G7a 330.43 0.31 740 357,59 0.30 802 376.29 0.29
493 278,64 0.33 65!i 290.12 0.32 817 310.17 0.32 070 330,76 0.32 741 357,00 0.31 603 378,59 0.30
404 271I.SO 0.34 650 200.4~ 0.33 010 319.49 0.32 Gao 339.00 0,31 742 358.20 0.30 804 376.09 O.W
409 270.31 0,33 657 =.70 0.33 OlD 319.61 0.32 DOl 339.37 0.31 743 358.61 0.31 1!05 3n.IO 0.30
~OO 270.1>1 0,33 056 300.10 0.32 o:!O 320.12 0,31 0D2 339,GO 0.31 7014 350.01 0.30 BOO 3n.49 0,30
407 270,00 0,3" 6$0 300,43 0.33 621 320,~4 0.32 D03 330,90 0.31 748 359,12 0.31 B07 m.70 0.30
400 200.31 0,33 fiOO 300.75 0.32 022 320.70 0.32 0D4 340,30 0,31 740 350,42 0.30 IlOO 370.09 0,30
400 2BO.64 0,33 501 301M 0.33 023 321.00 0.32 00!i 340,G2 0.32 747 359.72 0.30 8C9 378.39 0.30
000 280.80 0.34 662 301.41 0.33 G2iI 321.~O 0.32 DOD 340.94 0.32 740 300,03 0.31 610 370,08 0.29
501 281,31 0.33 G03 301.73 0.32 625 321.72 0.32 Ba7 341.25 0.31 749 3GO.33 0.30 811 378,98 0,30
002 261.04 0.33 664 302.06 0.33 626 322.03 0.31 6118 341.55 0,30 760 300.04 0.31 812 379.28 0.30
503 201.07 0.33 565 302.38 0.32 627 322.34 0.31 609 341.87 0,32 751 360,04 0.30 613 370,57 0.20
0D4 202.31 0,34 GOD 302.71 0.33 628 322.68 0.32 699 342.18 0,31 752 301.24 0.30 814 379.87 0.30
OO~ 202,64 0,33 507 393.03 0,32 829 322,98 0.32 691 342.49 0.31 753 361,55 0.31 815 380.17 0.30
GOO 262.07 0.33 6GQ 303.36 0.33 830 323.30 0.32 692 342.00 0.31 754 361,85 0.30 816 :180.48 0.29
607 203.30 0.33 6G9 303.68 0.32 631 323.61 0.31 893 343.11 0.31 755 362.15 0.30 817 380,76 0.30
600 203.83 0.33 570 304.01 0.33 632 323.93 0.32 694 343.42 0.31 756 362.48 0.31 618 331.05 0.29
609 2D3.97 0,34 671 304.33 0.32 633 324.25 Q.32 695 343.73 0.31 1ST 362.76 0.30 819 381.35 0.30
610 21l4.30 0,33 572 304.66 0.33 G34 324.57 0.32 696· 344.04 0.31 758 363.flIi 0.30 1l2o 381.65 0.30
611 21101.630,33 573 304.98 0.32 ..835 324.88 0.31 ~ 344.35 0.31 7SS 363.36 0.30 621 381.94 0.29
512 204.00 0,33 574 305.30 0.32 . 636 325.21 0.33 698 344,66 0.31 7t1l 363.67 0.31 822 382.24 0.30
013 205.29 0.33 575 305.63 0.33 037 325.53 0.32 699 344.97 0.31 761' 363.97 0.30 823 382,53 0.29
514 2OS.li2 0.33 578 305.95 0.32 '836 325.85 0.32 700 345.28 0.31 782 364.27 0.30 824 332.63 0.30
616 20$.05 0.33 srr, 3J6.29 0.33 839 326.18 0.31 701 345.59 0.31 763 364.57 0.30 B25 363.12 0.29
610 290,30 0.35 578 :D6.60 0.32 '640 326.48 0.32 702 3-15.90 0.31 784 364.88 0.31 e2s 383.42 0.30
517 286.63 0.33 1;79 300.92 0.32 841. 326.79 0,31 703 346.21 0.31 765 365,18 uso B27 383.71 ().29
518 200.00 0,33 580. 307.25 0.33' 842 327,11 0.32 704 346.S2 0,31 766 365,49 0.31 e2e 384.01 0.""
519 207.20 0,33 5~1 307.57 0,32 843 327,43 0.32 705 346,03 0.31 767 365,79 0.30 829 384.30 0.29
520 207.62 0,33 582 307.89 0.32 844 327.74 0.31 708 340,16 0.32 700 300.09 0,30 830 :184.60 0.30
521 207.05 0.33 ~ 308.22 0.33 645 328.00 0.32 707 347.~0 0,31 789 368.40 0.31 031 384.89 0.29
822 206.28 0.33 584 308.54 0.32 840 329.30 0.32 700 347.70 0.30 no 3GO.70 0.30 832 :185.18 0.29
523 208.61 0.33 5B5 3OB.BB 0.32 847 329.89 0.31 700 340,07 0.31 n1 307,00 0.30 833 385.46 0.30
624 208.94 0,33 588 309.10 0.33 &18 329.01 0.32 710 348.38 0.31 rn 307.30 0.30 B34 385.n 0.29
625 209.27 0.33 567 309.61 0.32 849 320.32 0.31 711 3'.8.69 0,31 173 307.60 0,30 835 380.07 0.30
626 269.00 0,33 588 309.63 0.32 GOO 320,04 0.32 712 340,00 0,31 n4 387.00 0.30 D30 306,37 0.30
627 2lI!l,03 0,33 589 310,16 0,32 651 320.06 0,31 713 349.31 0,31 n5 300.20 0.30 037 300,00 0,29
626 290.26 0.33 500 310,48 0.33 652 330,27 0.32 714 g,fg,OI 0.30 no 300.60 0,30 D3D 306.08 0,30
620 200.59 0,33 591 310.00 0.32 853 330.£8 0,31 715 340,02 0.31 m 308.01 0.31 838 387.25 0.29
530 200,92 0,33 692 311.12 0.32 654 330.00 0.32 716 350.23 0.31 no 389,11 0.30 S40 307.55 0.""
631 291.25 0.33 593 311.45 0.33 655 331.21 0.31 717 350.54 0.31 n9 369,41 0.30 641 387.64 Q.29
532 291.56 0,33 ~04 311.78 0.33 656 331.53 0.32 718 $0,85 0,31 780 369.71 0,30 042 388.13 0.29
533 201.00 0,32 595 312.10 0.32 657 331.84 0.31 719 351.15 0.30 781 370.01 0,30 843 338.42 0.29
534 202.23 0,33 500 312,43 0,33 658 332,18 0,32 720 351.40 0,31 782 370.31 0.30 044 360.72 0.30
535 202."56 0.33 697 312,75 0.32 659 332.47 0,31 721 351.n 0.31 783 370,61 0.30 045 38Ml 0.29
536 202.00 0.34 698 313.07 0.32 660 332.79 0.32 722 352.07 0,30 784 370.91 0.30 648 380.31 0,30
537 203ZJ 0.33 599 313.39 0.32 681 333.10 0,31 723 352.38 0,31 785 371.21 0."" 847 38o.el 0,30
630 293.56 0,33 eoo 313.71 0.32 6B2 333.41 0.31 724 352.69 0.31 766 311.52 0.31 B4D 389.90 0.29
639 293.09 0,33 601 314.D4 0,33 B63 333.73 0.32 725 352.99 0.30 787 311.92 0.30 849 390.19 0.29
840 294.21 0.32 602 314.30 0.32 664 334,84 0.31 126 353.30 0.31 78B 372.12 0.30 Ii50 390.46 0.29
841 294.64 0,33 eo:! 314.68 0.32 66S 334.36 0.32 727 353.6\ 0.31 789 372.41 0.29
Nolo: At tOOC./oSlslance Is 138.50 ohms. Z-254 (DIN43 760)

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, . . 233
Calibration
RTD Temperature
1° Celsius Increments
For American Curve, Alpha = .00392
-c 0hntS ·c ·Ohms ·c ot'wH 'c Ohms ·c Ohms ·C Ohms -c Ohms 'C Ohms 'C Ohms
-100 .59.57 -38 BUD 24 109.51 sa 133.75 1018 157.53' 210 180.86 212. 203.14 334 226.17 396
248.16
'-99
59.S8 $ 85.20 25 109.90 81 134.14 149 157.91 211 181.23 273 204.11 '335 226.53 397
24851
60.39 "36 85.80 ':!6 110.30 '88 134.52 150 158.29 212 181.111 274" 226.89 39B' 248.86
21)4.47 .. 3:36
.-96
60.80 -35 86.01 27 110.69 89 134.91 151 158.61 '213 181.98 215 204.84 331 227.25·398 249.21
·97
61.21 -34 86.41 2B 111.09 :90 135.30· 152 159.OS 21~ 182.35 276· 205.20 338 227.61 400 24956
-96
.-95 61.63 -. :!!, 85J!1 ,29 111.48 91· 136.68 . 153 159.43 .215 182.72 277: 21l5.57 339 227,96 401 249.91
.g.j
62.04 ~ 87.21 30 111.88 '92 136.07' 154 159.81 216 198.09 278 2<lS.93 340 22!1.32 402 2SO.26
62.45'-31 87.61 31 112.27' 93 136.46 155 160.19' 217 198.47 279 206.30' 341 228.68 403 250.61
·93 62.86 -30 saOI 32 112.66 94 136.84 156 180.57 218 198.84 280 2lI6.66 342' 229.04 404 250.96
-92
63.27 ~ 88.42 '33 113.06 95 137.23 157' 160.95 i!19 184.21 281 2<17.02' 343' 229.39 405 251.31
-91
63.65 .28 88.82 34 113AS 96' 137.62 ;SS' 161.33 220 184.58 282 2<17.39 344 229.75 406 251.66
-so 64.09 -'B 89.22 35 113.84 97 138.00 159 161.70' 221 184.95 283 207.75' 34S 230.11 4Q7 252.01
,-89
185.32 :i84
-sa 64.SO
64.91 .25
:26 89.62 36
90.02 '37
114.24
114.63
98 138.39 .,160 152.06
. 99" 138.71 '161 .162.48
222
'223 186.70 285
2lJ8.12 346 230.46 408 252.36
208.48 347 ZlO.82 409 252.71"
-37 65.32 ',24. 90A2 38 115.02 100. 139.16 162 162.84 224 186.07 288 2Il8.85 3M! 231.18 410 253.06'
-86
-35.
65.73 ,23 90.82' 33 115.42 10i 139.55' 163 163.22 225 188.44 2Irt 209.21 3:'19 231.53. 411 259.41
'-3; 66.14 .• 22
66.55 .21.
91.22 ····40
91.62 "41'
115.81
116.20
102 139.93 '164 16!l.60
103 140.32: 165 163.97
226
227
185.81 '2S8
187.18 21\9
209.57.350 231.89 .412 253.76~
209.94 '351. 232.25.413. 254.11 ",
-83 66.96 -20 92.02 '42 115.59 104 140.70 'loil) 164.35 ~ 187.55 290 210.30 .352' 232.60' 414 254.46';'
~~ =:~':: ~: ::~~ .:: ::::~ :~ ::~:~ :::~: :~ ~~::.':35S:,~::: ~:;!~::~

-82
-61'
-<10
68.18 ·., ,7 93.22 4S 117.71 107 141.86,169 165.48 231 168.66 293 211.39 233.67 ,.i7 255.50
,79
-78
68.59 -16 93.62' 48 118.16 .108. H2.24 '''170 165.86 :232 189.03 294 211.75 '356' 234.03 '-418: 2~.!j5
69.00 ::-15 94.02 .;:47 118.56 109 142.e:! :~17i; 166.24:= 189.40 295 212.11 357,: 234.38 :419 2~20'.
-71
·76
69.41 "14' 94.42 .48 118.95 110 143.01 '172. 166.62 .~ 189.77 ~ 212.48 ·358 234.74 420 2s'ii35 s,
GIlJll ·-1j· 94.B2 :49.119.34 Iii 143.39 173': 166.99 '235 190.14 297' 212.84 "359 235.09 421 256.89
·75
70.22 ".-12, 95.22 .'50 119.73 h:i 143.78 174 167.37 ':236 19051 "298'
213.20 360 235.45 422c' 257.2~·
-74
-73
, -72.
~:~::~
;;,,:9'
71.404
~~ ":~
':,53.,
1i6.42
::~~::r :::~·':i:
"'rr7
12Ml
:::~~:.~~::~
.':'Z23s4'
':1)5
~. ~:~::.;:
'301',
144.93 :'363;
;:~~ :~:
425
:;:.
,'I!8.li068.8801'99"
..6299 214.29 235.51 -, 258.29.
-71
:;.HiI.. ~
~.
-70
-68
71.85
72.26
::.-<1 96.81 :'54.'
".-7 97.21: 55'
72.66 ''--6, g7.61 .56"
121.30
121.89
122116
.115
'''7·
145.31
145.70.;.179:
'118 146.08 :ISO:' lse.83 '~. 19273
214.55' 364 238.87.428
169.25 '24L 192.36 303' 215.01 :.365,231.22
'30539'\~
'427'
366 237.58.428
212155.3.7~
2S8.63
2sa.$8
259.33.
~ 73.07 .;:.5.,98.01 ';57.,: 122.47 ",9. 146.47 :'·i8(. 170.00 .C2q 193.09 '·.,,3fi!' 237.93 .'429. 25S,61'
~:
.~.
-68 73.48'::4' 98.41 '.':58. 122.86 :120::,146.85 '.182' 170.38 ';244' 193.46 3il6. 216.10.~. ~~~~ '~.I. 260·02
73.68 ~~. 98.81 .~59 123.25 121' 147.23 "183. 170.76 :'245 193.83 307 216.45 - ~~ ~ 260.37
..65. 74.29 .,.~' 99.20' 60. 123.64 122 147,61' 184 171.13 ;'2460 ::::~. 216.82' 37Q 236.99 :'43:!' ~.7J'
:~:!!~~~~..3;~,
~
-lI4
.~ .:J:~::
~~:~g
75.51 .' 1 .. 100.40 ,'~:;
t,ti: :~::~~
.:~!:':::]:
124.81 .125. 14a76 ,:167 172.26 ':2(9
194Jl4
1115.31. 311. ~~~ ';.:~~;:: ~~
217.18 .371.
:~.: 28'-:7'5
239.35 .~. :::~
-<11
75.91 :'.2/100.eO '.114,.125.20 126. 149.15 ::.11!8172.63 '~~ .. ,,~.~: .'33,'32. 218.26 :·.~74; 240.41:436 262.10
.~
7632 .. S. 101.19 'S!!' 125.59 -,IP, 149.53 "1.89. 173.01 '~51.'· =~
218.63 '.:375' 2'!O.76 ::437. 262.45
:g::' ~,:::~ :: :~~~'{:l. :;;;: :i.~:~!.~:;'~::::::

,59'
~:sa
;-w. ;;:~ f..;
7153.fa 102.38 ::68:'.126.76.130: 150.67 ".:1# 174.13 ',:'~.' ,19977'5141'
33'1'67'.'"
219.71 '378' 241.82 '440.
;:!: =:;-:
~::~~
263.49
..56.
7134 .;;:7. 102.78 .:f,!9:. 127.15.131:: 151.06 ')93.' 174.51 '2.15' 220.07 ··~~9, 242.17 :'441 263.83
_::.: 78.34 ....·8 103.16',70 127.54: -,13?~
78.75 ., .. 9.103.57:.71",.127.93 .133
151.401 '194
151.82 .. 195
174.88 :.258
175.26.'257
197.sa 3i8 220.43 ':lSO" 2(2.53 :442
198.25 ·'3is. 220.79 ;:38".
242.88
264.18
'~43:.264.S2
<ss
'·52
79.15 .;:~10.. 103.97 .;-'72,.' 128.32 1:J4, 152.20 ,;19!(: 175.63 :'~. 198.61 .)iji( !121.15 ':.3!!2., 243.23 :;.444 264.87
79.56 -. 11 104.37,.73: 128.71 "35',. 152.58 ·:'197; 176.01'.259' lsaM' 321· 221.51 .:'363 243.58' 445' 265.21
'5'-
..'·SO·
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-46
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2;-255

with the permission of OMEGA Engineering, Inc., Stamford, cr 06907
www.omega.com
Thermocouple MAXIMUM TEMPERATURE RANGE

Revised Thermocouple Grade
~~~g~~!Wle Grade
Reference Tables o 10750·C
Extension Grade
32 10392'F
010200"<:
Iron LIMITS OF ERROR
VS. ~:~~:~!:'2q~~.75%
Copper-Nickel Specfat: 1.1·Cor0.4%
COMMENTS, BARE WIRE ENVIRONMENT:
Reducing. Vacuum. 'nett; Umlted Use In
OxidizIng at High Temperatures;
Not Rocommended fOi tow Temperalu:res
Extomlon
~~ TEMPERATURE DEGREES 'C m
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© Copyright OMEGA Engineering, Inc. All rights 'reserved. Reproduced

www.omega.com
Calibration 235
Thermocouple
MAXIMUM TEMPERATURE flANGE
Thermocoople Grme Grade Revised Thermocouple
3210 1382"1'
O1075O"C Reference Tables .
Extension Grade
3210392"F
~O1<>2OO"C
UIIlTS OF ERROR
Iron
(whlthe_1s !l<eali,) VS,
Standatd: 2.2"C or a.7S~
~peclal: 1.1·C«O.4%
COMMENTS, BARE WIRE ENVIRONMENT: .
copper-~NiCkel ~
Reducing. Vacuum. Inert Umi'led' Use In
O"kii2:ing at H'9h Tempefatures;
Not Recommanded fOI Low TemperatUl"es
TEMPERATURE IN OeGREES 'F ExtensIon
REFERENCE JUNCTION AT 32'F Grade
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Thermocouple MAXIMUM TEMPERATURE RANGE

Revised Thermocouple Grade
~~=~fJe
Grade
Reference Tables o 107SO·C
Extension Grade
32to392-F
OIoZOO'C
[ron LIMITS Of ERROR
VS. (whichever Is gl8alef)
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Spedal: 1.I·Coro.4%
copper-~NiCkel ~ COMMENTS, BARE WIRE ENVIRONMENT:
Roduc:lng. VscutJm, ~Brt; limited Usa In
Olldlzlng at High 1'emperatures;
Not Rocommonded 'or Low Temperatures
exlen.ron TEMPERATURE IN DEGREES of
OrMia REFERENCE JUNCTION AT 32'F
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www.omega.com
Calibration 237
l'hermor;ouple MAXIMUM TEMPERATURE RANGE

Revised Thermocouple Gr,od. Th.rmoeoupfe Grade
Reference Tables ~: - 328 10GG2"F
-200I0350·C
Extension Grade
-7G.,21i!"F
-60 10l00'C
Copper L... ITS OF ERROR
vs. ~e.:.::f.o~"l{7Sl'
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Mild OxfdWng. fledUcO>g Vacuum or Inert; Good
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MAXIMUM TEMPERATURE RANGE

Revised Thermocouple Tbermocoupte Grade
Reference Tables - 32B 106S2'F
- 200 1035O"C
Ext.nsfoa Grade
-76 to 212'F
-60 10' l00"C
Copper UMITS OF ERROR
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COMMENTS. BARE WIRE ENVIRONMENT:
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Revised Thermocouple Thermocouple
Grade Thermocouple Grade
Reference Tables - 328 to 22B2'F
- 200 10 1250·C
Exlension Grade
32 10392·F
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TYPE
Reference
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Nickel-Aluminum
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COMMENTS, BARE WIRE ENVIRONMENT:

N.I.S:r.
Monograph 175
RovlsccJto
ITS·90
Extonalon
Qrado
~: Clean Oxidizing and InBrt~Uml100 Use In
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Range; Most Popular Calibf'3lkln
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Calibration 241

Thermoccup'le Grade Revised Thermocouple
- 32810 2,;I82·F
- 200 '0
1250'C Reference Tables
Exten!;Jon Grade
32 10392"F
0102OO"C
UMITS OF eRROR Nickel-Chromium
(whicheVer '" 9'••,.,)
StaOO",d: 2.2'C Of 0.75% Above O'C VS.
22C (J{~8efow ere Nickel-Aluminum
Special: Ll·CorO.4%
COMMENTS,BARE WIRE ENVIRONMENT:
Clean (b:ldi,zing and Inert: UmlIed Use if'l
Vacuum or Re~ucjng; Wide Tempe-rature
Range; Masl Popular Calibralion
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Thermocouple MA)(JMUI4TE.W'ERATURE RANGE

Revised Thermocouple Gracie Thermocouple Grade
Reference Tables - 328 to2282"F
- 200 to 125O'C
Extension Grade
3210 39TF
Olo2OO"C
TYPE
Referenco
Nlckel-Chromium
VS.
LIMITS OF ERROR
(whlchovef is grealer)
Slondard: 2.2"'C or 0.75% Above o-c
0'
Et~
Tablos Nickel-Aluminum 2.2"C 2.0% Below O"C
SpncJnl.1.1·C 01'0.4%
COMMENTS,BARE WJAEENV1RONMENT:
N.I.S.T.
Monograph 176 ~~(Jc:~·~~I~~Su~~~~~~~~eu,:~~
Rango; Most Popular Calibration
RevIsed to exton.IDn TEhlPl!nATURE IN DEGREES"F
ITS·90 Qrado nEFEnENCE JUNCnON AT 32"F
ThotmOoIocttlc Vollogo In MIlItvoI14

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ThetmOCoupie
Grad. ,RevisedThermocouple
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with the permission of OMEGA Engineering, Inc" Stamford, CT 06907
www.omega.com
Appendix A-7
CONVERSION TABLES
, Temperature Conversion Chart (Courtesy Omega)
Pressure Conversion Factors (selected)
PRESSURE CONVERSION FACTORS
Refer to the ISA Handbook of Measurement Equations and Tables f~r more
conversion factors than you will ever need.
psi = in. of H20 x (0.0361273)
psi = in, of Hg x' (0.491154)
psi = mm of H20 x (0.00142233)
psi = mm of Hg x (0.0193368) I
I
psi = kg/cm2 x (14.223)
psi= bar x (14.50377) ,
I
j
psi = mbar x (0.014503 x 10-2) I

= Pa x (1.4503 x 10-4)
psi
psi = kPa x (0,1450377)
I
"
;co
= millitorrx
psi (1.93368 x ,10-5)
I
,-.0
245
246 Conversion Tables
Temperature Conversion Chart

°C"" (OF - 321 ·F.~·C ..32 TABLE EXAMPLE:
Kalvtn.,·C + 273.15 Ronklno A ·F + 459.67 To Convort 1000·C to -F, look up rooo and read leU
c--;:p -,----
From
-u;e
-4GD
10·C
-272.22
,. ." F,om
-Me
10'C
·180,09
·107.70
'oop
·I~.'
·2.0.2
Film,
.I!11l
·150
to"C
-res.sa
·104...4
To Convert 1000·F 10 DC,lookup 1000 and rood righl
.. "I'
-+17.6
+21.2
From
....
-0
'o'C
·U,22
·21.\1
.. OF
287.6
291.2
F.om
142
,.4
te-e
61-1 t
G=
·271.11 -000
.. 94 ·27000 ·,04 ·'0e.G7 ·2.5.2 ·1114 ·103.33 ..24.8 -4 -20,00
.,11.01) 2tH.8 1<0 G:llJ
-4,. '.<1.6 ·152 ·102.22 +28.4 2!lO.4 1<0 &4.44
..
.200 C~ .:J02 "05,00
..j'D ·207.70 .:JDO ·184.",( ·.30.0 ·150 '101.11 +-32.0 0 ·17.78 302.0 160 BS.5G
.., '200.07 ·.90 ·183.33 ·23.. ·14. '100.00 ill.6 2 ·'6.07 3OS.0 152 60.67
-4'0
-4'4
"O~,DO
·2G4.·111
·200
·.D.
·20.
"02.,
·101.1'
,'00.00
,,30.2
'227.2
·223.0
·14.
·144
·142
·00.90
-07.78
·00.67
+30.2
"'2.0
...
OA
•
0
0
"0.66
·1.,44
·13.33
3O!l2
3'2.8
310.4
164
lG.
150
07_76
00.69
70.00
"'.2 ·203,"
""0 ·2.222 ·200 ·170.00 ·220.0 ·140 '00.50 +50.0 10 "2.22 3~O.O 180 11.11
..(01
..(08
-4:)4
..(O~
..(00
·2Ot 11
-200 00
-2SO~0
-2!l.78
·2SO.07
·2M
·288
·.14
·212
·~IO
·m.7.
,'70.07
-11a.GO
·174,.. 4
·17:1,33
·2115."
·2'2.0
.2(1).2
·205.8
.202.0
·1:10
-130
·'34
·132
·130
'04,"4
-03.33
·02.22
·01.11
·00.00
053.0
+31.2
+60.0
+04.4
+<18.0
12
1.
10
'8
20
·11.11
,,0.00
·0.e 0
·7.70
-6.07
323.0
327.2
330.0
334,'
=0
..
102
,
104
"8
170
72_22
7333
7·.... "
7$_!.G
16.07
-42B ·215.15D ·270 ·172.22 ·1DS.4 ·12' -OU!! +71.G 22 ·5.SO 341.5 172 77.10
..no ·87.70 .78.2 24 .... 44 34,.2 17' 78.89
..
·21l-'-" ·270 -171.'1 -'04.2 ·12B
-424 ·253.33 ·274 -191.'2 -'24 ... .67 .78.8 28 .:J.J3 348JI 178 00.00
-422 -252.22 ·467.6 ·272
·'70.00
,'88.09 -187.6 ·'22 -05.50
-&4./14
~
_.0
26
30
·2.22
-1.11
352.4
35M
178
110
81.11
82..22
-420 ·251.11 ·45<.0 -27D -'87.78 ·'8>1.0 ·120
""0
-4'0
·25D.00
-240.09 ..,,,0.8
"'50.4 ·200
-266
-108.87
·'05.66
-'BO.'
·176.8
·118
-118
-83.33
-82.22
.aO.O
+93.2
32
3.
0.00
1.11
359.8
363.2
'.2
184
83.33
84.44
-414 -247.70
-246.87
~43.2
-439.6
·264
..2.62 ·'64.~'
-16J.3J
·'73.2
-'69.6
-114
·112
-0'.11
-80.00
+96.8
..100.4
38
38
2.22
3.33
366.8
310.4
118
188
85.~
80.87
..
"'2
-110 -2'S.56 -436.0 -250 -'-161.11
62.22 ·165.0 ·110 -78.89 +104.0 .0 4.44 374.0
377.6
190
. 192
87.78
"00 -2«."4 -432.' -258 ·1S2.4 ·108 -77.70 107.6 42 5sa

381.2 104
88. ..
90-00
0400
-4..
-243.33
·2412.22
.428.8
-425.2
·058
·254
,'60.00
-'5&.89
-'58.8
·'55.2 .,04
·108 -76.S7
-75.56
111.2
,,4.2 4&
8.67
7.70 384.8 '96 91.11
"'02 -241.11 """21.6
....,
-252 -157.78 -rst.e ·tll1 -74.~ 118.4 48 8.89 saa.' Il1B 92.22
-400
.:JUD
.:Jas
·3Q4
-240.00
·23••119
·237.78
-4.8.0
-4'4.'
"'0.8
·407.2
..248
-246
444'
,'50.67
·155.56
-154.44
'153.33
-'''8.0
-144.4
-140.8
-131.2
...
-tilO
·86
-94
·73.33
·72.22
·71.11
-70.00
122.0
125.6
129.2
13Z-S
59
52
54
58
'0.00
".It
'2.22
13.a~
~~
399.2
392.0
402.8
200
202
2.4
2.,
93.33
94.4"
95.56
96.61
·236.67
.:J12 '235.50 "03.6 ·242 "52.22 -133.6 -92 ·68.69 136.4 58 14.4' 408.4 206 97.78
-310 -400.0 ·240 -151.11 -'30.0 -90 ·87.78 '40.0 '0 15.56 410.0 210 98.89
..
·234."4
.:J5D
·380
-314
-382
·233.33
·232.22
·231.11
·230.00
-396.4
-JIIUI
-389.2
-385.6
-382.0
·236
-238
·234
·232
-230
·'50.00
-148.89
-147.78
-148-67
·145.56
.,22.2
-1245,4
-119.2
-115.6
·112.0
...
-08
-86
-02
-80
·66.87
-65.so
-04_44
-03.33
-62.22
'43.6
147.2
,50.8
154."
,58.0
62
14
68
70
'6.87
17.78
18.89
2O.DO
21.11
413.0
417.2
420.8
42-4.4
_0
212
214
21.
218
220
100.00
lQI.11
'02.22
,03.33
104.""
.:J80 ·22o.e9
-378 ·227.78 -370.' ·226 -144..... -108.4 ·78 ·61.1' 181.6 72 22.22 431.6 222 105.66
-370 ·220.07 -374.0 ·226 ·,..'3.33 -'04.8 ·16 ·80.00 165.2 14 23.33 "352 22. 100.07
-374 ·226.50 -371.2 ·22. "'2.22 -101.2 .7< ·58.00 '88.8 78 24.... 438.8 22. 107.7.
.:J72 -224."" -307.0 ·222 -1~I,U -07.8 ·72 ·57.78 172-4 78 2UO 442.4 22' 10~.OO
.:J70 ·2.23.33 -304.0 ·220 ·,"0.00 ·0'.0 ·70 ·G0.07 176.0 00 20.67 440.0 230 110.00
-308
.3UO
·222••2
·221.11
-3(i0.4
~SG.O
'2'.
·211
·'36.00
,'37.70
·00.'
-00.8
..,.-G. ·G5.50
-04.'4
'79.0
'032
82
84
27.70
20.88
'40.0
453,2
232
234
111.11
112.22
-304 '220.00 -asaz ·214 ·130.07 -03.2 -G. ·03.33 '80.8 08 30.00 460.0 230 113.33
.:J02 ·2,0.00 ~o .• ·212 ,'35.60 ·70.8 -Il2 ·62.22 10D.4 80 31.11 '00.4 230 114.404
.:JGO -.'1.78 ~O.O ·210 ·134."" ·70.0 -IlO ·51.11 104.0 110 32.22 4601.0 240 115.56
·358 '210 .• 7 -342.. ·2111 .133.33 -7M ·58 ·50.00 107.8 82 33.33 467.0 242 116.67
.:JOO
·3:1<1
'2'6.50
·2'4.44
-330.8
·3JS-Z
·208
--204
"32.22
·131.11
-e3.1l
~.2
·01.6
•••
.~ "8$
.. 7.7.
.. O.ll7
20'.2
204.8
20D.4
94
89
a8
3.....
35.IiG
39.07
471.2
474.8
478.4
244
240
117.70
118.89
.:J52 -2'3.33 ·331.6 -202 ,'30.00 ·52 2'0 '20.00
.:JSO --2'2.22 -32G.O ·200 "20.89 ·Ga.O ·5f -4S.66 2'2.0 100 37.70 -W.O 2S6 121.11
-3·1.
·3"0
'211.11
'2'0.00
-324,11
-320.0
-109
·190
·'27.1.
·,20.07 '~."
·66.0
-4.
-40
--1".44
...3.33
2'6.0
2102
102
104
38.ao
40.00
'85.6
'09.2
262
254
122.22
123.33
-3~4 ·200.80 ·3'1.2 ·104 -'26.60 "'7.2 -4' "'2.22 222.8 to. ".11 492.0 ",0 '24.44
-342 ·207.78 -3J3.0 ·182 -124.4~ -43.0 -4. ...,1.11 228.4 100 42.22 400.4 258 125.58
-340 ·200.07 oJ1D.Q ·100 -123.33 "0.0 ..,0 ...0.00 230.0 110 43.33 600.0 2.0 120.61
·338 -205,5<; .3011.' ·1118 -122.22 -38.4 ·38 -38.89 233.a 112 603.8 202 127.78
.:J30
.:J34
-332
·204•••
·203.33
·202.22
-302.8
·299.2
-295.&
·168
-184
-11ll
-121.11
,'20.00
-118.89
-32.8
''19.2
-25.6
.".
.:J4
-32
-37.7a
·36.67
-asss
237.2
2.0.2
24•. '
,,1
114
118
".4'
."50
40.07
47.78
507.2
6'0.8
5" .•
2M
"5
2'"
128.89
fSO.CO
'3\.11
·330 -201,11 -2920 ·180 ·117.78 -22.0 .:JO -34."4 248.0 120 48.s!) 518.0 270 132.22
-320 ·200.00 -289.4 -178 '118.07 -18.4 ·28 -33.33 251.6 122 50.00 52'.8 272 '33.33
.:J28 ·108.80 ·284.8 ·17& ·115.56 ·14.8 -26 "2.22 255.2 124 51.11 525.2 274 134.....
-ai.n
·32.
-322
-320
"07.78
-106.07
·'05.50
-281.2
-277.6
-274.0
-17.
·172
~-170
..1\4.of4
'113.33
-112.22
-11.2
-1.6
-4.0
....
·24
-2.
-30.00
·28.89
256.8
262.4
266.0
128
128
'3.
52.22
53.33
54.44
528.8
532.4
5:]8.0
278
278
280
135.56
136.67
137.78
-18 ·27.78 269.6 132 55.56 539.6 282 136,89
-310
·318
·'0 ••••
·103.33
-270.4
·266.8
·'66
·166
-111.11
-110.00
-0.'
-13.2 -18 -26.67 273.2 134 56.67 543.2 284 140.00
-314 ·'02.22 ·263.2 ·184 -,GO.89 -.6.8 ·1' -25.56 276.8 ,38 57.78 548.8 2•• 141."
·312
-310
·181.11 -259.8
-256.0
·162
-166
·107.78
106.67
...10.•
+1•. 0
-12
-1.
·2".44
-23..33
28tJ.'
284.0
131
140
58.89
GO.OO
SSM
... .0
288
m
'''2.22
'00.00 ' .. 3.33
..-:

www.omega.com
247
Calibration
tc 'f'
557.8
From
2.2 1414.44
to"
870.8
""'m
466 241.11 1832.0 1000
,_
'''"
537.78
543.33
339aO
3416.0
From
1810I_,..., to·C
1021.1
1026.7
to 'F
4964.0
4S82.0
From
2740
2150
to'C
1504.4
1510.0
,_
294 US.58 81<4.4 458 242.22 1850.0 10322 5000.0 27Bll 1515.6
561.2
564.8
558.•
296
290
146.67
147.78
878.0
881.&
470
472
243.33
244.44
1868.0
1886.0 1130
1040
548.89
554.44
560.00
3434.0
3452.D
3470,0 · 1910
'''' 1037.8
1043.3
5018.0
5036.0
2T7D
21110
1521.1
,526,7
300 'oIS.89 885.2 47' 245.56 1904.0
572.0 5054.0 %780 15322
246.67 1922.0 1050 56S.56 3489.0 104a.l1
57515 302 150.00 686.8 47S 571.11 35()6.0 1930 1054.4 5072.0 2801 1537.8
5792 304
~
16t.l1
152.22
892.4
896.0
471
481
247.18
248.89
Hl~.o
1958.0
1'"
,.70 576.67 3524.0 1940 1060.0 5090.0
5108.0
2411
28:20
1543.3
1548,9
Sll2.8 250,00 197ti.o 11180 582.22 3542.0 1950 1065.6
5I!6.4 3CI8 153.33 893.6 412 1960 1071.1 5126.0 2830 1554.4
251.11 1994.0 logO 587.78 3560.0
590.0 310 164.44 903.2 48' 2641) 15EO.0
1100 S93..33 3578.0 1910 1076.7 5144.0
.312 155.56 906.8 488 25222 20.12.0 5162.0 2!50 1565.6
59315 .253.33 2030.0 1111 5S8.89 3596,0 1980 1082.2
597.2 314 156.67 910.4 488 604.44 ~14.0 19'5lD 1087.8 5190.0 2860 1571.1
157.78 91• .0 490 254.44 2048.0 1120 2870 IS76.7
.600.8 31' 1130 610.00 3632.0 2000 1093.3 5198.0
31. 155.89 S17.6 492 255.56 2065.0 1098.9 5216.0 2660, 1582.2
604.4 114D 815.56 3650..0 2010
...
320 '60.00 921.2 494 256.&7 2084.0
608.0
su.e
6152
618.8
.22
324
826
161.11
162.22
163.33
924.8
928.4
932.0
4"
SOli
257.18
256.89
260.00
2102.0
2120.0
2138.0
1150 .
"'1&0
1170.
621.11 3568.0
626.67 3S86.o
632,22 3704.0
637.78 3722.0
2020:
2<130'
2040
2050
"04.4
"10.0
1156.6
1121.1
=0
5234.0
5270.0
5288.0
21M
2900
291D
2920
t597.8
1593.3
1598.9
1604,4
935.6 502.' 261.1t 2156.0 1160. 293(1' 1610.0
622.' 328 184.44
11911 643.33 3740.0 2050 1126.7 S306.O
.30 165.56 9392 S04 • 262.22 2174.0
628.D 2!l7D. 1132.2 5J2oUJ 2940 1615.6
33i , ... 61 942.8 500 263.33 2.192.0 . 1200 648.tIS 3758,0
2081) 1137.8 5342.0 "!!ISO 182,.t
6<9.6 264.44 2210.0 12f0 654.44 3776.0
633.2 334 167.78 940.4 501 660.00 3794.0 2000 1143.3 5360.0 2960 ,626,7
336 168.a9 950.0 510 265.56 2228.0 "1220 5:178.0 2970. 1632..2
636.8 268.67 2246.0 1230 66S.56 3812.0 2100 1148.9
840.' 338 170.00 953.6 51' 2110 '154.4 5lIS6.0 2!6D, 16372
611.11 3830.0
...
171.11 9572 514 ' 267.78 2284.0 .1240
544.0 340
51', 50414D :me 1843.3
.."
678.67 3848.0 · 2120 1160.0
172.22 9CSO.8 268.89 2262.0 1260 5432.0 3000 1648.9
847.6 342 126(1, 682.22 3886.0 2.1:30 1165.6
344 173.33 964.4 270.00 2300.0 1171.1 5450,0 3010 1654..4
651.2 271.11 23UI,Q 1270. 887.78 3U4.0 2140
854.8. 174.44 95:0.0 520 2150 117eo7 S488.O 3n20 1660.0
272.22 2336.0 12!O . 693.33 3902.0
.... 4 348
350 '
175.58
t76.67
971.6
9752
52.
524 273.33 2354.0 1210 . &98.89 :mil.0 216ti" ',82.2 54B6.O 3030 1665.6
662.0 S!i04.0 3040 1671.1
352' 528 274.44 2372.0 1300 .. 704.44 3938.0 · 2170', 1187.8
'3050 1676.7
665.6 177.78 978.8 710.00 3956.0 .2180 . 1t~..3 5522.0
17$.89 982,4 ·528 276.58 2390.0 . 1310 3060 1682.2'
669.2 .54 1320 715.58 3974.0 2190' '198.9 5540.0
27".~7 2408.0
572.8
616,4
680.0
356
358'
'!""
180.00
lSI. 1,
10222
986.0
989.6
9932
530
532
534
277.78.
273.89'
2426.0
2+14.0
.~~: 721.11 3992.0
72ti.tn 4010.0
22DO
221'
1204.4
1210.0
55Il8.Il
5516.0
3070
3Clao
·3090
1687..8
1693.3
1656.9
732.22 4028.0 1215.6 5594.0
683.6 362 183.33 996.8 536 280.00 2462.0 1350
737.78 4046.0 1221.1 5812.0 '3100~~ .1704.4.'
184.44 1000A 5'0 281.11 2490.0 1360. 3150' "732.2'
681.2 384 4064.0 1226.7 57112-0 _~ :1760.0
::=~;::::li1
358' 1004.0 · 640' 282.22 2496.0 1370 743.3.
-u::
690.8 18li.,56 lZl2.2 5'192.0
186.67 1007.6 '542· 283.33 2516.0 748.851 4002.0
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© Copyright OMEGAEngineering, Inc. All rights reserved- Reprodl,lced I

with the permission of OMEGA Engineerh{g,Inc" Stamford, CT 06907
www.omega.com
I
Appendix B
ANSWERS TO CHAPTER
REVIEW QUESTIONS
i
CHAPTER 1 REVIEW QUESTIONS j
1. Match the term on the left with the definition on the right. i
i
_E_ Calibration A. permissible deviation from specified
value
_H_ Instrument Range B. upper and lower values specifie&_fpr
I
I facility I
! .a, Calibration Range C. algebraic differencebetween the
upper and lower range value
_E_ Accuracy D. adjustment used to produce a parallel
shift of the input-output curve
.. ....A_ Tolerance E. comparison of instrument to a known
_1_ Traceability
value
F. percent error
I
..J2_ Zero G. characterizes the dispersion of the I
values that could reasonably be ·1
attributed to the measurand
.J:..... Span H. upper and lower values specified by
manufacturer
.. _G_ Uncertainty 1. measurement related to standards

through an unbroken chain of
comparisons
2. Which of the following errors is typically not correctable?
C. Linearity
249
250 Answers to Chapter Review Questions
3. Why should a calibration technicianhave:

A. Honesty and Integrity?
Calibrations must be performed in accordance with procedures
and must be properly documented even when the calibration
department may be understaffed and production schedules
demand unrealistic completion requirements.
B. Attention to detail?
The minute a technician is not paying attention to detail, safety
and proper performance nre jeopardized.
C. Excellentdocumentation practices?
If it isn't documented, it wasn't done. The impression of qllalih) is
determined by the content and appearance of documentation.
D. Understanding of processes?
Understanding processes, particularly how the instrument
monitors and controls the process, will enable the technician to
more efficiently calibrate process instrumentation without
disrupting the process. Also, the technician is more capable of
identifying and troubleshooting the cause of process problems.
4. What are the advantages of performing a field calibration?

Disadvantages?
ADVANTAGES OF FIELD DISADVANTAGES OF FIELD

1. May save time 1. Availability of instrument for

2. May identify and allow trouble- cleaning and inspection is limited
shooting of installation problems 2_ Difficult (and sometimes
3. Performed in actual ambient impossible) work environment
environment 3. Utilities (electrical, air, vacuum)
may not be available
Calibration 251
5. What are the advantages of performing a bench calibration?

Disadvantages?
ADVANTAGES OF BENCH DISADVANTAGES OF BENCH

,
1. Removed, cleaned, inspected 1. May take more time (removal,
.~ 2. Better work environment reinstallation)
"
3. Fixed calibration setup and utilities 2, Minimizes identification of
,I (electrical, air, vacuum) available installation problems,
3. Not performed in actual ambient
J
enviroriment where installed
II,
6. What are the advantages of performing a loop calibration?
Disadvantages?'
ADVANTAGES OF LOOP DISADVANTAGES OF LOO~~ "
CALIBRATION CALI BRATION ...-

1. Entire loop, including sensor, is 1. Wrong instrument may be adjusted ..;:
verified within tolerance to bring the loop within calibration

2. Mistakes on re-connect minimized 2. Not as compatible with
3. More efficient use of time to do multifunction calibrators used f9r ,
"
one calibration for loop as opposed "paperless" data collection

to one calibration for each loop
instrument .:£: ·i·
7. What are the advantages of performing an individual instrument,

I
, calibration? Disadvantages?
ADVANTAGES OF INDIVIDUAL DISADVANTAGES OF

CALIBRATION INDIVIDUAL CALIBRATION
1,.Correct instrument will be adjusted 1. Entire loop is not verified within.

2. More compatible with multifunction tolerance
calibrators 2. Mistakes on re-connect
3. Less efficient use of time to do one
calibration for each loop instrument
as opposed to one calibration for
the loop
8. What are the advantages of classifyinginstruments by their

"importance/ criticality" to a process?
• may be helpful in assigning calibration frequencies
• investigate oui-cf-tolerance calibrations more efficiently
9. Arrange the traceabilityhierarchy below,beginning with lowest

level and ending with the highest. __c_, ~ L .s: __IL
A. Primary Standards
B. WorkingStandards
C. ProcessInstrument
D. NIST(or recognized national standard)
E. SecondaryStandards
CHAPTER 2 REVIEW QUESTIONS

1. List the advantages of each procedure development method below.
A. straight from technical manual
• Very little time/resources required to develop procedures
• Technically accurate and detailed instructions jor the specific
instrument
B. genericprocedure for an instrument type
• Limits number of procedures to a manageable level
• Can be a good starting point for new facilihj startup until more
effort can be devoted to procedure development
C. procedure developed for a specificmanufacturer/model or
specificinstrument in the plant
• Calibrations are performed the same by all technicians
• May take into account the affect on process
• Technically accurate and detailed instructions Jor the specific
instrument
Calibration 253
2. If.test equipment with the specified accuracy is not available to

perform the calibration, what should you do?
Notify supervisor.
3. If a step of a calibration procedure cannot be followed as specified or

a procedure does not exist, what actions would you take?
Place instrument in a safe condition and notify supervisor.
4. What elements of a calibration data sheet reflect that the calibration is

NIST traceable?
Record the unique identification of any test standards used to perform the
calibration and, if required by procedure, record the calibration due date of
the standard. _',-
5. 'For an established facility, what is the most likely resource for -.,:
".
determining the calibration frequency of a new instru.n:{ept? .
-r-:
Calibration histon; of the specific.instrument and identical mfg/model.A -,

~I
6. For a new facility, what is the most likely resource for determining
initial calibration frequency?
Past experience.
7. What justification can be used to increase the calibration interval

(perform less often) of all instruments of the same type?
Once the calibration history of several calibrations have been performed on
similar instruments and the as-found data has been well within tolerance,
the calibration interval can be increased (with proper documentation of the
analysis and proper approvals per your company procedures). .
8. What event(s) can lead to'decreasing the calibration interval

(perform more often)?
Failed "as-found" data on successive calibrations (or on ~ven one calibration
in some cases).
I-
, >
9. Match the resources on the left with content on the right.
.c, P&ID A. includes general instrument

specifications for the facility
_Q_ Instrument Specification B. includes instrument range
Sheet capability and instrument
accuracy
E Loop diagram C. detailed overview of a process
system
_A_ Project specifications D. detailed device requirements
.JL Manufacturer's E. includes all associated
Specifications electrical and piping
connections
10. What is the purpose of a calibration seal?
Cover adjustments so that any unauthorized adjustments are detected.
11. What is theminimum information required on a calibration status

label?
• Instrument Identification (such as Tag Number, Instrument ID#, or

serial number)
• Date of calibration
• Next calibration due date
• Technician toh» performed the calibration (initials, employee ID, etc.)
12. When should a Limited Calibration status label be used?
For instruments that are not calibrated throughout the range of the
indication.
13. What criteria must be met for test equipment to be used for
calibra tion?
• Specified in the calibration procedure (appropriate range and accuracy for

calibration performed)
• Within its calibration periodicitv (do not use beyond calibration due date
with approved extension)
Calibration 255
• Recorded on Calibration Data Sheet (to ensure process instrument

calibration is traceable to NIST)
Situation for Questions 1-10: TT-300is installed in a process tank, which

is currently in production. This is the first calibration after initial startup.
Use the references in Appendix A to answer the following questions.
.accuracy for TT-300?(Appendix A-3)
Calibration Range specified is O.O°Cto l50.0°C - 4.00 rnA to 20.00 mA
(from row 112 of the Instrument Specification for IT-300) and the f
manufacturer's specified accuracy is 0.2% .span (from row 53 of same

specification) .
·:ft'
2. Select the correct procedure(s) that could be used for this calibr~tion
. of 1T-300? (Appendix A·4) ;::::
SOP-CAL-08, Calibration/Calibration Check 0/ RTD Input Electronic

.~
Temperature Transmitters. . ~. .,
3. What local/remote indications should be recorded during calibration

of TT-300?(Appendix A-1) , . r
;
Indication on TIC-300 (the components in the loop are the RTD (TE300),
transmitter (TT300), Indication controller. (TIC-300), lIP (TY-300) and the
control valve (TV300). The only indication in the loop is the TIC.
4. What must be done prior to removing RTD for calibration of TT-300?

(initial conditions of SOP) .
'~'
• Determine if temperature control loop performs control function which ,

I
t
could produce undesirable operating results while simulating test signale

(from the p&rD we can see that this instrument loop controls the cooling.
water supply to the jacket of Reactor R-300. Therefore, ifreactor R-300 is
in operation you 'Wouldneed to coordinate with production to determine
appropriate conditions to perform the calibration. In this case you 'Would
likely wait untzlsystem is not in operation).
• Determine if RTD is in a well or not (P&ID indicates the RTD is

installed in a well)
5. What are the correct resistance values to input for 10%,50%, and
90%? (refer to the correct RTDTable in App A-6)
From the Instrument Specification for TE-300, row 25 specifies 0.00385
ohm/ohmiC. Therefore:
10% = 15.0C ::;:;

105.85 ohms
50% = 7S.0C = 128.99 ohms
90% ::;:;
13S.0C ::;:;
151.71 ohms
6. What are the expected transmitter output values for the resistance
inputs from step 5?
10% output = 5.60 rnA
50% ouipui > 12.00 rnA
90% output::;:;18.40 rnA
The transmitter output is 4.00 to 20.00 rnA (span of16 rnA). 10% of 16m A
is 1.60 mA. The 1.60 mA must be added to the zero value of 4.00 mA. The
result is an expected output of 5.60 mAJor the 10% value. Fifty percent of
16mA is B.OOmA, and B.OOrnAadded to 4.00 mA results in 12.00 mA at the
50% value. Ninety percent of 16mA is 14.40mA, added to 4 mA results in
1B.40 mA at the 90% value.
7. Indicate the correct test equipment hookup for calibration of TT-300?
Deeede D ox
or other
Reslstenee
Slmulntcr
Temperature Transmitter
Tf-JOO
(polarity
does not
moUer for
resistance
input)
\
\
\
.:;;
"
Calibration 257
8. Assume a calibration tolerance of ± O.soC/D.OS rnA. With the results

indicated what instrumentfs) in the loop require(s) adjustment?
transmitter IT-300
% INPUT TT-300 rnA OUTPUT TIC-300 INDICATION
1Q% 5.70 15.9

50% 12.10 75,9
90% ' 18.50 135.9
9. What type of error is indicated by the results of question 8?

A. Zero error.
10. Following adjustment, all as-left data is within tolerance. What must
be performed to place the instrument loop back in service?
• Disconnect test equipment
• Reconnect RTD and mA output
• Install RTD in well
• Place controller in automatic
• Notify appropriate personnel of work performed
Situation for questions 11 - 15:You.will be performing an initial .1:

calibration of TT-200 on the bench, prior to installation. Use the references
in Appendix A to answer the following questions.
11. What are the correct reference temperatures and corresponding

millivolt values to input for a,calibration check at the following test
'j points? (The Instrument specification for IT-200 indicates range is 32.0°F
I
, to 212.0°F and the input sensor is Type T thermocouple. Note: 'itis typically
not necessary to look up millivolt values since calibrators will read out in
temperature), '
% INPUT lEMPERATURE MILLIVOLTS

0% 32.0OC . 1.279 rnv
25% 77.0oC 3.222 mv
50% 122.0oC .5.325 mv
75% 167.0°C 7.566 mv
100% 212.0oC· 9.930 [l1v
12. What are the expected transmitter outputs for the following
simulated inputs?
0% 4.00
25% 8.00
50% 12.00
75% 16.00
100% 20.00
13. Indicate the correct test equipment hookup for calibration of TT-200.
Thermocouple
Silnulntor
24VDC
Pewee
Supply
14. Assume a calibration tolerance of ± 1.0oP / 0.08 rnA. With the results
tolerance? adjust span
0% 4.00
25% 7.98
50% 11.96
75% 15.94
100% 19.92
15. Following adjustment, all as-left data is within tolerance. What steps
remain to complete the bench calibration?
Disconnect test equipment and restore transmitter to original condition.
Calibration 267
4. Prom your answer to question 1 and the procedure selectedin

question 3, what are the correctinput values to simulate TY-300?
4.0 mA, 12.0 mA,and 20.0 mA .
5. What are the expected output values for the inputs applied from
question 4?
3.0 psig, 9.0 psig, and 15.0 psig, respectively (assume direct acting IfP).
6. Indicatethe corr~cttest equipment hookup for calibration of TY-300.

Pressure
Standard H
UP Transducer
rv-soo
3.00 LP
rnA .
Output simulator
~
30 psig Supply'
L.3iJ . !,
Pressure
Source
7. With the results indicated what instrument irt the loop requires
adjustment?
lIP
.% INPUT OUTPUT (PSIG) VALVE POSITION
0 3.2 2%
50 9.5 54%
100 15.8 100%
8. How would the calibrationrequired in the previous step be

performed?
With 4 mA applied to the input adjust the zero for an output of 3.0 psig ..
Apply 20.0 mA to the input and adjust the span for 15.0 psig output. Repeat
zero and span until no further adjustment is required.
9. If a control valve is being checked during an T/P calibration and the

liP is properly calibrated, what is the most likely cause of an
improper valve position (no positioner is installed)?
Bench set of the control valve spring is not matched with the output of the
liP.
10. What is the purpose of a valve positioner?
Increase or decrease the air pressure from the liP to assure proper
positioning and finer control of the control valve.
11. Is the action (direct or reverse) verified during a positioner

calibration?
Yes.
12. What is the basic procedure for calibration of a positioner?
Apply pressure for the desired test points to the input of the positioner and
record corresponding valve position. This can be combined with the liP
calibration by teeing in the pressure standard and leaving the positioner
connected to the output loop.
13. What is the basic procedure for calibration of a control valve?
Apply pressure for the desired test points to the input of the control valve
and record corresponding valve position. This can be combined with the lIP
calibration by teeing in the pressure standard and leaving the control valve
connected to the output loop.

1. What are the ideal t1m V input values for a pH meter at 4,7, and 10
pH at 25°C?
177.48 mV, 0 mV, and -177.48 mV, respectively.
2. What buffer solution is used to standardize a pH meter?
7.0 buffer solution.

Calibration 269
3. What buffer is preferred for calibrationofthe slope? Why?

4.0 buffer solution because pH buffer solutions above 7.0 pH are less stable
and have a limited shelf life.
4. What is the purpose of a pH diagnostictest?

To evaluate electrode performance.
5. What are the basic steps of a pH

. diagnostictest?
.
• Short the inputand adjust for reading of 0.0 mv

• Insert pH electrode in 7.00 pH buffer solution and record this mv reading
as the asymmetnj potential (AP)
• Insert pH electrode in 4.01 buffer solution and record mv reading
• Calculate slope ..;".:~. ',-' .._," .."
6. What is the diagnostic-testacceptancecriterionthat determines. ,~~ .~:s.?

~:;;;"?.
whether the electrodeshould be replaced? ~ "2~~:
••••:"'1
':~J:-:::~
if AP is). ± 40 mV and/or the slope is < 91%.
. 1':
:~'1'" .
:~":'··-:F
7. What test equipment is used to simulatea conductivity signal tO~tt

conductivitymeter? ..n.
Resistance simulator such tis a decade box.

,I
8. How is the resistancevalue input for a conductivityinstrument
calibrationdetermined?
Resistance is the inverse of conductivity (Resistivity = 1T conductivity).
9. How is the 25°Ctemperature simulated during'a tonductivitr or
resistivity instrument calibration?
A resistor of the specific resistance to simulate 2SOCfor the specific
conductivity instrument is connected in place of the temperature sensor
leads (or a separate decadebox could be connected set to the required
·resistance).
10. Why is it important to know the cell constant for a conductivity

calibration?
The cell constant is used as a multiplication factor for the indicated

conductivity. If the cell constant is not knoum or accounted for, the
calibration will likely result in significant error.
INDEX
acceptance criteria 21 cell constant 107

accuracy 2 classification of instruments 12
ratio 3 conductivity 108
actuator 94 measuring 107
air pressure 49 control system technician (CST) 8 i
J
as-found data 23, 54,68,,69 characteristics 9
as-left data 23,69 control valve 94 .1
atmospheric pressure 49 calibration 97
coriolis.mass flowmeter 81
I
bench calibration 11 - correct fittings 51 .~,
Bourdon pressure gauge 53. critical 12 ~
~:
calibration 1 dip transmitter calibration 83 .

bench 11 dial thermometer 36
control valve 97 differential pressure 61, 78
dip transmitter 83. distributed control system (DeS) 42
data sheets 21 documentation 17
equipment combined accuracy 6 dry legs 66
"
field 11 .."
flowmeter 82 elevated zero 64
liP transducer 95 EPA 13
individual instrument 10 error
intervals 28 combined zero and span 7
loop 11 linearization 8
pH 105 span 6
. procedure number 22 zero 7
procedures, specific 19
~~ range 1, 22 field calibration 11
seal 38 filled-bulb sensors 35
status labels 30 final control eiement 91
tolerance 2, 22 flow instrumentation 77
"
valve positioner 96 flowmeter
..".
capacitance 62 calibration 82
level instrument 71 coriolis mass 81
probe 63 differential pressure 78
capacitor 62 magnetic 79
271
Index
272
turbine 81 pH 102, 108

vortex-shedding 80 calibration 105
electrode output 104
generic procedure 18 pneumatic signal 94
gJ'avimetl'icmethod 87 preliminary operating point check 41
gravity, specific 64 pressure 49
air 49
hysteresis 51 atmospheric 49
calibrating 50
lIP transducer 91, 92 gauge, Bourdon 53
calibration 95 gauges 52
individual instrument calibration 10 switch, calibrating 55
instrument transmitter, calibrating 55
identification number 21 process instrument combined accuracy 6
range 2 programmable logic controller (PLC) 42
specification forms 26 project specifications 27
tag number 21 prover 86
instrumentation
accuracy and reliability 17 radio frequency (RF) 62
interface 66 reference only 12
resistance temperature detectors (RTDs)34
leakage 51 resistivity 107
level instruments 61 RID calibration check 38
linearization error 8
liquid head measurement 65 safety 20, 29
loop considerations 52
calibration 11 signal conversion 35
diagrams 25 span 2
error 6
magnetic flowmeter 79 standardize 103
calibration 84 suppressed zero 64
manufacturer's specifications 27
master meter 86 technical manual procedure 18
measurement by weight 87 temperature 33, 103, 108
motion-balance positioner 93 controller loop 42
sensors 34
nameplate data 22 switch 44
Nationallnstitute of Standards and Tech- transmitter 40
nology (NIST) 4 test
non-critical 12 equipment 36
normally closed (NC) 44 procedure 21
normally open (NO) 44 standards 23
thermistors 35
OSHA 13 thermocouples 34
out-of-tolerance standard 4
tolerance 2
traceability 4, 5
P&IDs23
trip 44
r .
273
Calibration
turbine flowmeter 81
ultrasonic 63, 64
level transmitter 72
.uncertainty 5
unit of measure 50
valve positioner
calibration 96
vapor 66
vortex-shedding flowmeter 80
wet legs 66
zero error 7
zero point 103
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Printed in the United States of America.

Library of Congress Cataloging-in-Publication Data inprocess.

About the Author . . . . . . . . • . . . . . . . ..' • . . . , , , , , , , , , . . • . ix

Acknowledgements, . , . , .. : , .. , .. , .... " , , , , , , , . , , , . , , xi

Introduction ... , . , . , ... , , . , , . , .. , , .. , , , , . , , , , , , , , : xiii

Chapter 1 Calibration Principles .. ,.: :; , . , .'1 i

1.6 Loop Calibration vs. Individual Instrument ;~

2.4 . Loop Diagrams (See Examples.in

2.5 Instrument Specification Forms

Chapter 3 Temperature Instrument Calibration 33

Chapter 4 Pressure Instrument Calibration. . . . . . . . . . . . . • . 49

Chapter 5 level Instrument Calibration 61

Chapter 6 Flow Instrument Calibration . . . . 77

6.2 Calibration of Flowmeters ' 82

Chapter 7 Final Control Devices Calibration . . . . . . .'. . . . . . . 89

Review Questions :0';:' 9<7 " , .: I

Bibliography ........•............... " . . • . . . . . . . .. 113

, Appendix A-1. Piping & Instrument Diagrams(P~IDs) . . . . . . .. 117

,Appendix A-2. loop Diagrams..... : . . . . . . . . . . . . . . . . . . . 119

Appendix A-3. Instrument Specifications . . . . . . . . . . . . . . . .. 123

Appendix A-5. Test Equipment ......•.............•.•• 227

Appendix A-G. RTD and Thermocouple Tables 229

Appendix A-7. ConversionTables .....•............... ~ 245

Appendix B. Answers to Chapter Review Questions... '. . . • • . 249

Index ....•. ~ 271

Michael Cable is a Level 3 Certified Control System Technician. He is

Instrument Qualification projects and-then starting up a Calibration

ISA's Certified Control System Technician (CCST)program

• Study guide for the Calibrationdomain in CCSTcertification. ,!!

..I • Reference for technicians who perform process instrument :

• Reference in the classroom for students pursuing studies related to »:

,After completing this chapter, you should be able to:

List the advantages and disadvantages of classifying

I] instruments according to process.importance -"-for example, ,

1.1 WHAT IS CALIBRATION?

1.2 WHAT ARE THE CHARACTERISTICS OF A

Tolerance: Permissible deviation from a specified value; may be expressed

For example, you are assigned to perform the calibration of the

The calculated tolerance is rounded down to 0.10 mA, because

• - Requirements of the process I

• Manufacturer's specified tolerance.

, Example: The process requires ±soC; available test equipment is capable

good rule of thumb is to ensure 'an accuracy ratio of 4:1when performing r

equipment (such as a field standard) used to calibrate the process

Traceability: All calibrations should be performed traceable to a nationally

from the calibration lab.are periodically checked for cali~ration by "higher

Uncertaintu: Parameter, associated with the result of a measurement that

multiple calibration equipment accuracies to arrive at a single calibration

J(calibrator 1 errol) 2 + (calibrator2 erroj 2 + (etc. erroj 2

(sensor erroj 2 + (transmitter erroj 2 + (indicator errol) 2 + (etc. errol) 2

1.3 WHY IS CALIBRATION REQUIRED?

Zero and span errors are corrected by performing a calibration. Most

1.4 WHO PERFORMS CALIBRATIONS? - THE

those that are computer-based. Typically, he or she has received training

.' . Attention to Detail: Calibrations should be performed ~ accordance with .\-

detailed instructions. Each different make/model instrument is adjusted

detail, safety and proper performance are jeopardized ..

Excellent Documentation Practices: In many facilities, the impression of

Understanding of Processes: One thing that sets technicians apart is an

1.6 LOOP CALIBRATION VS. INDIVIDUAL

DISADVANTAGES OF INDIVIDUAL ADVANTAGES OF INDIVIDUAL