DEAD WEIGHT CALIBRATOR

1. OBJECTIVE:
 To familiarize with the use and operation of dead weight calibrator.
 To calibrate pressure gauge by using a dead weight calibrator.

2. ABSTRACT:
The main objective of this experiment is to calibrate the pressure gauge by using a
dead weight calibrator. By applying the known loads on the calibrator we found the
values of pressure gauge. We found the values of pressure gauge by loading and
unloading of the weights. At the end we calculated the error to find how much the
system is deviating from ideal case. In ideal case the values of weight applied and the
reading from pressure gauge must be equal to each other, but in the experiment the
values are deviating. The deviation may be due to the certain factors. These factors
are already explained in the report.

3. INTRODUCTION:
A Dead Weight Calibrator is an apparatus used to compare a fluid pressure with a
measured weight. It is usually used to calibrate the pressure gages statically. Dead
weight calibrator works on the principle of Pascal’s Law. It is basically a device used
to measure pressure and producing pressure. A Bourdon Gauge is supplied for
calibration. Gauge calibration means inputting an accurately known pressure sample
into the test manometer and then observing the manometer response [1].

Calibration is process of finding a relationship between two unknown quantities.

When one of the quantities that is made or set with one device is known, another
measurement is made as similar as possible with the first device using a second
device. The measurable quantities may differ in two equivalent devices. Calibration is
important for the following reasons [2]:
 To ensure readings from an instrument are consistent with other
measurements.
 To determine the accuracy of the instrument readings.
 To establish the reliability of the instrument i.e. that it can be trusted.
DESCRIPTION:
A dead weight tester is usually used in pressure gauge calibration. The dead weight
tester consists of an oil reservoir containing enough hydraulic oil to fill the tester's
passageway. It has a round platform attached to a piston, on which a specific pressure
applied to the oil inside the tester is placed a standard weight. A hand operated
plunger in the tester is used to exert pressure on the oil to balance the weight on the
tester's surface. The tester's fundamental principle is to pressurize oil by turning the
hand-operated plunger and to balancing this pressure with the pressure applied by the
known area piston, which is loaded with a standard mass. The pressure is obtained
through the use of total weights divided by piston region [3].
Dead weight testers are the primary standard for pressure measurement. This device
consists of three main parts which are given below [4]:

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  A fluid that transmits the pressure (Hydraulic Oil)
 A weight and piston used to apply the pressure
 A connection port for the gauge to be calibrated

Fig: 1 (Description of Dead Weight Calibrator) [4]

TYPES OF THERMOCOUPLES:
In general, there are three different kinds of DWT's divided by the medium which is
measured and the lubricant which is used for its measuring element [5]:
 Gas operated gas lubricated PCU's (Piston Cylinder Unit)
 Gas operated oil lubricated PCU's
 Oil operated oil lubricated PCU's

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Pressure Gauge Weights

Plunger Oil Filled

Body

Valve
Support

Fig: 2 (Dead Weight Calibrator)

The name of this apparatus is dead weight tester is because, we put the weight on the
weight stand of dead weight tester putting weight is reference weight which is to be
calibrate and further we applied pressure by moving piston ,when applied pressure
and reference weight (Pressure) is equal at this condition reference weight will be
zero(Dead). Therefore, it is called dead weigh tester. The accuracy of the dead weight
tester is affected due to the friction between the piston and cylinder, and due to the
uncertainty of the value of gravitational constant ‘g’ [6].

APPLICATIONS:
The applications of dead weight testers are given below [6]:

 Primary standard for calibrating the pressure scale in a hydraulic range up to

1,400 bar (20,000 psi).
 Reference instrument for factory and calibration laboratories for the testing,
adjustment and calibration of pressure measuring instruments.
 Complete, stand-alone system, also suitable for on-site use.
 It is used to calibrated all kinds of pressure gauges such as industrial pressure
gauges, pressure transmitters etc.

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 FACTORS AFFECTING:
The factors which are affecting dead weight calibrator are given below [7]:

Local Gravity:
If the gravity at the location where the dead weight tester is being used is different to
where it was calibrated then the readings will need to be corrected since the force
generated by the weights will change.

Pressure Coefficient:
The effective area of the dead weight tester will change with pressure due to the
expansion and contraction of the piston and cylinder at different pressures.

Tare Force:
This represents a force error in the determination of the mass of the weights, the
calculation of the piston/cylinder and carrier weight or a known characteristic of the
dead weight tester.

Horizontal Leveling:
If the dead weight tester is not level with the horizontal plane and therefore the piston
cylinder assembly is not perfectly upright there will be a friction force due to a
leaning towards one side.

Air Buoyancy:
The air pressure and humidity will affect the density of air which contributes a
relatively small lifting force to the weights.

Thermal Expansion:
As the temperature changes the cross sectional area of the piston and cylinder will
change affecting the effective area of the dead weight tester.
Surface Tension:
For fluid filled dead weight testers a surface tension force is exerted on the piston.
This surface tension force depends on the type of fluid used and the circumference of
the piston.

Height Difference:
If the dead weight tester is used at a different height to the unit being tested, a force
will be generated due to the head of air or fluid in the connecting test hose.

4. PROCEDURE:
 First close all the valves (5, 6, 6) of the dead weight calibrator only open the
valve close to the cup which is valve 2.
 Add the hydraulic oil in the cup into the tester to fill it.
 After that, rotate the plunger outward to suck the oil in it.

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  Now open valve 2 and open valve 5 and 6.
 After the above step, put the standard weights on the pan. The pressure of the
pan is 0.5 atm.
 Now turn the plunger while slowly rotating the pan to transmit the pressure
towards the weight and pressure gauge.
 When the fluid pressure is equal to the pan, it is lifted as well as the gauge
indicates the corresponding pressure.
 Weight should be lifted to red line only.
 Note the reading on pressure gauge.
 After that release the pressure and put next weight on the pan.
 Repeat the experiment to get more values.
 Also note down the readings from the pressure gauge for the unloading.
 At last draw the graph between weight and pressure gauge for loading and
unloading.

5. RESULT AND CALCULATIONS

For Loading:

Sr.No Weight Pressure Pressure Gauge Pressure Gauge Error (%)

(atm) (Kg/cm2) (atm)
1. 1 0.5 0.4839205 51.60795
2. 2 1.6 1.5485456 22.57272
3. 3 2 1.935682 35.47726667
4. 4 3.8 3.6777958 8.055105
5. 5 4.2 4.0649322 18.701356
6. 6 5.6 5.4199096 9.668173333
7. 7 6 5.807046 17.0422
8. 8 7.8 7.5491598 5.6355025

Loading
8
7
Pressure Gauge (atm)

6
5
4
3 Pressure Gauge (atm)
2
1
0
0 2 4 6 8 10
Weight Pressure (atm)

Graph 1

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 For Unloading:

Sr.No Weight Pressure Pressure Gauge Pressure Gauge Error (%)

(atm) (Kg/cm2) (atm)
1. 7 6.1 5.9038301 15.65957
2. 6 5.6 5.4199096 9.668173333
3. 5 4.12 3.98750492 20.2499016
4. 4 4 3.871364 3.2159
5. 3 2.1 2.0324661 32.25113
6. 2 1.8 1.7421138 12.89431
7. 1 0.5 0.4839205 51.60795

Unloading
7
6
Pressure Gauge (atm)

5
4
3
Pressure Gauge (atm)
2
1
0
0 2 4 6 8
Weight Pressure (atm)

Graph 2

6. DISCUSSION:

7. REFRENCES:

[1] “Working of Dead Weight Tester – Instrumentation and Control Engineering.”

[Online]. Available: https://automationforum.co/working-of-dead-weight-
tester/. [Accessed: 26-Jan-2020].
[2] H. Rana, “Calibration of Pressure Gauge Using a Dead Weight,” 2015.
[3] “lab1 che 215 - Experiment 1 DEAD WEIGHT TESTERS 1 Objective 1 To
familiarize students with the use and operation of a pressure Dead Weight
Tester 2 To | Course Hero.” [Online]. Available:
https://www.coursehero.com/file/11837890/lab1-che-215/. [Accessed: 09-Feb-
2020].

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[4] “How to Calibrate a Pressure Gauge With a Dead Weight Tester ~ Learning
Instrumentation And Control Engineering.” [Online]. Available:
https://www.instrumentationtoolbox.com/2013/08/how-to-calibrate-pressure-
gauge-with.html. [Accessed: 09-Feb-2020].
[5] “Deadweight tester - Wikipedia.” [Online]. Available:
https://en.wikipedia.org/wiki/Deadweight_tester. [Accessed: 09-Feb-2020].
[6] “What is a Dead Weight Tester? - InstrumentationTools.” [Online]. Available:
https://instrumentationtools.com/dead-weight-tester/. [Accessed: 26-Jan-2020].
[7] “Dead Weight Tester.” [Online]. Available: https://www.sensorsone.com/dead-
weight-tester/. [Accessed: 26-Jan-2020].