CONTENTS

 Safety

 Understand the requirement

 Calibration Documentation

 Calibration procedure for various instrument

  Safety :

Before removing the instrument from field/ panel for calibration always ensure
1) Necessary work permit is obtained
2) System is stopped
3) Isolation valve are properly closed
4) Approach to the device is earlier
5) Use of safety glass, helmet & shoe
6) Isolate the power supply.

 Understand the requirement

1) Before starting calibration study the instrument.

Range connection, Dial /size and ensure that proper fittings master gauge
etc. details are available, Do not run around on it afterwards.
2) In case of electrical instrument. Ensure power supply as necessary (24V DC/
110V / 230V etc.) With protection. Master instrument & tools multimeter etc.
ready in case of temperature and pressure calibration .
3) Define points of calibration and decide your action plan before start up of job.

 Calibration Documentation

Always make a procedure of calibration for each variety of instruments (pressure

gauge, pressure transmitter, pressure switch, safety valve, temperature gauge,
temperature indicator, digital temperature transmitter etc.)
Procedure should be approved by concerned authority and signed master
instrument records shall be maintained and ensure that they are valid all non.confirmity
records shall be maintained separately.
Only trained personal shall carry out calibration history cards for each instruments
and proper instrumentation shall be preserved.
History card shall contain complete data of instrument (Like Make, Range, connection,
power supply and accuracy etc). to enable for any replacement in future.
  Calibration procedure
I. Pressure gauge
II. Level gauge
III. Temperature gauge
IV. Digital process indicator
V. Pressure transmitter
VI. Digital temperature indicator / controller

 Calibration of Pressure Gauge

1) Isolate the gauge from system carefully and remove gauge

2) Check for zero of gauge before calibration.
3) Connect the gauge to the calibration set up and ensure no leaks.
4) Apply pressure 20%, 40%, 60%, 80% and 100% of range and note down the
readings.
5) In descending order same way note down the readings.
6) Correct the error (zero and span) by internal adjustments after opening the
instrument bezel, cover and dial etc.
7) Repeat the exercises 3 & 4 until correct readings are obtained.
8) Now assemble the instrument
9) Check for 20%, 40%, 60%, 80% and 100% in both ascending and descending
order and note down the reading.
10)Make documentation and issue the certificate of calibration
  Calibration of Level Gauge

1) Carefully close both positive and negative side isolation valves. Open equalization
valve in the three way manifold.
2) Remove positive and negative pressure connection of gauges and associated
protection cover, clamp etc and take out the level gauge.
3) Connect the gauge to testing instrument set up(Pressure generating pump and
master gauge ). Positive side to pressure port and left open the negative side to
atmosphere.
4) Ensure no leakage with soap solution as even small leak will cause error.
5) Note zero (May be with/ without error)
6) Apply pressure equivalent to 20%, 40%, 60%, 80% and 100% of full range and
note down the reading
7) In descending order again check the reading and note down.
8) Correct the errors in zero and span range (By opening the Bezel glass window, dial
and access to the adjustments).
9) Repeat the exercise 5& 6 until both zero and readings in all range are okay
10) Assemble the gauge.
11)Take final reading in both ascending and descending order and note down the
reading.
12) Install back in position and carefully open isolation valves of the system and leak
test with soap water .Now close the equalization valve after opening negative side
and positive side valves slowly and carefully and test for leakages and ensure no
leaks by tightening the connections
13)Document readings and issue of certificates.
  Calibration of Temperature Gauges

1) Get ready the temperature source oil bath or dry block type
2) Keep the master temperature indicator ready.
3) In general industrial application temperature gauges are checked from ambient
range to high range in case of low temperature application. Chilled water / brine
solution are used along with standard master instrument.
4) Put the temperature gauge under test and master instrument is the respective
test setup (oil bath/ dry block or chilled water/ brine solution).
5) In case of all set up expect dry block. Stir the solution and note down master
instrument reading and test gauge reading.
6) Raise the temperature of both in steps of 20%, 40%, 60%, 80% & 100% range of
the test gauge and note down the reading of master gauges and test gauges.
7) Again check the readings at all range and repeat that until correct readings are
obtained through out the range.
8) Note down the reading (after calibration).
9) Prepare document with all relevant data (instrument make, tag No, range,
accuracy etc.)

 Calibration of Digital Process Indicator

1) connect the process indicator with 230 v ac supply

2) Apply 4 MA from standard MA source to the process indicator via the input
terminals
3) Check the indicator shows the zero reading or adjust the zero pot and make
the indicator readings zero.
4) Apply 20 MA from standard MA source to the process indicator via the input
terminals
5) Check the indicator shows the full scale reading or adjust the span pot and
make the indicator readings as full scale.
6) Also apply 12 MA from standard MA source to the process indicator via the
input terminals
7) Check the indicator shows the middle scale reading.
8) Note down the readings and prepare documentation.
 Calibration of Pressure Transmitter

The procedures are same as of pressure gauge but calibrated electronically, Digital
multifunction calibrator is used instead of master gauge and output is measured in term
of 4 to 20 MA corresponding to zero and span. Error corrected through zero and span
pots.

 Calibration of Digital Temp.Indicator/Controller

1. Connect the instrument with 230 v ac supply

2. Apply resistance/millivolt from standard calibrator (source) to the instrument
via the input terminals in 5 or 6 intermittent ranges-of the instrument
3. Note down the indicator readings compared to master input reading.
4. If no error or error is with in limit (accuracy of the instrument) prepare
document
5. If error is above the limit (accuracy of the instrument) then adjust the relevant
Potentiometer / soft cal key.
6. Repeat exercise 2 and take the readings
7. Make documentation