Transmitter Calibration Procedure

In today’s environment of shrinking cost margins and increased regulations,

maintaining properly calibrated equipment becomes ever important. Even the smallest
inaccuracy in process measurements can cause a significant loss in revenue,
especially if the process handles large volumes. Electronic equipment can lose
accuracy over a period of time, leading to incorrect readings; this is where calibration
comes in. Calibrating electronic equipment, in this case transmitters, brings the
measured values of the device in line with a known value from an applied standard.

Instrument Loops
In order to understand transmitter calibration, it may be beneficial to first review
instrument loops. An instrument loop refers to a configuration of equipment, connected
in such a way to deliver power to all devices and obtain a reading from these
devices. An instrument loop can be either electrical or pneumatic. The figure below
shows a simple instrument loop with a power supply, transmitter, and a meter to
measure current in the loop.

Smart Transmitters
Smart transmitters are microprocessor-based transmitters that are capable of being
reprogrammed with various parameters without the need for board replacement.
Smart transmitters are more accurate than traditional analog transmitters, have a
much greater turndown ratio, and are much easier to calibrate.

Calibration Guidelines
All calibrations should follow some general guidelines, which are true of any type of
transmitter, smart or traditional. Some of the guidelines are discussed here.
Primary vs. Secondary standards
• Primary standards produce a certified output that can be used to
calibrate a piece of equipment. Deadweight testers are examples of
primary standards. These devices use a precision mass to measure
pressure.
• Secondary standards typically measure a variable with a transducer or
electronics, then display it electronically.

Gravitational Constants and Corrections

Since the gravitational constant throughout the world changes slightly from place to
place, this must be taken into account when using a primary or mass-to-pressure
device like a dead weight tester. When using a primary tester to calibrate an
instrument, make sure that the weights have the proper gravitational constant stamped
on them for the area the tester is being used in.

Some commonly used constants are below:

• “Standard/International” gravity is 980.665 cm/sec2

• US mean gravity is 980.000 cm/sec2
All instrument calibrations should be made to .1% of calibrated span.

General Calibration Routine

All calibrations have common elements. The following is a general procedure for
performing any calibration:

1. Isolate the transmitter from the source. This means taking the transmitter
off service.
2. Connect a primary device, such as a dead weight tester or a decade box,
to the input of the transmitter. Make sure the primary device has been
certified. The setup should be similar to the figure below. In this figure,
a HART communicator has also been connected to aid in programming
a smart transmitter.
3. Record on the appropriate form. A sample chart is shown below for a 0
to 150“ differential pressure transmitter.
4. Apply the desired input from the table to the transmitter and read the
output. Record it in the chart under the “As Found” column.
5. If the “As Found” number is outside of the minimum acceptable and the
maximum acceptable ranges, then the transmitter must be recalibrated.
Even if the readings are inside the limits, but still a bit off, it is a good
idea to recalibrate the transmitter.
6. Recalibrate the transmitter according to the procedure for that
transmitter. This usually involves putting the 0% value of input on the
transmitter and zeroing the transmitter to 4 milliamps out. Then, put the
100% value on the transmitter and set the span to read 20 milliamps.
7. Perform the calibration checks again as in step 4 and record the values
in the “As Left” column.
 •
What is a Active Barrier ?
An active barrier uses transformers, optoisolators or relays to provide isolation
between the hazardous area and the non-hazardous area. It does not require an
intrinsically safe ground connection. Either or both the hazardous area or the non-
hazardous area signals may be grounded. This may be the most logical barrier choice
if a high quality I.S. grounding point is not available.
The below Figure shows a diagram of an active barrier. The barrier requires a 24 VDC
power supply, and can typically drive larger loads than a loop powered zener barrier.

Active Barrier
Intrinsically safe systems should satisfy these requirements:
• Ensure that there is a positive separation of intrinsically safe and non-
intrinsically safe circuits. This prevents the ignition capable energy from
intruding into the intrinsically safe circuit.
• Separate conduit, panduit, cable trays, etc. should be used for I.S. wiring
to keep it separate from the non-I.S. wiring. If conduit is used, it must be
sealed per the applicable code. This is to prevent the conduit from
becoming a means of conducting flammable material from the
hazardous to the non-hazardous location. I.S. wiring must always be
identified. This can be performed by tagging the wires, labelling the
junction boxes, and/or color-coding the I.S. wires light blue.
• Ensure that the entity parameters, upon which approval of the system is
based, match up correctly.