2013 13th International Conference on Control, Automation and Systems (ICCAS 2013)

Oct. 20-23, 2013 in Kimdaejung Convention Center, Gwangju, Korea

Pressure Control Design by Fieldbus System for the Pressure Gauge Calibration
l* 2
Chatchaval Pornpatkul and Wipawan Suksathid
I Department of Instrumentation and Control Engineering, Pathumwan Institute of Technology, Bangkok, Thailand
(Tel : +66-2-104-9099; E-mail: chatchaval@ptwit.ac.th)
2Department of Computer Technology, Sipraya Polytechnic College, Bangkok, Thailand
(Tel : +66-2-236-1312; E-mail: Suksathid@hotmail.com)

Abstract: This paper presented the pressure control by Fieldbus system for the pressure gauge calibration. The data
in control is standard communication. The programs for control system are classified into 2 parts, the one for
controlling the external element and the other for creating the graphic display. The result of control can be monitor.
The program for control can be create the function to computer and send the result to control external element. The
program for creating graphic and monitor the result of control can be setting the method of monitoring and the result
of control. We can be control the both of the programs for control the external element and the program for create
graphic and monitor the result of the control system. Finally, the pressure gauge calibration using air pressure gauge
as an intermediary is presented in this paper. The standard pressure gauge is calibrated in the working standard
commonly used in the industry. The calibration method of DAkkS-DKD-R 6-1 standard guide line is deployed,
where the error margin in measuring the pressure of the pressure gauge does not exceed the accuracy value to set by
the factory manufacturers throughout the measurement range (±0.5% of span). At least seven uncertainties are
determined. It is found that the value of expanded uncertainty is significantly affected by some certain variables. The
experimental result of the UUC studied in this paper show that the maximum error value of measurement is +0.008
kg/cm2 at 2.0 kg/cm2, which is in the range of accuracy value specified by the manufacturer (±0.5% of span ± 0.02
=

kg/cm2 ). Moreover, when combining the maximum error value of the measurement obtained from the experiment
with the expanded uncertainty (Uexp) ± 4.672x 10-3 kg/cm2, it is also found that the result is still in the accuracy
=

value specified by the manufacturer. Therefore, a calibration certificate of UUC can be issued for UUC utilization.

Keywords: pressure control, fieldbus system, pressure gauge calibration

1. INTRODUCTION with the working pressure standard for the calibration

Digital communication is becoming very popular of pressure gauge to the general pressure calibrator.
nowadays. This makes digital communications have a
role in instrumentation and control engineering. Digital 2. PRESSURE CONTROL SYSTEM
communication has been used in industrial control 2.1 Fieldbus system communication [1-4]
system and instrumentation for a long time. However, Fieldbus system is the serial communication by the
the known and familiar as it is in the distributed control bidirectional digital signals between devices connected
system (DCS), but digital communication system will on the network. For the fieldbus communication is used
be used in the network between the controller with the in the instrumentation and control engineering by the
display or input and output parameters. The communication between the devices have two network
measurement and control of the devices to the input or systems are the process fieldbus and the device bus.
output are still the analog standard signal, which is in
the current signal 4-20 mAdc. The current performance DOC OCS FCS
of these measuring devices have been developed to be
able to communicate with the digital devices connected
on the network. This communication system is called
the fieldbus system has been used in the manufacturing
that have been deployed. Thus saving power cord
connected to the devices, amount of information in the
communication between the devices to measure and
control of data more than the analog signal. The user
can recognize status and information of those devices.
When applied to control the pressure in process tank
can lead to the desired result of the pressure that come Fig. 1 The communication systems in process control.

978-89-93215-05-295560/13/$15 ©1cROS 1565

2.1.1 Process fieldbus
The process fieldbus system is used with a device
to measure a basis for the loop control in industrial
processes such as measuring the flow transmitter, the
level transmitter, the pressure transmitter, the
temperature transmitter and the control valve, which
measure these devices can be communicate directly
with digital devices on the network or digital control Fig. 4 Block diagram of pressure process control.
system. There were two systems, foundation and
profibus.

R(s)

L------1 Hp �-------'

C(s)
•

Fig. 2 Process fieldbus system.

2.1.2 Device bus

Device bus system used for measuring devices is
the device detection for general control such as limit L(s) GnGr
switch, proximity, bar code, the detector image and 1 + GJ)GVGFGp
solenoid valve, which measure these devices which
can't communicate directly with digital devices. +
R(s) G[JGVGFGp + C(s)
t<.
'<Y
Network system and digital control communicated with
1 + G[JGvGFGpHp
different devices. It has to connect to the remote input /
output or multiplex. That is the data signal before
sending and receiving data to other devices on the Fig. 5 Transfer function of the pressure process control.
device with the bus system, widely used devices
L .J
mentioned above will be in the automotive industry and
yes) LTIGj
/�l J�l
electronics assembly majority. G = =
(1)
S Xes) 1+ tn Gj
k=l i=l
2.2 Pressure process control system
Here is the pressure process control system for where G, is the transfer function of the pressure
pressure gauge calibration. In this paper, a PI controller process control system.
used to control the pressure in process tank is deployed. R(s) is the set point variable
The feedback control system is shown in Fig. 3. L(s) is the disturbance
C(s) is the process output
Hp is the measurement system

2.2.1 SYSCON program

Fig. 3 Pressure process control system.
SYSCON program is the program, which control
devices are used in fieldbus system. The program will
consist of two main parts: the Logical Project likened
for control area and the Physical Project virtual storage
devices.

1566
 " Syscon - PROJECT 2.2.3 OPC Link program
Project File Edit View Tools Arrange Options Window Help
OPC Link program used to defme the topic name is
an application for communicating data between the
IlliplD dQl29 application SYSCON program and Intouch Runtime
......................... : ....... � program

Topic Name:
I:-pv --=====
I_ =--
Node Name:
� �
ope Server Name: I
Smar.DfiOleServer.O
:::.:J �
OPCPath: jPID.PV.
�
L..J ................. � Update Interval: 11000 Enable access to update interval P'

CU"5CJ" ;(-)51 v=' 3 r

L Poke asyncl-fonouslo; Refresh after poke

Poke mode-------; Lifecheck SettinQs------,

r
r.
('" Control mode
Lifecheck

Fig. 6 Control area by Logical Project. Transition mode

Timeot:.lt: 10
('" Full optimization

II Syscon - PROJEU
Project File Edit Search Communication Window Help
Fig. 9 OPC Link program for define topic name.

3. EXPERIMENTS
� F.eldbusl 3.1 Pressure Control design 151
El .®i Fieldbu5!
$ .�
.

Bridge!
ItJ .. @ DC302
El··@ LD292
.
' @: MIBVFD
Elt�i FBVFD
�·O RES_LD
$0 TR_LD
$0 DIS_LD
$·OAUD
$··0 PID_LD 302
1±l·· @ B
,
,
, _______________ L ________,
,
I
I
,

� FI302

Fig. 7 Control area by Physical Project. I

:
I

:
I

2.2.2 Intouch Runtime Program :

I
I

Intouch Runtime program is used to create HMI

applications on the Microsoft Windows operating
system that is simple and easy. Divided into two sub­
programs, which is the window to make for creating
graphics, schedule of work and the window viewer
graphics for display of graphics created and controlled.

.=J.QI12>J
File Edit View Arrange Text Line Special Windows Help Runtimel

I [FI lm Cl I ··•• d' §: � §ll un qj< llll i #0 I 'Ij, 'f;j, I·... I :-.: ,. ::

·����Nrr::-"D
�ows Fig. lO P-I diagram of the pressure process control.
. :01 1 1-.&
:02
�03 0
··04 3.1.1 P-I action for pressure control and calibration
1tJ...� Scripts 0
P-I Control at 1.0 kg/cm2 (25%) [6]
1tJ···' Configure /
: ····m Tagname Dictionary
:.....4' Cross Reference + where Kp 1.7234
=

i.....� �
iii··· .
TemplateMaker
SQL Access Manager
Ti 4.995 sec
=

IB··� Applications .J� (!, steady state time 22 sec

..!.I , -
Ready r:::iI:::- � Ai standard gauge 0.995 kg/cmz =

error l.0 kg/cm2 - 0.995 kg/cm2

=

Fig. 8 Intouch Runtime program. 0.005 kg/cmz

=

1567
 P-I Control at 3.0 kg/cmz (75%)
Sp
py where Kp l.7234
MY
_ =

Ti 4.995 sec
_
=

steady state time 57 sec

standard gauge 2.995 kg/cm2
=

error 3.0 kg/cm2 - 2.995 kg/cm2

=

0.005 kg/cm2
=

�
SP

�
�04.":
PY
'00.00
_ MY

Il!."
� ... ,

Fig. 11 P-I Control at 1.0 kg/cm2

P-I Control at 2.0 kg/cmz (50%)

where Kp = 1.7234
Ti = 4.995 sec
steady state time 38 sec
standard gauge l.992 kg/cmz
=

error 2.0 kg/cm2 - l.992 kg/cm2

=

= 0.008 kg/cm2

Sp Fig. 13 P-I Control at 3.0 kg/cmz

py
MY
_

3.1.2 Expanded uncertainty of measurement

The uncertainty of standard gauge

( accuracy) x p
Us = j3 (2)

u, = �4
0
= 0.0023 kg / cm2

Uncertainty of Resolution
resolution
Ures =
(3)

The uncertainty of resolution

The value of the approach UUC from guide line
DakkS-DKD-R 6-1 [7], interval scale division 0.05 =

kg/cmz smallest needles are thin enough. be placed into

Fig. 12 P-I Control at 2.0 kg/cm2
the small scale has 5 needle (can be visually estimated
that 2 pin, 5 pin or 10 pin) that are estimated to drop
only five stitches to the readability equal interval
scale/5 0.05/5 0.01 kg/cm2.
= =

1568
Ures = �
O l
=0.006 kg / em
2 The uncertainty of repeatability

UO(lIl',/)
'
=
[(X3,j -x3,a ) - (xl,j -xl,a ) ] (7)
The uncertainty of acceleration due to gravity 2J3
Local gravity in each area to be calculated. The
uncertainties not more than ± 50 ppm. Calibration (X3,9 -x3,o ) =(3.996-0.002) =3.994kg / em2
laboratory in Pathumwan Institute of Pressure equals (XI,9 -xl,o ) =(3.995-0.002) =3.993kg / em2
9.783228 m/s2 ± 50 ppm 9.783228x50x 10.6; [(3.994)-(3.993)]
=2.886x10-4kg / en1 2
=

U (g) 0.0004892 m/s2. Ua(lIp,9) =

2J3
=

I
= � xp xU(g)x!1h (4)
ugh
,, 3
0

Ua(down,J)
'
[(X4,j -X4,O ) - (X2,j -X2,O ) ]
= =------'--=-------'--=- (8)
2J3
1
Ugh = x1.2x 0.0004892 x (-0.068)
J3 (X4,9 -X4,o ) =(3.995-0.002) =3.993kg / em2
(X2,9 -X2,a ) =(3.996-0.002) =3.994kg / em2
Ugh =2.304xl0-5 Fa

[(3.993)-(3.994)]
Uo(down,9) = =-2.886xlO-4kg / em2
2J3

The combined uncertainty

�
9 2
U gh =0.2349 x10- 0 kg / em

(9)
The uncertainty of difference in altitude
Because the iron feet of measuring the height of an
STD compared to UUC difference !1h -0.050 m by = Uc = .J0.00232 + 0.0062 + 2.886xl 0-4
the iron feet of the uncertainty with the readings
Eye ± 5 milliliters; U (h) ± 0.005 m. =

(5) The expanded uncertainty

DAkkS-DKD-R 6-1 define the coverage factor ; K = 2
1 at level of confidence 95%
uh = x1.2 x 9.783228 x 0.005 =0.03389 Fa
J3
U = 2xuc (10)
4.672x 10-3 kg / cm2
2
Uh =0.03389x(1.019716xlO-5) kg/ em U = 2x 2.336x 10-3 =

�
2
Uh =0.034558 x I 0-5 0 kg / em 4. CONCLUSION
The PI controller designed by Zeigler-Nichols
The uncertainty of hysteresis tuning method employing to control the pressure in the
process tank has been proposed [8 ]. The fine tune is

U"JW -
_ lX {[(X2/ -XIO )-(XI/ -x1,o )] + [(x4/ -x;o )-(x;;-x;o )]} (6) needed. The proposed pressure control system can be
nx 2.J3 used as a pressure working standard source for the
pressure gauge calibration. The pressure calibration
where n is cycle on calibration, in this case 2 cycle
points consists of 0.Okg/cm2, 1.Okg/cm2, 2.0kg/cm2,
or 4 series. M I is 1 series , M I to M2 is I cycle , M 1
to M4 are 2 cycles, therefor n 2 and j is the test point
=
3.0kg/cm2 and 4.0kg/cm2 are performed and found that
the expanded uncertainty is 4.672x 10.3 kg/cm2 and the
(X2,9 -xl,a ) = (3.996 - 0.002) = 3.994 kg/cmz maximum error of pressure is 0.008 kg/cmz at 2.0
(XI,9 -xl,a ) = (3.995 - 0.002) = 3.993 kg/cmz kg/cmz.
(X4,9 -x3,o ) = (3.995 - 0.002) = 3.993 kg/cm2
(X3,9 -x3,o ) = (3.996 - 0.002) = 3.994 kg/cm2

_lx{[(3.994)-(3.993)]+[(3.993)-(3.994)]} - k
/
2
Uhvs -O g em
, - 2x2,,�3

1569
 5. ACKNOWLEDGMENT
We wish to thank the referees and the editor for
their helpful comments and suggestions and thank you
very much for the kindness of Asist. Prof. Boonreang
wangsilabud, head of Instrumentation and Control
Engineering Department, Pathumwan Institute of
Technology.

REFERENCES

[1] Foundation Fieldbus technical overview, FD-

043, Rev l.0, Austin, Texas, 1996.
[2] IEC 1158-2, Fieldbusfor Use in Industrial
Control System-Part-2, Physical layer
specification.
[3] Profibus Technical Description, September 1999.
[4] Edmundo R.Gorini, The Fieldbus Book. SMAR
FIRST IN FIELDBUS,.
[5] Katsuhiko Ogata, Modern Control Engineering,
Prentice-Hall International Editions , 2nd Edition,
1990.
[6] N. Bignell, R. R. Cook, D. G . S. Groeneveld, E.
C. Morris, D. B. Prowse, Pressure measurement
and calibration for industrial laboratories, Course
on pressure measurement, CSIRO Division of
Applied Physics, NML, 1986.
[7] Deutscher Akkreditierungsstelle GmbH, German
Accreditation Body, mass, balances and pressure
gauge calibration, DAkkS-DKD-R 6-1, National
calibration laboratory - Avenida Carrera 50 N°
26-55, Interior 2, Bogota D. C., Colombia, March
2012.
[8 ] J. G. Ziegler and N.B. Nichols, Optimum Settings
for Automatic Controller, ASME Trans., Vol. 64,
pp.759-768, 1942.

1570