Calibration All

INSTRUMENTAION
CALIBRATION
NOTE’S
MOHAMMAD MUZAMMIL
KNPC CFP - MAB2 Project
P6022MAB.000.10.30.010
Rev.: A1, 09-Mar-15
DEP/Project
Specifications
32.37.20.10.Gen
Title
FULL FORM
Instrument Signal Lines
Project Variations
32.37.20.10-P6000CFP-000-PV
31.37.00.11.Gen Instrument Air Supply 31.37.00.11-P6000CFP-000-PV
32.37.10.11.Gen Installation of on-line instruments 32.37.10.11-P6000CFP-000-PV
Relief devices - Selection, Sizing and
80.36.00.30.Gen 80.36.00.30-P6000CFP-000-PV
Specification
Inspection and functional testing of
62.10.08.11.Gen 62.10.08.11-P6000CFP-000-PV
instruments
P6000CFP.000.10.64.009 Instrumentation and Fiber Optic Cables --
Document Numbering (Derived from
FDH-008-JB-0005 --
Technical Bulletin No. 33)
SPI Implementation EPC Contractor
P6000CFP.000.10.10.013 --
Requirement
P6000CFP.000.10.10.014 SPI EPC Contractor Requirement --
P6000CFP.000.10.30.023 SPI Tagging EPC Contractor Requirement --
1.4. List of Abbreviations

Table 1: Abbreviations
Term Definition
AAMS Automatic Asset Monitoring System
AAQMS Ambient Air Quality Management System
AMADAS Analyser Management and Data Acquisition System
AML Approved Manufacturing List
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
CCR Central Control Room
CEMS Continuous Emission Monitoring System
DCS Distributed Control System
DPDT Double Pole Double Throw
EMC Electro Magnetic Compatibility
EPC Engineering, Procurement and Construction
FAR Field Auxiliary room
FF Foundation Fieldbus
FGS Fire and Gas System
FMEDA Failure Modes Effects Diagnostics Analysis
FNPT Female National Pipe Thread
HART Highway Addressable Remote Transducer
P6022MAB.000.10.30.010_A1.docx Page 6 of 46
KNPC CFP - MAB2 Project
P6022MAB.000.10.30.010
Rev.: A1, 09-Mar-15
Term Definition
ICSS Integrated Control and Safety System
IEC International Electrotechnical Commission
IP Ingress Protection
IPS Instrumented Protective System
ISA Instrument Society of America
KNPC Kuwait National Petroleum Company
LCR Local Control Room
MCC Motor Control Centre
NACE National Association of Corrosion Engineers
NFPA National Fire Protection Association
NAMUR Normenarbeitsgemeinschaft für Mess- und Regeltechnik
OSHA Occupational Safety and Health Administration
PEFS Process Engineering Flow Scheme
PID Piping and Instrumentation Diagram
PLC Programmable Logic Controllers
PMC Project Management Consultant
PST Partial Stroke Test
SIH Satellite Instrument House
SIL Safety Integrity Level
SIS Safety Instrumented System
SP Smart Plant
SPI Smart Plant Instrumentation
SPDT Single Pole Double Throw
UPS Uninterruptible Power Supply
2.0 DEFINITIONS
Definitions and Abbreviations used in this document are provided in the following Table.
Table 2: Company Definitions
Term Definition
CFP Clean Fuels Project
COMPANY KNPC, Kuwait National Petroleum Company
Fluor, Daewoo Engineering and Construction and Hyundai Heavy Industries Joint
EPC CONTRACTOR
Venture (FDH)
MAB Mina Abdullah Refinery
MAB 2 MAB EPC Package 2 referred as Project Scope
P6022MAB.000.10.30.010_A1.docx Page 7 of 46
Page 2 of 19
LOOP CHECK STEP USING HART - 475
FARMULA FOR LOOP CHECK AND CALIBRATION:-
Rnge Rnge MA PSI Percentage Degree Celsius Resistance Farenhight

(-30 to 80) (-1 to +1) 4 to 20 3 to 15 0 to 100% 0 to 100 Ohms 32 TO 212
-30 -1 4 3 0 0 100 32
-2.5 -0.5 8 6 25 25 109.625 77
25 0 12 9 50 50 119.25 122
52.5 0.5 16 12 75 75 128.875 167
80 1 20 15 100 100 138.5 212
% TO VALUE MA TO % % TO MA VALUE TO MA
%×𝑆𝑃𝐴𝑁 𝑀𝐴 − 4 𝑉𝐴𝐿𝑈𝐸−𝐿𝑅𝑉
100
+LRV % × 0.16 + 4 𝑆𝑃𝐴𝑁
× 16 +4
0.16
VALUE TO % MA TO VALUE ERROR CHECK ℃ TO ℉
𝑀𝐴 − 4
𝑉𝐴𝐿𝑈𝐸 − 𝐿𝑅𝑉 × 𝑆𝑃𝐴𝑁 + 𝐿𝑅𝑉 𝐴𝐶𝑇𝑈𝐴𝐿 𝑆𝑃 − 𝐷𝐸𝑆𝐼𝑅𝐸𝐷 𝑆𝑃
× 100 16
𝑆𝑃𝐴𝑁𝐸
× 100 ℃ ×1.8+32
𝑆𝑃𝐴𝑁
℉ TO ℃ ℃ TO Ohms Ohms TO ℃ RANGE
℉ − 32 𝑂ℎ𝑚𝑠 − 100 𝑈𝑅𝑉 − 𝐿𝑅𝑉
℃ ×0.385+100
1.8 𝑂. 385 4
PSI TO MA MA TO PSI LEVEV DP TYPE DP TYPE FLOW TX
√% × 10 × 𝑆𝑃𝐴𝑁
SPAN
DP = HP-LP 100
𝑃𝑆𝐼 − 3 𝑀𝐴 − 4 25% = 5
× 16 + 4 × 12 + 3
12 16 URV = H ×SG (D) 50% = 7.0710
LRV = H ×SG (D) 75% = 8.6602
100% = 10
℃ TO MILLIVOLT MILLIVOLT TO ℃
SCAL FACTOR(VIBRATION) SPAN
(K) (K)
𝑀𝐼𝐿𝐿𝐼𝑉𝑂𝐿𝑇 𝐶𝐻𝐴𝑁𝐺𝐸 𝐼𝑁 𝐺𝐴𝑃 𝑉𝑂𝐿𝑇𝐴𝐺𝐸

℃ ×0.041 SF= 𝐶𝐻𝐴𝑁𝐺𝐸 𝐼𝑁 𝐺𝐴𝑃
URV-LRV
0.041
COMPLETED BY: - MD MUZAMMIL (EMAIL: - MUZAMMIL9308@GMAIL.COM)

Page 1 of 60
INSTRUMENTATION (CALIBRATION) NOTES
Sr. No. CHAPTERS PAGE NO.
1 Calibration of pressure switch 2
2 Calibration of Temperature switch 3
3 Calibration of RTD type TT. 4
4 Calibration of T/C type TT. 5
5 Calibration of pressure guage. 6
6 Calibration of Pressure Transmitter 7
7 Calibration of DP Type transmitter 8
8 Calibration of DP Transmitter at field 9
9 Calibration of pH Electrode 10
10 Calibration of Magnetostrictive Level Transmitter 11
11 Calibration of capacitance type level transmitter 12
12 Calibration of DP LT with actual pressure 13
13 Calibration of DP LT at field 15
14 Calibration of DP LT for low side Dry Leg 16
15 Calibration of Bubbler type DP LT 17
16 Calibration of DP LT for Capillary type 18
17 Calibration of DP LT for Capillary type with offset 20
18 Calibration of Displacer LT 21
19 Calibration of Displacer LT with offset 22
20 Calibration of level troll or Displacer type LT. 23
21 Calibration of Displacer type LT with weight 24
22 Calibration of LT– (Zero Suppression and Zero elevation) 27
23 Calibration of steam flow DP Transmitter 29
24 Calibration of (Pitot tube) DP FT 31
25 Calibration of Capillary type FT 32
26 I/P converter calibration 33
27 P/I converter calibration 34
28 Stroke checking of Control Valve 35
29 Calibration of Control Valve 36
30 Calibration of Control Valve Positioner. 37
31 Replacement of Valve Stem Packing 38
32 Calibration of Fieldbus Transmitters 39
33 Control valve in a stuck (Maintenance) 41
COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

Page 2 of 60
1. Calibration of pressure switch.

 Equipments required
 Pressure Source
 Accurate Gauge
 Micro switch contact
monitoring device.
 For high pressure
application Hand pump is
more suitable.
 For low pressure shop air
or simple regulated pressure can be used or electronic pressure source
can be used.
 Pressure should have an accuracy of 0.25 %.
 Procedure of the Pressure Switch Bench Calibration
 Connect the pressure
switch to a hand
pressure regulator and
test gauge, as shown
in the diagram above.
 With a Multimeter,
set to the continuity
range to check and
verify that the switch contacts are as indicated: NO (Normally open)
and NC (Normally close).
 Connect the Ohmmeter or DMM between the normally open contacts
(NO) and the common terminal (C) of the switch. The meter should
read “open circuit”. Adjust the hand pressure regulator to increase the
pressure to the set point of the pressure switch until the contacts
change over. The meter should now read “short circuit”. Note the
pressure reading and write it down. This pressure is the switch set
point for a “rising” pressure.
 Increase the pressure to the switch to its maximum rating. Slowly
reduce the pressure to the switch until the switch changes over from
closed to normally open again. Note and write down this pressure
reading. This pressure is the switch setting for a “falling” pressure.

Page 3 of 60
When error found, adjust set point by screw adjustment and repeat
until desired value obtained.
 From the readings you have taken work out the pressure difference
between the rising and falling pressure settings. This is called the
“dead band” of the switch. The dead-band calculated should be equal
to or less than the manufacturers’ dead-band. The maximum dead-
band is usually stated by the manufacturer.
 Following information must be present in Pressure Switch
Calibration Certificate:
 Unique instrument identifier .E.g.: P&ID Tag.
 Mfg., Model, Serial Number, Location.
 Set point with units of pressure
 Reset point (if necessary) or some way to indicate “trip on increasing
input”
 NO or NC contacts
 Tolerance with units of measure
 Test equipment used with unique identifier and next due date
 As found and As left data
 Results
 Technician signature / Date
2. Calibration of Temperature Switch.
a) Temperature Bath.
b) Switch Contact
Monitoring Device
 Procedure of Temperature Switch Calibration:

 Remove temperature sensor from process.
 Connect test equipment
 For high Temperature Switch (TSH), place sensor in a calibrated
bath/block test standard at a temperature below the specified trip point
and allow to stabilize.

Page 4 of 60
 For low Temperature Switch (TSL), place sensor in a calibrated
bath/block test standard at a temperature above the specified trip point
and allow to stabilize.
 Slowly increase or decrease temperature to obtain trip point.
 Slowly decrease or increase temperature to obtain reset point.
 Repeat “X” times for repeatably.
3. Calibration of RTD type Temperature Transmitter

a) Temperature Transmitter,
b) 24 VDC power supply
c) Multimeter digital
d) Decade (Resistance) box.
 Formula for calibration:
Formula: - Rt = R0+αt
For a pt100 RTD:
α = 0.385
R0 = 100.
 Procedure of RTD
Temperature transmitter Calibration:
 Remove the temperature element (RTD) from transmitter.
 Connect the circuit as shown in figure above.
 Put multimeter in ma.
 By the equation we can find what will be the output resistance of RTD
in specific temperature.
Example: Range: - 0° C ~ 200° C
Formula: - Rt = R0+αt
Let’s take the temp= 50°C
So,
R50°C = 100+0.385*50
=100+19.25 =119.25Ω Ans,
Temperature Resistance O/P Current
0°C 100 Ω 4ma
50°C 119.25 Ω 8ma
100°C 138.5 Ω 12ma
150°C 157.75 Ω 16ma
200°C 177 Ω 20ma

Page 5 of 60
 So by the equation we can find resistance values for 5 point calibration
(4ma,8ma,12ma,16ma,20ma)
 By setting these resistance values using decade box we can find the
corresponding ma in multimeter.
 By changing the zero and span potentiometer in transmitter we can do
the 5 point calibration.
 Repeat the process.
4. Calibration of Thermocouple type Temperature Transmitter

a) Temperature Transmitter,
b) 24 VDC power supply
c) Multimeter digital
d) Milli volt source {(DPC-725/754 (documenting process
calibrator)}
Formula for calibration:
Formula: - For a ‘K’ type thermocouple:
mV = °C × 0.0416
°C = mV ÷ 0.0416
 Procedure of Thermocouple Temperature transmitter Online Calibration
 Connect the circuit as shown in figure.

 Put multimeter into ma.
Example:
Range = 0 ~ 200°C
Formula: - mV = °C × 0.0416
Let’s take the temp= 50°C
mV = 50 × 0.0416 = 2.08 mV Ans.
So 5 point calibration values are like this:-
Page 6 of 60
Temperature mV O/P Current
0°C 0 mV 4ma
50°C 2.08 mV 8ma
100°C 4.16 mV 12ma
150°C 6.24 mV 16ma
200°C 8.32 mV 20ma
So right now we know the corresponding values of temp to ma.
 Select thermocouple option in process calibrator.
 And give different values of temperature in process calibrator and
check the mA in multimeter and by adjusting zero and span
potentiometer in the transmitter correct the ma values.
 Repeat this procedure.
5. Calibration of pressure guage.
 Procedure of pressure guage Calibration:

 Connect the equipment’s as shown in above figure to calibrate the
pressure gauge.
 Apply pressure 0%(zero adjust)
 Adjust the zero screw or put the pointer on 0%
 Apply pressure 100%(span adjustment)
 To correct the indication increase or decrease the sector arm
 Apply pressure 50%(linear adjust)
 Adjust the length of link or pull the pointer using puller and place at
correct spot
 Check points 0%,25%,50%,70% and 100%
 Repeat these steps to get correct values

Page 7 of 60
6. Calibration of Pressure Transmitter.
 Pressure transmitter,
 Multimeter,
 HART communicator,
 Hand held test pump
(pressure source).
 Procedure OF Pressure Transmitter online calibration

 Isolate the Pressure Transmitter from the Process.
 Slowly open the vent plug and the vent valve to release the pressure.
 Connect the multimeter with the transmitter and ensure that output is
4ma when 0% pressure is applied.
 Connect the hand held test pump (pressure source) to the transmitter.
Ensure there is no leak.
 Apply pressure range at 0%, 25%, 50%, 75%, and 100% and check
there is any error.
 If there is any error calibration should be done.
If transmitter is analog transmitter
 Apply 0% pressure as per LRV with hand held test pump and check
multimeter if it is not 4ma adjust the zero pot in the transmitter and
correct transmitter output to 4ma
 Apply 100%pressure as per the URV and correct 20ma in multimeter
by adjusting span pot in the transmitter
NOTE: Repeat these steps to rectify error.
In case of SMART Transmitter
We have to use
HART
communicator.
Connect the
communicator with
the transmitter
select the HART
Communicator
Menu for lower
Page 8 of 60
range value trim and upper range value trim using these
steps:
 HART communicator will automatically calibrate
the transmitter.
 Restore the process connection
 Take the transmitter on line. Ensure there is no
leak
NOTE: Small example of five point calibration is given below:
Low range value = 0psi
Upper range value = 200psi
PERCENT OF RANGE OUTPUT CURRENT
INPUT PRESSURE
(%) (IDEAL)
0% 0 PSI 4.00 mA
25% 50 PSI 8.00 mA
50% 100 PSI 12.00 mA
75% 150 PSI 16.00 mA
100% 200 PSI 20.00 mA
75% 150 PSI 16.00 mA
50% 100 PSI 12.00 mA
25% 50 PSI 8.00 mA
0% 0 PSI 4.00 mA
7. Calibration of DP Transmitter.
a) 24 VDC power supply
b) Multimeter digital
c) Pneumatic hand pump
d) Low pressure hand pump
e) High precision digital test gauge
f) HART communicator.

Page 9 of 60
 Procedure of DPT transmitter bench Calibration
 Remove the differential pressure transmitter from the process
 Make sure the equalizing valve manifold is closed.
 connect the transmitter with the calibration equipments as shown in fig
 Apply the LRV pressure with the hand held test pump and check the
multimeter reading
 If it is not 4ma then calibration is required.
If transmitter is analog transmitter
 By applying 0% pressures by test pump adjust the zero pot in
transmitter to get 4ma output in multimeter.
 Apply 100% pressure and adjust span pot to get 20ma in multimeter.
 Check for 25%, 50%, and 75%.
 Repeat the process to ensure that no error is occurred.
In case of SMART Transmitter
We have to use HART communicator, connect the communicator with
the transmitter select the HART Communicator Menu for lower range
value trim and upper range value trim.
 Basic Set up – Calibration – Zero Trim/Sensor Trim
—Lower/Upper range value trims.
 HART communicator will automatically calibrate
the transmitter.
 Restore the process connection
 Take the transmitter on line. Ensure there is no leak
8. Calibration of DP Transmitter at field.

 Example calculation:
Transmitter range = 0-2 kg/cm2

LRV = 0 kg/cm2
URV = 2 kg/cm2.
Note: Capillary flange at same elevation
 Data sheet,
 Pressure calibrator,
 Multimeter,
 Hart communicator.

Page 10 of 60
 Procedure of DP Transmitter Calibration:
 Ask panel man to put the controller in manual mode for control loop
and to put it on MOS for ESD loop.
 Hook up HART Communicator and verify some parameters by refer to
data sheet. Typical parameters are, tag number, PV, LRV and URV.
 Isolate the instrument from the process.
WARNING: If the process is hazardous, please unsure proper flushing
is done to remove the entire hazard.
 Open vent valve at drip ring and open plug at the top of the drip ring
(if available) to release the process pressure.
 Clean the liquid inside the drip ring and put back the plug for high side
only (if available) & Expose the low side to atmosphere.
 Hook up a multimeter in series with the signal to the DCS to measure
current signal.
 In this condition both capillary flange will be atm pressure at
difference high.
 Multimeter should show 4mA and PV at HART communicator should
shows 0 (LRV).
 If not, do zero adjustment at transmitter using HART Communicator.
 Connect pressure calibrator to high side flange (drip ring).
 Apply pressure depend data sheet span (URV).
 Multimeter should show 20mA and PV at HART communicator
should shows same with URV.
 If not, do span adjustment at transmitter using HART Communicator.
 Verify the linearity by increasing and decreasing the pressure (0%,
25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of range).
 After completion of the job ask panel operator to put loops back in
normal mode or normalize the MOS.
 Fill the calibration form and file it for future reference.
9. Calibration of pH Electrode?
 Procedure of pH electrode Calibration
Select two buffers that bracket the expected sample
pH.
More buffers can be used for greater accuracy over a
wider pH range. For best accuracy, use buffers that are
no more than 3 pH units apart.

Page 11 of 60
 Procedure of pH meter calibration - Buffer solution
 Refer PH meter manual for specific details on operating your meter.
 Remove the electrode and rinse it distilled water. Wipe the electrode
with tissue paper to remove excess water and place electrode into the
first buffer of pH 7.
 Calibrate the meter to read the temperature corrected value of the first
buffer.
 Rinse the electrode as before and place in the second buffer. Wait for a
stable reading. Calibrate the meter to read the temperature corrected
value of the second buffer.
 Rinse the electrode as before. Place the electrode in the sample and
wait for a stable reading. Record the pH and temperature of your
sample.
 Tips for pH meter/Electrode calibration
 Always use fresh pH buffers.
 The electrode calibration slope should be 95-102%
 Remove the electrode filling solution cover when measuring, to
ensure a uniform flow of filling solution.
 Between measurements, rinse the electrode with distilled water
and then with the next sample to be measured.
 Stir all buffers and samples consistently.
 Place some insulating material between your stirrer and your
sample to prevent heating of your sample.
 Avoid rubbing or wiping electrode bulb.
 Store your pH electrode properly.
10. Calibration of Magnetostrictive Level Transmitter.
 Procedure of Magnetostrictive level transmitter Bench Calibration.
Magnetostrictive Level Transmitter calibration can be changed with the unit
push buttons
Setting the 4mA point:
 Establish a tank level of
0% or move the float to
the desired 0% point
 Enter the calibration
mode by pressing the UP
& DOWN buttons
together for 1 second.

Page 12 of 60
 Press the DOWN button for 1 second to set the output at 4.00mA.
Setting the 20mA point:
 Establish a tank level of 100% or move the float to the desired 100%
point
 Enter the calibration mode by pressing the UP & DOWN buttons
together for 1 second.
 Press the UP button for 1 second to set the output at 20.00 ma
Note: The above steps can be repeated as many times as required.
11. Calibration of capacitance type level transmitter

 Procedure of capacitance type level Transmitter calibration:
 Remove the level transmitter
from the system (tank).
 Check whether transmitter
shows zero reading by
connecting with multimeter
otherwise release the
pressure.
If the transmitter is smart
 Connect 475 hart
communicator and
multimeter to the level
transmitter.
 Put Multimeter to ma.
 Fill the corresponding liquid
in correct density and note down the readings. Fill liquid at 25%, 50%,
75% and 100% in both ascending and descending orders and note
down the readings.
 Check for errors if there is zero and span adjusts should be done.
 For zero calibration : Drain the liquid and check the multimeter if it
is not 0 then go to sensor trim option in the HART then go to zero trim
and the HART communicator will automatically trim the sensor in to
zero.
 For span calibration: Fill 100% and wait for some time then go to
sensor trim and select span trim in HART communicator the 475 will
automatically trim the sensor into 20ma.
 After doing zero and span trimming again check the reading at 0%,
25%, 50%, 75% and 100%.
Page 13 of 60
In case of non smart capacitance type transmitter.
 Connect a multimeter and rotate the zero pot and stop when
multimeter shows 4ma.
 Fill the chamber to maximum liquid level and rotate the span screw to
20ma.
 Repeat these steps and check all readings.
12. Calibration of DP Level transmitter with actual pressure.
Example Calculation:
Product S.G=0.89
Glycol S.G = 1.02
Measurement length = 2000mm.
Off set = 100mm.
Full length =2000+100 = 2100mm.
DP = pressure at high side – pressure at low side
LRV = (Off set × Product S.G) – (Measurement length × Glycol S.G)

= (100mm x 0.89) – (2000 x 1.02) = 89 – 2040
= -1951 mmH2O
URV = (Full length × Product S.G) – (Measurement length × Glycol S.G)

= (2100mm x 0.89) – (2000 x 1.02) = 1869 – 2040
= -171 mmH2O
Note: LRV and URV calculation may have small variation as compare
with HART communicator reading due to calibration with actual
pressure.
 Procedure of DP LT Calibration with actual pressure:


Page 14 of 60
 Release both pressure and drain low side liquid only through manifold
drain.
 PRECAUTION 1: During this process, please do not open the
equalizing valve at the manifold.
 Open both plug at seal pot.
 Top up the seal liquid for low side until half of seal pot.
 Remove the tubing at high side of the flange (not at the manifold side)
to drain remaining liquid in equalizing tube.
 PRECAUTION 2: Do not remove the process fluid in tubing of HP
Side. Please ensure it is full with process liquid.
 Install back both plug and connect back tubing at high side of the
flange
current signal.
 Open low side (top) isolation valve only and high side (bottom)
isolation valve remain closed.
 Multimeter should show 4mA If not, do zero adjustment at transmitter
using HART Communicator.
 Isolate back low side (top) isolation valve and released the pressure
through high side vent valve seal pot.
 Close the vent at seal pot.
 Fill up the equalizing tube until full with product by removed the top
fitting and slowly open the isolation valve (high side) until the
equalizing tube is full (or up to 100% level) with product.
 Close the high side isolation valve.
 Install back any fitting that was remove for filling up the equalizing
tube.
 Open low side (top) isolation valve only and high remain closed.
 Multimeter should show 20mA. If not, do span adjustment at
transmitter using HART Communicator.
Note: The reason to open the low side (top) isolation valve is to get the
actual pressure vessel.

Page 15 of 60
13. Calibration of DP Level Transmitter at field.
Product S.G=0.89
Glycol S.G = 1.02
Off set = 100mm.
Full length =2000+100 = 2100mm.
DP = HP –LP
LRV = (Off set × Product S.G) – (Measurement length × Glycol S.G)

= (100mm × 0.89) – (2000 x 1.02) = 89 – 2040
= -1951 mmH2O
URV = (Full length × Product S.G) – (Measurement length × Glycol S.G)
= (2100mm × 0.89) – (2000 x 1.02) = 1869 – 2040
= -171 mmH2O
Note: Calculation for apply pressure at high side manifold transmitter.
0% = (Off set × Product S.G) = (100mm × 0.89) = 89 mmH2O
100% = (Full length × Product S.G) = (2100mm × 0.89) = 1869 mmH2O
Equipments required
 Data sheet,
 Multimeter,
 Procedure of DP Level Transmitter Calibration at field:
 Release both pressure and drain low and high side liquid throughout
manifold drain.
 Open both plug at seal pot.
 Top up seal liquid for low side until half of seal pot.
 Remove tubing at high side of manifold.
Page 16 of 60
 Hook up pressure calibrator at high side and isolate the vent valve.
current signal.
 Apply pressure as per calculation when level equivalent to zero,
Multimeter should show 4mA.
 Apply pressure as per calculation when level equivalent to 100%,
Note: There is many way to perform calibration for DP level but the
important thing is the DP reading at HART communicator should
same with the LRV and URV.
14. Calibration of Differential Pressure Level transmitter for

low side Dry Leg.
Product S.G =0.89

Off set = 100mm.
Full length =2000+100 = 2100mm.
DP = HP – LP
LRV = (Off set × Product S.G) – pressure at low side

= (100mm x 0.89) – 0 = 89 – 0 = 89 mmH2O
URV = (Full length × Product S.G) – pressure at low side

= (2100mm x 0.89) – 0 = 1869 – 0 = 1869 mmH2O

Page 17 of 60
 Procedure of DP LT Calibration with actual pressure:
 Remove connection at manifold to the process after release the process
pressure
 Connect pressure calibrator to high side of manifold.
 Expose the low side to atmosphere.
current signal.
 Apply pressure as per datasheet LRV. Multimeter should show 4Ma.
 Apply pressure as per datasheet URV. Multimeter should show 20mA.
 Verify the linearity by increasing and decreasing the pressure
(0%,25%,50%,75%,100%,75%,50%,25% and 0%of range)
Note: LRV and URV range from data sheet should include the pressure
effect from bottom flange height to the transmitter and the SG of
process liquid.
15. Calibration of Bubbler type DP LT.
Product S.G = 0.89

Off set = 100mm.
Full length =2000+100 = 2100mm.
DP = HP – LP
LRV = (Off set × Product S.G) – LP.

= (100mm x 0.89) – 0 = 89 – 0 = 89 mmH2O
URV = (Full length × Product S.G) – pressure at low side
= (2100mm x 0.89) – 0 = 1869 – 0 = 1869 mmH2O

Page 18 of 60
 Procedure of Displacer LT Calibration with two S.G.:
WARNING: If the process is hazardous, please unsure proper
flushing is done to remove the entire hazard.
 Remove the tubing connection at manifold to the process after released
the process pressure.
 Connect pressure calibrator to high side of the manifold.
current signal.
 Apply pressure as per data sheet LRV. Multimeter should show 4mA.
 Apply pressure as per data sheet URV. Multimeter should show
20mA.
25%,50%, 75%, 100%, 75%, 50%, 25% and 0% of range)
16. Calibration of DP LT for Capillary type.
Product S.G =0.667
Capillary S.G = 1.113
DP = HP – LP

Page 19 of 60
LRV = 0 – (Measurement length × Capillary S.G)
= 0 – (888 x 1.113) = – 988.34mmH2O
URV = (Measurement length × Product S.G) – (Measurement length ×
Capillary S.G)
= (888 x 0.667) – (400 x 1.113) = 592.3 – 988.34
= – 396.04 mmH2O
The span is (Measurement length × Product S.G) = 592.3 mmH20
Note: This example is for onsite calibration without bringing down the
flange.
 Procedure of DP LT with capillary Calibration:
(if available) to release the process pressure
only (if available).
 Expose the low side to atmosphere
current signal.
difference high
shows same with LRV
 If not, do zero adjustment at transmitter using HART Communicator
 Connect pressure calibrator to high side flange (drip ring)
 Apply pressure depend on calculation for span= (A x Product S.G)
should shows same with URV
 If not, do span adjustment at transmitter using HART Communicator
 Verify the linearity by increasing and decreasing the pressure
(0%,25%,50%,75%,100%,75%,50%,25% and 0%of range)

Page 20 of 60
17. Calibration of DP LT for Capillary type with offset.
Product S.G=0.635
Capillary S.G = 1.07
Off set = 400mm.
DP = HP – LP
LRV = 0 – (offset length × Capillary S.G)
= 0 – (400 x 1.07) = – 428mmH2O
URV = (Measurement length × Product S.G) – (Full length × Capillary S.G)
= (235 x 0.635) – (400 x 1.07) = 149.225 – 428
= – 278.775 mmH2O
The span is (Measurement length × Product S.G) = 149.225 mmH20
Note: This example is for onsite calibration without bringing down the
flange.
 Procedure of DP LT capillary type with offset Calibration:

WARNING: If the process is hazardous, please unsure proper
flushing is done to remove the entire hazard.

Page 21 of 60
current signal.
difference high.
shows same with LRV.
 If not, do zero adjustment at transmitter using HART Communicator
 Connect pressure calibrator to high side flange (drip ring).
 Apply pressure depend on calculation for span.
should shows same with URV.
25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of range).
18. Calibration of Displacer level transmitter.
Low S.G = 0.802

High S.G = 0.992
0% = (Measurement length × Low S.G)

= (810 x 0.802) = 649.42 mm
100% = (Measurement length × High S.G)
= (810 x 0.992) = 803.52 mm
 Procedure of Displacer LT Calibration with two S.G.:
Page 22 of 60
 Remove isolation drain valve and open the vent flange.
 Connect water pump to drain line and line up the reference tube.
 Calculate the new measurement to get equivalent up trust force with
S.G and length.
 Mark on the chamber for reference calibration (0%, 25%, 50%, 75%,
100 %,).
current signal.
 Apply water level until 0% marking on chamber. Multimeter should
show 4mA.
show 20mA.
 Verify the linearity by increasing and decreasing the pressure. (0%,
25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of range)
normal mode or normalize the MOS
19. Calibration of Displacer level transmitter with offset.
Low S.G = 0.802

High S.G = 0.992
Off set = 410mm.
Displacer length =810+410 = 1220mm.
0% = (High S.G x off set length) + (low S.G x Measurement length)

= (0.992 x 410) + (0.802 x 810)
= 406.72 + 649.62 = 1056.34mm
100% = (High S.G x Displacer length)
= (0.992 x 1220) = 1210.24mm

Page 23 of 60
 Procedure of offset Displacer LT Calibration with two S.G.:
 Remove isolation drain valve and open the vent flange.
 Connect water pump to drain line and line up the reference tube
 Calculate the new measurement to get equivalent up trust force with
S.G and length.
 Mark on the chamber for reference calibration (0%, 25%, 50%, 75%,
100 %,).
current signal.
show 4mA.
show 20mA.
 Verify the linearity by increasing and decreasing the pressure.
(0%,25%,50%,75%,100%,75%,50%,25% and 0%of range)
20. Calibration of level troll or Displacer type level transmitter.
a) Leveltroll,
b) Multimeter digital
c) Transparent tube
 Procedure of Leveltroll/displacer level transmitter Calibration:

 Close the both primary isolation valves.
 Drain the liquid in the displacer chamber through the drain valves

Page 24 of 60
 Now there is no liquid in the chamber so it means 0%, so adjust the
zero pot in the transmitter and check the value in multimeter and
correct to 4ma.
 Now open 1st primary isolation valve and fill the liquid to the center
of the top flange(if the liquid is water, otherwise calculate the length
of full level of the liquid by taking product of specific gravity of liquid
and height of the displacer)
 Adjust the span pot in the transmitter and adjust 20ma in multimeter.
 Repeat the process.
21. Calibration of level troll or Displacer type level transmitter

with weight.
 Wet Calibration with Water for Liquid level
Zero:
 Hang displacer on torque tube
arm rod.
 Adjust Zero to 3 psi.
Span:
 Fill up water into the chamber.
 Adjust Span to 15 psi.
 0%, 25%, 50%, 75% & 100%.
Mark on chamber.
 Fill up & Drain water to
check 0%, 25%, 50% , 75% &
100%.Check output.
 Check function two three times.
Note: Compensate specific gravity difference of water & process liquid.

Process liquid specific gravity is 0.7
Water specific gravity is 1.0
To calibrate level transmitter 100% level.
Water level to be fill up in chamber = 0.7/1.0 x 100 % = 70 %.
 Dry Calibration with Weights

Find out Displacer
W= Displacer weight in 2400Gram (2.4 kg)
Specific gravity of process liquid. (WATER)= 1.0

Page 25 of 60
V = Volume of displacer. 1620.84
Displacer diameter 7.620 Centimetre (3 inches)
Length of Displacer 35.56 centimetre (14 inch)
Volume= 3.14 × r² × h = 3.14 × 3.81 × 3.81 × 35.56 = 1620.84
Zero:
 For 0% hang displacer or 2400 gram weight on torque tube arm rod.
Span:
 For 100% Hang weigh
t= Displacer weight – Volume X Specific gravity
= 2400 – 1620 X 1= 780.
 Check function two three times for calibration.
Level (%) Hang weight (gram) Transmitter o/p (psi)
0 2400 3
25 1995 6
50 1590 9
75 1180 12
100 780 15
For each 25% step subtract 405 Gram weight from hang weight.1620/4=405.
Note: Compensate specific gravity difference of water & process liquid.
 Wet Calibration with Water For Interface level

Zero:
Displacer in lighter liquid:
Process liquid specific gravity is 0.7
Water specific gravity is 1.0
 Mark chamber at 70%
 Fill up water in chamber
 To calibrate level transmitter 0% level.
 Water level to be fill up in chamber = 0.7/1.0 x 100 %= 70 %
Span :
Displacer in heavier liquid:
 Process liquid specific gravity is 1Fill up 100% water into
the chamber.

Page 26 of 60
 Dry Calibration with Weights
Find out Displacer
W = Displacer weight in 2400Gram (2.4 kg)

Specific gravity of process liquid Oil = 0.7
V = Volume of displacer. 1620.84
Displacer diameter: - 7.620 Centimetre (3 inches).
Length of Displacer: - 35.56 centimetre (14 inch)
Volume= 3.14 X r² X h= 3.14 X 3.81 X 3.81 X 35.56= 1620.84
Zero :
Displacer in lighter liquid
 For 0% hang weight on torque tube arm rod.

 Hang weight= Displacer weight – Volume X Specific gravity
= 2400 – 1620 X 0.7= 2400 - 1134
= 1266
Span:
Displacer in heavier liquid.
 For 100% Hang weight= Displacer weight – Volume × S.g.

= 2400 – 1620 X 1 = 780
 Check function two three times for calibration.
Level (%) Hang weight (gram) Transmitter o/p (psi)

0 2400 3
25 1145.5 6
50 1023 9
75 901.5 12
100 780 15
For each 25% step subtract 121.5 Gram weight from hang weight.
(1620-1134=486)
(486÷4=121.5).
Page 27 of 60
22. Level Transmitter Calibration – (Zero Suppression and Zero

elevation).
 Level Measurement – Zero Suppression (WET LEG)
If an instrument is mounted below a vessel it sense a total head but the
head due to the distance from the instrument location to the bottom of the
vessel does not represent level in the vessel. This head must be must be
cancelled by a range suppression calibration, using the zero adjustment
provided in the instrument.
Product S.G =1
Glycol S.G = 1.02
Off set = 100mm.
Full length = 2100mm.
Span = (H × D)
= 2000 × 1 = 2000 mmH2O.
DP = HP – LP
LRV = (offset length × product S.G) – (Full length × glycol S.G)
= (100 × 1) – (2100 × 1.02) = 100 – 2142 = – 2042 mmH2O.
URV = (Measurement length × Product S.G) – (Full length × glycol S.G)
= (2100 × 1) – (2100 × 1.02) = 2100 – 2142 = – 42 mmH2O.
Span = URV – LRV = -42 - (2042) = -42 + 2042 = 2000mmH2O
SO,
The Range will be: – 2042 to -42 mmH2O.
 Level Measurement – Zero Suppression (DRY LEG)
Product S.G =1
Off set = 100mm.
Full length = 2100mm.
Span = ( H × D)
= 2000 × 1 = 2000 mmH2O.
Page 28 of 60
DP = HP – LP
LRV = (offset length × product S.G) – (Full length × product S.G)
= (100 × 1) – (2100 × 1) = 100 – 2100 = – 2000 mmH2O.
URV = (Measurement length × Product S.G) – (Full length × product S.G)
= (2100 × 1) – (2100 × 1) = 2100 – 2100 = 0 mmH2O.
Span = URV – LRV = 0 – (-2000) = 0 + 2000 = 2000mmH2O
SO,
The Range will be: – 2000 to 0 mmH2O.
 Level Measurement – Zero Elevation (WET LEG)

If an instrument is mounted above a vessel, the distance from the
instrument location to the zero level of the level must be added by a range
elevation calibration again using the zero adjustment provided in the
instrument.
Product S.G =1
Glycol S.G = 1.02
Off set = 100mm.
Full length (LP Side) = 1900mm.
Span = ( H × D)
= 2000 × 1 = 2000 mmH2O.
DP = HP – LP
LRV = {0 - (offset length × product S.G)} – (Full length × glycol S.G)
= {0 - (100 × 1)} – (1900 × 1.02) = (0 – 100) – 1938
= -100 - 1938 = – 2038 mmH2O.
URV = (Measurement length × Product S.G) – (Full length × glycol S.G)

= (1900 × 1) – (1900 × 1.02) = 1900 – 1938 = – 38 mmH2O.
Span = URV – LRV = -38 - (-2038) = -38 + 2038= 2000mmH2O

SO,
The Range will be: – 2038 to -38 mmH2O.

Page 29 of 60
 Level Measurement – Zero Elevation (DRY LEG)
Product S.G =1
Off set = 100mm.
Full length (LP Side) = 1900mm.
Span = ( H × D)
= 2000 × 1 = 2000 mmH2O.
DP = HP – LP
LRV = {0 - (offset length × product S.G)} – (Full length × product S.G)
= {0 - (100 × 1)} – (1900 × 1) = (0 – 100) – 1900
= -100 - 1900 = – 2000 mmH2O.
URV = (Measurement length × Product S.G) – (Full length × product S.G)

= (1900 × 1) – (1900 × 1) = 1900 – 1900 = 0 mmH2O.
Span = URV – LRV = 0 - (-2000) = 0 + 2000 = 2000mmH2O

SO,
The Range will be: – 2000 to 0 mmH2O.
Once zero calibration is complete for either zero suppression or
elevation, the span adjustment provided in the instrument is used
to calibrate the actual range of level change measured in the
vessel.
23. Calibration of steam flow DP Transmitter.
Instrument calibrated range: 0 – 2500 mmH2O
Process calibrated range: 0 – 7000 kg/h
Q = K×P
0% (0 mmH2O) = (0/2500) × 7000 = 0 × 7000
= 0 kg/h
50% (1250 mmH2O) = (1250/2500) × 7000
= 0.5 × 7000 = 3500 kg/h
100% (2500 mmH2O) = (2500/2500) × 7000
= 1 × 7000 = 7000 kg/h
Page 30 of 60
 Data sheet,
 Multimeter,
 Procedure of steam flow DP Transmitter Calibration:
 Release both pressure and drain low and high side liquid throughout
manifold drain.
 Connect pressure calibrator to high side of manifold.
current signal.
 Apply pressure as per data sheet LRV (normally 0mmH2O),
 Apply pressure as per data sheet URV, Multimeter should show
20mA.
25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of range).
 Fill up back water until half of seal pot.

Page 31 of 60
24. Calibration of flow (Pitot tube) DP Transmitter.
Instrument calibrated range: 0 – 5000 mmH2O.
Process calibrated range: 0 – 22900 kg/h
Q = K×P
0% (0 mmH2O) = (0/5000) × 22900
= 0× 22900 = 0 kg/h.
50% (2500 mmH2O) = (2500/5000) × 22900
= 0.5× 22900 = 11450 kg/h
100 % (5000 mmH2O) = (5000/5000) × 22900
= 1× 22900 = 22900 kg/h
 Procedure of flow (Pitot Tube) DP Transmitter Calibration:

 Remove connection at manifold to the process after release the process
pressure and Connect pressure calibrator to high side of manifold.
current signal.
 Apply pressure as per data sheet LRV, Multimeter should show 4mA.
 Apply pressure as per data sheet URV, Multimeter should show
20mA.
25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of range).

Page 32 of 60
25. Calibration of Capillary type flow Transmitter.
Instrument calibrated range: 0 – 2500 mmH2O
Process calibrated range: 0 – 130 m3/h.
Q = K×P
0% (0 mmH2O) = (0/2500) × 130 = 0 × 130 = 0 m3/h.
50% (1250 mmH2O) = (1250/2500) × 130 = 0.5 × 130 = 65 m3/h
100% (2500 mmH2O) = (2500/2500) × 130 =1× 130 = 130 m3/h
Equipments required
 Data sheet,
 Multimeter,
 Procedure of capillary type FT Calibration:
 Ask panel man to put the controller in manual
mode for control loop and to put it on MOS for
ESD loop.
 Hook up HART Communicator and verify
some parameters by refer to data sheet. Typical parameters are, tag
number, PV, LRV and URV.
 Connect pressure calibrator to high side of manifold & Expose the low
side to atmosphere.
 Hook up a multimeter in series with the signal to DCS to measure
current signal.
 Apply pressure as per data sheet LRV, Multimeter should show 4mA.
 Apply pressure as per data sheet URV,Multimeter should show 20mA.
 Verify the linearity by increasing and decreasing the pressure.

Page 33 of 60
26. I/P converter calibration.
 I/P converter,
 Milliamp source,
 Pressure source(20 psi),
 Master gauge.
Note: No need of external power supply (24vdc) for working (neither for
calibration)
 Procedure of I/P converter online Calibration:
 Remove the I/P

from the process.
 If there is any top
cover in I/P
remove it.
 Connect 20-psi
supply pressure
and connect a
milliamp source
to the I/P.
 Set the input signal to 4 mA and check the output pressure on gauge as
3 psi.
 If the pressure is showing more or less than 3 psi then adjust zero.
 Turn zero adjustment screw slowly by very small turn to obtain 3-psi
pressure. More turning of zero adjustment may damage the I/P
converter. Counterclockwise rotation increases the pressure, and
clockwise rotation decreases the pressure.
 Set the input current signal to 20 mA and check the output pressure on
gauge as 15 psi.
 Turn the span adjustment potentiometer very slowly by small turn to
obtain 15-psi pressure. More turning of span adjustment may damage
the I/P converter.
 Repeat step 4 to check that the desired low value (4 ma ~ 3 psi) has
not changed after adjusting the span. If necessary repeat from steps 3
 Reconnect the I/P in the process.

Page 34 of 60
27. P/I converter calibration.
 Supply voltage 24vdc,

 Pressure source(handheld test pump),
 Multimeter.
 Procedure of P/I converter Bench Calibration.
 Set digital calibrator on measure mode.

 Connect input signal i.e. 3-15 psig.
 Set the input signal to 3 psig and check the output current as 4 mA.
 If the current is showing more or less than 4 mA then adjust zero pot to
make output 4ma.
 Set the input pressure signal to 15 psig and check the output current 20
mA.
 Turn the span adjustment potentiometer on Converter and adjust 100%.
 Repeat step 3 to check that the desired low value (3 psig ~ 4mA) has not
changed after adjusting the span.
NOTE: If necessary repeat steps 3 through 4 to fine-tune the unit.

Page 35 of 60
28. Stroke checking of Control Valve.
 Equipment and Materials Required:
a) Air Instrument.
b) Loop Calibrator (4 – 20 mA).
c) Connector.
d) Tubing and ferrule sets.
 Procedure of Control Valve Stroke checking:

 Connect control valve and its accessories as per connection diagram
(consider control valve is an ‘air to close’ valve).
 Apply Air Instrument for Supply pressure to Regulator.
 Adjust Regulator until pressure as per datasheet for Supply Pressure to
POSITIONER.
 Set Loop Calibrator to provide current Input Signal (4-20mA) to
POSITIONER.
 Apply 4 mA to positioner using loop Calibrator.
 Check the stem movement it must be at minimum position, if there is
any error adjust the zero calibrating screw in positioner.
 Apply 20 mA to positioner using loop Calibrator.
 Check the stem position it must be at 100% position ,if there is any
error adjust the span screw in the positioner
 Apply 0%, 25%, 50%, 75%, and 100% of the signal & observe the
corresponding stroke of the valve & stem position.

Page 36 of 60
29. Calibration of Control Valve.
Example calculation:
A: Max travel from stem = 70mm
B: Scale plate = 50mm
New open adjustment should be (50/70) × 100 = 71.48%
 Data sheet,
 Procedure of Control Valve Calibration:
 Ask panel man to put the controller in manual mode for control loop.
 Isolate the Valve from the process.
WARNING: The Isolation of control valve from the process shall be
done by field operator. Careful step shall be done to
ensure no upset to the operation.
data sheet such as Tag Number, OP and etc.
 Change from normal mode to setup mode.
 Select auto find stop (wait some minute).
 If full open is more than 100% select open adjustment and put new
number as per calculation.
 Make an auto calibration (wait some minute).
 Verify the linearity by increasing and decreasing the travel (0%, 25%,
50%, 75%, 100%, 75%, 50%, 25% and 0% of range).
normal mode.

Page 37 of 60
30. Calibration of Control Valve Positioner.
 Equipments required:
 positioner,
 Control valve.
 Pressure source.
 Procedure of Control Valve positioner Calibration:

 Zero adjustments are done at the nozzle
 Span adjustment is done by moving flapper assembly (follower
assembly) along the summing beam
 Air supply to the positioner is 20 psi.
 To calibrate move the flapper assembly to midrange of direct side or
about no.6
 Increase the input signal to 3 psi.
 Adjust the nozzle in or out slowly to make the output gauge output 0
psi.
 Increase the input pressure to 15 psi.
 If the output saturates too soon (at the output gauge) before giving
15psi move the flapper assembly to smaller number in the summing
beam.
 If the output saturates too late or above 15 psi move flapper assembly
to larger number at the summing beam.
 Every time when you move the flapper assembly reset the nozzle to
zero also.

Page 38 of 60
31. Replacements of Valve stem packing.
Valve stem packing is the

process of tightening the valve
gland follower with packing
material to reduce or eliminate
process leaks. The rings are metal with a hole at the centre. Which allows
lubrication to forced into the space between the ring and the stem. The
lubrication usually used is silicon grease.
 Procedure for Removing the Valve packing:
 Open the gland follower dog bolts & open the gland follower.
 Remove the packing rings using packing tools, without scratching the
shaft.
 If there is a lantern ring, remove this with a piece of wire bent into a
hook.
 Make sure all packing scraps have been removed.
 Procedure for Installing New Valve Packing
 Clean the shaft well using a non-flammable, non-toxic solvent.
 Brush down and then wipe the area with a clean rag.
 Calculate how many rings will be required by measuring the gap
between the shaft and the stuffing box, the depth of the stuffing box
and the thickness of the lantern ring.
 Wind the packing material round the mandrel as many times as the
number of rings required.
 Cut the rings with a sharp knife.
 Check how many rings you need to put below the lantern ring. Only
correct number of rings can place below the lantern ring. Otherwise, it
will not be in line with the lubricator.
 Lubricate the rings with an anti-seize compound, so they will go in
more easily.
 Insert the packing rings and lantern ring one by one, pushing them into
the stuffing box as far as they can go.
 Ring joints should stagger and cut on a slant, as shown:

Page 39 of 60
32. Calibration of Fieldbus Transmitters.
 Calibration in Fieldbus terminology
The terminology differs between the calibration of the conventional

instrument and the digital one. Traditionally in metrology, the word
calibration means that the instrument under test is compared to a more
precise instrument and may include trimming or adjusting the instrument
to show the correct readings again. In fieldbus terminology, the word
calibration means that the instrument is being configured or verified. The
main reason to calibrate is that even the best instruments drift and lose
their ability to give precise measurements. Drift makes calibration
necessary. Environment conditions, elapsed time and type of application
can affect the stability of a instrument. Even instruments from the same
manufacturer, type and range can show varying performance. You can find
that a unit has good stability, while another performs differently.
 Difference between conventional & fieldbus transmitters:
 Conventional transmitters
 Analogue one-way signal
 Only one variable.
 A pair of cable to each instrument.
 Conversion of mA signal to digital for I/O subsystem.

Page 40 of 60
 Field-bus transmitters
 Digital two-way signal.
 Huge amount of information is transferred.
 Several instruments in one bus cable (multi-drop).
 No conventional I/O systems needed.
 Open standard – Instruments from any manufacturer can be in the
same Field-bus.
The main difference between a

Fieldbus transmitter and
conventional transmitters is that the
output signal is a fully digital
Fieldbus signal. Change the output
signal does not change the need for
periodic calibration.
 Procedure for calibrating Fieldbus transmitters

Beamex MC5 Fieldbus Calibrator is a combination of a multifunction process
calibrator and a Field-bus configurator, which can be used with both industrial
standards Foundation Field-bus H1 and Profi-bus PA. It also houses HART
configuration and calibration facility.
 STEPS for calibrating Fieldbus transmitters

 2 persons needed for calibration.
 Make connections.
 Calibrate and document automatically – Simulate or generate the input
and read the digital output of the Field-bus instrument.
 Trim (adjust) if required and perform As Left calibration automatically
or manually.
 Upload calibration results to calibration software and print the
calibration certificate.
Page 41 of 60
33. If a control valve in a stuck how will you start checking?
a) Obtain the permit.
b) First of all get the control valve is passed from operation.
c) Check the lingual to the diaphragm of the control valve.
d) Disconnect it possible the actuator stem from the control valve stem.
e) Stroke the actuator and see whether the actuator operates or not. If not
then the diaphragm may be punctured.
f) If the actuator operates connect it back to the plug stem stroke the
control valve. If it does not operate loosen the gland nuts a bit and see
if it operates. If it does not then the control valve has to be removed
from the line to w/shop.

Page 42 of 60
1. Formula for current 4-20ma to Percentage
Conversion
Formula:
Percentage, % = ((X-
4)/16)(100)
Where
X is current signal in ma
Example:
An electronic Pressure transmitter is ranged -1 to 5 Bar
and has a 4-20 ma. Calculate the Percentage output by
this transmitter if the measured output current is 13ma.
Percentage % = ((X-4)/16)(100)
= ((13-4)/16)(100)
= 56.25
2. Formula for percentage to 4-20ma Conversion
Formula:
Current (mA) = [(16ma)(X/100)]+4
Where “X” is desired percentage of
signal
Example:
calculate the ma for 40 % of signal
Current (mA) = (16 ma)(x/100)+4
= (16)(40/100)+4
= 10.4 ma
3. Formula for Percentage to Process Variable

Conversion
Formula:
Process Variable =
Span(X/100) +LRV
Span = (URV) – (LRV)
Where
X is Percentage of signal
URV is Upper Range of value
LRV is Lower range of value

Page 43 of 60
Example:
A pressure gauge is ranged -1 to 1 bar; calculate the Measured
Variable for 40 % of signal
Span = (URV) – (LRV)
= 2 Bar
Process Variable = Span(X/100) +LRV
= (2)(40/100)+(-1) = -0.2 Bar
4. Formula for Process Variable to Percentage
Conversion
Formula:
Percentage % = ((Process
Variable – LRV)/Span)(100)
Span = URV-LRV
Where
URV upper range value
LRV lower range value
Example:
An electronic Pressure transmitter is ranged -1 to 5 Bar and has
a 4-20 ma. Calculate the Percentage output by this transmitter
if the measured Pressure is 1 Bar
Span = 5 – (-1) = 6
Percentage % = ((Process variable – LRV)/Span)(100)
=((1-(-1))/6)(100) = 33.33 %.
5. 4-20 mA formulas and Examples
Calling I the output

current and V the
Voltage—or other physical
variables (PV) —
between Vmin(which is
usually 0) and Vmax; the
conversion formulas are as
follows:
 I [mA] = ( ( (V − Vmin) / ( Vmax − Vmin) ) × 16 ) + 4

 V [Voltage] = ( (I − 4 ) / 16) × ( Vmax − Vmin) + Vmin

Page 44 of 60
 PV [units] = ( (I − 4 ) / 16) × ( PVmax − PVmin ) +
PVmin
Where,
I is the current,
V is the voltage,
PV is the Process Variable
min is the Lower Range Value of the respective signal
max is the Upper Range Value of the respective signal
Note that the values and units of min and max are units must
be same.
Example 1 :
A Analog output card gives an output voltage of 2.5V and its
overall range is 0-5V. calculate the equivalent 4-20mA current
value.
I = ( ( (V − Vmin) / ( Vmax − Vmin) ) × 16 ) + 4
I = ( ( (2.5 − 0) / ( 5 − 0) ) × 16 ) + 4
I = 12 mA
Example 2 :
A transmitter output range is 13.5mA and its output range is 4-
20mA. Calculate equivalent voltage. consider 0-10V is the
output voltage range.
V = ( (I − 4 ) / 16) × ( Vmax − Vmin ) + Vmin
V = ((13.5 – 4)/16 x (10 – 0 ) + 0
V = 5.9375 V
Example 3 :
A Flow transmitters output current is 16.5mA and its range is
0-1500 m3/hr. Calculate the equivalent flow rate value.
PV = ( (I − 4 ) / 16) × ( PVmax − PVmin ) + PVmin
PV = ( (16.5 − 4 ) / 16) × ( 1500 − 0 ) + 0
PV = 1171.87 m3/hr

Page 45 of 60
Standard 4 to 20 mA current conversion formula

A 4 to 20 mA current signal represents a 0 to 100 percent scale.
Usually, this scale is linear, as such:
Being a linear function, we may

use the standard slope-intercept
linear equation to relate signal
percentage to current values:
y = mx + b
Where,
y = Output from instrument
x = Input to instrument
m = Slope
b = y-intercept point (i.e. the live
zero of the instrument’s range)
Once we determine suitable values for m and b, we may then
use this linear equation to predict any value for y given x, and
vice-versa. This is very useful for predicting the 4-20 mA signal
output of a process transmitter, or the expected stem position
of a 4-20 mA controlled valve, or any other
correspondence between a 4-20 mA signal and some
physical variable.
Before we may use this equation for any practical purpose, we
must determine the
slope (m) and intercept
(b) values appropriate
for the instrument we
wish to apply the
equation to. Next, we
will see some
examples of how to do
this.For the linear
function shown, we
may determine the
slope value (m) by
dividing the line’s rise by its run. Two sets of convenient

Page 46 of 60
points we may use in calculating rise over run are 4 and 20
milliamps (for the rise), and 0 and 100 percent (for the run):

Page 47 of 60
6. Formulas to calculate ma from PV
The formula is:
SPAN = URV – LRV

Where
PV = Process
Variable
LRV = Low Range Value
URV = Upper Range Value
ma = milli ampere
Consider left side of formula for Process variable, LRV of
transmitter lower range, Span is the difference between LRV &
URV of transmitter ranges.
Consider right side of formula for current (ma), LRV of standard
current range .i.e is 4ma, Span is the difference between LRV
(4ma) & URV (20ma) of standard current range.i.e. 20-4 =
16Using this formula we can calculate ma from pv and as well
as pv from ma.
Calculate Current (4-20ma) from Process variable PV
For example: The temperature transmitter range is 0 to 50 deg c
and known current ma is 12 then how to calculate the PV of the
transmitter ?
Known values :
LRV = 0
URV = 50
mA = 12mA
Standard mA LRV and URV
LRV = 4mA
URV = 20mA
Span = URV – LRV
Span = 20 – 4
Span = 16

Page 48 of 60
Required :
PV = ?
Formula :
Solution:
Put Values in Formula
PV – 0 = mA – 4
SPAN 16
SPAN = URV – LRV
SPAN = 50 – 0
SPAN = 50
PV – 0 = 0.5 * 50
PV = 0.5 * 50
PV = 25
4-20mA signal from Porcess Variable conversion formula
Formula :
First calculate equivalent
percentage from the process
variable
Percentage = ( X – LRV / URV
– LRV ) . 100
Then calculate equivalent 4-
20mA signal from percentage
4-20mA = ( Percentage + 25 ) / 6.25

Page 49 of 60
Where,
X is Process Variable
LRV is Lower Range value
URV is Upper Range Value
Example:
A Flow transmitter has a range of 0 to 2500 m3/hr and it is
displaying flow rate of 1500 m3/hr. calculate the transmitter
output current.
Process variable = 1500 m3/hr
Lower Range Value, LRV = 0 m3/hr
Upper Range Value, URV = 2500 m3/hr
Note: units must be same for process variable, LRV & URV
Percentage = (1 500 – 0 / 2500 – 0 ) . 100 = 60 %
4-20 mA Signal = (Percentage + 25) / 6.25 = (60 + 25) / 6.25
= 13.6 mA
Process variable from 4-20mA conversion formula
Formula :
First Calculate equivalent
Percentage from 4-20mA
signal
Percentage = (X * 6.25 ) – 25
Process Variable =
[(Percentage * (URV – LRV)
/100)] + LRV
Where,
X is 4-20mA signal
LRV is Lower Range Value
URV is Upper Range Value
Example :
A Temperature transmitter with a range of 0 to 250 deg C and
its output is 15.5 mA. Calculate equivalent temperature value.
Lower Range Value, LRV = 0
Upper Range Value, URV = 250
Output Current in range of 4-20mA, X = 15.5 mA
Percentage = ( X * 6.25 ) – 25 = (15.5 * 6.25) – 25 = 71.875 %

Page 50 of 60
Process Variable = [ { Percentage * ( URV – LRV ) } / 100 ] + LRV
= [(71.875 * 250) / 100] + 0 = 179.6875
Air pressure(3-15psi) for a current signal(4-20mA)

conversion formula
(I – 4)/16 = (P – 3)/12
Example:
Calculate the equivalent
amount of air pressure for a
current signal of 17.5mA?
P = ((I – 4)/16) x (12) + 3
P = ((17.5 – 4)/16) x (12) + 3
P = 13.125 psi
Formula for Linear ma to Square root ma conversion
Formula:
Square root ma = {√ [(X-4)/16] }
.16 + 4
Where
X is Linear ma Value
Example:
Convert 12 ma linear to square root ma
Square root ma = {√ [(X-4)/16 ] } .16 + 4
= √ ((12-4)/16 ).16)+4
= 15.31 ma
Formula for Linear Percentage to Square root Percentage
conversion
Formula:
Square root % = Sqrt(X). (10)
Where
X is Linear Percentage Value
Example:
Convert 50 % linear to square root
Square root % = √X*10
= √50*10 = 70.71%

Page 51 of 60
6. The calculation of input-output relationships of
transmitter
Have you ever had that actually forget something simple? And
generally forgotten it was in the form like a formula. For
example, the formula to convert temperature unit of degrees
Celsius to degrees Fahrenheit. Generally we use the formula:
{(9/5) * x + 32 ° F}
Where “x” is the temperature in Deg C
So as to know how to calculate ° F of the temperature of 50 ° C,
if using the above formula to
{(9/5) * x + 32 ° F} = {(9/5) * 50 ° F} + 32 = 122 ° F
Easy enough right? Yes, if we memorized formula. The problem
is if we completely forgot the formula.
The calculation of input-output relationships of transmitter
Something similar may happen when we’re doing calibration,
like a pressure transmitter. For example, with an input pressure
of 0-300 PSI and 4-20mA output. If we use the method of 5-
point calibration (0%, 25%, 50%, 75% and 100%), it may be
quite easy for us, it should be how we put pressure on the
transmitter at the time of testing at 50% (12mA). But it is
different if we verify the pressure transmitter is already on-line
with different process value. For example, we find the pressure
on the input side of the transmitter is 235 PSI, then what is
the pressure transmitter output signal?
Back to the issue of conversion of temperature. If we forget the
formula, we can actually do the conversion without having
memorized the formula, the condition we know the upper limit
and lower limit for the second unit. Then, using the equation of
general comparison, we can create their own respective formula.
We know that the units Celsius has a measuring range
(measuring scale for the calculation) between 0-100 ° C and
Fahrenheit 32-212 ° F. So if asked, 50 ° C was how ° F, then:

Page 52 of 60
See calculation above, it may be longer than we memorize the

formula, here we do not try to memorize formulas, but
understand the concept, because the first formula above were
true simplification of calculations a second.
The concept of how it mean? This calculation is a calculation of
comparison, to compare two different scales.
Let’s agree that:
x ° C = value ° C
C min = minimum scale ° C = 0 ° C
C max = maximum scale ° C = 100 ° C
x ° F = value ° F
F min = minimum scale ° F = 32 ° F
F max maximum scale ° F = 212 ° F
thus:
Using the above equation:

Page 53 of 60
This applies to calculate the output

of a transmitter at the time of a
particular input. For example, as the
above example, we have a pressure
transmitter with 0-300 PSI pressure
input range and output 4-20mA.
Let’s agree:
x in = value transmitter input
(235PSI)
In min = scale of minimum input
transmitter = 0PSI
In max = maximum scale transmitter
input = 300PSI
x out = transmitter output value (mA)
Out min = minimum scale transmitter output = 4mA
Out max = maximum scale = 20mA transmitter output
With reference to the equation of comparison, the value of
235PSI input transmitter can be calculated:

Page 54 of 60
By understanding the concept of the above, we can make a
generic equation for the relation between the input and output
of a transmitter as follows:
Where:
x dit = value in question (want to know)
dit min = minimum scale range in question
dit max = maximum scale range in question = 300PSI
x dik = value unknown
dik min = minimum scale of a range of known
dik max = maximum scale of the known range
Example:
A temperature transmitter with an input range +50 to 200 ° F
and output range is 4-20mA. what is the output if input
temperature is 61 ° F:
completion:
dit min = 4
dit max = 20
x dik = 61
dik min = 50
dik max = 200
Then:

Page 55 of 60
Thus, the input temperature of 61 ° F, the transmitter output
is 5.1737 mA
Thus, a generic formula for calculating the relationship of input
and output transmitter or vice versa, can use:
Please try to calculate:

A temperature transmitter with input range -25 to 100 ° C and
output 4-20mA range, Transmitter output is 17.5 mA, and find
out temperature reading ?
May be useful.
Displacer Level Measurement Calculations
Problem 1 :-
A steel displacer of volume 0.25 cubic feet is 50% immersed
in oil of relative density 0.78;
the density of steel = 490 lbs per cubic foot
the density of water = 63 × lbs per cubic foot
Calculate the apparent weight of the displacer.
true weight of displacer = 0.25 ×

490 = 122.5 lbs
volume of oil displaced = 0.25 ×
0.5 = 0.125 cubic feet
weight of oil displaced = (0.125
× 0.78 × 63) lbs = 6.143 lbs
∴ Apparent weight of displacer

= true weight − displaced
weight
Apparent weight of displacer =

122.5 − 6.143 lbs = 116.36 lbs

Page 56 of 60
Problem 2 :-
A steel displacer of volume 0.1 cubic feet is to be used as a
level sensor in a vessel to store water.
Calculate the following;
1:- the maximum and minimum weights of the displacer.
2:- the maximum range of level able to be sensed, if the
diameter of the displ. is 2 inch.
true weight of displacer = 0.1 × 490 lbs = 49 lbs

volume of water displaced = 0.1
cubic feet
weight of water displaced = 0.1 ×
63 lbs = 6.3 lbs
∴ min. weight of the displacer = 49
− 6.3 lbs = 42.7 lbs
∴ max. weight of the displacer =
49 lbs
volume of the sensor = πr2L
Note : π = 3.142, 1 in = 1/12 ft =
0.0833ft
volume of the sensor ⇒ 0.1 ft3 =
3.142 × (0.0833)2 × L
0.1 ft3 = 0.0218 × L
hence, the length of displacer, L = 0.1 / 0.0218 = 4.587 ft , or 55
inches
Problem 3 :-
A steel displacer 1 metre long, and volume of 1000 CCs. is
to be used to measure the interface level in an oil and water
separator. The SG of oil is 0.78, the density of water is 1
kg/litre. Density of steel is 8000 kg per cubic meter.
Find,
1:- the diameter of the displacer.
2:- the displacer weight in air, oil & water.
3:- the “0%” and “100%” weights, if the 50% interface level
is set at the displacer’s mid-point, and the span is 0.5
metres.
The displacer is assumed to be totally covered with oil or water.

Page 57 of 60
volume of the sensor = πr2L

1000 c.c.s = 3.142 × r2 × 100 cm
thus, we now have, r2 = 1000 / (3.142 x 100 ) = 3.183 cm2
∴ the radius of displacer, r = Sqrt (3.183) cm = 1.78 cm
hence, the diameter of displacer = 1.78 × 2 cm = 3.56 cm
displacer’s weight in air = density × volume
Note that volume unit has to be inconsistent with density unit 1
ccs = 10−6 m3
= 8000 kgm−3 × (1×103/106) m3 = 8.0 kg
displacer’s weight in oil = (weight in air) − (weight loss in oil)
= 8.0 – (0.5 × 1 × 0.78) kg = 7.61 kg
displacer’s weight in water = (weight in air) − (weight loss in
water)
= 8.0 – (0.5 × 1 × 1) kg = 7.50 kg
at 0% interface level, the displacer’s length will be covered
25% with water and 75% with oil. Hence, the displacer’s total
weight will be made up of 75% of its weight in oil and 25%
weight in water;
∴ displacer weight at 0% = (0.75 × 7.61) + (0.25 × 7.5) = 7.582 kg
at 50%, the displacer’s total weight will be made up of 50%
weight in water, and 50% weight in oil;
∴ displacer weight at 50% = (0.5 × 7.61) + (0.5 × 7.5) = 7.555 kg
at 100%, the displacer’s total weight will be made up of 75%
weight in water, and 25% weight in oil;
∴ displacer weight at 50% = (0.25 × 7.61) + (0.75 × 7.5) = 7.527
kg

Page 58 of 60
Foundation field bus signal conversion formula
Every foundation fieldbus transmitters have mainly two types of
scales or ranges. one is XD scale & second one is OUT Scale.
Transducer scaling (XD_SCALE) is applied to the value from the
channel (sensor measurement) to produce the FIELD_VAL in
percent.
The OUT_SCALE is normally the same as the transducer, but if
L_TYPE is set to Indirect or Ind Sqr Root, OUT_SCALE
determines the conversion from FIELD_VAL to the
output. OUT_SCALE provides scaling for PV.
The PV is always the value that the block will place in OUT if the
mode is Auto.
You can set the signal conversion type with the Linearization
Type (L_TYPE) parameter. You can view the converted signal (in
percent of XD_SCALE) through the FIELD_VAL parameter.
You can choose from direct, indirect, or indirect square root

signal conversion with the L_TYPE parameter
Direct
Direct signal conversion allows
the signal to pass through the
accessed channel input value
(or the simulated value when
simulation is enabled)
PV = Channel Value
Indirect
Indirect signal
conversion converts the
signal linearly to the
accessed channel input
value (or the simulated
value when simulation
is enabled) from its
specified range
(XD_SCALE) to the range and units of the PV and OUT
parameters (OUT_SCALE).

Page 59 of 60
Indirect Square Root

Indirect Square Root
signal conversion
takes the square root of
the value computed
with the indirect
signal conversion
and scales it to the
range and units of
the PV and OUT parameters.
Plc analog input conversion formula
For any unit conversion

on any PLC you can use
four function math with
the following, which
assumes integer math:
Formulas:
EU = ((EUSpan x (DATA – DataOffset))/DataSpan) + EUOffset
ProcessValue = EU / FACTOR
DataOffset = Data in input register at 4 mA (or zero analog
signal of whatever range – for example 0 VDC on a 0-10 VDC
transmitter)
DataSPan = Data at 20 mA – Data @ 4 mA
FACTOR = arbitrary factor (multiple of 10) needed to get proper
resolution and accuracy
EU = Engineering Units x FACTOR
EUOffset = Engineering Units @ 4 mA x FACTOR
EUSpan = (Engineering Units @ 20 mA – Engineering Units @ 4
mA) x FACTOR
DATA = Actual data reading in input register
For Example,

Page 60 of 60
A Pressure transmitter of range 0 to 60 psig is connected to an
PLC analog input card. The PLC Analog input card raw count
starting from 6240 for 4mA and 31208 for 20mA. PLC reading
18975 raw counts and calculate equivalent pressure transmitter
reading.
Note: PLC raw counts may vary from system to system.
0-60 psig from 4-20 mA with resolution of 0.1 psig:
FACTOR = 10
Data @ 4 mA = 6240
Data @ 20 mA = 31208
DataOffset = 6240
DataSpan = 31208 – 6240 = 24968
EUOffset = 0 x 10 = 0
EUSpan = (60 – 0) x 10 = 600
DATA = 18975
EU = ((EUSpan x (DATA – DataOffset))/DataSpan) + EUOffset
EU = ((600 x (18975 – 6240)) / 24968) + 0 = 306
ProcessValue = EU / FACTOR
Process Value = 306 / 10 = 30.6 psig
Formula of AMP, KW, KVA, HP for AC and DC Voltages

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INSTRUMENTAION

1.4. List of Abbreviations

LOOP CHECK STEP USING HART - 475

FARMULA FOR LOOP CHECK AND CALIBRATION:-

Rnge Rnge MA PSI Percentage Degree Celsius Resistance Farenhight

𝑀𝐼𝐿𝐿𝐼𝑉𝑂𝐿𝑇 𝐶𝐻𝐴𝑁𝐺𝐸 𝐼𝑁 𝐺𝐴𝑃 𝑉𝑂𝐿𝑇𝐴𝐺𝐸

COMPLETED BY: - MD MUZAMMIL (EMAIL: - MUZAMMIL9308@GMAIL.COM)

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

1. Calibration of pressure switch.

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

2. Calibration of Temperature Switch.

 Procedure of Temperature Switch Calibration:

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

3. Calibration of RTD type Temperature Transmitter

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

4. Calibration of Thermocouple type Temperature Transmitter

 Connect the circuit as shown in figure.

5. Calibration of pressure guage.

 Procedure of pressure guage Calibration:

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

 Procedure OF Pressure Transmitter online calibration

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

8. Calibration of DP Transmitter at field.

Transmitter range = 0-2 kg/cm2

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

11. Calibration of capacitance type level transmitter

12. Calibration of DP Level transmitter with actual pressure.

DP = pressure at high side – pressure at low side

LRV = (Off set × Product S.G) – (Measurement length × Glycol S.G)

URV = (Full length × Product S.G) – (Measurement length × Glycol S.G)

 Procedure of DP LT Calibration with actual pressure:

 Hook up HART Communicator and verify some parameters by refer to

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

LRV = (Off set × Product S.G) – (Measurement length × Glycol S.G)

14. Calibration of Differential Pressure Level transmitter for

Product S.G =0.89

LRV = (Off set × Product S.G) – pressure at low side

URV = (Full length × Product S.G) – pressure at low side

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

Product S.G = 0.89

LRV = (Off set × Product S.G) – LP.

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

16. Calibration of DP LT for Capillary type.

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

17. Calibration of DP LT for Capillary type with offset.

 Procedure of DP LT capillary type with offset Calibration:

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

Low S.G = 0.802

0% = (Measurement length × Low S.G)

Low S.G = 0.802

0% = (High S.G x off set length) + (low S.G x Measurement length)

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)

20. Calibration of level troll or Displacer type level transmitter.

 Procedure of Leveltroll/displacer level transmitter Calibration:

COMPLETED BY: - Mohammad Muzammil (EMAIL: - muzammil9308@gmail.com)