Field Pressure Calibration & Equipment Maintenance Whitepaper Ronit Mukerji GMI/PTI Product Manager

GMI/PTI Product Manager Presenters Ronit Mukerji GMI/PTI Product Manager

Topics

Topics Introduction to Pressure Sensors Transmitters Verification & Calibration Basics FieldMate Basics Unique Solutions Applications

Pressure Introduction

Basic Physics of Pressure What is Pressure? It is a measure of force One of four common plant measurements Mathematically, pressure is expressed: P = F / A P = Pressure F = Force A = Area

Pressure Reference Gauge Absolute Vacuum Differential Positive Gauge Pressure Vacuum Atmospheric Pressure (Sea Level) 0 psig +14.7 psia Positive Absolute Pressure Reference Negative Gauge Pressure Vacuum Reference Absolute Zero Pressure (Perfect Vacuum) -14.7 psig 0 psia Reference Reference

Pressure Transmitters Absolute DP Gauge

Pressure Sensor Technologies

Pressure Sensor Types Capacitance Silicon Resonant Piezoresistive Typical Capacitance Pressure Sensor Two ‘H’ shaped bridges resonating @ 90 kHz are located in a silicon substrate Capacitor Plates Isolating Diaphragm Sensor Plates Fill Fluid 15-50 pf differential Piezoresistive Wheatstone Bridge Diaphragm Piezoresistor (4x) Silicon Pyrex Glass

Silicon Resonant Sensor

Silicon Resonant Sensor When a D.P. is applied Low Pressure Side High Pressure Side Tension Compression The outer sensor goes into tension (freq ) While the inner sensor goes into compression (freq ) The resultant D.P. is linear with the difference in frequency

Advantages of Resonant Sensor Inherently Digital Output Frequency Signal No A/D Conversion Errors Re-ranging Errors Eliminated Large Change in Output Excellent Resolution Frequency Shift 40K Hz Silicon Resonator Minimal Hysteresis Minimal Temperature Coefficient

Transmitter Overview

Quckly, Accurately, Reliably Transmitter Overview Process variable Sensor Convert to analog or digital signal Transmit signal Controller or monitor Quckly, Accurately, Reliably

Transmitter Terminology Lower Range Limit (LRL): Minimum value that a sensor can measure. Upper Range Limit (URL): Maximum value that a sensor can measure. Range: Total pressure that the sensor can measure. (Range = URL + │LRL│) Lower Range Value (LRV): The lowest value that the transmitter has been adjusted to measure. This value corresponds to the 4 mA analog signal. Upper Range Value (URV): The highest value that the transmitter has been adjusted to measure. This value corresponds to the 20 mA analog signal. Span: The difference between the URV and LRV (Span = URV – LRV). Sensor have a minimum span requirement that must be considered while assigning the 4 to 20 mA analog output. SPAN LRV URV N >N URL LRL 4 mA 20 mA RANGE

Verification and Calibration Overview

Calibration Basics Sensors convert pressure, current, voltage, temperature, humidity, light, sound, etc to a quantity that can be measured by a process controller (voltage, current, or resistance) Various types of field sensors include: Thermocouples/RTD’s – Temperature measurement Current Transformers – Current (mA,A) measurement Strain Gauges – Force (applied pressure) Photodiodes – Light Manometers – Pressure Microphones – Sound

Characterization Curve Characterization of Sensor Each sensor is unique; therefore it yields a unique output for a give input. Input Pressure Unique Sensor Unique Output Characterization Curve Input Pressure Unique Sensor Characterization Curve Unique

Sensor Readings and Scaling Calibration Basics Sensor Readings and Scaling Most, if not all, transmitters have default factory settings that are may or may not be matched accurately with the quantities they are measuring The idea is to linearize the process variable measurement range of the transmitter across its full span For example, if a pressure sensor is rated for 2000 PSI, we’d want it to output maximum current (20 mA) when we apply that pressure to the input For this discussion, we will focus exclusively on pressure sensors, due to their ubiquitous nature Temperature, flow and level can all be derived from pressure

CA150 Multifunction Calibrator Calibration Basics Portable Calibrators These calibrators are best designed for in field usage and combine accuracy with portability. They are mostly battery operated, although some may have connections for a wall socket They can support some of the most commonly used industrial protocols such as HART, BRAIN, ProfiBus, Modbus, and Ethernet/IP Other features include data logging to internal memory or and external drive for offline analysis CA150 Multifunction Calibrator CA450 Process Multimeter

When and Why to Use a Calibrator Calibration Basics When and Why to Use a Calibrator A calibrator is a type of instrument that functions both as a sourcing and a sinking device. Some of the most commonly encountered types of calibrators measure: Temperature Voltage/Current Power Pressure Resistance Their function is to verify sensor output by producing a stimulus (either current or voltage) and verify the reading of the transducer under test

Calibration Basics For example, A technician may want to verify that his or her temperature controller is displaying the proper output (in degrees C or F) based on thermocouple type A Temperature calibrator, which, at its core, is a highly precise DC voltage source that can output a wide range of voltages for different thermocouple types can be used for this purpose The calibrator’s output would then be used to adjust the sensitivity or verify the accuracy of a controller

Calibration – Why it is important Calibration Basics Calibration – Why it is important All test and measurement devices come with a certain accuracy as per specifications Over time, these instruments degrade due to normal wear and tear, as well as due to exposure to hazardous environments Periodic maintenance (anywhere from monthly to annually) is thus essential to making sure these instruments maintain their reliability At its core, calibration involves adjusting the tolerance levels of a measuring device against a known reference, so the two are in sync

As Found vs As Left Calibration Calibration Basics As Found vs As Left Calibration There are two commonly used types of calibration data available to manufacturers and end users of field instruments As Found data refers to the performance of the instrument in its latest state. For example, a company may have a pressure transmitter in a refinery for a year, and would like to know if the device is out of tolerance. He would then run through his calibration procedures to verify proper functionality. As Left data refers to the performance of the instrument after adjustment. If the As Found tests passed successfully, this step would not be necessary, or would only need minor adjustment

Calibration vs Verification Although the terms are sometimes used interchangeably, it is important to note that they are two different processes Calibration is used to determine what correction is needed for an instrument to meet its rated settings Verification determines the percentage error of the instrument’s readings relative to a maximum percentage error the end user is willing to accept I.e., a 2% error on a verification test with a maximum tolerance of 1% would be a “NO-PASS”

Pressure transmitter verification involves Choosing a span around which to linearize the transmitter 1 This need not necessarily be the maximum specifications of the unit, and often times is not As mentioned earlier, this is the (URV – LRV) Linearization involves the transmitter outputting maximum current (20mA) at the URV and 4mA at the LRV, with 12mA corresponding the average of the URV and LRV

Verification Comparing the measured value of the transmitter against a known reference point – A pressure calibrator 2 The rule of thumb is to have a calibrator which is at least four times as accurate as the unit under test For example, if our transmitter is rated for 0.04% of reading, we would want a pressure calibrator that has at least 0.01% accuracy First an As Found calibration is performed at predetermined tolerance levels Tolerance levels are specified in percentages, which then correlate to a mA deviation limit Yokogawa calculates this as ±((100% value of the measurement function – 0% value of the measurement function) × tolerance setting / 100)

Verification So if we use 4mA as our low range, 20 mA as the upper range, with a 1% tolerance, our threshold for pass/fail would be ±(20 mA – 4 mA)×0.01/100 = ±0.0016 mA Thus, if we are calibrating the URV at 1% tolerance, we should expect to get a reading from the transmitter between 19.9984 mA and 20.0016 mA If the unit passes the As Found test, no further calibration is necessary

If the unit does not pass the As Found test Verification If the unit does not pass the As Found test We then perform an adjustment This involves changing the URV and LRV parameters on the transmitter to match what is being read on the calibrator I.E., if our span is 0-2000 PSI, we’d want the transmitter to output 20mA when the calibrator is reading 2000 PSI, and 4 mA when it is reading 0 PSI We then do an As Left Calibration in a similar fashion as the As Found If adjustments were done properly in the previous step, we should see the transmitter reacting more similarly to the calibrator

Verification Once the As Left calibration process is finished, it is typical to generate a calibration report which details All tests performed on the unit The results (Pass/Fail) of each test and the margin by which the test results differed from the expected results The model and serial number of the UUT The date/time the tests occurred The pressure ranges and response times of each test

Verification Device Information Callibration Information: As Found: Device Tag Model EJX110A Serial No 91H336726 Product Date 1900/00/00 Loop Name Pressure Test Press. Range 0.00 – 100.00 kPa Output Range 4.00 – 20.00 mA Dsplay Range 0.0 – 100.0% Tolerance ±1% Callibration Date 2017.10.02 Callibration Model CA700 Callibration Serial 91PA10134 Generated by FieldMate Yokogawa Electric Corporation As Found: Target data Measured data Input Output Error Judge kPa mA % 0.000 4.000 -0.080 4.400 2.58% FAIL 50.000 12.000 49.440 11.886 -0.16% PASS 100.000 20.000 100.030 19.955 -0.32% Comment As Left: Target data Measured data Input Output Error Judge kPa mA % 0.000 4.000 0.040 4.010 0.02% PASS 50.000 12.000 50.990 12.174 0.09% 100.000 20.000 100.760 20.142 0.12% Comment

CA700 The Yokogawa CA700 Portable Pressure Calibrator uses the same DPharp sensor technology as our EJA-E and EJX-A series pressure transmitters. It provides an accurate and efficient calibration and verification tool for any pressure transmitter or other type of field device.

PM100 2300 PSI Module Due to high demand in the US market to calibrate larger pressure ranges, Yokogawa released the PM100 2300 PSI (16 MPa) module Effectively extends the calibration range of the CA700, while still maintaining the same basic accuracy of 0.01% of reading This unit plugs into the top of the CA700 via a connection cable that converts the measured pressure to digital data. CA700’s with firmware version earlier than 1.10 will need to be updated to 1.10 to communicate with this unit 112 (W) × 75 (H) × 148 (D) mm Approx.1.2Kg

FieldMate Overview

What is FieldMate?? Field Device Configuration and Management Tool Portable PC Based One Tool for All Instruments (Regardless of Comm. Protocol or Manufacturer)

Unable to edit its test pattern Differences in FieldMate versions Lite Edition vs Full Function Edition Functionality FieldMate Remark Lite Edition Full Function Edition FieldMate recording the information of the device connected in the past (Number of Device Maintenance Information) 7 Devices 500 Devices FieldMate Lite Edition does not support importing/exporting function. FieldMate showing 10 Typical parameters on Home Screen (Segment Viewer) Not Selectable Selectable FieldMate conducting “Input Loop Check” based on its test pattern Unable to edit its test pattern Editable test pattern Report function is limited (Max. only 7 devices) FieldMate generating the report of parameter comparison between past and current one No support Support

FieldMate Communication FieldMate is a single tool which supports device configuration of multiple vendors and leading industry standard communication protocols.

FieldMate HART Hardware Setup HART/BRAIN EJA/EJX Pressure Transmitter 24 VDC Power Supply Load Resistor (250Ω) USB Modem (HART/BRAIN) SUPPLY CHECK USB FieldMate MODEM EJA USB Load Resistor PC/FieldMate No porlarity + - 24VDC Power Unit

FieldMate Maintenance Features Home screen (New Interface of Segment Viewer) Conduct frequently used functions from Home Screen 1 Device Icon Yokogawa Device only Device Status Color coded status of online device Typical Parameters 10 frequently used parameters can be selected by user Memo, Photo, Configuration Tool Latest device appearance Device Configuration from Action button Device Info. Tag, Vendor, etc. Frequently used function Last conducted data is also shown 2 1 3 4 2 3 6 4 5 5 6

FieldMate Maintenance Features Home screen (New Interface of Segment Viewer) Conduct frequently used functions from Home Screen Multi protocol support Users do not usually change the communication protocol, hence this function is not shown as default. From this button, show and change the communication protocol.

FieldMate Maintenance Features Example: User’s work flow for Device Installation Configuration & Parameter Check Zero Adjustment Calibration Check (if users want) Installation of Devices Zero Adjustment Loop Check Work Report Home screen

New Features for R3.03 c FieldMate CA700 with PM100 Calibration Procedure Link with Pressure calibrator expands device maintenance and management capability Trend Data and Alarm List History Selected data are displayed and stored every time on its connection BT200 displayed New look and feel

Field Equipment Maintenance New Features for R3.03 c Field Equipment Maintenance USB cable Measurement Leads FieldMate modem Air tube Pressure transmitter Pressure pump

Field Mate Core Features Field Mate Additional Features Review of Field Mate BACKGROUND Configure the Field Device parameters to fit a users’ process and to bring out the Field Device performance, which in turn will help to optimize facilities operations. Field Mate Core Features Provide better screen an onscreen configuration guides to ensure the efficient device configuration. Field Mate supports a dedicated configuration tool for Yokogawa devices. Support device configuration of multiple vendors and leading industry standard communication protocols. Field Mate Additional Features Generate the reports by only one click Save the additional information about a device condition Share Maintenance info with PRM for Total Asset Management

Applications

Applications Maintenance Recalibration Flow Measurement Filter Measurement

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