Practical Calibration Plan & Execution of Field Instrument

Practical Calibration
Plan & Execution of

Industrial Instruments
Practical Experienced Based Training.
Calibration Steps & Execution Plan.
Farooq Ali Chaudhry
(Instrument & Control)
11/3/22
Practical Calibration Plan & Execution of Industrial Instruments
Table of Contents
Recommendations & Approvals at Shuwaikh Power Station Kuwait ........................................................ 5
Recommendations, Reviewed & Approval at DEPS Kuwait ....................................................................... 6
Dedications .................................................................................................................................................. 7
About Author ............................................................................................................................................... 8
1. Calibration Steps of .......................................................................................................................... 10
1.1 Pressure & Differential Pressure Gauge Calibration Steps ......................................................... 11
1.1.1. Selection of standard pressure gauge against faulty gauge. .............................................. 11
1.1.2. Selection of pressure source or Test Equipment: ............................................................... 11
1.1.3. Function test of Pressure gauge (Internal Checkup). .......................................................... 11
1.1.4. Set up the Calibration Loop & Leak Test. ............................................................................ 11
1.1.5. Pressure Gauge Calibration Loops with different Test Equipment..................................... 11
1.1.6. Check & Record 5 pints of readings & Units. ...................................................................... 12
1.1.7. Calculate the error in % before calibration. ........................................................................ 12
1.1.8. Error Calculation Formula in %age...................................................................................... 13
1.1.9. Calibration Process of a pressure Gauge. ........................................................................... 13
1.1.10. Record 5 pints’ readings After Calibration. ......................................................................... 15
1.1.11. Again calculate the error in %age after Calibration. ........................................................... 15
1.1.12. After Calibration Completion. ............................................................................................. 15
1.2 Temperature Gauge Calibration / Test (Steps) ........................................................................... 16
1.2.1 Set up the Temperature Gauge Calibration Loop. .............................................................. 16
1.2.2 Record 5 pints’ readings (0%, 25%, 50%, 75% & 100%). ..................................................... 17
1.2.3 Calculate the error in %age before calibration. .................................................................. 17
1.2.4 Error Calculation Formula in %age...................................................................................... 17
1.2.5 Calibration Process of a Temperature Gauge. .................................................................... 17
1.2.6 Record 5 pints’ readings After Calibration. ......................................................................... 19
1.2.7 Again calculate the error in %age after Calibration. ........................................................... 20
1.2.8 After Calibration Completion. ............................................................................................. 20
1.3 Calibration of different types of Switches .................................................................................. 21
1.3.1 Complete Calibration / Test, Loop Setup of a Switch. ........................................................ 21
1.3.2 Start Calibration & Adjustment of a Switch ........................................................................ 22
1.4 Pressure & Diff. Pressure Transmitter Calibration ...................................................................... 24
1.4.1 Set up the loop for analog Calibration, Output 4~20 mADC only ....................................... 24
1.4.2 Calculation of Current against Pressure or Differential Pressure. ...................................... 25
FAROOQ ALI CHAUDHRY 1

1.4.3 Record 5 pints’ readings (0%, 25%, 50%, 75% & 100%) (4~20mADC) ................................ 25
1.4.4 Analog Calibration of Pressure or Diff. Pressure Transmitter. ............................................ 26
1.4.5 Record 5 pints’ readings in calibration sheet “After calibration column” .......................... 27
1.5 Level Transmitter Calibration / (Steps). ...................................................................................... 28
1.5.1 Calculate current against level transmitter. ....................................................................... 28
1.5.2 Set up the calibration loop. ................................................................................................. 28
1.5.3 Record 5 pints’ readings “Before Calibration Readings”. ................................................... 29
1.5.4 Analog Calibration of Pressure or Diff. Pressure Transmitter. ............................................ 29
1.5.5 Record 5 pints’ readings in calibration sheet “After calibration column” .......................... 30
1.6 Test of of Thermocouples / RTD Test (Steps). ............................................................................ 31
1.6.1 Set up the continuity test loop of a Thermocouple (T/C) / RTD. ........................................ 31
1.6.2 Thermocouple (T/C) continuity Test loop. .......................................................................... 31
1.6.3 RTD continuity Test Loop. ................................................................................................... 32
1.6.4 Setup the actual Test of T/C & RTD with Ice Pot & Temperature Bath. ............................. 32
1.6.5 Start Calibration / Test: ....................................................................................................... 33
1.6.6 Test of Ambient Temperature ............................................................................................ 33
1.6.7 Test of Maximum Temperature .......................................................................................... 33
1.7 Control Valve Calibration ............................................................................................................ 35
1.7.1 Set up the calibration loop of control valve. ....................................................................... 35
1.7.2 Record 5 pints’ readings (0%, 25%, 50%, 75% & 100%) (4~20mADC) ................................ 36
1.7.3 Error calculation formula of control valve Positions........................................................... 37
1.7.4 Start calibration of control valve. ....................................................................................... 37
1.7.5 Record 5 points of valve positions’ readings “in after calibration column”. ...................... 38
2. Practical Execution Plan for 6 Weeks Training. ............................................................................ 39
2.1 Practical Execution Plan .............................................................................................................. 40
2.2 Responsibilities of all Trainees. ................................................................................................... 41
2.3 Arrangement of Instrument LAB ................................................................................................. 41
2.4 List of Instrument Trainees ......................................................................................................... 42
3. 6 Weeks Practical Calibration Plan ................................................................................................. 43

3.1 1st Week, 3 Groups / 6 Weeks Practical Calibration Training .................................................... 44

3.2 2nd Week, 3 Groups / 6 Weeks Practical Calibration Training ................................................... 45
3.3 3rd Week, 3 Groups / 6 Weeks Practical Calibration Training .................................................... 46
3.4 4th Week, 3 Groups of 6 Weeks Practical Calibration Training .................................................. 47
4. Attendance & Calibration / Practice / Test Sheets ...................................................................... 50
3.1 Practical Training of Instrument Technicians .............................................................................. 51
3.1.1 Trainees Weekly Attendance Sheet .................................................................................... 51
3.2 Pressure / Diff. Press. & Temperature Gauge Calibration / Test ................................................ 52
3.3 Pressure, Temperature, Level & Flow Switch Calibration / Test ................................................ 55
3.4 Pressure/Diff. Pressure, level & Flow Transmitter Calibration / Test ......................................... 57
3.5 Thermocouple / RTD Calibration / Test ...................................................................................... 59
3.6 Control Valve Calibration / Test .................................................................................................. 61
5. Weekly Rotation Duty of Technicians ............................................................................................ 63
5.1 Weekly Rotation Duty of Technicians ......................................................................................... 64

Table of Figures
Figure 1: Pressure Gauge Calibration Loops with different Test Equipment.............................................. 12
Figure 2: Temperature Gauge Calibration Loop ......................................................................................... 16
Figure 3: Different types of Switches .......................................................................................................... 21
Figure 4: Loop for Press. DP Switch ............................................................................................................ 21
Figure 5: Loop for Temperature Switch ...................................................................................................... 21
Figure 6: Loop for Level Switch ................................................................................................................... 21
Figure 7: Process Loop with High & Low Alarms SP. ................................................................................... 22
Figure 8: High & Low SP Chart of Different Switches.................................................................................. 22
Figure 9: Analog Pressure & DP Transmitter .............................................................................................. 24
Figure 10: SMART Pressure & DP Transmitter ............................................................................................ 24
Figure 11: level transmitter Calibration Loop ............................................................................................. 28
Figure 12: T/C Test Loop for (0C) ................................................................................................................ 32
Figure 13: RTD Test Loop for (0C) ............................................................................................................... 32
Figure 14 :C/V Calibration Loop with Pn. Positioner.................................................................................. 36
Figure 15: C/V Calibration Loop of SMART Positioner ................................................................................ 36
Figure 16: Practical Execution Plan ............................................................................................................. 40
Figure 17: 1st Week, 3 Groups / 6 Weeks Practical Calibration Training ................................................... 44
Figure 18: 2nd Week, 3 Groups / 6 Weeks Practical Calibration Training .................................................. 45
Figure 19: 3rd Week, 3 Groups / 6 Weeks Practical Calibration Training. .................................................. 46
Figure 20; 4th Week, 3 Groups / 6 Weeks Practical Calibration Training ................................................... 47
Figure 21: 5th Week, 3 Groups / 6 Weeks Practical Calibration Training ................................................... 48
Figure 22: 6th Week, 3 Groups / 6 Weeks Practical Calibration Training ................................................... 49
Figure 23: Trainees Weekly Attendance Sheet ........................................................................................... 51
Figure 24: Pressure & Diff. Pressure & Temperature Gauge Calibration / Test ......................................... 52
Figure 25: Pressure, Temperature, Level & Flow Switch Calibration / Test ............................................... 55
Figure 26: Pressure / Diff. Pressure, level & Flow Transmitter Calibration / Test ...................................... 57
Figure 27: Thermocouple / RTD Calibration / Test ..................................................................................... 59
Figure 28: Control Valve Calibration / Test ................................................................................................. 61
Figure 29: Weekly Rotation Chart ............................................................................................................... 64

Recommendations & Approvals at Shuwaikh Power

Station Kuwait

Recommendations, Reviewed & Approval at

DEPS Kuwait
Recommended by:
Eng. Ahmed Abbas Ashkanani
IMD Section Head
(Instrument Superintendent)
MEW - DEPS – Kuwait
Reviewed and formation advised by:

Eng. Vankatesh Srinivasa Rangan
IMD Consultant
MEW - DEPS - Kuwait
Reviewed & Verified by:

Eng. Gherghe Gheorghe
IMD Consultant
MEW - DEPS - Kuwait
Approved by:
Eng. Muhammad Abdulla Al-Ali
Director
MEW – DEPS - Kuwait

Dedications
I dedicate this book, with special thanks to my beloved Parents, Wife and Children with
their support I learned to be honest, hardworking and follow the right path in life.
The books published are:
 Industrial Instrument Training Course. (Part - 1 & 2)
 Standard Calibration Procedures (SCP).
 Practical training plan & calibration execution of field instruments &
practices in the field.
 How to write Technical specifications of spare parts of a Power Plant.
Special thanks to ENG. YAMAMOTO & ENG. HORIGOME from YAMATAKE CO.
JAPAN (New Name: AZBIL CO. Japan), who
helped my theoretical and practical training of
all types of instrumentation including Control
Room Instruments, Analog Control system,
Interlocks, Safeties & Field Instruments
Thanks to Eng. Ejaz-u-Din Shaikh (MEW IMD

Section Head 1979) who gave me liberty to
challenge myself to enhance my knowledge &
practical experience in this field.
Thanks to Eng. Iqbal Hussain (Senior

Instrument Engineer) who trained me for
specialized skills at Boilers, Turbine Interlocks and its safety protections of power Plant.
Special thanks to Eng. Ahmad Ashknani (IMD Superintendent of Doha East & West
Power Station Kuwait) who motivated me to utilize my skill and experience to write in my
books.
Special thanks to Eng. Salah Al-Mail (IMD Superintendent of Doha East Power Station
& Shuwaikh Power Station Kuwait) whom I worked closely at Boilers, Turbines and
Auxiliaries maintenance. In office coordinator.

About Author
Farooq Ali Chaudhry
Senior Instrument Supervisor (Instrument Trainer)
DEPS & SHKPWS – Kuwait

 Mr. Farooq Ali Chaudhry has completed his Electrical Associate Engineering in
1974 from Government Collage of Technology Lahore Pakistan.
 Experience started from Jan. 1978 to May 1979 at MEW project DEPS for 7 units
including common unit of Distillation Plants (MSF) with IHI CO. This was alongside
with Japanese engineers of sub. Contractor: YAMATAKE INSTRUMENT CO. Japan
– which is one of the well-known industrial instrumentation companies around the
globe. Each plant has a capacity of 6 Million Gallons / Day. Calibrated, Configured
and installed all field and control room instruments with auxiliaries, commissioned
and put in service for production.
 Completed 1.5 Year with Sub. contractor YAMATAKE Co. Japan in DEPS Kuwait.
 Joined MEW from May 1979 working at Doha East Power & water Station Kuwait,
with a total tenure of 38.5 years and retired January 2019.
 During this period Mr. Farooq Ali Chaudhry has worked on 7 units of Toshiba T
Turbo-Generators with all auxiliaries, each generator having 150 MW capacities.
 Worked on 4 units of FCB Boilers (Each having capacity of 650 Tons/Hr.) & 7
Units of Toshiba Turbo-Generators (Each having capacity of 150 MW.) - with all
their auxiliaries,
 Worked 1 year with DESCON Engineering Co. at their Client ICI Khewra (Salt Mine
Area) Pakistan Project. Completed their Extension of Soda Ash Plant in Pakistan.
From Aug. 1990 till Sep. 1991 (Installation, Commission & startup).
 Rejoined as Senior Instrument Supervisor & Trainer (for Instrument Engineers
& Technicians) in MEW IMD Section at Shuwaikh Power & Water Station Kuwait
as manpower supply through Al- Dhow Contracting Co from January 2019 till Jan.
2022. (3 Years) Here we have 3 Boilers, 3 Distiller Units. Each unit having a
capacity of each 6 Million Gallons / Day and RO Plant (2 Chains) having a capacity
of 30 Million Gallons / Day.
 Engaged with IMD Section Superintendent and Section Engineers by providing
technical support in keeping much complex record of spare parts and streamlining
spare parts processes in MEW DEPS & SHKPWS.
 To spread the knowledge, he has gained throughout his service to MEW DEPS.
He decided to pass it on to the coming generation from January 2014 onwards.
This included theoretical and practical trainings to new MEW Kuwaiti employee
may it be Instrument Engineers or Technician.
 Total experience is 44 years in this field at Doha East Power & Water Station and
Shuwaikh Power & Water Station Kuwait.
 Mr. Farooq Ali Chaudhry has been rewarded and appreciated “Many Times” by
MEW Directors of DEPS & SHKPS for being internally motivated to training young
Instrument Engineers & Technicians making an effort to develop several training
programs (Theoretically & Practically) and refining them throughout.

1. Calibration Steps of
1. Pressure & Differential Pressure Gauges.
2. Temperature Gauge.
3. Different Types of Switches.
4. Pressure & Differential Pressure Transmitter (DPT for Level & Flow).
5. Displacement Type Level Transmitter.
6. Thermocouple & RTD (Continuous & Actual Test).
7. Control Valve.

1.1 Pressure & Differential Pressure Gauge Calibration

Steps
1.1.1. Selection of standard pressure gauge against faulty gauge.

8. Select proper standard pressure gauge having minimum / very less error.
9. In case of Druck tester and multifunction tester std. pressure gauge is not required.
10. Only range selection is important on the Druck or Multifunction calibrator.
1.1.2. Selection of pressure source or Test Equipment:

1. Dead weight tester.
2. Hand pump (Air / Hydraulic).
3. Instrument air pressure,
4. Vacuum pump,
5. Druck tester.
6. Multifunction tester -.etc.
1.1.3. Function test of Pressure gauge (Internal Checkup).

1. Pressurizing the pressure gauge sensor.
2. See any restriction of Needle stuck by increasing and decreasing pressure.
3. If needle stuck any place on scale, then open the glass.
4. Remove the needle and scale plate then check the internal parts of the gauge.
5. Check the Pressure sensor.
6. Hair spring should be OK.
7. Rack and pinion gear teeth.
8. All fittings, screws and links.
9. Finally lubricating the gears if dry.
1.1.4. Set up the Calibration Loop & Leak Test.

1. Connect the faulty gauge with selected test equipment, according to the procedure.
2. Pressurize the gauge and check the leakage in the loop.
3. If there is leak, tightened it and fix it.
1.1.5. Pressure Gauge Calibration Loops with different Test Equipment.

1. Hand Pump with Multifunction Calibrator Loop & Druck Calibrator Loop.

Figure 1: Pressure Gauge Calibration Loops with different

Test Equipment.
2. Calibration Loop with Dead Weight Tester / Calibrator.
1.1.6. Check & Record 5 pints of readings & Units.

1. 5 points are 0%, 25%, 50%, 75% & 100%.
2. Increasing pressure in pressure gauge.
3. Decreasing pressure in the pressure gauge.
4. This is called before calibration readings.
5. Record these 5 points readings in “as found column / before calibration
column” as shown below chart.
1.1.7. Calculate the error in % before calibration.

1. Write the standard approved error in the calibration sheet.
2. To understand that calibration is required.
3. If error should be more than the standard max. Approved error, then calibration is
required.
4. Write the error in the calibration sheet in “as found or before calibration
column”.
5. This error can be (+) or (-)

1.1.8. Error Calculation Formula in %age.
Input Pressure Actual Pressure Difference Error

Order or “As found” Input / Output %age
Diff. Pressure or Before Pressure (+) or (-)
Calibration
0%
25% ↑
50% ↑
75% ↑
100% ↑
75% ↓
50% ↓
25% ↓
0%
1.1.9. Calibration Process of a pressure Gauge.

1. Write the pressure range of the pressure gauge.
2. Write the standard approved error of instrument in the calibration sheet.
3. Mark 3 points on the frame of the gauge.
4. “0%”, “50 %” and “100%” positions of units for calibration.
5. Now remove the Pointer / Needle.
6. Remove the Scale plate to reach the span adjustment screw.
7. Now Fix only pointer without scale.
8. Adjust Zero from the needle (Remove the Needle and refit at “0” or adjust
zero if adjustment screw available.
9. Increase (↑) input pressure & observe the needle is reached to 100%”.
10. If not reached to marked point 100% then adjust Span adjustment screw till
that reading should be very near to the input standard pressure.

11. Now Decrease (↓) input pressure till “0%” & if not reached then adjusts
needle again at “0%”.
12. Repeats steps (8, 9, 10 & 11) by increasing (↑) and decreasing (↓) pressure
in the pressure gauge and adjust the zero and span screws every time till
that reading should be very near to the input pressure at each point and error
should be less than standard approved error.
13. If “0%” and “100%” is correct.
14. Then check 3 points (“0%”, “50 %” and “100%”) became correct.
15. Now remove the needle again and fix back the scale plate.
16. Now refit the needle and adjust Zero of needle.
17. Now check the 5 points of the gauge (“0%”, “25%” “50 %” “75%”and “100%”).
18. Cheek, there should be No hysteresis by ascending and descending in the
readings on any point.
19. If all 5 points readings are correct then record these readings in “after calibration
column”
20. Now check and write the difference between input and output readings / values
on each point.
21. Now calculate the error in %age each point at according to the above Formula.
22. Error should be less than the standard approved error at all 5 points.

23. Then pressure gauge is passed and ready to install back to its location for
service.
1.1.10. Record 5 pints’ readings After Calibration.

0%, 25%, 50%, 75% & 100% by increasing and decreasing pressure in the
pressure gauge.
Input Pressure Actual Pressure Difference Error

Order or After Calibration Input / Output %age
Diff. Pressure Pressure (+) or (-)
0%
25% ↑
50% ↑
75% ↑
100% ↑
75% ↓
50% ↓
25% ↓
0%
1.1.11. Again calculate the error in %age after Calibration.

Now this error should be less than standard approved error on each point.
According to above procedure Calibration will be passed.
1.1.12. After Calibration Completion.

1. Remove test equipment & fix the cover after calibrating.
2. I & C Inspector & Quality Inspector should be witness & check the calibration.
3. Complete the calibration certificate for approval and Signed by I & C Engineer.
4. It is ready to install in the field.

1.2 Temperature Gauge Calibration / Test (Steps)
Different types of Temperature Gauges used in Process Lines.
1.2.1 Set up the Temperature Gauge Calibration Loop.

Connect the faulty gauge with test equipment, according to the procedure.
Figure 2: Temperature Gauge Calibration Loop

1.2.2 Record 5 pints’ readings (0%, 25%, 50%, 75% & 100%).
1. Write the temperature gage range as marked on the scale in the calibration sheet.
1. Write the standard approved error of instrument in the calibration sheet.
2. Insert bulb in the Ice Box and wait to stabilize the “0” C.
3. Read the temperature gauge, needle should reach to “0” C.
4. Insert the bulb in the Temperature bath to increase temperature.
5. By increasing (↑) and decreasing (↓) temperature in the temperature bath.
6. This is called “as found or before calibration” readings.
Input Actual Temperature Difference Error

Temperature “As found” Input / Output %age
Order or Before Calibration Temperature (+) or (-)
0%
25% ↑
50% ↑
75% ↑
100% ↑
75% ↓
50% ↓
25% ↓
0%
1.2.3 Calculate the error in %age before calibration.

1. To understand that calibration is required.
2. Write the error in error column.
3. If error is more than the standard max. Approved error, then calibration is required.
1.2.4 Error Calculation Formula in %age.
1.2.5 Calibration Process of a Temperature Gauge.

1. Mark 3 points on the frame of the gauge.
2. 3 points are “0%”, “50 %” and “100%” positions of units for calibration.

3. Now remove the Pointer / Needle.

4. Remove the Scale plate to reach the span adjustment screw.
5. Now Fix only pointer without scale.
6. Insert bulb in to the Ice Box and wait to stabilize temperature at “0” C.
7. Adjust Zero from the needle. (Remove the Needle and refit at “0” C or adjust
Zero if adjustment screw available).
8. Insert bulb in to the temperature bath and wait to stabilize maximum
temperature.
9. Increase (↑) input temperature & observe the needle is reached to 100%”.
10. If not reached to marked point 100% then adjust Span adjustment screw till
that reading should be very near to the input temperature.
11. Now Decrease (↓) input temperature till “0%” in the ice bath & if not reached
then adjusts needle again at “0%”.
12. Repeats steps (6 to 11) by increasing (↑) and decreasing (↓) temperature in
the temperature gauge and adjust the zero and span screws every time till
that reading should be very near to the input temperature at each point and
error should be less than standard approved error.

13. If “0%” and “100%” is correct.

14. Then check 3 points (“0%”, “50 %” and “100%”) became correct.
15. Now remove the needle again and fix back the scale plate.
16. Now refit the needle and adjust Zero of needle.
17. Now check the 5 points of the gauge (“0%”, “25%” “50 %” “75%”and “100%”).
18. Cheek, there should be No hysteresis by ascending and descending in the
readings on any point.
19. If all 5 points readings are correct then record these readings in “after calibration
column”
20. Now check and write the difference between input and output readings / values
on each point.
21. Now calculate the error in %age each point at according to the above Formula.
22. Error should be less than the standard approved error at all 5 points.
23. Then temperature gauge is passed and ready to install back to its location for
service.
1.2.6 Record 5 pints’ readings After Calibration.

0%, 25%, 50%, 75% & 100% by increasing and decreasing pressure in the
pressure gauge.
Input Actual Difference Error

Order Temperature Temperature Input / Output %age
After Temperature (+) or (-)
Calibration
0%
25% ↑
50% ↑
75% ↑
100% ↑
75% ↓
50% ↓
25% ↓
0%

1.2.7 Again calculate the error in %age after Calibration.

1.2.8 After Calibration Completion.

1 Remove test equipment & fix the cover after calibrating.
2 I & C Inspector & Quality Inspector should be witness & check the calibration.
3 Complete the calibration certificate for approval and Signed by I & C Engineer.
4 It is ready to install in the field.

1.3 Calibration of different types of Switches
There are many types of switches installed in the field like Pressure switch, Differential
Pressure switch & Temperature switch, Level switch & Flow switch. These all types of
switches need calibration.
FS
PS LS
LS
Figure 3: Different types of Switches
DPS
1.3.1 Complete Calibration / Test, Loop Setup of a Switch.
1. High / Low Pressure or DP Alarm,

2. High / Low Temperature Alarm
3. High / Low Level Alarm.
4. Low Flow Alarm.
Figure 4: Loop for Press. DP Switch Figure 5: Loop for Temperature Switch Figure 6: Loop for Level Switch

1- Write the SP Value & Unit, in calibration sheet: ------------------------------------------

2- Check the Contacts used for alarms “NC or NO”: ------------------------------------
Order Alarm Contact SP “as found “or
H / L Used Before Calibration
(a) ON at High by Increasing (↑) (Set)
(a) OFF by Decreasing (↓) (Reset)
Difference between (Set & Reset)
or
(b) ON at Low by Decreasing (↓) (Set)
(b) OFF by Increasing (↑) (Reset)
1.3.2 Start Calibration & Adjustment of a Switch

1. The process chart of switches is shown in this picture.
2. Remove the cover of a pressure Temp. or
Level switch.
3. Increase (↑) input Pressure /
Temperature or Level…etc & observe SP
(set) contact position on multi-meter.
4. It will change his position when process
will touch the switch sensor.
5. As soon as ON-OFF contacts changed,
write this value in the calibration sheet in
“as found or before calibration
column”.
6. Now check the SP value is matching with
this reading.
7. If yes, then decrease (↓) the input value
& check the Re-Set value by decreasing
input.
8. In this condition, also write the Set &
Reset Values in the calibration sheet in
after calibration column.
Figure 8: High & Low SP Chart of Different Switches.
9. If this ON-OFF value Not matching with
set point (SP), then calibration is required.
Figure 7: Process Loop with High & Low Alarms SP.
10. Now increase (↑) input value adjust the

(SP) with set point adjustment screw that ON-OFF contact should be change
it position at required set point of Pressure, Temperature or Level .. etc.

11. Decrease (↓) input Pressure, Temperature or Level .. etc. & observe the (Reset)
contact position.
12. If there is No differential adjustment, then Rest value should be as minimum
as possible.
13. Repeats steps (10 & 11) by Increasing (↑) and Decreasing (↓) Pressure,
Temperature or Level .. etc.
14. Adjust the Set Point Screw till that Switch contacts should be ON - OFF exactly
on SP value.
15. If calibration is completed and SP values is OK, then, write the Set & Reset
Values in the calibration sheet in “After calibration column”
Order Alarm Contact SP

H / L Used After Calibration
(a) ON at High by Increasing (↑) (Set)
(a) OFF by Decreasing (↓) (Reset)
or
(b) ON at Low by Decreasing (↓) (Set)
(b) OFF by Increasing (↑) (Reset)


1.4 Pressure & Diff. Pressure Transmitter Calibration
There are 2 types of transmitters.
1. Analog type Pressure & Differential Pressure Transmitter.

Output: Only 4~20 mADC.
2. SMART type HART Pressure & Differential Pressure Transmitter.
Output: 4~20 mADC & Frequency.
SMART PT
PT
SMART DPT
DPT
Figure 9: Analog Pressure & DP Transmitter
Figure 10: SMART Pressure & DP
Transmitter
1.4.1 Set up the loop for analog Calibration, Output 4~20 mADC only
Connect the transmitter with selected test equipment.

APT ADPT
SPT SDPT
1.4.2 Calculation of Current against Pressure or Differential Pressure.

Current Calculation Formula:
1.4.3 Record 5 pints’ readings (0%, 25%, 50%, 75% & 100%) (4~20mADC)
1. Write the Pressure or Diff. Pressure transmitter range in the calibration sheet.
2. Record above 5 points by increasing (↑) and decreasing (↓) pressure / Diff.
Pressure in the transmitter.
3. This is called “as found or before calibration readings”.

Input Ideal Output Actual mADC Difference Error

Order Pressure or Current As found / in Ideal mA %age
Diff. Pressure mADC Before & (+) or (-)
Calibration Actual mA
0% 4.00
25% ↑ 8.00
50% ↑ 12.00
75% ↑ 16.00
100% ↑ 20.00
75% ↓ 16.00
50% ↓ 12.00
25% ↓ 8.00
0% 4.00

4. If error is more than standard max. Approved error, then calibration is required
of the Transmitter.
1.4.4 Analog Calibration of Pressure or Diff. Pressure Transmitter.
1. Without Pressure input, check 4.00 mADC. (0%) If it is not 4.00 mADC then
adjust from the zero adjustment screw.
2. Increase (↑) 100% input Pressure or Diff. Pressure & observe the output
current 20.00 mADC on mA meter.
3. If not reached to the 20.00 mADC, (100%) then adjust Span adjustment screw
till that reading should reached 20.00 mADC.
4. Now Decrease (↓) 0% input Pressure or Diff. Pressure & observe the output
current 4.00 mADC on mA meter.
5. If not reach to 4 mADC then adjust the output current 4.00 mADC (0%) from
the zero adjustment screw.
6. Repeats steps (1~5) by increasing (↑) and decreasing (↓) pressure in the
Pressure / Diff. Pressure transmitter and adjust the zero and span
adjustment screws till output current should be adjusted as 4.00 to
20.00mADC.

7. If output current mADC of the above values, 0% 4.00 mADC & 100% 20.00 mADC
values are correct then check middle 3 points (at 25% input pressure, output =
8mADC, at 50% input Pressure, output =12mADC and at 75% input pressure,
output=16mADC) for rising and falling values.
1.4.5 Record 5 pints’ readings in calibration sheet “After calibration

column”
(0%, 25%, 50%, 75% & 100% mADC).
Input Ideal Output Actual mADC Difference in Error

Order Pressure or Current After Ideal mA %age
Diff. Pressure mADC Calibration & (+) or (-)
Actual mA
0% 4.00
25% ↑ 8.00
50% ↑ 12.00
75% ↑ 16.00
100% ↑ 20.00
75% ↓ 16.00
50% ↓ 12.00
25% ↓ 8.00
0% 4.00


1. Remove test equipment & fix the cover after calibrating.
2. I & C Inspector & Quality Inspector should be witness & check the calibration.
3. Complete the calibration certificate for approval and Signed by I & C Engineer.
4. It is ready to install in the field.

1.5 Level Transmitter Calibration / (Steps).

There are many types of level transmitters available in the market.
We will calibrate only displacement type level transmitter as shown below.
1.5.1 Calculate current against level transmitter.

Current Calculation Formula:
1.5.2 Set up the calibration loop.

Connect the level transmitter with selected test equipment and other
arrangement.
Figure 11: level transmitter Calibration Loop

1.5.3 Record 5 pints’ readings “Before Calibration Readings”.

(0%, 25%, 50%, 75% & 100%) (4~20mADC)
1. Write the level range in the calibration sheet.
2. Record above 5 points by increasing (↑) and decreasing (↓) the level in the of
displacement level chamber.
3. This is called “as found or before calibration readings”.
Input Ideal Output Actual mADC Difference Error

Order Level of water Current As found / in Ideal mA %age
in mm mADC Before & (+) or (-)
Calibration Actual mA
0% 4.00
25% ↑ 8.00
50% ↑ 12.00
75% ↑ 16.00
100% ↑ 20.00
75% ↓ 16.00
50% ↓ 12.00
25% ↓ 8.00
0% 4.00

5. If error is more than standard max. Approved error, then calibration is required
of the Level Transmitter.
1.5.4 Analog Calibration of Pressure or Diff. Pressure Transmitter.
1. Without level (0% level), check 4.00 mADC on mA meter. If it is not 4.00 mADC
then adjust from the zero adjustment screw.
2. Increase (↑) Level 100% & observe the output current 20.00 mADC on mA
meter.
3. At 100% level, if not reached to the 20.00 mADC then adjust Span adjustment
screw till that current should reached 20.00 mADC.
4. Now Decrease (↓) 0% level & observe the output current 4.00 mADC on mA
meter.

5. If not reach to 4 mADC then adjust the output current 4.00 mADC (0% level)
from the zero adjustment screw.
6. Repeats steps (1~5) by increasing (↑) and decreasing (↓) level in the Level
transmitter chamber and adjust the zero and span adjustment screws till
output current should be adjusted as 4.00 to 20.00mADC.
7. If output current of the above 0% level is 4.00 mADC & 100% level is 20.00 mADC
values are correct then check middle 3 points (at 25% level, output = 8mADC, at
50% level, output =12mADC and at 75% level, output=16mADC) for rising and
falling values.
1.5.5 Record 5 pints’ readings in calibration sheet “After calibration

column”
Input Ideal Output Actual Difference Error
Order Level of water Current mADC After in Ideal mA %age
in mm mADC Calibration & (+) or (-)
Actual mA
0% 4.00
25% ↑ 8.00
50% ↑ 12.00
75% ↑ 16.00
100% ↑ 20.00
75% ↓ 16.00
50% ↓ 12.00
25% ↓ 8.00
0% 4.00



1.6 Test of of Thermocouples / RTD Test (Steps).

1. There are different types of T/C available in the market. Mostly test process is the
same as shown below.
2. Also different types of RTD available. We will test 3 wires RTD as shown below.
T/C RTD Pt100 Ω
1.6.1 Set up the continuity test loop of a Thermocouple (T/C) / RTD.
1.6.2 Thermocouple (T/C) continuity Test loop.

1. Connect the Thermocouple (T/C) both wires with
Multi meter.
2. Select the Resistance Measurement Range.
3. Check the continuity of both wires of T/C.
4. Multi-meter will show be some resistance.
5. If both wires showing some resistance means T/C
is healthy.
6. If showing open circuit (OL) means T/C is faulty.
7. After continuous test, select the range mVDC on
Multi-meter or use mVDC Tester for T/C.
8. It will show some mVDC according to the ambient
temperature or process Temperature.

1.6.3 RTD continuity Test Loop.

1. Connect the RTD (Pt100 Ω at 0C) with Multi
meter as shown here.
2. Select the Resistance Measurement Range.
3. In RTD (Pt100 Ω), B1 & B2 will show (0 Ω)
resistance.
4. Check the continuity in between wires A & B1
or A & B2.
5. It should show more than 100 Ω. Because of
Ambient temperature.
6. If wires B1 & B2 showing (0 Ω) resistance
mean these wires are healthy.
7. If wires A & B1 or B2 Showing more than 100
Ω resistance means RTD is healthy
8. If any wire shows open circuit (OL) means
RTD is faulty.
1.6.4 Setup the actual Test of T/C & RTD with Ice Pot & Temperature
Bath.
T/C
Figure 12: T/C Test Loop for (0C)
RTD
Figure 13: RTD Test Loop for (0C)

1.6.5 Start Calibration / Test:

Actual Test loop of a T/C or RTD as shown in figure 10 & 11.
Note:
We can check the T/C or RTD by connecting directly with Temperature Digital Monitor.
Test of “0”C
1. To check the “0”C, put the T/C or RTD in the Ice pot.
2. Mow wait to stabilize the ”0” C.
3. After stabilize “0”C we can check the temperature ”0”C on the Temperature
Monitor.
4. For T/C, we can also check the mVDC on Multi-meter equal to the ”0”C
5. For RTD, we can check the Resistance in 100 OHMS on the Multi-Meter. or
Resistance tester.
1.6.6 Test of Ambient Temperature
1. Keep the T/C & RTD in the ambient atmosphere.

2. Wait to stabilized the temperate on the Temperature Digital Monitor.
or
3. When temperature stopped to change. It will show the ambient temperature.
4. We can check the mVDC or Resistance on the Multi-meter.
5. Now we can see the temperature conversion chart and check the temperature
values against the mVDC & Resistance.
6. These values (mVDC or Resistance) should be matched with ambient
temperature.
1.6.7 Test of Maximum Temperature
1. Setup the T/C or RTD with temperature bath as shown in the figures: 10 &
11.
2. Heat the hot Junction point of T/C / RTD (In different ranges).
3. Let temperate stabilized on each point we want to check.
4. Note the mVDC / OHMS Resistance and match with the temperature Conversion
chart.
5. Check temperature like: 25%, 50%, 75% & 100% points of temperature against
mVDC / OHMS.
6. Increasing and Decreasing temperature on the temperature dry bath.

7. Note down the value of mVDC / OHMS on each point and compare with
temperature converting chart.
8. All points should be matching with their relevant temper
9. If both T/C & RTD give output (mVDC or Resistance) means both are healthy.
Input Actual Actual Temperature Temperature Error

Temperature mVDC Ohms in Conversion on Digital %age
Order Chart Monitor (+) or (-)
in “C” (T/C) (RTD)
0%
25% ↑
50% ↑
75% ↑
100% ↑
75% ↓
50% ↓
25% ↓
0%
Note:
If Not showing any output (mVDC or Ohms), then replace the T/C or RTD with New
One.

1.7 Control Valve Calibration

There are 2 types of control valves and positioners used control the process variables.
Calibration steps are most commonly same, accept working principle of Positioners.
1. Single acting control valves with Pneumatic S/A positioners or SMART S/A
positioner.
2. Double acting control valves with Pneumatic D/A positioner or SMART D/A
positioner.
S/A Actuator with Pn. Positioner D/A actuator with Pn. Positioner
S/A actuator with SMART Positioner
1.7.1 Set up the calibration loop of control valve.

1. Connect the 4~20mADC source with I/P converter or Air filter regulator for
signal air supply 0.2~1.0 Bar with Pneumatic positioner and open the air supply
to the control valve.
2. Connect the 4~20mADC Source with SMART Positioner and open the air
supply to the control valve.

3. Connect the Multi Meter to measure the 4~20 mADC output from the P/I
converter or SMART positioner output for valve position in the control room.
Figure 14 :C/V Calibration Loop with Pn. Positioner Figure 15: C/V Calibration Loop of SMART Positioner
1.7.2 Record 5 pints’ readings (0%, 25%, 50%, 75% & 100%) (4~20mADC)
1. Check 5 points positions of control valve by increasing the input signal current
4 to 20 mADC to I/P converter or SMART positioner.
2. Check 5 points positions of control valve by decreasing the input signal current
20 to 4 mADC to I/P converter or SMART positioner.
3. Record these 5 points in the calibrations sheet in “as found or before
calibration column”.
Output
Input Input Actual Difference in Error current
Order (4~20)
Ideal Signal Signal Position of Ideal Position %age
& mADC
Position (0.2~1.0) (4~20) C/V Before (+) or (-) C/V
Actual Position
Bar mADC Calibration Position
0% 0.2 Bar 4.00

25% ↑ 0.4 Bar 8.00
50% ↑ 0.6 Bar 12.00
75% ↑ 0.8 Bar 16.00
100% ↑ 1.0 Bar 20.00
75% ↓ 0.8 bar 16.00
50% ↓ 0.6 Bar 12.00
25% ↓ 0.4 Bar 8.00
0% 0.2 bar 4.00

1.7.3 Error calculation formula of control valve Positions.
1.7.4 Start calibration of control valve.

1. Before calibration check & adjust stroke of control valve according to the
Stroke adjustment procedure.
2. Apply 4.00mADC, to I/P converter or SMART positioner & see the position of
control valve should be “0%”
3. If not reached to 0% Position, then adjust “Zero” adjustment screw and bring
the control valve at 0% at local valve indicator.
4. Apply 20mADC to I/P converter or SMART positioner. Observer control valve
position should be “100% “Opened.
5. If not reached to 100% Position, then adjust “SPAN” adjustment screw,
observe control valve should be opened 100% at local.
6. Repeats steps 5~8 by adjusting the zero and span adjustment screws till the
valve should be fully closed at 4.00 mADC & Fully opened “100%” at
20.00mADC.
7. After calibration check other 3 points at 25% at 8.00mADc, 50% at 12.00mADC,
and 75% at 16.00mADC.
8. After calibration of control valve need to calibrate output current 4~20mADC for
valve position transmitter in the control room.
9. If output current not matching with control valve position, then adjust output
current by ZERO & SPAN adjustment screws.
10. In case of SMART Positioner, control valve will be automatically calibrating
according to the Auto calibration procedure.
11. Output current of SMART Positioner 4~20mADC will also automatically
configured from the SMART Positioner.

1.7.5 Record 5 points of valve positions’ readings “in after calibration

column”.
(0%, 25%, 50%, 75% & 100%) (4~20mADC).
Output
Input Input Actual Difference in Error current
Order (4~20)
Signal Signal Position of Ideal Position %age
C/V After & mADC
Ideal (0.2~1.0) (4~20) (+) or (-) C/V
Calibration Actual Position
Position Bar mADC Position
0% 0.2 Bar 4.00

25% ↑ 0.4 Bar 8.00
50% ↑ 0.6 Bar 12.00
75% ↑ 0.8 Bar 16.00
100% ↑ 1.0 Bar 20.00
75% ↓ 0.8 bar 16.00
50% ↓ 0.6 Bar 12.00
25% ↓ 0.4 Bar 8.00
0% 0.2 bar 4.00



2. Practical Execution Plan for 6 Weeks

Training.

2.1 Practical Execution Plan
Figure 16: Practical Execution Plan

2.2 Responsibilities of all Trainees.
 All trainees should have paper & pen with them to note down all steps.
 1st day of every week, calibration will be performed by a Senior Instrument

technician in front of all Instrument trainees.
 According to the above calibration procedures by Senior Instrument technician,

all instrument trainees should be Note Down the all steps point by point and
readings before and after calibration.
 All Instrument trainees should follow the all calibration steps point by point for
their practice sessions, when they start calibration by then selves.
2.3 Arrangement of Instrument LAB
 Name of LAB Supervisor: Mr. -----------------------------------------

 Instrument LAB Supervisor will be responsible for the following
 Supply of all types of Standard Test Equipment.
 Supply of all field Instruments to be calibrated.
 Senior Instrument Technician to perform calibration 1st day of each week in front
of all Instrument Trainees.
 Trainer should supervise & guide all the trainees during training.

2.4 List of Instrument Trainees
Name of the Plant: ----------------------------------------------
# NAMES OF TRAINEES Groups Work Location in the Plant
1 G-1
2 G-1
3 G-1
4 G-1
5 G-2
6 G-2
7 G-2
8 G-2
9 G-3
G-3
10
G-3
11
G-3
12
List approved by: -------------------------------------------------------------------

3. 6 Weeks Practical Calibration Plan
Note:
1 Daily 3 groups or 2 Groups will perform their Practice according to the time
schedule given in the weekly plan (5 Days in a week plan).
2 Max. Nos of Technicians: Each group should be consisting of 4 Technicians for
better Training.
3 IMD Section Head / Superintendent can arrange their own time schedule
according to their own connivance timings.
4 Training Time Duration can be increase or decrease according to the IQ level of
instrument technicians.
5 No. of Weeks can be increase or decrease according to the training practices of
the Trainees.

3.1 1st Week, 3 Groups / 6 Weeks Practical Calibration Training
Figure 17: 1st Week, 3 Groups / 6 Weeks Practical Calibration Training

3.2 2nd Week, 3 Groups / 6 Weeks Practical Calibration Training
Figure 18: 2nd Week, 3 Groups / 6 Weeks Practical Calibration Training

3.3 3rd Week, 3 Groups / 6 Weeks Practical Calibration Training
Figure 19: 3rd Week, 3 Groups / 6 Weeks Practical Calibration Training.

3.4 4th Week, 3 Groups of 6 Weeks Practical Calibration Training
Figure 20; 4th Week, 3 Groups / 6 Weeks Practical Calibration Training

Figure 21: 5th Week, 3 Groups / 6 Weeks Practical Calibration Training

Figure 22: 6th Week, 3 Groups / 6 Weeks Practical Calibration Training

4. Attendance & Calibration / Practice /

Test Sheets

3.1 Practical Training of Instrument Technicians

3.1.1 Trainees Weekly Attendance Sheet
Figure 23: Trainees Weekly Attendance Sheet

3.2 Pressure / Diff. Press. & Temperature Gauge Calibration / Test
Figure 24: Pressure & Diff. Pressure & Temperature Gauge Calibration / Test

We can also use these types of Charts to record 5 Points “As Found or Before
calibration” Readings or “After Calibration” Readings for Pressure & Diff. Pressure
Gauges.

calibration” Readings or “After Calibration” Readings for Temperature Gauges.

3.3 Pressure, Temperature, Level & Flow Switch Calibration / Test
Figure 25: Pressure, Temperature, Level & Flow Switch Calibration / Test

We can also use these types of Charts to record “As Found or Before calibration”
Readings or “After Calibration” Readings for Switches.

3.4 Pressure/Diff. Pressure, level & Flow Transmitter Calibration / Test
Figure 26: Pressure / Diff. Pressure, level & Flow Transmitter Calibration / Test

calibration” Readings or “After Calibration” Readings for Transmitters.

3.5 Thermocouple / RTD Calibration / Test
Figure 27: Thermocouple / RTD Calibration / Test

calibration” Readings or “After Calibration” Readings for T/C r RTD.

3.6 Control Valve Calibration / Test
Figure 28: Control Valve Calibration / Test

calibration” Readings or “After Calibration” Readings for Control Valves.

5. Weekly Rotation Duty of Technicians

5.1 Weekly Rotation Duty of Technicians

Practical Practices in Field.
Figure 29: Weekly Rotation Chart

The End

Practical Calibration Plan &amp; Execution of Field Instrument

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Practical Calibration Plan &amp; Execution of Field Instrument

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Practical Calibration

Plan & Execution of

FAROOQ ALI CHAUDHRY 1

FAROOQ ALI CHAUDHRY 2

3.1 1st Week, 3 Groups / 6 Weeks Practical Calibration Training .................................................... 44

FAROOQ ALI CHAUDHRY 3

FAROOQ ALI CHAUDHRY 4

Recommendations & Approvals at Shuwaikh Power

FAROOQ ALI CHAUDHRY 5

Recommendations, Reviewed & Approval at

Reviewed and formation advised by:

Reviewed & Verified by:

FAROOQ ALI CHAUDHRY 6

Thanks to Eng. Ejaz-u-Din Shaikh (MEW IMD

Thanks to Eng. Iqbal Hussain (Senior

FAROOQ ALI CHAUDHRY 7

FAROOQ ALI CHAUDHRY 8

FAROOQ ALI CHAUDHRY 9

FAROOQ ALI CHAUDHRY 10

1.1 Pressure & Differential Pressure Gauge Calibration

1.1.1. Selection of standard pressure gauge against faulty gauge.

1.1.2. Selection of pressure source or Test Equipment:

1.1.3. Function test of Pressure gauge (Internal Checkup).

1.1.4. Set up the Calibration Loop & Leak Test.

1.1.5. Pressure Gauge Calibration Loops with different Test Equipment.

FAROOQ ALI CHAUDHRY 11

Figure 1: Pressure Gauge Calibration Loops with different

2. Calibration Loop with Dead Weight Tester / Calibrator.

1.1.6. Check & Record 5 pints of readings & Units.

1.1.7. Calculate the error in % before calibration.

FAROOQ ALI CHAUDHRY 12

1.1.8. Error Calculation Formula in %age.

Input Pressure Actual Pressure Difference Error

1.1.9. Calibration Process of a pressure Gauge.

FAROOQ ALI CHAUDHRY 13

FAROOQ ALI CHAUDHRY 14

1.1.10. Record 5 pints’ readings After Calibration.

Input Pressure Actual Pressure Difference Error

1.1.11. Again calculate the error in %age after Calibration.

1.1.12. After Calibration Completion.

FAROOQ ALI CHAUDHRY 15

1.2 Temperature Gauge Calibration / Test (Steps)

Different types of Temperature Gauges used in Process Lines.

1.2.1 Set up the Temperature Gauge Calibration Loop.

Figure 2: Temperature Gauge Calibration Loop

FAROOQ ALI CHAUDHRY 16

Input Actual Temperature Difference Error

1.2.3 Calculate the error in %age before calibration.

1.2.4 Error Calculation Formula in %age.

1.2.5 Calibration Process of a Temperature Gauge.

FAROOQ ALI CHAUDHRY 17

3. Now remove the Pointer / Needle.

FAROOQ ALI CHAUDHRY 18

13. If “0%” and “100%” is correct.

1.2.6 Record 5 pints’ readings After Calibration.

Input Actual Difference Error

FAROOQ ALI CHAUDHRY 19

1.2.7 Again calculate the error in %age after Calibration.

According to above procedure Calibration will be passed.

1.2.8 After Calibration Completion.

FAROOQ ALI CHAUDHRY 20

1.3 Calibration of different types of Switches

Figure 3: Different types of Switches

1.3.1 Complete Calibration / Test, Loop Setup of a Switch.

Practical Calibration Plan & Execution of Field Instrument

Practical Calibration Plan & Execution of Field Instrument