Calibration: A Technician's Guide provides a comprehensive overview of process instrument calibration, laying a foundation for understanding the principles and applications of common tasks performed by technicians. It also serves as an excellent study resource for the calibration section of the ISA Certified Control Systems Technician (CCST) exam.
Topics covered in this book include:
- Terminology
- Bench calibration vs. field calibration
- Loop calibration vs. individual instrument calibration
- Instrument classification systems
- Documentation
- Calibration techniques for temperature, pressure, level, flow, final control and analytical instrumentation
This book serves as a structured learning tool with questions and answers in each chapter. The extensive appendix is an outstanding reference, including sample piping and instrumentation diagrams (P&IDs), loop diagrams, specification sheets, sample calibration procedures and conversion and reference tables. If you calibrate instruments or oversee someone who does, this book is an excellent addition to your library.
Table of Contents:
About the Author ix
Acknowledgements xi
Introduction xiii
Chapter 1 Calibration Principles 1
1.1 What Is Calibration? 1
1.2 What Are the Characteristics of a Calibration? 2
1.3 Why Is Calibration Required? 6
1.4 Who Performs Calibrations? – The Control System Technician 8
1.5 Characteristics of a Control System Technician 9
1.6 Loop Calibration vs Individual Instrument Calibration 10
1.7 Bench Calibration vs Field Calibration 11
1.8 Classification of Instruments 12
Chapter Summary 13
Review Questions 14
Chapter 2 Documentation 17
2.1 Calibration Procedure Content 19
2.2 Calibration Data Sheets (See Examples in Appendix A-4) 21
2.3 P&IDs (See Example in Appendix A-1) 23
2.4 Loop Diagrams (See Examples in Appendix A-2) 25
2.5 Instrument Specification Forms (See Examples in Appendix A-3) 26
2.6 Project Specifications 27
2.7 Manufacturer's Specifications 27
2.8 Calibration Intervals 28
2.9 Safety Considerations 29
2.10 Calibration Status Labels 30
Review Questions 31
Chapter 3 Temperature Instrument Calibration 33
3.1 What is Temperature? 33
3.2 Temperature Sensors 34
3.3 Signal Conversion 35
Review Questions 44
Chapter 4 Pressure Instrument Calibration 49
4.1 What is Pressure? 49
4.2 Challenges When Calibrating Pressure 50
4.3 Calibrating Pressure Gauges 52
4.4 Calibrating Pressure Transmitters 55
4.5 Calibrating Pressure Switches 55
Review Questions 56
Chapter 5 Level Instrument Calibration 61
5.1 Types of Level Instruments 61
5.2 Special Considerations with Level Calibration 64
5.3 Calibrating a Differential Pressure Level Transmitter 67
5.4 Calibrating a Capacitance Level Instrument 71
5.5 Calibrating an Ultrasonic Level Instrument 72
Review Questions 74
Chapter 6 Flow Instrument Calibration 77
6.1 Types of Flow Instruments 77
6.2 Calibration of Flowmeters 82
6.3 D/P Transmitter Calibration 83
6.4 Example: Magnetic Flowmeter Calibration 84
6.5 Flowmeter Calibration Using a Master Meter (Prover) 86
6.6 Gravimetric Method for Flowmeter Calibration (Measurement by Weight) 87
Review Questions 88
Chapter 7 Final Control Devices Calibration 89
7.1 Calibration of an I/P Transducer 95
7.2 Calibration of a Valve Positioner 96
7.3 Calibration of a Control Valve 97
Review Questions 97
Chapter 8 Process Analytical Instrument Calibration 101
8.1 pH Calibration Procedure 105
8.2 Diagnostic Test for pH Electrodes 106
8.3 Measuring Conductivity 107
8.4 Calibration Procedure with Explanations 109
Review Questions 111
Bibliography 113
Appendix A-1 Piping & Instrument Diagrams (P&IDs) 117
Appendix A-2 Loop Diagrams 119
Appendix A-3 Instrument Specifications 123
Appendix A-4 Calibration Procedures 145
Appendix A-5 Test Equipment 227
Appendix A-6 RTD and Thermocouple Tables 229
Appendix A-7 Conversion Tables 245
Appendix B Answers to Chapter Review Questions 249
Index 271
About the Author :
Michael Cable is a Level 3 Certified Control System Technician. He is currently the Validation Manager at Argos Therapeutics in Durham, NC where his responsibilities include managing the Calibration Program. Michael started his career as an Electronics Technician in the Navy Nuclear Power Program, serving as a Reactor Operator and Engineering Watch Supervisor aboard the USS Los Angeles submarine and then at the AIW prototype in Idaho Falls. After leaving the Navy, he started his civilian career at Performance Solutions performing technical services for the pharmaceutical industry. His 11 years there was highlighted by an assignment to Eli Lilly Corporate Process Automation managing Instrument Qualification projects and then starting up a Calibration Services division within Performance Solutions. His practical expertise in instrumentation and controls led him to his current career path in Validation, which has been his main focus for the last 7 years.
