Betalink Instrumentation & Calibration Service LLC

CALIBRATION OF PRESSURE GAUGE

CALIBRATION PROCEDURE FOR PRESSURE GAUGES

Ref. Norm: DKD-R 6-1 ISO /IEC 17025

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Reviewed By:

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Approved By:

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COPYRIGHT
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means wholly or partially, or disclosed to any person outside BICS without a written permission.

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

1. SCOPE OF WORK
Calibration Description : The subpart of DKD-R 6-1 gives recommendations
for the Calibration of pressure gauges within,

Parameter Performance specification Test method

CRYSTAL XP 2i Range: - 14.5 to 10000psi Comparison with
Gauge pressure Accuracy: 0.1% of reading (from pressure comparator.
Measurement 20-100%of fullscale).
0.02% of fullscale(0-20%
of fullscale).
0.25% of fullscale (in
vaccum).
Resolution: 1 psi/0.01Bar

 Equipments Requirements:

Source/measure 4 to 20 mA and 24 V loop power devices under test pt100 RTD

input for temperature measurement, accurate to 0.2 ⁰F.

Equipment Used Specifications Requirement Calibration

Equipment
WIKA CPH6600 Range:- -11 to 30 psi Pressure gauges
Accuracy:- 0.025%
Resolution:- 0.01 psi/0.001 Bar

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

2. PURPOSE OF METHOD STATEMENT:-

The purpose of method statement is to ensure that the Calibration & Testing of
Pressure gauges are carried out in compliance with the requirements according to
the regulations and quality.

REFERENCE STANDARD:-

 DKD-R 6-1 DIN EN ISO/IEC 17025:2003 “Code of practice for the calibration and
testing”.

PROCEDURE:

3. Preliminary Operation

3.1 Read the entire before beginning calibration.

3.2 Visual check the unit under calibration

3.3 Mount the comparator to your bench or table: At higher pressure

the force required to rotate the handle may cause the base of
comparator to lift .We recommend that the comparator be bolted to
your bench or table . Refer to Document No :
3171_Rev_C_GaugeCalXP_US_Web_Manual , Figure 1 for hole
pattern and suggested bolt size .

3.4 Install the flange stem or stem adaptor : There are two stainless
steel flange bases. Each base has ¼“ female (tapered) NPT thread.
These bases are intended to have either a flange stem or stem
adaptor for quick connectors installed. It is possible to install XP2i
reference gauge directly into the base, but this is practical if only one
XP2i will be regularly used with the comparator.

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 If testing is limited to 5000 psi (350bar) or less , quick connect fitting
that eliminate wrenches, thread tape or sealant , may be used . use
PTFE thread tape when installing either the flange stem or the stem
adapter into the flange base .

3.5 Fill the reservoir: the reservoir holds the test fluid that fills the
system each time you test a gauge. The test fluid can be either water,
lightweight hydraulic oil , or isopropyl alcohol .Wind the handle fully
counter –clockwise , then clockwise for at least 10 turns(this prevents
fluid flow through the comparator and potential fluid spillage). Then
fill the reservoir with the test fluid to within 6mm(1/4”) of the top.
Turn the handle counter-clockwise until you see the fluid level in the
reservoir drop. This fills the system with fluid and removes any
trapped air bubbles. The reservoir cap has no o-ring to allow the
GaugeCalXP to be transported with the test fluid in place. Due to the
sealing capabilities of the cap , It must be removed or ajar during
testing to allow proper equalization of the systems .

3.6 Install the digital gauge: Use a ¼” female NPT gauge adapter
(figure 4). If you are using the flange stem, apply PTFE thread tape to
the pressure gauge threads, then screw the gauge in to the
adapter(PN: 3116). Be sure to use wrenches on both the fitting and
the gauge when tightening the fitting.

CAUTION: Never use wrenches when connecting the gauge adapter to the
stem fitting-hand tight is sufficient to insure a leak free connection.
The wrenches are intended to help separate gauge adapter from
the stem adapter fitting, if necessary.

If you are using the quick connect adapter (PN 3126), just screw it
onto the gauge, finger tight, then onto the stem adapter, also finger
tight. Although wrench flats are provided on the quick connect
adapter, these are intended only to help remove the adapter.

CAUTION: Never use a wrench to tighten a quick connect adapter.

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 3.7 Install the gauge to be tested: As with the digital gauge, choose the
appropriate adapter, either the quick connect or regular gauge
adapter (Figure 4).

3.8 Remove any remaining air from the system: Each time you install a
new gauge, air bubbles may be introduced in to the comparator and
cause problems with calibration. Check again that reservoir is full,
then turn the handle counter-clockwise until it stops at the full out
position. If air bubbles are present in the system, the test fluid level
in the reservoir will drop as it flows in to the comparator. If
necessary, repeat this step until all trapped air has been removed.
Another way to remove air bubbles is to tilt the comparator. Wind
the handle fully counter clockwise, then lift the back of the
comparator. Any remaining bubbles will come out the black flange
adapter.

3.9 Set up the digital pressure gauge: Turn on the XP2i, and then select
the pressure units required for the gauge to be tested – kg/cm2, bar,
kPa, or PSI. (Refer to the documentation you received with your
Crystal Engineering XP2i for detailed operating instructions.)

4. Pressure Cycle Exercise:

Unless otherwise specified , the pressure cycles must be applied to
exercise (preloading) the UUC according to the accuracy class stated
in the DKD R 6-1 :2002, pressure calibration guideline . the pressure
cycle must be consisted of starting at zero , going to full scale then
back to zero pressure as described in table 1 below.

Table 1: Calibration sequences

Measurement
Calibra- Number of Waiting time at
uncertainty aimed Number Number of
tion measure- Load change upper limit of
at. in % of the of pre- measurement
se- ment + waiting time measurement
measurement loadings series
quence points range
span

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 (*) with zero (**)
(***) up down
up/down seconds
minutes
A < 0.1 9 3 > 30 2 2 2
B 0.1 ... 0.6 9 2 > 30 2 2 1
C > 0.6 5 1 > 30 2 1 1

(*) Reference to the span was used to allow the sequence (necessary
calibration effort) to be selected from the table. as the accuracy
specifications of the manufacturers are usu- ally related to the
measurement span.

(**) One has in any case to wait until steady-state conditions (sufficiently
stable indication of standard and calibration item) are reached.

(***) For Bourdon tube pressure gauges. a waiting time of five minutes is to be
observed. For quasi-static calibrations (piezoelectric sensor principle). the
waiting times can be re- duced.

Note :For the calibration of items with a range of measurement greater than
2500 bar. calibration sequence A is in principle to be used. If clamping effects
are observed. the calibration is to be repeated clamping the calibration item
anew.

IMPORTANT NOTE :Pressure gauge can be can damage the pressure sensor ,
smooth pressure changes is required throughout the calibration .

5. Calibration Procedure:

IMPORTANT NOTE:

- Before calibration, a zero reading at the UUC while the hydraulic is

opened to an atmosphere after exercise shall be observed. If not, zero set
is needed.

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 - The number of the pressure calibration points of the UUC can be
determined according to the requirement in the DKD R 6-1:2002
Calibration of pressure gauges guideline which described in table1.
- After applying the input pressure at every measurement point, 30
seconds minimum are needed to wait before taking a reading.

5.1 Generate a known pressure ,step by step; from minimum to

maximum range which explained in table 1 to the UUC. An accurate
input pressure which being developed by pressure comparator can
be calculated from following equation .

Ix= MGcal + δId+Ir

MGcal=Reference value from calibration certificate of master test gauge .
δId = uncertainty due to resolution of UUC gauge.
Ir = Repeatability of UUC gauge

5.2 UUC gauge reading has to be observed and recorded in the table
attached in Appendix A.

5.3 Repeat step 5.1 and 5.2 until the calibration is completed .

5.4 Release all pressure from the measurement system and disconnect
all of the equipment .

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 6. Data Analysis and Uncertainty Calculation:

The measurement result and uncertainty of measurement can be calculated by

using the method stated in DKD R 6-1 :2002 , calibration of pressure gauge

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

APPENDIX A

Calibration Test Repair Inspection

Customer: Job No:

Inst. description: Range:

Model: Sr.No.:

Dial Size: Connection:

Manufacturer: Resolution:

Work Instruction, WI-

Reading
Pressure
from UUC
P standard
M1 M2 M3 M4 M5 M6

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

Attachment 1

Now we have listed down all input estimates (Xi) which are going to define
output estimate (y) , i.e, pressure value of UUC gauge .

In this case , systematic corrections for indicated pressure are negligible.

Hence , instead of applying them as a correction to the indicated pressure , we

will treat them as systematic uncertainties .

Since, Y= y±(U) and in this case “y” will be average measured pressure of the
DPI. This output estimate “y” in conjunction with Expanded uncertainty “U”
will define our measurand “Y” i.e , the Pressure.

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 Now we will calculate the uncertainties associated with input quantities and
calculate the combined uncertainty for output.

a) MGcal = Cal Certificate of DWT reports an uncertainty.

b) δId uncertainty due to resolution of DPI

c) Ir is Type “A” uncertainty due to non-repeatability of DPI

Take 06 or 10 readings of DPI:

Red . No Xi (Xi-Xavg) (Xi-Xmean)² S.D
MPa

∑𝑋 ∑(Xi − x) ∑(Xi
− Xmean)²

Uncertainty budget. Once we have calculated all components of

uncertainty for a measurement process, we will make the budget.

Symbol Uncertainty Value Probability Divisor Ci U(xi)

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013

 source ± Pa distribution Pa
±
MGcal Cal Uc for Normal
DWT
δId Resolution Rectangular
Ir Repeatability Normal

U(Ix) Combined Std UC Normal

U Expanded Uncertainty K=2

RELATED DOCUMENTS:-

 Instrument work sheet

 Calibration certificate

Doc.No.QSP-16 Rev:00 Issued Date: 30-09-2013