-----------Calibrate For

Pressure
Module 12408

Instrument Trainee Task Module 12408

CALIBRATE FOR PRESSURE_

Objectives:
Upon completion of this module, the trainee will be able to:
1.
2.
3.
4.
5.

Discuss and describe elements used in pressure measurement.

Discuss and describe instruments to be calibrated.
Select and set up test equipment based on available data sheets.
Discuss and prepare required documentation of test performance.
Perform test procedure for calibration of pressure.

Prerequisites
Successful completion of the following Task Modules is required before
beginning study of this task module: Task Module 12401 through 12407.

Required Student Materials

1. Student Modules
2. Required Safety Equipment

Instrument Trainee Task Module 12408

COURSE MAP
This course map shows all of the Wheels of Learning task modules in the
fourth level of the Electrical curricula. The suggested training order begins at
the bottom and proceeds up. Skill levels increase as a trainee advances on
the course map. The training order may be adjusted by the local Training
Program Sponsor.

LEVEL 4 COMPLETE

Calibrate For Pressure Module 12408

TABLE OF CONTENTS
Section Topic ..
Page
1.0.0
2.0.0
2.1.0
2.1.1
2.1.2

Introduction .........................................................................5
Types of Pressure Measuring Devices ..................................5
Diaphragm-Type Pressure Sensors ......................................5
Pressure Capsules ...............................................................7
Bellows Pressure Devices
8

Instrument Trainee Task Module 12408

2.1.3
3.0.0
4.0.0
5.0.0
5.1.0
6.0.0

Bourdon Tube (Pressure Spring) Pressure Sensors ..

9
Instruments to be Calibrated ..............................................10
Selection of Test Equipment ................................................11
Calibration/Test Procedures .................................................11
Calibration/Adjustment .......................................................12
Test Performance Documentation .......................................13

Calibrate For Pressure Module 12408

Trade Terms Introduced In This Module

Deflection: movement as a result of stress.
Differential pressure: The difference in pressure between two pressure
sources, measured relative to one another.
Drift: a deviation from the actual reading.
Elastic Modulus Coefficient: a term relating to the elasticity of an material.
A temperature dependent property of a material.
Hysteresis: The failure of a property that has been changed by an: external
agent to return to its original value when the cause of the change is removed.
Linearity: The degree to which the calibration curve of a device matches or
conforms to a straight line.
Sector: The large oscillating gear or segment in a pressure gauge which is
actuated by the elastic chamber.
Vacuum: Space at pressure below atmospheric pressure.

1.0.0 INTRODUCTION_
There are a wide variety of pressure sensing and measuring devices used in
industry ranging from the simple bourdon tube pressure gauge to complex
electronic digital pressure sensors. Pressure detection instruments can be
classified on the basis of the pressure levels they can measure, by the design
principles involved in their operation, or by their application.
The accurate calibration of these pressure sensing devices is essential to the
proper operation of the systems in which they are installed.
This module will cover several types of pressure sensors including
operational description, calibration procedures, and requirements.

2.0.0 TYPES OF PRESSURE MEASURING DEVICES_

In general, pressure sensing elements translate a pressure signal into some
type of mechanical movement. This movement may provide indication or may
cause a control function to occur. In any case, the relationship between the
input signal and the output of a particular device is proportional and may be
varied by adjusting the sensing element. This section will describe the
operational characteristics of several different pressure sensing devices
commonly used in process systems.

Instrument Trainee Task Module 12408

2.1.0 Diaphragm Type Pressure Sensors

The metallic diaphragm gauge consists of a metal disc built into a housing
with one side of the disc exposed to the pressure to be measured and the
other side exposed to atmospheric pressure. A basic diaphragm gauge is
shown in Figure 1.

Figure 1. Basic Diaphragm Gauge

The distortion of the diaphragm under pressure is transmitted to the gauge

dial by a linkage connected to the center of the diaphragm. Under pressure,
a circular metallic diaphragm will exhibit a deflection curve shaped roughly
like the letter "S," starting at the origin and approaching the point of
bursting pressure. The proportional limit occurs at approximately 0.5
percent of the bursting load. Therefore, the deflection of a flat metallic
diaphragm is proportional to pressure in a linear fashion only for a small
range of low pressures and low vacuums.
The deflection characteristics of a metal diaphragm can be somewhat
improved by corrugating the surface of the disc. A corrugated diaphragm
produces approximately four times the deflection of a flat diaphragm
subjected to the same pressure. In addition, the deflection curve is slightly
more linear in character. Figure 2 shows a corrugated diaphragm.

Calibrate For Pressure Module 12408

Figure 2. Corrugated Diaphragm

The actual deflection depends on the diameter of the diaphragm, the

thickness of the diaphragm, the shape of the corrugations, the number of
corrugations, the elasticity of the diaphragm and the magnitude of pressure
applied.
The single metallic diaphragm is not generally used as a pressure gauge
element because of the following disadvantages:
1. The diaphragm must be large enough to produce a satisfactory de-flection
under pressure. This limits the pressure range to low ranges.
2. The dial scale must be hand calibrated to account for the peculiarities of
each diaphragm. This is not an unusual practice (precision bourdon
tubes require it) but it does add to the cost of the instrument.
3. Even a small pressure over-range of the gauge can cause a permanent set,
causing inaccuracies in subsequent readings.
4. The elastic modulus coefficient of the metal is sensitive to temperature
changes. The pressure readout must, therefore, be corrected in some way
for temperature.
Non-metallic diaphragms are used to measure extremely low pressures or
vacuums. Leather, teflon, impregnated silk, and neoprene are typical
materials used in these gauges.

2.1.1

Pressure Capsules

Frequently, two circular diaphragms are soldered or welded together to form

a pressure capsule. These capsules can be used singularly or stacked, as
shown in Figure 3.

Instrument Trainee Task Module 12408

Figure 3. Stacked Pressure Capsule Gauge

The pressure capsules are commonly made of phosphor bronze, stainless

steel, and Ni-Span C (a nickel alloy). The phosphor bronze capsules are
suitable for most applications from 0 to 30 psi. The stainless steel capsules
are used with corrosive fluids. Their range is also higher: 0 to 50 psi. The
advantage of the Ni-Span C capsule is that it is virtually unaffected by
temperature changes. Their range is a compromise: 0-30 psi.

2.1.2 Bellows Pressure Devices

The need for a pressure-sensing element more sensitive than the Bourdon
tube or the basic metallic diaphragm to low pressures and able to provide
greater power for actuating, recording and indicating mechanisms resulted
in the development of the metallic bellows. The use of metallic bellows has
been most successful on pressures ranging from 0.5 to 75 psig. Figure 4
illustrates a basic bellows sensing element.

Figure 4. Basic Bellows

Calibrate For Pressure Module 12408

The bellows-type pressure gauge is usually built as a one-piece, collapsible,

seamless metallic unit with deep folds formed from very thin-walled tubing.
The moving end of the bellows is usually connected with a simple linkage to
an indicator pointer. The flexibility of a metallic bellows is similar to that of a
helical, coiled compression spring. The relationship between increments of
load and deflection is linear up to the elastic limit. - However, this linear
relationship exists only when the travel of the bellows occurs under the
influence of a minimum compressive force. It is necessary to arrange that all
travel of the bellows be made on the compressive side of the point of
pressure equilibrium. For this reason, the spring in Figure 4 is exerting a
compressive force on the bellows that the movement or measuring action of
the bellows must overcome. In practice, the bellows is always opposed by a
spring, and the deflection characteristics of the unit is the net result of the
spring and the bellows.
The stroke usually encompasses from 50 to 90 percent of the bellows length.
Beyond these points, serious distortion of the load-deflection curve occurs.
The most desirable dimensions for a bellows are those that hold the ratio of
bellows length to its diameter at less than one. To ensure that only the
correct portion of the total available motion of the bellows is used, both
minimum and maximum overtravel "stops" are used. This prevents the
metallic bellows from taking a "set" from being expanded or compressed
beyond the normal limits too frequently or for long periods.

The hysteresis of a properly designed and constructed bellows is nearly

always less than 1 percent of the maximum allowable deflection and tends to
decrease in value with the number of cycles that the bellows has undergone.
The materials suitable for bellows are brass, phosphor bronze, beryllium,
copper-nickel alloys, and monel.

2.1.3 Bourdon Tube (Pressure Spring) Pressure Sensors

Bourdon tube pressure sensors are the elastic pressure elements most often
used for industrial purposes. They have been in use for over a century. Their
accuracy was substantially improved around 1930 when the friction effects,
drift and elastic hysteresis were reduced, and 0.1 percent inaccuracies
became possible. These elements are not ideally suited for low-pressure,
vacuum or compound measurements because the spring gradient in the
Bourdon tube is too low for precision measurements at spans of 30 psi (200
kPa) or below. Frequently used Bourdon tube materials include bronze,
Monel, alloy, and stainless steel.
Figure 5 illustrates a C-Bourdon tube used in a direct indicating gauge,
which usually has an arc of 250 degrees.

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Figure 5. C-Bourdon Pressure Element

The process pressure is connected to the fixed socket end of the tube, while
the tip end is sealed. Because of the difference between inside and outside
radii, the Bourdon tube presents different areas to pressure, which causes
the tube to tend to straighten when pressure is applied. The resulting tip
motion is non-linear because less motion results from each increment of
additional pressure.
This non-linear motion has to be converted to linear rotational pointer
response. This is done mechanically by means of a geared sector and pinion
movement. The tip motion is transferred to the tail of the movement sector
by the connector link.

The free end motion of the C-Bourdon tube is insufficient to operate some of
the motion balance devices, such as the transmitters. The spiral element
shown in Figure 6 is essentially a series of C-Bourdon tubes joined end to
end. When pressure is applied, this flat spiral tends to uncoil and produces
a greater movement of the free end requiring no mechanical amplification.
This increases the sensitivity and accuracy of the instrument because no
lost motion or friction is introduced through the links and levers.

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Figure 6. Spiral Bourdon Element

Standard spiral materials include bronze, steel, stainless steel, beryllium

copper, Monel, and Ni-Span C. Spans as low as 10 psi (69 kPa) are available
for positive,. negative, or compound ranges. The various manufacturers use
different break points between the spiral and the helical elements. Some
start using helical elements at above 200 psi (1.4 MPa) spans, others stay
with the spiral element up to 4,000 psi (27 MPa) and higher.
Unflattened, heavy-wall, spiral tube springs to detect pressures up to
100,000 psig (690 MPa) are also available in direct indicators.

3.0.0 INSTRUMENTS TO BE CALIBRATED_

In the previous sections, we have discussed a variety of pressure sensing
devices. These devices fall into four basic categories based on their
functions. These categories are indicators, controllers, switches, and
transmitters.
Indicators, such as pressure gauges, provide local and remote indication of
pressure in a system. They are necessary to allow constant monitoring of
system parameters. It is essential that these instruments provide accurate,
reliable readings for safe operation of a system.
Switches are used to automatically control component operation and often
provide protective functions. An example is the automatic cycling of an air
compressor in a high-pressure air system. As the system pressure falls to a
preset pressure the switch closes, completing the electrical circuit to the
compressor motor controller. The compressor starts and begins to raise
pressure in the system. At a preset higher pressure, the switch opens,
interrupting power to the compressor, causing it to shut down. In this
application, a pressure switch assists in maintaining an operating band and
prevents an overpressure condition.
Controllers take inputs from various sensing devices in the system, processes
these inputs, and sends signals to various components to maintain the
desired system parameters within a specific band. The theory of operation of

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a controller is much the same as a central processing unit in a computer.

Transmitters are merely translators. They convert a pressure signal to an
electrical/electronic or pneumatic signal that can be used to drive a motor or
other electrical/electronic component.

4.0.0 SELECTION OF TEST EQUIPMENT_

NOTE:

Ensure that all calibration equipment meets the accuracy

requirements stated in the calibration procedure.

The calibration of pressure sensing devices requires detailed preparation to

ensure successful results. One of the most important steps in this process
is the selection of the correct test equipment for the device to be tested. This
selection will be based on the type of instrument, type of test signal, and
range of test parameters.
The written test document should provide, along with a procedure, data
sheets which will identify values of minimum or maximum pressure,
voltage, amperage, etc. With this information, an instrument craftsperson
can select the "right tool for the job."
The following are examples of the uses of the various types of test
equipment:

Electronic simulators used to calibrate electromechanical pressure

transmitters.
Pneumatic power supplies and simulators provide variable test pressure
for calibration of gauges and setting pressure switches.
Vacuum pumps are necessary for calibrating instruments that sense
pressure below atmospheric.
Precision gauges provide the resolution needed for calibration that
requires accuracies of 1.0 percent or less.
Dead weight testers are used in applications where pressures may exceed
10,000 psi.
Hand pumps allow the instrument craftsperson to have positive control
of pressure increase and are invaluable for prime standard alignments of
calibration equipment.

5.0.0 CALIBRATIONITEST PROCEDURES_

This section will outline a basic procedure for the calibration of pressure
sensing devices. It is important to note that a field calibration procedure will
be more detailed and should be followed verbatim.

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Figure 7. C-Sourdon Pressure Element

5.1.0 Calibration/Adjustment
The following is a general procedure for calibrating a Bourdon tube pressure
gauge. Refer to Figure 7 for test equipment connection points.
Step 1: Check pneumatic simulator (gauge comparator) general condition
and ensure that low and high range master gauges are in
calibration. Also verify that the supply is still under sufficient
pressure.
Step 2: Lockout and isolate gauge from the system.
Step 3: Connect test hose to the gauge.
Step 4: Shut test rig vent valve.
Step 5: Open pressure control valve on simulator and slowly raise test
pressure to the first increment of pressure.
Step 6: Compare reading on master gauge to test gauge and note any
difference.
Step 7: Raise pressure to each subsequent test pressure increment and
note readings.
Step 8: Adjust gauge so that its reading corresponds to that of the master
gauge on the simulator.
Step 9: Open vent valve on simulator and incrementally lower pressure,
noting the gauge readings as pressure decreases.

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Step 10: Repeat the procedure as necessary to verify the correct adjustment
and repeatability.
Step 11: Disconnect test hose from gauge and vent simulator.

6.0.0 TEST PERFORMANCE DOCUMENTATION_

One of the most important tools for any test or calibration evolution is the
written procedure from which instructions for performance will be obtained.
This document, if properly written, will be the recipe for timely and accurate
calibration of the various components in the system.
The following is a brief list of information that should be part of this
procedure:

Component operational schematic showing test connections and leads.

Test equipment list.
Personnel and equipment safety precautions.
Component specifications, i.e., maximum and minimum supply
pressures, voltages, current, any operating temperature limits, flow
rates, etc.
Component operating instructions.
Data sheets for annotating various parameters.
Acceptance criteria.
Detailed steps for correct performance of the procedure.

A final report should also be prepared to document successful completion of

the procedure with any data associated with it.

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Summary
Calibration/adjustment of various pressure instruments in a process system
is essential to the efficient and safe operation of the system. Each of the
components discussed in this module require different types of test
equipment and procedures for proper adjustment. A thorough understanding
of how each test is performed and the test equipment to be used will prove
invaluable to a trainee in the field.

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References
Instrument Engineer's Handbook, Chilton Book Company, Pennsylvania,
1982.
Basic Instrumentation - Industrial Measurement, McGraw-Hill, New York,
1966.

SELF-CHECK REVIEW/PRACTICE QUESTIONS

1. What is a disadvantage of using a single metal diaphragm as a pressure
gauge element?
a. Too expensive.
b. Inaccurate at low ranges.
c. Small pressure overrange can damage the diaphragm.
d. Must be temperature compensated.
2. What conditions are non-metallic diaphragms well suited for?
a. Low temperature, high pressure conditions.
b. Low pressure or vacuum conditions.
c. High temperature, high pressure conditions.
d. None of the above.
3. What components make up a pressure capsule?
a. Two circular diaphragms soldered or welded together.
b. Several bellows assemblies combined in series.
c. A differential pressure transmitter and bellows.
d. A differential pressure transmitter and pressure switch.
4. What is the useful range of operation of a metallic bellows?
a. 0.5 to 75 psig

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b. 1.0 to 50 psig
c. 100 to 1,000 psig
d. 100 to 10,000 psig
5. What is the purpose of a pressure transmitter?
a. Converts an electric signal to a pressure signal.
b. Converts an electronic signal to a control valve signal.
c. Provide control function for pressure switches.
d. Converts a mechanical or pneumatic signal to an usable signal.

PERFORMANCE/LAB EXERCISES
1. Calibrate a Bourdon tube pressure gauge.
Step 1: Write a test procedure to calibrate the gauge.
Step 2: Select the proper test equipment.
Step 3: Set up test equipment and perform calibration.
Step 4: Document test results.
2. Calibrate a bellows operated pressure switch.
Step 1: Write a test procedure to set the switch to an arbitrary range.
Step 2: Select the proper test equipment.
Step 3: Set up test equipment and perform calibration.
Step 4: Document test results.

ANSWERS TO SELF-CEHCK REVIEW / PRACTICE QUESTIONS

1.
2.
3.
4.
5.

c
b
a
a
d

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