Calibration of Current to Pressure Transducer

Basic Operation
The I/P transducer receives a 420 mA DC input signal from a control
device and transmits a proportional fieldconfigurable pneumatic output
pressure to a final control element usually a control valve. The I/P converter
is typically used in electronic control loops where the final control element is
a control valve assembly that is pneumatically operated. In most applications
the I/P transducer is mounted on a control valve or very close to it in a
mounting bracket.
Typical Input/output configuration for the I/P Converter
It is possible to configure the I/P transducer for various input output
configuration. For an input of 4 20mA, we could have outputs of 3 to 15psig
(typical), 6 to 30psig and 2 to 33psig all depending on the field application.
Similarly, we have inputs of 4 12mA and 12 20mA both corresponding to
an output of 3 to 15psig
Calibrating the I/P Transducer
I to P transducers are calibrated in much the same way analog DP
transmitters are calibrated howbeit with a little difference. A DP transmitter
senses process pressure and outputs a standard 4 20mA signal. In
calibrating them, we apply pressure within the calibration range of the
transmitter and confirm that the output of the transmitter is within the 4
20mA current range throughout its calibration range with little or no
deviations by making ZERO and SPAN adjustments.
In an I to P converter, current in a specific range e.g 4 20mA is
supplied to it and the device outputs a pneumatic output of a specific range
commonly 3 15psig in most applications. Therefore to calibrate the I/P
transducer, we simply supply it current in a specific range with 4 20mA the
most common and we confirm that the output of the transducer is within the
range 3 15psig by also making ZERO and SPAN adjustments.
Calibration Procedure
As already noted, calibration of the I/P converter involves basically a
ZERO and SPAN adjustment.
Safety Precaution

The steps and guideline provided here are meant as a general guide.
Before embarking on an actual calibration, consult your manufacturers
manual for the I to P converter. It should be your de facto guide. Make sure
you are wearing all the necessary safety gear and that you are complying
with all the requirement for Hazardous Area classification and any other
requirement that will ensure the exercise is done safely.
Materials Required:
a) Current Source capable of delivering 150% (30m A) of maximum
output of transducer with the required compliance voltage.
b) Supply pressure of at least 20psig.
c) A milliammeter (In the absence of a milliammeter, a 0 10VDC
voltmeter with a 250 ohm resistor connected across it can serve the
same purpose 1VDC indication for 4m A and 5VDC indication for
20m A)
Equipment Set up

Calibration Steps:
a) To access the transducer terminal, remove the electronics module
cover.
b) Confirm that the switch settings for different input
configuration is set to achieve the desired input/output range

output

c) If the control device in the control loop is being used as the input
current source, connect the control device to the I/P transducer as
shown above otherwise, disconnect the device and connect the current

source to the transducer incorporating a current meter to monitor the

calibration operation as shown above
d) Confirm that the supply pressure to the I/P transducer is at least 20psig
e) Adjust the input current to the low mA DC value e.g 4mA in the case of
a 4 20mA output calibration.
f) Confirm that the output pressure of the I/P transducer is now 3psig
(0.2barg). If not, locate the ZERO adjustment screw and adjust the
ZERO potentiometer until the output pressure is 0.2 bar (3 psig). Note
ZERO and SPAN adjustment screws are conspicuously visible and
labelled. They can be easily seen after removing the electronics
module cover.
g) Next adjust the input current to the high mA DC value e.g 20mA in the
case of a 4 20mA input calibration.
h) Confirm that the output pressure should be 1.0 bar (15 psig). If not,
locate the SPAN adjustment screw and adjust the SPAN potentiometer
until the output pressure is 1.0 bar (15 psig).
i) Repeat steps 5 through 8 until the output pressure of the I/P converter
is within the referenced accuracy requirements stated by the
manufacturer without further adjustment.
j) If you used a current source other than the control device, disconnect
the current source and reconnect the control device. Your I/P converter
is now ready to be in operation
CONTROL VALVE MAINTENANCE
An ideal valve in operation should satisfy the following steps:
1. Stroke the valve and observe the plug position next to the stroke
indicator plate. The plug should change position in a smooth, linear
fashion.
2. Check for full stroke by making the appropriate instrument signal
change
3. Check the valve fails in the right direction in case of air failure. This is
done by shutting off the air supply. If any difficulty is suspected with
the control valve check the following:
a) Make sure the valve has sufficient air supply.

b) Check for air leaks in the supply instrument signal system and valve
positioner.
c) Make sure the packing is not too tight by loosening the gland flange
bolting and re-tightening to just over finger tight.

PREVENTIVE MAINTENANCE
These steps can be performed while the valve is in-line and without
interrupting process.
1. Look for signs of gasket leakage through the end flanges and bonnet. If
required tighten flange and bonnet bolts.
2. Check for leakage to the atmosphere through the pressure-balance
sleeve, metal bellow seal, body drain plug, etc.
3. Examine the valve for damage caused by corrosive fumes or process
drippings.
4. Clean the valve and paint areas of severe oxidation.
5. Check packing box bolting for proper tightness.
6. If the valve is supplied with a lubricator, check lubricant if necessary.
7. If possible, stroke valve and check for smooth full stroke operation.
8. Make sure the positioner linkage and the stem clamp are securely
fastened. If the stem clamp is loose, check plug thread engagement
9. Ensure all accessories, brackets and bolting are securely fastened.
10.
If possible remove air supply and observe actuator for correct
fail-safe action.
11.
Check rubber bellows for wear.
12.
Spray soap solution to check air leakage through O ring
13.
Clean any dirt and other foreign material from the plug stem.
14. If any air filter is supplied, check and replace cartridge if necessary

** Calibration Data Sheet, instead of temperature units, us Percentage of

opening or closing**