Pressure automatic calibration system

Pressure automatic calibration system

It has the following auxiliary functions: sending standard current and voltage signals, testing DCS channels, verifying pneumatic base devices (such as P/P, E/P, I/P, pneumatic regulators, pneumatic valves, etc.), providing working power to field instruments, etc.

Basic functions:

1.1 Automatic interface with metrology management system

This system can interface with third-party measurement management systems using EXEL or WORD.

1.2 Parameters for managing on-site instruments

1) Management process measurement point parameters: measurement point number, measurement number, confirmation interval, measurement point location, management department, management team, drawing number (instrument electrical diagram and process PID diagram), measurement range, rated parameters, process location, control location, calibration guidance, and other user specified parameters;

2) Manage on-site instrument parameters: factory number, model, manufacturer, input type and range, output type and range, set values of logic switches, ideal input-output relationship of transmitter calibration points, power supply and accuracy, etc.

1.3 Automatic management of calibration results

Can manage calibration results for many years: pre calibration test results, post calibration test results, * large errors, calibration date and time, data input method (communication or manual), calibration instrument model, operator, calibration frequency and calibration method (passed without adjustment once or after adjustment or replacement), etc. The verification results can be retrieved by equipment, measurement points, management teams, weekly inspection notices, or by verification time.

1.4 Comprehensive management personnel and standard equipment

2. Management of verification personnel: department, team, name, gender, password, job number, position, education level, date of birth, as well as the name, expiration date, scope of evidence collection, issuing unit, etc. of the verification certificate.

3 Management personnel: department, name, job number, position, password, database modification permission, report approval signature permission, etc.

4. Management standard equipment: factory number, name, model, range, accuracy, calibration certificate, calibration cycle, expiration date, calibration unit, etc.

1.5 Facilitate the generation of weekly inspection plans (work task lists)

1) The system only needs a short amount of time to print out a list of instruments that have expired within a certain period of time (such as a month or a week) and must be calibrated, a list of instruments that have failed calibration, and a list of instruments that have been scheduled for calibration but have not been calibrated for some reason. This is very helpful for managers to arrange their work.

2) We can calculate the pre school pass rate.

1.6 Automatic Printing of Calibration Reports

The format of the verification report can be specified by the user. There can be multiple formats, such as pressure/differential pressure transmitter calibration report, pressure/differential pressure switch calibration report, spring tube pressure indicator calibration report, temperature transmitter calibration report, etc.

1.7 Automatic calibration of thermal instruments

1) Fully automatic calibration of pressure transmitters and switches;

2) Fully automatic calibration of thermocouples, thermistor temperature transmitters, and switches;

3) Verify DC signals and frequency/speed signals;

4) Verify the on-site indicator table.

1.8 Automatically generate stable calibration pressure source

By using a fully automatic pressure calibration table, stable pressure sources with various range of measurement can be generated.

1.9 Directly setting the parameters of the smart transmitter

By selecting accessories, the system can directly modify the zero position and range of Honeywell and Rosemount smart transmitters.

1.10 Other auxiliary functions

Features of the fully automatic pressure calibration system: 1) It adopts the Windows 2000/XP platform and has network functions. Managers can see the calibration status of on-site instruments on the factory MIS network.

2) On site instruments can be managed by instrument type (such as transmitter, logic switch) - instrument function (such as pressure transmitter, temperature transmitter, etc.) - instrument factory number, or by region (such as unit) - system (such as host or auxiliary) - process TAG (measuring point).

3) The system can manage on-site instruments that are regularly calibrated, as well as on-site instruments that are not regularly calibrated; It can manage on-site instruments and spare parts for on-site instruments.

4) The system can use a fully automatic pressure calibration table and calibration instrument to automatically calibrate on-site instruments, generate calibration databases, calibration reports, and calibration certificates. Other calibration instruments can also be used to manually calibrate on-site instruments, generating calibration databases, calibration reports, and calibration certificates.

5) Historical data can be retrieved by device, measurement point, management team, weekly inspection notice, or calibration time: it is convenient to view the calibration status of a certain instrument or measurement point, avoiding the tedious work of establishing a calibration record book for each instrument.

6) The system can ensure the authenticity of the verification report. The verification instrument stores the name, work permit number, pre adjustment verification data, post adjustment verification data, adjustment and replacement information of the verification personnel, with strict qualified or unqualified marks. The verification results are not artificially changed, avoiding the phenomenon of filling out the verification report based on memory afterwards, thus ensuring the authenticity, reliability, and scientific standardization of the verification report.

7) This system can significantly improve the efficiency of calibration work. After setting up the calibration instrument by the thermal technician (28 on-site instrument parameters can be set in a short time), the calibration personnel do not need to bring other instruments, paper, and pens to the site except for one set of calibration instruments. The operation on site is quite simple, and the calibration personnel only need to press the "SYS", "ENTER", "AUTO" and other keys to complete the work. If in the calibration room, a fully automatic pressure calibration table can be used, and one calibration personnel can calibrate about 50 transmitters or pressure switches per day.

8) Each BETA calibration instrument can store the parameters of 28 transmitters or logic switches, and the fully automatic pressure calibration table can store the parameters of 56 transmitters or logic switches. Each transmitter can calibrate 20 points with strict pass or fail marks.

The composition of the fully automatic pressure calibration system consists of a database for managing equipment data throughout the factory, software for collecting and communicating calibration data, software for printing calibration reports, a fully automatic pressure calibration table, and a multifunctional calibration instrument.

Verification process:

On site verification process

(1) Technicians pre build a database and input the content related to the calibration plan, process measurement points, and on-site instruments into the computer.

(2) Before calibrating a certain instrument, the calibration personnel download the relevant parameters (mainly calibration points) of the instrument to the required fully automatic pressure calibration table or calibrator.

(3) The verification personnel bring the fully automatic pressure verification table or calibrator with downloaded data to the site to verify the on-site instruments (transmitters, logic switches, or indicators). During calibration, the calibration personnel only need to perform simple operations to complete the work, and the calibration results are automatically recorded in the calibration station.

(4) The verification personnel upload the verification results from the verification table or BETA950 calibrator to the historical database of the computer, print out the verification report, and the verification work is completed.

Automatic calibration process in the laboratory

(1) Technicians pre build a database and input the content related to the calibration plan, process measurement points, and on-site instruments into the computer.

(2) During calibration, the computer is directly connected to the fully automatic pressure calibration table, forming a fully automatic pressure calibration system. If a fully automatic calibration table is used, simply click the "Start Calibration" button with the mouse to automatically complete all tasks such as pressurization, stabilization, data recording, and error analysis.

(3) After the instrument calibration is completed, the data processing work is also synchronized, and the calibration report and certificate can be printed immediately.

Verification of pressure transmitter

As shown in Figure 3, after selecting the process measurement points and on-site instruments, the computer automatically downloads the range, calibration points, and other parameters of the transmitter to the calibration station. The calibration station sends the real-time pressure signal and transmitter current feedback signal back to the computer for display on the screen. The system automatically stabilizes the voltage point by point according to the calibration points set in the database (such as 0%, 25%, 50%, 75%, 100%, 100%, 75%, 50%, 25%, 0%). The computer records the parameters when there are 3 seconds left in the stabilization time, and the stabilization time can be modified in real time. If the initial calibration is not qualified, zero and range adjustment operations will be carried out, followed by post calibration verification. A single channel calibration table can calibrate one transmitter. The calibration time before or after each school is within 6 minutes.

U Pressure switch calibration

As shown in Figure 4, after selecting the measuring point, the computer automatically downloads the range, trip point and other parameters of the pressure switch to the calibration platform. The calibration platform sends the real-time pressure signal, switch contact status and contact resistance signal back to the computer for display on the screen. When the system is far from the set value, it quickly increases the pressure. After the pressure rises to 10% of the lower range of the set value, it slowly increases the pressure until the switch is activated. The pressure value at the moment of the switch activation is recorded in the set value window of the calibration table. The calibration table is in a stable state, and the computer reads the activation point for resetting. The pressure slowly decreases, and the pressure value during resetting is recorded in the set value window of the calibration table. After the computer reads the reset value, the calibration table releases pressure and resets.

Pressure gauge calibration

As shown in the figure on the right, after selecting the measuring point, the computer automatically downloads the range, calibration point and other parameters of the pressure gauge to the calibration platform. The calibration platform sends the real-time pressure signal back to the computer for display on the screen. The system automatically stabilizes the pressure point by point according to the calibration points set in the database (such as 0%, 25%, 50%, 75%, 100%, 100%, 75%, 50%, 25%, 0%), manually reads and inputs the pressure gauge display value and lightly taps the change amount, and confirms the input before entering the calibration table to stabilize the pressure at the next calibration point. A single channel calibration station can simultaneously calibrate two pressure gauges.

Figure 5 Real time calibration of pressure gauge

The database editing software for the fully automatic pressure calibration system has database modification functions for areas, measuring points, on-site instrument types, on-site instrument functions, on-site instruments, calibration personnel, management personnel, calibration instruments, calibration modules, manufacturing plants, and other databases. It can safely and conveniently manage the database of the TMMS2000 on-site instrument automatic calibration and maintenance management system. It has the characteristics of safety and convenience.

U Security

The permissions of this system are divided into four levels: system administrator level, director level, technician level, and verification personnel level.

The system administrator level has the highest authority for database management, which allows them to import and modify the database at will, as well as assign and revoke permissions to legitimate personnel in the system. Without administrative management functions, it is not possible to review and accept inspection results.

Director level can modify database content but cannot perform import operations, has high administrative management functions, can authorize technician level, and can review and accept verification results.

Technicians can only modify authorized databases and can review and accept authorized calibration results. You can browse the entire database.

The verification personnel cannot operate the database but can modify their own password. They can perform up and down operations on the verification instrument or perform real-time single or double point verification.

U Convenience

When users are editing measurement point data and want to browse or modify the corresponding on-site instrument parameters, they can directly switch to it. After the on-site instrument parameters are modified and saved, they can switch to the process measurement point operation interface. If errors are found in the database during downloading or real-time verification, the corresponding measurement points or instrument data can be adjusted for modification.

The parameter editing screen for measuring points is shown in Figure 6. The left side is the tree directory of measuring points in the factory area/system/process, and the right side is the specific parameters of the selected measuring points. The management department, management team, mandatory inspection classification, management status, and measuring point purpose can be selected in the list box. The content of the list box can be configured by the user. Generally, the measuring point purpose includes automatic, display, protection, etc. The management department and management team will prepare and set the management status, online, standard table, etc. according to the actual situation of the factory. Operation guidance provides technical personnel with assistance information for calibration personnel, such as which instruments, piping joints, and tools must be brought during calibration work. The corresponding instrument panel displays the instrument installed on the selected measuring point. Double click on the instrument to enter the corresponding instrument screen, as shown in Figure 7.

On the left side of the instrument parameter editing screen is a tree directory of instrument types/functions/field instruments, and on the right side is the specific parameters of the selected instrument, including instrument nameplate parameters such as instrument model, input range, output range, output response, manufacturer, production date, power supply voltage, power supply current, accuracy, etc. Instrument input setting parameters, such as input type, input low and high limits and units, engineering quantity low and high limits and units, input units, etc. Instrument output setting parameters, such as output type, output low and high limits and units, engineering quantity low and high limits and units, square root low and high limits and units, interval time, allowable error, allowable hysteresis value, etc.

If the input unit is not available in the options, you can select "Quantity Conversion" in the linearization column of the input settings, enter the low limit, high limit, and unit of the quantity, and the input of the calibration point will be displayed in custom units.

If you want to display the output in engineering units, you can select "Engineering Conversion" in the linearization column of the output settings, enter the engineering low limit, high limit, and unit, and the output of the calibration point will be displayed in custom units.

If the instrument is a flow transmitter, select "square root" in the linearization column of the output settings, and the square root correspondence will be automatically generated when generating calibration points.

Click the "Ideal Input/Output Relationship of Verification Point" button to enter the ideal input/output relationship screen of verification point, as shown in Figure 8.

The generation of calibration points only requires the user to determine the number of calibration points and whether the instrument needs to be calibrated. The system will automatically generate calibration points based on the input upper and lower limits, output upper and lower limits, and input/output line systems (standard conversion, engineering quantity conversion, square root conversion), which is convenient, fast, and error free. Users can manually modify the generated calibration points.

The calibration instrument library manages the model, name, range, accuracy, protocol version, calibration unit, calibration certificate and other information of the calibration instrument. For standard equipment with automatic online function, such as fully automatic calibration table, BETA calibration instrument, etc., the information can be directly uploaded from the instrument.

The manufacturing plant database manages information such as the name of the manufacturing plant, the name of the person in charge, contact phone number, address, etc.

The weekly inspection plan can be imported from EXCEL, managed by group, and arranged by team, unit, etc.

The 7 automatic pressure calibration system calibration report printing software calibration report printing system can print calibration reports according to the user specified report format (see Chapter 9).

As shown in Figure 9, the verification results can be retrieved by time, measurement point, on-site instrument, department team, and weekly inspection notice.

Figure 9 Printing Screen of Verification Report