How to Use a Portable Bath to Improve Calibration of Sanitary RTD's and Transmitter's

How to Use a Portable Bath to Improve Calibration of Sanitary RTD's and Transmitter's

• 1.
  Fluke Calibration Web SeminarSeries Principles and practical tips about temperature, humidity, electrical, flow, pressure, and RF calibration How to Use a Portable Bath to Improve Sanitary Temperature Sensor and Transmitter Calibration
• 2.
  How to Usea Portable Bath to Improve Sanitary Temperature Sensor and Transmitter Calibration May 10, 2017 Dry-block calibrators are easy to transport for on-site sensor calibration, but not as accurate as baths. Compact calibration baths are more accurate than dry-blocks, but are limited to lab use due to size. Portable baths give you the benefits of both -- dry-block portability plus bath accuracy. Attend this free webinar where we’ll describe how the Fluke Calibration 6019A and 7109A Portable Calibration Baths can improve the calibration throughput and accuracy of sanitary temperature sensors and transmitters. Since production downtime can be costly, increasing sensor calibration throughput is critical. Today’s Webinar
• 3.
  Your Presenter • FlukeCalibration – Electrical (Everett, WA) – RF (Norwich, UK) – Temperature (American Fork, UT) – Pressure/Flow (Phoenix, AZ) Fluke Calibration, Temperature, American Fork, UT • Presenter: Michael Coleman – Fluke Corporate Temperature Metrologist • With Fluke/Hart Scientific 20 years – Primary Temperature Calibration Lab – TCAL Service Department
• 4.
  Introduction There are severaltemperature source options available for calibrating RTDs (resistance temperature device) and transmitters on-site  Calibration baths  Best uncertainties  Slow temperature transition  Difficult to transport  Fluids can be messy and difficult to cover entire range  Dry-block calibrators  Fast, portable, clean (no fluids)  Don’t accommodate many sensor sizes and shapes  Larger uncertainties  Portable calibration baths  Excellent specifications  Sensor size/shape compatibility  Portable and fast temperature transition  Can be equipped with process electronics features  Fluids can be messy and difficult to cover entire range
• 5.
  On-Site Temperature Calibration •On-site – calibration work is done at the DUT (device under test) location to minimize down time and to calibrate the measurement loop • Industrial temperature measurement systems – DUT sensor (RTD, thermocouple) – resistance or voltage sensor that measures the process temperature – DUT transmitter head – measures and transmits sensor readings to control room using 4-20 mA current loop – Other – PLC (programmable logic controller) systems, ovens, chambers, furnaces • Calibrate the RTD and transmitter as a system (connected) or separately – RTDs can degrade and drift with use – don’t rely solely on simulation – In most cases the sensor is placed in a temperature source to calibrate a range of temperatures
• 6.
  Other On-Site Considerations •Sanitary conditions – clean rooms, medical device manufacturing, pharmaceutical • Explosive atmosphere – refineries, oil/gas plants, intrinsically safe equipment requirements • Non-instrument friendly environment – heat, cold, water, vibration, chemical exposure • Access – ladders, cat walks, outdoors, transport in trucks
• 7.
  On-Site Sensor Shapesand Sizes
• 8.
  Sanitary Temperature Sensors Used in a number of process manufacturing industries  Very common in pharmaceutical and biotechnology clean room production  They come in a variety of shapes and sizes  Tri-clamp  Short  Odd geometries  Integrated with transmitters Examples of tri-clamp sanitary sensors Examples of short, odd geometry sanitary sensors and temperature sanitary transmitters
• 9.
  What is aTri-Clamp Sensor? • “Tri-clamp” refers to the mechanical housing of a temperature sensor used in process manufacturing where a liquid seal is required • A tri-clamp sensor includes a stainless steel (SST) flange ranging from ½-in to 3-in diameter that clamps to a pipe ferrule creating a seal SST Flange Transmitter housing
• 10.
  Tri-Clamp Sensor Photos Tri-clampsensor (side view) Tri-clamp sensor (bottom view)
• 11.
  Three Important Factorsfor Good Sanitary Sensor Calibration • Temperature source accuracy (bath or dry-block calibrator): Accuracy needs to cover all sources of error including calibration uncertainty, stability, uniformity, and repeatability. Use the most accurate source available to get the best calibration results. • Immersion depth: Sanitary sensors need to be immersed to a proper depth in the source to minimize the effects of temperature gradients and stem conduction. • Calibration throughput: Calibrating more than one tri-clamp sensor or a batch of sanitary RTDs and temperature transmitters at a time improves technician productivity. That leads to shorter calibration time and getting production back on line quicker. Short sensor can’t reach full immersion in a dry-block calibrator
• 12.
  Sanitary Sensor ImmersionDepth • Tri-clamp sensors vary in length and diameter • The tank diameter of Fluke Micro-Baths (6102/7102/7103) or a dry-block with liquid insert may not be large enough to accommodate a tri-clamp sensor 51 mm (2 in) diameter or bigger and a reference thermometer • Best to immerse the tri-clamp sensor and flange in the bath fluid during calibration • For best results with a 6109A/7109A bath, position the sensor tip 15 mm (0.6 in) above the bottom of the tank Example Tri-Clamp Sensor 6109A/7109A baths with four tri- clamp sensors and reference probe mounted in Probe Holding Fixture
• 13.
  Temperature Sources for SanitarySensor Calibration • Dry-block calibrators: Block/insert size limits capacity to one tri-clamp sensor. May not be able to get full insertion due to flange and short sensor length • Circulating calibration baths: Sometimes used because of large working area – but not designed for calibration. Stability/uniformity specs typically not provided and are usually not very good. • Fluke portable calibration baths: – 6102/7102/7103 Micro-Baths: Good ± 0.25 °C accuracy. Working area limited to one tri- clamp or small batch of sensors at a time. – 6109A/7109A Portable Calibration Baths: Designed for calibrating sanitary sensors in clean room production areas, capacity of four sensors
• 14.
  6109A / 7109APortable Calibration Baths Calibrate four tri-clamp sanitary sensors at a time! 7109A6109A Four times more calibration throughput Much better accuracy than micro-baths and dry-block calibrators  Calibrate up to four tri-clamp sanitary sensors, or a batch of sanitary RTDs and temperature transmitters, at the same time  Wide temperature range covers most clean process applications: 6109A: 35 °C to 250 °C 7109A: –25 °C to 140 °C  Excellent display accuracy of ±0.1 °C [Accuracy covers all sources of error including calibration uncertainty, stability, uniformity, and repeatability]  Excellent uniformity (0.02 °C) and stability (0.01 °C) to use with an external reference  Perfect for clean room use -- Stainless steel panels and tank withstand harsh sterilizing chemicals and are rust proof; Made from materials that don’t harbor bacteria
• 15.
  Two Methods forCalibrating Sanitary Sensors 1. Connected to the control system  Unmount sensors from clamp and immerse in bath  When sensors have stabilized, record the bath temperature and the control room display temperature  Advantages: Calibrates the whole system (loop). Faster since sensors don’t need to be disconnected from system.  Disadvantages: May require two people to record data. Errors with the sensors and/or transmitters may go undetected. 2. Disconnected from the control system  Place sensors in the bath and disconnect cable from the transmitter  Connect the sensors to a readout such as a 1586A Super-DAQ (to calibrate multiple).  When sensors have stabilized, record the bath temperature and the sensor temperature displayed on the 1586A Super-DAQ  Calibrate the transmitter with the 4-20 mA 6109A/7109A 4-20 mA circuit  Advantages: Requires only one person to record data. Errors with sensors and transmitters are identified in calibration.  Disadvantages: Slower than leaving sensors connected to the system. Not all data is in temperature units
• 16.
  Example using a7109A Portable Calibration Bath to calibrate four tri-clamp sensors at a time The 7109 bath has a temperature range of -25 to 140 °C The tri-clamp sensors will be calibrated at three temperature points: 0, 70, and 140 °C Method 1: Calibrate Sanitary Sensors Connected to the Control System (Loop)
• 17.
  Step 1: Immersethe sensors in the bath fluid Use the Adjustable Probe Holding Fixture to hold up to four tri-clamp temperature sensors The fixture fits inside the tank opening. The height of the platform can be adjusted. Immerse the tri-clamp sensors with the flanges below the surface of the bath fluid. Adjustable Probe Holding Fixture Four tri-clamp sensors mounted in 7109A bath tank Method 1: Calibrate Sanitary Sensors Connected to the Control System (Loop)
• 18.
  Step 2: Selectthe Setpoint Temperatures Push the “Program” button on the control display. In Program mode, you can define a program with several setpoint temperatures. See the Operators Manual for details on programming setpoints. For this example, we’ll assume a “Program 1” with three setpoint temperatures (0, 70, and 140 °C) and a dwell time of 20 minutes at each setpoint. 7109A Display Method 1: Calibrate Sanitary Sensors Connected to the Control System (Loop)
• 19.
  Step 3: Runthe Program To run a program, push the “Program” key, select “Program 1”, and run. The bath will begin cooling from room temperature to 0 °C which is the first setpoint. The display shows bath and setpoint temperatures. The upper right corner of the display includes a Control Indicator and Heating or Cooling Status. 7109A Display Method 1: Calibrate Sanitary Sensors Connected to the Control System (Loop)
• 20.
  Step 3. Runthe Program Continued To view the bath temperature over time, select the “Monitor” button and F2 “View Graph”. The graph scales automatically to best fit the data. The Control Indicator will show stable when the bath fluid is at the setpoint and ready for temperature measurement. A Ready Indicator on the top of the bath also changes from amber to green when the bath is at setpoint. Ready Indicator Control Indicator Method 1: Calibrate Sanitary Sensors Connected to the Control System (Loop)
• 21.
  Step 4. Recordthe Data When the bath is at setpoint, record the bath temperature value and the sensor readings in the control room. Depending on the distance between the bath and the control room, you may need another person to help record data. Then the bath will ramp to the next two setpoints, 70 and 140 °C. Complete the same steps at the other two temperatures Method 1: Calibrate Sanitary Sensors Connected to the Control System (Loop)
• 22.
  Steps: 1. Connect the1586A Super-DAQ to the 7109A bath with the data cable 2. Insert a reference probe and the tri-clamp sensors to be tested into the 7109A bath. 3. Connect the reference probe and sensors to the 1586A. Enable the channels they are connected to. Method 2: Calibrate Sanitary Sensors Disconnected from the Control System Reference Probe Tri-clamp Sensors 1586A Super-DAQ Precision Temperature Scanner 7109A Portable Calibration Bath
• 23.
  Steps Continued: 4. Allsetup is done from the 1586A. Setup measurements and test points. – Configurations can be named and stored in memory for quick recall and consistency 5. Start the test – Several options to monitor progress Method 2: Calibrate Sanitary Sensors Disconnected from the Control System
• 24.
  Steps Continued: 6. Collectand analyze data • Files stored in CSV format, easily read by Excel or other analysis or reporting tools • Two files stored with each test – Setup.csv – records all configuration details – Data.csv – all measurement data with time tag Method 2: Calibrate Sanitary Sensors Isolated from the Control System
• 25.
  Method 2: CalibrateTemperature Transmitter  Temperature transmitters have a sensing device such as an RTD or thermocouple and a transmitter to read and relay the signal to the control system  All sensors, including RTDs, drift with time  Testing the transmitter with the sensing device is a good practice to ensure the overall effectiveness of the temperature transmitter in a process system Example of Temperature Transmitter
• 26.
  Method 2: CalibrateTemperature Transmitter  Let’s demonstrate how to do a loop calibration of a temperature transmitter with a 7109A-P Portable Calibration Bath  The 7109A-P model with Process Electronics includes a panel for connecting a Reference Probe and terminals for measuring and powering a 4-20 mA transmitter 7109A-P Portable Bath -25 to 140 °C 7109A-P Process Input Module 1. Current fuse 2. RTD terminals 3. Reference PRT connector 4. Thermocouple input 5. Transmitter terminals
• 27.
  Method 2: CalibrateTemperature Transmitter Steps: 1. Isolate the temperature transmitter from the process. 2. Immerse a Reference Probe into the 7109A bath so tip is 15 mm from bottom of bath. 3. Immerse the transmitter sensor in the bath allowing fluid to cover the flange. Immerse Reference Probe and Temperature Transmitter Tip: a rule of thumb for reference probe immersion depth is 20 times the diameter of the sheath, plus length of the sensor
• 28.
  Method 2: CalibrateTemperature Transmitter 7109A-P Process Input Module Steps Continued: 4. Connect the Reference Probe to the Reference PRT connector of the Process Input Module. 5. Connect the 4-20 mA circuit of the transmitter to the Transmitter Terminals of the Process Input Module. Reference Probe Temperature Transmitter
• 29.
  Method 2: CalibrateTemperature Transmitter Steps Continued: 6. Turn on loop power from the 7109A bath. 7. Adjust the bath temperature to each of the test points. 8. At each test point, record the reading of the Reference Probe and the transmitter output to determine if adjustment is required.
• 30.
  Other Applications for6109A/7109A • Ideal calibration bath for a lab to get started with – Great specs – Small size – Flexible (in lab use, on-site use, etc.) • Calibrate PRTs, thermistors, thermocouples in the laboratory or calibration shop • Calibrate digital thermometer systems (readout and probe connected) • Interface with 1586A readout system and high-quality PRT for improved uncertainties and process throughput
• 31.
  6109A and 7109ASpecifications ©2016 Fluke Calibration
• 32.
  Additional Resources Free fordownload from Flukecal.com • “6109A/7109A Portable Calibration Baths Operators Manual” • “Automated Temperature Sensor Calibration with the 1586A Super-DAQ” Application Note, 6002875A • “Temperature Calibration Applications and Solutions” Brochure, 6005929A ©2016 Fluke Calibration
• 33.
  Current Promotion • FREEFluke Calibration 5615 or 5609 temperature probe (up to $1,311 value) – With purchase of a Portable Bath with a qualifying accessory – Detail at Transcat.com – Deals page
• 34.
  Questions or Comments? EmailNicole VanWert-Quinzi nvanwert@Transcat.com Transcat: 800-828-1470 www.Transcat.com For related product information, go to: www.transcat.com/brand/fluke-store