WP - EDDL Calibrationtrim
WP - EDDL Calibrationtrim
WP - EDDL Calibrationtrim
transmitter to perform the sensor trim, the technician keys in the applied value (on a computer or handheld communicator) communicated to the transmitter, allowing the transmitter to correct itself. The physical input values applied for lower and upper sensor trim respectively are stored in the transmitter memory and are referred to as Lower Sensor Trim Point and Upper Sensor Trim Point respectively. Sensor trim requires a very accurate input to be applied. The factory calibration equipment is usually more accurate than equipment at site. Moreover, transmitters these days are typically very stable. Therefore, sensor trim of brand new transmitters is rarely done at commissioning. Sensor trim is the aspect of calibration which this white paper focuses on. That is: Pressure calibration Flow calibration Temperature calibration Level calibration Etc. Range Setting (Re-range) Range setting (re-ranging) refers to setting the scale for the 4 mA and 20 mA points. That is, at what input shall the transmitter output be 4 mA; Lower Range Value (LRV) often referred to as "zero" meaning 0%, and at what input shall it be 20 mA; Upper Range Value (URV), sometimes called "full scale" meaning 100%. Note that the term "span" is not the same as URV. Span is the magnitude of difference between URV and LRV. For instance, if LRV is 20 and URV is 100, the span is 80. History Lesson: Rangeability and Turn-down Ratio Rangeability is the ratio of the smallest permitted span to the Upper Sensor Limit. For instance, if the Upper Sensor Limit is 80 kPa and the minimum span is 2 kPa, then the turndown ratio (rangeability) of that transmitter is 40:1. Transmitter range setting is done without applying input, and therefore can be done remotely from the control room. For instance, set range of pressure transmitter to get 4 mA when input is 0 bar and 20 mA when pressure is 40 bar. Range must be set within the Lower Sensor Limit (LSL) and Upper Sensor Limit (USL). Transmitters usually also have a minimum span to be observed. The difference between URV and LRV must exceed the minimum span, or else the output resolution and percentage accuracy is too poor. The transmitter will reject range setting attempts not observing the LSL, USL, and minimum span limits. History Lesson: Elevation and Suppression (As per ISA 51.1) When the lower range value (4 mA point) is above zero, for instance a range of 20 to 100, is called suppression. When the lower range value (4 mA point) is below zero, for instance range of -25 to +100, or -100 to 0, or -100 to -20, this is called elevation. That is, elevation and suppression relates to the lower range value (the 4 mA of the transmitter range). Elevation and suppression are chiefly used in differential pressure measurement since this make it possible to measure liquid levels with wet legs and remote seals etc. In smart transmitters it is all done in firmware and nobody ever asks for it anymore. The ability of a transmitter to do elevation and suppression was stated in % and relates to rangeability (turndown). A popular analog pressure transmitter had a 6:1 rangeability and therefore used to sport 600% elevation and 500% suppression. Smart pressure transmitters have capabilities in order of several thousand percent so it is never even discussed. www.eddl.org 2
Range setting is only applicable to transmitter with 4-20 mA output. That is, for 4-20 mA/HART transmitters, not for pure digital solutions like FOUNDATION fieldbus (FF) or WirelessHART transmitters. The reason being that FF and WirelessHART transmitters has no 4-20 mA output, therefore there is no need to set 4 mA and 20 mA range points. For 4-20 mA systems the range is set in both the transmitter and controller. For FF and PROFIBUS the range is set in the controller, and need not be set in the transmitter which can lead to some confusion for beginners. The only exception for FF, WirelessHART, and PROFIBUS transmitters may be for differential pressure (DP) flow and level measurement where the end-points of the DP scale (e.g. 0-250 inH2O in XD_SCALE) and corresponding flow or level scale (e.g. 0-400 bbl/day in OUT_SCALE). This also enables DP transmitters to locally indicate in flow or level units. FF and PROFIBUS devices have provision for setting a range in the transmitter even though it may not used for the application.
4-20 mA Transmitter
Sensor Sensor Trim Range Current Trim A m 0 2 4
DCS
Current Trim Range (AI) PID
Bus Transmitter
Sensor Sensor Trim
Valve / Controller
s u B Range & PID
AI
However, the nominal operating range has to be specified also for FOUNDATION fieldbus and WirelessHART transmitters for sizing purposes when buying, such that the device supplier can pick the appropriate sensor model. There is also a need to select the desired engineering unit in the device. The DCS may need a range set in database as scaling end-points for bargraphs and trend and will also need a range for PID control even though there is no range in the FOUNDATION fieldbus or WirelessHART device. The output of both the FF transducer block and the AI function block is engineering unit. For most applications there is no need to set range in either block. If a range is set in the AI block, the percentage of range can be seen from the FIELD_VAL parameter.
Transmitter
Sensor Transd ucer Block
E.U.
AI
E.U.
4-20 mA Range Mismatch If the range set in the transmitter does not match the range in the DCS, alarms, controls, and indication will not function correctly. Therefore it is important to document any range changes such that the correct range is set when transmitters are replaced. Range in Specification Forms Range is not required to be set in transmitters using pure digital communication, but it is required to be specified in instrument specification forms (ISA20) such as with bid documents for sensor element selection. For instance, the pressure transmitter supplier needs to know the pressure range (and other process data) to select the sensor module for the application. The temperature transmitter vendor needs to know the temperature range (and other process data) to select the temperature element model for the application. There are typically two ways to set the range of the transmitter: Direct numeric value entry www.eddl.org 3
To applied input
Direct numeric value entry means the desired lower and upper range values are simply keyed in from device software or handheld field communicator, and sent to the transmitter, for instance, keying in 20 to 100 kPa.
To applied input
Range setting to applied input requires a physical input corresponding to the desired range value to be applied to the transmitter. This is often used in level measurement applications. For instance, first the tank is emptied to its lower level and then the set PV LRV command is sent to the transmitter to set the lower range value to whatever the input happens to be. For instance for a DP level transmitter, if the pressure is 20 kPa when the tank is empty (the pressure tap is slightly below the datum), this becomes the new lower range value, thus ensuring the reading is 0% and output current is 4 mA whenever the tank is empty. Conversely, next the tank is filled to its upper level and then the set PV URV command is sent to the transmitter to set the upper range value to whatever the input happens to be. For instance, if the pressure is 100 kPa when the tank is full, this becomes the new upper range value, thus ensuring the reading is 100% and output current is 20 mA whenever the tank is full. In between the reading is linear. Note that the technician need not know what the physical input is, just that the tanks is full and empty respectively. The set PV LRV command is also common to cancel wet-leg for DP transmitters in all kinds of application including flow. The set PV LRV and set PV URV commands are equivalent to pushing the 'zero' and 'span' buttons respectively found on some transmitters. History Lesson: Non-interactive zero and span One of the major time saving benefits that came with microprocessor-based transmitters was noninteractive zero and span: When lower range value is set to applied input, the span (i.e. the difference between upper range value and lower range value) is maintained. That is, the upper range value is shifted by the same amount as the lower range value. For instance, if the original range was 0-100 kPa, and lower range value is set to applied input when the applied input is 20 kPa, the new range will be 20-120 kPa, maintaining the original span of 100 kPa. That is, the upper range value was also shifted by 20 kPa just like the lower range value. However, if upper range value is set to applied input, the lower range value zero) is not changed. For instance, if the original range was 0-100 kPa, and upper range value is set to applied input when the applied pressure is 80 kPa, the new range will be 0-80 kPa, maintaining the original zero of 0 kPa. That is, the lower range value was not shifted. That is, changing the zero does not affect the span, changing the span does not affect the zero. This is non-interactive zero and span. Corrupting the range to make 4-20 mA right Don't use range setting to correct a sensor error. For example, a 4-20 mA/HART pressure transmitter ranged 0-100 inH2O may due to mounting position get a shift in reading of 1 inH2O. The output will be 4.16 mA when no pressure is applied, making the remote indicator or HMI show 1 inH2O. A common mistake is to isolate, equalize, and vent the manifold and click the 'Set PV LRV' command in the device management software or handheld field communicator, or pushing the 'zero' and button on the device thus changing the range bringing the output to 4 mA. However, checking the PV in the device management software or local transmitter indicator will reveal the sensor reading with no pressure applied is still 1 inH2O and the range is changed to 1-101 www.eddl.org 4
in H2O. Two wrongs appear to make a right The correct way to correct for shift or drift is to do a sensor trim Corrupting the sensor reading to make 4-20 mA right Don't use sensor trim to cancel a wet-leg. For example, a 4-20 mA/HART pressure transmitter ranged 0-100 inH2O may when mounted below the tank read 1 inH2O. The output will be 4.16 mA when the level is zero (at the tank datum point), making the remote indicator or HMI show 1 inH2O. A common mistake is to click the 'Zero Trim' command in the device management software or handheld field communicator thus changing the sensor reading bringing the output to 4 mA. However, if the 4-20 mA/HART pressure transmitter is isolated and vented, and the PV checked in the device management software or local transmitter indicator, it will show the sensor reading with no pressure applied is -1 inH2O. Two wrongs appear to make a right The correct way to cancel a wet-leg is to set the range Transmitter Output Current Trim It is rare for the output current circuitry of a 4-20 mA transmitter to drift. However, should the output current be incorrect, use current trim to correct the output signal. For instance, if the current output is 4.13 mA when it should be 4.00 mA, then current trim is used to adjust it to 4 mA. Current trim is used to match the transmitter current output to the current input of the analog input card channel on the DCS. For instance, the transmitter may be reading 0.00% but the DCS may show 0.13% because of differences in current calibration. Current trim is only applicable to transmitter with 4-20 mA output. That is, for 4-20 mA/HART transmitters, not for FOUNDATION fieldbus (FF) or WirelessHART transmitters, the reason being pure digital transmitters have no 4-20 mA output. Current trim requires the technician to measure the physical output from the transmitter. Therefore the technician must either do current trim in the field at the process location by connecting a multimeter to the transmitter test terminals, or the transmitter has to be brought back into the workshop to perform current trim. Current trim in the field is possible using a handheld communicator. Task Sensor trim Local / Remote Local Example 4-20 mA HART Yes FOUNDATION Fieldbus Yes PROFIBUS Yes
Range setting
Local or remote
Correct the sensor reading to applied input. For instance, if pressure is 0 bar but transmitter reading is 0.03 bar, then sensor trim is used adjust it to 0 bar. Set the 4 mA and 20 Yes mA points. For instance, set range of pressure transmitter to get 4 mA when input is 0 bar and 20 mA when 5
No*
No*
www.eddl.org
pressure is 40 bar. Current Local Correct the current Yes No trim output. For instance, if the current output is 4.13 mA when it should be 4 mA, then current trim is used to adjust it to 4 mA. * Range setting in transmitter only done for DP-flow and DP-level measurement
No
Figure 1 Positioner manufacturer uses EDDL to illustrate connection for current trim procedure
is just like sensor trim for a pressure or temperature transmitter, only that a known reference need not be connected, the positioner will automatically stoke the valve over its full travel to discover the open and closed end-positions.
Likewise, the 4-20 mA actual valve position feedback current output of a 4-20 mA positioner is calibrated just like a 4-20 mA transmitter. Again, this process is not required for FOUNDATION fieldbus positioners or for position feedback transmitters based on WirelessHART.
Device Integration
Plants have a great mix of transmitters for different kinds of measurements from different manufacturers. Since all sensors drift, at some point in time all sensors need a trim. The procedure for calibration depends on the type of transmitter: Pressure transmitter: apply pressure from calibrator or dead weight tester or the manifold can be equalized for zero trim Temperature transmitter: apply milli-voltage or resistance from calibrator or resistance decade box Flowmeter: has to be calibrated in a flow rig Valve position transmitter: stroke the valve fully opened and fully closed The procedure for sensor trim may also vary slightly from one manufacturer to the next depending on the requirement for the particular sensor technology.
Poor Hosts
Original DD technology from 1992 made it possible to calibrate all transmitters using the same handheld field communicator or laptop software. Before DD only proprietary solutions existed. The most basic content of a DD file is the Device Definition describing the blocks and the parameters in the device, including limits, options, and help etc. The original DD technology from 1992 also included Business Logic such as "wizards" (aka "methods") which is a kind of script created by the transmitter manufacturer to guide the technician through the sensor trim process. Wizards thus make sensor trim easy. Wizards, conditionals, and help are explained further in the section on EDDL. However, not all transmitters provided wizards in their DD file and not all www.eddl.org 7
intelligent device management software supported wizards. That is, on many systems and for many types of transmitters, sensor trim in the past was not so easy. For instance, FOUNDATION fieldbus transmitters which in the past had to set the correct mode, in the correct block, write value to correct parameter, and remember to return block mode. At the same time the technician also had to remember to inform operations. All of this in addition to actual sensor trim task itself such as applying input, or working the manifold etc. Lack of wizards was not a problem with the DD technology itself, it was poor implementation in many early products.
EDDL
Device Definition Blocks Parameters Business Logic Wizards Conditionals User Interface Description Menus Graphics
Figure 3 Not all systems supported Business Logic, and the User Interface Description was not introduced until 2006.
The EDDL enhancement done in 2006 is a User Interface Description which includes graphics such as trend charts, waveform graphs, dial gages, bargraphs, bar charts, and tables etc. Graphics, menu system, wizards, and conditionals are now mandatory for all FOUNDATION fieldbus and 4-20 mA/HART compliant host systems.
Instruct technician to tell operations to put the associated control loop in manual so control is not upset when PV changes when sensor reading changes. inform the technician the sensor reading will change Instruct the technician to apply zero physical input (e.g. by isolate, equalize, and vent the manifold) Instruct the technician to wait while the sensor reading stabilizes and is corrected by the transmitter. Inform the technician the zero sensor trim was successful Instruct technician to tell operations the associated control loop can be put back in automatic
Because the sequence is driven according to the steps defined by the transmitter manufacturer, all technicians will follow that same sequence when calibrating that type of transmitter. All transmitters will be calibrated the same way every time. Transmitter manufacturers use conditionals to make the wizards more intelligent, for instance only ask for user input which is relevant based on prior selection, only display valid options, and evaluate plausibility (if it is reasonable) of any user input.
Figure 4 Calibration wizard is created by the device manufacturer's expert to guide the user
Consistent EDDL (www.eddl.org) has a multilingual dictionary including standard text for user prompts in the wizards, error messages, parameter labels, and even help. This dictionary is references by transmitter manufacturers, thus providing consistency making work more intuitive and reducing errors because transmitters of different type from different manufacturers will use the same message (refer to separate white paper on consistent look & feel). Context Sensitive Help The transmitter manufacturers factory experts share their know-how in the form of help text embedded into the EDDL file for their device. This includes help for configuration/setup and diagnostics parameters, status indicators, and wizards such as for sensor trim. The help for any wizard or parameter can be pulled up at the click of a button. This simplifies work by minimizing the need to refer to manuals. Even if the information is buried deep in the manual, it's easily accessed from the device management software thanks to EDDL.
www.eddl.org
Pre-Commissioning Calibration
If there is a need to "calibrate" (perform sensor trim) or not the transmitters before installation is a common question. Since sensor trim is done in the factory when the transmitter is manufactured, to trim the sensor or not before installation depends on if it will drift during shipment. These days transmitters are very rugged and don't drift during shipment. Hence there is typically no need to perform sensor trim before installation. The 4-20 mA/HART, FOUNDATION fieldbus, WirelessHART, and PROFIBUS version of a device use the same sensor. Therefore they have the same basic accuracy and stability. The 4-20 mA current loop adds a little inaccuracy and drift, but less than the sensor. Thus doing sensor trim or not before installation does not depend on the protocol, it's how rugged the sensor is. Pressure transmitters needs zero trim to correct mounting position effect. Usually, this question only comes up for pressure and temperature transmitters - presumably because portable calibrators exist for temperature and pressure. There is no discussion about site www.eddl.org 10
calibration of the flowmeters for gas or liquid, and not for many other transmitters - presumably because it would be very much more difficult to do. Loop Check The big commissioning difference between 4-20 mA/HART and Fieldbus is that 4-20 mA/HART requires five point loop test at 4 mA, 8 mA, 12 mA, 16 mA, and 20 mA to detect range mismatch between the system and transmitter, make sure the current signal is not limited (insufficient voltage for the loop resistance) or otherwise distorted due to installation issues (ground loop) and to ensure that range setting and analog current trim in the transmitter and in the system is matching. Typically the range of the 4-20 mA transmitter is also verified. There is no analog current or range in Fieldbus, PROFIBUS, or WirelessHART so five point loop test need not be done. This saves plenty of time. A simple plausibility check is sufficient.
Audit Trail EDDL-based device management software also supports audit trail functionality. This includes tracking of configuration changes, as well as calibration records including and "as found" / "as left"; that is percentage error graph at five points before and after sensor trim was performed. Maintenance Schedule EDDL-based device management software is also able to schedule maintenance tasks such as inspection and calibration.
www.eddl.org
11
Single Solution
Because EDDL is a text file from which the device page graphics is rendered by the device management software, the calibration wizards and help are rendered the same way for all devices regardless of protocol, manufacturer, or type. This consistency achieved thanks to EDDL makes calibration easier and intuitive (see separate technical white paper on consistency of use). No other technologies can provide a comparable result.
Conclusion
For plants that are looking for an easy solution to calibrating multiple types and versions of transmitters, EDDL technology is a perfect match. EDDL meets the need of plants to calibrate all types of devices from a single software application using a single technology while at the same time making it fast and easy to keep the system up to date with new device versions. Plants should upgrade existing DD systems to EDDL with enhancements to enjoy the greater ease of use afforded by the standard graphical display. Calibration trim is just one of the ways in which intelligent device management software based on EDDL reduces maintenance & operational cost. Please refer to other technical white papers on advanced diagnostics, configuration/setup, and system administration etc.
References
EDDL Brochure and Technical Description on www.eddl.org site Jonas Berge, "Fieldbuses for Process Control: Engineering, Operation, and Maintenance", ISA, 2002, ISBN 1-55617-760-7 ANSI/ISA51.11979 (R1993) Process Instrumentation Terminology, Reaffirmed 26 May 1995, ISBN 0-87664-390-4
Appendix: FF Parameters
Systems based on enhanced EDDL shows range, calibration, and other information organized in hierarchical menu trees, tabs, and frames with human readable labels etc. However, older systems based on traditional DD (without EDDL enhancements) typically show parameters in list form, displayed with a cryptic parameter name. These are the parameters: Data Lower Range Value (LRV) Upper Range Value (URV) Converted Converted PV% Lower Sensor Limit Upper Sensor Limit Minimum Span Lower Sensor Trim Point Upper Sensor Trim Point *Lower Range Value (LRV) *Upper Range Value (URV) Block AI function AI function AI function AI function AI function Transducer Transducer Transducer Transducer Transducer Transducer Transducer Parameter Name XD_SCALE.EU_0 XD_SCALE.EU_100 OUT_SCALE.EU_0 OUT_SCALE.EU_100 FIELD_VAL SENSOR_RANGE.EU_0 SENSOR_RANGE.EU_100 CAL_MIN_SPAN CAL_POINT_LO CAL_POINT_HI PRIMARY_VALUE_RANGE.EU_0 PRIMARY_VALUE_RANGE.EU_100
In most devices, the transducer block PRIMARY_VALUE_RANGE cannot be configured from the transducer block. If at all used, transmitter range is configured in the AI function block parameter XD_SCALE which automatically updates the transducer block PRIMARY_VALUE_RANGE. However, some transmitter may require the range to be configured manually in both places. www.eddl.org 12
www.eddl.org
13