Flange type transmitter calibrating device and calibrating method

Abstract

This invention discloses a flange-type transmitter calibration device and method, relating to the technical field of transmitter calibration equipment. It includes a main support frame and a Hart handheld communicator that communicates with the transmitter to be calibrated. The main support frame is equipped with a full-size flange compatible with various flange specifications. The full-size flange has locking bolts for positioning, clamping, and fixing the transmitter to be tested onto the main support frame. The lower end of the locking bolts is connected to the main support frame via a nut. A sealing plate is fitted around the center of the upper surface of the full-size flange. This invention integrates a full-size flange into the main support frame, enabling a single device to be compatible with multiple flange transmitter specifications without requiring the replacement of flange fixtures according to transmitter specifications. It integrates a portable hand pump, a high-precision digital standard meter, and a Hart handheld communicator into one unit, replacing scattered and independent equipment, simplifying the on-site assembly and debugging process, and reducing labor costs.

Description

Technical Field

[0001] This invention belongs to the technical field of transmitter calibration equipment, specifically relating to a flange-type transmitter calibration device and calibration method. Background Technology

[0002] In the fields of industrial automation such as oil refining and chemical industry, pressure and differential pressure transmitters and dual-flange level gauges are the core instruments for process monitoring and control. They are used in large quantities and have many different specifications. According to national metrology regulations and instrument maintenance procedures, these instruments must be calibrated regularly to ensure that indicators such as accuracy, hysteresis, and repeatability meet production requirements. Only instruments within the valid calibration period can be put into use.

[0003] Currently, the common methods for calibrating pressure and differential pressure transmitters are specification-specific adaptation, modular assembly, and manual replacement calibration. This means that on-site calibration requires dedicated calibration flanges, adapters, and gaskets of corresponding sizes based on the transmitter's flange diameter and diaphragm specifications. A single calibration fixture can only accommodate one or a few transmitter specifications. During calibration, operators must first identify the flange specifications of the transmitter under test, select matching parts from over ten types of dedicated fixtures, and complete a series of operations including disassembling the old fixture, assembling the new fixture, tightening the seal, and pressure testing for leaks. Furthermore, calibration equipment such as manual pressure pumps, high-precision standard gauges, high-pressure connecting hoses, and Hart handheld communicators are all separate and independent components, requiring temporary assembly, wiring, and step-by-step debugging on-site.

[0004] However, this inspection method requires a large number of specialized tooling fixtures of various specifications. The equipment is diverse, difficult to manage, occupies a lot of space, and is prone to misuse. Moreover, when calibrating instruments of different specifications, it is necessary to frequently change the matching tooling. The operation steps are repetitive and cumbersome, which greatly reduces the calibration efficiency and increases the labor intensity and labor costs of operators. Summary of the Invention

[0005] The purpose of this invention is to provide a flange-type transmitter calibration device and calibration method that can be applied to the calibration of various types of transmitters, saving labor costs and solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A flange-type transmitter calibration device includes a main support and a Hart handheld device that communicates with the transmitter to be calibrated. The main support is equipped with a full-size flange that is compatible with various flange specifications. The full-size flange is provided with locking bolts for positioning, clamping and fixing the transmitter to be tested on the main support. The lower end of the locking bolts is connected to the main support through a nut.

[0008] A sealing plate is fitted around the center of the upper surface of the full-size flange. The sealing plate is tightened and sealed to the transmitter to be calibrated by a nut. A portable hand pump is connected to the lower end of the full-size flange via a high-pressure hose for manually providing the calibration pressure source. One end of the portable hand pump is connected to a high-precision digital standard gauge for displaying the output pressure value.

[0009] Preferably, there are two sets of full-size flanges, each set of full-size flanges is set independently, and the air outlet of the portable hand pump is connected to the two sets of full-size flanges respectively.

[0010] Preferably, the full-size flange includes a disc body, the center of which is provided with a connecting mechanism for communicating with a portable hand pump, and a plurality of elongated holes are provided on the disc body located on the outer periphery of the connecting mechanism, and the plurality of elongated holes are equidistantly distributed.

[0011] Preferably, the connecting mechanism includes a connector fixedly embedded in the center of the disc body, the high-pressure hose connected to the lower end of the connector, a boss connected to the high-pressure hose at the upper end of the connector, a sealing plate sleeved on the boss, and a rubber ring embedded in the edge of the connector.

[0012] Preferably, the sealing plate is a PEEK adapter sealing plate, the center of the sealing plate has a mounting hole for the boss to be inserted, and the edge of the sealing plate has an annular groove that matches the transmitter to be calibrated, and a sealing ring is installed in the annular groove.

[0013] Preferably, the sealing plate has an adaptation range of dn1-4 inch, and the size of the sealing plate is customized according to the flange size of the transmitter to be calibrated.

[0014] Preferably, the number of locking bolts used is the same as the number of elongated holes, and the main support has multiple elongated holes for installing locking bolts, with the elongated holes aligned with each other.

[0015] Preferably, the locking bolt is a long rod with external threads on its outer wall. One end of the locking bolt passes through an elongated hole and is threaded to a nut. The other end of the locking bolt passes through the elongated hole and is also threaded to a nut on the transmitter to be calibrated. The nuts at both ends press and fix the transmitter to be calibrated onto the full-size flange.

[0016] The present invention also provides a method for calibrating a flange-type transmitter, using the flange-type transmitter calibration device described above, the method comprising the following steps:

[0017] S1. Fix one end of the locking bolt to the main support with a nut to form a positioning and locking structure;

[0018] S2. Assemble the full-size flange onto the locking bolts, and then install the sealing plate onto the full-size flange to complete the sealing assembly assembly;

[0019] S3. Connect the full-size flange to the portable hand pump via a high-pressure hose, and install a high-precision digital standard gauge at one end of the portable hand pump;

[0020] S4. Apply test pressure to the transmitter to be calibrated by operating a portable hand pump, compare the output of the transmitter to be calibrated on the high-precision digital standard meter with that on the Hart handheld communicator, and determine the calibration result.

[0021] Preferably, when the portable hand pump applies test pressure to the transmitter to be calibrated, it applies pressure sequentially at 25%, 50%, 75%, and 700% of the transmitter's range, and the results are compared and judged based on the applied pressure.

[0022] The flange-type transmitter calibration device and calibration method proposed in this invention have the following advantages compared with the prior art:

[0023] 1. This invention integrates a full-size flange into the main support, enabling a single device to be compatible with multiple flange transmitters without the need to change flange tooling according to transmitter specifications; it also uses locking bolts to achieve quick positioning and clamping, eliminating the need to disassemble and assemble accessories; and it integrates a portable hand pump, a high-precision digital standard meter, and a Hart handheld device into one unit, replacing scattered and independent equipment, simplifying the on-site assembly and debugging process, and reducing labor costs.

[0024] 2. This invention integrates a portable hand pump, a high-precision digital standard meter, and a Hart handheld device into a single design, eliminating the need for temporary assembly on-site, minimizing space requirements, and making it easy to carry and use;

[0025] 3. The present invention has two sets of full-size flanges, and each set of full-size flanges is set independently, which can be adapted to the calibration of dual-flange level gauges or two transmitters. It can be used flexibly according to actual calibration needs, thus improving the versatility of the device.

[0026] 4. By connecting the sealing plate to the full-size flange, the present invention allows for the selection of sealing plates of different sizes according to different transmitters to be calibrated, thereby improving the sealing performance between the full-size flange and the transmitter to be calibrated and further enhancing the calibration accuracy. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the present invention;

[0028] Figure 2 This is a structural schematic diagram of the full-size flange of the present invention;

[0029] Figure 3This is a cross-sectional structural diagram of the full-size flange of the present invention;

[0030] Figure 4 This is a schematic diagram of the cross-sectional structure of the sealing plate of the present invention;

[0031] Figure 5 This is a flowchart of the verification method of the present invention.

[0032] In the diagram: 1. Main support; 2. Full-size flange; 21. Long hole; 22. Boss; 23. Connector; 24. Disc; 3. High-precision digital standard gauge; 4. Portable hand pump; 5. Transmitter to be calibrated; 6. Hart hand communicator; 7. Locking bolts; 8. Sealing plate; 81. Mounting hole; 82. Annular groove; 9. High-pressure hose. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] This invention provides, for example Figure 1-4The flange-type transmitter calibration device shown includes a main support 1 and a Hart handheld device 6 that communicates with the transmitter 5 to be calibrated via Hart communication. The Hart handheld device 6 is used for parameter setting and monitoring the output signal of the transmitter 5. A full-size flange 2, compatible with various flange sizes, is mounted on the main support 1 for fixing the transmitter 5 and a sealing plate 8. The full-size flange 2 is equipped with locking bolts 7 for positioning, clamping, and fixing the transmitter 5 to the main support 1. The lower end of the locking bolts 7 is connected to the main support 1 via a nut. A sealing plate 8 is fitted around the center of the upper surface of the full-size flange 2. The sealing plate 8 and the transmitter 5 are pressed tightly together by the nut to ensure a leak-free seal. The lower end of the disc 2 is connected to a portable hand pump 4 via a high-pressure hose 9, which is used to manually provide a calibration pressure source. The high-pressure hose 9 is a special high-pressure testing hose for instrument calibration, and the optional models are one of the ConST107, ConST108, HS-YFT2002Y, and HFH2 series, with a nominal pressure of 6MPa-100MPa, an inner diameter of DN2-DN3, and a length of 0.5m-2m. Both ends use M20×1.5, G1 / 4, or M16×2 standard threaded connectors, which are sealed to the pressure outlet of the portable hand pump and the lower end connector of the full-size flange, respectively, to achieve stable and leak-free pressure transmission and ensure calibration accuracy and safe use. One end of the portable hand pump 4 is connected to a high-precision digital standard gauge 3, which is used to display the output pressure value.

[0035] By integrating a full-size flange 2 into the main support 1, a single device can be compatible with multiple flange transmitters without the need to change flange tooling according to transmitter specifications; with locking bolts 7, quick positioning and clamping can be achieved, eliminating the need to disassemble and assemble accessories; the portable hand pump 4, high-precision digital standard meter 3, and Hart hand communicator 6 are integrated into one unit, replacing scattered independent equipment, simplifying the on-site assembly and commissioning process, and reducing labor costs.

[0036] To improve the versatility of the calibration device, two sets of full-size flanges 2 are provided, each set of full-size flanges 2 is set independently, and the air outlet of the portable hand pump 4 is connected to the two sets of full-size flanges 2 respectively, so that the calibration device can be adapted to the calibration of dual-flange level gauges or two transmitters, and can be used flexibly according to actual calibration needs.

[0037] like Figure 2As shown, the full-size flange 2 includes a disc body 24. The center of the disc body 24 is provided with a connecting mechanism for communicating with the portable hand pump 4. Multiple elongated holes 21 are provided on the disc body 24 located on the outer periphery of the connecting mechanism. The multiple elongated holes 21 are equidistantly distributed. The fixed position can be flexibly adjusted by using the elongated holes 21 in conjunction with locking bolts to match different flange hole spacings, so that it can be compatible with more flange installation sizes, expand the adaptation range, and eliminate the need for additional processing and customization of flanges.

[0038] Furthermore, such as Figure 3 As shown, the connection mechanism includes a connector 23 embedded and fixed in the center of the disc 24. The high-pressure hose 9 is connected to the lower end of the connector 23. The upper end of the connector 23 is provided with a boss 22 that communicates with the high-pressure hose 9. The sealing plate 8 is sleeved on the boss 22. A rubber ring is embedded in the edge of the connector 23. The connector 23 and the boss 22 achieve stable connection between the high-pressure hose 9 and the sealing plate 8, ensuring smooth pressure transmission and ensuring a stable and reliable pressure test process.

[0039] Furthermore, the sealing plate 8 is a PEEK adapter sealing plate. The center of the sealing plate 8 has a mounting hole 81 for the boss 22 to be inserted. The edge of the sealing plate 8 is provided with an annular groove 82 that matches the transmitter 5 to be calibrated. A sealing ring is installed in the annular groove 82. The PEEK material sealing plate 8 has high hardness and low deformation characteristics. The central mounting hole 81 and the annular groove 82 are precisely matched with the transmitter diaphragm size. The sealing ring is used to increase the sealing performance between the sealing plate 8 and the transmitter 5 to be calibrated, thereby improving the sealing fit with the transmitter 5 to be calibrated, without damaging the instrument diaphragm, adapting to diaphragm transmitters of different specifications, and having a long sealing life.

[0040] Preferably, the sealing plate 8 has an adaptation range of DN1-4 inches. The size of the sealing plate 8 is customized according to the flange size of the transmitter 5 to be calibrated. That is, the size can be customized within the four standard specifications of DN1 inch, DN2 inch, DN3 inch and DN4 inch according to the nominal flange diameter of the transmitter to be tested. Its sealing surface diameter, bolt hole position and boss 22 structure are completely matched with the corresponding specification of transmitter flange, so as to achieve universal sealing adaptation of all flange transmitters from 1 inch to 4 inches without replacing the full-size flange 2 body.

[0041] Furthermore, the number of locking bolts 7 used is the same as the number of elongated holes 21. The main support 1 has multiple elongated holes for installing locking bolts 7, and the elongated holes are aligned with the elongated holes 21, so that the position of the locking bolts 7 is adjustable to adapt to different flange installation spacings, and the fixing is firm and without loosening.

[0042] Furthermore, the locking bolt 7 is a long rod with external threads on its outer wall. One end of the locking bolt 7 passes through an elongated hole and is threaded to a nut. The other end of the locking bolt 7 passes through an elongated hole 21 and is also threaded to a nut on the transmitter 5 to be calibrated. The nuts at both ends press and fix the transmitter 5 to be calibrated onto the full-size flange 2, achieving three-layer clamping and fixing of the transmitter, sealing plate 8, and flange. The clamping is quick and the fastening is reliable. Disassembly and assembly only require rotating the nuts, greatly simplifying the operation steps.

[0043] This invention also provides a method for calibrating a flange-type transmitter, using the flange-type transmitter calibration device described above, such as... Figure 5 As shown, the method includes the following steps:

[0044] S1. Fix one end of the locking bolt 7 to the main bracket 1 with a nut to form a positioning and locking structure;

[0045] S2. Assemble the full-size flange 2 onto the locking bolts 7, and then install the sealing plate 8 onto the full-size flange 2 to complete the sealing assembly assembly;

[0046] S3. Connect the full-size flange 2 to the portable hand pump 4 via the high-pressure hose 9, and install the high-precision digital standard gauge 3 at one end of the portable hand pump 4.

[0047] S4. Apply test pressure to the transmitter 5 to be calibrated by operating the portable hand pump 4, compare the output of the transmitter 5 to be calibrated on the high-precision digital standard meter 3 with the output of the transmitter 5 to be calibrated on the Hart handheld device 6, and determine the calibration result.

[0048] When the portable hand pump 4 applies test pressure to the transmitter to be calibrated, it applies pressure sequentially at 25%, 50%, 75%, and 700% of the transmitter's range. The pressure is then compared and judged based on the applied pressure. Specific judgment methods include basic error judgment, hysteresis error judgment, repeatability error judgment, and zero-point / full-scale error judgment. The basic error judgment requires that the absolute value of the basic error not exceed the instrument's permissible error, typically ±0.1%FS to ±0.5%FS. The basic error value is calculated as: (Transmitter output value - Standard output value) / Range * 100%.

[0049] Hysteresis error = Absolute value of boost output value minus buck output value at the same pressure point. The requirement for judging hysteresis error is that the hysteresis error is not greater than the absolute value of the allowable error.

[0050] Repeatability error is the maximum difference in output calculated when the same pressure point is pressurized three times. The requirement for repeatability error is that the repeatability error is no greater than 1 / 2 of the allowable error.

[0051] Zero point error is 0% of the pressure point output error, and full scale error is 100% of the pressure point output error. The zero point error and full scale error judgment requirements are that both the zero point error and the full scale error are within the allowable range.

[0052] If the basic error, hysteresis error, repeatability error, zero-point error, and full-scale error all meet the allowable limits, it is deemed qualified and can continue to be used; if any one of them exceeds the tolerance, it is deemed unqualified and needs to be calibrated, repaired, or replaced.

[0053] Based on the above verification method, a differential pressure transmitter with a range of 0-12 kPa was actually verified. The allowable error of the differential pressure transmitter is ±0.1%FS. The portable hand pump is model FLUKE700PTP-1, with an adjustment range of -0.0087~4.1 MPa. The high-precision digital standard meter used for verification is FLUKE700GA4, with a range of (0-100) kPa and an accuracy of 0.05 class. The verification environment is 20℃ and 45%RH.

[0054] The verification process is as follows: First, the four locking bolts are fixed in the elongated holes of the main support with nuts to form a stable positioning structure;

[0055] Then, insert the full-size flange into the locking bolts, insert the DN2 inch PEEK sealing plate into the flange boss, and confirm that the O-ring seal is in place;

[0056] Secondly, a high-pressure hose is used to connect the bottom connector of the flange to the portable hand pump, and a high-precision digital standard gauge is installed at the pressure outlet of the hand pump.

[0057] Furthermore, fit the flange hole of the differential pressure transmitter to be calibrated into the locking bolt, tighten it with the nut until there is no gap in the sealing plate, and connect the Hart handheld device to read the transmitter output current.

[0058] Finally, operate the portable hand pump to gradually increase the pressure according to the transmitter's range of 0%, 25%, 50%, 75%, and 100%. After holding the pressure for 30 seconds, record the standard pressure value and the transmitter's output current. Then, gradually decrease the pressure to 0% and record the return data.

[0059] The calibration results of the differential pressure transmitter are shown in Table 1 below:

[0060] Table 1

[0061]

[0062] The data in Table 1 shows that the maximum error of the differential pressure transmitter to be calibrated is -0.22%, the maximum hysteresis error is 0.02%, the zero-point error is -0.12%, and the full-scale error is -0.12%. All test data are within the accuracy requirement of ±0.5%, which meets the requirements of the national metrological verification regulations.

[0063] In summary, the calibration device of this invention does not require changing flange tooling throughout the entire process, effectively shortens the calibration time of a single transmitter compared to traditional devices, and ensures no pressure leakage or damage to the instrument diaphragm during the calibration process. It also features stable sealing performance, compatibility with multiple specifications of flange-type transmitters, and significantly superior versatility, safety, and calibration efficiency compared to traditional calibration devices. It is suitable for large-scale transmitter calibration operations in industrial fields such as oil refining and chemical industries.

[0064] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A flange-type transmitter calibration device, characterized in that: Includes a main support (1) and a Hart handheld device (6) that communicates with the transmitter (5) to be calibrated. The main support (1) is equipped with a full-size flange (2) that is compatible with a variety of flange specifications. The full-size flange (2) is provided with locking bolts (7) for positioning, clamping and fixing the transmitter to be calibrated on the main support (1). The lower end of the locking bolts (7) is connected to the main support (1) by a nut. A sealing plate (8) is fitted onto the center of the upper surface of the full-size flange (2). The sealing plate (8) and the transmitter (5) to be calibrated are sealed by a nut. The lower end of the full-size flange (2) is connected to a portable hand pump (4) via a high-pressure hose (9) for manually providing the calibration pressure source. One end of the portable hand pump (4) is connected to a high-precision digital standard meter (3) for displaying the output pressure value.

2. The flange-type transmitter calibration device according to claim 1, characterized in that: The full-size flange (2) is provided in two sets, and each set of the full-size flange (2) is set independently. The air outlet of the portable hand pump (4) is connected to the two sets of full-size flanges (2) respectively.

3. The flange-type transmitter calibration device according to claim 2, characterized in that: The full-size flange (2) includes a disc body (24), and a connection mechanism for communicating with a portable hand pump (4) is provided at the center of the disc body (24). Multiple elongated holes (21) are provided on the disc body (24) located on the outer periphery of the connection mechanism, and the multiple elongated holes (21) are equidistantly distributed.

4. The flange-type transmitter calibration device according to claim 3, characterized in that: The connecting mechanism includes a connector (23) embedded and fixed in the center of the disc (24), the high-pressure hose (9) is connected to the lower end of the connector (23), the upper end of the connector (23) is provided with a boss (22) connected to the high-pressure hose (9), the sealing plate (8) is sleeved on the boss (22), and the edge of the connector (23) is fitted with a rubber ring.

5. The flange-type transmitter calibration device according to claim 4, characterized in that: The sealing plate (8) is a PEEK adapter sealing plate. The center of the sealing plate (8) is provided with a mounting hole (81) for the boss (22) to be inserted. The edge of the sealing plate (8) is provided with an annular groove (82) that matches the transmitter (5) to be calibrated. A sealing ring is installed in the annular groove (82).

6. The flange-type transmitter calibration device according to claim 5, characterized in that: The sealing plate (8) has an adaptation range of dn1-4inch, and the size of the sealing plate (8) is customized according to the flange size of the transmitter (5) to be calibrated.

7. A flange-type transmitter calibration device according to claim 6, characterized in that: The number of locking bolts (7) used is the same as the number of elongated holes (21). The main support (1) has multiple elongated holes for installing locking bolts (7), and the elongated holes are aligned with the elongated holes (21).

8. The flange-type transmitter calibration device according to claim 7, characterized in that: The locking bolt (7) is a long rod. The outer wall of the locking bolt (7) is provided with external threads. One end of the locking bolt (7) passes through the elongated hole and is threaded to a nut. The other end of the locking bolt (7) passes through the elongated hole (21) and is also threaded to a nut on the transmitter (5) to be calibrated. The nuts at both ends press and fix the transmitter (5) to be calibrated on the full-size flange (2).

9. A method for calibrating a flange-type transmitter, using the flange-type transmitter calibration device according to any one of claims 1-8, characterized in that: Includes the following steps: S1. Fix one end of the locking bolt (7) to the main support (1) with a nut to form a positioning and locking structure; S2. Assemble the full-size flange (2) onto the locking bolts (7), and then install the sealing plate (8) onto the full-size flange (2) to complete the assembly of the sealing components; S3. Connect the full-size flange (2) to the portable hand pump (4) via a high-pressure hose (9), and install a high-precision digital standard (3) at one end of the portable hand pump (4); S4. Apply test pressure to the transmitter (5) to be calibrated by operating the portable hand pump (4), compare the output of the transmitter (5) to be calibrated on the high-precision digital standard meter (3) with that on the Hart handheld device (6), and determine the calibration result.

10. A method for calibrating a flange-type transmitter according to claim 9, characterized in that: In step S4, when the portable hand pump (4) applies test pressure to the transmitter (5) to be calibrated, it applies pressure in sequence according to 25%, 50%, 75% and 700% of the range of the transmitter (5) to be calibrated, and compares and judges according to the applied pressure.

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