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AUTOMATIC DETECTION TEMPERATURE TRANSMITTER FOR CALIBRATION

PROCESS USING RTD

MUSTAQIM BIN HAZMI

This thesis is submitted as partial fulfillment of the requirements for the award of the

Bachelor of Electrical Engineering (Electronics)

Faculty of Electrical and Electronics Engineering

UNIVERSITI MALAYSIA PAHANG

29 NOVEMBER 2010

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“I hereby acknowledge that the scope and quality of this thesis is qualified for the award of

the Bachelor Degree of Electrical Engineering (Electronics)”

Signature : ______________________________________________

Name : NAJIDAH BINTI HAMBALI

Date : 29 NOVEMBER 2010

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“All the trademark and copyrights use herein are property of their respective owner.

References of information from other sources are quoted accordingly; otherwise the

information presented in this report is solely work of the author.”

Signature : ____________________________

Author : MUSTAQIM BIN HAZMI

Date : 29 NOVEMBER 2010

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ACKNOWLEDGEMENT

First of all, I am grateful to ALLAH S.W.T for blessing me in completion of my

final year project (PSM) with success in achieving my objectives to finishing this project.

The project also has been complete on the time given.

Secondly, I want to thank my family for giving morale support and encouragement

in completing my project. I also would like to thank my supervisor Puan Najidah Bt

Hambali for guiding and supervising my final year project. I really apologize to her for any

mistakes, and things that I done wrong while doing my project.

I, myself are fully in dept with Faculty of Electrical and Electronics Engineering

(FKEE) for providing me the necessary instruments, hardware and all information for my

project. Without their helped, this project was deeming to be unfinished.

Last but not least, I want to thank my entire friend especially Muhamad Farid Bin

A. Wahab, that given me advice, helps, and encouragement in completing my project. To

En. Shahrizal Bin Saat and En. Muhammad Hamka Bin Embong, thanks for your support

and your time to teach us about calibration of the instruments and all connection of the

hardware. Thank you very much to all and May ALLAH bless you.

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ABSTRACT

The purpose for this project is to detect temperature for Calibration Process using

Resistive Thermal Device (RTD) automatically. This project will be used Visual Basics

(VB) programmed to develop Graphical User Interface (GUI). An RTD will be use as

temperature sensor in this Calibration Process. The software and the temperature sensor

will be interfaced by using a Data Acquisition (DAQ) card. Proportional–Integral–

Derivative (PID) controller will be purpose for automatic detection for temperature system.

The expected result for this project is an automatic detection system for temperature

measure during the Calibration Process. The accuracy of the measurement will be monitor

beside the analysis of uncertainty and confidence limit.

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ABSTRAK

Projek ini adalah bertujuan untuk mengesan suhu bagi proses kalibrasi

menggunakan Thermal Device Resistive (RTD) secara automatik. Projek ini akan

menggunakan Visual Basics (VB) yang diprogram untuk membina Graphical User

Interface (GUI). Sebuah RTD akan digunakan sebagai pengesan suhu dalam proses

kalibrasi. Perisian dan pengesan suhu akan dihubungkan dengan menggunakan kad Data

Acquisition (DAQ). Proportional Integral Derivative (PID) bertujuan untuk pengesanan

automatik kepada sistem suhu. Keputusan yang dijangkakan dalam projek ini adalah sistem

pengesanan automatik pengukuran suhu dalam proses kalibrasi. Ketepatan pengukuran

akan dipantau, di samping analisis ketidakpastian dan had keyakinan.

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TABLE OF CONTENTS

ELEMENTS PAGES

TITLE ii

SUPERVISOR’S DECLARATION iii

STUDENT’S DECLARATION iv

DEDICATION v

ACKNOWLEDGEMENT vi

ABSTRACT vii

ABSTRAK viii

TABLE OF CONTENTS ix

LIST OF TABLES xii

LIST OF FIGURES xiii

LIST OF SYMBOLS xv

LIST OF ABBREVIATIONS xvi

CHAPTER 1 INTRODUCTION

1.1 Background 1

1.2 Introduction to the Project 2

1.3 Problem Statement 3

1.4 Objectives 4

1.5 Scope of the Project 5

1.6 Thesis Overview 6

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CHAPTER 2 LITERATURE REVIEW

2.1 Infrared Temperature Detection 8

2.2 Temperature Transmitter 9

2.3 Temperature Measurement and Control System 9

2.4 ULTRA-Accurate Temperature Measurement 10

2.5 Temperature Coefficient 10

2.6 Ge-Film Resistance and Si-Based Diode sensors 12

2.7 Temperature Measurement via Laser Fluorescence 12

2.8 Thin Film Resistance Temperature Sensors 13

CHAPTER 3 METHODOLOGY

3.1 Introduction 14

3.2 Resistance Temperature Detector (RTD) 15

3.3 Four Wires RTD 17

3.4 Dry Block Calibrator (furnace) 17

3.5 Temperature Transmitter 19

3.6 Calibrate a HART Temperature Transmitter 20

3.7 Advantech USB-4716, PC-Lab Card. 21

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3.8 Visual Basic (VB) 28

3.9 Software Development 29

4.0 Calibration Technique 42

CHAPTER 4 RESULT AND DISCUSSION 48

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 58

5.2 The Obstacles and Recommendations 59

REFERENCES 61

APPENDICES A Student’s t-distribution table 63 B Advantech USB-4716 specification 64 C HART Calibration Data Sheet 67 D Furnace Data Sheet 69 E Pt100 Resistance Table 73 F Yokogawa YTA110 Data Sheet 75 G Source Code for the Software 80

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LIST OF TABLES

TABLE NO. TITLE PAGES

3.1 Pins Function of every port in DAQ card. 24

3.2 Table of draft UUT calibration data. 43

3.3 Five point calibration table. 44

4.1 Result from software implementation 54

4.2 The comparison between software and manual calculation 56

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LIST OF FIGURES

FIGURE NO. TITLE PAGES

2.1 Sensitivity as a function of temperature for sample low, moderate, and high resistance CX-1030s samples and CX-1050s samples used in this analysis.

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3.1 The system roughly interconnection base on picture and

the flow of the data. 15

3.2 Circuit design for 4-wires RTD Pt100. 17

3.3 Isotech Jupiter 650B, the Dry Block Calibrator as a

furnace. 18

3.4 The temperature controller of Isotech Jupiter 650B. 18

3.5 Yokogawa YTA110, temperature transmitter. 19

3.6 HART documenting process calibration by section 20

3.7 HART calibrator. 21

3.8 Data Acquisition (DAQ) card. 22

3.9 Software installation for Advantech USB-4716. 22

3.10 Pins Assignments for DAQ card Advantech USB-4716. 23

3.11 The Advantech Device Manager. 25

3.12 Advantech Device Test, Analog Output. 26

3.13 Advantech Device Test, Analog Input reading. 27

3.14 Connection of instruments, hardware and software. 28

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3.15 Selecting device. 30

3.16 Capture data for Data Analog in Voltage and Degree Celsius data.

31

3.17 GUI for Data Storage for the software system. 34

3.18 GUI for generate graphs for the project. 35

3.19 Average graph for the calibration. 36

3.20 Error graph. 37

3.21 Voltage input versus Temperature. 38

3.22 Data Progress shows the input data in volts. 39

3.23 Uncertainty calculation in the software. 40

3.24 Flow chart for software implementation. 41

3.25 Calibration technique. 42

3.26 Flow chart of the project. 47

4.1 Data Storage as a last result after running the system. 49

4.2 Average graph from the data storage. 50

4.3 Error graph. 51

4.4 Voltage input versus average temperature. 52

4.5 Uncertainty value for 95.45% of confident interval. 53

4.6 Uncertainty for 99.00% of confident interval. 54

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LIST OF SYMBOLS

γ Degree of Freedom Ω Ohms ∞ Infinity

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LIST OF ABBREVIATIONS

RTD Resistance Temperature Detector DAQ Data Acquisition VB Visual Basic software USB Universal Serial Bus GUI Graphical User Interface HART Highway Addressable Remote Transducer 3D Three Dimension PID Proportional Integral Derivative Ni Nickel Pt Platinum Ge Germanium PSM Power Sensor Microsystem PSM Final Year Project (Projek Sarjana Muda) PV Process Variable LRV Lower Range Value URV Upper Range Value PC Personal Computer AGND Analog Ground AI0 Analog Input 0

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LED Light Emitting Diode V Volts mA Mille-Ampere IDE Integrated Development Environment MSU Master Standard Unit UUT Unit Under Test Std Dev Standard Deviation Mean Median or Average TUR Test Uncertainty Ration U Uncertainty A Maximum Error

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CHAPTER 1

INTRODUCTION

1.1 BACKGROUND

In this thesis there is a basic idea to recognize a temperature measurement system

that has instrumentation or control considerations in addition to simple temperature

measurement considerations. The need for temperature calibration is obvious, and the

need for instruments to bring about that calibration control is also obvious. The limits of

calibration control, the acceptable variations in temperature for process, are less obvious.

The types of instrumentation involve so many combinations of precision, cost, reliability,

and utility that is impossible to present a suitable analysis without analyzing a particular

system to make sure the temperature calibration system is accurate [1].

Although temperature sensors are usually checked as part of a calibration of the

connected device, it may be necessary to check a suspect temperature sensor or to verify

the accuracy of a new RTD. The principles of this Automatic Detection Temperature

Transmitter for Calibration process using RTD, would apply to any sensor type. All

modern test equipment performs the temperature compensation, but it is important to

verify. The calibration process in this thesis is used RTD that connected to the transmitter

to make sure resistance value of RTD are converted into ampere value. In order to

interfacing, using DAQ card that only receive voltage, a 250 Ω resistor needed to make

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sure the voltage reading is from 1V minimum and 5V maximum, with it respect current 4

mA until 20 mA. 1V will represent minimum temperature and 5V represent maximum

value of temperature.

When the calibration is heading for measurements, there is a chance that errors in

the measurement influence the decision. The primary purpose of uncertainty analysis is to

provide a measure of that influence and likelihood of presented a wrong decision.

Uncertainty analysis requires understanding of the measurement, usually in terms of

mathematical models of the various influence effects that cause errors. This thesis is

running a systematic error that occurs when the value is recorded in repeatedly. The

result of the accuracy of the RTD is present with it uncertainty to make sure the error is

estimated in the result.

1.2 INTRODUCTION TO THE PROJECT

Temperature is the one parameter that needs to measure their value and the

accuracy in the calibration process. A system must be developing using software to make

the system to detect and calculate all the uncertainty and provide the value of temperature

with it accuracy. The major change occurring at the present is the increasing number of

user friendly software that make it possible for user to experience new and fast ways of

learning. In minutes, simulation, controller and real world interfacing can be created

instantly. In this project, the software is developed to help user to learn and explore the

calibration and uncertainty process with an interesting and interactive way in order to

reduce the human error.

The Data Acquisition (DAQ) card will be use for interfacing process between

temperature instrumentation and the software. Besides that, the temperature measurement

calibration will consume a long process compared to pressure measurement calibration

due to measurement repeatability and therefore, it needs the monitoring of the operator

until the process is finish. Therefore, the automatic detection temperature measurement

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from the temperature source using the Resistance Temperature Detector (RTD) is

proposed in this project. The computer software is menu-based to give the user flexibility

and ease of use. The user needs no programming experience to operate the systems. This

project is to detect temperature for Calibration Process using RTD sensor automatically.

All the reading that comes from the calibration system will be display by the computer.

The best measurement capabilities in temperature calibrations by comparison

strongly relate to some particular and some typical uncertainty contributions. In general

there are four main uncertainty contributions in calibration of thermometers;

repeatability, uncertainty of a calibration furnace, uncertainty of a reference thermometer

and uncertainty of a measuring devices [2]. All the uncertainty need to measure to know

the accuracy of the value that has been provided.

1.3 PROBLEM STATEMENT

Most of the industry using a machine that provide heating process whether it to

soldering, melting an iron or just to provide the optimum temperature for the element.

Temperature is one of the most frequently measured parameters in process system. The

electrical thermometer is used, to sense and control the process temperatures. Regular

calibration of these thermometers is critical to ensuring consistent quality of product

manufactured, as well as providing regulatory compliance for some industries.

The industry needs an automatic detection for the temperature sense by the

electrical thermometer. Thus, this project comes to solve the problem in industrial by

provided temperature detection using electrical thermometer, this project used RTD and a

system that provided the measurement of the uncertainty to make sure the degree of

accuracy is high.

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1.4 OBJECTIVES

The objectives of this project are:

i. To develop software application to help in student learning process.

Visual Basic (VB) 2008 Express Edition will be used as a main

programming language. The software is developed to be interactive and user

friendly for student. Student can understand well about the flow of the program

when it’s running.

ii. To interface the temperature transmitter output using Resistance

Temperature Detector RTD to Visual Basic application.

The interface process is done with Data Acquisition process (DAQ).

Advantech USB-4716 DAQ card will be used to interface between instrument and

the computer. All the hardware is connected to input of the DAQ and then the

USB to the computer. The value of the temperature can be received by the

computer after interfacing is done properly.

iii. To design an automatic detection of temperature measurement in the

software from the temperature source port within the range of the setting

temperature.

All the complete set of the temperature readings will be used directly for

the calibration and uncertainty calculation process. The program is developed to

make sure all the data can be captured by the software and it can transfer it to

calculate the uncertainty for the calibration.

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1.5 SCOPES OF PROJECT

i. Develop a programming language using Visual Basic in software application

for the project.

The software is to develop GUI to describe how the program runs. It will

help the person to save all the data needed. The data is saved in the table and also

can be saved in Microsoft Office Excel. The software also can generate all the

graph needed from the data obtain. It also develops to calculate the uncertainty for

three reading; each reading is in five point calibration.

ii. DAQ card is used to interface between computer and temperature

instrument such as temperature transmitter, HART communicator, etc.

The DAQ card is to connect inputs or outputs for the hardware to interface

with the software. So, the software can receive the reading from the hardware.

DAQ card can receive a change of voltage only. So, transmitter is needed to

convert the resistance reading from RTD to current and then the converter is used

to convert the current to voltage before connected to the DAQ card.

iii. The Resistive Temperature Detector (RTD) will use as an input device to

detect temperature changes.

RTD is a sensor to detect the change of the temperature. The RTD will be

inserted into the furnace to read the value of the temperature inside it. RTD Pt100

is giving the reading in value of resistance. When it gives 100 Ω reading it mean

the temperature is at 0 oC. That is how the RTD Pt100 works.

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1.6 THESIS OVERVIEW

This thesis is consist seven chapters. There are the topics that include in this

thesis:

CHAPTER 1: Introduction

This chapter introduce about the thesis is all about. Why the thesis is

operated. It also includes the objective of the project and all the scope in

this project.

CHAPTER 2: Literature review

This chapter discuss about published information from other experiment in

this subject area.

CHAPTER 3: Methodology

All the method used to construct the project is arranged in the flow of the

step that is consisted all the important point below:

i. It included how the hardware, software and the GUI work. How to

interface between software and hardware; get the value of the temperature.

It also includes mathematical method use in this project.

ii. Introduction of the instruments used in the project.

iii. Hardware Implementation.

It discussed about the interface used and how it implements.

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iv. Software Development.

It discussed about the software use and how it implements.

v. Formulas use in this project especially for the development of the

software. Uncertainty calculation.

CHAPTER 4: Result and discussion

It presents the result from this experiment and the related discussions on

the result obtain in this project.

CHAPTER 5: Conclusion

This chapter discussed the project overview and how to improve the

project.

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CHAPTER 2

LITERATURE REVIEW

2.1 3D Device of Infrared Temperature Detection.

In a certain field, it is important to measure temperature information in variable

direction at the same time. However, there are few instruments to accomplish the

function now. To implement the measure in 3 dimensions, an experimental table of

temperature detection by infrared is designed. It is the integration of detection, control

and monitor. The infrared device in the table can detect and measure temperature in real

time and the three dimension electric motional device can adjust the detection distance by

the user. The mechanical bar for displacement is controlled by a circuit with the control

button. The infrared temperature sensor is fixed on the bar, so it can move along with the

bar controlled by the circuit. The method of temperature detection is untouched, so it can

detect small object and its tiny variable temperature, which cannot be detected by the

thermometer or the electronic temperature sensor. In terms of the 3-D parallel motion

control, the device can implement temperature measurement in variable directions.

According to the results of the temperature values, the 3-D temperature distributed curve

can be described. By using of the detection device, temperature of some special objects

can be detected, such as the live anatomical animal, small sensor, nondestructive object,

and so on [3].

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2.2 Temperature Transmitter with On-Line Calibration Using Johnson Noise.

The relationship between resistance of a RTD and temperature tends to change

over time. These changes can be periodically calibrated out of the system to maintain

accuracy of the temperature measurement. For example, periodically an operator may be

required to journey into the field to calibrate the transmitter. The transmitter is calibrated

by placing the RTD sensor in a bath of a known temperature and monitoring output from

the temperature transmitter. The difference between the actual temperature of the

temperature bath and the output temperature is used as a calibration factor and stored in

memory for subsequent use by the microprocessor. The transmitter injects a current into

the RTD and the resultant voltage drop across the RTD is used to measure resistance. The

voltage is converted into a digital format using an analog to digital converter and

provided to a microprocessor. The microprocessor converts the measured voltage into a

digital value representative of temperature [4].

2.3 Designing a Temperature Measurement and Control System for Constant

Temperature Reciprocator Platelet Preservation Box Based on LabVIEW.

On LabVIEW, a temperature measurement and control system for constant

temperature reciprocator platelet preservation box is designed based on Fuzzy-PID

control. For temperature measurement part, we use multi-sensor data fusion algorithm to

optimization data, and output fault early warning signal for sensors; Using Fuzzy-PID

control algorithm to control the system, that will make the system has good dynamic

characteristics, and has more ideal steady-state quality; Using LabVIEW software

developing the temperature measurement and control system, that will make the

measurement and control charts real-time display; Real-time state monitoring functions

guarantee system security operation. And compared with traditional design method, using

virtual technology allows the system to operation simply, to set up or reconstruct easily,