15. Calibration Measurement,

7/25/2019 15. Calibration Measurement,

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Copyright 2005, TWI Ltd World Centre for Materials Joining

TWICSWIP 3.2

WIS 10

SENI! WE"#IN$INSPECTIN

C%"I&!%TIN


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Cali'ration()alidation

BS 7570: 1992 Covers the cai!ratio"BS 7570: 1992 Covers the cai!ratio"a"d vaidatio" o# $edi"g e%&ip'e"t(a"d vaidatio" o# $edi"g e%&ip'e"t(

)rade 1 *ge"era p&rpose e%&ip'e"t+)rade 1 *ge"era p&rpose e%&ip'e"t+

a para'eters sho&d !e -. 10/(a para'eters sho&d !e -. 10/(

)rade 2 *&to'atic or a&to'ated)rade 2 *&to'atic or a&to'ated

e%&ip'e"t+ para'eters sho&d !e -.e%&ip'e"t+ para'eters sho&d !e -.2(5/ #or c&rre"t a"d -. 5/ #or a2(5/ #or c&rre"t a"d -. 5/ #or a

other para'eters(other para'eters(


3/36


Cali'ration()alidation

Cai!ratio" ca" o"y !e do"e o" e%&ip'e"tCai!ratio" ca" o"y !e do"e o" e%&ip'e"t$ith 'eters or ga&ges as theses ca" !e$ith 'eters or ga&ges as theses ca" !e

ad&sted(ad&sted(

aidatio" ca" !e do"e o" e%&ip'e"t $ithaidatio" ca" !e do"e o" e%&ip'e"t $itha"d 3$itho&t 'eters or ga&ges(a"d 3$itho&t 'eters or ga&ges(

4i tra"s#or'ers etc(4i tra"s#or'ers etc(

e%&ip'e"t ca" !e aidated !&t "ot a e%&ip'e"t ca" !e aidated !&t "ot a

e%&ip'e"t ca" !e Cai!rated(e%&ip'e"t ca" !e Cai!rated(


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Meas*ring in +elding

6ara'eters to !e 'eas&red:6ara'eters to !e 'eas&red:

$edi"g c&rre"t$edi"g c&rre"t

arc votagearc votage

trave speedtrave speed

shiedi"g gas o$ rateshiedi"g gas o$ rate

TheThep&rposes o#p&rposes o#

'eas&ri"g'eas&ri"g

8e'o"stratio" o#8e'o"stratio" o#co"#or'a"ce toco"#or'a"ce to

speciedspecied

re%&ire'e"tsre%&ire'e"ts

preheat-i"terpapreheat-i"terpa

ss te'perat&ress te'perat&re

#orce-press&re#orce-press&re

h&'idityh&'idity

Wedi"gWedi"gprocessprocess

co"troco"tro


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Welding c*rrent,eas*re,ent

8e"itio": the c&rre"t deivered !y a8e"itio": the c&rre"t deivered !y a$edi"g po$er so&rce d&ri"g $edi"g$edi"g po$er so&rce d&ri"g $edi"g

'eas&red $ith a" a''eter'eas&red $ith a" a''eter

'eas&red i" 'eas&red i"

the a''eter 'ay !e co""ected at a"y poi"tthe a''eter 'ay !e co""ected at a"y poi"ti"i"the circ&itthe circ&it

i" case o# C, either the root 'ea" s%&arei" case o# C, either the root 'ea" s%&are

va&e *0,707 pea va&e+ or the 'ea" va&eva&e *0,707 pea va&e+ or the 'ea" va&e

o# the rectied $ave#or' is 'eas&redo# the rectied $ave#or' is 'eas&red d&e to its se"sitivity, a sh&"t is "eededd&e to its se"sitivity, a sh&"t is "eeded

i"direct 'eas&re'e"t: tachoge"erator a"di"direct 'eas&re'e"t: tachoge"erator a"d

to"g&e testerto"g&e tester

h


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Thetachogenerator

directy co&ped to thedirecty co&ped to the

#eed 'otor spi"de#eed 'otor spi"de

the o&tp&t is a" a"aog&ethe o&tp&t is a" a"aog&e

8C votage $hich is a8C votage $hich is a

precise #&"ctio" o# rotatio"precise #&"ctio" o# rotatio"

speedspeed

this votage is &sed tothis votage is &sed to

provide a speed #eed!acprovide a speed #eed!ac

sig"a #or the 8C 6o$ersig"a #or the 8C 6o$er

8rive po$eri"g the 'ai"8rive po$eri"g the 'ai"'otor'otor


7/36Copyright 2005, TWI Ltd World Centre for Materials Joining

The tong*e tester

&sed #or C c&rre"t&sed #or C c&rre"t

specia types ca" !e &sedspecia types ca" !e &sed

aso #or 8C *;a.e



%rc -oltage ,eas*re,ent

8e"itio": the pote"tia di



Tra-el seed,eas*re,ent

8e"itio": the rate o# $ed progressio"8e"itio": the rate o# $ed progressio"

'eas&red i" case o# 'echa"ised a"d'eas&red i" case o# 'echa"ised a"d

a&to'atic $edi"g processesa&to'atic $edi"g processes

i" case o# >> ca" !e deter'i"edi" case o# >> ca" !e deter'i"ed

&si"g ?4L a"d arc ti'e&si"g ?4L a"d arc ti'e

$ /



$as /o+ rate,eas*re,ent

8e"itio": the rate at $hich gas is8e"itio": the rate at $hich gas is

ca&sed to o$ca&sed to o$ set $ith a gasset $ith a gas

reg&atorreg&ator

ca" !e checedca" !e checed

$ith a o$'eter$ith a o$'eter

W ldi t t



Welding te,erat*resdenitions

6reheat6reheat

te'perat&rete'perat&re

is the te'perat&re o# the $orpiece i" theis the te'perat&re o# the $orpiece i" the

$ed @o"e i''ediatey !e#ore$ed @o"e i''ediatey !e#ore a"ya"y$edi"g$edi"goperatio" *i"c&di"g tac $edi"g=+operatio" *i"c&di"g tac $edi"g=+

"or'ay eApressed as a 'i"i'&'"or'ay eApressed as a 'i"i'&'

I"terpassI"terpasste'perat&rete'perat&re

is the te'perat&re i" a '&tir&" $edis the te'perat&re i" a '&tir&" $ed

a"d adace"t pare"t 'eta i''ediateya"d adace"t pare"t 'eta i''ediatey

prior to the appicatio" o# the "eAt r&"prior to the appicatio" o# the "eAt r&"

"or'ay eApressed as a 'aAi'&'"or'ay eApressed as a 'aAi'&'

6reheat6reheat

'ai"te"a"ce'ai"te"a"ce


is the 'i"i'&' te'perat&re i" theis the 'i"i'&' te'perat&re i" the

$ed @o"e $hich sha !e 'ai"tai"ed i#$ed @o"e $hich sha !e 'ai"tai"ed i#

$edi"g is i"terr&pted$edi"g is i"terr&pted

sha !e 'o"itored d&ri"g i"terr&ptio"sha !e 'o"itored d&ri"g i"terr&ptio"

>i"i'&' i"terpass te'perat&re 6reheat>i"i'&' i"terpass te'perat&re 6reheatte'perat&rete'perat&re

W ldi t t



Welding te,erat*resWE!E

6oi"t o# 'eas&re'e"t .6oi"t o# 'eas&re'e"t .

see BS IS4 1D91Esee BS IS4 1D91E

i# ti# t 50 ''50 '' F A t F A t

!&t 'aA( 50 ''!&t 'aA( 50 ''

the te'perat&re sha !ethe te'perat&re sha !e'eas&red o" the s&r#ace'eas&red o" the s&r#ace

o# the $orpiece #aci"go# the $orpiece #aci"g

the $ederthe $eder

W ldi t t



Welding te,erat*resWE!E

6oi"t o# 'eas&re'e"t .6oi"t o# 'eas&re'e"t .

see BS IS4 1D91Esee BS IS4 1D91E

i# t G 50 ''i# t G 50 '' 'i"( 75 'i"( 75''''

$here practica!e, the$here practica!e, the

te'perat&re sha !ete'perat&re sha !e'eas&red o" the #ace'eas&red o" the #aceopposite to that !ei"gopposite to that !ei"gheatedheated

ao$ 2 'i" per every 25ao$ 2 'i" per every 25'' o# pare"t 'eta'' o# pare"t 'eta

thic"ess #or te'perat&rethic"ess #or te'perat&ree%&aisatio"e%&aisatio"

i"terpass te'perat&rei"terpass te'perat&resha !e 'eas&red o" thesha !e 'eas&red o" the$ed 'eta or i''ediatey$ed 'eta or i''ediatey

adace"t pare"t 'etaadace"t pare"t 'eta

W ldi t t



Welding te,erat*resW

Test e%&ip'e"tTest e%&ip'e"t

Te'perat&rTe'perat&re se"sitivee se"sitive

'aterias'aterias

*TS+*TS+

Co"tactCo"tact

ther'o'etther'o'et

er *CT+er *CT+

Ther'oco&pTher'oco&p

e *T+e *T+

4ptica-eectric4ptica-eectric

a devices #ora devices #orco"tactessco"tactess

'eas&re'e"t'eas&re'e"t

*TB+*TB+

Ther'istorTher'istor

*CT+*CT+

T t t t



Te,erat*re teste4*i,ent

Te'perat&reTe'perat&re

se"sitive 'aterias:se"sitive 'aterias:

crayo"s, pai"ts a"dcrayo"s, pai"ts a"d

pispis

cheapcheap

co"ve"ie"t, easy toco"ve"ie"t, easy to

&se&sedoes"Ht 'eas&re thedoes"Ht 'eas&re the

act&a te'perat&re=act&a te'perat&re=

T t t t




Co"tact ther'o'eterCo"tact ther'o'eter

&se !i'etaic strips .&se !i'etaic strips .

stee I? *DE/ i .stee I? *DE/ i .

EF/ e aoy+EF/ e aoy+

acc&rateacc&rateeasy to &seeasy to &se

gives the act&agives the act&a


"eed cai!ratio""eed cai!ratio"

s&ita!e #or 'oderates&ita!e #or 'oderate

te'perat&reste'perat&res

T t t t




Ther'oco&peTher'oco&pe

!ased o" 'eas&ri"g the ther'oeectric!ased o" 'eas&ri"g the ther'oeectric

pote"tia di




Ther'istorsTher'istors

are te'perat&re.are te'perat&re.

se"sitive resistors $hosese"sitive resistors $hose

resista"ce variesresista"ce varies

i"versey $ithi"versey $ith


&sed $he" high&sed $he" high

se"sitivity is re%&iredse"sitivity is re%&ired

gives the act&agives the act&a


"eed cai!ratio""eed cai!ratio"

ca" !e &sed &p to D20JCca" !e &sed &p to D20JC

Te,erat re test




8evices #or8evices #or

co"tactessco"tactess'eas&re'e"t'eas&re'e"tI? radiatio" a"dI? radiatio" a"d

optica pyro'eteroptica pyro'eter

'eas&re the'eas&re the

radia"t e"ergyradia"t e"ergye'itted !y the hote'itted !y the hot

!ody!ody

co"tactessco"tactess

'ethod'ethod ca" !eca" !e&sed #or re'ote&sed #or re'ote

'eas&re'e"ts'eas&re'e"ts

very co'peAvery co'peA

#or 'eas&ri"g high#or 'eas&ri"g high

P%MS 5P t 'l % M it


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P%MS 5Porta'le %rc MonitorSyste,6

TheThep&rposes o#p&rposes o#

a 6>Sa 6>Soror

cai!rati"gcai!rati"g

a"da"dvaidati"gvaidati"g

the $edi"gthe $edi"g

e%&ip'e"te%&ip'e"t

oror

'eas&ri"g'eas&ri"g

a"da"drecordi"grecordi"g

the $edi"gthe $edi"g

para'eterspara'eters

P%MS 5P t 'l % M it


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P%MS 5Porta'le %rc MonitorSyste,6

What does a 6>SWhat does a 6>S

'eas&reK'eas&reKWedi"gWedi"g

c&rre"tc&rre"t

*;a*;a

e


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7se of PM%S

Wedi"g c&rre"t 'o"itori"g . the ;aWedi"g c&rre"t 'o"itori"g . the ;a

e


23/36


7se of PM%S

Wire #eedWire #eed

speedspeed'o"itori"g'o"itori"g

I"corporated pairI"corporated pairo# ros co""ectedo# ros co""ected

to ato a

tachoge"eratortachoge"erator


24/36


7se of PM%S

Shiedi"g gasShiedi"g gas

o$ rateo$ rate'o"itori"g'o"itori"g

;eati";eati"

gg

ee'e"ee'e"

tt

se"sorse"sor


25/36


7se of PM%S

Shiedi"g gas o$ rateShiedi"g gas o$ rate

se"sorse"sor

Heating

resistance

I"creased gas o$I"creased gas o$

raterate

Thermocouple

I"creasedI"creasedcooi"gcooi"g

8rop i"8rop i"


6ote"tia6ote"tia

di


26/36


Cali'ration8 -alidation and,onitoring

8e"itio"s:8e"itio"s: >eas&re'e"t>eas&re'e"t set o# operatio"s #or deter'i"i"g a va&e set o# operatio"s #or deter'i"i"g a va&e

o# a %&a"tityo# a %&a"tity

?epeata!iity?epeata!iity cose"ess !et$ee" s&ccessive 'eas&ri"g cose"ess !et$ee" s&ccessive 'eas&ri"g

res&ts o# the sa'e i"str&'e"t carried o&t &"der theres&ts o# the sa'e i"str&'e"t carried o&t &"der the

sa'e co"ditio"ssa'e co"ditio"s

cc&racy casscc&racy cass cass o# 'eas&ri"g i"str&'e"ts that are cass o# 'eas&ri"g i"str&'e"ts that are

i"te"ded to eep the errors $ithi" specied i'itsi"te"ded to eep the errors $ithi" specied i'its

Cai!ratio"Cai!ratio" checi"g the errors i" a 'eter or 'eas&ri"g checi"g the errors i" a 'eter or 'eas&ri"g

devicedevice

aidatio"aidatio" checi"g the co"tro "o!s a"d s$itches checi"g the co"tro "o!s a"d s$itches

provide the sa'e eve o# acc&racy $he" ret&r"ed to aprovide the sa'e eve o# acc&racy $he" ret&r"ed to a

pre.deter'i"ed poi"tpre.deter'i"ed poi"t

>o"itori"g>o"itori"g checi"g the $edi"g para'eters *a"d other checi"g the $edi"g para'eters *a"d other

ite's+ are i" accorda"ce $ith the proced&re orite's+ are i" accorda"ce $ith the proced&re or

specicatio"specicatio"


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Cali'ration and -alidation

Whe" it is re%&iredKWhe" it is re%&iredK

o"ce a year &"ess other$ise speciedo"ce a year &"ess other$ise specied

$he"ever there are i"dicatio"s that the$he"ever there are i"dicatio"s that the

i"str&'e"t does "ot register properyi"str&'e"t does "ot register propery

$he"ever the e%&ip'e"t has !ee" da'aged,$he"ever the e%&ip'e"t has !ee" da'aged,

'is&sed or s&!ect to severe stress'is&sed or s&!ect to severe stress

$he"ever the e%&ip'e"t has !ee" re!&id or$he"ever the e%&ip'e"t has !ee" re!&id or

repairedrepaired

See BS IS4 17EE2 #or detais=See BS IS4 17EE2 #or detais=


28/36



Whe" it is 4T re%&iredKWhe" it is 4T re%&iredK $he" vericatio" o# the process is "ot re%&ired$he" vericatio" o# the process is "ot re%&ired

i" case o# s'a series a"d si"ge piecei" case o# s'a series a"d si"ge piece

prod&ctio" $he" a the #oo$i"g co"ditio"sprod&ctio" $he" a the #oo$i"g co"ditio"s

are #&ed:are #&ed:. proced&res are approved !y proced&re. proced&res are approved !y proced&re

testi"gtesti"g

. prod&ctio" is carried o&t !y the sa'e. prod&ctio" is carried o&t !y the sa'e

$edi"g 'achi"e &sed d&ri"g proced&re$edi"g 'achi"e &sed d&ri"g proced&retesti"gtesti"g


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Whe" it is 4T re%&iredKWhe" it is 4T re%&iredK

i" case o# 'ass prod&ctio" $he" a thei" case o# 'ass prod&ctio" $he" a the

#oo$i"g co"ditio"s are #&ed:#oo$i"g co"ditio"s are #&ed:

. prod&ctio" is co"troed !y pre.prod&ctio". prod&ctio" is co"troed !y pre.prod&ctio"

testi"g, #oo$ed !y testi"g o# sa'pestesti"g, #oo$ed !y testi"g o# sa'pes#ro' prod&ctio" at reg&ar i"tervas#ro' prod&ctio" at reg&ar i"tervas

. a statistica %&aity co"tro syste' is &sed. a statistica %&aity co"tro syste' is &sed

. the process is sta!e !et$ee" testi"g o#. the process is sta!e !et$ee" testi"g o#

sa'pessa'pes. pre.prod&ctio" testi"g a"d sa'pi"g are. pre.prod&ctio" testi"g a"d sa'pi"g are

per#or'ed separatey #or each prod&ctio"per#or'ed separatey #or each prod&ctio"

i"e *ro!otic ces+i"e *ro!otic ces+

Welding ara,eter


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Welding ara,etercali'ration(-alidation

Which para'eters "eed cai!ratio"-vaidatio"KWhich para'eters "eed cai!ratio"-vaidatio"K

depe"ds o" the $edi"g processdepe"ds o" the $edi"g process

see BS IS4 17EE2 a"d BS 7570 #or detaissee BS IS4 17EE2 a"d BS 7570 #or detais

;o$ acc&rateK;o$ acc&rateK depe"ds o" the appicatio"depe"ds o" the appicatio"

$edi"g c&rre"t . 2,5/$edi"g c&rre"t . 2,5/

arc votage . 5/arc votage . 5/

$ire #eed speed . 2,5/$ire #eed speed . 2,5/

gas o$ rate . 20/ *25/ #or !aci"ggas o$ rate . 20/ *25/ #or !aci"g

gas o$ rate+gas o$ rate+

te'perat&re *ther'oco&pe+ . 5/te'perat&re *ther'oco&pe+ . 5/

E9a,le 1 MM% ele,entary


31/36


E9a,le 1 MM% ele,entary,onitoring

I T;4?MI T;4?Ma"y >(>(( operatio" co&da"y >(>(( operatio" co&d

re%&ire 'o"itori"g o#:re%&ire 'o"itori"g o#: $edi"g c&rre"t$edi"g c&rre"t

arc votagearc votage

?(4(L(?(4(L(

preheat-i"terpass te'perat&repreheat-i"terpass te'perat&re

eectrode treat'e"t a"d storageeectrode treat'e"t a"d storage

I 6?CTICI 6?CTIC*depe"di"g o" the appicatio"+*depe"di"g o" the appicatio"+

o"y the $edi"g c&rre"t co&d re%&ireo"y the $edi"g c&rre"t co&d re%&ire

'o"itori"g $ith a to"g&e test a''eter'o"itori"g $ith a to"g&e test a''eter

E9a,le 2 igh integrity MM%


32/36


E9a,le 2 igh integrity MM%oeration

I T;4?MI T;4?M, this 'ight re%&ire 'o"itori"g o# a the, this 'ight re%&ire 'o"itori"g o# a the

activities previo&sy 'e"tio"ed(activities previo&sy 'e"tio"ed(

a o# the a!ove e%&ip'e"t $o&d re%&irea o# the a!ove e%&ip'e"t $o&d re%&ire

cai!ratio"N a"y 'eters tted to thecai!ratio"N a"y 'eters tted to the

po$er so&rce or eectrode ove"s $o&dpo$er so&rce or eectrode ove"s $o&d

aso re%&ire cai!ratio"(aso re%&ire cai!ratio"(

the e%&ip'e"t th&s re%&ired $o&d !e:the e%&ip'e"t th&s re%&ired $o&d !e: a''etera''eter

vot'etervot'eter

stop $atchstop $atch

tape 'eas&retape 'eas&re

ther'o'eterther'o'eter

cac&atorcac&ator

4?4? a 6>Sa 6>S

E9a,le 3 MI$(M%$ +elding +ith a


33/36


E9a,le 3 MI$(M%$ +elding +ith aro'ot

I T;4?MI T;4?M, the #oo$i"g $o&d re%&ire 'o"itori"g:, the #oo$i"g $o&d re%&ire 'o"itori"g:

$ire #eed speed$ire #eed speed

a'peragea'perage

votagevotage

trave speedtrave speed

gas o$ rategas o$ rate

repeata!iity o# the co"trosrepeata!iity o# the co"tros

I 6?CTICI 6?CTIC, a data ogger $o&d !e pre#erred, a data ogger $o&d !e pre#erred

to 'o"itor a the para'etersN aso a 6>Sto 'o"itor a the para'etersN aso a 6>S

$o&d !e re%&ired to chec the repeata!iity$o&d !e re%&ired to chec the repeata!iity

o# the co"tro "o!s(o# the co"tro "o!s(


34/36


S*,,ary

a $edi"g po$er so&rce ca" o"y !ea $edi"g po$er so&rce ca" o"y !ecai!rated i# it has 'eters ttedcai!rated i# it has 'eters tted

the i"spector sho&d chec #or cai!ratio"the i"spector sho&d chec #or cai!ratio"

sticers, dates etc(sticers, dates etc(

a $edi"g po$er so&rce $itho&t 'etersa $edi"g po$er so&rce $itho&t 'etersca" o"y !e vaidated that the co"troca" o"y !e vaidated that the co"tro

"o!s provide repeata!iity"o!s provide repeata!iity

the 'ai" roe is to carryo&t Oi" processthe 'ai" roe is to carryo&t Oi" process

'o"itori"gP to e"s&re that the $edi"g'o"itori"gP to e"s&re that the $edi"gre%&ire'e"ts are 'et d&ri"g prod&ctio"re%&ire'e"ts are 'et d&ri"g prod&ctio"

Tyical e9a,ination


35/36


Tyical e9a,ination4*estion 1

OOThe 'eas&re'e"t o# $edi"g para'eters is co''o"The 'eas&re'e"t o# $edi"g para'eters is co''o"

i" arc $edi"g practice( Co''e"t o" the para'etersi" arc $edi"g practice( Co''e"t o" the para'etersthat ca" !e 'eas&red a"d recorded,i"c&di"g thethat ca" !e 'eas&red a"d recorded,i"c&di"g the

di


36/36

Tyical e9a,ination4*estion 2

This 4*estion is related ,ore to the +holeThis 4*estion is related ,ore to the +hole

fa'rication rocess: e.g.fa'ricationrocess: e.g.

Q-QC re%&ire'e"tsQ-QC re%&ire'e"ts

Trai"i"g, eAperie"ce a"d %&aicatio" o# $edersTrai"i"g, eAperie"ce a"d %&aicatio" o# $eders

a"d i"spectorsa"d i"spectors I"spectio" proced&res *d&ri"g $edi"g+I"spectio" proced&res *d&ri"g $edi"g+

&diti"g to e"s&re that the a!ove is tai"g pace&diti"g to e"s&re that the a!ove is tai"g pace

Cai!ratio"-vaidatio" a"d i" process 'o"itori"gCai!ratio"-vaidatio" a"d i" process 'o"itori"g

OO8escri!e ho$ yo& $o&d e"s&re that the $edi"g8escri!e ho$ yo& $o&d e"s&re that the $edi"g

para'eters isted i" a W6S are !ei"g adhered topara'eters isted i" a W6S are !ei"g adhered tod&ri"g prod&ctio" $edi"g( )ive the adva"tagesd&ri"g prod&ctio" $edi"g( )ive the adva"tages

a"d i'itatio"s o# the 'ethods &sed(Pa"d i'itatio"s o# the 'ethods &sed(P

15. Calibration Measurement,

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