Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Title: Calibration of Gages and Equipment
1.0
Page:
E
1 of 9
Purpose:
The purpose of this procedure is to define the program used to assure that all measuring and test
equipment is properly calibrated, validated and controlled. This calibration procedure and the function it
controls are intended to comply with the requirements of ANSI Z-540.3.
2.0
Scope:
This procedure applies to all gages calibrated in-house as well as gages calibrated by outside laboratories.
3.0
Responsibility:
Quality Management is responsible for ensuring the requirements of this procedure are implemented and
maintained.
Engineering is responsible for ensuring that any measurement/metrology requirements (tolerances, specific
equipment requirements, etc.) that may affect the use or control of monitoring and measuring equipment
are communicated to the Calibration/Quality Technician/Department.
Calibration Technician is responsible for maintaining and monitoring the calibration system, calibration and
recall of gages, review of calibration records for adequacy and compliance to requirements, and any other
task directly related to gage calibration. Technician is responsible for providing training or operating/use
material for equipment, when required.
4.0
Definitions:
Calibration Technician: Personnel with demonstrated ability to verify, test, and calibrate monitoring and
measuring equipment. Competency may be achieved through education, training and/or experience, and
demonstrated by testing or observed performance.
CAU: Calibrate After Use
CBU: Calibrate Before Use
IM&TE: Inspection, Measurement and Test Equipment
5.0
Procedure:
5.0.1
Written By:
E. Hunnicutt
General. The measurement process is designed to prevent erroneous measurement results by
ensuring that equipment used to validate requirements is capable of giving accurate and
repeatable reading. This is accomplished through review of the requirements by Engineering and
Quality, as appropriate. Internal test as well as the specifications and warnings provided by the
equipment manufacturer help to determine any impact/influence that may result during the
measurement process.
Approved By:
Stamp
Ken Seise
Quality Manager
12/19/2011
Date
Randy Boofer
Production Manager
12/19/2011
Date
Randy Scharfenberg
Engineering Manager
12/19/2011
Date
Copy#
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Title: Calibration of Gages and Equipment
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Page:
E
2 of 9
5.0.2
General Calibration Requirements. Unless specified otherwise, IM&TE is calibrated to
manufacturer’s specifications. If no specifications are available, the equipment is calibrated based
on intended use. The specifications must be reviewed, planned and validated by Engineering
and/or Quality Engineering. Calibration requirements are documented within this document or in
the calibration record for the individual gage/gage type.
5.0.3
Gage Receipt. All IM&TE must be received, reviewed, verified, and approved by the Calibration
Technician before it can be used in production or inspection reject/accept decisions.
5.0.4
Gage ID. Any IM&TE used to verify or validate product or components, or the characteristics of
such items, will be given a unique identification number in the calibration system. When possible,
all IM&TE will be labeled with a sticker indicating Gage ID, Calibration Date, Next Due Date, and
identification of Person performing the Calibration.
5.0.4.1 IM&TE that do not have a calibration sticker (due to surface space limitations) must be
checked-out (logged) from the Calibration Room in the Quality Control Department, and returned upon job completion.
5.0.5
Handling & Storage. Any Essex Cryogenics personnel handling, transporting, or storing IM&TE
must ensure that care is taken to prevent damage or deterioration to the equipment. If personnel
are not familiar with the use or application of equipment, they are responsible for asking their
supervisor and/or calibration personnel for training. Measuring equipment will be used in an
environment that is controlled or known to the extent necessary to ensure valid measurement
results.
5.0.6
Outside Suppliers must meet the requirements set forth in the procedure. Preference for
suppliers will be to those who hold A2LA and/or ISO/IEC 17025 certification, but will be made
based on their technical competence. Calibration Technician is responsible for ensuring that
outside calibration service providers are on the Essex Cryogenics Approved Supplier List.
5.0.7
Environmental controls shall be exercised to the extent necessary to assure required accuracy of
calibration and repeatability. Gage temperature must be comparable to the standard at time of
calibration. If a gage or standard comes from a warmer/cooler climate than the other, they must
both be allowed to stabilize in the same environment before calibration can be performed. The
temperature should be maintained between 68 and 80 degrees Fahrenheit (F) with a Relative
Humidity (RH) not exceeding 68.
5.0.8
Calibration Frequency. Initial calibration frequencies for IM&TE shall be based on the frequency
and set points described in Table-1. If history or usage warrants a shorter or longer frequency, it
will be documented in the calibration record and placed in the file for the equipment. Specific calibration instruction, where required, is given in Section 5.1-5.13. All IM&TE is to be calibrated to the
instrument’s full range regardless of the application range that the device is used for.
5.0.9
Adjustments. Access to adjusting means and devices on confirmed IM&TE, whose settings affect
the performance, must be sealed or otherwise safeguarded to prevent unauthorized changes.
When possible, seals or safeguards will be used such that tampering will be detected. If adjustments are known or suspected, it will be considered an Out of Tolerance Condition, and reviewed
as such. (See Section 5.0.11.)
5.0.10 Calibration Records. The Calibration Technician is responsible for ensuring that the all calibration
documentation records (both internally and externally calibrated) are complete. All records must be
reviewed to ensure they contain, at a minimum, the following information:
• Identification of the gage—unique ID number and description, also, as applicable: serial
number, manufacturer, model number, etc.
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Title: Calibration of Gages and Equipment
Revision Level:
Page:
E
3 of 9
• Identification of the master used to perform calibration (ID, S/N, or Cert. #, etc.)
• Calibration date completed and next due date (and/or calibration cycle.)
• Incoming (before repair) and Outgoing condition, as appropriate. If gage is out of
tolerance, it must be noted and a review must be performed per Section 5.0.9.
• Environmental conditions, as applicable.
• Any limitations of use.
• Identification of person performing calibration.
• Maximum permissible error(s) allowed (tolerance.)
• Calibration history for gage.
All calibration records of IM&TE shall be maintained by the Calibration Technician and shall be
retained for a minimum of 15 years. The calibration records will be signed, dated and stamped by
the Calibration Technician and either the Inspection Supervisor, Quality Engineer, or Quality
Manager.
5.0.11 Out of Tolerance Conditions. If any IM&TE is found to be out of tolerance during an in-house
calibration or received from an outside laboratory, the IM&TE shall be reviewed for possible impact
on measured product since the equipment’s last known acceptable calibration/verification. The
Quality Manager, or delegate, must make a determination as to the appropriate action required
concerning use of the equipment and any product potentially affected by its prior use (use as is,
scrap, recall, etc.) A notation of actions taken on equipment and product will be maintained in the
calibration files and the Engage software. The Calibration Technician must provide a copy of the
equipment’s calibration history at time of review.
5.0.12 Non-conforming Measuring Equipment. Any confirmed measuring equipment that is suspected
or known to be damaged, overloaded, malfunctioning in such a way to invalidate its intended use,
producing incorrect measurement results, safeguard broken or damaged, or otherwise considered
unfit for use must be removed from service and segregated or identified in such a way to preclude
its use. This is done by performing the following:
•
Mark the gage as inactive in the Engage software.
•
Record the date, reason for defect, replacement status, and whether any product has
been affected and why in the notes section of the gage entry.
•
Place a Hold Tag (Q7.5F0030) on the non-conforming equipment until disposition.
Equipment cannot be returned to service until the reasons for its nonconformity have been eliminated and its full function has been confirmed, or it is designated for Limited Use only. If the gage
is sent out for repair, the vendor will also calibrate the equipment. Accompanying documents will
be reviewed upon its receipt to Essex to ensure that calibration was completed. If the gage is replaced, a new entry with a new gage number will be created in the Engage software. The nonconforming gage will remain inactive.
5.0.13 Limited Use. If any equipment is not functioning to its full capabilities, but is acceptable for limited
or other use, this information must be clearly identified and apparent for the operator/user. For
example, this could be used for ‘reference only’ measurements.
5.0.14 Lost Gages. Any gage that cannot be located at the calibration due date shall require the
notification of the departmental supervisor. Gages that cannot be located for a period exceeding 2
months shall require notification of the departmental manager and the Quality Manager who will
confer on the appropriate actions required.
5.0.15 Traceability. All calibrations shall be traceable to the National Institute for Standards and
Technology (NIST).
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Title: Calibration of Gages and Equipment
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Page:
E
4 of 9
5.0.16 Validation of measurement processes. If necessary, measurement processes will be validated
by comparing results of other validated processes, by comparing results to other measurement
methods, or by continuous analysis of measurement process characteristics.
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Title: Calibration of Gages and Equipment
Page:
E
5 of 9
Table-1
Gage/Equipment Type
Calibration Frequency
(Minimum)
Accuracy Required
Calipers, Vernier,
Dial, & Digital
1 Year
± 0.001”
Capacitance
1 Year
4:1
Dosimeters
1 Year
Mfg’s
Flow Meter, Working
1 Year
± (1) Division
Functional/Specialty
Gages
1 Year
Drawing Specific
1 Year
+ 0.00004
- 0.00002
+ 0.00008
- 0.00004
+ 0.00010
- 0.00005
+ 0.00012
- 0.00006
± 0.00009
± 0.00010
Gage Blocks
Thru 3”
1 Year
1%
Height Gage
1 Year
± 0.001”
Hypot
1 Year
+/-3%
Indicators, Dial
1 Year
± 0.001”
Manometer
1Year
± (1) Minor Unit
Megohmmeter
1 Year
Mfg’s
Micrometers, Outside
1 Year
± 0.001”
Micrometer, Depth
1 Year
± 0.001”
CBU
± (1) Minor Unit
1 Year
Pressure Gage, Master
1Year
Per Drawing
N/A
ANSIZ540.3
Q7.6P0003
5.12
I
E
E
E
I/E
Gage Block Nominal
Q7.6P0003
5.4
E for masters/
I for other
USNRC
E
ATP105
E
Thru 7”
Thru 8”
Halogen Leak Tester
Photometer
Q7.6P0003
5.3
ANSIZ540.3
Thru 4”
0-10mR/hr
1 Year
25%, 50%, 75% and 100%
full scale
Calibration Source Dependent
Calibration Source Dependent
Calibration Source Dependent
Calibrated by
(I)nternal or
(E)xternal
Thru 2”
1 Year
Particle Tester
Specific
Instructions
Thru 1”
Geiger Counter
Micrometer, Inter
Set/Inspection Points
+/-5% of normal
flow rate
+/-5.0% of the
listed transfer
standard when
exposed sequentially to light
sources
+/-0.05%
Calibration Source Dependent
Calibration Source Dependent
25%, 50%, 75% and 100%
full scale
Calibration Source Dependent
25%, 50%, 75% and 100%
full scale
25%, 50%, 75% and 100%
full scale
25%, 50%, 75% and 100%
full scale
25%, 50%, 75% and 100%
full scale
25%, 50%, 75% and 100%
full scale
Calibration Source Dependent
Q7.6P0003
5.6
ANSI Z540.3
Q7.6P0003
5.5
Q7.6P0003
5.8
ANSI/NCS
L/Z540-11994
Q7.6P0003
5.1
Q7.6P0003
5.2
Q7.6P0003
5.15
IEC-1851:1993
4 points @ 0, 2, 100, 400 for
foot candles, 4 points @ 000,
25K, 50K, 150K for foot lamberts
ANSI/NCS
L Z540-1,
MIL-STD45662A
E
Calibration Source Dependent
ANSI/Z540.
3
E
Calibration Source Dependent
I
E
I
I
E
I
I
I
E
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Title: Calibration of Gages and Equipment
Gage/Equipment Type
Page:
Calibration Frequency
(Minimum)
Accuracy Required
Pressure Gage,
Working
1 Year
± 1% Scale
Plugs, Thread, Set
2 Years
4:1
Plugs, Thread
2 Years
4:1
Reticle – English
Reticle – Metric
Reticle – Diameter
Reticle – Radius
Reticle – Angle
Independent verification
upon receipt/ visual
thereafter prior to use
Independent verification
upon receipt/visual
thereafter prior to use
Independent verification
upon receipt/visual
thereafter prior to use
Independent verification
upon receipt/visual
thereafter prior to use
Independent verification
upon receipt/visual
thereafter prior to use
E
6 of 9
Set/Inspection Points
Specific
Instructions
25%, 50%, 75% and 100%
full scale
Calibration Source Dependent
Calibration Source Dependent
Q7.6P0003
5.7
ANSIZ540.3
ANSIZ540.3
E
± .001
Full range
ANSIZ540.3
E
± .025
Full range
ANSIZ540.3
E
± .002
Full range
ANSIZ540.3
E
± .001
Full range
ANSIZ540.3
E
± 0°0’30”
Full range
ANSIZ540.3
Calibration Source Dependent
Calibration Source Dependent
ANSIZ540.3
ANSIZ540.3
Ring Gages, Cylindrical
2 Years
4:1
Ring Gages, Thread
2 Years
4:1
Rules, Steel and
Tape Measures
1 Year
±0.015”
Scales, Weight
1 Year
+/-1 lb.
Temperature Gage &
Controls
1 Year
+/-2 deg.
Timers / Stop Watch
2 Year
± .13 Second
Torque Wrench
1 Year
2% Full Scale
Voltmeter
1 Year
0.02 Milliamp/
2.0 ohm
Weights, Master
1 Year
4:1
X-Ray Stedwedge
1 Year
+/-.05
TIG Welder
1 Year
10%
6 Major divisions each scale,
then overall length on subsequent calibrations
Calibration Source Dependent
Calibration Source Dependent
25%, 50%, 75% and 100%
full scale
Calibration Source Dependent
Calibration Source Dependent
Calibration Source Dependent
Full Range (.30, 1.0, 2.0, 3.0,
4.0)
Full Range
Q7.6P0003
5.13
ANSIZ540.3
Q7.6P0003
5.11
Q7.6P0003
5.12
ANSI
Z-540.3
ANSI
Z-540.3
ANSZ-540.3
Q7.6P0003
5.12
ANSZ-540.3
Calibrated by
(I)nternal or
(E)xternal
I
E
E
E
E
I
E
E/I
I
E
E
E
I
E
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Title: Calibration of Gages and Equipment
5.1
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Page:
E
7 of 9
Micrometers, Outside
After checking the zero setting, certified gage blocks are used to check for accuracy at the set
points in Table-1. To reset the mike, the graduated sleeve may be rotated to read properly using a
specially designed wrench. On some brands the graduated thimble must be loosened to align the
proper graduation. To adjust the play in the threads, remove the thimble and adjust the nut on the
threaded split sleeve to obtain the correct thread clearance. Dirty depth micrometers are cleaned
ultrasonically in a bath of high-detergent petroleum based solvent, blown dry and oiled with
“Starrett M-1” rust preventive lubricant or equivalent.
5.2
Depth Micrometer
Use certified gage blocks and a certified surface plate to perform all checks. Check the points
specified in Table-1. To reset a stem to read correctly, turn the nut at the end of the stem
clockwise or counter clockwise depending on the adjustment to be made, with a special wrench.
Some models have self-locking nuts; others have a jam nut that must be securely tightened after
making any adjustments. To adjust the play in the threads, remove the thimble and adjust the nut
on the threaded split sleeve to obtain the correct thread clearance. Dirty depth micrometers are
cleaned ultrasonically in a bath of high-detergent petroleum based solvent, and then blown dry and
oiled with “Starrett M-1” rust preventative lubricant or equivalent.
5.3
Vernier & Dial Calipers
After checking the zero setting, certified gage blocks are used to check for accuracy per Table-1.
Check for a spring condition in the outside measuring jaws by comparing readings taken close to
the ends of the jaws to readings taken with the jaws in full contact with the gage blocks. To check
the inside dimension measuring jaws and the depth measuring stem use a 1 inch gage block and
compare readings obtained to the readings on the outside dimension measuring jaws over a 1 inch
gage block. If any of the measuring surfaces are outside of the allowable tolerances per Table-1
and are not repairable, they shall be marked as “Limited Use”, denoting the condition or taken out
of service.
5.4
5.3.1
Disassembly for cleaning need not be performed each month. When dirt accumulation
begins causing inconsistent readings, carefully clean the calipers with a brush or
compressed air, if possible. If the calipers must be disassembled for cleaning, refer this
task to qualified personnel only, due to the complicated and delicate mechanisms inside
many dial calipers.
5.3.2
If the movable jaw is too tight or too loose on the beam, adjust the 2 screws at the top of
the movable jaw for proper tension by turning them clockwise until snug then back off 1/4
turn. Lightly lubricate using “Starrett M-1” or equivalent on the beam where it contacts the
movable jaw. Oil on the gear rack and pinion gear of the dial calipers only attracts dirt.
Gage Blocks
Any worn or defective gage blocks shall be replaced. Certifications are kept on file in the
Measuring and Testing Equipment control room. The blocks are wiped clean and “Starrett M-1” or
equivalent is applied to prevent rust or corrosion from forming after each use.
5.5
Dial Indicators
First check for repeatability at zero, then use certified gage blocks to check for accuracy at a
minimum of 4 points per inch, spread out so as to encompass the entire range of the indicator.
Indicators that are inaccurate or lack good repeatability are sent out for repair and calibration.
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Title: Calibration of Gages and Equipment
Document Number:
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Page:
E
8 of 9
Stands are cleaned and oiled with “Starrett M-1” or equivalent to prevent rust. Granite bases are
cleaned with Starrett or equal surface plate cleaner.
5.6
Height Gages
Insert the scriber attachment and using a certified surface plate, check for correct zero setting. Use
certified gage blocks to check for accuracy throughout the entire range of the height gage. Visually
check for condition & repeatability of the scale. Refer service to a qualified repair lab. Clean &
lubricate with “Starrett M-1” or equivalent to prevent rust.
5.7
Working Pressure Gages
Use the appropriate master gage and check for smooth operation on the working gage. Working
pressure gages in service on hydraulic systems must be checked on a master pressure gage.
Working gauges used with hydraulic fluid should not be checked with a gauge cleaned for oxygen
use, as contamination would result. Only working gages that have been cleaned for oxygen use
should be used on oxygen supply line. Use of a contaminated gauge will likely result in an
explosion and/or fire. Refer repair and calibration for defective gages to a certified test lab.
5.8
Manometers
5.8.1
Water Manometers and Red Oil Manometers
Make sure that the liquid level is zeroed out when at rest. If needed, add or subtract liquid
as required. Connect the master gage to Manometer. Apply pressure to the manometer
and compare readings of both gages. Readings obtained on the inches of water gage are
direct; therefore, conversions in the readings are not necessary. Check for accuracy at
each major division on the working gage.
5.8.2
Mercury Manometer
Make sure the level of mercury in the manometer is at zero before proceeding. Adjust
scale if possible or add or subtract mercury as necessary. Connect the master gage to the
manometer. Apply pressure to the set-up and note the readings obtained. The readings of
the master pressure gages must be converted to inches of mercury by means of AN-05101. Check for accuracy at each major division on the working gage.
5.9
Weight Scales
Use master weights to check for accuracy at several points throughout the range of the scale.
Balance scales must be set for zero each use.
Essex Industries, Inc.
8007 Chivvis Drive
St. Louis, Missouri 63021-2395
Q7.6P0003
Revision Date:
12/19/2011
Revision Level:
Title: Calibration of Gages and Equipment
5.10
Document Number:
Page:
E
9 of 9
Processing Department Voltmeter/Ampmeter
Shall be calibrated by use of a certified voltmeter and ampmeter with certified shunts or Fluke
digital multimeter master 8020B or equivalent. Disconnect the power supply line to the plating tank
and connect it to check the accuracy of the power supply voltmeter at each major division on its
scale. With the power supply disconnected from the tank, connect a snorting loop with the proper
range shunt in series across the power supply output. Connect a precision ammeter across the
shunt and check the accuracy of the power supply ammeter at each numbered increment to full
scale. Refer calibration of out of tolerance meters to a certified test lab.
5.11
Temperature Gages and Controls
Temperature controls shall be calibrated at the required operating temperature and shall be
recalibrated if operating temperature requirements are changed.
5.12
Functional/Specialty Gages
All functional gages that are designed to check the product quality of a feature of a part shall be
calibrated against a known standard.
5.13
Steel Rules (Scales)
Steel rules shall be certified by checking 6 major divisions on each scale and overall length.
Subsequent certifications only require measurement of the overall length to measure end wear.
6.0
Reference Documents:
TABLE OF REVISIONS
Revision
Summary of Revision
A
B
C
Released per IDR 431
DCN 1829
DCN 1990
D
E
DCN 2239
DCN 3062
Revised By
E. Hunnicutt
E. Hunnicutt
T. Greenlee
Date of
Revision
3/07/07
05/07/2008
12/01/2008
T. King
T King
10/27/2009
12/19/2011