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NT TR 226 - When Do We Need Calibration of Equipment Used in Testing Laboratories - Nordtest Technical Report PDF
NT TR 226 - When Do We Need Calibration of Equipment Used in Testing Laboratories - Nordtest Technical Report PDF
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NT TECHN REPORT 226
Approved 1994-02
One of the most important elements in a testing laboratory quality system is a practical,
well-functioning equipment management system. The validation of equipment with respect
to use can be carried out at various levels of uncertainty, depending mostly on the technical
capability of the equipment, the requirements set by the clients of the laboratory or by the
standard or test method used. Costs can be saved if no calibration is needed, or if calibration
can be performed using the most suitable and simplest way, which produces the acceptable
uncertainty level for the measurement in question.
The purpose of this report is to give recommendations for testing laboratories with respect
to calibration, and to present tools and data for facilitating the planning of a practical
equipment assurance system.
The project was financed by NORDTEST and managed by Esa Vitikainen (VTT,
the Technical Research Centre of Finland). Heikki Lehto, Tapio Manstén, Pekka
Immonen and Juha Sillanpää (VTT) contributed by supplying material and giving
their views for the report.
-3-
CONTENTS
ABSTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 BACKGROUND MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 NORDTEST REPORTS ON CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 EQUIPMENT ASSURANCE PROGRAMMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 UNCERTAINTY BUDGET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1 INTRODUCTION
One of the most important elements in a testing laboratory quality system is a prac-
tical, well functioning equipment management system. The validation of equip-
ment with respect to use can be carried out on various levels of uncertainty
depending mostly on the technical capability of the equipment, the uncertainty
requirements set by the clients of the laboratory or by the standard or test method
used. Costs can be saved if no calibration is needed, or if calibration can be per-
formed by using the most suitable and simplest way, which produces the accept-
able uncertainty level for the measurement in question.
- In many cases one is only interested in the measuring equipment and its cali-
bration and uncertainties connected with them without taking into account the
other components of the measurement uncertainty (measuring process, environ-
ment, personnel, object to be measured etc.)
- Calibrations are required for the measuring equipment which do not need it, for
instance, measuring equipment which is used in different direction-giving,
-6-
The purpose of this report is to give views and recommendations to testing labo-
ratories with respect to calibration, and to present tools and data for facilitating
the planning of a practical equipment assurance system.
2 BACKGROUND MATERIAL
Calibration, its role and effects on the quality of test results are also discussed in
some earlier Nordtest Reports (Andersson 1991, Forstén 1991, Kjell et al. 1993).
2. Short guidelines for the planning and structure of the calibration programme
which could contain
- requirements for testing standards and quality systems,
-7-
- responsibilities, training,
2. The mutual acceptance of test results should be based more and more on the
overall capability to perform the test correctly. The increased use of interlabo-
ratory test comparisons, round robin testing and proficiency testing must be
encouraged.
Kjell et al. (1993) reported on the documentation of methods and procedures for
internal calibration. According to them, traceability is essential and must not be
compromised as such. Depending on the purpose of the calibration or check, the
degree of ambition can be modified. They say that interlaboratory test compari-
sons serve well to ensure coordinated measurement capabilities and these are offen
useful but should not be regarded per se as warranting traceability. They also dis-
cuss factors influencing the choice of calibration or check frequency, documenta-
tion and requirements on personnel performing the task.
-8-
A simple method for uncertainty analysis, which is tailored specifically for inter-
nal calibration purposes is presented in their report.
Testing Allowed
principles uncertainty Equipment assurance program
(Calibration program)
Testing Optimizing of
- 10 -
procedure the total
containing
individual uncertainty
measurements (Total budget)
Equipment Choice of the
accuracy equipment and Calibration
Equipment
optimum method
Uncertainty calibration
Measurement of a (Other) Factors
procedures measurement affecting the
(Budget) measurement Uncertainty of
uncertainty calibration
• Environment
• Staff
Calculations /
Uncertainty of • Method • Uncertainty of
Collection of
calculations / • Object to be reference
measurement
Software measured standard
results
• Calculation / • Environment
Software • Calibration
• Physical equipment
constants • Staff
Results with • Method
the allowed • Sampling • Equipment
uncertainty • Calculations /
Software
• Physical
constants
Fig. 1. A schematic presentation of interactions between testing, measurement and calibration including their uncertainties.
- 11 -
1. The assessment and analysis of the testing processes of the laboratory with
respect to the measurements needed and their effects on the test results.
3. For each measurement, the selection of such measuring equipment which is able
to cover the required measurement range and optimally is in agreement with the
permitted measurement uncertainty. This requires analyzing the uncertainty budg-
et of the measurement process with the chosen equipment. Thus all components of
uncertainty need to be defined. The accuracy (uncertainty) of the equipment
according to the budget defines the maximum uncertainty allowed in calibration of
the equipment. A transfer ratio 3:1 between measurement uncertainty and calibra-
tion uncertainty is normally used.
tions. These can be used in assessing the effects of the different uncertainty com-
ponents on the total uncertainty when optimizing the measuring process. EXCEL-,
LOTUS- or other calculation tables which are easy to use for optimization of the
measurement uncertainty are recommended.
This chapter deals with the measurement of the basic quantities; length, mass,
force, time, temperature, voltage, resistance and current, and gives for each quan-
tity a set of tables / graphical presentations that contain the uncertainty levels,
which can readily be reached in different calibration organizations, and the uncer-
tainty levels of different measuring instrument/equipment types. These tables are
intended to help define suitable measuring equipment and its calibration level.
Under each quantity, also some advice is given as regards the calibration of the
instruments.
In addition, an assessment of the factors with respect to their weight in the total
uncertainty is discussed. Since the uncertainty of a test may consist of several
measurements - and an uncertainty of a measurement always depends on the whole
measuring process, including measuring staff, objects to be measured, environ-
ment etc. - this report only identifies factors contributing to the total uncertainty.
Contribution of the uncertainty, which relates to calibration of equipment to the
- 14 -
total uncertainty of a test, is in many cases, so small that its optimization and
detailed budgeting is marginal.
3.1 LENGTH
10-1
In-house calibration
10-2
Relative uncertainty
10-3
10-4
Accredited calibration
laboratory
10-5
10-6
10-7
National standards laboratory
10-8
Fig. 2. Uncertainty levels of different organizations performing length calibration (CMA 1993a, b).
Length measurement
A = Scanning electron I = Base lines meas. with an
microscope interference comparator
B = Laser interferometer J = Base lines / Invar wires
10-1 C = Gauge blocks K = Mekometer
D = Transducer, dial gauge L = Laser geodimeter
H E = Micrometer M = GPS (Military)
10-2 F = Vernier Calliber N = Interferometry microwaves
G = Steel rule flight time measurements
A G
Relative uncertainty
10-5
B K
10-6
B L
I
10-7
Quartz meter (abs) M
J
Quartz meter (rel)
10-8
Fig. 3. Typical attainable uncertainty levels for different length-measuring instruments (CMA 1993b, etc.).
- 16 -
This is probably the most commonly used accuracy level and measuring range in
testing laboratories. Graduated rules, tape measures and sometimes vernier cal-
lipers are used in the measurements. In-house calibration of these instruments is
recommended to be carried out by using the comparison to a reference steel rule
(length 1 - 3 m), which is calibrated, for example, every second year in an accred-
ited calibration laboratory.
Usually vernier callipers, micrometers, dial gauges and length indicators are used
in this accuracy level and measuring range. If the laboratory only has one or a few
pieces of each instrument type, it is in generally recommended to calibrate these in
an accredited calibration laboratory. If there are plenty of these instruments and
they are frequently used, a special length-measuring apparatus for inhouse cali-
bration is recommended. If the use of the instruments is less frequent, a pertinent
series of reference gauge pieces can be used in calibration.
Calibration intervals
Calibration intervals depend on the type and use of the equipment. For length
measuring instruments it usually varies between 3 and 12 months.
Typical uncertainty sources for different instrument groups used in length meas-
urement are:
3.2 MASS
The OIML (International Organization of Legal Metrology) has defined and clas-
sified the mass standards and test weights used in the calibration of weighing
machines. The series of mass standards are identified in accuracy order (beginning
from most accurate), with the letter codes E1, E2, F1, F2, M1, and M2. The Relative
uncertainties of these standards as a function of measuring range are given as
curves in Fig. 4. The figure also gives an example of the capability range of a
national standards laboratory and a field calibration laboratory. In the calibration
of weights or mass standards, the reference shall be at least one accuracy class
higher than the weight to be calibrated. The verification officers, for example, use
F1 series for M1 and F2 series for M2.
Mass calibration
1
OIML reference Verification officers:
mass standards F1 series for M1 weights
M1 F2 series for M2 weights
10-1
F2
F1
10-2
E2
E1 Uncertainty depending on
Relative uncertainty
1000
10-4 3000 Field calibration of
5000 weighing machines
10000
(A calibration lab.)
10-5
10-6
10-7
Table 1. Weighing equipment classes and their typical use (Harris 1993)
In some cases, higher transfer ratios, like 4:1, are required. Where it is not techni-
cally possible to ensure this transfer ratio of device accuracy to test weight toler-
ance, it is recommended that a calibration of the test weights is performed. The
assigned values, rather than the nominal values, should then be used to adjust the
accuracy of the weighing instrument. Table 2 gives some information on mass
standard accuracy classes and their typical use (Harris 1993).
Table 2. OIML mass standard and test weight accuracy classes and their typical
use (Harris 1993). The ASTM-, NBS- and NlST-standard classifications are not
referred to in this report.
- 21 -
3.3 FORCE
The measuring range of a force transducer is usually about one decade, and trans-
ducers can be constructed for almost any measuring range. Therefore, uncertain-
ties of individual transducers/transducer types are not given here.
1
Uncertainty levels in force measurement and calibration
10-1
Relative uncertainty
10-5
10-6
1N 10 100 1kN 10 100 1MN 10 100 1GN
Measuring range
Periodical checks with known masses (one weight per force range) can be used in
the verification of the instruments between the calibrations.
The level of uncertainty depends on the equipment and procedures used in the
measurement and calibration, thus, the uncertainty of each measurement should be
evaluated individually.
In the following, the factors which affect the uncertainty in force measurements are
given.
3.4 TIME
The quantity, time, contains both instant time and time interval. Both use second
as their unit. Instant time is Universal Coordinated Time (UTC) from a large group
of atomic clocks. UTC is maintained by BIPM, Paris. The best accuracy of the syn-
chronization to UTC at a National Standards Laboratory is a few hundred nanosec-
onds. Time comparisons between National Standards Laboratories are nowadays
made mainly via GPS (Global Positioning System) satellites. Countries use differ-
ent time zones as their Local Time for practical reasons. Usually local time is dis-
tributed by using radio time signals. The uncertainty of a radio time signal is at best
about ± 0.1 ms.
Absolute time is not a very common object of calibration. Usually, only the
National Standards Laboratories maintain absolute time. Many measurements that
seem to need accurate time need, in fact, only clock synchronization at the begin-
ning. Time interval measurements are common and normal frequency counters
usually measure time intervals as well. Time interval calibrations are thus an
important part of equipment calibrations.
1E-02
Relative uncertainty, dT/T
1E-04
1E-06
1E-08
National standards laboratory,
accredited calibration laboratory
Electrically controlled digital clocks
1E-10 and stop watches
1E-12
1E-09 1E-07 1E-05 1E-03 1E-01 1E+01 1E+03 1E+05 1E+08
Time interval T, s
When more accurate time intervals are needed, electronic means of starting and
stopping the time interval counts are used. If the starting and stopping signals are
sharp pulse edges, this can easily be done within a few nanoseconds, even picosec-
onds. In this case, the frequency error of the main clock of the measuring equip-
- 26 -
ment starts to dominate, even in measuring short intervals. If, for instance, a count-
er with an uncompensated crystal oscillator is used for measuring a 1 s interval, the
error from triggering may be about 2 * 10-9, but the error from the main clock is
about 10-5 - 10-6. If more accuracy is needed, a measuring device with an oven crys-
tal oscillator, or locking of the main clock to an accurate external source is recom-
mended.
The basic accuracy of a quartz watch is better than 1 min/24 h, thus << 10-3.
Therefore, if the accuracy requirement is smaller than that (> 10-4) and the watch
is known to be reliable, it can be used in time interval measurements without cal-
ibration.
The largest contributors to the uncertainties in time and time interval measure-
ments are often the links between the process to be measured and the measuring
equipment (delays or other errors in starting and/or stopping of the measuring
instrument, especially if there are human performances involved) and the sig-
nal/noise level of the start/stop signals.
- 27 -
3.5 TEMPERATURE
Uncertainty levels and utilization ranges of different thermometer types are given
in Fig. 7. If, for example, the required uncertainty of measurement is 0. l °C, one
can use in the measurement either an accurate liquid-in-glass thermometer, an
accurate thermocouple, or a resistance thermometer, but in the calibration of those
instruments only resistance thermometers or fixed point calibration can be used.
Temperature measurement
Liquid-in-glass thermometers
Thermocouples
Resistance thermometers
100
Radiation thermom. / Pyrometers
Allowed uncertainty [°K], [°C]
10
In-house calibr.
UT UP Liquid-in-glass ete
m
yro
range and uncertainty allowed in the measurement are the most important param-
eters in selecting the thermometer.
The selection of thermometers used in the laboratories and their accuracies and
calibration accuracies are so wide that, in this report, it is impossible to give any
practical general procedure for their calibration.
The choice of calibration temperatures should cover the range which is used in the
temperature measurement. It is important that the sensing head of the thermome-
ter is calibrated and the actuating element of the reference thermometer is at the
same temperature. Metal blocks which have drilled holes for thermocouples, or
other sensing elements, can be used in furnaces for homogenizing the temperature
during calibration.
The level of uncertainty depends on the equipment and procedures used in the
measurement and calibration, thus, uncertainty of each measurement should be
evaluated individually.
In the following, factors are given which affect the uncertainty in temperature
measurements.
Liquid-in-glass thermometers
- reading error, parallax error,
- change rate of the temperature,
- immersion depth,
- hysteresis/elasticity of the glass (temperatures over 100 °C).
Thermocouples
- homogeneity and purity of the wires,
- cold-point stability and accuracy,
- stability,
- isolation resistance and isolation defects in the mantel,
- compensation cables, measuring cables, connections,
- immersion depth/axial temperature gradients,
- uncertainty in potential measurements,
- electro-magnetic disturbances.
Surface thermometers
- surface properties; roughness, conductivity,
- thermal mass of the thermometer.
The national standards for direct voltage and resistance are directly based on the
Josephson and quantum-Hall effects, or indirectly via international comparisons.
Standards of the best accuracy are maintained for the values 1 or 10 volts and 1,
- 31 -
100 or 12906 ohms. The reference standards of calibration laboratories are usually
solid state voltage standards, stable wire-wound resistors and/or multifunction cal-
ibrators and digital multimeters.
Josephson junction
1E-03
Relative uncertainty, dU/U
1E-04
1E-05
1E-06
1E-07
1E-08
0.001 0.01 0.1 1 10 100 1000 10000
Voltage, volts
Quantum hall
Relative uncertainty, dR/R
1E-03
1E-04
1E-05
1E-06
1E-07
1E-08
1E-09
1E-04 1E-02 1E+00 1E+02 1E+04 1E+06 1E+08 1E+10
Resistance, ohms
1E-03
1E-04
1E-05
1E-06
1E-09 1E-07 1E-05 1E-03 1E-01 1E+01 1E+03
Current, amperes
The national standards for AC/DC ratio may have an accuracy of 10-6 but an uncer-
tainty of 10-4 is sufficient for most calibrations. The best measurement capability
of the calibration laboratories usually strongly depends on the voltage, current and
frequency values in question.
Figs. 11, 12 and 13 show classification examples where the instruments have been
divided in to two price groups, 80 - 100 USD and 800 - 1000 USD. The uncertainty
ranges which can be reached by using these price-group instruments are given.
1E-03
1E-04
1E-05
1E-06
0.01 0.1 1 10 100
Measured voltage, volts
1E-02
1E-03
1E-04
1E-05
1E-02 1E+00 1E+02 1E+04 1E+06 1E+08
Measured resistance, ohms
Fig. 12. Typical uncertainty ranges attainable by different price-group resistance meters.
1E-02
1E-03
1E-04
1E-05
1E-06
1E-05 1E-04 1E-03 1E-02 1E-01 1E+00 1E+01
Measured current, amperes
- 36 -
By calibration of a multimeter, one often wants to check the validity of the manu-
facturer's specifications. The less accurate meters can be compared to a calibrated
multimeter with well-defined characteristics. However, for full verification of all
ranges, the services of a calibration laboratory are usually needed.
In a good quality system, the method of calibration and calibration interval is clear-
ly described for each measuring instrument. A testing laboratory can send one of
the multimeters or a calibrator, e.g. once a year, to an accredited calibration labo-
ratory. This instrument can be used as the reference standard to which all other
measurements are traced. To ensure the traceability, the comparison results
between all measuring instruments and the reference must be documented.
In the following, factors are given which affect the uncertainty in electrical meas-
urements.
Environment:
- Leakage resistances can depend on air humidity. Also, the properties of some
electronic components may be affected by humidity.
- Net stability may affect the operation and the internal temperature of the instru-
ments.
Measuring instruments:
- Calibration uncertainty of the measuring instruments.
- Linearity of the instruments whenever the measured values differ from the cali-
bration points.
It is also important to define the measuring equipment which does not need cali-
bration, for instance, measuring equipment which is used in different directiongiv-
ing, relative or comparative measurements, or in intermediate measurements
which do not affect the quality of the final results. Especially in research work,
there are usually several such measurements.
The logical chain of the measurements should be understood and taken into
account when defining the accuracy requirements for the property to be measured,
for the measuring equipment used and for the calibration.
1. Assessment and analysis of the testing processes of the laboratory with respect
to the measurements needed and their effects on the test results.
2. For each testing process, budgeting of the permitted total uncertainty to the
different measurements.
The National Standards Laboratories, together with the accredited calibration lab-
oratories should be encouraged to gather data and experience from accuracy prop-
erties of different measuring equipment, as well as from calibration uncertainties
and distribute the data to the users in the form of an uncertainty chart in the same
way as given in Chapter 3 of this report.
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