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QUALITY PROCEDURE Date: January 11, 2016

Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

REVISION STATUS SHEET

REVISION DATE PAGES AFFECTED

NAME DESIGNATION SIGNATURE DATE

Nwabude Alex Managing Director 11/01/2016

Iduseri George Operations Manager KL 11/01/2016

CONFIDENTIAL Not to be copied except by permission of Head of Operation

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QUALITY PROCEDURE Date: January 11, 2016
Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

TABLE OF CONTENT
1. PURPOSE
2. SCOPE
3. EXPLANATION / DEFINITIONS
4. REFERENCE DOCUMENTS
5. MATERIALS REQUIRED
6. DIVERSION
7. RESPONSIBILITIES
8. CALIBRATION
9. REGISTRATION AND CONTROL OF CALIBRATION.
10. ACCEPTANCE CRITERIA
11. DOCUMENTS

KL

CONFIDENTIAL Not to be copied except by permission of Head of Operation

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QUALITY PROCEDURE Date: January 11, 2016
Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

1. PURPOSE
1.1. To established technical guidelines to perform and calibrate inverter welding
machine, rectifier welding machine, A/C transformer welding machine, an
engine driven welding machine. And to ensure that only those calibrated
welding machines will produce acceptable quality professional weld as per
national and international standards.

1.2. To minimize the current and voltage deviations between welding machine
set parameters and work piece and certify the welding machine.

1.3. Several national and international standards specify that the welding
machine to be used for welding machine products shall be calibrated.
1.4. Welding machine current / voltage is an essential variable in all of the
national and International Standards. A change in current / voltage can change
weld joint properties and introduce unacceptable discontinuities. Hence having
correct current / voltage reading on the welding machine is very vital to
produce acceptable quality welds.

2. SCOPE
This procedure details the requirement that is required to be implemented for the
welding machine calibration.

3. EXPLANATION / DEFINITIONS
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Open Circuit Voltage (OCV) Is the voltage at the output terminal of the
welding machine when it is energized but no
current is being drawn.

Arc Voltage Is the voltage between the electrode and the work
during welding

Metrological comparison between a measurement device or an instrument with

their respective benchmarks, certificates and their accuracy, in order to detect,
report or eliminate by adjustment any inaccuracy of the instrument.

4. REFERENCE DOCUMENTS

4.1. ISO 17025

4.2. BS ISO 1766
4.3. MILLER- Welding Equipment Meter Calibration
4.4. ANSI/NCSL Z540-1
4.5. BS 7570

CONFIDENTIAL Not to be copied except by permission of Head of Operation

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QUALITY PROCEDURE Date: January 11, 2016
Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

5. MATERIALS REQUIRED

5.1. Fluke 8808A 5.5 Digit Multi Meter

5.2. Fluke Software

5.3. Leads
5.4. Clamp on meter

6. DIVERSION

It is the difference in magnitude between the current rating of the welding machine
and the actual value measured in amperage volt ammeter clamp, taking as basis
the corresponding nominal value.

7. RESPONSIBILITIES

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7.1. Production Supervisor and / or Sr. Foreman responsibility
7.1.1. Use only calibrated welding machines.
7.1.2. Advice the staff involved and apply the requirements of this procedure
7.1.3. Arrange and meet with the minimum premises and equipment calibration.
7.1.4. Notify the Quality Control prior to the date for the calibration of welding
machine.
7.2. The Section of the Quality / Welding Inspector responsibility
7.2.1. Notify the Technical Dept. prior to the date for the calibration of welding
machine.
7.2.2. Receive the welding machine calibration certificates from Technical Dept.
and inspect, the welding machine calibration certificate in acceptable
criteria,
7.2.3. Calibration certificate to be stamped, sign and authorized to use the
welding machine.

7.2.4. Verify the validity of the calibration time.(As per Client requirement)
7.2.5. Affix labels on the welding machine indicating the calibration.
7.2.6. Maintain proper inventory and calibration records.

7.3. The Section of the Technical / Inspector responsibility

7.3.1. Receive the notification for welding machine calibration.
7.3.2. Test the welding machine prior to calibration and certification.

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QUALITY PROCEDURE Date: January 11, 2016
Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

7.3.3. Assigning competent technician to perform welding machine calibration.

7.3.4. Perform and calibrate the welding machine, utilizing calibrated master
instrument.(Calibration standards traceable to Internal standards)
7.3.5. Adjust and minimize the parameter deviation.
7.3.6. Verify the validity of the calibration time.(As per Client requirement)
7.3.7. Issue welding machine calibration certificate.
7.3.8. Issue labels to stick on the welding machine indicating the calibration.
7.3.9. Maintain proper inventory and calibration records.

8. CALIBRATION

8.1. Calibration and certification of welding machine.

8.2. Technical staff required for welding machine calibration.
8.2.1. Welding inspector.(Witness)
8.2.2. An Electrician.
8.2.3. Qualified Welder
8.2.4. Document controller

8.3. Materials required for welding machine Calibration

8.3.1. Welding PPE.
8.3.2. Welding Consumable.
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8.3.3. Steel plate appropriate.
8.3.4. Accessory.
8.3.5. Clamp on meter/Avometer (Third party Calibrated certify and valid,
traceable to internal standards) properly protected from damage and
deterioration during handling, maintenance and storage.
8.3.6. Suitable and standard welding cables.
8.3.7. Suitable and standard welding cable connectors.
8.3.8. Suitable and standard welding earth clamp.
8.3.9. Suitable and standard welding electrode holder

8.4. FREQUENCY OF CALIBRATION.

8.4.1. All welding machine such as inverter welding machine, rectifier welding
machine, A/C transformer welding machine, an engine driven welding
machine should be Calibrated and certify before use, and thereafter every
six months.
8.4.2. All Master instruments (clamp on meter, multimeter) should be Calibrated
and certify before use, and thereafter every six months.
CONFIDENTIAL Not to be copied except by permission of Head of Operation
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QUALITY PROCEDURE Date: January 11, 2016
Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

Note: This period can be set by the inspector but not higher than that
specified above.

8.4.3. Welding machine Calibration Technique.

8.4.4. Welding Electrode cable clamp connect to the positive terminal of the
welding machine to be test and calibrate.
8.4.4.1. Welding ground cable clamp connector to the negative terminal of
the welding machine to be test and calibrate.
8.4.4.2. Energize the welding machine. (ON) Electrically or (Start) Engine
driven
8.4.4.3. Test and record welding machine OCV (Open Circuit Voltage) and
verify with the welding machine name plate.
8.4.4.4. Set the welding parameter positioning liver in the desired position
(Set point)
8.4.4.5. Engage with the volt ammeter clamp the cable clamp electrode.
8.4.4.6. Carry out the reading of the clamp volt ampere ammeter,
comparing it with the values shown on the recorder panel of the

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welding machine.(Welding machine Dial)

Note: Evidence records calibration results of deviations in from. Calibrations should happen in
bands of every (It should indicate the calibration bands for gradual measurement are
taken e.g. every 40A, 60A, 80A

9. REGISTRATION AND CONTROL OF CALIBRATION.

9.1. The results of the calibration process must be registered in the Control of
Calibration of welding machine. It should be kept track of time calibration, so no
equipment is used with their deadlines expired.

9.2. The equipment may only be labeled when they are approved.

10. ACCEPTANCE CRITERIA/ MEASUREMENT RANGE

10.1. The maximum permissible deviations/tolerance for calibration will be + / - 10%
on the Set point.
10.2. Measurements will be taken at regular intervals Min to Max scale

11. DOCUMENTS
1. Master instrument Calibration Certificate. (Sample)
2. Electric Welding machine Calibration Certificate. (Sample]

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QUALITY PROCEDURE Date: January 11, 2016
Revision No: 0
Prepared by: IDUSERI GEORGE
Approved by: NWABUDE ALEX
PROCEDURE FOR CALIBRATION OF A WELDING MACHINE

3. Engine Driven Welding machine Calibration Certificate. (Sample)

4. Electrode oven Calibration Certificate. (Sample)

KL

CONFIDENTIAL Not to be copied except by permission of Head of Operation