Calibration_Standards_Specification_19-1009.pdf

CALIBRATION STANDARD

SALIENT SPECIFICATION

DIAL INDICATOR CALIBRATOR

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

CSS 19-1009

DISTRIBUTION STATEMENT C. DISTRIBUTION AUTHORIZED TO U. S. GOVERNMENT AGENCIES AND THEIR

CONTRACTORS TO PROTECT PUBLICATIONS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR

OPERATIONAL PURPOSES ONLY. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO

MEASUREMENT SCIENCE DIRECTORATE, NAVAL SURFACE WARFARE CENTER, CORONA DIVISION, P.O.

BOX 5000, CORONA

A, CA, 91718-5000.

OCTOBER 2018

CALIBRATION STANDARD

SALIENT SPECIFICATION

DIAL INDICATOR CALIBRATOR

Prepared by:

Measurement Science MS33

Physical/Mechanical Standards (MS 33)

Measurement Science Department

Naval Surface Warfare Center, Corona Division

P.O. Box 5000

Corona, CA 91718-5000

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

DIAL INDICATOR CALIBRATOR CALIBRATION STANDARD SPECIFICATION CSS 19-1009

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Table of Contents

1.0 SCOPE

1.1 General

1.2 Usage

1.3 Classification

1.3.1 Class

1.3.2 Configuration

1.3.3 Color

1.4 Navy shipboard use

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents

2.2 Order of precedence

3.0 REQUIREMENTS

3.1 Equipment components

3.1.1 Equipment Configuration

3.1.1.1 Benchtop Instrument

3.1.2 Readout

3.1.3 System fittings and connectors: The

3.1.4 Finish

3.1.5 Interchangeability

3.2 Design and construction

3.2.1 Operator adjustments and controls

3.2.1.1 Operator adjustments

3.2.1.2 Operator controls

3.2.2 Wiring, internal

3.2.3 Warranty

3.2.4 Electrical power source

3.3 Environmental requirements

3.3.1 Warm-up

3.3.2 Temperature and humidity

3.3.2.1 Temperature operating

3.3.2.2 Humidity operating

3.4 Performance requirements

3.4.1 Range

3.4.2 Resolution

3.4.3 Flatness

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3.4.4 Measurement accuracy

3.4.5 Stem bushing

3.5 Maintainability

3.5.1 Fault isolation

3.5.2 Repair

3.6 Calibration

3.6.1 Calibration certificate

3.6.2 Calibration methodology

3.6.3 Calibration interval

3.6.4 Calibration procedure

3.6.5 Alignment

3.7 Technical manuals

3.7.1 Style and format, technical manuals

3.7.2 Content, technical manuals

3.7.2.1 Safety, technical manual section

3.7.2.2 General, technical manual section

3.7.2.3 Use and installation, technical manual section

3.7.2.4 Maintenance and servicing, technical manual section

3.7.2.4.1 Cleaning maintenance

3.7.2.4.2 Part replacement information

3.7.3 Symbols

3.8 Workmanship

3.9 Installation

3.10 Training

4.0 VERIFICATION

4.1 General

4.2 Technical Manual Review

4.3 Conformance inspections

4.3.1 Production inspection, Group A

4.3.1.1 Group A inspection and test

4.3.1.1.1 Preoperational inspection

4.3.1.1.2 Level A performance tests

4.3.2 Test plan

4.3.3 Failure criteria

4.3.4 Test conditions

4.3.5 Accuracy of test instruments

1.0 SCOPE

The purpose of this Calibration Standard Specification (CSS) is to provide the requirements necessary to replace the Navy’s current Calibration Equipment (NCE) Dial Indicator Calibrators, the 716 by L.S Starrett and 400B1 by Mahr Federal Inc.

1.1 General. This document specifies the minimum requirements for the dial indicator calibrator procurement. This equipment may be of a commercial design or modified commercial design. The Indicator Calibrator is intended to be used by Navy personnel in shipboard and shore-based calibration laboratories for calibration of a wide variety of indicators including dial, digital indicators (ASME B89.1.10M-2001 standard) comparators and electronic probes.

1.2 Usage. Equipment covered by this Calibration Standard Specification (CSS) is intended for use in calibrating indicators in the controlled environments.

This equipment requires to measure all type of indicators including test indicators, dial indicators, dial comparators, digital comparators and electronic probes. The requirements of this CSS are tailored to the intended use of the equipment. Specific requirements of MIL-PRF-28800F, as identified in this CSS, are invoked according to the class of equipment.

1.3 Classification. Test equipment specified herein is categorized by class, (requirements arising from the intended operational environment), as specified below in 1.3.1 Class through 1.3.3 Color. The class is assigned by the most severe environmental condition expected for the equipment.

1.3.1 Class. The Dial Indicator Calibrator shall be classified as Class 3 equipment and shall conform to Class 3 requirements in accordance with MIL-PRF- 28800, and as specified in this specification. Class 3 equipment is designed for operational environments where conditions are routinely encountered in a diverse, controlled climate.

1.3.2 Configuration. The Dial Indicator Calibrator shall at a minimum cover the range of 0 to 1 inch. The minimum length of the mounting shaft for the indicator calibrator stand in this configuration must be 6 inches or greater to allow mounting of 2 inches dial indicator.

1.3.3 Color. The color of the calibrator and the transit cases shall be the color normally provided by the manufacturer but shall not be green, magenta, or red.

1.4 Navy shipboard use. Mechanical test equipment furnished to the Navy that uses material restricted for Navy use (see 3.2.3.1 Material restricted for Navy use), or that exceeds the size limitations (see 3.6.1 Dimensions) of this specification, requires approval by the Navy prior to procurement.

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issues of these documents shall be those in effect on the date of this solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-28800F - Test Equipment for use with Electrical and Electronic Equipment, General Specification for

MIL-PRF-38793 Manuals, Technical: Calibration Procedures Preparation of.

(Copies of DoD specifications are available online at https://quicksearch.dla.mil/qsSearch.aspx/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

NIST Technical Note 1297 - Guidelines for Evaluating and Expressing the Uncertainty of NIST Measurement Results

Copies of NIST Technical Notes are available online at http://physics.nist.gov/Pubs/guidelines/TN1297/tn1297s or from the National Institute of Standards and Technology, Gaithersburg, MD 20899-0001

NAVY METROLOGY AND CALIBRATION PROGRAM

NAVAIR 17-35QAC-01B Navy and Marine Corps Calibration Laboratory Audit/Certification Manual

2.2 Order of precedence. In the event of conflict between the text of this CSS and the references cited herein, the text of this specification shall take precedence. Nothing in this CSS, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 Equipment components. Parts, materials, and process shall be as specified below in 3.1.1 Equipment Configuration through 3.1.5 Interchangeability.

3.1.1 Equipment Configuration. The Dial Indicator Calibrator shall consist of a Benchtop Instrument and a Readout (Digital Display). The Benchtop shall consist of a tester main unit (linear encoder with spindle), stem bushing, a http://physics.nist.gov/Pubs/guidelines/TN1297/tn1297s duct cover, a mounting shaft, adapters and other components required to generate and measure the indicators necessary to meet the performance requirements of this CSS. The Readout shall be clearly readable digital display and has Universal Serial Bus Specification (USB) interface. The system manufacturer must provide initial National Institute of Standards and Technology (NIST) traceable calibration for the unit.

3.1.1.1 Benchtop Instrument. The Dial Indicator calibrator shall be designed to facilitate quick and easy installation and removal of test instruments. The Test Section shall be designed to calibrate all dial indicators including lever type indicators. The length of a mounting shaft for the test stand shall be 6 inches or greater to allow mounting of 2 in. indicators. The stem bushing shall be of sufficient size to accommodate all the indicators contact points which is 0.375

in. normally.

3.1.2 Readout. The Readout shall be a large clearly readable LCD monochrome digital display and is selectable for either Inch or Metric unit. The readout shall have a digital interface in the form of a USB connection conforming to the USBs Revision 2.0 or higher, or equivalent RS232.

3.1.3 System fittings and connectors: The Dial Indicator calibrator as a system shall include all fittings and connectors required to connect the system together for measurement.

3.1.4 Finish. Unless otherwise specified the equipment shall be the finish normally provided by the manufacturer.

3.1.5 Interchangeability. A model number shall be designated for all units provided.

All units with the same model number and the replaceable assemblies, subassemblies, and parts comprising the unit shall be interchangeable on a noninterference basis.

3.2 Design and construction. The Dial Indicator Calibrator shall be designed and constructed to permit compliance with all applicable requirements, as defined in this CSS as well as the operation, performance, accuracy, and other requirements in this CSS.

3.2.1 Operator adjustments and controls. Operator adjustments and controls shall be as specified below in 3.2.1.1 Operator adjustments and 3.2.1.2 Operator controls.

3.2.1.1 Operator adjustments. The Dial Indicator Calibrator shall include adjustments or compensating methods for any function or parameter that would exceed the specified tolerance within the calibration interval defined in 3.6.3 Calibration interval. Under all specified service conditions the variation of any adjustment or control shall produce the desired control action to bring the system within tolerance.

3.2.1.2 Operator controls. Operating controls and indicators shall be readily accessible to the operator from the front of the equipment. The readings presented on the controls and indicators shall be available to the operator without conversion or calculation. All operator controls shall be clearly labeled.

3.2.2 Wiring, internal. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance and calibration.

3.2.3 Warranty. The Dial Indicator Calibrator shall have a minimum of a one year warranty after initial installation.

3.2.4 Electrical power source. The Dial Indicator Calibrator shall operate at nominal voltage of 120 Vrms, single-phase 50 Hz and 60 Hz source.

3.3 Environmental requirements. The Dial Indicator Calibrator environmental performance requirements shall be as specified below in 3.3.1 Warm-up through 3.3.2 Temperature and humidity. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.3.1 Warm-up. The Dial Indicator Calibrator shall comply with the specified performance requirements after a 30-minute warm-up period preceded by a maximum 12-hour non-operating temperature stabilization period.

3.3.2 Temperature and humidity. The temperature ranges and humidity limits for operating conditions shall be as specified below in 3.3.2.1 Temperature operating and 3.3.2.2 Humidity operating.

3.3.2.1 Temperature operating. The Dial Indicator Calibrator shall conform to the specified performance and accuracy while being operated at temperatures over the range of 63 °F to 73 °F.

3.3.2.2 Humidity operating. The Dial Indicator Calibrator shall conform to the specified performance and accuracy while being operated a humidity range of 20% RH to 45% RH.

3.4 Performance requirements.

3.4.1 Range. The Dial Indicator Calibrator shall be capable of measuring repeatability, linearity and hysteresis of dial indicators in the range of 0 to 1 in., using a precise linear encoder to eliminate the backlash.

3.4.2 Resolution. The Dial Indicator Calibrator as a complete system shall be capable of recording a measurement within 5 µin. resolution.

3.4.3 Flatness: The spindle of the dial indicator calibrator shall be capable of meeting accuracy of ±10 µin flatness requirement.

3.4.4 Measurement accuracy. The Dial Indicator Calibrator as a complete system, shall be capable of generating and measuring repeatability, linearity and hysteresis with total uncertainty, (Coverage factor of 2 IAW NIST Technical Note 1297), not to exceed ±12.5 µin.

3.4.5 Stem bushing. The Dial Indicator Calibrator as a complete system, shall come with a 0.375 in. (3/8”) bushing

3.5 Maintainability. Maintainability shall be as specified below in 3.5.1 Fault isolation through 3.5.2 Repair.

3.5.1 Fault isolation. The design of the equipment shall permit isolation of faults, and repair down to the component/subassembly item or lowest replaceable unit with the maintenance provisions furnished.

3.5.2 Repair. Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies and subsequent testing procedures to ensure the performance of the component or the repair action taken. Spare parts information shall be provided for all major components of the system.

3.6 Calibration. The Dial Indicator Calibrator shall meet the calibration requirements as specified below in 3.6.1 Calibration certificate through 3.6.5 Alignment. For the purpose of this CSS, calibration refers to the process of comparing a test instrument with a calibration standard to determine the indicated error at specified test points. Alignment refers to the process of characterizing and adjusting a test instrument to cause it to indicate within its specified accuracy limits.

3.6.1 Calibration certificate. The equipment provided under this CSS shall have a current calibration certificate, with a calibration data sheet, traceable to the National Institute of Standards and Technology (NIST).

3.6.2 Calibration methodology. The preferred calibration methodologies for the Indicator Calibrator shall be through a direct comparison method. The flatness of spindle of the Indicator Calibrator shall be compared with an optical flat by the interferometry. The linearity of the Indicator Calibrator shall be compared against gage blocks using gage block set and electronic height gage in both inward and outward directions. A minimum 1.5:1 test uncertainty ratio is necessary.

3.6.3 Calibration interval. The minimum interval between calibrations shall be 12 months. At the end of this interval, a minimum of 85 percent of the system parameters shall remain in tolerance.

3.6.4 Calibration procedure. The calibration support methodology for the system shall be provided in the system documentation. The information provided must be sufficient to allow development of a Navy calibration procedure in accordance with MIL-PRF-38793.

3.6.5 Alignment. Alignment is the process by which individual Indicator Calibrator and their measurement circuitry and displays are adjusted to ensure that the system parameters are within the requirements for the overall system measurement uncertainty. Alignment shall not require use of external devices other than commercially available calibration/measurement standards. The Indicator Calibrator shall be capable of alignment in place.

3.7 Technical manuals. Two copies of an operation and maintenance manual shall be provided with each unit. Technical manuals shall conform to the requirements specified in 3.7.1 Style and format, technical manuals through

3.7.3 Symbols. The technical manuals shall be provided in both printed and electronic format. The electronic copy shall be in a Portable Document Format (PDF) and Microsoft Word on a CD or DVD.

3.7.1 Style and format, technical manuals. All text shall be legible. A cover page shall include, equipment name and model number. A table of contents shall be provided.

3.7.2 Content, technical manuals. The contents of the technical manuals shall include sections addressing safety, general information, use and installation, maintenance and service. Drawings of the Dial Indicator Calibrator with sufficient detail to identify all controls and connections shall be supplied. The content of the sections shall conform to the description provided below in 3.7.2.1Safety, technical manual section through 3.7.2.4.2. Part replacement information.

3.7.2.1 Safety, technical manual section. The manual shall contain warnings, cautions and notes to prevent injury to personnel and damage to equipment.

The warnings shall contain safety precautions where hazards such as high voltage, high pressure, and high temperature may be present during installation, operation, or maintenance.

3.7.2.2 General, technical manual section. The manual shall contain the following:

purpose and functions, capabilities, performance characteristics, description (model number, dimensions, and weight), power information, and operational environment requirements.

3.7.2.3 Use and installation, technical manual section. This section shall contain information on the following: operating instructions (illustrations and explanations of the uses and functions of all controls and indicators), initial adjustments and control settings, startup procedures, required clearances, illustrations of equipment connections, and installation precautions.

3.7.2.4 Maintenance and servicing, technical manual section. The level of maintenance philosophy shall be unit operational verification, and component level. Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies on the systems. Testing procedures to ensure the performance of the component or the repair action taken shall be provided.

3.7.2.4.1 Cleaning maintenance. Cleaning information covering intervals, types of solvents, and materials used shall be listed in the maintenance and servicing section of the technical manual.

3.7.2.4.2 Part replacement information. Common commercial parts shall be identified by part number and description to facilitate substitutions of parts from other sources.

3.7.3 Symbols. All symbols used in the technical manual shall be standard or common to the trade. Where nonstandard symbols are used, explanations shall be provided.

3.8 Workmanship. The manufacture and assembly of the items covered by this CSS shall be representative of the best commercial practices and shall conform to the requirements of this CSS. All items will remain securely held in place during normal transit. Adequate protection will be afforded for the equipment on all sides to avoid transient damage.

3.9 Installation. The manufacturer will be responsible for installation of the Dial Indicator Calibrator. The manufacturer will be responsible for shipping of the Dial Indicator Calibrator to the receiving site. Any damage to the shipping container will be reported to the manufacturer when received by the Navy.

The Navy shall locate a delivered Dial Indicator Calibrator in the test area where it will be used. The Navy will uncrate the Dial Indicator Calibrator from its shipping container and position it as required. The manufacturer is responsible for all wiring and connections between the Dial Indicator Calibrator and Interface electronics, as well as all connections to power. The Navy will provide the required power, facility air pressure source, and ventilation in the test area. The Dial Indicator Calibrator must meet all CSS performance, functional and design requirements at the delivery site before the system is considered installed.

3.10 Training. After completion of the Dial Indicator Calibrator installation, on-site training shall be provided by the manufacturer. Training shall include instruction on how to operate, maintain, and calibrate the Dial Indicator Calibrator and shall include a) A complete review of all topics in the operating manual b) Instruction on the use of all software functions and menus. c) Calibration of the Dial Indicator Calibrator d) Instruction on required periodic maintenance. Only one training session will be required at each installation site.

4.0 VERIFICATION

4.1 General. All Dial Indicator Calibrator procured shall be capable of satisfying all of the requirements indicated in Section 3 of this CSS and shall be subjected to testing. Verification shall be accomplished by using the test procedures in MIL-PRF-28800 for Class 3 equipment for those tests identified and as modified in the following paragraphs.

4.2 Technical Manual Review. The Dial Indicator Calibrator Technical Manual(s) shall be reviewed and examined for compliance with the requirements specified in paragraph 3.7 Technical manuals of this CSS.

4.3 Conformance inspections. The test methods, procedures, and conditions specified in 4.3.1 Production inspection, Group A through 4.3.5 Accuracy of test instruments are required for conformance inspection.

4.3.1 Production inspection, Group A. Each unit shall be subjected to the Group A inspection and test of 4.3.1.1 to ensure qualitatively the proper functioning of the equipment, including all operating controls, and conformance with safety requirements.

4.3.1.1 Group A inspection and test. Group A inspection shall consist of the inspections of 4.3.1.1.1 Preoperational inspection through 4.3.1.1.2 Level A performance tests.

4.3.1.1.1 Preoperational inspection. The preoperational inspections shall consist of mechanical and visual examination and test to determine that all materials, workmanship, and safety characteristics comply with the specified requirements. The equipment shall be examined or tested to confirm that all electrical wiring is correct and that no mechanical problems are evident.

4.3.1.1.2 Level A performance tests. The Level A performance tests shall verify conformance of the system to the performance requirements of this CSS.

At a minimum the Level A performance tests shall include the following:

calibration of all required system parameters, flatness calibration demonstrations including optical flats, mounted mirrors, and short and long gage blocks.

4.3.2 Test plan. An equipment test plan shall be developed by the manufacturer.

The test plan must be reviewed and approved by the Navy prior to installation of the system. The test plan shall be used to verify conformance to the requirements of the contract and this specification.

4.3.3 Failure criteria. For the purposes of this CSS, equipment failure is defined as any departure from the required performance requirements or operation outside of the required accuracies (not correctable by normal use of the operating controls), or deviation from the criteria specified in 3.4 Performance requirements after the test is initiated. The item shall have failed the test when any of the conditions specified in a. through g. below occur:

a. Monitored functional parameters deviate beyond acceptable limits

b. Catastrophic or structural failure

c. Mechanical binding or loose parts, including screws, clamps, bolts, and nuts, that results in component failure or a hazard to personnel safety

d. Malfunction

e. Degradation of performance beyond limits established in the purchase description

f. Any additional deviations from acceptable criteria established before the test

g. Deterioration, corrosion, or change in tolerance limits of any internal or external parts that could in any manner prevent the test item from conforming to operational service or maintenance requirements

4.3.4 Test conditions. Unless otherwise specified the inspections specified herein shall be performed under the conditions of a. through d. Ambient conditions within the specified ranges need not be controlled. For equipment having a specified warm-up or stabilization period after turn-on, formal measurements and observations shall be made only after the specified time period as specified previously in 3.6.1 Warm-up.

a. Temperature: 63 °F to 73 °F

b. Humidity: 20% RH to 45% RH

c. Power: Nominal or alternate power source specified for the equipment

d. Attitude: Normal operating position

4.3.5 Accuracy of test instruments. The test instruments used to control or monitor the test parameters shall be verified to be within their calibration cycle prior to performing tests.