Instruments basic training for iti,dme.

1. Instruments

2. Objectives of this training
 Awareness about instrument calibration
 Acceptance criteria
 Method used
 Standards / Master used
 Correct way of measurement
 Do and Do not for each instrument usage
 Correct instrument selection
 Knowledge of how to ensure instrument is
acceptable for use
 Grooming Inspectors for instrument Calibration

3. Calibration
Calibration- is the process to evaluate
relationship between unknown
values(Gauge) with known values(Master).
1/10th Rule-Master used for
calibration must be 10 times precise than
that instrument used in measurement.

4. Temperature for Calibration.
Internationally accepted
temperature for measurement is
20º and all instruments are
calibrated at this temp.
Temperature needs to be
maintain constantly because of
behavior of materials at
different temperature varies.

5. NABL
 National Accreditation Board
For Testing And Calibrating
Laboratories-This is body which
accredits testing and calibration
laboratories for their competence
to perform consistently and
accurately.

6. Least Count
It is least value measured by an instrument.
For Vernier-
L.C= Smallest division on main scale
No of division on vernier scale
=1/50 =0.02 mm
For Micrometer-
L.C=Smallest division on main scale
No of divisions on micrometer scale
=0.5/50=0.01 mm

7. Calibration Sticker
I – Type Of Instrument
II – Sr. No. Of Instrument
III – Location Of Instrument
X
(III)
XXX
(II)
XXX
(I)

8. Masters used for Calibration
 Slip Gauges Grade-0.
 Dial Calibrator.
 Digital Plunger Dial.
 Sine Bar.
 Electronic Level Meter.
 Surface Plate Grade 0.
 Wear Gauges.
 Lever Dial
 Digital Micrometer.

9. Instruments being calibrated In-house
 Vernier calipers
 Analog & Digital Micrometers
 Plunger & Lever Dials (L.C. 0.01mm)
 Bore Gauges (L.C. 0.01mm)
 Depth Micrometers
 Inside Micrometers
 Surface Plates
 Electronic Level Meters
 Height gauges
 Thread Plug Gauges up to M12
 Bevel Protractors
 Measuring Pins

10. Precaution to be taken during Instrument use
 Don’t apply additional pressure during measurement to
inside jaws & Outside jaws of verniers. It may Lead to
Out ness of Parallelism of jaws.
 Don’t apply extra pressure to Depth blade of vernier
caliper. It may lead to Bending of Blade.
 Don’t apply additional pressure to External / Internal
micrometers. It can Lead to have a zero error to
Instruments.
 Don’t apply additional pressure to Thread gauges. It
may lead to wear out of gauges where tolerances are
very tight.
 Don’t apply additional pressure to Plunger dial. It may
lead to damage of spring or variation in Repeatability of
Plunger dials.

11. Measurement Correction for Lever Dials

12. Thank You
Any Questions ?

13. Calibration of Vernier Caliper
Standard used- IS 3651
Master Used- Slip Gauges
 Features to be calibrated
 External Jaws : Linearity
Parallelism
 Internal Jaws : Linearity
Parallelism
 Depth Blade : Linearity

14. Linearity & Parallelism Measurement
Slip Gauge
Holder
Slip Gauge
Holder

15. Linearity Measurement for Depth Blade
Slip Gauge

16. External & Depth measurement :
1000
10
± 40
± 30
700
9
500
8
300
7 ± 40
± 30
200
6
150
5
100
4
50
3
30
2
± 20
± 10
10
1
For Depth Measurment
ForExt. Measurement
Ver
Dig
Digital Caliper
Observed Error (mm)
Permissible (m)
Nominal Value
of Slip Size
(mm)
Sr.
No.
Parallelity of External Jaws (Hold 10 mm Slip) :
 0.02 upto 300 mm range
 0.04 mm above 300 mm range
Parallelism
(mm)
Top of Jaw (mm)
Middle of Jaw (mm)
Bottom of Jaw (mm)
Permissible Error (mm)
Internal Jaws
 0.04 mm
 0.02 mm
10 mm
or ____ mm
Permissible Error in Measurement
Actual Error
in
Measurement
Permissible
Error in
Parallelism
Actual
Error in
Parallelism
Reading on
Bottom of
the Jaw
Reading
on Top of
the Jaw
Set Slip
Guage
Acceptance Criteria for Vernier Caliper

17. Calibration of Micrometers
Standard Used- IS-2967
Master Used- Slip Gauge
Features to be calibrated
 Zero Setting.
 Linearity.

18. Micrometer Check Set

19. Linearity calibration With Check Set

20. Micrometer Above 150 mm

21. Aceeptance limits for Micrometer
For Ext. Micrometer For Setting Rods
______
______
______
______
______
______
______
______
______
______
±0.002 upto 100
mm
±0.003 upto 300
mm
±0.005 upto 500
mm
±0.020 above
500 mm
_______
_______
_______
_______
_______
_______
_______
_______
_______
_______
________
________
________
________
________
________
________
________
________
________
5 microns for
upto 500 mm
range
2.5 _________
5.1 _________
7.7 _________
10.3 ________
12.9 _________
15.0 _________
17.6 _________
20.2 _________
22.8 _________
25.0 _________
ERROR
OBSVD.
(mm)
PERMISSIBLE
ERROR
(mm)
NOMINAL
ROD SIZE
(mm)
ERROR
OBSVD.
(mm)
PERMISSIBLE
ERROR
PARAMETERS
(mm)

22. Plunger And Lever Dials
Standard used-IS-2092 for Plunger Dials
IS- 11498 for Lever Dials
Master used- Dial Calibrator
Features to be calibrated-
 Determination of Accuracy.(Rotation)
 Clockwise.
 Anticlockwise.
 Repeatability
 Sensitivity

23. Dial Calibration With Dial Calibrator
Dial
Calibrator
Plunger
Dial
Dial
Calibrator
Lever
Dial

24. Acceptance Criteria for Lever Dials
ACLK
For :
0.1mm - 5m
1mm -30m
CLK
TURN 1
Errors in 
SPEC. RANGE
0
10
20
30
40
30
20
10
0
DIV OF DIAL
0.002
Sensitivity (mm)
0.003
Repeaibility (mm)
Acceptable
Observed Reading

25. Bore Gauge
 Master used- Dial Calibrator
 Features to be calibrated
 Accuracy

26. Bore Gauge Calibration
Dial
Calibrator
Bore Gauge

27. Acceptance Criteria fro Bore Gauge
Turn 2
Deviation
( )
1/10th
of Rev -5
1 Rev-10
2 Rev-15
Turn 1
Deviation
( )
Allow. Dev.
as per CAL/
50.70
90
80
70
60
50
40
30
20
10
0
Reading on
Calibrator
Div. of
Dial

28. Electronic Level Meter (Wyler)
 Basic Principle
The Measuring principle is based on a
changing of condenser built in two electrodes
and pendulum. The measured change of
capacity is directly influenced by change of
the inclination of the pendulum.This capacity
change is primarily used signal for angle to be
measured.
 Master Used – Sine Bar
 Feature to be measured
1. Angular Error

29. Schematic of Wyler

30. Zero Setting of Wyler
Sine Bar Wyler

31. Calibration Of Wyler
Wyler
Sine Bar
Slip Gauges

32. Acceptance Criteria for Wyler
15 /1000 mm.
Perpendicularity of Vertical Face
 2
 2
 2
 2
 4
 8
Inclination  per 200 mm
25
50
75
100
500
1500
For Measuring and Reference Unit
2
2
2
2
2
4
8
Inclination  per 200 mm
25
50
75
100
500
1500
For Measuring Unit
1
Observed Error () in 200mm.
Allowable Deviation in  per
200 mm.
Height Difference between
slips (m )
Sr. No.
Measuring accuracy for different value of inclination :

33. Surface Plates
 Standard Used- IS-7327
 Master Used- Electronic Level
Meter (Wyler)
 Features to be calibrated
 Flatness

34. Surface Plate Calibration

35. Inside Micrometer
Standard used- IS-2966
Master used- Slip Gauge
Digital Micrometer
Digital Dial
Features to be checked:
 Zero Setting.
 Linearity

36. Zero Error & Linearity check
for Inside Micrometer Head
Inside
Micrometer
Head
Digital Micrometer

37. Linearity Check For Extension Rod
Inside Mic. With
Extn. Rod
Slip gauge

38. Acceptance Criteria for Inside
Micrometer Extension
11
10
9
8
7
6
50
Above 600
5
25
450-600
4
20
300-450
3
15
150-300
2
10
25-150
1
Error (micron)
Size
(mm)
Error
(micron)
Nominal
Permissible Error
Size of Extension rod + Micrometer Head
Size of Extension Rod
Sr.
No.

39. Depth Micrometer
 Standard used- IS 2967
 Master used- Slip Gauges Grade 0
Features to be checked:
 Zero Setting
 Linearity

40. Zero Setting Linearity Check

41. Acceptance Criteria For Depth Micrometer
Set Value(mm) Error (mm)
Size (mm) Permissible
Error
0 – 25 5 Microns
25 – 300 10 Microns
I. Depth Bar 1
i. Smallest Size of Depth Bar +2.5
ii. Smallest Size +10.3
iii. Smallest Size +17.6
iv. Smallest Size +25
_____________
_____________
_____________
_____________
___________
___________
___________
___________
I. Depth Bar 2
II. Depth Bar 3
III. Depth Bar 4
IV. Depth Bar 5
V. Depth Bar 6
VI. Depth Bar 7
VII. Depth Bar 8
VIII. Depth Bar 9
IX. Depth Bar 10
X. Depth Bar 11
XI. Depth Bar 12
25
50
75
100
125
150
175
200
225
250
275
300
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________

42. Height Gauge
Standard used- IS 2921
Master used- Slip Gauges Grade 0
Granite Square
Features to be checked:
 Perpendicularity
 Linearity

43. Linearity check with Slip gauge

44. Perpendicularity Checking
Height
Gauge
Granite Square Block
Lever Dial

45. Acceptance Criteria for Height Gauge
Perpendicularity of Measuring Head & Measuring Head Slides with Base :
20
900
Observed error
()
Permissible error
( )
Measuring Range
(mm)
Error in Measurement of Height :
800
700
500
300
200
100
10
0
Observed Error ()
Permissible Error ()
Set Height (mm)

46. Measuring Pins/ Cylindrical pins
 Master Used- Plunger dial 0.0005mm
 Features to be checked
 Diameter of Pin
 Cylindericity of pins

47. Zero Setting Actual measurement
0.5 micron
Dial gauge

48. Bevel Protractor
 Standard used- IS-4239
 Master used- Sine Bar
Plunger Dial
Slip Gauge
 Features to be checked-
 Zero Setting
 Angle Measurement

49. Zero Setting

50. Angle Measurement
Slip gauge
Bevel
protector
Sine Bar

51. Acceptance Criteria for Bevel protractor
00/1800
---
4020’
15.11
8035’
29.85
14030’
50.08
17025’
59.86
23035’
80
 5 min.
300
100
Observed
Deviation
[B - A]
Allowable
Deviation
Angle Measured
(deg)
[B]
Angle Reqd.
(deg.)
[A]
Slip Gauge Size
(mm)
Measuring Accuracy
2
Refer Table in
W.I :
CAL/50.60
Straightness/Flatness of Blade & Stock
1
Observed
Deviation
Allowable
Deviation
Measurement Accuracies
Sr.
No.

52. Thread Plug Gauge
 Master used- Plug Wear Gauge
 Features to Be Checked-
No.of Threads entered

53. Wear Ring Gauges

54. (I) TYPE OF INSTRUMENTS :
Coating Thickness Gauge
CTG
Clamp Meter
CLM
Megger
MGR
Digital Multi Meter
DMM
Vernier Calliper
VRC
Vernier Height Gauge
VHG
Ultrasonic Thickness Gauge
UTG
Ultrasonic Flaw Detector
UFD
Try Square Precision
TSP
Thermometer
THM
Tachometer
TCM
Span Gauge Micrometer
SPN
Sine Bar
SNB
Slip Gauge Block
SGB
Surface Table
SFT
Plunger Dial Indicator
PDI
Outside Micrometer
OMM
Micrometer Depth Gauge
MDG
Linear Height Gauge
LHG
Lever Dial Indicator
LDI
Inside Micrometer
IMM
Gear Tooth Calliper
GTC
Digital Vernier Calliper
DVC
Dial Thickness Gauge
DTC
Digital Electronic Level
DEL
Dial Calibration Tester
DCT
Dial Bore Gauge
DBG
Bevel Protractor
BVP
Ball Micrometer
BMM
Angle Gauge Block
AGB
Type of Instrument
Character Code for Instrument
(III) LOCATION OF INSTRUMENTS :
Design
D
Raw Material Stores
R
Electrical
E
Assembly
A
Maintenance
M
Tool Crib 19
C
Tool Crib 09
T
Inspection
I
Location
Character Code