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QUALITY SYSTEM WORK INSTRUCTION

INSTRUMENT PERFORMANCE CHECK AND CORRECTIVE CALIBRATION FOR FERITSCOPE MP-30 1.0 OBJECTIVE

Page 2 of 5 Doc. No. 7.6 W05 Rev. 0 Date: 14 June 2006

This work instruction is established to ensure that the Feritscope MP-30 is operating properly and still calibrated correctly in order to take corrective measures if necessary.

2.0

SCOPE This work instruction applies to Feritscope MP-30 in the need to confirm and calibrate the said instrument for qualification and verification purposes.

3.0

DEFINITIONS/ABBREVIATIONS 3.1 Corrective Calibration adjustment and calibration of the instrument using a Base and three (3) Calibration standards.

3.2

Normalization adjustment of the instrument to a new zero value, recommended to ensure stability of measurements especially when measuring a wide range of ferrite content values. Reference Sample object with a known ferrite content in a defined reference area that can be used to check/ monitor the test equipment. Ferrite content is determined using a reliable and properly calibrated instrument and is used as a pre-production check item so as to prevent the base and calibration standards from significant wear and tear. Average or mean the value obtained according to the equation below, as configured in a block. Ave = Fe1 + Fe2 + .FeN / N where: Fei, single reading N, number of single readings evaluated

3.3

3.4

3.5

Sigma or Standard Deviation, s the measure of the deviations of single measurements of a measurement series from their common mean value. A low sigma value usually denotes a more stable the measurement.

QUALITY SYSTEM WORK INSTRUCTION


INSTRUMENT PERFORMANCE CHECK AND CORRECTIVE CALIBRATION FOR FERITSCOPE MP-30 4.0 EQUIPMENT/TOOLS 4.1 4.2 4.3 4.4 Ferritscope MP-30 Reference Samples (Weld and Base Metal) Probe Base and Calibration standards

Page 3 of 5 Doc. No. 7.6 W05 Rev. 0 Date: 14 June 2006

5.0

REFERENCE DOCUMENTS 5.1 5.2 5.3 ISO 9001:2000 Standard clause 8.2.4 Monitoring and Measurement of Product Fischer Ferritscope MP-30 Manual ANSI/ AWS A4.2M (latest edition), Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic and Duplex FerriticAustenitic Stainless Steel Weld Metal Ferrite Test for GCT Goro Nickel Project (80051001-8.2.4 W11)

5.4

6.0

RESPONSIBILITY 6.1 The QC Inspector shall be responsible in taking good care of the instrument. He/ she shall monitor and handle instrument performance check and calibration.

7.0

WORK INSTRUCTIONS 7.1 Confirmation of Measurement Accuracy through Calibration Blocks 7.1.1 7.1.2 Refer initially to the Ferritscope MP-30 Operation. Measure all available calibration blocks at two (2) blocks setting, corresponding to ten (10) times repetition. Obtain mean value for all the calibration blocks measured and record for further evaluation. Evaluate the mean measurements in accordance with Table 4 ANSI/AWS A 4.2M (latest edition).
Ferrite Number Range
0 to 5 FN over 5 to 10 FN over 10 to 15 FN over 15 to 25 FN over 25 to 50 FN over 50 to 90 FN

7.1.3

7.1.4

Maximum Allowable Deviation


0.30 0.30 0.40 0.50 5% of assigned FN 8% of assigned FN

QUALITY SYSTEM WORK INSTRUCTION


INSTRUMENT PERFORMANCE CHECK AND CORRECTIVE CALIBRATION FOR FERITSCOPE MP-30 7.1.5

Page 4 of 5 Doc. No. 7.6 W05 Rev. 0 Date: 14 June 2006

For measurement results falling outside the specifications, perform remeasurement. If the results are still out of specifications, proceed to item B or Corrective Calibration. On the other hand, for measurement results falling within the specifications make a summary report indicating the actual measured values (Attachment A).

7.2

Corrective Calibration (Three-point Calibration) 7.2.1 Select three (3) blocks that can be set to the instrument as low, mid and high FN or FE-% ranges. Refer to the applicable project specifications to establish the most suitable range for the application to be made. Open the Calibration Setting by pressing the CAL key. Measure at the Base (Normalization). Perform ten (10) times measurement until s or the standard deviation is 1 or lower. Measure the first calibration block chosen for Low FN/ FE-% range. Repeat the measurements until the mean value is stable (refer to the rated value of the block). If the mean value is equal to the rated value of the first block, press the ENTER key to confirm and save the calibration. Otherwise, use the UP and DN keys to input the rated value of the block. Pressing the ENTER key confirms and saves the adjustment made. The instrument is now ready for the next point or calibration level. Repeat item 7.2.4 for the middle and high FN/ FE-% ranges. Upon finishing, the instrument is considered as calibrated and shall undergo re-confirmation based on item 7.1. After confirming and verifying that the instrument is producing accurate results, make a report based on the activity performed (Attachment A).

7.2.2 7.2.3

7.2.4

7.2.5

7.2.6

7.3

Pre-Production Ferrite Content Check This procedure is done prior to production measurements to ensure instrument measurement accuracy in between calibration periods. Reference samples are used during the check with FN values obtained statistically through repetitive measurements from a newly calibrated instrument in accordance with this work instruction. 7.3.1 After switching the instrument on, measure all the Reference Samples with varying FN ranges at two (2) blocks setting, for ten (10) times repetition. Evaluate the mean data of the measurements performed to the specifications of the corresponding reference sample. All measured values should fall within the specifications otherwise, perform re-measurement to the affected sample. Record the data to be included in the ferrite test report representing the actual item to be tested.

7.3.2

7.3.3

QUALITY SYSTEM WORK INSTRUCTION


INSTRUMENT PERFORMANCE CHECK AND CORRECTIVE CALIBRATION FOR FERITSCOPE MP-30 8.0 NOTES 8.1 8.2

Page 5 of 5 Doc. No. 7.6 W05 Rev. 0 Date: 14 June 2006

Calibration shall be maintained/ performed every six (6) months or if there is a need to verify or qualify the instrument. Calibration (corrective) is NOT necessary if at the confirmation stage, the instrument is verified to be giving accurate measurement results based on Table 4 of AWS A 4.2M (latest revision), refer to item 7.1.4.

9.0

ATTACHMENT 9.1 Attachment A In-House Calibration/ Confirmation Report

Attachment A

IN-HOUSE CALIBRATION RECORD


Date: Probe: Instrument: Serial No.: Traceability: Reference: 27-Mar-06 EGAB 1.3-FE Helmut Fischer Feritscope MP30 055-21878A IIW Certificate No. 7238 ANSI/ AWS A4.2M-97 Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic and Duplex Ferritic -Austenitic Stainless Steel Weld Metal

Calibration Method: The Feritscope was checked and calibrated in accordance with the recommended procedures of AWS A4.2 and Helmut-Fischer using Reference Blocks with varying FN ranges traceable to IIW. Results: Confirmation Check (Refer to Graph 1, see attached)
Stds. No. %Fe-WRC 0,3/80 %Fe-WRC 0,3/80 %Fe-WRC 1,5/30 %Fe-WRC 0,3/80 %Fe-WRC 1,5/30 %Fe-WRC 0,3/80 %Fe-WRC 1,5/30 %Fe-WRC 0,3/80 Reference value, FN Measured FN 0.47 2.39 2.45 13.32 13.71 34.69 34.90 96.41 Max. deviation* LL 0.21 2.00 2.12 12.60 13.00 32.78 33.06 88.69 UL 0.81 2.60 2.72 13.40 13.80 36.23 36.54 104.11 Judgment by AWS A4.2 Pass Pass Pass Pass Pass Pass Pass Pass

0.51 2.3 2.42 13 13.4 34.5 34.8 96.4

Remarks: 1. Calibration (Corrective) was not performed since the instrument passed Confirmation Check based on the criteria set in Table 4 of AWS A4.2M-97. 2. *Deviation Limits as per AWS A4.2M, Table 4. 3. This instrument was confirmed and/ or calibrated in accordance with AWS A4.2M-97, for production measurements in Delta-Ferrite Content of Austenitic and Duplex Stainless Steels. 4. FN = Ferrite Number

Calibration Due: Performed by:

26-Jun-06 Checked by:

QC Inspector

QC Supervisor

Approved by:

QA/ QC Manager