INDEX

SECTION TITLE PAGE

- REVISION RECORD 2

- INDEX 3

1.0 PURPOSE 4

2.0 SCOPE 4

3.0 DEFINITION 4

4.0 DIVERSION 4

5.0 RESPONSIBILITIES 4

6.0 CALIBRATION 5

7.0 REGISTRATION & CONTROL OF CALIBRATION 6

8.0 ACCEPTANCE CRITERIA 6

9.0 DOCUMENTS 6

’
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

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. 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.

5. RESPONSIBILITIES

5.1. Production Supervisor and / or Sr. Foreman responsible for :

5.1.1.Use only calibrated welding machines.
5.1.2.Advice the staff involved and apply the requirements of this procedure
5.1.3.Arrange and meet with the minimum premises and equipment calibration.
5.1.4.Notify the Quality Control prior to the date for the calibration of welding
machine.

5.2. The Section of the Quality / Welding Inspector responsible for

5.2.1.Notify the Technical Dept. prior to the date for the calibration of welding
machine.
5.2.2.Receive the welding machine calibration certificates from Technical Dept. and
inspect, the welding machine calibration certificate in acceptable criteria,
5.2.3.Calibration certificate to be stamped, sign and authorized to use the welding
machine.
5.2.4.Verify the validity of the calibration time.(As per Client requirement)
5.2.5.Affix labels on the welding machine indicating the calibration.
5.2.6.Maintain proper inventory and calibration records.

5.3. The Section of the Technical / Electrical responsibility for:

 5.3.1.Receive the notification for welding machine calibration.
5.3.2.Test the welding machine prior to calibration and certification.
5.3.3.Assigning competent technician to perform welding machine calibration.
5.3.4.Perform and calibrate the welding machine, utilizing calibrated master
instrument.(Calibration standards traceable to Internal standards)
5.3.5.Adjust and minimise the parameter deviation.
5.3.6.Verify the validity of the calibration time.(As per Client requirement)
5.3.7.Issue welding machine calibration certificate.
5.3.8.Issue labels to stick on the welding machine indicating the calibration.
5.3.9.Maintain proper inventory and calibration records.

6. CALIBRATION

6.1. Calibration and certification of welding machine.

6.2. Technical staff required for welding machine calibration.
6.2.1. Welding inspector.(Witness)
6.2.2. An Electrician.
6.2.3. Qualified Welder
6.2.4. Document controller

6.3. Materials required for welding machine Calibration

6.3.1. Welding PPE.
6.3.2. Welding Consumable.
6.3.3. Steel plate appropriate.
6.3.4. Accessory.
6.3.5. Master instrument. (Third party Calibrated certify and valid ( traceable to
internal standards) (properly  protected  from  damage  and  deterioration 
during handling, maintenance and storage)
6.3.6. Suitable and standard welding cables.
6.3.7. Suitable and standard welding cable connectors.
6.3.8. Suitable and standard welding earth clamp.
6.3.9. Suitable and standard welding electrode holder

6.4. Frequency of Calibration.

6.4.1. 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.
6.4.2. All Master instruments should be Calibrated and certify before use, and
thereafter every six months.

Note: This period can be set by the contractor (CLIENT) but not higher than
that specified above.

6.4.3. Welding machine Calibration Technique.

6.4.3.1. Welding Electrode cable clamp connect to the positive terminal of the
welding machine to be test and calibrate.
6.4.3.2. Welding ground cable clamp connector to the negative terminal of the
welding machine to be test and calibrate.
6.4.3.3. Energize the welding machine. ((ON)Electrically or (Start)Engine
driven)
 6.4.3.4. Test and record welding machine OCV (Open Circuit Voltage) and
verify with the welding machine name plate.
6.4.3.5. Set the welding parameter positioning liver in the desired
position.(Set point)
6.4.3.6. Engage with the volt – ammeter clamp the cable clamp electrode.
6.4.3.7. Carry out the reading of the clamp volt – ampere ammeter,
comparing it with the values shown on the recorder panel of the 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
Numbering is the same numbering allocated as indicated in the procedure
)

7. REGISTRATION AND CONTROL OF CALIBRATION.

7.1. 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.

7.2. The equipment may only be labelled when they are approved.

8. ACCEPTANCE CRITERIA

The maximum permissible deviations for calibration are: + / - 20% on the Set point.

Note: The maximum deviation is in accordance with the criteria established by Client.
Porum not exceeding the amount fixed by the Standard.

9. DOCUMENTS

1. Master instrument Calibration Certificate. (Sample)

2. Electric Welding machine Calibration Certificate. (Sample]

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

4. Electrode oven Calibration Certificate. (Sample)