Metrology and Calibration (METCAL) Overview

Transcription

WARFARE CENTERS
CORONA
WARFARE CENTERS
CORONA
Metrology and Calibration (METCAL)
Overview
NAVAL SURFACE WARFARE CENTER, CORONA DIVISION
MEASUREMENT SCIENCE DEPARTMENT
Bob Fritzsche (MS 20)
951.273.5244
[email protected]
1
Keeping America’s Navy #1 in the World
1
Measurement
WARFARE CENTERS
CORONA
“When you can measure what you are speaking about
and express it in numbers, you know something about
it; and when you cannot measure it, you cannot express
it in numbers, your knowledge is of a meager and
unsatisfactory kind. It may be the beginning of
knowledge, but you are scarcely in your thought
advanced to the stage of a science.”
Lord Kelvin
You don’t know anything about
anything unless you can measure it.
2
Overview
WARFARE CENTERS
CORONA
• NSWC Corona Background
• Why Calibrate?
• Metrology and Calibration Program
• Measurement Reliability
• Measurement-Related Standards
• Conclusion
3
NSWC Corona Mission
WARFARE CENTERS
CORONA
To serve as the Navy’s independent assessment agent
throughout the lifecycle:
"To gauge the warfighting capability of ships
and aircraft, from unit to battlegroup level, by
assessing the suitability of design, the performance
of equipment and weapons, and the adequacy of
training."
Ref: OPNAVNOTE 5450
4
Navy Organization
WARFARE
WARFARECENTERS
CENTERS
CORONA
CORONA
MISSION
Secretary
Secretary of
of the
the
Navy
Navy
Operate the Navy's full
spectrum research,
development, test and
evaluation, engineering
and fleet support Center
for ship hull, mechanical
and electrical systems,
surface ship combat
systems, coastal warfare
systems, and other
offensive and defensive
systems associated with
surface warfare.
Chief
Chief of
of
Naval
Operations
Naval Operations
Naval
Naval Sea
Sea
Systems
Command
Systems Command
Naval
Naval Surface
Surface
Warfare
Warfare Center
Center
Reference:
OPNAVNOTE 5450 Ser 09B22/1U510577 of 23
Dec 1991
SHIPS AND
SHIP SYSTEMS
SURFACE SHIP COMBAT SYSTEMS
Carderock
Division
Dahlgren
Division
NAVSSES,
NAVSSES
NAVSSES,,
Philadelphia
Philadelphia
CSS,
CSS, Panama
Panama
City
City
CDSA,
CDSA, Dam
Dam
Neck
Neck
Commandant
Commandant of
of
the
Marine
Corps
the Marine Corps
Crane
Division
Pt.
Pt. Hueneme
Division
Det.,
Det., Louisville
Louisville
Det.,
Det., Virginia
Virginia
Beach
Keeping America’s Navy #1 inBeach
the World
ORDNANCE
ASSESSMENT
Indian Head
Division
Corona
Division
NAVSSES,
NAVSSES,
Seal
Seal Beach
Beach
Philadelphia
Philadelphia
Det.
Det.
5
NSWC Corona Division
WARFARE CENTERS
CORONA
Commanding
Commanding Officer
Officer
CAPT
CAPT RR.. Shafer
Shafer
Technical
Technical Director
Director
Vacant
Vacant
Deputy
Deputy Technical
Technical Director
Director
JJ.. Stone
(
Act)
)
Act
Stone (Act)
Measurement
Measurement
Science
Science
A.
A. Hovakemian
Hovakemian
Product
Product Engineering
Engineering
Assessment
Assessment
DD.. Sugg
Sugg
Performance
Performance
Assessment
Assessment
DD.. Bergstrom
Bergstrom
Quality
Quality
Assessment
Assessment
Force
Force Training
Training
Assessment
Assessment
DD.. Costlow
Costlow
M
Act)
Act)
M.. Gammon
Gammon ((Act)
Command
Command
JJ.. Cardany
Cardany
Readiness
Readiness
Assessment
Assessment
JJ.. Watson
Watson
6
Measurement Science
WARFARE CENTERS
CORONA
Measurement Science Department
Arman Hovakemian
MS00
Measurement
Requirements Assessment
Ken Felix
MS10
Air Programs
MS11
A. Fritzsche
FMS Programs
MS12
I. Garcia
Ground Programs
MS13
L. Poling
Requirements Analysis
MS14
M. Doerr
METCAL In-Service
Assessment
Bob Fritzsche
MS20
METCAL Systems
MS21
R. Greenhalge
Metrology Engineering
Assessment
Vacant
MS30
L. Rice
Fleet METCAL In-Service
MS23
R. Zaja
MS31
S. Buckman
Microwave/
Electro-Optics
MS32
Ed Trovato
Physical/Mechanical
MS33
SSP METCAL In-Service
MS24
John Griffith
MS40
DC/Low Frequency
NAVSEA METCAL
In-Service
MS22
Advanced
Measurement Systems
R. Figuerres
B. Heglar
R&D Coordinator
MS40A
J. Walden
CBNR Warfare
Systems Metrology
MS41
M. Bishop
Advanced Automated
Calibration
MS42
R. Schumacher
Sensors and Special
Projects
MS43
A. Luh
Analytical Metrology
MS25
J. Davis
7
Definitions
WARFARE CENTERS
CORONA
Metrology:
The Science of Measurement
Calibration:
VIM: Set of operations that establish, under specified
conditions, the relationship between values of quantities
indicated by a measuring instrument or measuring
system, or values represented by a material measure or
a reference material, and the corresponding values
realized by standards.
Navy: Calibration is the comparison of a measurement
system or device of unverified accuracy, to a
measurement system or device of known or greater
accuracy, to detect and correct any variation from
required performance specifications.
8
Measurement Possibilities
WARFARE CENTERS
GO
AL
CORONA
Not Precise/
Precise /
Precise /
Not Accurate
Not Accurate
Accurate
9
Why Calibrate?
WARFARE CENTERS
CORONA
• Ensure the readiness of test equipment to perform accurate
measurements and provide valid data
• Limit the number of erroneous test decisions
• Maintain overall measurement integrity and traceability
10
Why Calibrate? – Data Integrity
WARFARE CENTERS
CORONA
• How do we know the data is good?
–
–
–
–
Accurate? Precise? Stable?
Can you trust the person collecting the data?
Can you trust the measurement instrument?
What proof do you have that the numbers reflect reality?
• Can you trust the decision you are about to
make using the collected data?
• What is the cost if you are wrong?
In Tolerance
Out of Tolerance
Difference?
11
Uniform Measurement Accuracies
WARFARE CENTERS
CORONA
12
NSWC Corona – METCAL Role
WARFARE CENTERS
CORONA
NSWC Corona serves as the
Scientific and Technical Agent for the
Navy Metrology and Calibration (METCAL) Program
per
OPNAVINST 3960.16A, Navy Test and Monitoring Systems (TAMS)
and
NAVAIRINST 13640.1B
NAVSEAINST 4734.1B
SSPINST 4355.8B
MARCOR ORDER 4733.1B
13
Navy Calibration Program
WARFARE CENTERS
CORONA
METCAL
Executive Director
TAMS Executive Board
NAVSEA
TMDE
SISCAL
NAVAIR
SSP
USMC
METCAL
NPSL
Shore Calibration Laboratories
Afloat Calibration Laboratories
14
METCAL Processes and Products
WARFARE CENTERS
CORONA
Navy METCAL Program
NIST
METCAL
Technical Agent
Acquisition Support
Acquisition
• Cal Rqmts Analysis
• Cal Logistics
NPSL
In-Service
Test Equipment
Navy Cal Lab
Engineering
• Procedures
• Intervals
• Standards
• Training
• Database Mgmt
• Traceability
• Technical Support
R&D
Maintenance
• Standards
(State-of-the-art)
Mission
Ensure that TMDE used to make measurements on Navy Systems is accurate and traceable to
National Standards to reduce or eliminate the safety and cost impacts of wrong test decisions.
15
METCAL Products and Services
WARFARE CENTERS
CORONA
Metrology Engineering
Products and Services
16
METCAL Program Scope
WARFARE CENTERS
CORONA
Test Equipment
Different Models:
~ 140K
Models:
140K
Different S/
~ 1,850K
S/N:
1,850K
Approved
Calibration Standards
(Different Model #s)
~ 1.85M
~5,000
Approved Calibration
Procedures
Annual Engineering
Inquiries/Actions
Annual Calibrations
~800K
Calibration Laboratories
Shore 165
Ship 244
~5,000
~2,000
409
17
Measurement Traceability
WARFARE CENTERS
CORONA
Weapon System
(F/A-18)
National Institute of
Standards & Technology
Support Equipment
Custodians
Navy Primary
Standards Lab
Fleet “I” Level
Calibration Labs
Depot “D” Level
Calibration Labs
18
METCAL Acquisition Life Cycle
WARFARE CENTERS
CORONA
A
B
Concept & Technology
Development
• Metrology
Guidance/
Consideration
C
System Development
& Demonstration
• Requirements
Analyses
• Verify
Contractor
Traceability
• ILSMT
• International/
National
Measurement
Technology
Assessment
• LSA
• Technology
Validation
• Logistics
Document
Reviews
• CMRS
Development
• CMRS
Guidance
• CSP
Development
• TEMP Inputs
• Metrology
R&D
• Evaluation
Criteria
• SERD
• CMRS Review,
Approval
• Calibration Support
Plan Approval
• Cal Standard Design,
Develop,
Procurement
• Evaluation Criteria
• Cal Procedure
Development,
Approval
(Contractor, DoD)
IOC
Production & Deployment
• Contractor’s
Calibration
System
Evaluation
(Follow-on)
• Calibration Std
ILS
• Deploy
Calibration
Support
FOC
Operational Support
• TMDE Calibration
• Feedback
Responses
• Technical/Engrg/
Training Assists
• Interval
Reliability
Analysis
• Measure
Process
Control
• Joint Service
Support
• Modification/Rqmt
Planning
• Establish Cal
Support Level
• Tech, Mgt, Pol. Docs
• Facility (Incl Environ)
Requirements
• Training
Requirements
• Manpower, Workload
Requirements
• Interval Analyses
19
Calibration Logistics Lifecycle
WARFARE CENTERS
CORONA
Maintenance
Maintenance
Requirement
Requirement
Identified
Identified
• Testing
• Preventive
Maintenance
• Inspection
• Repair
TMDE
TMDE
Requirement
Requirement
Identified
Identified
• Assist in identifying
TMDE to support:
– Testing
– Preventive
Maintenance
– Inspection
– Repair
• Begin developing
calibration support
requirements
Calibration
Calibration
Requirements
Requirements
Analysis
Analysis
• Determine if current
calibration support is in
place
• If not, determine proper
calibration support for
application
• Identify R&D rqmts
• Maintain calibration
support
• Identify replacement /
replenishment for
obsolete TMDE and
Standards
• Technical Support
• Retire support
Initial
Initial
Calibration
Calibration
Support
Support
Calibration
Calibration
Support
Support
Sustainment
Sustainment
20
Navy Metrology R&D Program
WARFARE CENTERS
CORONA
Provide Advanced Measurement Technology for Emerging Weapons Systems /
Improve Effectiveness and Efficiency of Existing Measurement Systems
NAVY / MARINE CORPS
• Electrical
SEA
AIR
LAND
SPACE
TECHNOLOGY AREAS
• Physical/Mechanical
Calibration
Standards
&
Traceability
• Electro-Optic
• mm/Microwave
• Analytic Metrology
• Radiation
• Chemical/Biological
Defense
21
Joint Service Metrology
WARFARE CENTERS
CORONA
Joint Chiefs – Joint Logistics Commanders
OFFICES
OFFICESOF
OF PRIMARY
PRIMARYRESPONSIBILITY
RESPONSIBILITY
(OPRs)
(OPRs)
JOINT
JOINTTECHNICAL
TECHNICAL COORDINATING
COORDINATINGGROUP
GROUPon
onCALIBRATION
CALIBRATIONAND
ANDMEASUREMENT
MEASUREMENT TECHNOLOGY
TECHNOLOGY
(JTCG-CMT)
(JTCG-CMT)
TMDE
TMDEPROGRAM
PROGRAM
STANDARDS
STANDARDS
GROUP
GROUP
CALIBRATION
CALIBRATION
COORDINATION
COORDINATION
GROUP
GROUP(CCG)
(CCG)
STANDARDS
STANDARDSLAB
LAB
OPERATIONS
OPERATIONS
WORKING
WORKINGGROUP
GROUP
ANALYTICAL
ANALYTICAL
METROLOGY
METROLOGYSUBGROUP
SUBGROUP
ENGINEERING
ENGINEERING
WORKING
WORKING
GROUP
GROUP
ELECTRICAL
ELECTRICAL//ELECTRONIC
ELECTRONIC
SUBGROUP
SUBGROUP
CHEMICAL
CHEMICAL//BIOLOGICAL
BIOLOGICAL
SUBGROUP
SUBGROUP
INTERSERVICE
INTERSERVICE
SUPPORT
SUPPORT
GROUP
GROUP(IS)
(IS)
CALIBRATION
CALIBRATION
PROCEDURES
PROCEDURES
GROUP
GROUP
CHEM/BIO
CHEM/BIO
SUPPORT
SUPPORT
WORKING
WORKINGGROUP
GROUP
AUTOMATED
AUTOMATED
PROCESSES
PROCESSES
WORKING
WORKINGGROUP
GROUP
RF
RF//MICRO
MICRO//MM-WAVE
MM-WAVE
SUBGROUP
SUBGROUP
PHYSICAL
PHYSICAL//MECHANICAL
MECHANICAL
SUBGROUP
SUBGROUP
ELECTRO-OPTIC
ELECTRO-OPTIC
SUBGROUP
SUBGROUP
RADIOLOGICAL
RADIOLOGICAL
SUBGROUP
SUBGROUP
17 Jan22
2008
Industry/Professional Involvement
WARFARE CENTERS
CORONA
Represents the Navy in the Measurement Science Field
National Conference of
NATIONAL DEFENSE INDUSTRIAL ASSOCIATION
International
National
Standards Laboratories
International
DoD
Navy
METCAL
JTCG-CMT
Joint Technical Coordinating Group
Calibration and Measurement Technology
ASME
23
False Accept/False Reject
WARFARE CENTERS
CORONA
24
Calibration Testing
WARFARE CENTERS
CORONA
Calibration Tests
Test Instrument
Test Steps
ICP
• A Test Instrument is considered In Tolerance if it passes all
the steps of an Instrument Calibration Procedure (ICP)
25
True In-Tolerance
WARFARE CENTERS
CORONA
A Unit Under Test (UUT) is truly in tolerance if:
Lower Tolerance Limit < UUT Bias < Upper Tolerance Limit
UUT Bias
(True)
Lower Tolerance Limit (-L)
0
Upper Tolerance Limit (L)
The UUT Bias is unknown
26
True Out Of Tolerance
WARFARE CENTERS
CORONA
A Unit Under Test (UUT) is truly out of tolerance if:
UUT Bias < Lower Tolerance Limit
UUT Bias > Upper Tolerance Limit
or
UUT Bias
(True)
0
The UUT Bias is unknown
27
Observed In Tolerance
WARFARE CENTERS
CORONA
A Unit Under Test (UUT) is observed in tolerance if:
Lower Tolerance Limit < Deviation < Upper Tolerance Limit
Deviation
(Observed)
0
The Deviation is the observed difference between the UUT and the CAL
28
False Accept
WARFARE CENTERS
CORONA
Deviation
(Observed)
Calibration
System Error
UUT Bias
(True)
Acceptance
-L
0
L
False Accept (FA):
• The Deviation is observed in tolerance [ -L < Deviation < L ]
• The UUT Bias is out of tolerance [ Bias > L or Bias < -L ]
• The decision to accept the UUT is incorrect
29
Measurement Reliability
WARFARE CENTERS
CORONA
•• Measurement
MeasurementReliability
Reliabilityisisthe
theprobability
probabilityof
ofbeing
beinginintolerance
tolerance(the
(the
probability
probabilityall
allthe
thecalibration
calibrationprocedure
proceduresteps
stepspass).
pass).
•• Measurement
Reliabilitydecreases
decreaseswith
withtime
timeafter
aftercalibration
calibration(which
(whichisis
why
whywe
wecalibrate
calibrateperiodically).
periodically).
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
0
6
12
18
24
30
36
Time Since Calibration (Months)
30
WARFARE CENTERS
Calibration Intervals
And Test Decisions
CORONA
• Good test decisions:
–
Detect bad items and repair or replace them
–
Verify good items and return them to the Fleet
• Good test decisions require accurate test equipment
• Accuracy in test equipment is maintained by periodic
calibration
–
TMDE accuracy, or measurement uncertainty degrades with time
–
TMDE “Out of Tolerance” (OOT) not obvious to user - insidious error
–
TMDE OOT can only be determined by calibration
–
Periodic calibration keeps measurement uncertainty at acceptable levels
• Accurate calibration intervals keep false accept risk
(acceptance of bad test equipment) low
31
Calibration Intervals
WARFARE CENTERS
CORONA
•• To
Toobtain
obtainaaCalibration
CalibrationInterval,
Interval,you
youneed:
need:
–– AAMeasurement
ReliabilityCurve
Curve(Estimated
(Estimatedusing
usingCalibration
CalibrationResults)
Results)
–– AAMeasurement
ReliabilityTarget
Target
100 %
vs. Calibration Interval
90 %
80 %
70 %
60 %
50 %
40 %
30 %
20 %
10 %
0%
0
6
12
18
24
30
36
42
48
Calibration Interval (Months)
32
ISO 9001 – Calibration Requirements
WARFARE CENTERS
CORONA
7.6 Control of monitoring and measuring devices
• Requires organization to assess/understand
measurement needs
• Requires that measuring equipment
– be accurate to ensure product conformity to specification
– be calibrated or verified at specified intervals, or prior to use,
against measurement standards traceable to international or
national measurement standards
33
Z540-1 Withdrawal
WARFARE CENTERS
CORONA
Test & Measurement Equipment/Cal Lab Accreditation
1994
2005
2006
2007
ANSI/NCSL
Z540.1
ANS/ISO/IEC
17025:2005
ANSI/NCSL
Z540.1
Approved
Approved
ANSI/NCSL
Z540.32006
Approved
Withdrawn
Z540.1 is replaced by Z540.3 and 17025
34
9001, 17025, & Z540.3 Relationship
WARFARE CENTERS
CORONA
ENTERPRISE
Quality System
ISO 9001
Independent
Calibration Lab
Products / Services
ISO/IEC 17025
Measurement and Test Equipment
ANSI/NCSL Z540.3
Internal Calibration Laboratory
ISO/IEC 17025 (or Z540.3)
35
Distribution of Z540.1 Requirements
WARFARE CENTERS
CORONA
•
17025
Z540.1
Part I – Cal Lab
– Cal lab requirements
– Cal lab competency
demonstration (ISO G25)
•
–
–
General requirements for the
competence of testing and
calibration laboratories
Calibration service component
competency demonstration
Z540.3
Part II – Cal System
– M&TE cal requirements
– Cal system requirements
–
–
Cal service component technical
requirements
Optional use of ANS/ISO 17025 with
SC 5.3 for Cal service component
competency demonstration
–
–
M&TE cal requirements
Cal system requirements
36
Roles of New Standards
WARFARE CENTERS
CORONA
• ANSI/ISO/IEC 17025:
– Competence of test and calibration laboratories
– Demonstration requirements:
• Able to operate a management system
• Are technically competent
• Able to generate technically valid results
Laboratory
Competence
Requirements
• ANSI/NCSL Z540.3
– Technical requirements for calibration of M&TE
– System for control of the accuracy of M&TE:
• Calibration system performance requirements
• Calibration laboratory performance requirements
• Link to use of 17025 accredited cal labs
METCAL
Program
Requirements
– ISO 17025 accredited cal lab “smart customer”
37
WARFARE CENTERS
Calibration Program Functions
CORONA
•
Calibration Requirements
–
•
Calibration Procedure
–
•
•
•
Development, Review, Approval
TMDE/Calibration Standards
–
Inventory Control
–
Reliability, Interval Assessment
–
Specification, Evaluation, and Management
Calibration Laboratory
–
Facility/Technical/Management Requirements
–
Assessment (Accreditation)
Calibration Data
–
•
Determination, Assessment
Collection, Management, Assessment
Training
–
Development / Assessment
•
Technical Support
•
Professional Society Involvement
38
So, Why Calibrate?
WARFARE CENTERS
CORONA
Test, Measurement, and Diagnostic Equipment
Must Be …
Supportable
Compatible
• Repair parts
• Requirements
– Form-fit-function
– Accuracy
– Traceability
– Repeatability
• Repair procedures
• Allowances
• Training
• Inventories
• ICPs
• Standards
• Documentation
Affordable
• Control proliferation
• Prevent unauthorized
substitution
• Ensure adequate
support
To operate and maintain safe and reliable systems
39

Metrology and Calibration (METCAL) Overview

Transcription

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