SOP For System Accuracy Test
Uploaded by
Balram JiSOP For System Accuracy Test
Uploaded by
Balram JiWI for System Accuracy Test (SAT)
Scope: - SAT shall be performed for all control, monitoring and recording thermocouples, to
check the accuracy of system. Note: - This does not include the “over temperature”
thermocouple which are solely to protect the furnace from overheating.
Method of SAT: - 1. Probe method, 2. Comparative method
In our furnace probe A type method is applicable.
SAT test Requirements: - A new SAT shall be performed after any maintenance that could
affect the SAT accuracy, e.g. the replacement of the lead wire, control thermocouple, or the
replacement of the control, monitoring, or recording instrument. The SAT shall be performed at
operating temperature range.
Maintenance activity:-
Change in heating element number type or location.
Changes to air flow (baffle position, fan speed, fan quantity, etc.)
Change of refractory thickness.
New refractory with different thermal properties.
Change of vacuum furnace hot zone design or materials.
Change of control sensor location.
Temperature control scheme changes (proportional vs. high-low/on-off)
Changes in temperature control tuning constants
Work zone volume increase covering area not previously tested.
Work zone location change covering area not previously tested.
Increase in the maximum qualified operating temperature
Decrease in the maximum qualified operating temperature
Repair activity:-
Replacing a heating element with an identical heating element
Refectory repair using material with identical thermal property
Replacing a control thermocouple without changing its documented location.
Replacing a controller with an identical controller with same tuning constant
System accuracy test failure
Repair of furnace door seal.
Frequency of SAT: - Quarterly with grace period of 2 week.
SAT acceptance Value: - ± 5°C.
Step for conducting SAT
Code:- DC-289, Rev. No.00, Eff. Date:- 01/07/21
WI for System Accuracy Test (SAT)
1. Start the furnace, set temperature for hardening and tempering furnace at operating range.
Allow 4 hours of heating for achieving the set temperature.
2. Attach a test thermocouple near to the control thermometer, be ensure tip to tip distance
between both thermocouple is 50mm. as shown in fig.
3. Attach test instrument with test thermocouple as shown in fig.
4. Now record the readings of test thermocouple and control thermocouple and put in
calculation formula:
5. Any electronic offset value introduced into the control instrument for the purpose of
centering a TUS result or other shall be mathematically removed when calculating the
SAT difference as shown in fig
CONTROL CONTROL ADJUSTED TEST TEST TEST CORRECTED CALCULATED
INSTRUMENT INSTRUMENT CONTROL INSTRUMENT THERMOCOUPLE INSTRUMENT TEST SAT
TEMPERATURE TUS OFFSET INSTRUMENT TEMPERATURE CORRECTION CORRECTION INSTRUMENT DIFFERENCE
INDICATION TEMPERATURE INDICATION FACTOR FACTOR TEMPERATURE
READING
(A) (B) (C)=(A)-(B) (D) (E) (F) (G)=(D)+(E)+(F) (C)-(G)
900°C 0°C 900°C 901°C + 0.3°C + 0.1°C 901.4°C -1.4°C
(1652°F) (0°F) (1652°F) (1654°F) (+ 0.5°F) (+ 0.2°F) (1654.7°F) (-2.7°F)
6. IF the calculated SAT difference exceeds 5°C the appropriate corrective action shall be
taken before commencing with additional thermal processing.
7. After corrective action a New SAT is shall be conducted.