Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Rotary Tool Inspector Training Course:
Introduction to Measuring Equipment
Rev 0 Page 1 of 1 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Introduction to measuring equipment
Inspection of rotary connections using visual inspection, dimensional inspection and Magnetic or
Penetrant inspection methods involves the use of several types of measuring equipment.
For certain measurements more than one type of equipment may be used.
This document discusses the different measurements which are normally made and the various types of
equipment which may be employed
Section 1.0: Visual Inspection Equipment
1.1 Light Meter.
Visual inspections are performed either in natural daylight or in artificial light. In
either case, the light intensity at the surface being inspected must meet the minimum
requirements of the standard being used for the inspection.
Visible light intensity is typically measured in Lux or Foot-Candles where 10 Lux =
1 Foot Candle.
The most commonly employed standards require a minimum of 1000 Lux when
working in daylight conditions and 500 Lux when working under artificial light.
Light intensity is measured using a light meter.
Several types are available with the following variations:
• Light sensor in built or connected to the meter via a cable
• Analogue display or digital display of measured light intensity
• Visible light only or combined visible and UV-A (2 separate sensors
required)
Note 01: Light meters require regular calibration as specified by the relevant inspection
standard (typically every 6 months or 1 year)
Figure No. 01:
Combined Visible / UV-A Intensity meter with Separate Sensors
Rev 0 Page 2 of 2 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
1.2 Inspection Mirror
Inspection mirrors are required when performing wet fluorescent magnetic particle
inspection of box connections. The thread roots require detailed examination for
cracks.
They are also useful for reflecting sunlight into the bores of drillstem components
allowing a limited visual inspection to be performed.
Note 02: Mirrors should be kept clean and replaced when the glass is cracked or broken.
Use the largest mirror available which can do the job
Figure No. 02:
Typical Inspection Mirrors
1.0” & 2.0” in Diameter
Rev 0 Page 3 of 3 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Section 2.0: Dimensional Measuring Equipment
In a typical visual and dimensional inspection of a single rotary connection, up to 15
measurements may be required.
Depending on the location of the measurement and the accuracy required, some or all
of the following types of measuring instruments may be required:
2.1 Ruler
Only steel rulers are acceptable and satin finish stainless steel types are preferred
because they are less prone to glare and the contrast between the scale markings and
the surface of the ruler is maximised.
At least one scale should be in inches with graduations of 1/64”
Rulers should be kept clean and dry so that they do not rust.
Rulers should only be used for the purpose of measuring, not as a lever for opening
paint tins or as a scraper etc.
When the markings become unclear or the corners become rounded, the ruler should
be discarded.
Figure No. 03:
Steel Rule
Figure No. 04:
Steel Rule with
1/64” Graduations
Rev 0 Page 4 of 4 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
2.2: Calipers
Separate Calipers are typically used to measure external and internal dimensions.
These are normally referred to as O.D. and I.D Calipers.
Calipers come in 2 basic varieties;
Spring & Stiff joint.
Both types are commonly used for dimensional inspection of rotary connections.
Figure No. 05:
Spring Type OD & ID Calipers
Figure No. 06:
Stiff Joint OD & ID Calipers.
Rev 0 Page 5 of 5 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Note 03: For both varieties of caliper, it is important that measuring edges remain sharp and
clean.
2.3: Making measurements with rulers and Calipers
Spring type Calipers, when carefully adjusted, will produce more consistent and
accurate results than the stiff joint type.
The stiff joint type tend to expand slightly as they go over the outer dimension being
measured and then contract after the caliper has passed over the largest point.
Ensure that both the contact points of the caliper and the ruler (end and scale) are
clean before placing the caliper against the ruler.
When reading the measured value from the scale of the ruler ensure that your
viewpoint is in line with the point on the scale where the caliper touches. This
minimises parallax error
Figure No. 07:
Different Viewing Angles when Taking Measurements:
Note Parallax Error when Viewed from Right & Left Sides
Rev 0 Page 6 of 6 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
2.4: Pin Relief Groove Diameter Measurement.
Experiments measuring the pin relief groove diameter with spring and stiff joint
Calipers have shown differences in measured values of up to 1/16”.
In the case of the relief groove diameter, this variation in measurement is twice the
allowable tolerance on the dimension.
When compared to measurements made with digital Vernier Calipers, the spring type
caliper can make measurements with an accuracy of 1/64”, but the time involved in
making fine adjustments to the exact setting of the spring calliper is excessive and
not practical when many measurements have to be made
Figure No. 08:
Close Up View of 1/64” Scale
Figure No. 09:
Normal View of 1/64” Scale
Rev 0 Page 7 of 7 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
In general, measuring dimensions with Calipers and ruler to tolerances closer than
1/32” does not produce consistent results.
For comparison purposes it should be noted that the size of the largest text on the
Jaeger J1 vision chart is 1/32”
Dimensions with tolerances less than 1/32” should wherever possible be measured
with a Vernier caliper (preferably digital)
2.5: Vernier Calipers
Vernier Calipers allow more consistent measurements of a higher accuracy to be
made.
In addition, a Vernier caliper can be used as a go/no go gauge for many of the
dimensions which require measurement during the dimensional inspection of rotary
connections.
Analogue Vernier Calipers use the position of a moving scale against a fixed scale to
allow measurements down to 0.001” or 0.02mm.
The exact point of alignment between the 2 scales is used to determine the last 2 or 3
decimal places of the dimension being measured.
Example:
When measuring inches with an analogue Vernier, the smallest division on the fixed
scale is normally 1/40”(0.025”) The moving scale is marked with 25
At the point where the 2 scales are aligned the number of divisions on the moving
scale is added to the value on the fixed scale to give an answer correct to 1/40 X 1/25
= 1/1000 inch (0.001”)
Figure No. 10:
Use of Vernier Calipers - Alignment
In practice, using an analogue Vernier caliper to this level of accuracy is difficult
because judging the exact alignment of the 2 scales is not easy. (It is somewhat
easier when using the Metric scale) and for this reason (and because they are now
relatively cheap) digital Vernier Calipers are usually preferred.
Rev 0 Page 8 of 8 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Figure No. 11:
Analogue & Digital Vernier Calipers
Because they display the measured value directly and to an apparently high degree of
accuracy, they are often regarded as the solution to all our measuring problems.
It is true that when used correctly they can produce consistently accurate results, but
inspectors should remember these points:
Note 04: Digital Vernier need batteries, always have at least one spare available and change
the battery as soon as the low battery warning comes on, accuracy and repeatability
worsen when the battery is near the end of it’s life.
Note 05: Always zero the instrument before making a measurement. When fully closed, check
that no light is visible between the contact faces before setting the display to zero
Note 06: Keep the instrument clean, dirt on the fixed section can cause reading errors as can
moving the slide too quickly
Rev 0 Page 9 of 9 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Figure No.12:
Digital Verniers Being Used on Appropriate Components.
Using a Vernier caliper as a go/no go gauge by setting it to the limit of the
acceptance criteria for a specific attribute can both speed up the job and produce
more consistent results.
Example:
When inspecting used rotary connections to DS-1 dimensional 2 or 3, the maximum
counterbore diameter on an NC50 box connection is 5.3/8” (5.375”)
Set the Vernier caliper to this dimension and then lock the slide to prevent it from
moving.
Place the fixed edge of the caliper against the surface of the counterbore near the
shoulder and then pivot the caliper around the fixed edge so that the other edge of the
caliper is near the diameter of the counterbore.
If the counterbore is within the maximum tolerance, the other edge of the caliper
should not go into the counterbore.
If it does go in, the counterbore diameter is larger than the specified maximum.
Figure No. 13:
Illustration of Example Above
Rev 0 Page 10 of 10 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
2.6: Pit Depth Gauge
As its name suggests the pit depth gauge is indeed used for measuring the depth of
pits and other discontinuities on a surface.
The heart of the pit gauge is the dial indicator which typically has a scale graduated
in divisions of 0.001” or 0.02mm
Figure No. 14:
Left Pit Gauge General View, Centre Set to Zero and Right Indicating Notch Depth
As can be seen from the photographs, the dial indicator rod passes through the base
plate and ends in a pointed tip which makes contact with the surface on which the
measurement is being taken.
Rev 0 Page 11 of 11 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
In use, the gauge is placed on the surface near to the pit and the dial gauge is set to
zero.
Note 07: It is important to rock the gauge backwards and forwards to determine the correct
position for turning the dial to zero.
When the gauge has been correctly set to zero, slide the gauge along the surface so
that the point of the gauge goes into the pit. Move the gauge around the pitted area
until the maximum reading on the dial indicator is obtained.
2.7: Thread Profile Gauges.
Rotary tool inspectors primarily use thread profile gauges to detect stretched threads
and assess thread damage in used rotary connections.
They are used in machine shops to check the profile of newly machined connections
and can also be used to confirm the number of threads per inch when identifying
rotary connections.
Two types of profile gauges are in common use. These are:
1. Pressed steel field use gauge which typically has 4 different thread
profiles
2. Hardened and ground plate gauge with a single thread profile.
Note 08: Note that inspections performed in accordance with DS-1 require the use of hardened
and ground profile gauges. Pressed steel gauges are not permitted
Each thread profile is defined by 3 elements:
1. Number of threads per inch (typically 3 , 4 or 5)
2. Taper in inches per foot (typically 2 or3)
3. Thread form (typically V0.038R, V0.040 or V0.050)
The profile gauge being used must match the thread being checked in all 3 respects.
With field use gauges in particular, it is easy to select the wrong profile for the
connection being inspected.
When checking for thread stretch on pin threads, the first thread at the front of the
gauge must be placed in the first full thread of the pin nearest the shoulder.
Note 09: Stretch only occurs in the first 2 or 3 threads nearest the shoulder and will not be
detected unless the gauge is in the correct location.
Rev 0 Page 12 of 12 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
(a) (b)
(c) (d)
Figure No. 15:
(a) Profile Gauges (b) Profile Gauge on Connection
(c) Good Profile (d) Stretched Threads
Rev 0 Page 13 of 13 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
2.8 : Lead gauge.
The Lead Gauge is used to measure thread lead which is defined as the distance from
a point on one thread to the same point on the next thread.
In practice thread lead is measured over a fixed number of threads and any difference
between the measured distance and the specified distance is displayed on a suitably
marked dial indicator.
Rotary tool inspectors use the lead gauge to measure pin thread stretch which has
been detected by the thread profile gauge.
Several types of lead gauge are available, but for rotary tool inspection purposes, the
GageMaker LG5003 3 point gauge is highly recommended and will be the only lead
gauge used in this course. (The relevant parts of the operating manual for this gauge
are attached to the end of this document).
Prior to use all lead gauges must be fitted with the correct contact points and then set
to zero on the correct setting standard
For most rotary connections the 0.144” diameter ball contact points are required.
The setting standard must have the same number of threads per inch and the same
taper as the connection being inspected.
Figure No. 16:
Lead Setting Standard
Rev 0 Page 14 of 14 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
After fitting the correct contact points to the base of the gauge so that the measuring
interval is 2 inches, place the gage on the setting standard with the contact points
resting against the flanks of the setting grooves and the back plate and then adjust the
dial indicator to zero.
Figure No 17:
Lead Gauge on Setting Standard and Dial Indicator set to Zero
To measure thread lead, place the gauge on the thread so that the moving contact is in
the first full thread.
The fixed contacts will rest against the flanks of the thread 2 inches further down the
connection.
With 3 points of contact, the gauge should not move once correctly positioned.
With the gauge correctly positioned, the thread lead can be read directly from the dial
indicator.
“Fast” (positive) readings indicate lead that is greater than specified. Stretched
threads will always give “Fast” readings.
Rev 0 Page 15 of 15 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
New rotary connections have a lead tolerance of +/- 0.0015inches per inch of thread
length.
Connections which may have been manufactured within the negative tolerance may
still produce “Slow” readings after considerable use as long as they have not been
subjected to excessive torsional loads
Figure No. 18:
Gauge in Position on Good
Connection (Above)
Gauge on Stretched
Connection (Right)
Rev 0 Page 16 of 16 January 2006
Rotary Tool Inspector
Training Course:
Introduction to Measuring
Equipment.
Appendix 01: Extracts from GageMaker Manual
Rev 0 Page 17 of 17 January 2006
