Attachment 3-PWP Mod. 1 - Auxiliary Unit and Mini-Auxiliary Unit Test & Inspection Procedu.pdf

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PWP Mod. 1 - Auxiliary Unit and Mini-Auxiliary Unit Test & Inspection Procedures

References:

(1) 593-7556857, PWP Mod 1, Mini-Aux Controller Assembly and Details

(2) 593-7556850, PWP Mod 1, Auxiliary Unit Assembly

(3) 593-7556860, PWP Mod 1, Auxiliary Junction Enclosure Assembly and Details

(4) 593-7556853, PWP Mod 1, Cooling Water Return Spool

1.0 MINI-AU / AU VISUAL INSPECTION. Complete the following inspections prior to applying power to the unit. Record the results of this inspection in the data sheet. If item is satisfactory without adjustment or repair, check the SAT box on the data sheet; if repair or adjustment is required, check the “SAT w/Repair” box on the data sheet.

a. Verify that the nameplate (ref. l, pc 65) is attached to the front / top of the Mini-AU /

AU.

b. Verify that the valves are all labeled. The following valve labels should be visually verified: AVA, AVB, BVA, BVB, CVA, CVB, DVA, DVB, FSA, FSB, RVA, and RVB (ref. l, pcs 52~ 57, 59-64).

c. Verify that the filter is labeled F1 (ref. l, pc 58).

d. Verify that each electrical enclosure has a nameplate (ref. 2, pc 11) and an electric shock hazard sticker (ref. 2, pc 12) attached.

e. Verify that the check valves (ref. 3, pc 16) are oriented to allow free flow from the - 12 size JIC 37° flare fittings (ref. 3, pc 7) to the outlet flange (ref. 3, pc 6).

f. Verify that the each air manifold (ref. l, pc 12) has a bleed valve (ref. l, pc 11) installed in the bottom port.

g. Verify that each air manifold has a nipple (ref. 1, pc 87), an elbow (ref. 1, pc 86), and a pressure switch wired assembly (ref. l, pc 83 or 84) installed.

h. Verify that plugs (ref. l, pc 24) are installed in all unused ports on the air manifolds.

i. Verify that cap nuts (ref. l, pc 18) are installed on the four -12 size JIC 37° flare fittings on the pipe spools.

j. Verify that the compression fittings on the flow switch wired assemblies (ref. 1, pcs 5 and 6) are oriented so that connections can be made from the rear of the AU to these switches.

k. Verify that the large mufflers have been installed in ports 3 and 5 of the ram control valves, RVA and RVB, and in the EXH port on the blocking valves, BVA and BVB.

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l. Verify that all the union fittings on the pipe spools are tight

m. Verify that the electrical cables have been attached to the correct devices. Check that the label on the cable matches the device to which it is attached.

n. Verify that the air hoses are routed correctly per the following table. Note that air manifold port numbers start with port 1 at the top.

Hose Designation Routed from Routed to

H101ADVA Air manifold “A” port 2 DVA port 1 (center) H104ABVA Air manifold “A” port 1 BVA “IN” port (front) H105ARVA BVA “CYL” port (rear) RVA port 1 (center) HJ08ACVA Air manifold “A” port 4 CVA port 1 (bottom) H101B DVB Air manifold “B” port 2 DVB port 1 (center) HJ04B BVB Air manifold “B” port l BVB “IN” port (rear) H105BRVB BVB “CYL” port (front) RVB port l (center) H108B CVB Air manifold “B” port 4 CVB port l (bottom)

Table l. AU Hose Routing

2.0 FUNCTIONAL TEST. The test procedure outlined below is described for the “A” side of the Mini-AU / AU. These tests must be repeated for the “B” side of the Mini-AU / AU as well. In the steps below, “A” side hoses, cables, and valves are designated by HXXXA, WXXXA, or XXA. When repeating these tests for the “B” side, substitute “B” for “A” in all hose, cable and valve designations.

2.1 Door Control Valve Test

a. Close manually operated air isolation valves AVA and AVB.

b. Attach a regulated air source to the air inlet fitting at the rear of the Mini-AU / AU.

Regulate the air pressure to “60 psig.

Note: Air will flow from the door control valve DV A when AVA is opened. It may be advantageous to throttle air flow with valve AVA to reduce noise levels.

c. Open manually operated air isolation valve AVA.

d. Apply 110 VAC to pins B and E of connector J2 on the rear of the “A” side electrical junction enclosure. This will cause the door control valve DVA solenoid L3 to energize and shift the valve to the unlock position.

e. Remove 110 VAC from pins B and E of connector J2. The door control valve will remain shifted to the unlock position.

f. Verify that air flows from port 2 of the door control valve DVA.

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g. Apply 110 VAC to pins B and C of connector J2. This will cause the door control valve

DVA solenoid L2 to energize and shift the valve to the lock position.

h. Remove 110 VAC from pins B and C of connector J2. The door control valve will remain shifted to the lock position.

i. Verify that air flows from port 4 of the door control valve DVA.

j. Close manually operated air isolation valve AVA.

k. Cap ports 2 and 4 on the door control valve DV A.

2.2 Ram Control Valve Test

a. Open manually operated air isolation valve AVA.

b. Apply 110 VAC across pins H and L of connector J2 on the rear of the “A” side electrical junction enclosure. This will cause blocking valve BVA solenoid L 7 to energize.

c. Verify that air flows from either port 2 or port 4 of the ram control valve RVA

d. Remove the 110 VAC from pins Hand L of connector J2.

e. Verify that air stops flowing at the ram control valve RVA.

f. Apply 110 VAC to pins H and L of connector J2. This will cause the blocking valve to open.

g. Apply 110 VAC to pins Band F of connector J2. This will cause the ram control valve RVA solenoid L5 to energize and the ram control valve will shift to the extend position. ·

h. Remove 110 VAC from pins B and F. The ram control valve will remain shifted to the extend position.

i. Verify that air flows from port 2 on the ram control valve RVA.

j. Apply 110 VAC to pins B and G of connector J2. This will cause the ram control valve RVA solenoid L to energize and the ram control valve will shift to the retract position.

k. Remove 110 VAC from pins B and G. The ram control valve will remain shifted to the retract position.

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l. Verify that air flows from port 4 on the ram control valve RVA.

m. Remove 110 VAC from pins H and L of connector J2.

2.3 Cooling Water Valve Test

a. Apply 110 VAC to pins B and A of connector J2.

b. Verify that the cooling water ball valve CVA rotates to the open position.

c. Remove 110 VAC from pins B and A of connector J2.

d. Verify that the cooling water ball valve CVA rotates to the closed position.

2.4 Air Flow Switch Test

a. Connect air flow test fixture as shown in figure 1. Is text fixture calibrated for cfm?

Do not use figure 1 in Test Procedure!

b. Turn the Exhaust Fan OFF.

c. Use a volt/ohm meter to check the resistance across pins J and K in connector J2. The reading should show an open circuit (infinite resistance).

d. Turn the Exhaust Fan back ON.

e. The resistance reading across pins J and K in connector J2 should change to show a closed circuit (zero resistance).

f. If steps C &E are not satisfied remove cover from the FS”X” electrical junction box.

g. Use a nut driver to loosen the adjusting nut until there is no tension on the spring. Use a volt/ohm meter to check the resistance across pins J and K in connector J2. The reading should show a closed circuit (zero resistance).

h. Tighten the adjusting nut until the resistance reading across pins J and K in connector J2 changes to show an open circuit (infinite resistance).

i. Loosen the adjusting nut just until the reading shows a closed circuit (zero resistance)

j. Loosen the adjusting nut another ½ turn.

k. Turn the exhaust fan off. Verify the reading shows an open circuit (infinite resitance).

l. Turn the exhaust fan back on. Verify the resistance reading changes to a close cicuit (zero resistance,

m. If the conditions from steps “K” and “L” are met, adjustment is complete. Replace the cover of the junction box. If the conditions are not met, repeat steps “B” through “L” until satisfactory adjustment is achievd.

n. Turn the exhaust fan OFF.

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2.5 Pressure Switch Test

a. Use a volt/ohm meter to check the resistance across pins J and Min connector J2. The reading should show an open circuit (infinite resistance).

b. Increase the regulated air pressure slowly from 60 psi to 120 psi.

c. Using the volt/ohm meter, note the approximate pressure where the resistance across pins J and M in connector J2 changes to a closed circuit (zero resistance). Record this pressure: ____________.

d. Decrease the regulated pressure slowly from 120 psi to 60 psi.

e. Using the volt/ohm meter, note the approximate pressure where the resistance across pins J and M in connector J2 changes to an open circuit (infinite resistance). Record this pressure: ____________.

2.6 B-Side Tests. Repeat all tests in sections 2.1 thru 2.5 on the “B” side of the auxiliary unit

3.0 WATER AND AIR TIGHTNESS TESTS

3.1 Hydrostatic Test. The AU (Mini-AU has a remotely located cooling valve) must be hydrostatically tested to 275 psi to assure there are no leaks. Record the results of this test in data sheet. Note any leaks repaired. The test procedure outlined below is described for the “A” side of the AU. These tests must be repeated for the “B” side of the AU as well. In the steps below, “A” side hoses, cables, and valves are designated by HXXXA, WXXXA, or XXA When repeating these tests for the “B” side, substitute “B” for “A” in all hose, cable and valve designations.

a. Connect a water source capable of 275 psi to the inlet (lower) flange at the rear of the

AU. This source should have a valve to control flow and isolate pressure. This valve should remain closed at this time.

b. Connect the upper flange at the rear of the AU to a drain. This line should contain a valve to control flow and isolate pressure. This valve should be open.

c. Remove the cap nuts from each of the four hose fittings on the rear of the AU.

d. Connect a loop of A-inch nominal ID hose between the “A” side fittings (-12 size JIC 37° male flare fittings) on the AU pipe spools.

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e. Apply 110 VAC to pins A and B on connector J2 on the rear of the “A” side electrical junction enclosure. This will cause the cooling water valve CV A to rotate to the open position.

f. Tum on the water at low pressure and allow the AU to fill until water runs freely from the valve on the drain connection.

g. Close the valve on the drain connection.

h. Pressurize the AU water loop to 275 psi and hold for 15 minutes. Visually inspect all fittings and for leaks. Verify that water is not leaking from the “B” side isolation valve CVB or from the “B” side check valve. All leaks must be repaired and the AU must be held at 275 psi for 15 minutes after the last repair to assure all joints are tight.

i. Vent all pressure from the AU water loop by closing the inlet isolation valve and opening the drain valve.

j. Remove 110 VAC from pins A and Bon connector J2.

k. Remove the loop of hose from the “A” side pipe spools.

l. Repeat steps “d” thru “k” above for the “B” side of the AU.

m. Remove the water source from the inlet flange and remove the drain from the outlet flange.

n. Allow water to drain from the pipe spools and reinstall the cap nuts on the four hose fittings.

3.2 Air Tightness Test. The AU air system must be tested to 120 psi to assure there are no leaks.

Record the results of these tests in the data sheet. The allowable blocking valve air tightness test of the AU shall allow for a maximum leakage rate of 200 mL/min or the equivalent of 100 bubbles per minute when checking with a soap solution. The allowable leakage rate for a 1” valve check valve during hydrostatic test of the AU shall allow a maximum of 25 cc/hr.

Note any leaks repaired. The test procedure outlined below is described for the “A” side of the AU. These tests must be repeated for the “B” side of the AU as well. In the steps below, “A”

a. Close manually operated air isolation valves AVA and AVB.

b. Attach a 120 psi air source to the air inlet fitting on the rear of the AU.

c. Open the bleed vavle at the bottom of the “A” side air manifold.

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d. Hold 120 psi for 5 minutes. Use soap solution on the bleed valve on the “A” side to check for leakage. No leakage assures that valve AVA is tight.

e. Close the bleed valve in the bottom port of the “A” side air manifold.

f. Cap ports 2 and 4 on the door control valve DVA and ram control valve RVA.

g. Open manually operated air isolation valve AVA.

h. Apply 110 VAC to pins B and C on connector J2 on the rear of the “A” side of the AU junction enclosure. This will shift the door control valve to the unlock position.

i. Remove 110 VAC from pins B and C on connector J2. This will leave the door control valve shifted to the unlock position.

j. Apply 110 VAC to pins B and F on connector J2. This will shift the ram control valve to the extend position.

k. Remove 110 VAC from pins B and F on connector J2. This will leave the ram control valve shifted to the extend position.

l. Hold 120 psi for 5 minutes. Use soap solution on all pressurized joints to check for leaks.

Leaks should be repaired and pressure must be held for 5 minutes after the last repair.

m. Apply 110 VAC to pins B and E on connector J2. This will shift the door control valve to the lock position.

n. Remove 110 VAC from pins B and E on connector J2. This will leave the door control valve shifted to the lock position.

o. Apply 110 VAC to pins B and G on connector J2. This will shift the ram control valve to the retract position.

p. Remove 110 VAC from pins B and G on connector J2. This will leave the ram control valve shifted to the retract position.

q. Apply 110 VAC to pins B and A on connector J2. This will cause the cooling water valve

CVA to rotate to the open position.

r. Hold 120 psi for 5 minutes. Use soap solution on all pressurized joints to check for leaks.

Leaks should be repaired and pressure must be held for 5 minutes after the last repair.

s. Remove 110 VAC form pins B and A on connector J2. Cooling water valve CVA should close.

t. Close manually operated air isolation valve AVA.

u. Open the vent valve in the “A” side air manifold to allow pressure to bleed off the “A” side air loop.

v. Remove the caps from ports 2 and 4 of the door control valve DVA and the ram control valve RVA.

w. Repeat above procedure for “B” side.