WMSL512-002 NSC TP Zone Pressurization Test Before Laundry Mods.pdf

TEST TITLE: Validated TP Zone Pressurization Test Page 1 of 17 Before Laundry Modifications NO.:WMSL512-002

REV/CHG: -

MARITIME SECURITY CUTTER, LARGE (WMSL BERTHOLF)

TEST PROCEDURE PREPARATION

United States Coast Guard__________

SFLC-ESD-NAME-AUX MACHY SECTION

SECURITY REVIEW CHECK

X UNCL__CONF__SECRET

/s/B. Baker 12/18/09 Prepared By Date

/s/M. Sirak 12/18/09 Checked By Date

/s/C.J. Martin 12/18/09 Approved By Date

TEST COMPLETION CERTIFICATION

Cutter Name USCG Cutter No.

Test Conductor Date

Government Witness Date

REMARKS:

TEST TITLE: Validated TP Zone Pressurization Test Page 2 of 17

REVISION RECORD

APPROVAL

REV/CHG DESCRIPTION INITIAL DATE

TEST TITLE: Validated TP Zone Pressurization Test Page 3 of 17

LIST OF EFFECTIVE PAGES

PG-REV/CHG PG-REV/CHG PG-REV/CHG PG-REV/CHG PG-REV/CHG PG-REV/CHG

1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - 11 - 12 - 13 - 14 - 15 - 16 - 17 -

TEST TITLE: Validated TP Zone Pressurization Test Page 4 of 17

TEST OUTLINE

1.0 OBJECTIVE

Demonstrate the Collective Protection System (CPS) is in conformance with system design and specification requirements with the Total Protection (TP) Zone in the pressurized condition.

2.0 ESTIMATED TESTING TIME

20.0 Hours

3.0 REFERENCES

3.1 WMSL Class Dwg. 750-WMSL-512-001, HVAC System Diagram

3.2 WMSL Class Dwg. 750-WMSL-512-059, HVAC Equipment List

3.3 Technical Specifications, Sections 095-512 and 512

3.4 MCMS HMI Operational Manual JA26-8498

3.5 Performance Specification from CDRL I030, T&E Program Plan, Appendix A:

Object No. 3.3.11.1, ID No. NSC-377

The above listing(s) are not intended to imply total performance verification and are shown for reference impact only.

4. TEST OR SUPPORT EQUIPMENT AND MATERIAL

GENERIC NAME QUANTITY IDENTIFYING INFORMATION

4.1 Anemometer 1 Rotating vane type with range

100 – 3000 ft/min

4.2 Velometer 1 With range 100 – 3000 Ft/Min

4.3 Orifice Plates As Required For balancing air sweeps

4.4 Variable Orifices 6 For installation in place of

CBR filters and capable of creating a pressure drop of 7.0 inches w.g.

4.5 Differential Pressure Gauge 1 Capable of reading –0.5 to with Atmospheric Zeroing +3.5 inches w.g.

Capability

5. COMPUTER PROGRAMS REQUIRED

None

TEST TITLE: Validated TP Zone Pressurization Test Page 5 of 17

6. PREREQUISITES

6.1 Prior to commencing tests specified in this test procedure, verify that an installation inspection for the components comprising the system, or that portion thereof, to be tested has been conducted and documented.

6.2 The system fans have been tested and the system balanced with the CPS envelope un-pressurized in accordance with Test Procedure WMSL512-001, Validated Zone, System, Compartment, and Terminal Volumetric Air Flow Test Before Laundry Modifications.

NOTE

Completion of the entire test procedure, document, or function listed as a prerequisite is not always required. Only those portions pertaining to the system being tested must be completed.

7. SPECIAL CONDITIONS AND SERVICES

440 VAC, 60 Hz, 3 Phase Power

8. EQUIPMENT INVOLVED IN TEST

CPS fans, dampers, and associated ducting Pressure Control Valves (PCV) Air Sweep Closures

9. CONFIGURATION

N/A

10. METHOD

The Total Protection (TP) Zone shall be brought up to an internal pressure of

3.0 inches w.g. with adjacent zones at atmospheric pressure. All boundaries of the zone shall be inspected for air leaks. Any air leaks shall be repaired.

After correction of air leaks, the TP zone shall be brought up to an internal pressure between 2.0 and 2.5 inches w.g. With the variable orifice sized for a pressure drop of 7.0 inches w.g., TP system and zone testing and balancing shall be performed to establish total air quantities of TP systems, to establish total airflow through Airlock and Decontamination Station air sweep closures, to verify that airflow through PCVs is acceptable per zone design leakage allowance, and to determine the TPES two-position damper intermediate position. The Pilot House shall then be taken out of the TP zone in order to test and balance the airlock between the main TP zone and the Pilot House and to determine the intermediate position of manual orifice damper 02- 29-2(34).

TEST TITLE: Validated TP Zone Pressurization Test Page 6 of 17

10. METHOD (Continued)

The Pilot House shall then be put back into the TP zone. With the variable orifice sized for a pressure drop of 5.0 inches w.g., total system airflow shall be determined to verify that the airflow through each CBR filter module does not exceed 660 CFM per individual module.

11. STATION ASSIGNMENTS

NO. OF

STATION PERSONNEL COMMENTS

TP Zone 3 Test Conductor/Operators

TEST TITLE: Validated TP Zone Pressurization Test Page 7 of 17

SAFETY INSTRUCTIONS

1. Test personnel will strictly adhere to all safety precautions, including, but not limited to, all CAUTION and WARNING notes contained in this test procedure and applicable documents.

2. Prior to conducting tests, CAUTION label plate data shall be available to test personnel for purposes of personnel safety.

3. Permit only necessary test personnel in vicinity of ventilation system under test.

TEST TITLE: Validated TP Zone Pressurization Test Page 8 of 17

INITIAL CONDITIONS AND SETUP

STEP STATION INSTRUCTIONS

1 N/A Prior to the performance of this test, ascertain that the minimum requirements necessary for the start of this test have been met as specified in the Test Outline.

2 N/A Verify that each test instrument to be used has been calibrated to provide the measurement accuracies specified in Paragraph 4. The instrument serial number or Metrology Laboratory number designation and calibration due date for each instrument used shall be recorded on the Test Equipment Used Sheet provided in this test procedure.

NOTE

Other test measurement equipment may be substituted for that specified in Paragraph 4 provided accuracy requirements are not compromised.

3 Ventilation System Variable orifices, installed in place of CBR filters and associated inert-type pre-filters, shall be maintained at the same setting as used in the initial testing and balancing as determined in

TP WMSL512-001.

4 Ventilation System The following dampers shall be in the full open position:

CPS Damper 01-37-4(5) CPS Damper 01-41-2(7) Orifice Damper 02-29-2(34)

WTC 02-37-1(35)

WTC 04-30-2(54)

The following damper shall be closed:

WTC 03-33-2 (19)

TEST TITLE: Validated TP Zone Pressurization Test Page 9 of 17

TESTING STEPS

STEP STATION INSTRUCTIONS

1 TP Zone Bring the TP Zone to an internal gauge pressure of at least 3.0 inches w.g. by taking the following steps:

a. Secure all weather access openings.

b. Secure all PCVs by blocking the PCV natural inlet.

c. Secure all Airlock and Decon Station closures.

d. Throttle the TPES as necessary by manipulating TPES two-position damper 01-37-2(6).

2 TP Zone Upon achieving an internal zone pressure of 3.0 inches w.g., inspect the boundaries of the TP zone for air leaks and repair all leaks. Record results on data sheet.

NOTE

TPSS and TPES total air quantities shall be measured at a point in the system main carrying the total system air quantity in a manner intended to provide the most accurate results practical.

3 TP Zone Open all Airlock and Decon Station air sweep closures. Allow PCVs to function normally. Bring the zone pressure to between 2.0 and 2.5 inches w.g.

adjusting TPES two-position dampers 01-37-2(6) so that when the specified zone internal pressure is achieved, the following conditions exist:

a. The TPSS total air quantity is between 98% and 110% of design.

b. The TPES total air quantity is between 95% and 105% of design.

c. The total airflow through the zone PCVs is between 50% and 120% of the zone design leakage air allowance.

TEST TITLE: Validated TP Zone Pressurization Test Page 10 of 17

STEP STATION INSTRUCTIONS

3 TP Zone (Continued)

d. The airflow through each Airlock and Decon Station air sweep closure is between 100% and 110% of design.

e. The pressure loss across the variable orifice is not less than 7.0 inches w.g.

4 TP Zone Once the conditions in Step 3 are established, record the following on the data sheets:

a. Total TPSS air quantity

b. Total TPES air quantity

c. Total airflow through the zone PCVs

d. Airflow through Airlock and Decon Station Air Sweeps and through the natural exhaust from Mk 46 Equipment Room

e. Pressure loss across the variable orifice Zone internal pressure readings from three or four representative spaces

Clearly and permanently mark the two-position damper intermediate position.

5 TP Zone Take the Pilot House out of the TP zone by closing WTC 02-37-1(35) and opening WTC 03-33-2(19). Open the air sweeps of Air Lock 02-36-3-L. Determine the orifice damper 02-29-2(34) intermediate position by gradually adjusting the damper position until an airflow of 50 CFM is supplied to the recirculation system serving the un-pressurized Pilot House. Clearly and permanently mark the intermediate position on the damper so that it may be manually reset to that position at any time. Record results on data sheet.

6 TP Zone Measure the airflow through Airlock 02-36-3-L.

Record results on data sheet.

TEST TITLE: Validated TP Zone Pressurization Test Page 11 of 17

STEP STATION INSTRUCTIONS

7 TP Zone Put the Pilot House back into the TP zone by opening WTC 02-37-1(35) and closing WTC 03-33-

2(19). Adjust the variable orifice substituting for the CBR filter bank to produce a pressure drop of not less than 5.0 inches w.g. nor more than 5.2 inches w.g. No other changes shall be made to the HVAC system. Record the following on the data sheets:

a. Total TPSS air quantity

b. Total TPES air quantity

c. Total airflow through zone PCVs

d. Pressure loss across the variable orifice

e. Zone internal pressure readings from three or four representative spaces

TEST TITLE: Validated TP Zone Pressurization Test Page 12 of 17

SHUTDOWN AND SECURING

STEP STATION INSTRUCTIONS

1 TP Zone Restore system to pretest configuration or configuration suitable for subsequent intended activities.

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TEST DATA RECORDING

EXPECTED ACTUAL

STEP TEST ELEMENT RESULTS RESULTS

PRE-TEST REQUIREMENT VERIFICATION

Satisfactory completion of the applicable requirements specified in the Test Outline Section, the Safety Instructions Section, and the Initial Conditions and Setup Section of this Test Procedure.

Complete:

(Test Conductor Signature) (Date)

EXPECTED ACTUAL

STEP TEST ELEMENT RESULTS RESULTS

2 All boundaries of the TP zone inspected for leaks and leaks repaired. No Leaks _________

Design Required 4 Total Air Quantities CFM CFM

TPSS 01-41-2(70) 3600 3528 – 3960 _________

TPES 01-37-2(125) 1620 1539 – 1701 _________

Design Required Total Airflow through PCVs CFM CFM

PCV 03-33-1(20) N/A N/A _________

PCV 02-37-1(21) N/A N/A _________

PCV 01-32-2(22) N/A N/A _________

Total Leakage Airflow 670 335 – 804 _________

Air Sweep Airflows Design Required (Pilot House in Zone) CFM CFM

Decon Station 01-42-1-L 420 420 – 462 _________

Airlock Type I 01-36-3-L 420 420 – 462 _________

Airlock Type II 1-43-1-L 420 420 – 462 _________

Mk 46 Equipment Rm 04-30-0-Q 50 50 – 55 _________

Pressure Loss Across Variable Orifices >7 inches w.g. _________

Zone Internal Pressure Readings

TEST TITLE: Validated TP Zone Pressurization Test Page 14 of 17

EXPECTED ACTUAL

STEP TEST ELEMENT RESULTS RESULTS

Passageways:

01-38-1-L 2.0 – 2.5” w.g _________

03-33-1-L 2.0 – 2.5” w.g _________

02-37-1-L 2.0 – 2.5” w.g _________

1-29-0-L 2.0 – 2.5” w.g _________

Intermediate position marked on Two-Position Damper 01-37-2(6) Sat _________

5 Intermediate position marked on Orifice Damper 02-29-2(34) Sat _________

Airflow adjusted to provide recirculation system serving the un-pressurized Pilot House. 50 CFM _________

6 Air Sweep Airflow Design Required (Pilot House Out of Zone) CFM CFM

Airlock Type II 02-36-3-L 420 420 – 462 _________

7 Total Air Quantities

TPSS 01-41-2(70) 3528-3960 CFM _________

TPES 01-37-2(125) As Measured _________

Total Airflow through PCVS

PCV 03-33-1(20) As Measured _________

PCV 02-37-1(21) As Measured _________

PCV 01-32-2(22) As Measured _________

Total Leakage Airflow 335-804 _________

Pressure Loss Across variable Orifices 5.0 – 5.2” w.g. _________

Zone Internal Pressure Readings

Passageways:

01-38-1-L 2.0 – 2.5” w.g _________

01-38-1-L 2.0 – 2.5” w.g _________

03-33-1-L 2.0 – 2.5” w.g _________

TEST TITLE: Validated TP Zone Pressurization Test Page 15 of 17

02-37-1-L 2.0 – 2.5” w.g _________

1-29-0-L 2.0 – 2.5” w.g _________

TEST TITLE: Validated TP Zone Pressurization Test Page 16 of 17

List all test equipment utilized in the test including all general and specialized test equipment, special test cables, attenuators, and any other materials requiring calibration. Include extra sheets as required.

CALIBRATION DATE

GENERIC NAME MODEL SER. NO. DUE DATE USED REMARKS

TEST TITLE: Validated TP Zone Pressurization Test Page 17 of 17

COMMENTS

This sheet is provided for the test conductor or government witness to make appropriate comments including:

a. Visual observations of dynamic responses

b. Erratic or unusual equipment behavior.

c. Operational or handling difficulties.

d. Procedural corrections.

e. Equipment malfunctions.

f. Discrepancies noted during test conduct.

g. Waivers, including reference to authorization document; i.e., letter, message, etc.

Indicate if a Test Problem Report (TPR) was generated with respect to these or other problems.

USCG HULL NO. GOVERNMENT WITNESS DATE

TEST CONDUCTOR DATE QUALITY DATE