Reference a Performance and Testing Specification.pdf

Enclosure (02)

Naval Surface Warfare Center Carderock Division Radiation Technology Group – Code 632

IM-272A/WDQ Performance and Testing Specification

Developed by: M. Spierenburg --- NSWCCD Reviewed by: M. Farruggia --- ISEA

Revision 03 14 May 2019

SCOPE

1.1. Scope. This specification covers the performance and testing requirements for the IM-272A/WDQ Radiacmeter, Air Monitor for Radioactive Particles, hereinafter referred to as the radiacmeter.

2. APPLICABLE DOCUMENTS

2.1. Government documents.

2.1.1. Specifications, standards, and handbooks. Unless otherwise specified, the following specifications, standards, and handbooks of the issue listed in that issue of the Department of Defense Index of Specifications and Standards (DoDISS) specified in the solicitation form a part of this specification to the extent specified herein.

SPECIFICATIONS - MILITARY

MIL-S-901D Shock Tests. H. I. (High Impact) Shipboard Machinery, Equipment, and Systems, Requirements for

MIL-STD-461G Department of Defense Interface Standard: Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-167-1A Department of Defense Test Method, Mechanical Vibrations of Shipboard

Equipment (Type I – Environmental and Type II - Internally Excited)

MIL-STD-1399 Interface Standard for Shipboard Systems, Section 300B, Electric Power, Alternating Current

DOD-STD-1399 Department of Defense Interface Standard for Shipboard Systems, D. C.

Section 070 Magnetic Field Environment

MIL-STD-810G(1) Test Methods, Environmental Engineering Considerations and Laboratory Tests

MIL-STD-108E Definitions of and Basic Requirements for Enclosures for Electric and Electronic

Equipment

Air Particle Detector (APD) Noise Limit Specification

Interface Design Description for Air Particle Detector (APD) PPMC-78-IDD-RP-03 Rev F

(Copies of specifications, standards, and handbooks required by manufacturers in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the contracting officer.)

2.2. Order of precedence. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence.

3. RADIACMETER DESCRIPTION AND PERFORMANCE

3.1. Radiacmeter general description. The radiacmeter is a detection and monitoring system for radioactive particles suspended in the air. The radiacmeter is to be used whenever a continuous and accurate measurement of radioactive air particulate is required to ensure that these radiation levels remain within safe levels. Airborne particles of a certain size containing radiation-emitting alpha and beta particles are of the greatest concern. The radiacmeter is designed to have required sensitivity to beta and alpha radiation, as specified herein, while discriminating against a gamma background.

Radioactive gas measurement is not a primary function of the radiacmeter because such measurements are to be provided by other equipment.

3.1.1. Radiacmeter dimensions and interfaces. The IM-272/WDQ radiacmeter design re-uses the IM- 239/WDQ radiacmeter cabinet and meets the requirements of the Cabinet Assembly Drawing 28687- 0309122. Therefore, the external dimensions, space envelope, and mounting points shall be identical to the IM-239/WDQ. Also, the electrical power and air inlet and outlet connections shall be identical to the IM-239/WDQ. As required by the IM-239/WDQ Radiacmeter Installation Drawing (0309110), the electrical input and output connections (Jacks J1/J2) must be able to be mounted on either side or on the rear of the cabinet at the existing connection locations.

3.1.2. Weight. The total weight of the radiacmeter shall not exceed 375 pounds.

3.1.3. Power. Power required by the radiacmeter shall be 115 volts (V), 60 hertz (Hz) ±5%, 10 amperes (A) maximum running current.

3.1.4. Remote alarm. The remote alarm relay connections and power requirements shall be as specified in a through c:

3.1.4.1. a. Relay normally closed (NC) 115 V alternating current (VAC): 5 A alarm contact

3.1.4.2. b. Relay normally opened (NO) 115 VAC: 5 A alarm contact

3.1.4.3. c. 115 VAC: 0.4 A remote alarm power

3.1.5. External Isolation Valve Controller. Jack J3 of the Radiac Cabinet shall be wired to provide power and interface with an external isolation valve controller as described in Table 3-2 of the IM-239/WDQ technical manual. A 28VDC power supply (.1A max) shall be added to the prototype IM-272/WDQ design for this purpose. Jack J3 must be able to be mounted on either side or on the rear of the cabinet at the existing connection locations.

3.1.6. Profibus interface. The capability to install and utilize a Profibus interface shall be provided in all units. The procuring activity will specify the number of units in each order that shall include the Profibus hardware. When the Profibus hardware is ordered, the radiacmeter shall be supplied with duplex fiber optic connections for the Profibus interface. The data to be communicated shall be the radiation level and the status of the low flow alarm, high radiation level alarm and maintenance required alarm, as well as four other status conditions reserved for future use. Details of the Profibus interface are included in the Interface Design Description for Air Particle Detector (APD) PPMC-78- IDD-RP-03 Rev F. The location of the Profibus connections shall be on the rear of the cabinet at the existing connection location.

3.2. Characteristics. Characteristics shall be as specified in 3.2.1 through 3.2.7.

3.2.1. Performance. The radiacmeter shall be designed for optimum response to airborne particulate emitting beta radiation. Radiacmeter detector sensitivity to alpha particles shall be used to compensate for radon progeny.

3.2.1.1. Range of response. The radiacmeter shall respond to beta and alpha particles over a range of energies. In particular, the radiacmeter shall respond to isotopes having beta end point energies between 0.3 million electron-volts (MeV) and 5.3 MeV, and to isotopes having alpha energies between 6.0 MeV and 9.0 MeV. It is desirable for the radiacmeter to provide the capability for the operator to determine the specific isotope(s) causing an indicated reading of 1e-10 microcuries per milliliter (µCi/ml) or greater. The potential isotopes to be identified are Cobalt 60, Cesium 137, and Rubidium 88.

3.2.1.2. Sensitivity. The radiacmeter shall have a sensitivity to Co 60 source of 8e-11 µCi/ml, with an accuracy of + 25%. This sensitivity shall be achieved in a count time of two hours or less, and in an environment with a radiation level due to radon progeny of 1e-9 µCi/ml.

3.2.1.3. Alarm. The audible alarm shall produce a sound of 85 decibels (dB) to 90 dB at 1 meter (m) from the unit. There shall also be a visual alarm indication. The alarm shall activate when the signal exceeds the alarm threshold. The operator shall be capable of adjusting the alarm threshold at any range point from 1e-11 to 1e-5 µCi/ml at the front console.

3.2.1.4. Operating range. The range of detection shall be linear such that the total system error does not exceed ±10% from actual radioactivity for each decade of range. The operating range extends from 1e-11 to 1e-5 µCi/ml. Any reading within this range shall be capable of being read on the front console.

3.2.1.5. Operating background. The radiacmeter shall be capable of operating in a uniform gamma background of 15 milliroentgens per hour, with the energy of this gamma radiation being equal to or greater than that produced by Co 60.

3.2.1.6. Calibration. Calibration shall be accomplished by using a calibration source inserted under the detector. The operating range point for calibration shall be near the midrange of the radiacmeter.

The calibration source shall be Technetium (Tc) 99, and shall have an activity significantly less than the amount that would require Nuclear Regulatory Commission (NRC) license. The calibration source shall be secured within the radiacmeter cabinet. Calibration or other periodic response checks conducted by the operator shall be accomplished without use of an external device such as a laptop computer.

3.2.1.7. Saturation. The radiacmeter shall have a saturation level of not less than 8e-7 µCi/ml. For any actual radioactive concentration above the saturation level, the radiacmeter shall indicate that its saturation level has been exceeded.

3.2.1.8. Particle collection efficiency. The radiacmeter shall use the same filter paper as the IM-239/WDQ (NSN 6640-01-188-5418) or an alternate filter material, which has an efficiency of at least 98% for particles with diameters greater than 0.3 micrometer.

3.2.1.9. Warm-up time. The time for the radiacmeter to stabilize within the specified requirements shall be less than 10 minutes.

3.2.2. Environmental conditions. The radiacmeter shall operate in or withstand the following:

a. Non-operating temperature range from -62°Celsius(C) to 71°C (-80° Fahrenheit (F) to 160°F).

b. Relative humidity of 95%.

c. Shock per MIL-S-901D, Grade A Class 1.

d. Vibration per MIL-STD-167-1A, Section 5.1

e. Magnetic field per DOD-STD-1399, Section 070, paragraph 6.

3.2.2.1. Operating temperature range. The radiacmeter shall be capable of operating with less than 5% change in calibration and response over a temperature range of 5°C to 50°C (41°F to 122°F) for duration of the temperature cycling test of 4.5.3.

3.2.2.2. Pressure. The radiacmeter pressure capabilities are as specified in 3.2.2.2.1 through 3.2.2.2.4.

3.2.2.2.1. Altitude. For air transport, the radiacmeter shall be capable of withstanding pressure down to

5.72 x 10e4 pascals (8.3 pounds-force per square inch absolute (psia)).

3.2.2.2.2. Sealed system. The radiacmeter shall have a sealed sampling system capable of processing and returning sampled air from an area without significant leakage to the surrounding area as specified herein. The sealed sampling system shall withstand internal air pressure up to 70 pounds per square inch gauge (psig) at 24°C (75° F). The sealed sampling system shall also be capable of containing the steam pressurization transient specified in 3.2.2.2.4.

3.2.2.2.3. Pressure relief. A pressure relief valve shall relieve pressures within the sealed sampling system greater than 70 psig. The relief valve shall actuate at a pressure of 70.0+10 psig. A pressure vent valve shall be provided to relieve pressure in the sealed sampling system during maintenance and prior to opening the upper or lower pressure housing.

3.2.2.2.4. Steam transient. The sealed sampling system shall contain the following steam pressurization transient: The sealed sampling system of the radiacmeter operating in an ambient temperature of not less than 38°C (100°F) shall be capable of containing pressurization steam of 22 psig at 113°C (235°F).

3.2.3. Electromagnetic compatibility (EMC). The radiacmeter shall conform to the requirements of MIL-STD-461G for below deck equipment (tests CE101, CE102, CS101, CS109, CS114, CS115, CS116, RE101, RE102, RS101, and RS103)

3.2.4. Major assemblies. The major assemblies are as specified in a through m:

a. Paper feed assembly

b. Detector assembly

c. Charge coupled preamplifier assembly

d. Input power and control assembly

e. Multichannel analyzer assembly

f. Microprocessor

g. Graphical User Interface assembly

h. Electronics Power Supply, for detector and electronics

i. Pump motor assembly

j. Motor controller and power supply

k. Flow meter assembly

l. Lower Pressure housing

m. Upper pressure housing

3.2.4.1. Paper feed assembly. The paper feed assembly shall move the filter paper once per day, or when an alarm event occurs or when either the differential pressure or air flow indicate the paper is clogged. The paper shall also be moved when the level of deposited radiation exceeds the point where the detector is able to detect changes in the level consistent with the required sensitivity. The paper feed assembly shall have a manual advance capability. The paper drive shall have an indicator visible on the operator's panel that indicates when less than 12 inches of filter tape remains.

3.2.4.2. Detector assembly. The detector assembly shall provide the sensitivity required herein.

3.2.4.3. Detector power supply and preamplifier assembly. The detector power supply shall provide filtered and regulated power to the detector.

3.2.4.4. Input power and control assembly. Controls shall be included on the front of the unit to perform the necessary functions specified herein. The controls shall include alarm setting and resetting, calibration, air flow, ON-OFF power, required test modes, and malfunction diagnostics.

3.2.4.5. Electronics power supply assembly. The electronics power supply shall provide filtered and regulated power to the electronics assemblies including the amplifiers, signal processing, and display, but excluding the pump motor. The electronics power supply shall conform to all line noise and other interference problems experienced in a shipboard environment as specified herein. Power line noise as specified herein shall not interfere with the electronic processing of the radiacmeter.

3.2.4.6. Pump motor assembly. The pump motor assembly shall be one replaceable unit that has adequate air volume moving capability to conform to the minimum detection requirements specified herein.

3.2.4.7. Flow meter assembly. The air flow shall be measured within an accuracy of ±5%. The flow meter assembly shall provide airflow measurement data to the microprocessor.

3.2.5. Enclosure. The radiacmeter enclosure shall be drip proof (at 45 degrees) in accordance with MIL-

STD-108E.

3.2.6. Airborne and Structure Borne Noise – The radiacmeter shall meet the noise requirements of “Air Particle Detector (APD) Noise Limit Specification”. The airborne and structure borne noise requirements are classified CONFIDENTIAL and are included in a separate document.

3.2.7. Electrical interface. The radiacmeter shall meet the electrical interface requirements of MIL-STD-1399 Section 300B.

3.3. Workmanship screen. Each production radiacmeter shall withstand a defect detection vibration screen as specified in 4.5.6.

3.4. Parameter adjustment. Parameters that are adjustable by the operator shall be limited to: display units (English or SI); alarm set point; and time period displayed on the graphical user interface for trend analysis.

4. QUALITY ASSURANCE PROVISIONS

4.1. Responsibility for inspection. Unless otherwise specified in the contract or purchase order, the contractor is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1. Government verification. All quality assurance operations performed by the contractor will be subject to Government verification at any time. Verification will consist of, but is not limited to, a) surveillance of the operations to determine that practices, methods, and procedures of the written quality program are being properly applied, b) Government product inspection to measure quality of the product to be offered for acceptance, and c) Government inspection of delivered products to assure compliance with all inspection requirements of this specification. Failure of the contractor to promptly correct deficiencies discovered by him or of which he is notified shall be cause for suspension of acceptance until corrective action has been taken or until conformance of the product to prescribed criteria has been demonstrated.

4.2. Classification of inspections. The inspection requirements specified herein are classified as specified in a through c:

a. First article inspection (see 4.3)

b. Quality conformance inspection:

1. Production inspection (see 4.4.1)

c. Inspection of preparation for delivery (see 4.6)

4.3. First article inspection. Two units shall be required for first article inspection. First article inspection shall consist of all examinations and tests necessary to determine compliance with the requirements of this specification. First article inspection shall include the tests specified in TABLE I

TABLE I. First article inspection.

(*1) Only one unit shall be subjected to the shock test.

4.4. Quality conformance inspection. Quality conformance inspection shall be as specified in 4.4.1.

4.4.1. Production inspection. Production inspection shall be made on every unit offered for delivery, except as specified under “Sample size” column in TABLE II. Production inspection shall comprise of such

Examination or test Requirement paragraph Test paragraph Profibus 3.1.6 4.5.12 Performance See Below See Below Range 3.2.1.1 4.5.1.1 Sensitivity 3.2.1.2 4.5.1.2 Alarm 3.2.1.3 4.5.1.3 Operating range 3.2.1.4 4.5.1.4 Operating background 3.2.1.5 4.5.1.5 Calibration 3.2.1.6 4.5.1.6 Saturation 3.2.1.7 4.5.1.7 Pressure 3.2.2.2 4.5.7 Temperature 3.2.2, 3.2.2.1 4.5.3 Humidity 3.2.2 4.5.2 Shock (*1) 3.2.2 4.5.8 Vibration 3.2.2 4.5.9 Enclosure 3.2.5 4.5.11

EMC 3.2.3 4.5.4

Airborne and Structure Borne Noise 3.2.6 4.5.10 Electrical interface 3.2.7 4.5.5 examinations and tests which will prove the workmanship and reveal omissions and errors of the production process such as, functional and performance tests at a limited number of points in the required range, tests which detect deviations from design, tests of controls and adjustments, and tests which detect hidden defects of materials. Production inspection shall include the examinations and tests specified in TABLE II.

TABLE II. Production inspection.

Examination or test Requirement paragraph Test paragraph Sample size Performance Range 3.2.1.1 4.5.1.1 All Alarm 3.2.1.3 4.5.1.3 See Sample Size in Table III Operating range 3.2.1.4 4.5.1.4 See Sample Size in Table III Calibration 3.2.1.6 4.5.1.6 All Pressure 3.2.2.2 4.5.7.1, and 4.5.7.4 All Airborne and Structure Borne noise

3.2.6 4.5.10 All

Electrical interface 3.2.7 4.5.5 See Sample Size in Table III EMC 3.2.3 4.5.4 See Sample Size in Table III Workmanship screen 3.3 4.5.6 All

TABLE III. Sample Size Assessment for Production Testing

Standard ANSI/ASQ Z.4-2003 General Inspection Level

II

Lot Size 9 to 15 16 to 25 26 to 50 51 to 90 Sample Size 3 5 8 13 Acceptance Quality Level

0.010

Allowable nonconformance’s

4.5. Test methods. Test methods shall be as specified in 4.5.1 through 4.5.11.

4.5.1. Nuclear performance tests. Nuclear performance tests shall be conducted in accordance with detailed test procedures prepared by the contractor and approved by the Government. The tests shall include the following performance factors. Many of the test requirements below are stated in terms of indicated display readings in units of µCi/ml. For tests conducted by placing a fixed test source under the detector, the detailed test procedures shall explain the methodology for determining the appropriate test source strength and for determining the appropriate radiacmeter response.

4.5.1.1. Range. Using appropriate test sources inserted under the detector, test shall demonstrate the range of response as stated in 3.2.1.1. Contractor shall determine the specific readily available test sources to be used to best demonstrate the required beta and alpha energy range responses and the desired isotope identification capability. Efficiency of response approximately equal to or greater than that of Co 60 over the required energy ranges shall be considered acceptable.

4.5.1.2. Sensitivity. Using appropriate test source inserted under the detector, test shall demonstrate the sensitivity as stated in 3.2.1.2. The actual reading shall be within ±25% of the expected reading from the test source. The contractor shall propose the methodology to demonstrate this capability in the radon progeny environment as stated in 3.2.1.2.

4.5.1.3. Alarm. Using the test sources used for the operating range test specified in 4.5.1.4, test shall demonstrate that the alarm is successfully activated in each of the specified three decades. The sound level of the alarm in dB at 1 m shall be measured and shall be between 85 dB and 90 dB.

4.5.1.4. Operating range. Three appropriate test sources covering approximately three decades of source strength shall be used. The three decades shall be 1e-10, 1e-9, and 1e-8 µCi/ml. Each source shall produce a display reading that is within ±10% of the actual reading expected.

4.5.1.5. Operating background. The radiacmeter shall be placed in a 15 mr/hr Co 60 gamma background.

The indicated count rate shall be such that, with the alarm set at 4e-10 and an actual radioactivity level of 8e-11, no more than one false alarm in 5,000 hours will occur. The radioactive source used for the test shall be placed at the front, back, and both sides of the radiacmeter.

4.5.1.6. Calibration. Using a calibration source as specified in 3.2.1.6, the radiacmeter shall be calibrated to indicate correctly within ±10%. The contractor shall propose the methodology to calibrate the radiacmeter for radon progeny compensation.

4.5.1.7. Saturation. Using appropriate test sources inserted under the detector, test shall demonstrate saturation capability and indication as stated in 3.2.1.7.

4.5.2. Humidity test. Humidity tests shall be conducted in conjunction with temperature testing in accordance with MIL-STD-810G(1), section 501.5. Specifically, during the last of the 10 temperature cycles of section 4.5.3, establish the condition of 95% relative humidity and 50 degrees C with radiacmeter power on for at least 6 hours before conducting the final performance measurements.

4.5.3. Temperature test. Temperature testing shall be conducted in accordance with MIL-STD-810G(1), sections 501.5 and 502.5. The radiacmeter shall be subjected to the temperature curve of FIGURE 1.

The temperature rate of change shall not be less than 5°C per minute. Radiacmeter power shall be turned on and off at the indicated times. When practical, the radiacmeter panels and enclosures shall be opened or removed for maximum exposure to the changing temperature. When performance measurements are called for, a functional operating test shall be performed. The dwell time shall be 80% of the time required for the largest electrical or electronic part to become temperature stabilized.

Temperature stabilization shall be as defined in MIL-STD-810G(1) for the nonoperating condition.

When failures occur, the radiacmeter shall be reworked and the cycling continued for a cumulative total of 10 cycles.

4.5.4. EMC test. The requirements of 3.2.3 shall be verified by tests performed in accordance with MIL- STD-461G. For this testing, the radiacmeter shall provide 115 VAC power and 28 VDC power via Jack J3 to an external isolation valve controller that is connected to two automatic isolation valves, with the valves in the open position. An isolation valve controller and two automatic isolation valves will be provided by the procuring activity. For production inspection only, tests CE102 and RE102 shall be performed.

4.5.5. Electrical interface test. Electrical interface tests shall be conducted in accordance with MIL-STD- 1399, section 300B, paragraph 5.3. For this testing, the radiacmeter shall provide 115 VAC power and 28 VCD power via Jack J3 to an external isolation valve controller that is connected to two automatic isolation valves, with the valves in the open position. For production inspection only, perform Simulated Human Body Leakage Current Tests for Personal Safety.

4.5.6. Workmanship. Workmanship screen testing shall be as specified in 4.5.6.1 through 4.5.6.1.1.

4.5.6.1. Workmanship screen. Vibration testing (see 4.5.6.1.1) shall be performed on each radiacmeter.

4.5.6.1.1. Vibration testing. The radiacmeter shall be vibration tested in accordance with MIL-STD-167-1A, paragraph 5.1.2.4.2. The test radiacmeter shall be energized during vibration and appropriate input signal applied to observe any abnormal conditions of the output functional characteristics. All failures occurring during test shall be corrected and the test resumed.

4.5.7. Pressure test. The radiacmeter shall be tested under various pressure conditions to determine if the equipment can hold the pressure as specified herein.

4.5.7.1. Altitude. The radiacmeter shall be subjected to a test pressure of 5.72 x 10e4 pascals (8.3 psia) for one hour in accordance with the requirements of MIL-STD-810G(1). The radiacmeter shall be turned off during this testing and shall operate satisfactorily after the testing.

4.5.7.2. Sealed system test. The radiacmeter shall be connected to a closed pressure system containing 70 psig air pressure at 24°C (75°F). After 30 minutes, pressure shall be no less than 63 psig.

Pressure relief valve shall be blocked or kept from operating during this test.

4.5.7.3. Relief valve test. The radiacmeter shall be pressurized above 70 psig and the pressure relief valve shall actuate between 70 psig and 80 psig.

4.5.7.4. Steam test. The sealed sampling system in surrounding air of 100°F shall be pressurized to 22 psig with 235°F steam. After reaching 22 psig, the radiacmeter shall be isolated and the pressure and temperature within the sealed sampling system allowed to decay by heat loss to surrounding air. At 20 to 30 minutes after pressurization, the accessible parts of the sealed sampling system shall be inspected for evidence of leakage of steam or moisture. No detectable leakage is permitted.

4.5.8. Shock test. The radiacmeter shall be shock tested in accordance with the requirements of MIL-S- 901D for Grade A Class 1 equipment.

4.5.9. Vibration test. The radiacmeter shall be vibration tested in accordance with MIL-STD-167-1A, section

5.1. For this test, a major failure is one that would cause malfunction or maloperation of the unit for a long period. A minor failure is a non-repetitive failure of such parts as connectors, knobs/buttons, fasteners, and wiring, which can be easily replaced or repaired.

4.5.10. Airborne and Structure Borne Noise. The radiacmeter shall be tested in accordance with the requirements of “Air Particle Detector (APD) Noise Limit Specification”. The airborne and structure borne noise requirements are classified CONFIDENTIAL and are included in a separate document.

4.5.11. Enclosure test. The radiacmeter shall be tested in accordance with the requirements of MIL- STD-108E for a dripproof (at 45 degrees) enclosure. The IM-272A/WDQ shall be tested with the Cooling Fan Assembly in each of the three possible locations.

4.5.12. Profibus test. The Profibus connection shall be tested to verify the data listed in Section 3.1.6 is being communicated.

4.6. Inspection of preparation for delivery. Inspection shall be conducted to ensure conformance with the packing and packaging requirements specified in the contract.