C12 SDV Test Procedure.pdf

NSWC PCD

SEAL DELIVERY VEHICLE

TEST PROCEDURE

TEST PROCEDURE NO.

K-302

REV.

D

TITLE: Pneumatic Cylinder, Mast Tightness, PIT

PREPARING ACTIVITY: NSWC PCD, Code E43 NAVSEA APPROVAL

PREPARED BY: DATE:

David Fonzi 26-Apr-96

APPROVED BY: DATE:

D.A. Whithaus 26-Apr-96

APPROVED BY: DATE:

R.S. Cummins 01-Oct-96

RECORD OF REVISIONS

LETTER DESCRIPTION DATE APPROVED

A Revised in accordance with DRN 1997-016 dated 13-May-97. 15-May-97 D. Fonzi

B Revised in accordance with NOR R-0377 dated 04-Apr-05 on ECP E- 297. 25-Apr-05 R.E. Mattson

C Revised in accordance with NOR R-0567 dated 24-Feb-11 on ECP E-0449. 21-Apr-11 S.D. Albertson

D Revised in accordance with NOR R-0861 dated 01-Nov-16 on ECP E-0666. 28-Apr-17 D. Maglich

PART NAME AND PART NUMBER(S) WITH ASSOCIATED SERIAL NUMBER(S)

Part Name P/N S/N

Pneumatic Cylinder, Mast 7110006-1

CERTIFICATION, REVIEW, AND APPROVAL OF TEST RESULTS

Test Certification Signature

TEST CERTIFIED COMPLETE AND ACCURATE

Testing Activity:

TEST CONDUCTOR: DATE:

QCI: DATE:

Not Required

TEST DIRECTOR: DATE:

Review & Acceptance Signatures

REVIEW AND ACCEPTANCE OF TEST RESULTS

Reviewing Activity: NSWC PCD, Code ________

REVIEWER: DATE:

BRANCH HEAD: DATE:

NAVSEA ACCEPT: DATE:

K-302-D

1.0 TEST DESCRIPTION

1.1 TITLE: Pneumatic Cylinder, Mast Tightness

1.2 AUTHORITY

1.2.1 This Test Procedure is generated per the requirements of the MK8 MOD1 SDV drawing package and in accordance with CSS-SDV-0019, Integrated Test Plan for MK8 MOD1 SEAL Delivery Vehicles.

1.3 OBJECTIVE

1.3.1 To verify the tightness and operation of a mast pneumatic cylinder prior to installation in an SDV.

1.4 TYPE OF TESTING REQUIRED

1.4.1 The following testing is required for each pneumatic cylinder tested.

a. Air Tightness Test

2.0 REFERENCES

NOTE

Only current revisions of direct support and/or supplemental documents shall be used in the conducting of this test.

2.1 DIRECT SUPPORT DOCUMENTS

2.1.1 None

2.2 SUPPLEMENTAL DOCUMENTS

2.2.1 CSS-SDV-0019, Integrated Test Plan for MK8 MOD1 SEAL Delivery Vehicles

2.2.2 Drawing 7110006, Pneumatic Cylinder, Mast

2.2.3 Title 29, Code of Federal Regulations, Part 1910 Subpart S of the Occupational Safety and Health Standards.

3.0 GENERAL NOTES

3.1 NOTIFICATION

3.1.1 This test requires only a Test Conductor and a Reviewer.

3.2 TEST DATA RECORDING

3.2.1 Remarks and general observations are particularly important in maintaining an accurate and meaningful record. Any unusual event occurring during the performance of the test shall be noted on the Data Sheet.

3.2.2 If space is not provided on the Data Sheet for recording certain data, it shall be recorded on Supplemental Data Sheet(s), Section 7.0.

3.2.3 The Data Sheet(s) shall be completely filled in, dated, and signed. If certain data called for was not recorded, an entry shall be made explaining the missing data.

3.2.4 Any substitution of components or equipment during the course of the test must carry complete documentation IAW Section 3.3.

3.2.5 All times shall be documented using 24-hour time convention notation using one of the following formats: ‘hh:mm’ or ‘hhmm’ (e.g. 09:23 or 0923).

3.3 DEPARTURES

3.3.1 No deviations from test methods specified or changes in installation from approved plans shall be made without prior written approval from cognizant Lead Engineer through the procuring Government agency, as required.

3.3.2 Any changes to the specified tolerances will require NSWC PCD Engineering concurrence. Every effort shall be made to meet specific tolerances. Where this is not possible, the NSWC PCD cognizant Lead Engineer shall be consulted immediately, through the procuring Government agency, as required.

4.0 PREPARATION

4.1 PREREQUISITE AND CONCURRENT TESTS

4.1.1 There are no prerequisite tests.

4.1.2 There are no concurrent tests to be performed.

4.2 TEST LOGISTICS

4.2.1 Applicable test equipment used in conducting this test shall be maintained to the same cleanliness level of the equipment being tested.

4.2.2 Calibrated Test Equipment

NOTE

Test equipment shall have been calibrated in accordance with ISO 10012-1, Calibrated System Requirements. The Test Conductor shall be responsible for using only IN DATE calibrated instruments.

4.2.2.1 0-200 to 0-400 psig Pressure Gauge with an accuracy of +0.5% or better

4.2.3 Special Test Equipment

4.2.3.1 None

4.2.4 Standard Test Equipment

4.2.4.1 Clean Connecting hoses and fittings

4.2.4.2 4-Way Control Valve

4.2.5 Test Spares and Consumables

4.2.5.1 Container of clean water

4.2.5.2 Clean regulated compressed air supply

4.3 SAFETY AND EMERGENCY CONSIDERATIONS

4.3.1 The Test Conductor shall be familiar with the Occupational Safety and Health Standard

29 CFR 1910. The Test Conductor shall also ensure that the test personnel are aware of potential hazards, safety precautions, and emergency procedures associated with this test.

4.3.2 The Test Conductor shall:

• Review this test procedure throughout to become familiar with specific tasks to be performed, as well as any warning or caution statements which may be contained herein;

• Verify that the test and support equipment meet the requirements of this test procedure; and

• Inspect all test and support equipment for serviceability and repair or replace as required prior to commencement of this test.

If any condition develops which, in the judgement of the Test Conductor, constitutes a danger to personnel or equipment, he shall stop the test until the condition is corrected.

4.3.3 Specific Safety Procedures

4.3.3.1 Fittings shall not be tightened nor loosened while under pressure.

4.3.3.2 Safety Glasses shall be worn while working with compressed air.

4.3.4 Specific Emergency Procedures

4.3.4.1 None

4.3.5 Additional Required Personnel

4.3.5.1 None

5.0 PROCEDURE

5.1 TEST PREPARATION

5.1.1 Verify that the Pneumatic Cylinder, Mast has been tagged QC acceptable. Enter the quantity of cylinders to be tested on the data sheet.

5.1.2 Install appropriate fittings and hoses to the pneumatic cylinder and the 4-way operating valve.

5.1.3 Connect air supply, regulated to 125 +10/-0 psig, to the operating valve.

5.1.4 Fully tighten the air cushion bleed valves, 2 ea., on the pneumatic cylinder.

5.2 AIR TIGHTNESS TEST

5.2.1 Verify the test pressure and record the gauge calibration information and the actual test pressure on the Data Sheet.

5.2.2 Using the operating valve, operate the pneumatic cylinder through its full range 10 times to verify proper operation of the pneumatic cylinder. Record the results on the Data Sheet.

5.2.3 Fully immerse the pneumatic cylinder in clean fresh water ensuring sufficient room in the container for the fully extended stroke of the pneumatic cylinder.

5.2.4 Cycle the operating valve to fully extend the pneumatic cylinder rod. Note the start time.

5.2.5 Observe the water for evidence of escaping air for 5 +1/-0 minutes. No leaks are acceptable. If no leaks are detected, note the stop time, record the results and elapsed times on the Data Sheet. If a leak is detected, record the results on the Data Sheet and abort the test.

5.2.6 Cycle the operating valve to fully retract the pneumatic cylinder rod. Note the start time.

5.2.7 Observe the water for evidence of escaping air for 5 +1/-0 minutes. No leaks are acceptable. If no leaks are detected, note the stop time, record the results and the elapsed time on the Data Sheet. If a leak is detected, record the results on the Data Sheet and abort the test.

5.2.8 Remove the pneumatic cylinder from the water and secure the air supply. Bleed the air form the hoses, remove the pneumatic cylinder from the test setup.

5.2.9 If a failure occurs, tag the cylinder as failed and deliver the failed cylinder to NSWC PCD

QC.

5.2.10 Upon completion of all testing, complete the Data Sheet.

DATA SHEET

PNEUMATIC CYLINDER, MAST

Pneumatic Cylinder, Mast, P/N 7110006-1, S/N

Required Actual Serial Calibration Accuracy Accuracy Number Due Date

0- psig Pressure Gauge +/-0.5% (0-200 to 0-400 psig)

AIR TIGHTNESS TEST (5.2)

Measurement Required Actual

10 Cycle Operation Proper Operation PASSED

FAILED

Cylinder Rod Fully Extended

Air Pressure 125-135 psig psig

Elapsed Time 5-6 Min. min

Leak Test Proper Operation PASSED

Cylinder Rod Fully Retracted

Air Pressure 125-135 psig psig

Elapsed Time 5-6 Min. min

Leak Test Proper Operation PASSED

DATA SHEET (Continued)

PNEUMATIC CYLINDER, MAST

Pneumatic Cylinder, Mast, P/N 7110006-1, S/N

TEST ACCEPTANCE CRITERIA:

No leaks during either of the 5 minute test intervals.

THE OVERALL TEST RESULTS ARE: ( ) SAT ( ) UNSAT

Sections 2.0 and 4.1 have been fully complied with, as required.

Supplemental Data Sheet(s) are used: ( ) No ( ) Yes pgs.

Test Conductor ORG Date Signature

QC Inspector Not Required ORG Date

6.0 CONCLUSION

6.1 DEFICIENCIES

6.2 EVALUATION OF TEST

6.2.1 Actual in-service conditions and environment have been encountered or simulated.

( ) Yes ( ) No

Comments:

6.2.2 The system has complied with test objectives. ( ) Yes ( ) No

Comments:

6.3 RESULTS ( ) Satisfactory ( ) Unsatisfactory

( ) Satisfactory with Conditions

6.4 COMMENTS

Pneumatic Cylinder, Mast, PN 7110006-1, S/N _____________

Reviewer: Date:

Title: Code:

7.0 SUPPLEMENTAL DATA SHEET

TEST NAME: PART NO. / SERIAL NO:

REASON FOR TEST:

COMMENTS:

RESULTS:

Test Conductor ORG Date

QC Inspector Not Required ORG Date