3558_Modernization_CSS_Final_1.docx

pressure test chamber CALIBRATION STANDARD SPECIFICATION CSS 06-2187

CSS 06-2187

CALIBRATION STANDARD SPECIFICATION PROCUREMENT PACKAGE

Pressure test chamber

DISTRIBUTION STATEMENT C. DISTRIBUTION AUTHORIZED TO U. S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS TO PROTECT PUBLICATIONS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR OPERATIONAL PURPOSES ONLY. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO MEASUREMENT SCIENCE DIRECTORATE, NAVAL SURFACE WARFARE CENTER, CORONA DIVISION, P.O. BOX 5000, CORONA

A, CA, 91718-5000.

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

June 2017

CALIBRATION STANDARD SPECIFICATION PROCUREMENT PACKAGE

pressure test chamber

Prepared by:

Physical/Mechanical Standards (MS 33) Measurement Science Department Naval Surface Warfare Center, Corona Division P.O. Box 5000 Corona, CA 91718-5000

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

Table of Contents

pressure test chamber CALIBRATION STANDARD SPECIFICATION CSS 06-2187 i

1.0 SCOPE

1.1 General. This document specifies the minimum requirements for a Pressure Test Chamber. The Pressure Test Chamber is intended to be used by Navy personnel in shore-based depot laboratories for calibration of caisson gauges, diver depth gauges, and hyperbaric atmospheric monitors.

1.2 Usage. Equipment covered by this Calibration Standard Specification (CSS) is intended for use in calibrating depth gauges, caisson gauges, and hyperbaric atmospheric monitors in controlled environments. The requirements of this CSS are tailored to the intended use of the equipment. Specific requirements in accordance with ASME Section VIII Division 2 and ASME PVHO-1, as identified in this CSS, are invoked according to the class of equipment.

1.3 Classification.

1.3.1 Class. The Pressure Test Chamber shall be classified as Class 3 equipment and shall conform to Class 3 requirements in accordance with MIL-PRF-28800, and as specified in this specification. Class 3 equipment is designed for operational environments where conditions are routinely encountered in a diverse, controlled climate.

1.3.2 Configuration. The Pressure Test Chamber shall at a minimum cover the range of a minimum allowable working pressure of 50 micron Hg absolute pressure to a maximum allowable working pressure of 1000 psig. The Pressure Test Chamber shall have a minimum internal diameter of 12 inches with an internal depth of 14 inches.

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issues of these documents shall be those in effect on the date of this solicitation.

DEPARTMENT OF DEFENSE specifications

(Copies of DoD specifications are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

National Institute of Standards and Technology NIST Technical Note 1297 - Guidelines for Evaluating and Expressing the Uncertainty of NIST Measurement Results Copies of NIST Technical Notes are available online at http://physics.nist.gov/Pubs/guidelines/TN1297/tn1297s or from the National Institute of Standards and Technology, Gaithersburg, MD 20899-0001

NAVY METROLOGY AND CALIBRATION PROGRAM

NAVAIR 17-35QAC-01B Navy and Marine Corps Calibration Laboratory Audit/Certification Manual

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE AS4841 - Fittings, 37 Degree Flared, Fluid Connection (Copies of SAE documents are available at http://www.sae.org/technical/standards/AS4841or SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001.)

American society of mechanical engineering ASME BPVC Section VIII-Rules for Construction of Pressure Vessels Division 2-Alternative Rules -

Copies of ASME Section VIII Division II Alternative Rules available online at https://www.asme.org/products/codes-standards/ptb1-2014-section-viii-division-2-criteria ASME PVHO-1 Standards - Standard Provides Requirements for the Design, Fabrication, Inspection Testing, Marking, and Stamping of Pressure Vessels for Human Occupancy Copies of ASME PVHO-1 Requirements are available online at https://www.asme.org/products/codes-standards/pvho1-2016-safety-standard-pressure-vessels-human

2.2 Order of precedence. In the event of conflict between the text of this CSS and the references cited herein, the text of this specification shall take precedence. Nothing in this CSS, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 Equipment components. Parts, materials, and process shall be as specified below in 3.1.1 Equipment Configuration through 3.1.7 Interchangeability.

3.1.1 Equipment Configuration. The Pressure Test Chamber shall consist of a Pressure Chamber, a Test Stand, a Gauge Mounting Frame, and a Test Hose. The Pressure Chamber shall consist of all plumbing/piping/valves, light source, electrical and data connections, door, viewport, and other components required to control the pressure necessary to meet the performance requirements of this CSS.

3.1.2 Pressure Chamber. The Pressure Chamber shall include the following features: a door, a safety lock mechanism for the door, a viewport, an internal lamp, a lamp switch, a relief valve, three ports for external pressure sources/gauges, one of which with a pressure fitting inside the chamber to allow for a hose connection, a connection for a temperature probe, a data connection port to communicate with equipment under pressure inside the pressure chamber, and an internal electrical port to power equipment under pressure inside the pressure chamber.

3.1.3 Test Stand. The Test Stand shall be capable of supporting the Pressure Chamber and be capable of being secured to a bench or table of suitable strength via 3/8th inch bolts. The test stand may be incorporated into the pressure chamber as one item, provided the chamber may still be secured to a bench or table.

3.1.4 Temperature Probe Connection. A temperature probe shall be capable of being installed in the pressure chamber on an as-needed basis. The temperature probe installation location shall not interfere with the Gauge mounting frame. The temperature probe connection shall be wired to the outside of the Pressure Test Chamber to a location that is easily accessible by the user. The connection port shall be an AN, pipe thread, or similar fitting. An end cap shall be provided for use when the port is not utilized for a test configuration.

3.1.5 Data Connection. A data connection shall be capable of being installed in the pressure chamber on an as-needed basis. The data connection installation location shall not interfere with the Gauge mounting frame. The data connection shall be wired to the outside of the Pressure Test Chamber to a location that is easily accessible by the user. The connection port may be an AN, pipe thread, or similar fitting. An end cap shall be provided for use when the port is not utilized for a test configuration. The data connection shall be RS-232 or USB.

3.1.6 Pressure Inputs and Outputs. The Pressure Test Chamber shall have inputs and outputs that are readily accessible to the end-user. The Pressure Test Chamber shall have ports suitable for connecting vacuum pumps, pressure gauges, and external pressure sources that operate in the pressure ranges of the Pressure Test Chamber. The Pressure Test Chamber shall have overpressure protection and pressure ports with installed pressure fitting connections as described in 3.1.5.1 Relief Valve and 3.1.6.2 Pressure Ports below.

3.1.6.1 Relief Valve. The Pressure Test Chamber shall have a pressure relief valve to allow the pressure chamber to vent automatically when the max operating pressure is exceeded. The relief valve shall also allow for manual venting of the Pressure Test Chamber to return to atmospheric conditions.

3.1.6.2 Pressure Ports. The Pressure Ports shall have male 37-degree AN4 flare tips with end caps. There shall be three Pressure Ports. One port shall be in immediate proximity to the Relief Valve to allow for a pressure gauge/monitor to be mounted/connected for monitoring the internal pressure of the Pressure Test Chamber. The additional two pressure ports must be readily accessible to allow for connection to an external pressure source. One of the two additional ports shall feed through to a pressure port with a male 37-degree AN4 flare tip fitting accessible from the inside of the Pressure Test Chamber to allow for a test hose to be connected. End caps, in accordance with 3.7.4.2, shall be provided for use when the port(s) are not utilized for a test configuration. AN flare fittings shall be in accordance with SAE AS4841. The pressure input/output ports shall be a minimum of 2” apart from each other and the relief valve to allow for the connection of a pressure gauge.

3.1.7 Finish. Unless otherwise specified the equipment shall be the finish normally provided by the manufacturer.

3.1.8 Interchangeability. A model number shall be designated for all units provided. All units with the same model number and the replaceable assemblies, subassemblies, and parts comprising the unit shall be interchangeable on a noninterference basis.

3.2 Design and construction. The Pressure Test Chamber shall be designed and constructed to permit compliance with all applicable requirements, as defined in this CSS as well as the operation, performance, accuracy, and other requirements in this CSS. The Pressure Chamber shall be designed and constructed according to ASME Section VIII Division 2 for the specifications called out in this CSS. The viewport shall be designed and constructed according to ASME PVHO-1 for the specifications called out in this CSS.

3.2.1 Operator controls. Operating controls and indicators shall be readily accessible to the operator from the front of the equipment. The readings presented on the controls and indicators shall be available to the operator without conversion or calculation. All operator controls shall be clearly labeled. For example, the Relief Valve, Pressure Ports, and door locked state (unlocked and locked).

3.2.2 Connectors, electric. Provision shall be made to ensure that connectors will be mated only with the appropriate counterparts. All connectors shall be clearly labeled. Where design considerations require close proximity of connectors of similar configuration, the mating connectors shall be suitably coded or marked to minimize risk.

3.2.3 Wiring, internal. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance and use.

3.3 Electrical power sources and connections. The electrical power sources and connections shall be as specified below in 3.3.1 Electrical power source and 3.3.1.3 Pressure Chamber.

3.3.1 Electrical power source. The Pressure Test Chamber shall operate at 115 VAC single-phase 50 Hz and 60 Hz source.

3.3.1.1 Input power cable. Unless specified, the input power cable shall be a detachable power cable normally provided by the manufacturer.

3.3.1.2 Input power switches. The operator shall be able to energize the internal lamp with a switch readily accessible at the front of the Pressure Test Chamber. The operator shall be able to energize equipment connected to the power supply inside the pressure chamber with a switch that is readily accessible at the front of the pressure chamber.

3.3.1.3 Pressure Chamber. The Pressure Test Chamber Test Stand shall be provided with a fuse or circuit breaker to protect the equipment in the Pressure Test Chamber in the event of excessive current.

3.4 Physical characteristics. The physical characteristics of the Pressure Test Chamber shall be as specified in 3.4.1 Dimensions through 3.4.2 Weight.

3.4.1 Dimensions. Minimum and/or maximum dimensions of the Pressure Test Chamber shall be as specified in 3.4.1.1 Internal Dimensions through 3.4.1.4 Gauge Mounting Frame Dimensions.

3.4.1.1 Internal Dimensions. The Pressure Chamber shall have internal dimensions of at least 12 inches in diameter and 14 inches in depth.

3.4.1.2 Viewport Dimensions. The Viewport shall be a minimum viewable dimension of 8 inches in diameter. The viewport shall be accessible from the front and shall be a part of the door of the Pressure Chamber.

3.4.1.3 Door Dimensions. The door that seals the Pressure Chamber shall provide a minimum opening of 12 inches in diameter.

3.4.2 Weight. The weight of the fully assembled Pressure Test Chamber including all components and accessories shall not exceed 300 pounds.

3.5 Marking and identification. Marking and identification of the Pressure Test Chambers shall be as specified below in 3.5.1 Marking through 3.5.2 Panel markings and processes.

3.5.1 Marking. The Pressure Test Chamber shall be marked in a manner that does not adversely affect safety or performance. At a minimum the manufacturer, model number, serial number, and pressure range of the unit shall be identified.

3.5.2 Panel markings and processes. Panel markings shall enable the operator to identify the functions and use of all items requiring operator intervention.

3.6 Environmental requirements. The Pressure Test Chamber environmental performance requirements shall be as specified below in 3.6.1 Temperature and humidity. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.6.1 Temperature and humidity. The temperature ranges and humidity limits for operating conditions shall be as specified below in 3.6.1.1 Temperature operating and 3.6.1.2 Humidity operating.

3.6.1.1 Temperature operating. The Pressure Test Chamber shall conform to the specified performance and accuracy while being operated at temperatures over the range of 60 °F to 85 °F.

3.6.1.2 Humidity operating. The Pressure Test Chamber shall conform to the specified performance and accuracy while being operated in a humidity range of 20% RH to 60% RH.

3.7 Performance requirements.

3.7.1 Pressure Chamber. The Pressure Test Chamber must be designed and constructed to conform to ASME Section VIII Division 2 for the requirements listed in this CSS. The Pressure Test Chamber and all of its components must be capable of being cycled in pressure to its maximum allowable working pressure.

3.7.2 Viewport. The Viewport must be designed and constructed to conform to ASME PVHO-1 for the requirements listed in this CSS.

3.7.3 Pressure Range. The Pressure Test Chamber shall be capable of maintaining and controlling a working pressure range of 50 micron Hg absolute pressure to 1000 psig.

3.7.3.1 Input pressure. Maximum allowable working pressure inputs shall not be less than 1000 psig. Minimum allowable working pressure inputs shall not be greater than 50 micron Hg absolute pressure.

3.7.4 Accessories. The Pressure Test Chamber shall, at a minimum, have the accessories below in 3.7.4.1 Test Hose through 3.7.4.3 Gauge Mounting Frame as well as any other accessory required for the Pressure Test Chamber to meet the requirements of this CSS.

3.7.4.1 Test Hose. The Pressure Test Chamber shall be provided with a test hose for use internal to the Pressure Test Chamber. The test hose provided shall have a rated operating pressure of 1,000 psig, a proof pressure of 1,500 psig and a minimum burst pressure of 4,000 psig. The hose shall terminate with a female 37-degree AN4 flare tip on each end in accordance with SAE AS4841. The hose shall have the working pressure and burst pressure clearly marked on a metal tag and permanently attached to the hoses. The hose shall be designed with a protective outer covering that shall resist damage from crimping or abrasion. The hose shall have a minimum bending radius of 2.5 inches at maximum working pressure. In addition, hose ends shall have sufficient strain relief to prevent damage to the hose/fitting interface. The hose shall have tethered caps/plugs for each end to prevent contamination and or damage during non-use or storage. The hose shall be 24 inches in length.

3.7.4.2 End Caps. End caps shall be provided to cap pressure ports of the Pressure Test Chamber that are not in use. The caps shall allow for the Pressure Test Chamber to be exercised to various pressures in the use range by preventing any loss in pressure via unused pressure ports. The caps shall be female AN-fittings that are able to meet the minimum use requirements of the Pressure Test Chamber. AN flare fittings shall be in accordance with SAE AS4841.

3.7.4.3 Gauge Mounting Frame. The Gauge Mounting Frame shall be capable of being installed in the pressure chamber on an as-needed basis. The Gauge Mounting Frame shall be capable of mounting pressure gauges so that the gauge faces are viewable through the viewport. The mounting frame may be a cradle, a test stand, or other structure that is capable of mounting a variety of gauges in an orientation where the gauge face is perpendicular and oriented correctly for viewing from the viewport of the Pressure Test Stand. The mounting frame/cradle/test stand must be easily removable from the pressure chamber.

3.8 Maintainability. Maintainability shall be as specified below in 3.8.1 Fault isolation through 3.8.2 Repair.

3.8.1 Fault isolation. The design of the equipment shall permit isolation of faults, and repair down to the component/subassembly item or lowest replaceable unit with the maintenance provisions furnished.

3.8.2 Repair. Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies and subsequent testing procedures to ensure the performance of the component or the repair action taken. Spare parts information shall be provided for all major components of the system including but not limited to: valves, seals, viewports, filters, fuses, connectors, and light fixtures.

3.9 Technical manuals. Two copies of an operation and maintenance manual shall be provided with each unit. Technical manuals shall conform to the requirements specified in 3.9.1 Style and format, technical manuals through 3.9.3 Symbols. The technical manuals shall be provided in both printed and electronic format. The electronic copy shall be in a Portable Document Format (PDF) and Microsoft Word on a CD or DVD.

3.9.1 Style and format, technical manuals. All text shall be legible. A cover page shall include, equipment name and model number. A table of contents shall be provided.

3.9.2 Content, technical manuals. The contents of the technical manuals shall include sections addressing safety, general information, use and installation, maintenance and service. Drawings of the Pressure Test Chamber with sufficient detail to identify all controls and connections shall be supplied. The content of the sections shall conform to the description provided below in 3.9.2.1 Safety, technical manual section through 3.9.2.4.2 Part replacement information.

3.9.2.1 Safety, technical manual section. The manual shall contain warnings, cautions and notes to prevent injury to personnel and damage to equipment. The warnings shall contain safety precautions where hazards such as high voltage, high pressure, and high temperature may be present during installation, operation, or maintenance.

3.9.2.2 General, technical manual section. The manual shall contain the following: purpose and functions, capabilities, performance characteristics, description (model number, dimensions, and weight), power information, and operational environment requirements.

3.9.2.3 Use and installation, technical manual section. This section shall contain information on the following: operating instructions (illustrations and explanations of the uses and functions of all controls and indicators), initial adjustments and control settings, startup procedures, required clearances, illustrations of equipment connections, and installation precautions.

3.9.2.4 Maintenance and servicing, technical manual section. The level of maintenance philosophy shall be unit operational verification, and component level. Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies on the systems. Testing procedures to ensure the performance of the component or the repair action taken shall be provided. Testing procedures to include procedures and periodicity information for periodic pressure testing of the pressure test chamber.

3.9.2.4.1 Cleaning maintenance. Cleaning information covering intervals, types of solvents, and materials used shall be listed in the maintenance and servicing section of the technical manual.

3.9.2.4.2 Part replacement information. Common commercial parts shall be identified by part number and description to facilitate substitutions of parts from other sources.

3.9.3 Symbols. All symbols used in the technical manual shall be standard or common to the trade. Where nonstandard symbols are used, explanations shall be provided.

3.10 Workmanship. The manufacture and assembly of the items covered by this CSS shall be representative of the best commercial practices and shall conform to the requirements of this CSS

4.0 VERIFICATION

4.1 General. All Pressure Test Chambers procured shall be capable of satisfying all of the requirements indicated in Section 3 of this CSS and shall be subjected to testing. Verification shall be accomplished by using the test procedures in MIL-PRF-28800 for Class 3 equipment for those tests identified and as modified in the following paragraphs.

4.2 Technical Manual Review. The Pressure Test Chambers Technical Manual(s) shall be reviewed and examined for compliance with the requirements specified in paragraph 3.9 Technical manuals of this CSS.

4.3 Conformance inspections. The test methods, procedures, and conditions specified in 4.3.1 Production inspection, Group A through 4.3.5 Accuracy of test instruments are required for conformance inspection.

4.3.1 Production inspection, Group A. Each unit shall be subjected to the Group A inspection and test of 4.3.1.1 to ensure qualitatively the proper functioning of the equipment, including all operating controls, and conformance with safety requirements.

4.3.1.1 Group A inspection and test. Group A inspection shall consist of the inspections of 4.3.1.1.1 Preoperational inspection through 4.3.1.1.2 Level A performance tests.

4.3.1.1.1 Preoperational inspection. The preoperational inspections shall consist of mechanical and visual examination and test to determine that all materials, workmanship, and safety characteristics comply with the specified requirements. The equipment shall be examined or tested to confirm that all electrical wiring is correct and that no mechanical problems are evident.

4.3.1.1.2 Level A performance tests. The Level A performance tests shall verify conformance of the system to the performance requirements of this CSS. At a minimum the Level A performance tests shall include the following: full test to current performance specification including AMSE specifications and functional testing of all components.

4.3.2 Test plan. An equipment test plan shall be developed by the manufacturer. The test plan must be reviewed and approved by the Navy prior to delivery of the system. The test plan shall be used to verify conformance to the requirements of the contract and this specification.

4.3.3 Failure criteria. For the purposes of this CSS, equipment failure is defined as any departure from the required performance requirements or operation outside of the required parameters (not correctable by normal use of the operating controls), or deviation from the criteria specified in 3.7 Performance requirements after the test is initiated. The item shall have failed the test when any of the conditions specified in a. through g. below occur:

Monitored functional parameters deviate beyond acceptable limits Catastrophic or structural failure Mechanical binding or loose parts, including screws, clamps, bolts, and nuts, that results in component failure or a hazard to personnel safety Malfunction Degradation of performance beyond limits established in the purchase description Any additional deviations from acceptable criteria established before the test Deterioration, corrosion, or change in structure of any internal or external parts that could in any manner prevent the test item from conforming to operational service or maintenance requirements

4.3.4 Test conditions. Unless otherwise specified the inspections specified herein shall be performed under the conditions of a. through d. Ambient conditions within the specified ranges need not be controlled Temperature: 60 °F to 85 °F Humidity: 20% RH to 60% RH Power: Nominal or alternate power source specified for the equipment Attitude: Normal operating position

4.3.5 Accuracy of test instruments. The test instruments used to control or monitor the test parameters shall be verified to be within their calibration cycle prior to performing tests.

image1.wmf