Attachment 3 ModI-MGShredder_FabInsp.docx

MOD1 Plastics Shredder Fabrication Inspection Procedures and Record, PWS001

Revision: - Revision Date: 11/17/03 Security Classification: UNCLASSIFIED

MOD1 PS Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ _________________/_________

Vendor Approval: _________________________ _________________/_________

1.0 Introduction

2.0 Equipment.

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the measuring equipment finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required include: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None.

4.0 Services. None.

MOD1 Plastics Shredder Fabrication Inspection Procedures and Record, PWS001

Results

— Direct measurement or record review methods may be used —

Inspector Record Revision of Dwg. used. Initials

Reference - Dwg. No. 593-6960885, Assy 97, Section 30-A: Rev. _____ ______

Test Complete.

ATTACHMENT B

B4 – MOD1 Plastics Shredder

MOD1 Plastics Shredder Assembly Inspection Procedures, PWS002

Revision: - Revision Date: 11/17/03 Security Classification: UNCLASSIFIED

MGS Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this inspection is to ensure that components are assembled, to the required alignment tolerances.

2.0 Equipment.

Services. None.

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the measuring equipment finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required include: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None.

4.0 Services: None.

MOD1 Plastics Shredder Assembly Inspection Procedures, PWS002

Results

— Direct measurement or record review methods may be used —

Inspector Record Revision of Dwg. used. Initials

Reference - Dwg. No. 593-6960881 Rev. _____ ______ 7556873

Speed Speed Gap measured between shafts: _____ _____ (min = 0.438 inch, max = 0.500 inch)

Speed Speed Horizontal offset (indicated near ends of shafts) (max = .015 inch) _____ _____

Speed Speed Vertical offset (indicated near ends of shafts) (max = .015 inch) _____ _____

Speed Speed Angularity (max = 0.50 degree (or dimensional difference between shaft faces = .015" max) _____ _____

Test Complete.

MOD1 Plastics Shredder Verification Procedures and Record, PWS003

Revision: - Revision Date: 11/17/03 Security Classification: UNCLASSIFIED

MOD1 PS Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this inspection is to verify the electrical function and mechanical operation of the metal/glass shredder. The order of test steps can vary as long as all steps are done.

2.0 Equipment.

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the measuring equipment finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required include: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None.

4.0 Services.

4.1 440 Vac, 3 Phase, 60 Hz, 10 Amp supply (minimum) with circuit breaker element of 10 Amp

4.2 100 +/- CFM Exhaust Air Flow

MOD1 Plastics Shredder Verification Procedures and Record, PWS003

Results

— Direct measurement or record review methods may be used —

Inspector Record Revision of Dwg. used. Initials

Reference - Dwg. No. 593-6960881 Rev. _____ ______

Assumptions - Point-to-point wiring checkout and verification have been completed.

If any of the following verifications cannot be made as described, troubleshoot as required to isolate the cause and/or failed component.

Record results (Sat or Unsat). Initial and Date are required only where lines entered (at Step Completions). Government witness, when performed will be recorded in Initials/Date column.

ASSUMPTIONS:

The 440 Vac power feed is connected to the main switch. The main switch, motor, differential air pressure switch, feed hopper sorting tray limit switch, and the collection area door limit switch are connected to the electrical control panel.

The suction tube is connected from the differential air pressure switch to the exhaust connection on the collection area enclosure.

The temporary exhaust system 100 +/- 10 CFM to evacuate the collection area, shredder chamber, and feed hopper is connected.

Verify all areas free of items which are not to be shredded.

Verify that the EMERGENCY STOP pushbutton is PULLED OUT to the on position.

Set the MODE switch in the SHRED position.

Close and latch the FEED HOPPER DOOR.

Close and latch the COLLECTION AREA DOOR.

Turn on the temporary exhaust system.

Turn on the main switch and observe POWER AVAILABLE indicator is ON.

Put key in the POWER switch, turn ON and observe the TOTAL HOURS meter is running.

Turn the MODE switch to the CLEAN position and observe total hours meter is running.

Restore the MODE switch to the SHRED position. Step 3 completed.

Complete preoperation checkout (Test Step 3).

Push the EMERGENCY STOP pushbutton to the off position and observe the TOTAL HOURS meter stops.

Press the START pushbutton and verify that the shredder motor does not rotate.

Set the MODE switch to the CLEAN position. Press START pushbutton and verify shredder motor does not rotate.

Restore the EMERGENCY STOP pushbutton to the ON position and the MODE switch to the SHRED position.

Turn off the shredder exhaust system and verify the DOOR OPEN OR VENT OFF indicator goes ON.

Press the START pushbutton and verify that shredder motor does not rotate.

Set the MODE switch to the CLEAN position. Press the START pushbutton and verify that shredder motor does not rotate.

Restart the shredder exhaust system and observe the DOOR OPEN OR VENT OFF indicator goes OFF.

Restore the MODE switch to the SHRED position.

Open the feed hopper sorting tray latch and observe the DOOR OPEN OR VENT OFF indicator goes ON.

Press the START pushbutton and verify that shredder motor does not start.

Press the START pushbutton and verify that shredder motor does not start.

Set the MODE switch to the CLEAN position. Press the START pushbutton and verify that shredder motor does not start.

Close and latch the Feed Hopper Door and verify that the DOOR OPEN OR VENT OFF indicator goes OUT.

Restore the MODE switch to the SHRED position.

Open the collection area door latch and verify that DOOR OPEN OR VENT OFF indicator goes ON.

Press the START pushbutton and verify that shredder motor does not rotate.

Set the MODE switch to the CLEAN position. Press the START pushbutton and verify that shredder motor does not rotate.

Close the collection area door latch and verify that the DOOR OPEN OR VENT OFF indicator goes OUT.

Restore the MODE switch to the SHRED position. Step 4 completed.

Complete preoperational setup and interlock checkout (Test Steps 3 and 4).

Open and reclose the feed hopper sorting tray latch, then press the START pushbutton and observe:

- Verify the SHREDDER OPERATING indicator go ON and the RUNNING HOURS meter runs.

- Verify the speed reducer and/or shredder shafts rotate inwards (toward each other) when viewed from the top. Verify that they run for approximately 30 seconds and then shut off.

- Verify the motor stops, the SHREDDER OPERATING indicator goes out, and the RUNNING HOURS meter stops. Step 5 completed.

Complete the preoperational setup and interlock checkout (Test Steps 3 and 4).

Start the shredder using the Operation Checkout (Test Step 5).

Push the STOP pushbutton during the 30 second shred running period and verify that the motor stops and the SHREDDER OPERATING indicator goes OUT.

Restart the shredder (Test Step 5) with the MODE switch in the CLEAN position and push the STOP pushbutton during the 10-second running period and verify that the motor stops and the SHREDDER OPERATING indicator goes OUT.

Restore the MODE switch to the SHRED position. Step 6 completed.

Complete the preoperational setup and interlock checkout (Test Steps 3 and 4).

Turn the key-operated POWER switch to OFF.

Open and reclose the feed hopper sorting tray latch, then press the START pushbutton and verify the shredder motor does not rotate.

Set the MODE switch to the CLEAN position. Press the START pushbutton and verify that the shredder motor does not rotate.

Restore the MODE switch to the SHRED position and turn the key-operated power switch to ON. Step 7 completed.

Complete the preoperational setup and interlock checkout (Test Steps 3 and 4).

START the shredder using the Operation Checkout (Test Step 5).

Turn the MODE switch to the CLEAN position during the shred running period and observe the motor stops and the SHREDDER OPERATING indicator goes out. Immediately push the START pushbutton to verify that the shredder motor will not rotate for 3 seconds.

NOTE: This 3-second period starts when the MODE switch position is changed from the SHRED position to the CLEAN position.

Restart the shredder (Test Step 5) with the MODE switch in the CLEAN position and observe:

- The SHREDDER OPERATING indicator goes ON.

- Verify the speed reducer and/or shredder shaft rotate outward (away from each other when viewed from above), verify they run for approx. 10 seconds.

- The motor stops and the SHREDDER OPERATING indicator goes OUT.

Restart the shredder with the MODE switch in the CLEAN position. Turn the MODE switch to the SHRED position during the 10-second running period and observe:

- The motor stops and the SHREDDER OPERATING indicator goes out. Immediately push the START pushbutton to verify that the SHREDDER motor will not rotate for 3 seconds. Step 8 completed.

Complete the preoperational setup and interlock checkout (Test Steps 3 and 4).

Start the shredder suing Operation Checkout (Test Step 5).

Push the EMERGENCY STOP pushbutton during the shred running period and observe that the motor stops and the SHREDDER OPERATING indicator goes OUT.

Open and reclose the feed hopper sorting tray latch, then press the START pushbutton and verify that the shredder motor does not rotate.

Pull the EMERGENCY STOP pushbutton to the ON position and set the MODE switch to the CLEAN position.

Start the shredder by pushing the START pushbutton.

Push the EMERGENCY STOP pushbutton during the 10-second running period and verify that the motor stops and the SHREDDER OPERATING indicator goes out.

Open and reclose the feed hopper sorting tray latch, then press the START pushbutton to verify that the shredder motor does not rotate.

Restore the EMERGENCY STOP pushbutton to the ON position and the MODE switch to the SHRED position. Step 9 completed.

10. JAM TEST CHECKOUT:

Open the sorting tray and load suitable test material into the feed hopper.

Close and latch the sorting tray.

Turn on the main switch and the key-operated POWER switch.

Start the shredder by pushing the START pushbutton.

When the shredder jams, verify that the motor stops for 3 seconds, restarts in reverse for 3 seconds, stops for 3 seconds, and restarts in the forward direction.

If the shredder jams while running in the reverse direction, verify that the motor stops and the REMOVE JAM indicator lights goes ON. Also, verify that the SHREDDER OPERATING indicator goes OUT. Do not start the shredder until the jam is removed.

Open the feed hopper sorting tray and remove the jam and observe the REMOVE JAM indicator will go OUT and the DOOR OPEN OR VENT OFF indicator will go ON.

Close and latch the sorting tray door. Switch mode to CLEAN, press START and allow shredder to run through a cleaning cycle to clear any remaining test materials. Empty the collection bin. It is not necessary to remove 100% of the test materials from the shredder chamber. Step 10 completed.

Test Complete.