4Q1.7-108.pdf

Manual: 4Q1.7 Procedure: 108 Revision: 10

AIR FLOW TESTING ON HIGH AND LOW PRESSURE

PLASTIC HOOD AIRLINE RESPIRATORS

Effective Date: 04/11/2016 Type-Class: Tech-Ref Page: 1 of 10

1.0 INTRODUCTION

1.1 Purpose

To provide instructions for testing air flow in high and low pressure plastic hood airline respirators.

1.2 Scope

This procedure applies to the testing of airflow in high and low pressure plastic hood airline respirators in the Respiratory Equipment Facility (REF) by the REF personnel who are authorized to perform airflow testing.

This is a Reference procedure. The user is not required to have this procedure present while performing the activity.

The following OSR forms may be utilized in the performance of this procedure:

OSR 4-979, Plastic Hood Certification

OSR 4-510, Respiratory Equipment Record and QA

2.0 GENERAL INFORMATION

2.1 Definitions and Abbreviations

AQL – Acceptable Quality Level psig – pounds per square inch gauge scfm - standard cubic feet per minute

2.2 Responsibilities

1. The REF Lead is responsible for:

Evaluating hood test criteria for acceptance, Notifying the Respirator Program Administrator via email if significant issues are reported, Determining if issuance of a nonconformance report (NCR) is required when significant issues are found, Initiating and responding to NCRs per Manual 1Q, QAP 15-1, Control of Nonconforming Items, Approving implementation of switching rules.

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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2.2 Responsibilities, (cont.)

2. REF Personnel are responsible for:

Performing air flow testing on plastic hoods in accordance with this procedure, Completing qualification training as specified in the Job Performance Standard or approved equal.

2.3 Information

High and low pressure plastic hood airline respirators are tested to ensure that an adequate airflow of 6 to 10 cfm is supplied to the user. Using the REF lot size and the American National Standards Institute/American Society of Quality (ANSI/ASQ) Z1.4, Sampling Procedure and Tables for Inspection by Attributes (Appendix 8.1, 8.2, 8.3) and Switching Rules (Appendix 8.4), the number of hoods to be tested is determined.

2.3.1 Equipment Description

The airflow test chamber is a Plexiglas box. This Plexiglas box is equipped with two breathing air hose connectors with pressure gauges attached on the outside of the box. Coupled to the air hose connectors on the inside of the box is an orifice assembly for high pressure and a breathing air hose connector for low pressure. A mass flow meter is installed on the opposite side of the box to measure airflow. A 3/8 inch ID jumper hose is used to connect breathing air from the manifold to the connectors located on the outside of the box.

The pressure gauges and massflow meter are Measuring and Test Equipment (M&TE) and have calibration periods.

There are two different pressure regulators in use at the REF, both are manufactured by the same company, Norgren. The Norgren model numbers are

R74G-4AT-NMG

R74G-4AK-RMG

The differences in the two models are the T for Tbar and K for knob adjustment. The other difference is model R74G-4AT-NMG is a non-relieving regulator and must have air flow through it to accurately set the pressure.

3.0 PRECAUTIONS AND LIMITATIONS

1. A hazard analysis has been performed on this task.

2. Additional hazard analysis may be required to ensure that facility/job specific hazards are identified and that the appropriate actions are taken to eliminate/mitigate the identified hazard(s).

3. Safety glasses with side shields shall be worn when in posted work areas.

4.0 PREREQUISITES

None

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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5.0 PERFORMANCE

5.1 Inspection

1. PROCEED to the airflow test chamber.

2. VERIFY the pressure gauge on the manifold regulator is within its calibration period.

A. IF it is not within its calibration period, THEN

NOTIFY the REF Lead.

3. VERIFY both the Low Pressure (LP) and High Pressure (HP) gauges and massflow meter are within their calibration period.

A. IF it is not within calibration period, THEN

NOTIFY the REF Lead.

4. ENSURE that the REF manifold is NOT equipped with a restricting orifice.

5. WHEN testing hoods, THEN

PERFORM connections as follows:

For low-pressure hoods, connect the jumper hose from the manifold to the connector on the airflow test chamber labeled “LP” for low pressure.

For high-pressure hoods, connect the jumper hose from the manifold to the connector on the airflow test chamber labeled “HP” for high pressure.

The high-pressure connector is coupled to an orifice assembly (part number HP-7-64); the low pressure connector is not.

6. DETERMINE if the plastic hood is a high pressure or low pressure unit.

7. CONNECT the jumper hose to the manifold and to the appropriate connector for the type of hood being tested.

8. UNLATCH all latches on the top of the airflow test chamber (Plexiglas box).

9. PULL up on the top of the box to open the airflow test chamber.

10. PLACE the assembled hood with hose attached inside the airflow test chamber.

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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5.1 Inspection, (cont.)

11. WHEN testing hoods equipped with disconnect, THEN

TEST the hood with both an H-100 and an L-25 hose.

12. CONNECT the hose to the correct connector inside the airflow test chamber.

NOTE

The high-pressure connector is coupled to an orifice assembly (part number HP-7-64);

the low-pressure connector is not. Each is appropriately labeled HP (High Pressure) and LP (Low Pressure).

13. POSITION hose and hood so that the airflow to the mass flow meter is not blocked.

14. CLOSE the airflow test chamber top, AND

LOCK all latches on the top of the airflow test chamber.

NOTE

Always approach the desired pressure from a lower pressure. When reducing from a higher to a lower setting, first reduce to some pressure less than that desired, then bring up to the desired pressure.

15. WHEN applying inlet pressure to regulator, THEN

TURN adjustment counterclockwise 1 to 7 turns to remove all force on the regulating spring.

16. VALVE on the air at the manifold, AND

A. APPLY inlet pressure.

B. TURN adjustment clockwise 1 to 7 turns to increase and counterclockwise to decrease pressure setting.

17. SET the pressure at 100 psig when testing hoods with the H-100 hose and 25 psig when testing hoods with the L-25 hose.

18. ENSURE the pressure gauge on the exterior of the box is at the required airflow for the type of plastic hood being tested.

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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5.1 Inspection, (cont.)

NOTE

The pressure gauge on the exterior of the box should read 100 psig when testing high pressure plastic hoods. The pressure gauge on the exterior of the box should read 25 psig when testing low pressure plastic hoods.

19. CHECK the reading on the mass flow rate meter. Flow rates for both the high and low pressure plastic hoods shall be between 6 and 10 scfm.

20. IF the reading is within the given range, THEN

RECORD the reading on OSR 4-979.

21. VALVE off air at the manifold.

22. UNLATCH all latches on the top of the airflow test chamber (Plexiglas box).

23. PULL up on the top of the box to open the airflow test chamber.

24. DISCONNECT the hose from connector inside the airflow test chamber.

25. REMOVE the assembled hood with hose from airflow test chamber.

26. COMPLETE Steps 5.1.6 through 5.1.25 until the required number of plastic hoods have been tested using the REF lot size and the ANSI/ASQ Z1.4, Sampling Procedure and Tables for Inspection by Attributes (Appendices 8.1, 8.2, 8.3).

5.2 Post Performance Activities

1. TOTAL rejects, AND

RECORD on OSR 4-510.

2. FORWARD completed OSR 4-510 and OSR 4-979 forms to the REF Lead for evaluation and filing.

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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6.0 REFERENCES

1Q, Procedure 15-1, Control of Nonconforming Items

42 CFR 84.150 Table 8, Test/Inspection Program for all Supplied-Air Respirators

ANSI/ASQ Z1.4, Sampling Procedures and Tables for Inspection by Attributes

Hazard Analysis INF-19975

OSR 4-979, Plastic Hood Certification

OSR 4-510, Respiratory Equipment Record and QA

IM-200.200, Norgren R74G, R74R Installation and Maintenance Instructions

WSRC-IM-2006-00032, Quality Assurance Documentation for Savannah River Nuclear Solutions Plastic Hoods and Hoses

7.0 RECORDS

Records generated as a result of implementing this procedure are maintained in accordance with Manual 1B, Procedure 3.31, Records Management.

OSR 4-979, Plastic Hood Certification

OSR 4-510, Respiratory Equipment Record and QA

8.0 ATTACHMENTS

Appendix 8.1 ANSI/ASQ Z1.4, Inspection Sampling Plan for AQL 1.0 Normal

Appendix 8.2 ANSI/ASQ Z1.4, Inspection Sampling Plan for AQL 1.0 Tightened

Appendix 8.3 ANSI/ASQ Z1.4, Inspection Sampling Plan for AQL 1.0 Reduced

Appendix 8.4 ANSI/ASQ Z1.4, System Switching Rules

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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APPENDIX 8.1

ANSI/ASQ Z1.4, Inspection Sampling Plan for AQL 1.0 Normal

This single sampling plan is based on ANSI/ASQ Standard Z1.4-2008. Table I, General Inspection Level II, and Table IIA, Single Sampling Plans for Normal Inspection. The AQL is equal to 1.0.

Lot or Batch Size General Inspection

Lvl II Letter Sample Size Accept Reject

2 to 8 (A) 13 0 1

9 to 15 (B) 13 0 1

16 to 25 (C) 13 0 1

26 to 50 (D) 13 0 1

51 to 90 (E) 13 0 1

91 to 150 (F) 13 0 1

151 to 280 (G) 50 1 2

281 to 500 (H) 50 1 2

501 to 1200 (J) 80 2 3

1201 to 3200 (K) 125 3 4

3201 to 10000 (L) 200 5 6

10001 to 35000 (M) 315 7 8

35001 to 150000 (N) 500 10 11

150001 to 500000 (P) 800 14 15

Over 500000 1250 21 22

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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APPENDIX 8.2

ANSI/ASQ Z1.4, Inspection Sampling Plan for AQL 1.0 Tightened

This single sampling plan is based on ANSI/ASQ Standard Z1.4-2008. Table I, General Inspection Level II, and Table IIA, Single Sampling Plans for Tightened Inspection. The AQL is equal to 1.0.

Lot or Batch Size Sample Size Accept Reject

2 to 8 20 0 1

9 to 15 20 0 1

16 to 25 20 0 1

26 to 50 20 0 1

51 to 90 20 0 1

91 to 150 20 0 1

151 to 280 80 1 2

281 to 500 80 1 2

501 to 1200 80 1 2

1201 to 3200 125 2 3

3201 to 10000 200 3 4

10001 to 35000 315 5 6

35001 to 150000 500 8 9

150001 to 500000 800 12 13

Over 500000 1250 18 19

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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APPENDIX 8.3

ANSI/ASQ Z1.4, Inspection Sampling Plan for AQL 1.0 Reduced

This single sampling plan is based on ANSI/ASQ Standard Z1.4-2008. Table I, General Inspection Level II, and Table IIA, Single Sampling Plans for Reduced Inspection. The AQL is equal to 1.0.

Lot or Batch Size Sample Size Accept Reject

2 to 8 5 0 1

9 to 15 5 0 1

16 to 25 5 0 1

26 to 50 5 0 1

51 to 90 5 0 1

91 to 150 5 0 1

151 to 280 20 0 2

281 to 500 20 0 2

501 to 1200 32 1 3

1201 to 3200 50 1 4

3201 to 10000 80 2 5

10001 to 35000 125 3 6

35001 to 150000 200 5 8

150001 to 500000 315 7 10

Over 500000 500 10 13

Air Flow Testing on High and Low Pressure Plastic Hood Airline Respirators

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APPENDIX 8.4

ANSI/ASQ Z1.4, System Switching Rules

D is co n tin u e

In s p e ct io n u n d e r A

N S

I/ A

S Q

Z

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T

IG

H T

E N

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S T

A R

T o f o r fe w e r

C o n s e c u tiv e L o ts

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A cc e p ta b le

C o n s e c u ti ve

L o ts A c ce p ta b le

C o n s e c u ti ve

L

R m a in n

T ig h te n d

P re ce d in g

L

A c ce p te d w ith

T ta l N o n co n fo rm in g le ss t h a n L im it

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P ro d u c tio n s te a d y a p p ro v e d b y

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A u th o ri ty

L t n o t A cc e p te d r

L t

A cc e p te d b u t

N o n c o n fo rm iti e s fo u n d b e tw e e n c a d

R E o f

P la n o r P ro d u c tio n I rr e g u la r, r

O th e r

C o n d iti o n s W a rr a n t

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A L

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