standardization of watertight closures - nsrp · 2019. 3. 3. · • closure welds will remain...
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Standardization of Watertight ClosuresNSRP All PanelMarch 14, 2019
Mike PoslusnySpecialty Engineering
2
Objective and Scope
• Objective
– The project objective is to reduce the high cost of purchasing and maintaining
watertight closures on U.S. Navy and U.S. Coast Guard ships
• Minimize part count of “special” closures that deviate from Navy standard
• Consolidate designs to reduce variability and improve quality and schedule
performance
• Provide clear design documentation to door vendors
• Scope
– Develop standardized prototype single door designs
– Socialize designs with Navy stakeholders
– Build and test prototype doors (pressure and shock tests)
3Project Timeline
Project Selected for Funding
Dec 2015
Project Awarded
Feb 2016
Contract Mod – Include 30x66/36x66
Apr 2018
Phase 2 Funding – Include 26x66 Test
July 2017
Contract Mod – Add remaining
three doors, extension
Aug 2018
Contract Mod – Add time for testing
Dec 2018
26x66 Med Weight Shock Test
June 2018
26x66 Original Proof Test
May 2018
26x66 Tightness Test
Apr 2018
30x66 Med Weight Shock Test
Sep 2018
30x66 Tightness/Proof Test
Aug 2018
18x36 Med Weight Shock Test
Dec 2018
18x36 Tightness/Proof Test
Nov 2018
2016 2017 2018 2019
36x66 Tightness Test
Aug 2018
36x66 Med Weight Shock Test
Nov 2018
26x45 Tightness Test
Jan 2019
= Quarterly Meeting
26x45/26x54
Med Weight Shock Test
Feb 2019
Final Workshop
Feb 2019
4
Current Problems/Issues of Watertight Doors
• Installation issues – Variation of structural installation differences between ship classes causes additional
increase in configurations (lap vs. coaming)
• No clearly defined testing requirements – i.e., shock, fire, hydrostatic -proof versus max, proof with leakage (no permanent deformation) versus tightness, overall manufacturing or ship contract specific testing
• Navy Shock Qualification and survivability/damage control
• Manufacturing air pressure/hydro testing and quality– Welding processes and issues with cracking or incomplete welds/lack of fusion
– Overall alignment and sealing ability prior to installation Pressure Testing Requirements
• New construction installation processes/shipyard compartment completion testing and schedules
• Fleet sustainment – continued operation/sealing, maintenance/parts, and timely replacement in Post Shakedown Availabilities (PSA)
5
Navy Standard Doors – Consolidation Table
Quick-Acting Doors per 803-6397268 Individual Dogged Doors per 803-6397261
Size No. of Dogs MAX Press Panel THK Stiffener MAX Press Panel THK Stiffener
18x36 4 N/A N/A N/A 6 psi 0.075 3-1.5”x1.5”x1/8”
18x36 6 15 psi 0.075 3-1.5”x1.5”x1/8” 19 psi 0.075 4-1.5”x1.5”x1/8”
18x36 6 30 psi 0.120 5-1.5”x1.5”x1/8” 26 psi 0.075 5-1.5”x1.5”x1/8”
26x45 6 10 psi 0.075 3-1.5”x1.5”x1/8” 10 psi 0.075 3-1.5”x1.5”x1/8”
26x45 8 20 psi 0.090 4-1.5”x1.5”x3/16” 21 psi 0.075 5-1.5”x1.5”x3/16”
26x45 10 30 psi 0.120 6 - 1.5”x1.5”x3/16” 32 psi 0.120 5-1.5”x1.5”x1/4”
26x45 12 N/A N/A N/A 37 psi 0.120 5-1.5”x1.5”x1/4”
26x54 6 N/A N/A N/A 7 psi 0.075 4-1.5”x1.5”x1/8”
26x54 8 15 psi 0.090 4-1.5”x1.5”x3/16” 16 psi 0.075 4-1.5”x1.5”x3/16”
26x54 10 N/A N/A N/A 22 psi 0.075 6-1.5”x1.5”x3/16”
26x54 10 30 psi 0.120 6-1.5”x1.5”x3/16” 28 psi 0.120 6-1.5”x1.5”x3/16”
26x57 6 N/A N/A N/A 6 psi 0.075 5-1.5”x1.5”x1/8”
26x57 8 5 psi 0.075 5-1.5”x1.5”x1/8” 9.5 psi 0.075 5-1.5”x1.5”x1/8”
26x57 10 12.5 psi 0.075 5-1.5”x1.5”x3/16” 12.5 psi 0.075 5-1.5”x1.5”x3/16”
26x66 8 10 psi 0.075 5-1.5”x1.5”x1/8” 10 psi 0.075 5-1.5”x1.5”x1/8”
26x66 10 15 psi 0.120 6-1.5”x1.5”x3/16” 15 psi 0.120 6-1.5”x1.5”x3/16”
26x66 10 5/13 psi 0.120 6-1.5”x1.5”x3/16” 5/13 psi 0.120 6-1.5”x1.5”x3/16”
30x66 8 5 psi 0.075 5-1.5”x1.5”x1/8” 5 psi 0.075 5-1.5”x1.5”x1/8”
30x66 10 15 psi 0.120 6-1.5”x1.5”x3/16” 15 psi 0.120 6-1.5”x1.5”x3/16”
30x66 10 5/13 psi 0.120 6-1.5”x1.5”x3/16” 5/13 psi 0.120 6-1.5”x1.5”x3/16”
36x66 10 5 psi 0.075 6-1.5”x1.5”x1/4” N/A N/A N/A
36x66 10 15 psi 0.120 6-1.5”x1.5”x1/4” N/A N/A N/A
4 panels5 frames
1 panel1 frame
7 panels7 frames
1 panel1 frame
5 panels6 frames
1 panel1 frame
3 panels5 frames
6 panels6 frames
1 panel1 frame
5 panels6 frames
1 panel1 frame
2 panels1 frame
1 panel1 frame(including ID configuration)
Any use of 6” Dia lights within 10-dog doors drives additional panel configurations not currently noted.
WAS32 panels36 frames
IS6 panels6 frames
Consolidation effort solves many of the initial door issues
6
26” x 66” Quick Acting Door
7
New Assembly Number
• Assembly number example and
key will be on the front page of
every door drawing
• Assembly numbers offer a
more common sense way of
identifying and tracking doors
• Assembly number includes• Standard/nonstandard
• Door size
• Quick acting/individually dogged
• Left/right hand
• Hasp type
• Light type
• CPS latch
8
Major Changes to Door
Handle moved to
center dog
Standardized dog
locations
Upgraded dog sizes
Panel thickness
standardized
9
Other Changes
• Upgraded the CL 3B GR 30 gasket to the solid CL 2B
GR 40 gasket
• To accommodate the handle in the center location, a
new spindle was designed and implemented into the
design
• Replaced hinge pins with bolt and nut to stop pins from
shearing
10
Tightness and Proof Pressure
• The tightness and proof pressure requirements were chosen based on the highest rated for each door size. This was also the reason for choosing the panel thickness
• Determining the proof load was based on the original door testing of 1.5x tightness
pressure, for the 26x66 door this equated to 22.5 psi
• It was determined for testing that the proof test article is not required to be the same test
article for shock testing
11
Adding More Panel Stiffeners
• After the initial proof test for the 26x66 door, there was major deformation from the 22.5 psi.
• This prompted an investigation into adding more panel stiffeners based on FEA pressure analysis.
• Stiffeners were added to the 26x66 door and eventually all door sizes to accommodate the pressures.
12
Change of Panel Stiffeners
Original panel stiffeners • New panel stiffeners:
• Account for symmetry in door
design
13
Proof Test Acceptance Criteria
• Requirements:
– Watertight doors exhibit 1/8-in gasket compression around the perimeter of the door to provide a watertight seal
– Forces to un-dog, open, close, and dog the watertight door do not exceed 75 lbs. The transition from fully open to
the closed dogged position shall be smooth with no perceivable binding. Operational forces must be recorded prior
to the tightness pressure test and after the proof pressure test.
– The watertight door can withstand hydrostatic pressurization at the specified tightness pressure for 10 minutes
without leakage
– The watertight door can withstand hydrostatic pressurization at the proof pressure (150% of tightness pressure) for
10 minutes without permanent deformation of the door. Leakage is allowed. If minor physical deformation occurs,
pictures will be sent to the delegated Navy approval authority for approval guidance
– Following the proof test, and prior to draining the tank, verify that the door can maintain a watertight seal at
tightness pressure prior to shock testing
14
Tightness and Proof Test Results – 26x66 Summary
• Documented proof test procedure
• Process performed on 26 x 66 prototype door
1. Air test check out (@22.5 psi)- passed
2. Water tightness test (@15 psi)- leakage visible
• Significant deformation of panel and frame; leaks in frame
weld
• Straightened out frame; stiffened door panel; repair welds
3. Water proof test (@22.5 psi)- passed
• Frame weld leaked @22.5 psi; no leaks @22 psi
• Weld repaired and proceed to tightness test
4. Water tightness test (@15 psi) - passed
15
Shock Acceptance Criteria – Part 1
Each door will be considered to have successfully completed the shock
test series in accordance with the following Grade A requirements:
• No portion of the test item, its enclosure or sub-assemblies can come
adrift and cause a hazard to personnel or other Grade A systems.
• There shall be no distortion of any part that would make the closures
incapable of operating normally. Minor yielding of the structure is
acceptable.
• Closure welds will remain intact with no major cracks or weld
separation.
16
• Any failure or inelastic response of the test fixture shall invalidate the test
unless the vendor can prove that yielding or cracking did not reduce the
validity of the test.
• Opening of a closure door during the shock shots constitutes a failure and
a rejection of Grade A shock. Minor movement of dogs during shock
testing is acceptable. If re-dogging or dog adjustments are required to
achieve a watertight seal before a hydrostatic test, document and report
the actions required to seal the door to the delegated Navy approval
authority for approval guidance.
• The forces required to un-dog, open, close and dog the Watertight Doors
will be measured before and after each axis of the shock test series and
should be within 100 lbs. The transition from fully open to the closed and
dogged position shall be smooth with no perceivable binding.
Shock Acceptance Criteria – Part 2
17
Shock Acceptance Criteria – Part 3
• Before and after each axis of the shock test series, the watertight door
must be able to withstand hydrostatic pressurization at the specified
tightness pressure for 10 minutes without leakage. After the first blow,
the door may be adjusted to retain a watertight seal. Re-dog doors
prior to hydrostatic testing if required and document which dogs
loosened during the prior blow. If minor leakage occurs, the number of
drops per minute will be measured and reported to the delegated Navy
approval authority for approval guidance. The door does not require
pressurization during shock blows.
• Anomalies discovered after any blow will be discussed with the
delegated Navy approval authority.
18
Shock Test Video – 26x66
19
26” x 66” Shock Test Results – Vertical Axis
20
26” x 66” Shock Test Results – Vertical Axis
• Pre-Test Results
– Initial hydrostatic test – 15 psi no leakage over 10 minutes.
– Operation force checks performed: Dog 60 lbs, Un-dog 49 lbs
• Post Blow 1
– Hydrostatic test at 15 psi, minor drip occur on hinge side knife edge. Middle and lower dog tightened 1/8 turn. Drip stopped, 15 psi held 10 minutes without leakage.
– Operation force check performed.
• Post Blow 2
– Noticed hinge deformation on bottom casted hinge pads both top and bottom locations.
• Post Blow 3
– Slight increase in hinge deformation on bottom casted hinge pads both top and bottom locations. Sheared lower cotter pin on hinge pin.
– Hydrostatic test at 15 psi for 10 minutes, no leaks.
– Operational checks performed: Dog 47 lbs, Un-dog 42 lbs
21
26” x 66” Shock Test Results – Vertical Axis
BLOW 2 - lower hinge starting to shear cotter pin
BLOW 3 – bending of lower hinge pad causing gap and shearingt
22
26” x 66” Shock Test Results – Vertical Axis
23
26” x 66” Shock Test Results – Front to Back Axis
24
26” x 66” Shock Test Results – Front to Back Axis
• Post Blow 4
– No action. Door was visually inspected from the outside.
• Post Blow 5
– Door askew after the blow, 1/8” to 1/4” towards the top right corner.
– Hydrostatic test – The door began leaking at 12.5 psi, failing the test.
– Operated door: Dog 47 lbs, Un-dog 42 lbs
– Ingalls decided to continue to the next axis, despite problems with hydrostatic testing.
25
26” x 66” Shock Test Results – Front to Back Axis
Gasket Damage
26
26” x 66” Shock Test Results – Front to Back Axis
27
26” x 66” Shock Test Results – Side to Side Axis
28
26” x 66” Shock Test Results – Side to Side Axis
• Post Blow 6
– No action. Door was visually inspected from the outside. Top right dog loose (wiggle) after
blow.
• Post Blow 7
– Hydrostatic testing @ 15psi for 10 minutes: Passed – no leaks.
– Operational checks performed: Dog 48 lbs, Un-dog 42 lbs
29
26” x 66” Shock Test Results – Side to Side Axis
30
26” x 66” Shock Test Results – Repeat Testing
• The door successfully passed hydrostatic testing in the vertical and side to side
axis, resulting in Restricted Orientation Qualification. Ingalls discussed repeat
testing options with Christopher Merrill and Gus Pappas of the delegated Navy
approval authority.
• To attempt Vertical Axis Specified Qualification, Ingalls decided to repeat the
most severe blow in the front to back axis with the door in the “as is” condition
and attempt hydrostatic testing. If the door failed again, Ingalls would refurbish
the door (change gasket and tighten dogs) prior to repeating both required
blows in the front to back axis.
• Post Blow 8
– No additional physical damage.
– Hydrostatic testing @ 15psi for 10 minutes: Passed – no leaks.
– Operational checks performed. Undog 40 lbs, Dog 47 lbs
31
26” x 66” Shock Test Results – Lessons Learned
• Gasket compression will be reduced over the course of a shock test series due
to multiple shock events. Suggest tightening each dog nut after Blow #1 until
the dog forces reach 75lbs, to help pass hydrostatic testing throughout the test
series.
• Inspect and clean the gasket and knife edge after each operational test to
remove residue from the water source and paint chips that flake off the door
during shock.
• Replace the hinge pin on future door designs with a bolt and nut combination
to reduce the potential for hinge separation as seen after the vertical blows.
32
30” x 66” Individually Dogged Door
• Test fixture completed and installation of
door
• Tightness testing
– 15/22.5 psi hydrostatic test
• Passed tightness testing with added
stiffeners
• Upgrading to stiffer Grade 40 gasket
• Replaced hinge pin with a bolt / nut
combo
• Shock test successful
• Proof test successful
33
30” x 66” Individually Dogged Door
Hinge Bolt, Washer and Nyloc
34
30” x 66” Individually Dogged Door – Shock Test
35
30” x 66” Individually Dogged Door Shock Test
• Vertical Tests
– Blow 1: Minimal dog movement. Tightened each dog ~1/4” turn. Successful hydro
@15psi for 10 minutes. All dog forces less than 70 lbs.
– Blows 2 and 3: Dog #4 un-dogged during each blow and returned to 10 degrees off
center. Successful hydro @15psi for 10 minutes. All dog forces less than 60 lbs.
• Front to Back Tests
– Blows 4 and 5: Minimal dog movement. Successful hydro @15psi for 10 minutes.
All dog forces less than 55 lbs.
• Side to Side Tests
– Blows 6 and 7: Minimal dog movement. Successful hydro @15psi for 10 minutes.
All dog forces less than 55 lbs.
*Note: All dogs reset to center position prior to each blow IAW the test procedure.
36
36” x 66” Quick Acting Door
• Test fixture completed and installation of door
• Tightness testing
– 13 psi Hydrostatic Test
• Passed tightness testing with added stiffeners
• Upgrading to stiffer Grade 40 gasket
• Replaced hinge pin with a bolt / nut combo
• Shock test successful
• Proof test – to be done @ 19.5 psi
37
36” x 66” Quick Acting Door – Shock Test
38
36” x 66” Quick Acting Door Shock Test
• Vertical Tests
– Blow 1: Quick acting handle moved about a quarter of overall range. Successful
hydro @13.5 psi for 10 minutes after adjusting two dogs. Handle forces: Dog-84 lbs
Undog-65 lbs.
– Blows 2 and 3: Handle slightly opened (~10 deg). Successful hydro @14 psi for 10
minutes. Handle forces: Dog-84.5 lbs Undog-59.9 lbs.
• Front to Back Tests
– Blows 4 and 5: No handle movement during tests. Successful hydro @ 14 psi for
10 minutes. Handle forces: Dog-84.6 lbs Undog-64.9 lbs.
• Side to Side Tests
– Blows 6 and 7: No handle movement during tests. Successful hydro @ 14 psi for
10 minutes. Handle forces: Dog-89.6 lbs Undog-60.25 lbs
39
36” x 66” Quick Acting Door Shock Test
• Minor Damage• Hinge washer cupping• Gasket chipping
40
18” x 36” Individually Dogged Door
• Test fixture completed and installation of
door
• Tightness testing
– 30/45 psi hydrostatic test
• Passed tightness testing with added
stiffeners
• Upgrading to stiffer Grade 40 gasket
• Replaced hinge pin with a bolt / nut
combo
• Shock test successful
• Proof test successful
41
18” x 36” Quick Acting Door – Shock Test
42
26” x 45” Quick Acting Door
• Test fixture completed and installation of door
• Tightness testing
– 30 psi hydrostatic test
• Passed tightness testing with added stiffeners
• Upgrading to stiffer Grade 40 gasket
• Replaced hinge pin with a bolt / nut combo
• Shock tested – February 18th
• Results: Successful with tightness testing at 26 psi
• Proof test @ 39 psi – to be completed
43
26” x 54” Quick Acting Door
• Test fixture completed and installation of door
• Tightness testing
– 30 psi hydrostatic test
• Passed tightness testing with added stiffeners
• Upgrading to stiffer Grade 40 gasket
• Replaced hinge pin with a bolt / nut combo
• Shock tested – February 18th
• Results: Successful with tightness testing at 26.5 psi
• Proof test @ 40 psi – to be completed
44
Watertight Closure Prototype Test Plan Summary
26x66 30x66 36x66 18x36 26x45 26x54
Received From Juniper Completed
Hydro Test Procedure Working Towards
Intial Hydro - Ingalls Only * Repeat
Navy Witness Hydro
Set Hi-Test Shock Date
Ship to Hi Test
Shock Test Procedure
Medium Weight Shock Test
Upload Pictures/Video
Proof Test
Ship back to Ingalls
HiTest Shock Report Received
Ingalls Post Tear Down Inspection
Legend
45
Next Steps
• Receive shock test reports
• Proof test the remaining three doors
• Post shock inspections
• Deliver drawing package and test reports to NAVSEA
• Deliver final report
• Implementation by Shipyard
– Submit shock test CDRLs and hydro reports by contract
– Planned implementation on LPD 30, 26x66
– Implementation of remaining doors for future ships
– NNS planned implementation on CVN 80/81
46
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