standardization of watertight closures - nsrp · 2019. 3. 3. · • closure welds will remain...

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


Sep 2018

30x66 Tightness/Proof Test

Aug 2018


Dec 2018

18x36 Tightness/Proof Test

Nov 2018

2016 2017 2018 2019


Aug 2018


Nov 2018


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.


17


• 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


• 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


BLOW 2 - lower hinge starting to shear cotter pin

BLOW 3 – bending of lower hinge pad causing gap and shearingt

22


23

26” x 66” Shock Test Results – Front to Back Axis

24


• 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


Gasket Damage

26


27

26” x 66” Shock Test Results – Side to Side Axis

28


• 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


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


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


• Test fixture completed and installation of door


– 13 psi Hydrostatic Test

• Passed tightness testing with added stiffeners


• Replaced hinge pin with a bolt / nut combo


• 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


• Test fixture completed and installation of

door


– 30/45 psi hydrostatic test

• Passed tightness testing with added

stiffeners


• Replaced hinge pin with a bolt / nut

combo


• Proof test successful

41

18” x 36” Quick Acting Door – Shock Test

42




– 30 psi hydrostatic test




• Shock tested – February 18th

• Results: Successful with tightness testing at 26 psi

• Proof test @ 39 psi – to be completed

43




– 30 psi hydrostatic test




• 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

standardization of watertight closures - nsrp · 2019. 3. 3. · • closure welds will remain...

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