Technical Memorandum 104821

, 7' -

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Guide for Oxygen Component

Qualification Tests

Larry J. Bamford

Michelle A. Rucker

Douglas Dobbin

December 1996

Technical Memorandum 104821

Guide for Oxygen Component

Qualification Tests

Michelle A. Rucker

NASA White Sands Test Facility

and

Larry J. Bamford

Douglas Dobbin

Lockheed Martin Engineering & Science Company

December 1996
This publication is available from the NASA Center for AeroSpace Information, 800 Elkridge Landing

Road, Linthicum Heights, MD 21090-2934, (301) 621-0390
Contents

1.0

2.0

3.0

4.0

5.0

5.1

5.2

5.3

5.4

5.5

6.0

7.O

7.1

7.2

7.3

7.4

7.5

7.6

8.0

8.1

8.2

8.2.1

8.2.2

8_3

8.3.1

8.3.2

8.4

8.4.1

8.4.2

8.5

8.5.1

8.5.2

8.6

8.7

8.7.1

8.7.2

8.8

8.9

9.0

Objective .................................................................................................................

Approach ...............................................................................................................

Flow and Pressurization Test Systems ................................................................... 1

Data Acquisition and Control ................................................................................. 2

Pneumatic Impact Test Systems ............................................................................. 2

Particle Impact Test System ................................................................................... 2

Flow Test System .................................................................................................... 2

Specialized Test Systems ........................................................................................ 2

3

Pretest Procedures ................................................................................................ 3

Pretest Photographs ................................................................................................ 3

Initial Inspection ..................................................................................................... 3

Refurbishment ........................................................................................................ 4

Cleaning .................................................................................................................. 4

Nitrogen Functional Check .................................................................................... 5

Installation Leak Check ......................................................................................... 6

Flow and Impact Test Procedures .......................................................................... 6

General Procedures ................................................................................................ 6

Manual Valve Test Method .................................................................................... 6

Manual Valve Test Configuration 1.......................................................................... 6

Manual Valve Test Configuration 2 .......................................................................... 6

Remotely Operated Valve (ROV) Test Method ..................................................... 6

ROV Test Configuration 1........................................................................................ 7

ROV Test Configuration 2 ........................................................................................ 7

Check Valve Test Method ...................................................................................... 7

Check Valve Test Configuration 1 ............................................................................ 7

Check Valve Test Configuration 2 ............................................................................ 7

Relief Valve Test Method ....................................................................................... 7

Relief Valve Test Configuration 1 ............................................................................ 7

Relief Valve Test Configuration 2 ............................................................................ 8

Filter Test Method .................................................................................................. 8

Regulator Test Method ........................................................................................... 8

Regulator Pressurization Rate Simulation ................................................................. 8

Regulator Test Configuration ................................................................................... 8

Flexible Hose Test Method ..................................................................................... 8

Diaphragm-Type Gas Intensifier (Compressor) Test Method .............................. 9

Posttest Procedures .................................................................................................

9

iii
10.0 Reporting................................................................................................................ 9

References ............................................................................................................. 9

Figures

1

2

3

Pnemnatic impact component test system ................................................................. 3

Particle impact test system ........................................................................................ 4

Typical oxygen component test system ..................................................................... 5

iv
1.0 Scope

Although oxygen is a chemically stable element, it is not shock sensitive, will not decompose, and is

not flammable. Oxygen use carries a risk that should never be overlooked, because oxygen is a strong

oxidizer that vigorously supports combustion. Oxygen is reactive at ambient conditions, and its reactivity

increases with increasing pressure, temperature, and concentration. Most metallic and many nonmetallic

materials are flammable in high-pressure oxygen; therefore, systems must be designed to reduce or eliminate ignition hazards.

To promote safety in an oxygen system, the flammability of the materials used should be analyzed. If a

material is not flammable it may be used safely, even ff ignition sources exist. If the material is flammable but no ignition source exists, the material may still be used safely. However, if an ignition source

exists, tests should be performed on the component in the actual use configuration to determine the safety

margins to the ignition thresholds of the material.

At the NASA White Sands Test Facility (WSTF), conflgnrational tests of components that are specifically

engineered for oxygen service are performed. Such tests are only performed following a detailed WSTF

oxygen hazards analysis (Poe 1992). This document outlines recommended test systems, cleaning, handling, and test procedures. These recommendations apply to manual valves, remotely operated valves,

check valves, relief valves, filters, regulators, flexible hoses, and intensifiers. Component systems are

not covered.

2.0 Objective

The objective of this document is to describe the capabilities and procedures of WSTF configurational

tests on components. The objective of all tests outlined in this document is to provide performance test

data for use as part of a customer's qualification plan for a particular component in a particular configuration, and under worst-case conditions.

3.0 Test Article

The test article may be provided by the customer, purchased from customer-approved vendors through

WSTF's procurement system, or fabricated from customer-approved materials at WSTF.

4.0 Approach

First, a detailed oxygen hazards analysis is performed on the test article. After identifying the test

article's type, construction materials, limitations, etc., and its intended use (configuration, operating

conditions, etc.), potential oxygen hazards are analyzed (Poe 1992). When the oxygen hazards analysis

is completed, WSTF recommends an appropriate test system configuration and test sequence(s).

5.0 Flow and Pressurization Test Systems

WSTF oxygen component test systems are fabricated from materials suitable for oxygen use. All

hardware is cleaned for oxygen use to level 50A, per JSCM 5322 (Johnson Space Center (JSC), 1982).
5.1 Data Acquisition and Control

All WSTF test systems use digital data acquisition equipment to record test article and test system

parameters, such as thermocouple and pressure transducer data. Standard video coverage is available,

with the options of infrared video, high-resolution film, or high-speed video being employed. Comimterenhanced motion analysis can be used to study test footage in the event of a catastrophic test article

failure.

5.2 Pneanmtic Impact Test Systems

The pneumatic impact test system simulates sudden pressurizations such as might be caused by a rapidly

opening valve. Rapid pressurization genezates heat that can ignite some materials in the system. WSTF

pneumatic impact test systems are capable of test pressures up to 94.80 MPa (13,750 psi). Pressurization

from ambient to test pressure can be achieved in under 100 ms, with the exact time depending on the test

configuration. Pressurization times can be varied to simulate the actual use conditions of the test article.

A typical pneumatic impact component test system is shown in Figure 1.

These systems can heat or cool the test article, the test gas, or both. A heat pump is used for moderately cool or warm temperatures. Cryogens, heat lamps, and heat tapes are used for more extreme

temperatures.

5.3 Particle Impact Test System

Particle impact, caused by contaminates impacting components at high velocities, can cause ignition

in oxygen systems. The WSTF particle impact test system is a high-flow system in which particulate

simulating contaminates can be injected into the gas just upstream of the test article. At maximum

operating conditions, mass flow rates of 4.1 kg/s (9 lb/s) at 37.92 MPa (5,500 psi) for 30 sex can be

achieved. Gas temperatures can be varied between 366_5 K (200°F) and 810.9 K (IO00°F), and the test

article can be either heated or cooled to simulate actual use conditions. Cryogenic liquids can also be

flowed through the test article, either alone or simultaneously with a hot gas. The WSTF particle impact

test system is shown in Figure 2.

5A Flow Test System

A flow test system is designed to simulate the test article's actual use conditions by connecting it to the

test article port of a WSTF pneumatic impact test system. The test system is capable of test pressures up

to 94.80 MPa (13,750 psi). Pressurization and flow rates can be varied to simulate the actual use conditions of the test article. A typical flow component test system is shown in Figure 3.

5.5 Specialized Test Systems

Several specialized WSTF test systems are used to simulate a range of special test conditions or configurations. For example, the frictional heating test system simulates failures caused by unintentional

rubbing or parts, such as occurs in hydrostatic bearings or turbine blade tips. The promoted combustion

test system causes ignition of material samples or components to determine bum characteristics. Because

these specialized tests must be tailored to each test article configuration, details cannot be included in this

document.
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6.0 Test Gases

WSTF test systems can supply high-pressure gaseous oxygen (GO2) and gaseous nitrogen (GN2) to the

test article. WSTF uses aviator's breathing oxygen that conforms to MIL-0-27210E (GPO 1984). However, customer-specified particulate or hydrocmbon contaminants ca_ be introduced to simulate worst-case

test conditions. Special test gases, such as helimn or mixtures of inert gases with GO2, can also be used.

Some test systems are designed to operate with cryogenic fluids, such as liquid oxygen (LOX) or liquid

nitrogen (LN2).

7.0 Pretest Procedures

7.1 Pretest Photographs

Pretest photographs of the test article are taken upon receipt at WSTF.

7.2 Initial Inspection

After the test articles are photographed, each test article is submitted to the WSTF Fluid Components

Laboratory. If the test article is received at WSTF cleaned to a level 50A or 100A (JSC 1982), inspection
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is performed in a Class 100 flow bench. The test article is inspected for damage or contamination;

unusual findings are noted and reported.

7.3 Refurbishment

If repair or refurbishment of an article is requested by the customer, WSTF repairs or refurbishes the test

article. Replacement parts may be provided by the customer or purchased through WSTF's procurement

system. All soft goods and lubricants installed in the test article by WSTF are approved by the cognizant

materials control organization, as specified by the customer.

7.4 Cleaning

Test articles can be tested in an as-received condition, or they can be cleaned at WSTF to a level suitable

for oxygen use. If no customer direction is given, the test article is disassembled and cleaned for oxygen

4
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Figure 3 Typkai oxygen component test system

use to level 50A per JSCM 5322 (JSC 1982). If the test article is received in a certified clean condition,

no further WSTF cleaning is performed.

To maintain cleanliness, test articles are double-bagged and sealed before transportation or storage. All

testing or handling of a clean test article is performed in a Class 100 flow bench.

7.5 Nitrogen Functional Check

After cleaning (or after initial inspection if no cleaning is to be performed), the test article is reassembled

and functionally checked with GN2. Internal leakage or functional problems are reported to the customer.
7.6 InstallationLeakCheck

Beforefunctional testingwiththe test gas, the test article is installed in the test system and an external

GN2 leak check is performed. This leak check is intended to identify external leak paths at the interface

between the test article and the test system.

8.0 Flow and Impact Test Procedures

8.1 General Procedures

WSTF component tests are performed at worst-case pressure, or at 1.25 times the maximum desired

working pressure (as specified by the customer), whichever is higher. Each test article is subjected to

a number of pressure/vent or flow cycles. This number, which is determined by WSTF, is based on

information such as the WSTF hazard analysis results, the number of independent operating test parameters, and the required lifetime. After each test series, the test article is leak-tested at the maximum

desired working pressure. Other test conditions (temperature, contamination, etc.) simulate worst-case

conditions, as specified by the customer or the hazard analysis team.

8.2 Manual Valve Test Method

The test system simulates the manual valve's actual use configmation. The manual valve is tested in

Configurations I and 2 described below, and is subjected to the required number of cycles in each configuration.

8.2.1 Manual Valve Test Configuration I

The manual valve and the test article vent valve are dosed initially. Test pressure is applied to the

manual valve inlet, and the test article pressure transducers are observed to detect evidence of leakage

across the valve seat. If no leakage is noted, the valve's vent valve is opened, and the valve is cycled from

fully open to fully closed. The flow test system is vented, and the test is repeated until the required

number of pressure/vent cycles have been perfomled.

8.2.2 Manual Valve Test Configuration 2

The manual valve is adjusted to provide a GN2 flow rate of approximately 200 standard cm 3 (12.1 in 3) per

minute at an inlet pressure of 20.78 MPa (3,000 psia) across its seat. The valve is tested at the maximum

test pressure specified by the customer ff the manual valve's maximum allowed working pressure is below

20.68 MPa (3,000 psla). Manual valve adjustment is maintained during installation in the flow test

system. Test system vent valves located downstream of the manual valve are opened. Test gas is permitred to flow at the required pressure through the manual valve for 5 sec. The flow test system is

repressurized, and the test is repeated until the required number of flow cycles have been performed.

8.3 Remotely Operated Valve (ROAr) Test Method

The test system is configured to simulate the ROV's actual use configuration. All ROVs are tested in

Configurations 1 and 2 described below, and are subjected to the required number of cycles in each

configuration.
8.3.1 ROVTestConfiguration 1

The ROV is closed initially. The test system metering valve, located upstream of the ROV, is adjusted to

permit the ROV to be rapidly cycled without reducing the flow test system pressure below approximately

95% of the initial pressure, while allowing test gas to flow cross the test article seat.

After the test system metering valve is adjusted, the ROV inlet is pressurized. The ROV is then rapidly

cycled until flow system pressure decreases below the required valve. The flow test system is repressurized" and the test continues until the required number of cycles have been performed.

8.3.2 ROV Test Configuration 2

The ROV and the test ar_cle vent valve are closed initially. Test pressure is applied to the ROV inlet,

and the test article pressure monitoring devices are observed to detect evidence of leakage across the test

article seat. If no leakage is noted, the test article vent valve and the ROV are cycled open, then closed.

The flow test system is vented, and the test is repeated until the required number of cycles have been

performed.

8.4 Check Valve Test Method

The test system is configured to simulate the check valve's actual use configuration. Check valves are

evaluated in the following two configurations.

8.4.1 Check Valve Test Configuration 1

The check valve is installed in the test system in the direction that permits flow through it. The test

system vent valves are closed, and test pressure is applied. After pressure stabilization, the flow test

system is vented, and the test is repeated until the required number of cycles have been performed.

8.4.2 Check Valve Test Configuration 2

The check valve is installed in the direction that prohibits flow through it. The test system vent valves

are closed, and pressure is applied to the check valve. When the pressure has stabilized, the pressure

monitoring system is used to detect evidence of leakage past the check valve seat. The test system is

vented, and the test is repeated until the required numbe_ of cycles have bee n performed.

&5 Relief Valve Test Method

The test system simulates the relief valve's actual use configuration. The relief valve is installed in the

flow test system with the relief valve outlet port connected to the test system, if possible. The relief valve

is evaluated in two configurations.

8.5.1 Relief Valve Test Configuration I

In Configuration 1, the relief valve is pressurized to 1.25 times its set pressure, or to a pressure specified

by the customer. The relief valve is allowed to vent to its reseat pressure. Pressure upstream of the relief

valve is monitored for evidence of leakage across the relief valve seat after venting ceases. The flow test

system upstream of the relief valve is vented, and the test is repeated until the required number of cycles

have been performed.
8.5.2 Relief Valve Test Configuration 2

The relief valve is rapidly pressurized to 95% of its crack pressure to maximize the effect of adiabatic

heating on the relief valve seat. Pressure monitoring devices are observed to detect evidence of leakage

across the relief valve seat. The flow test system upstream of the relief valve is vented, and the test is

repeated until the required number of cycles have been performed.

8.6 Filter Test Method

The test system is configured to simulate the filter's actual use configuration. With test system vent

valves closed, test pressure is applied at 1.25 times the desired use pressure in the direction of flow

marked on the filter, or as otherwise specified on the test request. After pressure stabilization, the flow

test system downstream of the filter is vented at a rate that does not exceed the differential pressure limits

of the filter. The test is repeated until the required number of cycles have been performed. Normally, a

bubble point test and an internal visual inspection of the filter are performed before and after the test.

8.7 Regulator Test Method

8.7.1 Regulator Pressurization Rate Simulation

Because of high gas-flow rates through regulators, they m-e vulnerable to functional damage. To

adequately evaluate an oxygen regulator, WSTF recommends that testing be conducted at pressurization

rates simulating actual use conditions. Determining the required test pressurization rate requires detailed

knowledge of the upstream end use configuration (for example, valves and filters). WSTWs flow test

system is adjusted to provide the appropriate pressurization rate for each test.

8.7.2 Regulator Test Configuration

The test system is configured to simulate the regulator's actual use configm-ation. With the test system

vent valves closed, the regulator is adjusted to the fully reduced position (closed). Test pressure is introduced into the regulator inlet port at the wedetetmined rate. The pressure monitoring system is used to

detect evidence of leakage past the regulato¢ seat. For regulaters with self-venting features, the flow test

system is vented after pressure stabilizes. Venting of regulators without self-venting features is accomplished after pressure stabilizes by opening a flow test system vent valve downstream of a regulator while

the regulator is in the fully increased (open) position. After venting ceases, the regulator is adjusted to the

fully reduced position. The test is repeated until the required number of cycles have been performed.

8.8 Flexible Hose Test Method

The test system simulates the flexible hose's actual use configuration. In addition to the flexible hose,

WSTF also simulates the upstream and downstream components, as specified by the customer.

The flexible hose is pressurized with the test gas at a rate simulating the actual use pressurization rate.

When the temperature of the flexible hose returns m ambient, the pressure is vented. The test is repeated

until the required number of cycles have been performed. In addition to the standard instnnnentation, an

infrared camera is used to monitor the flexible hose temperature.
8.9 Diaphragm-Type Gas Intensifier (Compressor) Test Method

The test system simulates the intensifier's actual use configuration. The test system intensifier is removed

and the intensifier is installed in its place. Test system valves are opened between the intensifier and the

test system accumulator (minimum volume of 2.8 liters [0.10 ft3]). The intensifier is operated for 1 hour

using the manufacturer's suggested suction pressure.

9.0 Posttest Procedures

After testing, the test article is inspected, double-bagged, and sealed. The test article is transported to

the Fluid Components Lab, where it is disassembled, inspected, and photographed. If the test article is

in operable condition, it is cleaned, refurbished with new soft goods, functionally checked with an inert

gas, double-bagged, and sealed.

The test article is returned to the address specified by the customer, in its original shipping container. If

requested, pre-shipment photographs are taken.

10.0 Reporting

A formal test report is transmitted to the customer following completion of the testing. The report

includes test article part number and serial number, soft goods identification, I_ndling and processing

details, appropriate references to the oxygen hazards analysis, descriptions of the test system used and all

the procedures followed, and the test results.

References

GPO. MIL-O-2 7210E, Amendment 2, Military Specification: Oxygen, Aviator's Breathing, Liquid, and

Gas. US Government Printing Office (GPO), Washington, DC (1984).

JSC. Contamination Control Requirements Handbook, Revision B. JSCM 5332, NASA Johnson Space

Center, Houston, TX, November 1982.

Poe, R. Guide to Oxygen Component Hazard Analyses. TP-WSTF-713, NASA Johnson Space Center,

White Sands Test Facility, Las Cruces, NM (1992).

9

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1. AGENCY USE ONLY (LeaveBank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED

December 1996 NASA Technical Memorandum

4. TITLE AND SUBTITLE 5. FUNDING NUMBERS

Guide for Oxygen Component Qualification Tests

6. AUTHOR(S)

Larry J. Bamford*; Michelle A. Rucker; Douglas Dobbin*

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

Lyndon B. Johnson Space Center

White Sands Test Facility

1__ Cruces, New Mexico 88004-0020

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

Washington, D. C. 20546-0001

8. PERFORMING ORGANIZATION

REPORT NUMBERS

TM-104821

10. SPONSORING/MONITORING

AGENCY REPORT NUMBER

S-816

11. SUPPLEMENTARY NOTES

*Lockheed Martin Engineering & Science Company

12b. DISTRIBUTION CODE

12a. DISTRIBUTION/AVAILABILITY STATEMENT

Unclassified/Unlimited

Available from the NASA Center for AeroSpace Information (CASI)

800 Elkridge Landing Road

Linthicum Heights, MD 21090-2934

(301) 621-0390 Subject Category: 18

13. ABSTRACT (Maximum200 words)

Although oxygen is a chemically stable element, it is not shock sensitive, will not decompose, and is not flammable. Oxygen use

therefore carries a risk that should never be overlooked, because oxygen is a strong oxidizer that vigorously supports combustion.

Safety is of primary concern in oxygen service. To promote safety in oxygen systems, the flammability of materials used in them

should be analyzed. At the NASA White Sands Test Facility (WSTF), we have performed configurational tests of components

specifically engineered for oxygen service. These tests follow a detailed WSTF oxygen hazards analysis. The stated objective of

the tests was to provide performance test data for customer use as part of a qualification plan for a particular component in a

particular configuration, and under worst-case conditions. In this document - the "Guide for Oxygen Component Qualification

Tests" - we oudine recommended test systems, and cleaning, handling, and test procedures that address worst-case conditions. It

should be noted that test results apply specifically to: manual valves, remotely operated valves, check valves, relief valves, filters,

regulators, flexible hoses, and intensifiers. Component systems are not covered.

14. SUBJECT TERMS

oxygen; oxygen regulators; oxygen supply equipment; relief valves; check valves; manual

valves; operational hazards; fibers; oxygen regulators; hoses; intensifiers; safety factors

17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION

OF REPORT OF THIS PAGE OF ABSTRACT

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14

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