Heavyweight High Impact Shock Testing

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Heavyweight High Impact Shock Testing
SAVIAC 2007 Chris GrunauHI-TEST Laboratories,
Inc.
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Outline

• 1. Brief History
• 2. Test Preparations Planning
• 3. Test Operations
• 4. Test Report

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Section 1 Brief History of Shock Testing

• Prior to World War II
• During World War II
• Shock Test Machines
• Barge Testing

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Brief History of Shock Testing
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Brief History of Shock Testing
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Brief History of Shock Testing
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Brief History of Shock Testing
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Brief History of Shock Testing
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Floating Shock Platform (FSP)
FSP (16' x 31')
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Section 2 Test Preparations

• Military Specification
• Test Procedure Preparation
• Test Fixture Design
• Procedure and Fixture Approval
• Contract

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Government Documents
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Government Documents
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REFERENCES

• MIL-S-901D(NAVY) Military Specification, Shock
  Tests, H.I. (High Impact) Shipboard Machinery,
  Equipment, and Systems, Requirements for, dated
  17 March 1989.
• NRL Report No. 7396 Shipboard Shock and Navy
  Devices for its Simulation, dated 14 July 1972.
• NAVSEA Letter 9072 OPR 55X13, Ser. 55X1/164,
  Shock Tests, H.I. (High-Impact) Shipboard
  Machinery, Equipment, and Systems, Requirements
  for, dated 30 October 1990.
• DI-ENVR-80708 Shock Test Report, dated June
  1986.
• DI-ENVR-80709 High Impact Shock Test
  Procedures, dated June 1986.

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High Impact Shock Testing(MIL-S-901D)

• Lightweight Shock Machine (LWSM)
• Medium Weight Shock Machine (MWSM)
• Heavyweight Shock Testing Using the Floating
  Shock Platforms (FSP, LFSP, and IFSP)

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MIL-S-901D(NAVY) SCOPE

• Covers high impact shock testing requirements for
  shipboard machinery, equipment, systems, and
  structures, excluding submarine pressure hull
  penetrators.
• Verify ability of equipment to withstand shock
  loadings
• Intended to establish shock criteria to guide
  contractor

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ACQUISITION REQUIREMENTS

• Title, number, and date of MIL-S-901
• Other applicable specifications
• Shock Grade (A or B)
• Equipment Class (I, II, or III)
• Shock Test Type (A, B, or C)
• Mounting Location Aboard Ship
• Mounting Plane Aboard Ship
• Mounting Orientation Aboard Ship
• Method of Mounting Test Item
• Method of Simulating Shipboard Connections
• Mode(s) of Equipment Operation
• Shock Test Acceptance Criteria
• Acceptance Authority

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SHOCK GRADE

• Grade A
• Essential to the safety and continued combat
  capability of the ship.
• Grade B
• Not essential to the safety and continued
  combat capability of the ship but could
  become a hazard to personnel or Grade A items.

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GRADE A EQUIPMENT

• Ship Control and Propulsion
• Command and Control
• Navigation
• Communications
• Surface, Air, and Underwater Surveillance
• Countermeasures
• Lauching, Retrieving, Fueling, Defueling,
  Rearming, and Handling of Aircraft and Small
  Surface Craft
• Essential Checkout and Maintenance of Aircraft
  and Ordnance
• Fire Control, Firing, or Launching, and Guidance
  of Missiles and other Weapons

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EQUIPMENT CLASS

• Class I
• Class II
• Class I/II

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EQUIPMENT CLASS

• Class I
• Class II
• Class I/II

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EQUIPMENT CLASS

• Class I
• Class II
• Class I/II

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SHOCK TEST TYPE

• Type A
• Principal Unit (preferred test) - supported
  directly by ship structure or installed in
  piping systems or ducting systems
• - Required in all cases unless size or weight
  limitations are exceeded.
• Type B
• Subsidiary Component. - Shock response of
  Type A and C equipment are affected by Type B
  equipment.
• - Required when it is not possible to test a
  principal unit due to size or weight
  limitations.
• Type C
• Subassembly. -Shock response of Type C
  equipment is affected by Type A or B
  equipment. -Shock response of Type A and B
  equipment is not affected by Type C equipment.
• - Required when it is not possible to test a
  principal unit due to size or weight
  limitations.

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MOUNTING LOCATION

• Hull Mounted
• Deck Mounted
• Shell Mounted
• Wetted-Surface Mounted
• Note Shell and Wetted-Surface Mounted items
  require a heavyweight shock test.

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MOUNTING LOCATION

• Hull Mounted
• Deck Mounted
• Shell Mounted
• Wetted-Surface Mounted
• Note Shell and Wetted-Surface Mounted items
  require a heavyweight shock test.

http//www.btinternet.com/warship/Today/bay.htm
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MOUNTING PLANE ABOARD SHIP

• Base
• Front or Face
• Back
• Top
• Combination (base and back)
• Other

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MOUNTING ORIENTATION ABOARD SHIP

• Restricted
• Unrestricted
• - Shot 4R is required for test in lieu of Shot 1

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SIMULATION OF SHIPBOARD CONNECTIONS

• Piping, sway braces, drive shafts, control
  linkages, or similar items
• Restraining effects of connected items simulated
  when test item derives a substantial degree of
  support from the connected item.
• Subsidiary Components and Subassemblies simulated
  when not part of shock test.

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OPERATION OF EQUIPMENT

• Grade A Items normal operation modes.
• Grade B Items operated if operating mode
  increases potential of shock damage or a hazard.
• No more than three most significant operating
  modes represented during shock tests.
• Operating performance during shock testing
  monitored remotely to verify compliance with the
  shock acceptance criteria.

Normal Mode
Standby Mode
Battleshort Mode
Recirculate
Pump
Bypass
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OPERATION OF EQUIPMENT

• Remote Monitoring of Equipment

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ACCEPTANCE CRITERIA

• Adrift Portions personnel and Grade A
  equipment
• Fire Hazards smoke, sparks, flame
• Minor Damagebroken, loose, or deformed parts
• Grade A Items Component must perform its
  principal function
• Grade B Items Component does not need to perform
  principal function

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RESOLUTION OF FAILURES

• Retest failed component if corrective design mod
  is confined to subsidiary components or
  subassemblies
• Acceptance authority approval required
• Repeat qualifying shots (shots 1 and 4 or shots
  4 and 4R)

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• Test Fixture Design
• Minimum Rigid Adequately stiff and strong to
  support equipment under test.
• Simulates specific frequency or stiffness (Use of
  DSF)
• Class I Deck Mounted Items At Least 25 Hz
• Class II Deck Mounted Items 8-10 or 12-16 Hz
• Plastic Yielding/Cracking of Fixtures
• Hold-down bolts MIL-S-1222

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• Test Fixture Design

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• Test Fixture Design

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• Test Fixture Design

Wetted-Surface Mounted Fixture
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• Test Fixture Design

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• Auxiliary Services
• Power Requirements
• 440 220, 120 VAC, 60 or 400 Hz, single or 3-phase
  power, Maximum Amp, or DC service
• Cooling Requirements
• Cooling Water specify flow and pressure
• Compressed air/Gases
• specify pressure, material, flow
• Fuel
• Lubricating/Hydraulic Oils

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• Test Facility Considerations
• Statement of Work
• Consistent Nomenclature
• Equipment Class (Class I or Class II)
• Restricted or Unrestricted Orientations
• Mounting Location (Deck or Hull)
• Mounting Plane (Base, Back, Both)
• Drawings
• Installation Control Drawings (ICD)
• Weight, Dimensions, CG

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• Test Facility Considerations
• Security Services
• Classified, Unclassified, COMSEC, Confidential,
  Secret, Top Secret
• Shipping to Test Facility

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• Acceptance Authority Approval

Contractor-Furnished Equipment
Government-Furnished Equipment
NAVSEA 05P3(NSWCCD Philly) Code 669
NAVSEA 05P3(NSWCCD Philly) Code 669
Shipbuilding Supervisors(LW MW only)
Shipbuilder
Manufacturer
Government Entity
Shock Test Facility
Shock Test Facility
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Section 3 Test Operations

• Test Fixture Fabrication
• Floating Shock Platforms
• Equipment Installation
• Instrumentation
• Test Operations
• Repairs

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• Test Fixture Fabrication
• Performed by test facilities or in-house

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Floating Shock Platform (FSP)
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Intermediate Floating Shock Platform (IFSP)
IFSP (20' x 40')
FSP (16' x 31')
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Intermediate Floating Shock Platform (IFSP)
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Equipment Installation
FSP (16' x 30') with 14 Hz Deck Installed
FSP (16' x 22') with 25 Hz Deck Installed
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Equipment Installation
FSP Test with Water System Installed
Dual decks for systems with multiple deck
frequency requirements
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Deck Simulator Fixture

• DSF part of fixturing
• Vertical natural frequency
• -Mass of Payload
• -Pin Configuration

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Deck Simulator Fixture
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Deck Simulator Fixture
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Equipment Installation
FSP (16' x 22') with 25 Hz Deck Installed
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Equipment Installation
IFSP (20' x 40') Diesel Generator Set Installed
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• Heavyweight Shock Test Limitations
• FSP
• 16' x 28'
• 60,000 - 120,000 lbs
• IFSP
• 20' x 40'
• 60,000 - 250,000 lbs
• LFSP
• 29'-9" x 50'
• 400,000 lbs

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• Test Setup
• (Restricted Test Item on FSP)

Shot 2 (30)
Shot 3 (25)
Shot 4 (20)(Qualifying)
TestItem
Shot 1 (40)(Qualifying)
FSP
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• Test Setup
• (Unrestricted Test Item on FSP)

Shot 2 (30)
Shot 3 (25)
Shot 4 (20)(Qualifying)
Shot 4R (20)(Qualifying)
TestItem
TestItem
FSP
FSP
Test Item Rotated 90?
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• Charge Placement (FSP)

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• Charge Placement (IFSP)

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• Charge Placement (LFSP)

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Note Shot direction for shot 1 is fore-and-aft.
Shot direction for shots 2, 3, and 4 is
athwartship. Represent primary mode of operation
during shots 1 and 4. Represent next likely mode
of operation during shot 3. Represent next
likely mode of operation during shot 2.
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Heavyweight Shock Testing
IFSP (20' x 40') Testing of Diesel Generator Set
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Video of Heavyweight Shock Test (Shot 4)
Single click to play, pause, or resume
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Instrumentation

• Velocity Meters Dry/Wet
• Accelerometers
• Mechanical Deflection Gages
• Underwater Pressure Transducers
• Circuit/Current Monitoring
• Strain Gages
• High-Speed digital Cameras/Video

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Instrumentation
LP Filter
Data Acquisition Processor
Velocity Meter
Accelerometer
Signal Conditioner
PC
Signal Conditioner/Power Supply
Mechanical Deflection Gage
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Innerbottom Velocity
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DSF Acceleration
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DSF Frequency
14.6 Hz
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Section 4 Test Report

• Written Per DI-ENVR-80708, Shock Test Report,
  dated June 1986.
• Submitted to Approval Authority

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Completion!

• Submit Report
• Manufacture Equipment
• Take a vacation
• Any Questions?

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HI-TEST LABORATORIES, INC.
Chris.Grunau_at_hitestlabs.com 434-581-3204