Filter Test Facility Report On The Testing of HEPA Filters for the DOE
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1 Filter Test Facility Report On The Testing of HEPA Filters for the DOE Nuclear Air Cleaning Conference August 2008
2 Air Techniques International Test Laboratory 1708 Whitehead Rd., Baltimore, MD
3 Air Techniques International Test Laboratory Overview Air Techniques International established an independent Filter Test Laboratory in Baltimore, Maryland DOE performs a ASME/ANSI NQA-1 Quality Audit DOE issued contract to ATI Filter Test Laboratory (ATITL) to perform tasks of the former DOE Filter Test Facility Secretary of Energy Memo, June 4, 2001, the Filter Test Lab is to be utilized by DOE Site Contractors Testing service is provided to the DOE complex DOE work has top priority 3
4 Rejection Categories Resistance: Criteria of 1.0 w.g. for filters rated cfm and 1.3 w.g. for filters rated cfm Penetration: 0.03% Manufacturing Defects: Filter Frame/Case Defective Gaskets Faceguard installation Filter pack installation Defective media Sealant problems Separators Missing rivets or bolts Dimensional tolerance Out of square measurements 4
5 Rejection Categories P.O/ Specification Discrepancy: Missing UL labels Labeled incorrectly Filters rated incorrectly Wrong model number Packaging Shipping Damage: (Inspect Damage to Shipping Crates, Pallets & Filter Cartons) Reject Filter when Damaged 5
6 Summary Of Filter Rejections Fiscal Year (Oct 1 Sept. 30) Number Tested Number Rejected Percentage Rejected , % , % , % , % , % 2005* 2, % % % 2008** 1554** 184** 11.8%** *Test facility closed 5 months for relocation and audit **Partial Year 6
7 Summary Of Filter Rejections Fiscal Year (Oct 1 Sept. 30) Resistance Penetration Mfg. Defects P.O./Spec Discrepancy Shipping Damage Total * ** *Test facility closed 5 months for relocation and audit **Partial Year 7
8 HEPA FILTERS TESTED / REJECTED # Filters Tested and % Failure by Fiscal Year # Filters (10 Fiscal Year months) 25.0% 20.0% 15.0% 10.0% 5.0% 0.0% % Failure Total Tested Percent Rejected 8
9 HEPA FILTER REJECTION BY NUMBER Total Filters Rejected by Fiscal Year # Filters Rejected (10 Fiscal Year months) 9
10 HEPA FAILURES BY TYPE # Failures (Resistance, Penetration & Manufacturing ) by Fiscal Year # Failures (10 Fiscal Year months) Resistance Penetration Manufacturing 10
11 HEPA FAILURES BY TYPE # Failures (PO/Specification Discreps & Shipping ) by Fiscal Year # Failures (10 Fiscal Year months) PO/Spec Discreps Shipping Damage 11
12 ATI FILTER TEST FACILITY OPERATIONS 12
13 ATITL Quality Program Plan 1.0 POLICY 2.0 SCOPE 3.0 REFERENCES 4.0 DEFINITIONS 5.0 ORGANIZATION 5.1 Structure 5.2 Functional Responsibilities 6.0 QUALITY ASSURANCE REQUIREMENT 7.0 DESIGN CONTROL 8.0 PROCUREMENT CONTROL 9.0 INSPECTION & TEST 10.0 DOCUMENT CONTROL 13
14 ATITL Quality Program Plan 11.0 CONTROL OF PURCHASED ITEMS AND SERVICES 12.0 IDENTIFICATION AND CONTROL OF ITEMS 13.0 CONTROL OF PROCESSES 14.0 PERSONNEL TRAINING, QUALIFICATION AND CERTIFICATION 15.0 CONTROL OF MEASURING AND TEST EQUIPMENT 16.0 HANDLING, STORAGE AND SHIPPING 17.0 INSPECTION, TEST AND OPERATING STATUS 18.0 CONTROL OF NONCONFORMING ITEMS 19.0 CORRECTIVE ACTIONS 20.0 QUALITY ASSURANCE RECORDS 21.0 QUALITY ASSURANCE AUDITS APPENDICES Figures Organization Chart 14
15 RECOMMENDED SHIPPING CRATE 15
16 NOT RECOMMENDED FILTER SHIPPING METHODS 16
17 UNLOADING FILTER BOXES 17
18 INSPECTION CHECK LIST 18
19 DAMAGED BOX & FILTER 19
20 INSPECTION 20
21 CASE SQUARE INSPECTION 21
22 PENTRATION / RESISTANCE TEST 22
23 FILTER TEST 23
24 TEST LABEL - REPACKING 24
25 RE-BOX FILTER 25
26 RE-PACK FILTERS IN CRATE 26
27 SHIPPING 27
28 REJECT EXAMPLES 28
29 GASKET - REJECT 29
30 FLUID SEAL - REJECT 30
31 CASE - REJECT 31
32 FILTER CASE - REJECT 32
33 FILTER CASE - REJECT 33
34 Summary ALL MANUFACTURERS FILTER QUALITY HAS VARIED DURING LAST NINE YEARS AS SHOWN BY THE FILTER TEST FACILITY (FTF) REPORTS A NEED FOR SPECIFICATION CONSISTENCY (Reference To ASME AG-1 &/or DOE-STD ) A NEED FOR MANUFACTURERS TO TIGHTEN QUALITY CONTROL A NEED FOR QUALITY CONTROL INSPECTIONS OF MANUFACTURERS IN ADDITION TO AUDITS 34
35 Any Questions? Eric Hanson, ATI President Dave Crosby, Vice President of Filter Testing Julie Stormo, Lab Manager Jan Fretthold, Lab Supervisor ATI Test Lab address (phone) (fax) 35
36 DOE DISCLAIMER THE VIEWS EXPRESSED ARE SOLELY THOSE OF THE PRESENTERS AND NO ENDORSEMENT BY THE U. S. DEPARTMENT OF ENERGY IS INTENDED 36
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