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Home My WebLink AboutDRC-2025-001992 CLIVE SITE LETTER OF TRANSMITTAL DATE: 6/23/2025 ATTN: LLRW CC; Treesa Parker Karen Kirkwood RE: Transmittal 2025-036 Description of Documents Transmitted Qty See attached updates for Instruments. CL-IN-PR-422 Rev 6 Air Sample Pump Maintenance and Calibration 1 ------------------------------------------------------------------------------------------------------------ Please replace your current procedure revisions with the documents within this Transmittal. You are not required to sign any documents to verify receipt of this distribution. However, you should make every effort to ensure that your copy of the License is current. FROM: EnergySolutions Document Control Clive Facility Electronic documents, once printed, are uncontrolled and may become outdated. Refer to the Intranet or the Document Control authority for the correct revision. CL-IN-PR-422 Air Sample Pump Maintenance and Calibration Revision 6 Authored By: Mark White, Radiation Safety Specialist Date Reviewed By: Dale Thorne, Lead, Health Physics / ARSO Date Approved By Stephen Long, Lead, Health Physics / ARSO Date Approved By Thomas A. Brown, Radiation Safety Officer (RSO) Date Non-Proprietary New Proprietary Title Change Restricted Information Revision Safeguards Information Rewrite Sensitive Security Information Cancellation Mark White Digitally signed by Mark White Date: 2025.06.20 09:40:23 -06'00' Dale Thorne Digitally signed by Dale Thorne Date: 2025.06.23 07:40:14 -06'00' Stephen J. Long Digitally signed by Stephen J. Long Date: 2025.06.23 09:35:57 -06'00' Thomas Brown Digitally signed by Thomas Brown Date: 2025.06.23 10:12:01 -06'00' Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 2 of 24 Table of Contents 1 PURPOSE AND SCOPE ........................................................................................................ 3 1.1 Purpose........................................................................................................................... 3 1.2 Scope............................................................................................................................... 3 2 REFERENCES ....................................................................................................................... 3 3 GENERAL .............................................................................................................................. 3 3.1 Definitions ...................................................................................................................... 3 3.2 Responsibilities .............................................................................................................. 5 3.3 Precautions and Limitations ........................................................................................ 6 3.4 Document Control and Records .................................................................................. 6 4 REQUIREMENTS AND GUIDANCE .................................................................................. 7 5 ATTACHMENTS AND FORMS......................................................................................... 13 Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 3 of 24 1 PURPOSE AND SCOPE 1.1 Purpose This procedure provides detailed instructions for routine maintenance and calibration of air sample pumps, including those used for Thermal Desorption effluent air sampling. 1.2 Scope This procedure applies to the maintenance and calibration of High Volume (HV-1 or equivalent), Low Volume (0523-CV or equivalent) air sample vacuum pumps and Lapel sample pumps. 2 REFERENCES 2.1 Operating Manual for Venturi Digital Calibrator 2.2 Technical Manual, F&J Specialty Products HV-X series air sampler 2.3 Technical Manual, HI-Q Environmental Products VS-series air sampler 2.4 Magnehelic Differential Pressure Gage Operating Instructions 2.5 AirChek Touch Sample Pump Operating Instructions 2.6 CL-RS-PR-200, Air Sampling 2.7 UT 2300249, Radioactive Material License as amended 3 GENERAL 3.1 Definitions 3.1.1 Armature (HiVol Pump) - Primary spindle from the pump that contains the magnetic field that turns the pump. 3.1.2 Carbon Brushes (HiVol Pump) - Provides the electrical contact between the pump and the armature. 3.1.3 Carbon Cartridge - Cartridge used for sampling for Radioiodine. 3.1.4 Carbon Vanes (Low Vol Pump) - The replaceable moving parts of the vacuum pump impeller. 3.1.1 DryCal Calibrator - The DryCal Defender is a field-portable primary flow standard. This device serves as the calibration standard for Lapel Pump air samplers, and provides the reference readings for calibration. 3.1.2 Felt Filters (Low Vol pump) - Collects the carbon dust generated from the pump vanes during operation. 3.1.3 Hi-Q AFC-70L flow meter - Magnehelic Differential Pressure Gage used as a flow meter which indicates airflow rate in liters per minute. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 4 of 24 3.1.4 Hi Volume Air Sampler (HiVol) - Portable vacuum pump, model HV-1 or equivalent, designed for a normal flow rate of 120 liters per minute. This pump is not rated for a continuous duty cycle. 3.1.5 Hi Volume Air Sampler (HiVol) - Portable vacuum pump, model HV-1 or equivalent, designed for a normal flow rate of 120 liters per minute. This pump is not rated for a continuous duty cycle. Lapel Pumps - Commercially available portable battery powered air sample pumps used to collect breathing zone or work area air samples. An internal battery powers these small light pumps for 8 hours or more at a flow rate of 4 liters per minute. While normally used for breathing zone “lapel” samples, they may also be used for general area type samples when the appropriate sample volumes are collected. 3.1.6 Low Volume Air Sampler (LoVol) - Low-volume air sampler pumps are Hi-Q model VS23 series or equivalent, usually using a Gast model 0523- CV or equivalent vacuum pump and motor, designed for a normal flow rate of 60 liters per minute. This type of air sampler is rated for a continuous duty cycle. 3.1.7 Normal Flow Rate, The normal flow setting for the air sample pump. • HighVols - 120 lpm • LoVols - 60 lpm • Lapel – 4 lpm 3.1.8 Rotameter/Flow meter - Indicates the airflow rate through the air sampler pump in liters per minute. 3.1.9 Sample Filter - The sample filter is the sample media used to obtain samples of airborne particulates. A 47mm diameter 0.5-micron glass fiber filter is typically used. 3.1.10 Sample Head - Plastic or metal device that holds the sample filter. The assembled sample head attaches to the sample pump, either directly or through a remote sampling hose. 3.1.11 Standard Temperature & Pressure - Reference units used to normalize temperature and pressure measurements. Standard Pressure = 760 mm Hg Standard Temperature = 70 degrees F (21.1 C) 3.1.12 Vacuum Assisted Thermal Desorption (VTD) – A process that produces a physical separation of volatile and semi-volatile chemicals from contaminated waste materials. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 5 of 24 1.1.1 Lapel Pumps - Commercially available portable battery powered air sample pumps used to collect breathing zone or work area air samples. An internal battery powers these small light pumps for 8 hours or more at a flow rate of 4 liters per minute. While normally used for breathing zone “lapel” samples, they may also be used for general area type samples when the appropriate sample volumes are collected. 3.1.13 Venturi Calibrator - F & J Specialty Products model D-828 “Venturi” digital calibrator or equivalent as approved by the RSO. This device serves as the calibration standard for High Volume air samplers, Low Volume air samplers, and provides the reference readings for calibration. 1.1.1 DryCal Calibrator - The DryCal Defender is a field-portable primary flow standard. This device serves as the calibration standard for Lapel Pump air samplers, and provides the reference readings for calibration. 1.1.1 Standard Temperature & Pressure - Reference units used to normalize temperature and pressure measurements. Standard Pressure = 760 mm Hg Standard Temperature = 70 degrees F (21.1 C) 1.1.1 Carbon Brushes (HiVol Pump) - Provides the electrical contact between the pump and the armature. 1.1.1 Normal Flow Rate, The normal flow setting for the air sample pump. • HighVols - 120 lpm • LoVols - 60 lpm • Lapel – 4 lpm 1.1.1 Hi-Q AFC-70L flow meter - Magnehelic Differential Pressure Gage used as a flow meter which indicates airflow rate in liters per minute. 1.1.1 Sample Head - Plastic or metal device that holds the sample filter. The assembled sample head attaches to the sample pump, either directly or through a remote sampling hose. 1.1.1 Sample Filter - The sample filter is the sample media used to obtain samples of airborne particulates. A 47mm diameter 0.5-micron glass fiber filter is typically used. 1.1.1 Carbon Cartridge - Cartridge used for sampling for Radioiodine. 3.2 Responsibilities 3.2.1 Radiation Safety Officer (RSO) or designee is responsible for overall radiation safety, contamination control, and compliance with state and federal regulations 3.2.2 Lead, Health Physics (ARSO) or designee is responsible for overseeing radiation safety activities, reviewing calibration and maintenance work Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 6 of 24 performed by the Radiation Safety Calibration/ Maintenance Technician(s), specifying maintenance and calibration intervals IAW applicable requirements, and evaluating the implications of out-of- specification “as-found” readings. 3.2.3 Environmental Manager or designee is responsible for overseeing the environmental monitoring program and reviewing calibration and maintenance work performed by the Environmental Calibration/Maintenance Technician(s). 3.2.4 Calibration/ Maintenance Technician(s) are responsible for scheduling maintenance and calibration of air sample equipment. Ensuring timely calibration of air sample equipment. Notifying the ARSO of any out-of- specification “As Found” readings. Performing all required maintenance and calibration steps as outlined in this procedure. Documenting Calibration and Maintenance records completely, accurately, adequately, and then forwarding them to the ARSO for review. 3.3 Precautions and Limitations 3.3.1 Never open energized equipment. Always unplug equipment before the start of work or disassembly. 3.3.2 Good contamination control practices should be observed while working on potentially contaminated items. 3.3.3 Calibration shall be performed on a level surface. 3.3.4 All air sampling pumps shall be calibrated at intervals not to exceed six months. 3.3.5 Additionally, calibration shall be performed or verified after each repair involving the flow meter, motor, or controls, before using a filter media other than that which was used during the last calibration process and whenever erroneous readings are suspected. 3.3.6 Initial “As Found” measurements shall be performed on operable pumps before adjustment or disassembly. Preventative maintenance, as detailed in the attachments to this procedure, is done after “As Found” testing is complete. 3.3.7 The calibration procedure involves comparing the flow value displayed on the flow meter to the flow value displayed on the reference calibrator. The filter media used during calibration shall be the same as that used for sampling. 3.3.8 The Defender DryCal shall be calibrated annually. 3.3.9 The Venturi shall be calibrated annually by an approved supplier. 3.4 Document Control and Records Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 7 of 24 3.4.1 The ARSO or Environmental Manager shall review each completed CL- IN-PR-422-F1, Air Sampler Checklist and Calibration Record and CL-IN- PR-422-F2, Lapel Air Sampler Checklist and Calibration Record. 3.4.2 The reviewed CL-IN-PR-422-F1, Air Sampler Checklist and Calibration Record or CL-IN-PR-422-F2, Lapel Air Sampler Checklist and Calibration Record should be transmitted to Document Control within 60 days of receipt. 4 REQUIREMENTS AND GUIDANCE 4.1 Description Air sample pump calibration is achieved by comparing the indicated flow on the pump’s flow meter with a reference standard over its expected range of operation. The calibration process is completed in three stages. 4.1.1 First, pre-calibration “As Found” measurements shall be recorded for all operable pumps in the appropriate section on the CL-IN-PR-422-F1, Air Sampler Checklist and Calibration Record or CL-IN-PR-422-F2, Lapel Air Sampler Checklist and Calibration Record. This verifies and validates the continued accuracy of the pump since the last calibration. Unusual or out-of-specification readings during this check may trigger further evaluations of prior air sample data. 4.1.2 Next, preventative and corrective maintenance shall be performed. 4.1.3 Finally, the calibration is again checked, over the expected range of operation, and adjustments shall be made as needed to bring the pump error within tolerance. The “As Left” measurements shall be recorded on the calibration sheet, before the pump is returned to service. 4.2 HiVol and LoVol Calibration 4.2.1 “As Found” measurements shall be obtained on all operable pumps before calibration or servicing. Instruments found with “As Found” measurements out of the calibration range or instruments found that were being used out of calibration shall be reported to the ARSO. 4.2.2 After ensuring that the Venturi has a current calibration sticker, PLUG the calibrator in and turn it on. 4.2.3 The green indicator lamp next to “CFM” is lit, indicating the current display units. PRESS the “SELECT” button repeatedly to SWITCH between the available display options, noting the current temperature in degrees Fahrenheit and barometric pressure in mm Hg. 4.2.4 ENSURE the appropriate air filter and carbon filter (if necessary) is loaded in the sample head in the test adapter. 4.2.5 SECURE the sample head end of the adapter to the pump to be tested. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 8 of 24 4.2.6 SECURE the hose end of the adapter to the “flow” arrow side (outlet side) of the Venturi, and TIGHTEN the hose clamp. 4.2.7 ENSURE the Venturi inlet port is free of obstructions. The test hose should be free of kinks. 4.2.8 PLUG in the air sample pump and turn it on. 4.2.9 SELECT “LPM” on the Venturi display. 4.2.10 ADJUST the air sampler flow control until its normal flow rate is indicated on the VENTURI CALIBRATOR display. DO NOT make any other adjustments or changes during this step. • For Hi Vol (HV-1) or equivalent models, the normal flow rate is 120 lpm (liters per minute). The flow is adjusted by rotating the “variable” knob. • For Lo Vol (0523) or equivalent models, the normal flow rate is 60 lpm. The flow is adjusted by turning the regulator screw or moving the flow valve if so equipped. 4.2.11 ALLOW the display to stabilize at the desired reading. Small adjustments may be needed to the pump flow before a stable reading is achieved at the target flow. After a few seconds, the display should alternate between “CAL” and the flow reading. If the Venturi doesn’t stabilize sufficiently to alternate between “CAL” and the flow reading, determine the average of the displayed flow rates. 4.2.12 When the Venturi display remains stable at the normal flow rate or the average flow rate is determined, NOTE the corresponding flow indicated on the pump flow meter. This is the “As Found” reading. 4.2.13 Additional data shall be obtained if the “As Found” reading is not within +/- 10% of the reference reading (Hivols +/- 12 lpm, LoVols +/- 6 lpm). The following are examples of additional reference flow readings to obtain in addition to the rates outlined in Step 4.2.10 • HiVols: 40, 70, 90, and 130 lpm • LoVols: 30, 40, 50, and 70 lpm 4.2.14 When the necessary “As Found” data is obtained, PERFORM preventative maintenance as outlined in the attachments to this procedure. 4.2.15 After needed maintenance is completed, the pump calibration is set up as outlined in 4.2.2 through 4.2.9 above. 4.2.16 With the pump running at its normal flow rate (as indicated on the Venturi Calibrator), OBSERVE the flow rate indicated on the flow meter. The Venturi and flow meter should agree within a maximum tolerance of +/- 10%. If adjustment is needed for rotameter style flow meter follow the Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 9 of 24 steps listed below. If adjustment is needed for AFC-70L flow meter then follow steps listed in Magnehelic Differential Pressure Gage Calibration. • REMOVE the protective cap, if installed, from the adjusting screw on the rotameter. • LOOSEN any locking nut or locking ring to allow screw adjustment. • SET the flow meter calibration by turning the backpressure adjusting screw until pump flow and reference flow agree within tolerance. • LOCK and/or COVER the backpressure adjusting screw to prevent further inadvertent adjustments. 4.2.17 NOTE and RECORD the final reference and pump readings on CL-IN- PR-422-F1, Air Sampler Checklist and Calibration Record. 4.2.18 With the flow meter calibration set, OBTAIN additional readings over the pump’s anticipated operating range. For example • HiVols: 40, 70, 90, and 130 lpm • LoVols: 30, 40, 50, and 70 lpm 4.2.19 If the reference flow and pump flow do not agree within +/- 10% over the tested range, then AFFIX a chart of actual versus indicated flow data to the pump. 4.2.20 COMPLETE a calibration label with the following information and attach this sticker to the equipment. • Equipment Serial Number • Date of Calibration • Date of next Calibration • The name or initials of person performing the calibration 4.2.21 ENSURE all information is completed on the CL-IN-PR-422-F1, Air Sampler Checklist and Calibration Record. This information shall include, at a minimum: • Identification/Serial number of the equipment • Name of the persons performing the calibration • Date calibration was preformed • Date the next calibration is due • The results of the calibration • Identification of the procedure used to calibrate the equipment Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 10 of 24 • Traceability to NIST Standards • Maintenance performed 4.3 AirChek Touch Lapel Air Sampler Calibration 4.3.1 PERFORM “As Found” pump readings. 4.3.1.1 “As Found” measurements shall be obtained on all operable pumps before calibration or servicing. Instruments found with “As Found” measurements out of the calibration range or instruments found that were being used out of calibration shall be reported to the ARSO. 4.3.1.2 SELECT and RECORD the “As Found” sample media that was used in the previous calibration on CL-IN-PR-422- F2, Lapel Air Sampler Checklist and Calibration Record. 4.3.1.3 ENSURE that the Defender DryCal has a current calibration sticker. 4.3.1.4 PRESS and HOLD the Defender DryCal power button to TURN ON the calibrator. 4.3.1.5 SELECT Measure and PRESS Enter. 4.3.1.6 TURN ON the AirChek lapel air sampler. 4.3.1.7 VERIFY the Airchek lapel pump has a full battery charge. 4.3.1.8 ATTACH the sample hoses and ENSURE the appropriate sample media is loaded in the sample head in the test adapter, using Attachment 5.5 as a reference. Note: The configuration in Attachment 5.5 is an example and may vary depending on the sample media. 4.3.1.9 PRESS the Flow Rate display/run key to select desired flow rate for “As Found” reading(s) based on the previous calibration sample media. • For Breathing Zone and General Area Air Samples Using a Lapel Pump the desired flow rate is 4 lpm (liters per minute). • For Working Level Air Samples Using a Lapel Pump the desired flow rate is 3 lpm (liters per minute). • For Tritium Air Sampling Using the Lapel Pump and Bubbler desired flow rate is 2 lpm (liters per minute). 4.3.1.10 RUN the lapel sample pump and allow pump to stabilize. 4.3.1.11 ENSURE the Defender DryCal inlet port is free of obstructions. The test hose should be free of kinks. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 11 of 24 4.3.1.12 SELECT Burst on the Defender DryCal and press ENTER on calibrator. 4.3.1.13 VERIFY that it is set to 10 readings 4.3.1.14 RECORD average flow reading on CL-IN-PR-422-F2, Lapel Air Sampler Checklist and Calibration Record 4.3.1.15 PRESS Stop on the AirChek Lapel Pump. 4.3.1.16 Additional data shall be obtained if the “As Found” reading is not within +/- 10% of the reference reading. The following are examples of additional reference flow readings to obtain in addition to the rates outlined in Step 4.3.1.9 to 4.3.1.15. • Lapel: 5, 4, 3, 2, and 1 lpm 4.3.1.17 When the necessary “As Found” data is obtained, PERFORM maintenance checkpoints as outlined in CL- IN-PR-422-F2, Lapel Air Sampler Checklist and Calibration Record 4.3.2 Selecting Defender Data Port 4.3.2.1 On the Defender DryCal PRESS Exit. 4.3.2.2 PRESS the right arrow to Setup; PRESS Enter. 4.3.2.3 PRESS the right arrow to highlight Preferences; PRESS Enter. 4.3.2.4 PRESS the down arrow to navigate to Data Port. 4.3.2.5 PRESS left or right arrow to toggle to SKC. 4.3.2.6 PRESS the down arrow to highlight Confirm; PRESS Enter. 4.3.2.7 PRESS the down arrow to highlight Measure; PRESS Enter. 4.3.3 Prepare the Charging Cradle and Lapel Pump. Note: The Charging cradle must be plugged in for CalChek calibration. 4.3.3.1 ALIGN contacts on the bottom edge of the AirChek Lapel pump with contacts in the cradle and INSERT the pump in the cradle. 4.3.3.2 ATTACH the female end of the CalChek Communication Cable to the serial port on the back of the Defender DryCal Calibrator. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 12 of 24 4.3.3.3 INSERT Male end of the CalChek Communication Cable into the CalChek port on the back of the Charging Cradle. 4.3.4 Initiating CalChek Single Automatic Flow Calibration 4.3.4.1 On the Lapel Pump TOUCH the Setting soft key. 4.3.4.2 TOUCH Calibrate. 4.3.4.3 TOUCH CalChek Single 4.3.4.4 ENSURE calibration train is in place. 4.3.4.5 TOUCH checkmark to accept CalChek selection. 4.3.4.6 PRESS the Flow Rate display/run key to select desired flow rate for “As Found” reading(s) based on the “As Left” sample media. • For Breathing Zone and General Area Air Samples Using a Lapel Pump the desired flow rate is 4 lpm (liters per minute). • For Working Level Air Samples Using a Lapel Pump the desired flow rate is 3 lpm (liters per minute). • For Tritium Air Sampling Using the Lapel Pump and Bubbler desired flow rate is 2 lpm (liters per minute). 4.3.4.7 ENSURE the Defender DryCal inlet port is free of obstructions. The test hose should be free of kinks. 4.3.4.8 SELECT Cont. on the Defender DryCal and PRESS Enter on calibrator. 4.3.4.9 The pump will calibrate automatically. Top box on screen displays set flow, bottom box displays flow rate reading from the Defender DryCal. • Completion: “CalChek single-point calibration completed successful” TOUCH checkmark to accept and return to home screen. • Failure: “CalChek single-point calibration failed error-xx (explanation of error). NOTIFY ARSO. 4.3.5 Perform “As Left” pump readings. 4.3.5.1 ENSURE calibration train is in place. Note: The AirChek Lapel does not need to be in the cradle for “As Left” pump readings. 4.3.5.2 ENSURE the Defender DryCal inlet port is free of obstructions. The test hose should be free of kinks. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 13 of 24 4.3.5.3 PRESS the Flow Rate display/run key to restart pump for calibration. 4.3.5.4 SELECT desired flow rate for “As Left” reading(s). 4.3.5.5 RUN the sample pump to stabilize. 4.3.5.6 SELECT Burst and PRESS Enter on the calibrator. 4.3.5.7 VERIFY that it is set to 10 readings 4.3.5.8 VERIFY average flow is within a maximum tolerance of +/- 10%. Record average flow reading on CL-IN-PR-422- F2, Lapel Air Sampler Checklist and Calibration Record. 4.3.5.9 With the flow meter calibration set, REPEAT steps 4.3.5.3 to 4.3.5.8 to obtain additional readings over the pump’s anticipated operating range. For example: • Lapel: 5, 4, 3, 2, and 1 lpm 4.3.6 COMPLETE a calibration label with the following information and ATTACH this sticker to the equipment. • Equipment Serial Number • Date of Calibration • Date of next Calibration • The name or initials of person performing the calibration 4.3.7 ENSURE all information is completed on the CL-IN-PR-422-F2, Lapel Air Sampler Checklist and Calibration Record. This information shall include, at a minimum: • Identification/Serial number of the equipment • Name of the persons performing the calibration • Date calibration was performed • Date the next calibration is due • The results of the calibration • Identification of the procedure used to calibrate the equipment • Traceability to NIST Standards • Maintenance performed 5 ATTACHMENTS AND FORMS 5.1 CL-IN-PR-422 F1, Airflow Calibration Record and Checklist (Example) 5.2 Service and Maintenance Instructions 5.3 Magnehelic Differential Pressure Gage Calibration Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 14 of 24 5.4 CL-IN-PR-422 F2, Lapel Airflow Calibration Record and Checklist (Example) 5.5 Attachment 5.5 – AirChek Touch Sample Pump Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 15 of 24 Attachment 5.1 - CL-IN-PR-422-F1, Airflow Calibration Record and Checklist (Example) Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 16 of 24 Attachment 5.2 - Service and Maintenance Instructions HI-VOL SERVICE AND MAINTENTANCE INSTRUCTIONS Caution: Prior to performing any maintenance disconnect the air sampler cord from the power source. 1. If the pump has been in the Restricted Area survey the external surfaces and any internal surfaces exposed during disassembly for radioactive loose surface contamination. If any contamination is found above 20 dpm alpha and 200 dpm beta, decontaminate the affected surfaces before proceeding 3. Clean the exterior of the pump using damp paper towels as needed. Interior surfaces should be cleaned as they are exposed. 4. Inspect the motor brushes, and replace as needed. A. Inspection 1) Remove the bell-shaped cover that protects the motor by unscrewing the four screws that secure the cover to the aluminum housing. 2) Remove the two spring clips holding the plastic motor guard. 3) Examine the brush assembly. Note the arrangement, clamping and connection method. 4) Compare a new set of brushes with those on the motor. Brushes with excessive wear, based on operating experience (usually more than one third (1/3) worn), must be replaced. B. Replacement 1) Back out the two round head screws retaining the clip holding the brush assembly. 2) Grasp the outer end of the brush assembly and gently work the brush assembly away from the commutator until the connector almost touches the clamp. 3) Insert a screwdriver blade between the connector and insulator. Turn the screwdriver to force the connector toward the commutator, and work the connector free. 4) Inspect the motor commutator. It should be smooth and shiny. If it is excessively worn, grooved, or pitted, the motor must be replaced. If it is smooth but blackened, use cloth dipped in cleaning solvent to clean it. 5) To install the new brush, insert the connector between the brush housing and insulator, using a flat screwdriver. Hold the brush in position, seated on the stud, press the clamp downward and tighten the screws. Ensure the brush assembly is properly seated and the wires do not touch the metal of the motor frame. 6) Repeat with the second brush. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 17 of 24 Attachment 5.2 - Service and Maintenance Instructions (cont) 5. To replace the motor: A. Remove the bell-shaped housing if not already done. B. Do not unscrew the four screws attaching the motor to the aluminum plate. Instead, pry the aluminum plate away from the housing with two flat screwdrivers. C. Disconnect the power cable wire and controller wire. D. Remove and clean the aluminum plate. Remove and replace the gaskets, and clean the sealing surface of the housing. E. Replace the motor by performing the above steps in reverse order. 6 If the plastic controller module must be removed, unscrew the four hex nuts located on the front panel. Ensure a good seal is achieved upon reinstallation. 7. Inspect the condition of any visible wiring. Make sure the wiring has not frayed or come undone, and that all connections are tight and secure. 8. Ensure that the rotameter works and that the ON/OFF switch is in good working condition. If the rotameter must be removed for repair or replacement, ensure the intake O-ring is on the bottom opening of the flow meter before securing it. 9. At this time, while the pump is still torn apart, replace anything that is in need of repair. 10. Reassemble the pump and calibrate before returning it to service. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 18 of 24 Attachment 5.2 - Service and Maintenance Instructions (cont) LOW VOL SERVICE AND MAINTENTANCE INSTRUCTIONS Caution: Prior to performing any maintenance disconnect the air sampler cord from the power source 1. If the pump has been in the Restricted Area survey the external surfaces and any internal surfaces exposed during disassembly for radioactive loose surface contamination. If any contamination is found above 20 dpm alpha, and 200 dpm beta, decontaminate the affected surfaces before proceeding. 2. Clean the exterior of the pump using damp paper towels. Interior surfaces should be cleaned as they are exposed. 3. Unscrew the filter holders. 4. Unscrew the five (5) bolts on the muffler box to remove it. 5. Remove the six (6) end plate bolts. Tap the end plate lightly with a hammer to remove. Do not pry it loose with a screwdriver, as this will damage it. 6. Inspect the carbon vanes for excessive wear or damage and replace as necessary. If the pump has been in continuous use carbon vanes shall be replaced annually. 7. Inspect the pump surfaces for visible wear. Inspect the cord and timer for visible damage. Replace or repair any damaged parts. 8. Reassemble the pump in the reverse order of disassembly. Verify gaskets are not damaged before reinstalling the muffler box, and replace the gaskets if needed. 9. Replace the filter holder O-rings if needed, install new filters if needed, and screw the holders into the muffler box. 10. Unscrew the metal muffler from the muffler box. Clean the carbon out of the muffler with water and compressed air as needed. Reinstall the muffler. 11. Proceed with the calibration when this is complete. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 19 of 24 Attachment 5.2 - Service and Maintenance Instructions (cont) Gast Lubricated 23 Series LOW VOL SERVICE AND MAINTENTANCE INSTRUCTIONS Caution: Prior to performing any maintenance disconnect the air sampler cord from the power source 1. Survey the external surfaces and any internal surfaces exposed during disassembly for radioactive loose surface contamination. If any contamination is found above 20 dpm alpha, and 200 dpm beta, decontaminate the affected surfaces before proceeding. 2. Clean the exterior of the pump using damp paper towels. Interior surfaces should be cleaned as they are exposed. 3. Inspect the pump surfaces for visible wear. Inspect the cord. Inspect the pump surfaces for visible wear. Inspect the cord 4. Unscrew the glass intake and exhaust filter jars and clean. 5. Unscrew filters and inspect and clean. Replace filters if necessary. 6. Inspect and clean filter assembly cap. Inspect cork gasket and replace if necessary. 7. Remove the six (6) end plate bolts. Tap the end plate lightly with a hammer to remove. Do not pry it loose with a screwdriver, as this will damage it. Do not at any time remove the rotor or loosen any of the electric motor thru-bolts. 8. Inspect and clean the end plate. Care should be taken not to damage the siphon oiler. Do not turn the end plate upside down, as this will cause the oil to leak out of the oiler. 9. Inspect the vanes for excessive wear or damage and replace as necessary. If the pump has been in continuous use carbon vanes shall be replaced annually. 10. Apply a thin coat Gast Recommended Oil part#AD220, (an equivalent 10 st. high detergent oil can also be used) to the vanes. Re-install vanes, noting the proper direction of the beveled edge. 11. Reassemble the pump in the reverse order of disassembly. 12. Before putting pump back into service, ensure that any external accessories have not been damaged. 13. Proceed with the calibration when this is complete. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 20 of 24 Attachment 5.3 - Magnehelic Differential Pressure Gage Calibration *Refer to Exploded View on next page for reference. 1. Remove the front case on the magnehelic. 2. Set the flow meter calibration by turning the backpressure adjusting screw until pump flow and reference flow agree within tolerance. If the magnehelic is not equipped with a backpressure screw perform steps 3 to 8. 3. With gage case, P/N held firmly; loosen bezel, P/N by turning counter clockwise. To avoid damage, a canvas strap wrench or similar too should be used. 4. Lift out plastic cover and “O” ring. 5. Remove scale screws and scale assembly. Be careful not to damage pointer. 6. The calibration is changed by move the clam, P/N. 70-b Loosen the clamp screw(s) and move slightly toward the helix if gage is reading high and away if reading low. Tighten clamp screw and install scale assembly. 7. Place cover and O-ring in position. Make sure the hex shaft on inside of cover is properly engaged in zero adjust screw, P/N 230-b. 8. Secure cover in place by screwing bezel down snug. Note that the area under the cover is pressurized in operation and therefore gage will leak if not properly tightened. 9. Zero gage and compare to test instrument. Make further adjustments as necessary. Caution: If bezel binds when installing, lubricate threads sparingly with light oil or molybdenum disulphide compound. Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 21 of 24 Attachment 5.3 - Magnehelic Differential Pressure Gage Calibration (cont) Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 22 of 24 Attachment 5.4 – CL-IN-PR-422 F2, Lapel Airflow Calibration Record and Checklist (Example) Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 23 of 24 Attachment 5.5 – AirChek Touch Sample Pump (Example) Filter Media Air Sample Pump Maintenance and Calibration CL-IN-PR-422 Revision 6 Non-Proprietary Page 24 of 24