Pressure Testing Instructions
Contents
1. 3 With NFPA 1991 compliant Tychem TK and Tychem Responder ensembles take the inner chemical suit out of the overcover Access to the exhaust valves will be easier and the inner and outer garments need to be separated for visual inspection 4 Ifthe garment is equipped with airline pass thrus make sure these are capped or blocked 5 Exhaust Valve Preparation he test kit can be used to test Level A garments according to ASTM F 1052 29CFR1910 120 or EN 464 if the garments are fitted with either Auer or Pirelli exhaust valves Auer Exhaust Valve Pirelli Exhaust Valve There are separate instructions for preparing the exhaust valves on e DuPont Tychem TK Level A garments e DuPont Responder Level A garments e Other Level A garments fitted with Pirelli Exhaust valves a Preparation of DuPont Tychem TK Level A garments DuPont manufactured Tychem TK garments are fitted with Auer exhaust valves i Remove and save foam materials attached to the inside of the exhaust valves These will be replaced after testing ii Working from the outside of the garment remove the flexible outer rubber covers from all exhaust valves Set these aside to be re installed after testing iii Carefully remove the rubber diaphragm from each exhaust valve by rolling the edge of the diaphragm towards the center and peeling it off the center stem These diaphragms should be replaced every 2 years from the date of suit manuf2. The inflation hose connector for Pirelli valves has a 90 angle The sensing hose connector for Pirelli valves is straight After inserting the two connectors proceed to step 6 of these instructions c Preparation of other Level A garments fitted with Pirelli exhaust valves see illustrations immediately above i Working from the outside of the garment unsnap the perforated round outer covers from all exhaust valves Set these aside to be re installed after testing il Carefully remove the rubber diaphragm from each exhaust valve by rolling the edge of the diaphragm towards the center and gently pulling the stem of the diaphragm out of the center of the valve body ill Some Level A garments are fitted with more than two Pirelli exhaust valves Carefully remove the diaphragm from the outside of the additional exhaust valves and re install them on the inside of these additional exhaust valve bodies iv Choose the correct metal bayonet style connectors to fit the valves of the garment being tested Adapters engraved with P fit Pirelli exhaust valves v From the outside of the garment firmly push each connector into an exhaust valve from which the diaphragm has been removed Twist the adaptor clockwise approximately 1 8 turn to lock it in place DO NOT FORCE If the adapter is not locked in place a seal will not occur and the garment will not hold pressure HOWEVER FORCING THESE CONECTORS CAN PERMANENTLY DAMAGE TH
3. Working from the outside of the garment unsnap the perforated round outer covers from all exhaust valves Set these aside to be re installed after testing Carefully remove the rubber diaphragm from each exhaust valve These diaphragms should be replaced every 2 years from the date of suit manufacture Examine diaphragms that are not scheduled for replacement for cracks or deterioration with a magnifying glass Damaged or deteriorated diaphragms should be replaced iii Tychem Responder garments compliant with NFPA 1991 and Tychem TK garments compliant to the Class 1 of the 2001 edition of NFPA 1994 have 3 exhaust valves One of these 3 exhaust valves must be sealed during inflation testing Install one of the inspected or new diaphragms into the inside of that third exhaust valve body to seal it for the inflation test iv Choose the correct metal bayonet style connectors to fit the valves of the garment being tested Adapters engraved with P fit Pirelli exhaust valves installed in Tychem Responder and Tychem Reflector garments From the outside of the garment firmly push each connector into an exhaust valve from which the diaphragm has been removed Twist the adaptor clockwise approximately 1 8 turn to lock it in place DO NOT FORCE If the adapter is not locked in place a seal will not occur and the garment will not hold pressure HOWEVER FORCING THESE CONECTORS CAN PERMANENTLY DAMAGE THE EXHAUST VALVE
4. bubble solution Brush the solution on the garment in the suggested locations Look for formation and growth of bubbles This will pinpoint the location of the leak This picture shows bubbles created by a pinhole leak purposely created at the edge of the seam tape for demonstration purposes SUIT FILL a Soles and seams of the garment socks b The end of the sleeve and interface with the attached gloves c Around exhaust valves This pictures show leakage around an exhaust valve connection intentionally loosened for demonstration purposes d The closure starting with the area around the slider e Along seams staring from the head and systematically moving down the garment to the socks f Other seam or fabric locations that show signs of wear or abrasion Tychem garments are intended for a limited number of wears and must be replaced when damaged altered or contaminated Uncontaminated garments that fail the inflation test can be marked with a permanent marker and used for training garments Returning the Inspected Garment to Service 1 Disconnect the inflation and sensing air hoses from the garment and from the test kit Coil the hoses for storage in the test kit case Open the garment closure completely Hold the garment closure near the slider while firmly pulling the garment slide Lubricate the slider if necessary and according to instructions in the closure lubrication section of the Tychem Us
5. 1052 You can purchase a copy of the complete method at www ASTM org or by calling ASTM at 1 800 262 1373 USA and Canada or 610 832 9578 The method described in ASTM F 1052 exceeds the requirements specified in 29CFR1910 120 ASTM F 1052 is not a substitute for the procedure found in European standard EN 464 1 Press the large red button on the test kit to turn the blower on 2 Turn the large red valve lever one quarter turn counter clockwise to the SUIT FILL position for garment inflation NOTE the pressure gauge will not start to register pressure until the garment is nearly inflated 3 When the pressure gauge indicates between 5 and 6 inches of water turn the large red valve handle one quarter 1 4 turn clockwise placing the handle in the SUIT TEST position 4 Turn the blower off by pressing the large red button on the face of the test kit NOTE EXCESSIVE INTERNAL POSITIVE PRESSURE CAN DAMAGE THESE GARMENTS DO NOT OVER INFLATE THE GARMENT 5 Let the suit remain at a pressure of greater than 5 inches water gauge pressure for at least one minute OFF Suit FALE Set the timer on the test kit for 4 minutes Reduce the air pressure in the suit to 4 inches of water by partially turning the red lever counterclockwise towards the SUIT FILL position Then return the valve to the SUIT TEST position Start the timer NOTE DO NOT TOUCH OR MOVE THE SUIT DURING THE TEST PERIO
6. D At the end of 4 minutes read the pressure gauge he garment is considered to pass if the pressure remains at or above 3 2 inches 80 after 4 minutes 10 Complete a visual inspection as described in the Garment Inspection Section of the Tychem User Manual before deflating suit 11 Complete the garment inspection log form Record the ending pressure on the suit test log sheet found in the User Manual that accompanied the garment Include the date time inspector s name and results of the inspection and testing Instructions for Locating Leaks 1 2 If the garment does not pass the inflation test a Check the installation of the connectors inserted in the exhaust valves DO NOT FORCE b Check that the inflation and sensing hose are securely connected Check that the closure is fully closed Visually check the closure for mis aligned teeth Check that pass thru s are adequately blocked gt DO Qa If there are extra exhaust valves check that the caps are In place on the extra Auer exhaust valves or that the flappers are in place and sealed on extra Pirelli exhaust valves g Verify that the test kit is operating properly with the Self Test Device DuPont Number 999800 See Instructions on page 10 of this manual Inflate the garment to a pressure of between 5 and 6 inches water gauge pressure Check for leaks using children s soap bubble solution Mix equal parts of water and the
7. DuPont Personal Protection Instruction Manual for Universal Pressure Test Kit No 990810 Effective October 2006 BE SURE TO READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING TO PERFORM AN INFLATION TEST CALL CUSTOMER SERVICE AT 800 931 3456 843 335 8211 IF YOU HAVE QUESTIONS Kit Overview The DuPont Tychem Universal Pressure Test Kit is designed for testing DuPont Tychem Level A ensembles according to ASTM F 1052 Standard Test Method for Pressure Testing Vapor Protective Ensembles or the method described in 29CFR1910 120 Hazardous Waste Operations and Emergency Response HAZWOPER and EN 464 Determination of Leak tightness of Gas tight Suits The kit can be used with other Level A garments fitted with Pirelli or Auer exhaust valves The Universal Pressure Test Kit is contained in a black suitcase Inside the suitcase you will find e Self contained blower unit e Pressure gauge Magnehelic calibrated to 8 inch water gauge pressure e Timer e Four metal bayonet style connectors two marked with the letter A for Auer and two marked with the letter P for Pirelli e Two black rubber caps e A large diameter corrugated hose e Asmall diameter clear plastic hose e Power cord e Standard testing device The miracles of science Garment Inspection and Pressure Testing DuPont Personal Protection Level A garments should be visually inspected and inflation tested as described in the D
8. E EXHAUST VALVE 6 Connect the large diameter corrugated inflation hose to the appropriate exhaust valve connector on the garment 7 Connect the small diameter clear sensing hose to the other exhaust valve connector on the garment 8 Pull the garment closure closed Hold the garment closure near the slider while firmly pulling the garment slide Pull in the direction of the open portion of the closure Lubricate the slider if necessary and according to instructions in the Closure Lubrication section of the Tychem User Manual 9 Place the test kit suitcase near the garment 10 Plug the Test Kit into an electrical outlet he blower motor is designed for 110 V at either 50 or 60 electrical service A voltage converter not included may be required to supply 110 V service to the unit 11 Press the large red button once to test blower operation Press the large red button again to shut off the blower 12 Attach the larger diameter inflation hose to the black Air Outlet on the test kit This outlet is located above the red button on the test kit Lock it into place by folding up the two silver levers on either side of the end of the air hose 13 Connect the clear sensing hose to the sensing fitting on the test kit Check that the connector clicks in place and that the hose can not be easily pulled off the connector Inflation Testing per ASTM F 1052 The following briefly describes the inflation test method in ASTM F
9. It is the United States 1 800 931 3456 user s responsibility to determine the level of risk and the proper protective equipment needed for the user s particular purposes This information may be subject to revision as new knowledge and experience becomes available Since we cannot anticipate all S variations in actual end use conditions DUPONT MAKES NO WARRANTIES AND ASSUMES NO LIABILITY IN CONNECTION WITH www PersonalProtection DuPont com ANY USE OF THIS INFORMATION Nothing in this publication is to be considered as a license to operate under or a recommendation to infringe any trademark or patent right Copyright 2007 DuPont The DuPont Oval Logo DuPont The miracles of science Tychem Responder and Reflector are registered trademarks or trademarks of E du Pont de Nemours and Company or its affiliates All rights reserved K 16150 1 06 07 Printed in the U S A AE The miracles of science
10. acture Examine diaphragms that are not scheduled for replacement tor cracks or deterioration with a magnifying glass Damaged or deteriorated diaphragms should be replaced iv Tychem TK garments compliant with NFPA 1991 and Tychem TK garments compliant to the Class 1 of the 2001 edition of NFPA 1994 have 4 exhaust valves Two of these 4 exhaust valves must be sealed during inflation testing After removing the flexible outer cover and inspecting the diaphragm from each of the 2 extra exhaust valves these exhaust valve bodies are sealed during inflation testing with the flat rubber covers provided with the inflation test kit Choose the correct metal bayonet style connectors to fit the valves of the garment being tested Adapters engraved with A fit Auer exhaust valves installed in DuPont manufactured Tychem TK Level A garments vi From the outside of the garment firmly push each connector into an exhaust valve from which the diaphragm has been removed Twist the adaptor clockwise approximately 1 8 turn to lock it in place DO NOT FORCE If the adapter is not locked in place a seal will not occur and the garment will not hold pressure HOWEVER FORCING THESE CONECTORS CAN PERMANENTLY DAMAGE THE EXHAUST VALVE After inserting the two connectors proceed to step 6 of these instructions b Preparation of DuPont Tychem Responder and Tychem Reflector garments fitted with Pirelli exhaust valves i
11. er Manual Remove the bayonet connectors from the exhaust valve bodies Place the connectors in the appropriate location on the face of the test kit From the outside of the garment replace the exhaust valve diaphragms REMINDER Both Auer and Pirelli recommend replacement of the exhaust valve diaphragm every 2 years Visually inspect the diaphragms for cracks and deterioration with a magnifying glass during each suit inspection To replace the diaphragms in Pirelli valves insert the stem of the new diaphragm into the center of the valve body Gently pull on the diaphragm stem from the inside of the garment while gently pushing in on the center of the diaphragm until the diaphragm clicks into place You can damage the Pirelli diaphragm by pulling too hard on the flapper stem To replace the diaphragms in Auer valves center the new diaphragm over the stem and push down gently until the diaphragm snaps in place 5 Replace the exhaust valve covers To replace the flexible outer cover of Auer exhaust valves turn the cover inside out place it over the center of the exhaust valve body and roll the edges over the exhaust valve body until it snaps in place Snap the round perforated Pirelli valve covers onto the exhaust valve body 6 For NFPA compliant DuPont Manufactured Tychem TK garments remove the flat test covers from the remaining exhaust valves and re install the flexible outer covers 7 For NFPA compliant T
12. er diameter inflation hose to the black Air Outlet on the test kit This outlet is located above the red button on the test kit Lock it into place by folding up the two silver levers on either side of the end of the air hose 4 Connect the clear sensing hose to the sensing fitting on the test kit Check that the connector clicks in place and that the hose can not be easily pulled off the connector 5 Connect the inflation hose to the Self Test Device 6 Connect the sensing hose to the Self Test Device 7 Set the timer for 4 minutes 8 Turn the large red valve to the SUIT FILL position by turning the lever one quarter turn counterclockwise SLIT PUL 10 9 Turn on the blower by pressing the large red button The Magnehelic gauge will immediately register a pressure in excess of 6 inches water gauge 10 Immediately turn the large red valve to the SUIT TEST position by turning the lever one quarter turn clockwise 11 Turn the blower off by pressing the large red button 12 Adjust the pressure to 4 inches water gauge by partially opening the inflation valve 13 Start the countdown timer which you previously set to 4 minutes 14 The pressure should hold at 3 2 inches or higher after 4 minutes If after 4 minutes the pressure reading has fallen below 3 2 inches water gauge contact Customer Service to discuss repair or replacement options SUIT FILL SUIT FRE 11 Leve
13. l A Inflation Test Kit Gauge Calibration The pressure gauge installed in the DuPont Inflation Test Kit p n 990810 is calibrated by the manufacturer Dwyer Instruments before shioment and installation According to Dwyer Instruments under normal operating conditions no periodic servicing or lubrication is necessary to insure proper function of the gauge Occasionally the gauge may require re zero adjustment This requires setting the pointer exactly on the zero mark by way of adjusting the external zero adjust screw on the cover at the bottom This must be done while the gauge diaphragm is in the horizontal position as installed in the kit In order to check calibration a second gauge or manometer of known accuracy and range would be required and connected in line with this gauge and pressurized Readings of both would be compared for acceptability If the accuracy is unacceptable contact DuPont Personal Protection Customer Service to discuss repair or replacement options DuPont Personal Protection Customer Service Canada 1 800 387 9326 Product safety information is available upon request his information corresponds to our current knowledge on the subject Mexico 52 55 57 22 1222 It is offered solely to provide possible suggestions for your own determinations It is not intended however to substitute for any testing you may need to conduct to determine for yourself the suitability of our products for your particular purposes
14. uPont Tychem User Manual You can download a current copy of the Tychem User Manual at http www personalprotection dupont com or contact Customer Service at 800 931 3456 to have a copy mailed to you DuPont Personal Protection recommends inspection and pressure testing of ene Level A ensembles at the following times arts e Upon receipt from supplier e At least once per year e After the garment is worn and before the garment is worn again Note that contaminated damaged or altered garments should not be re used Operation of the test kit can be verified with the Self Test Device DuPont Part No 999800 Instructions for use of the Self Test Device are provided on page 10 of this manual Air Pressure Testing Instructions 1 Testing area You must provide a large enough area to allow the garment to be fully inflated with arms extended and to allow placement and operation of the inflation test kit This area should be clean and free of abrasive and sharp objects that may damage or tear the garment It is recommended that you cover the testing location with clean cloth The testing area should not be in the direct path of heating or airconditioning outlets a change in temperature during testing may change the internal pressure of the suit 2 Unfold garment face down on the smooth clean testing surface Remember how the garment is folded and stored you will refold and store the tested garment in the same manner
15. ychem Reflector and Tychem Responder garments remove the diaphragms from the inside of the exhaust valves install the diaphragms on the outside of the exhaust valves and re install the exhaust valve covers WARNING FAILURE TO PROPERLY REINSTALL THE EXHAUST VALVE DIAPHRAGMS CAN LEAD TO CHEMICAL VAPOR EXPOSURE AND POTENTIAL INJURY 8 Reinstall any foam padding on the inside of Tychem TK exhaust valves only if the garment will not be used immediately 9 Fold the garment in the same fashion as it was originally folded 10 Place the garment in its storage bag or container a Fill out the inspection tag with the date and the name of the person who tested and inspected the garment Be sure to also place the user manual in the bag b You may also want to use a String or anti tamper seal on the storage container or bag after inspection 11 Unplug the test kit Coil the power cord Store the cord hoses and extra caps in the lid of the kit Close the case lid and secure the latches Self Test Device Instructions Self Test Device DuPont Part No 999800 1 Plug the Test Kit into electrical outlet The blower mower is designed for 110 V at either 50 or 60 electrical service A voltage converter not included may be required to supply 110 V service to the unit 2 Press the large red button once to test blower operation Press the large red button again to shut off the blower p OFF 3 Attach the larg
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