Nuclear Air Cleaning Conference

Filter Test Facility Report On The Testing of HEPA

Filters for the DOE

August 2008

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Air Techniques International Test Laboratory1708 Whitehead Rd., Baltimore, MD 21207

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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

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Rejection Categories

Resistance: Criteria of ≤ 1.0 “ w.g. for filters rated ≥ 500-1250 cfm and 1.3” w.g. for filters rated ≤125 - ≥2000 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

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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

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Summary Of Filter Rejections

•*Test facility closed 5 months for relocation and audit

•**Partial Year

9.8%3543,59720008.0%2172,72220014.8%1022,1272002 5.4%1512,77220036.3%2153,44120047.2%1682,3312005*

11.8%**184**1554**2008**

19.6%4852472200710.4%21320442006

PercentageRejected

NumberRejected

NumberTested

Fiscal Year

(Oct 1 – Sept. 30)

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Summary Of Filter Rejections

•*Test facility closed 5 months for relocation and audit

•**Partial Year

3545270364302000

217491743002001

102832422002002

151527932602003

215486863632004

166281561982005*

184054923802008**

48502142382762007

213184814702006

TotalShipping Damage

P.O./Spec Discrepancy

Mfg. Defects

Penetration ResistanceFiscal Year

(Oct 1 – Sept. 30)

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HEPA FILTERS TESTED / REJECTED

# Filters Tested and % Failure by Fiscal Year

0500

1000150020002500300035004000

2000 2001 2002 2003 2004 2005 2006 2007 2008 (10

months) Fiscal Year

# Fi

lters

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

% F

ailu

re

Total Tested Percent Rejected

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HEPA FILTER REJECTION BY NUMBER

Total Filters Rejected by Fiscal Year

050

100150200250300350400450500

2000 2001 2002 2003 2004 2005 2006 2007 2008 (10

months) Fiscal Year

# Fi

lters

Rej

ecte

d

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HEPA FAILURES BY TYPE

# Failures (Resistance, Penetration & Manufacturing ) by Fiscal Year

0

50

100

150

200

250

2000 2001 2002 2003 2004 2005 2006 2007 2008 (10

months) Fiscal Year

# Fa

ilure

s

Resistance Penetration Manufacturing

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HEPA FAILURES BY TYPE

# Failures (PO/Specification Discreps & Shipping ) by Fiscal Year

050

100150200250300

2000 2001 2002 2003 2004 2005 2006 2007 2008 (10

months) Fiscal Year

# Fa

ilure

s

PO/Spec Discreps Shipping Damage

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ATI FILTER TEST FACILITYOPERATIONS

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ATITL Quality Program Plan

1.0 POLICY2.0 SCOPE3.0 REFERENCES4.0 DEFINITIONS5.0 ORGANIZATION

5.1 Structure5.2 Functional Responsibilities

6.0 QUALITY ASSURANCE REQUIREMENT7.0 DESIGN CONTROL8.0 PROCUREMENT CONTROL9.0 INSPECTION & TEST10.0 DOCUMENT CONTROL

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ATITL Quality Program Plan

11.0 CONTROL OF PURCHASED ITEMS AND SERVICES12.0 IDENTIFICATION AND CONTROL OF ITEMS 13.0 CONTROL OF PROCESSES14.0 PERSONNEL TRAINING, QUALIFICATION AND CERTIFICATION15.0 CONTROL OF MEASURING AND TEST EQUIPMENT16.0 HANDLING, STORAGE AND SHIPPING17.0 INSPECTION, TEST AND OPERATING STATUS18.0 CONTROL OF NONCONFORMING ITEMS19.0 CORRECTIVE ACTIONS20.0 QUALITY ASSURANCE RECORDS21.0 QUALITY ASSURANCE AUDITSAPPENDICESFigures – Organization Chart

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RECOMMENDED SHIPPING CRATE

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NOT RECOMMENDED FILTER SHIPPING METHODS

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UNLOADING FILTER BOXES

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INSPECTION CHECK LIST

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DAMAGED BOX & FILTER

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INSPECTION

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CASE SQUARE INSPECTION

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PENTRATION / RESISTANCE TEST

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FILTER TEST

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TEST LABEL - REPACKING

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RE-BOX FILTER

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RE-PACK FILTERS IN CRATE

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SHIPPING

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REJECTEXAMPLES

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GASKET - REJECT

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FLUID SEAL - REJECT

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CASE - REJECT

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FILTER CASE - REJECT

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FILTER CASE - REJECT

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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-3020-2005)

• A NEED FOR MANUFACTURERS’ TO TIGHTEN QUALITY CONTROL

• A NEED FOR QUALITY CONTROL INSPECTIONS OF MANUFACTURERS IN ADDITION TO AUDITS

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Any Questions?

• Eric Hanson, ATI President

• Dave Crosby, Vice President of Filter Testing

• Julie Stormo, Lab Manager

• Jan Fretthold, Lab Supervisor

• ATI Test Lab e-mail address ATITL@atitest.com410-277-8981 (phone) 410-277-3448 (fax)

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DOE DISCLAIMER

THE VIEWS EXPRESSED ARE SOLELY THOSE OF THE PRESENTERS AND NO ENDORSEMENT BY THE U. S. DEPARTMENT OF ENERGY IS INTENDED