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WHC-SD-TD-TRP-006, Rev. 0

Post Delivery Test Report for the Light Duty Utility Arm High Resolution Stereoscopic Video Camera System (HRSVS)

A l l a n F. Pa rd in i Westinghouse Hanford Company, Richland, WA 99352 U.S. Department o f Energy Contract DE-AC06-87RL10930

EDT/ECN: 701455 UC: 2060 6' Org Code: 8A800 Charge Code: HIE01 B&R Code: E\44010O0Ob4 To ta l Pages: 4 0

Kd Key Words: LDUA, High Resolut ion Stereoscopic Video Camera System (HRSVS), comnon v ideo end e f f e c t o r (CVEE), Labview, Nondest ruc t ive Examination

Abs t rac t : Resolut ion Stereoscopic Video Camera System (HRSVS) LDUA system, designed f o r use by t h e L i g h t Duty U t i l i t y A r m (LDUA) p r o j e c t . d e l i v e r y t e s t shows 'by demonstrat ion t h a t t he h i g h r e s o l u t i o n s tereoscopic v ideo camera system i s f u l l y ope ra t i ona l t o per form the t a s k o f a l i g n i n g t h e LDUA arm and mast w i t h t h e e n t r y r i s e r d u r i n g deployment operat ions w i t h i n a Hanford S i t e waste tank.

This r e p o r t documents the post d e l i v e r y t e s t i n g o f t he High

The post

T~EI I IRK DISCLAIMER. tr& rime, trademnrk, mnufacturer, or otheruise, docs not necessarily consti tute or i l p l y i t s ndorsanmt, reconmrdntion, or favoring by the United States Govcrnnmt or any a o m y thereof or i t s contractors or subcontractors.

Printed i n the United States of k r i c a . To obtain copies of t h i s docurrnt. Contact: Y W B C S D O C U m t Control Services, P.O. Box 1970, Mailstop H6-08, Richland W 99352. Phon (509 ) 372-2420; Fax ( 5 0 9 ) 376-4989.

Referme herein to any specific cannercia1 product, prccess, or service by

.,-/7 / /f< 0 , - * J'/ '&. ,J. - 4 Release bqprove.1 Date

Approved for Public Release

A-6400-073 (10195) GEF321

WHC-SD-ID-TRP-006, Rev 0

CONTENTS

POST DELIVERY TEST REPORT FOR THE LIGHT DUTY UTILITY ARM

HIGH RESOLUTION STEREOSCOPIC VIDEO CAMERA SYSTEM (HRSVS)

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 DESCRIPTION OF TEST . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.0 TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.0 CONCLUSIONS AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 4

5.0 DISPOSITION OF TEST ITEMS . . . . . . . . . . . . . . . . . . . . . . 4

6.0 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ATTACHMENTS

1. Completed Post D e l i v e r y Tes t Procedure f o r t h e L i g h t Duty U t i l i t y Arm High Reso lu t ion Stereoscop ic Video Camera System (HRSVS) . . . . . . . . . . . . . . . At t -1 -1

2. Nondest ruc t ive Examination (NDE) Leak Tes t Report . . . . Att-2-1

3. Labview V i r t u a l Instruments Used Dur ing t h e Post D e l i v e r y Procedure . . . . . . . . . . . . . . . . . . . Att-3-1

iii

WHC-SD-TD-TRP-006, Rev 0

POST DELIVERY TEST REPORT FOR THE LIGHT DUTY UTIL ITY A M

HIGH RESOLUTION STEREOSCOPIC VIDEO CAMERA SYSTEM (HRSVS)

1.0 INTRODUCTION

T h i s r e p o r t documents t h e pos t d e l i v e r y t e s t i n g o f t h e High Reso lu t ion Stereoscopic Video Camera System (HRSVS), LDUA system number 6230, designed f o r use by t h e L i g h t Duty U t i l i t y A r m (LDUA) p r o j e c t . was performed by t h e Remote System and Sensor A p p l i c a t i o n s (RSSA) group and t h e Nondest ruc t ive Examination (NDE) group. The p o s t d e l i v e r y t e s t shows by demonstrat ion t h a t t h e HRSVS i s f u l l y o p e r a t i o n a l t o per fo rm t h e t a s k o f s u r v e i l l a n c e and i n s p e c t i o n a c t i v i t i e s w i t h i n a Hanford S i t e waste tank . The t e s t d i d n o t i nc lude r a d i a t i o n t e s t i n g o r a l l environmental t e s t i n g . These f a c t o r s were reviewed d u r i n g t h e des ign phases o f t h e p r o j e c t and were deemed acceptable based on pub1 ished da ta on r a d i a t i o n and environmental components used i n t h e camera designs. T e s t i n g o f t h e purge system t o meet t h e requirements o f NFPA 70 Nat iona l E l e c t r i c a l Code (1993), Class 1 D i v i s i o n 1, Group B requirements, NFPA 496, Standard f o r Purged and Pressur ized Enclosures f o r E l e c t r i c a l Equipment (1993), and Hanford Safe ty Class 1 requirements f o r shutdown o f t h e system was n o t performed. requirements w i l l be performed d u r i n g t h e o v e r a l l LDUA q u a l i f i c a t i o n t e s t . The HRSVS d i d undergo pressure and decon t e s t i n g t o demonstrate end e f f e c t o r i n t e g r i t y . An a d d i t i o n a l t e s t t o v e r i f y maximum ex te rna l temperature o f t h e HRSVS under normal opera t ions was performed and documented. Completion o f t h i s p o s t d e l i v e r y t e s t r e p o r t s i g n i f i e s t h a t t h e HRSVS i s ready f o r i n t e g r a t i o n t e s t i n g w i t h t h e LDUA Supervisory Data A c q u i s i t i o n System (SDAS).

The p o s t d e l i v e r y t e s t

F u l l t e s t i n g t o meet these

2.0 DESCRIPTION OF TEST

The system under t e s t i s t h e LDUA system 6230, HRSVS. The p r o p e r t y number i s a Westinghouse Savannah R i v e r Company number, 00363307, w i t h s e r i a l number 005. The system t e s t e d inc luded t h e HRSVS end e f f e c t o r , common video end e f f e c t o r e l e c t r o n i c s (CVEE), and t h e CVEE power supply. The HRSVS i s t h e f i r s t s te reoscop ic end e f f e c t o r system developed f o r t h e LDUA program as p a r t o f t h e new techno log ies i n i t i a t e d through t h e U.S. Department o f Energy's O f f i c e o f Science and Technology. F i g u r e 1 shows t h e HRSVS end e f f e c t o r , which i n c l u d e s i n t e r n a l cameras and l i g h t s .

Attachment 1 i s t h e completed pos t d e l i v e r y t e s t d e s c r i b i n g each s tep o f t h e t e s t procedure. Attachment 2 i s t h e completed NDE r e p o r t . Attachment 3 i s a computer p r i n t ou t o f t h e Labview v i r t u a l ins t ruments t h a t were loaded t o operate t h i s system d u r i n g t e s t i n g .

1


- System (HRSVS).

3.0 TEST RESULTS

The HRSVS system performed satisfactory during the post delivery All system requirements were evaluated against the criteria in the

No exceptions occurred during the post delivery test.

It was noted in step 9 that no potentiometer exists on the large

testing. test procedure.

focusing lens. travel range the lens is. of its range to the other is 38.5 seconds at full speed. operator can set the lens approximately mid range by going one way for approximately 19 seconds at full speed. Further revisions to this end effector will consider using a method to mark the lens position.

Without this potentiometer it i s hard to discern where in the The time it takes for the lens to move from one end

Therefore, an

The turret rotation potentiometer settings were noted as follows, (these are from steps 11, 12, and 13) and can be used during SDAS integration.

Voltage readings using the 50 mm lens. PM3 (turret M3) -- 4.98 VDC PM4 (turret M4) -- 4.95 VDC

2


Voltage readings using the 25 mn lens. PM3 (turret M3) -- 3.557 VDC PM4 (turret M4) -- 3.482 VDC

Voltage readings using the 16 mm lens. PM3 (turret M3) -- 6.42 VDC PM4 (turret M4) -- 6.44 VDC

The temperature test in step #15 provided verification that the maximum external temperature of the protected enclosure was below the autoignition temperature of the flammable gas within the waste tank. Hanford's waste tanks has been hydrogen which has an autoignition temperature of 520 OC. Figure 2 is a graphical display of the temperature rise of the HRSVS end effector until the temgerature stabilized. The maximum temperature reached during the test was 172 C. This value is far below the autoignition temperature of hydrogen.

The gas of concern in

, _ _ _ l o o - - ' ' -

O . r I I i i I ! I 1 : / / / I ! : m m m m m z N (3 v m (D b

m m

Time (Minutes)

I 1

Figure 2 HRSVS Temperature Test

The decon test provided verification that the HRSVS end effector would The HRSVS was not leak a substantial amount during the decon spray process.

brought to a downtown car wash and sprayed using a rinse nozzle which was operated at approximately 1000 psi. The spray wand was held at a distance of approximately 8 inches from the HRSVS and was moved from top to bottom (HRSVS was setting vertical on the ground) in approximately 3 seconds. This was done in 4 passes, 90 degrees apart, around the circumference of the end effector. The HRSVS was dried off externally and then dissassembled so the interior of the end effector could be examined. It was noted that there was no intrusion of water into the end effector.

3


A pressure / leak t e s t was performed t o demonstrate i n t e g r i t y of t h e HRSVS under o p e r a t i n g pressures o f t/- 7 inches o f water. v i s i b l e degradat ion. standard c u b i c cent imeters pe r second (9.2 STD CC / Sec) a t t h e nominal LDUA o p e r a t i n g pressure o f 2.5 inches o f water. acceptable. The l e a k was concent ra ted around t h e lower O-r ing assembly near t h e f r o n t v iewing end o f t h e HRSVS.

The system showed no A l e a k r a t e was measured t o be approx imate ly 9.2

Th is l e a k r a t e i s considered t o be

4.0 CONCLUSIONS AND RECOMMENDATIONS

The pos t d e l i v e r y t e s t o f t h e HRSVS demonstrated t h a t t h e end e f f e c t o r system f u n c t i o n e d according t o des ign c r i t e r i a e s t a b l i s h e d i n t h e Westinghouse Hanford Company f u n c t i o n s and requirements document WHC-SD-TD-FRD-003, Rev. 1, Funct ions and Requirements f o r t he l i g h t - D u t y U t i l i t y A r m I n t e g r a t e d System (Kiebel 1996).

5.0 DISPOSITION OF TEST ITEM

The HRSVS end e f f e c t o r i s now ready f o r i n t e g r a t i o n t e s t i n g w i t h t h e LDUA SDAS system. F a c i l i t y u n t i l t h e complet ion o f q u a l i f i c a t i o n t e s t i n g .

It w i l l remain i n t h e Fuels and M a t e r i a l s Examinat ion

6.0 REFERENCES

Kiebe l , G. R., 1994, WHC-SD-TD-FRD-003, Func t ions and Requirements f o r t h e L igh t -Duty U t i l i t y Arm I n t e g r a t e d System, Westinghouse Hanford Company, Rich1 and, Washington.

Batterymarch Park, Quincy, Massachusetts. NFPA, 1993, Nat iona l E l e c t r i c a l Code, Nat iona l F i r e Prevent ion Assoc ia t ion ,

4


ATTACHMENT 1

COMPLETED POST DELIVERY TEST PROCEDURE FOR THE

LIGHT DUTY UTIL ITY ARM HIGH RESOLUTION STEREOSCOPIC VIDEO CAMERA SYSTEM (HRSVS)

Att-1-1


POST DELIVERY TEST PROCEDURE

FOR

LIGHT DUTY UTILITY AM HIGH RESOLUTION STEREOSCOPIC VIDEO CAHERA SYSTEH (HRSVS)

MARCH 20, 1996

BY

A. F. PARDINI

REHOTE SYSTEH AND SENSOR APPLICATIONS

WESTINGHOUSE HANFORD COMPANY RICHLAND, WASHINGTON

A t t - 1 - 2


APPROVAL SHEET

Th is document p rov ides f o r t h e pos t d e l i v e r y t e s t i n g o f t h e High Reso lu t i on Stereoscopic Video Camera System (HRSVS) end e f f e c t o r used f o r s u r v e i l l a n c e and i n s p e c t i o n a c t i v i t i e s d u r i n g deployment ope ra t i ons w i t h t h e L i g h t Duty U t i l i t y Arm (LDUA) system.

Approvals:

End E f f e c t o r Cognizant Engineer, Design Age

Technica l Lead Engineer, Design A u t h o r i t y w d / ’ Date ‘-f//;/f l -Gary . le

LDUA Test D i r e c t o r

Safety T+F Date @[9L T r a v i s mun son

ii

Att-1-3

WHC.SD.TD.TRP.006, Rev . 0

TABLE OF CONTENTS

POST DELIVERY TEST REPORT FOR

LIGHT DUTY UTILITY ARM HIGH RESOLUTION STEREOSCOPIC VIDEO CAHERA SYSTEH (HRSVS)

1.0 TEST ITEH IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . 1

2.0 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.0 TEST CONDITION LIHITS . . . . . . . . . . . . . . . . . . . . . . . . 1 3.1 EXCEPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.0 INSTRUHENTS AND CALIBRATION . . . . . . . . . . . . . . . . . . . . . 2

5.0 FACILITIES, EQUIPHENT. AND HATERIALS . . . . . . . . . . . . . . . . 2

6.0 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7.0 HAINTENANCE AND FAILURES . . . . . . . . . . . . . . . . . . . . . . 3

8.0 TESTDATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9.0 PERSONNEL REQUIREHENTS . . . . . . . . . . . . . . . . . . . . . . . 3

10.0 WITNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

11.0 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12.0 DISPOSITION OF TEST ITEH . . . . . . . . . . . . . . . . . . . . . . 4

13.0 DATA SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

APPENDIXA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

iii

Att-1-4



LIGHT DUTY UTIL ITY A M HIGH RESOLUTION STEREOSCOPIC VIDEO CAHERA SYSTEH (HRSVS)

1.0 TEST ITER IDENTIFICATION

The system under t e s t i s t he L i g h t Duty U t i l i t y A r m (LDUA) system 6230, High Reso lu t i on Stereoscopic Video Camera System (HRSVS). The p r o p e r t y number i s a Westinghouse Savannah R i v e r Company number, 00363307, and t h e s e r i a l number i s 005. The system t o be t e s t e d i nc ludes t h e end e f f e c t o r and c o n t r o l e l e c t r o n i c s .

2.0 GENERAL DESCRIPTION

The o b j e c t i v e o f t h e t e s t i s t o show by demonstrat ion t h a t t h e HRSVS i s f u l l y ope ra t i ona l t o pe r fo rm t h e t a s k o f s u r v e i l l a n c e and i n s p e c t i o n a c t i v i t i e s d u r i n g deployment ope ra t i ons w i t h i n a Hanford waste tank. The t e s t w i l l n o t i n c l u d e r a d i a t i o n t e s t i n g o r a l l environmental t e s t i n g . These f a c t o r s were reviewed d u r i n g t h e des ign phases o f t h e p r o j e c t and were deemed acceptable based on pub l i shed data on r a d i a t i o n and environmental components used i n t h e camera designs. Tes t i ng o f t h e purge system t o meet t h e requi rements of NFPA 70 Na t iona l E l e c t r i c a l Code (1993), Class 1 D i v i s i o n 1, Group B requirements, NFPA 496, Standard f o r Purged and Pressur ized Enclosures f o r E l e c t r i c a l Equipment (1993), and Hanford Sa fe ty Class 1 requi rements f o r shutdown o f t h e system w i l l n o t be performed d u r i n g t h i s t e s t . F u l l t e s t i n g t o meet these requi rements w i l l be performed d u r i n g t h e o v e r a l l LDUA q u a l i f i c a t i o n t e s t . Tes t i ng w i l l i n c l u d e a pressure t e s t t o v e r i f y end e f f e c t o r i n t e g r i t y under t h e normal ope ra t i ng pressures, a decon spray t e s t t o assure t h a t water does n o t l e a k i n t o t h e end e f f e c t o r , and an a d d i t i o n a l t e s t t o v e r i f y maximum temperature o f t h e camera under normal operat ions. Upon complet ion o f t h i s pos t d e l i v e r y t e s t , t h e HRSVS w i l l be ready f o r i n t e g r a t i o n t e s t i n g w i t h t h e LDUA Superv isory Data A c q u i s i t i o n System (SDAS).

3.0 TEST CONDITION L I H I T S

Test c o n d i t i o n s which cou ld cause t h e t e s t t o be abor ted would be a l o s s o f power i n t h e f a c i l i t y , o r complete f a i l u r e o f t h e camera system t o per form i t s in tended func t i ons . I f e i t h e r o f these occur, t h e t e s t w i l l be suspended u n t i l t h e problems a re reso lved . r e s o l u t i o n , t h e t e s t w i l l be resumed. I f necessary, sec t i ons o f t h e t e s t may be repeated a t t h e d i s c r e t i o n o f t h e end e f f e c t o r cognizant t e s t engineer.

A f t e r problem

1

Att -1-5


3.1 EXCEPTIONS

Exceptions noted d u r i n g t h e execu t ion o f t h e t e s t procedure s h a l l be recorded i n t h e spaces p rov ided i n Appendix A. excep t ion i s noted, a p p l i c a b l e s igna tu res must ob ta ined p r i o r t o c o n t i n u i n g t h e t e s t procedure. "none" and con t inue t h e procedure.

I f an

I f no except ions occur, w r i t e

4.0 INSTRUMENTS AND CALIBRATION

A temperature i n d i c a t i n g dev ice w i l l be used t o measure t h e temperature o f t h e o u t s i d e o f t h e camera f rom i n i t i a l s t a r t u p u n t i l a s t a b i l i z e d maximum temperature i s reached. Th is dev i ce w i l l have a c u r r e n t c a l i b r a t i o n s t i c k e r from t h e Standards Laboratory . pressure t e s t i n g , a pressure gauge w i l l be used t o measure pressures i n s i d e o f t h e end e f f e c t o r . Th i s sensor s h a l l have a c u r r e n t c a l i b r a t i o n s t i c k e r f rom t h e Standards Laboratory .

Dur ing

5.0 FACILITIES, EQUIPMENT, AND MATERIALS

The HRSVS w i l l be t e s t e d i n t h e Fuels and M a t e r i a l s Examination F a c i l i t y (FMEF) on t h e 42 ' -6" l e v e l and i n t h e Nondes t ruc t i ve Examination Laboratory i n 306E. The equipment and m a t e r i a l s l i s t e d below a re necessary t o pe r fo rm t h i s pos t d e l i v e r y t e s t :

- HRSVS camera system, i n c l u d i n g Common Video End E f f e c t o r E l e c t r o n i c s (CVEE), W E E power supply, and LDUA t e s t u m b i l i c a l

Computer (486 o r b e t t e r PC runn ing Windows 3 . 1 P w i t h program so f tware Labview 3.1.17*

Stereographics moni tor , view reco rd system, and s te reo g lasses

l l O V A C power source and power s t r i p

C a l i b r a t e d temperature i n d i c a t i n g dev i ce and thermocouple

C a l i b r a t e d pressure gauge

Leak t e s t equipment ( t o be p rov ided by NDE group)

Water, water hose, and spray nozz le

Miscel laneous (e.g. duc t tape, common t o o l s , e t c . )

*Windows i s a trademark o f M i c r o s o f t Corporat ion. **Kabview i s a trademark o f Nat ional 2

Inst ruments Corporat ion, Aus t i n , TX.

At t -1-6


6.0 SAFETY

The HRSVS system will be tested with its outer shell removed so that the internal mechanical assembly can be observed. The HRSVS electrical connections are low voltage (<35 V). Test personnel shall keep hands away from the electrical and mechanical assemblies during this testing. Exposed wiring at the Hypertronic connections is also low voltage.

During temperature testing, the surface of the end effector may reach approximately 140 degrees Celsius, therefore care must be taken by test personnel during this testing. A sign reading "HOT, DO NOT TOUCH", will be located next to the end effector.

7.0 MAINTENANCE AND FAILURES

There are no components within the HRSVS which should require maintenance during the testing period. the testing period, and it can be replaced immediately, then the condition shall be documented under the exception portion of Appendix A and testing shall continue. If the failure is catastrophic (component cannot be readily replaced or needs to be reordered) then the procedure will be stopped and repeated at a later date.

duration, so no test interruptions are expected.

If any component fails during

The extent of the HRSVS post delivery test should be short in

8.0 TEST DATA

Test data from the temperature and pressure measurements will be logged into the appropriate sections of Appendix A. depicting temperature versus time will be documented in an Post Delivery Test Report. During the post delivery test the witnesses will sign o f f in appropriate sections o f the test procedure to indicate that the equipment is operating as expected.

A graphical plot

9.0 PERSONNEL REQUIREMENTS

All personnel involved in the performance o f this test shall print and sign their name, initials, position, and date of signature prior to beginning the testing in the personnel record section of Appendix A.

The operation of the equipment will be performed by the LDUA end effector cognizant engineer and/or designated end effector technician. This person will perform the operations and the LDUA end effector

3

Att-1-7


cogn izant engineer w i l l s i g n o f f t h e assoc ia ted s teps as t o t h e i r acceptance. e f f e c t o r t e c h n i c i a n .

Temperature and pressure d a t a may be t r a n s c r i b e d by t h e end

10.0 WITNESSES

A l l wi tnesses w i l l be n o t i f i e d i m n e d i a t e l y proceeding t h e beg inn ing o f t h e t e s t . They s h a l l w i tness t h e procedure and concur the success fu l complet ion o f s p e c i f i c steps w i t h e i t h e r t h e i r s i g n a t u r e o r t h e i r i n i t i a l s and date. I f except ions are no ted and a re acceptable then the LDUA cogn izant engineer s h a l l r e c o r d t h e except ion , w r i t e i n t h e r e s o l u t i o n , and s i g n and date. A l l o t h e r s p e c i f i c wi tnesses addressed i n t h e except ion s h a l l a l so s i g n and date. i s such t h a t no immediate r e s o l u t i o n i s a t t a i n a b l e , t h e t e s t w i l l be aborted u n t i l t h e problems a re reso lved. Once r e s o l v e d t h e t e s t w i l l be repeated a t a l a t e r date.

hours.

I f t h e except ion

It i s expected t h a t t h e complete t e s t w i l l l a s t no more than 8

11.0 PROCEDURE

Appendix A p rov ides t h e step-by-step procedure f o r t e s t i n g t h e HRSVS. Appendix A a l so i n c l u d e s t h e personnel record , p ressure data, and t h e temperature d a t a sheet. Appendix E prov ides p i c t u r e s o f t h e components used as p a r t o f t h i s pos t d e l i v e r y t e s t . v i s u a l re fe rence t o those components descr ibed i n t h e t e s t procedure.

I t prov ides a

12.0 DISPOSITION OF TEST ITEH

A l l t e s t m a t e r i a l s w i l l remain i n t h e FMEF t e s t f a c i l i t y f o r f u t u r e use. i n t e g r a t i o n t e s t i n g w i t h t h e LDUA SDAS system.

The ac tua l end e f f e c t o r system t e s t e d w i l l now be ready f o r

13.0 DATA SHEETS

No f u r t h e r d a t a sheets w i l l be necessary t o suppor t t h e t e s t i n g o f t h i s end e f f e c t o r system. A l l v e r i f i c a t i o n s o f t e s t i n g w i l l be s igned d i r e c t l y w i t h i n t h i s procedure under Appendix A.

4

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APPENDIX A

LIGHT DUTY UTIL ITY ARM - - - . . - . . . HIGH RESOLUTION STEREOSCOPIC VIDEO CAMERA SYSTEM (HRSVS)


Th is procedure w i l l be used t o per form t h e ac tua l pos t d e l i v e r y t e s t i n g o f t he HRSVS system. procedure i n t h e b lank spaces as i nd i ca ted . o f sequence ( i . e . F u n c t i o n a l i t y t e s t i n g may be performed be fo re t h e decontaminat ion t e s t ) .

As each s tep i s performed s igna tu res s h a l l be logged onto t h e Major t e s t s may be performed o u t

Step 1: N o t i f y a l l w i tnesses ( t o i n c l u d e End E f f e c t o r Cognizant Engineer, NDE personnel, and End E f f e c t o r Technic ian) immediate ly p r i o r t o commencing t h e t e s t .

DECONTAMINATION TEST

Step 2: Transpor t t h e HRSVS t o a f a c i l i t y which has a h i g h pressure water wash system (-500 p s i ) . w i t h a gasket seal and cover p l a t e . on a p iece o f foam a t ground l e v e l . secured t o t h e t o p o f t h e HRSVS t o s t a b i l i z e d u r i n g the wash down.

Seal t h e end o f t h e HRSVS Set t h e HRSVS u p r i g h t Use a meta l p o l e

WARNING, WATER SPRAY AT 500 P S I CAN BE HAZARDOUS. TO ASSURE THAT PERSONNEL ARE PROTECTED FROM THE SPRAY.

USE CARE

Using t h e h i g h pressure water spray, r i n s e t h e e x t e r i o r o f t h e HRSVS u n i f o r m l y . Move t h e spray wand f rom t o p t o bottom, cove r ing t h e l e n g t h o f t h e HRSVS i n rough ly 3 seconds. Perform t h i s spray t e s t a t 0 degrees, 90 degrees, 180 degrees, and f i n a l l y a t 270 degrees around t h e c i rcumference o f t h e HRSVS. D i scon t inue t h e water r i n s e and immediately d r y o f f t h e e x t e r i o r o f t h e HRSVS. gasket seal and cover p l a t e so t h a t t h e i n t e r i o r o f t h e HRSVS can be examined f o r any water i n t r u s i o n . a f t e r assessment has been made.

Dura t i on of water spray: " / 2 T~+AI S e ~ a q h g Fan angle o f water spray:

Remove the

Reassemble

A- 1

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D is tance from nozz le t o HRSVS:

Est imate o f water pressure: /ODD As,

8

I Pd- Y - 2 / e

Exceptions/Notes:

-

This completes t h e decon t e s t .

PRESSURE/LEAK TEST

Step 3: Transpor t t h e HRSVS end e f f e c t o r , cover p l a t e assembly, and c a l i b r a t e d pressure gauge t o t h e 306E f a c i l i t y . group w i l l per fo rm an i n f o r m a t i o n o n l y p r e s s u r e / l e a k t e s t . Th i s t e s t w i l l p r o v i d e a v i s u a l assessment o f t h e i n t e g r i t y o f t h e HRSVS when sub jec ted t o a t/- 7 inches o f water pressure, and a q u a n t i t a t i v e assessment o f t h e l e a k r a t e ou t o f t h e HRSVS under t h e assumed maximum purge pressure of 7 inches of water. The pos t d e l i v e r y t e s t r e p o r t w i l l i n c l u d e t h e NDE t e s t data.

The NDE

Except i ons/Notes:

T h i s completes pressure t e s t i n g .

A-2

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FUNCTIONALITY TEST

Step 4: Transport the HRSVS to the mezzanine level of FMEF. Remove the outer cover shell of the HRSVS exposing the interior mechanical assembly. HRSVS testing. Level the HRSVS so that the cameras are level in the X and Y directions. Connect the LDUA umbilical between the CVEE box and the connectors on the HRSVS. connectors have been pre-marked. engineer or his designee can perform this step. wiring as show in the Figure 1. the end effector, the wiring interface between the end effector and the CVEE which will be located in the At Tank Instrument Enclosure (ATIE), and the operation of the CVEE. Since the LDUA i s not yet at Hanford, this test configuration will simulate the final conditions. Complete integration testing will be performed as the components are completed and assembled. Full testing will be performed during LDUA qualification testing.

Position the HRSVS on the nylon test fixtures used for

The Hypertronic Only the end effector cognizant

Connect all other This test configuration will test

n

Verification :

Exceptions/Notes:

I I I F i g u r e 1 HRSVS TEST CONFIGURATION

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Step 5: Plug in the power cord supplying power to the CVEE, computer, monitor, Stereographics System, TV monitor, and CVEE power supply chassis. Power up the system. This power up will include turning on each supply on the front o f the CVEE power supply chassis using the toggle switches. LED's above each o f the toggle switches should light up. A

Verification: ykh6, Exceptions/Notes:

Step 6: Record the make a Computer: As<

Turn on computer power. Also record version of software used.

Windows Software: Version 3 . / I /,~,&44+b&./cj7-795

Labview Software: Version 3. /, / Record the list of virtual instruments and their revision level that are booted on the system and include in the post delivery test report.

Computer system shall now be in "boot" procedure. Wait until it has booted into the "Labview" window. The HRSVS has a black and white video camera inside. provide a visual feed from the HRSVS camera.

The separate television monitor should If no picture is

A-4 *AST i s a trademark o f AST Research, Inc.

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Step 7:

present, make sure all coaxial connections have been made. If the camera system has failed, suspend the test.

Verification: 1 yLJkL

Excepti ons/Notes :

do-

Double click on the "Labview" icon. The "untitled l" window will come up. Open the file called "CVEES", then open "Unit.LLB", and then open "CVEES Main.VI". The "CVEES Screen Selection" should be on the monitor. Using the run command ("arrow") directly below the word file, run the VI. When this instruction is pressed, the "Init Mode Control Screen" will be on the monitor. Press the blue "Screen Select" button. The next screen should be the "CVEES Screen Selection" as before. button. The HRSVS main function control screen (virtual instrument) should now be operational. To test this, touch the G1 button with the mouse and click. A pair o f lights on the HRSVS should turn on. If not, make sure all power connections are on and perform the boot procedure again. If there still is no function control suspend the test.

Now press the HRSVS End Effector

Verification: I 4/fV&@

Exceptions/Notes:

A-5

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Step 8:

Step 9:

Position the HRSVS so that the LDUA test target can be viewed approximately 2 feet in front of the camera. set so that the large focusing lens is midway in its travel and the 50 mn pair of lens are in front of the two Sony cameras. Position the test target so that it is in focus and centered along the axis of the HRSVS as seen on the Stereographics monitor. Each set of lights will now be tested. Using the mouse button click on the G1 button. The first pair of lights should come on. that they are on and are bright. Again verify that they are on and are bright. Turn off 62. Repeat these steps for 63, 64, and 65. After each light pair has been shown to operate properly, turn on all light pairs and verify they are all on and are brightA Turn off all the lights except

The HRSVS should be

Verify Turn off G1. Now turn on 62.

m. b l . ' \

In this step we will test the HRSVS control functions. The slider to the right of each control button is a speed controller. begin with position the speed controller to the mid point for each function. adjustment can be used to slow down those functions, such as turret rotation, that are difficult to perform for precise image alignment. The speed adjustment can also be used to speed up the operation when there is a desire to move rapidly to a new setting. Using the Closeup "FAR" function, move the large focusing lens until it stops just in front of the turret assemblies. A microswitch is located along the bottom rail o f the frame assembly and shuts off the lens movement when the large focusing lens get close to the turret. large focusing lens the other direction until it contacts the microswitch near the end of the end effector and shuts off.

To

During this step and those following the speed

Using the Closeup "NEAR" function, move the

A-6 b i . k \:qh+s6@ q/./4'

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V e r i f y t h a t t h e focus ing l e n s movement i s unincumbered i n t h e complete focus range and t h e focus ing l e n s s tops a t these m ic rosw i t ch shutdown l o c a t i o n s . V e r i f y t h a t t h e speed c o n t r o l f u n c t i o n i s o p e r a t i n g by moving t h e l a r g e l e n s a t t h e near 0.0 s e t t i n g and a t t h e 1.0 s e t t i n g (note: t h e motor w i l l n o t operate w i t h 0.0 v o l t s a p p l i e d so t h e s e t t i n g f o r slow speed i s s l i g h t l y above t h e 0.0 s e t t i n g ) . Return t h e l a r g e focus ing l e n s t o t h e midwav o o i n t o f i t s t r a v e l .

Except i ons/Notes :

N o h e )vofe!

Step 10: To t e s t t h e camera convergence use t h e Convergence "NEAR" and "FAR" f u n c t i o n s and observe t h e Stereographics mon i to r . images on t h e screen should move apar t and then back toge the r . S ince t h e convergence mechanical assembly i s s imp ly a r o t a t i n g cam, e i t h e r "NEAR" o r "FAR" bu t tons can be used t o demonstrate proper func t i on . V e r i f y t h a t t h e images move apar t and then back toge the r smoothly w i t h l i t t l e o r no h e s i t a t i o n . speed c o n t r o l f o r t h i s f u n c t i o n i s o p e r a t i o n a l .

The two

V e r i f y t h a t t he

Except i ons/Notes :

No.-

A-7

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Step 11: In step 8 the two 50 nun lens were positioned in front of the two stereo cameras. Using the M3 "CCW" and "CW" functions rotate turret M3 until the 50 mm lens is precisely aligned on the LDUA target. The image can be viewed on the Stereographics monitor during the rotation. Set the image of the LDUA test target in the middle of the monitor. Using the M4 "CCW" and "CW" functions on turret M4, rotate the turret until this 50 mm lens is in front of the camera. The image can be viewed on the Stereographics monitor during the rotation. Using these rotation functions, align the two images so they are aligned in the vertical plane. Verify that the speed control is operational during this a1 ignment procedure. Using the convergence function, adjust so that the images are very near to overlaying each other, allowing for a small space between the two images (114 inch apart as viewed on the screen). the stereo glasses verify that the image is clear and in 3D. (Note: Viewer must be capable of seeing in 3D)

Using

n

Step 12: Using the M3 "CW" function for turret M3 rotate the turret clockwise until the 25 mm lens is in front of the camera. image can be viewed on the Stereographics monitor during the rotation. Set the image o f the LDUA test target in the middle of the monitor. Using the M4 "CCW" function for turret M4, rotate the turret counterclockwise until the 25 mm lens is in front of the camera. The image can be viewed on the Stereographics monitor during the rotation. Using these rotation functions, align the two images so they are precisely aligned in the vertical plane.

The

A-8

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Using t h e convergence f u n c t i o n a d j u s t so t h a t t h e images a re ve ry near t o o v e r l a y i n g each o the r , a l l o w i n g f o r a smal l space between t h e two images. Using t h e s te reo g lasses v e r i f y t h a t t h e image i s c l e a r and i n 30. (Note: View must be capable o f seeing i n 30)

V e r i f i c a t i o n : 4 &-F. cog *

Step 13: Using t h e M3 "CCW" f u n c t i o n f o r t u r r e t M3 r o t a t e t h e t u r r e t counterc lockwise u n t i l t h e 16 mm l e n s i s i n f r o n t o f t h e camera. The image can be viewed on t h e Stereographics mon i to r d u r i n g t h e r o t a t i o n . t h e moni tor . Us ing t h e M4 "CW" f u n c t i o n f o r t u r r e t M4, r o t a t e t h e t u r r e t c lockwise u n t i l t h e 16 mm l e n s i s i n f r o n t o f t h e camera. The image can be viewed on t h e Stereographics mon i to r d u r i n g the r o t a t i o n . Using these r o t a t i o n func t i ons , a l i g n t h e two images so they are p r e c i s e l y a l i gned i n t h e v e r t i c a l p lane. convergence f u n c t i o n a d j u s t so t h a t t h e images are ve ry near t o o v e r l a y i n g each o the r , a l l o w i n g f o r a smal l space between t h e two images. and i n 3D.

Set t h e image o f t h e LDUA t e s t t a r g e t i n t h e m idd le o f

Using t h e

Using t h e s te reo g lasses v e r i f y t h a t t h e image i s c l e a r (Note: Viewer must be capable o f seeing i n 3D)

n V e r i f i c a t i o n : y (gd-

EE Cog.

Exceptions/Notes:

A-9

Att-1-17


Step 14: Us ing t h e "Camera Se lec t " f u n c t i o n change t h e cameras from the Sony cameras t o t h e Watec b l a c k and w h i t e cameras. each Watec camera i s ope ra t i ona l and i n focus and w i t h proper i r i s s e t t i n g by s imply cove r ing one o f t h e Watec cameras and v iew ing on t h e Stereographics moni tor . camera and cover t h e second camera and v iew t h e image on t h e moni tor .

V e r i f y t h a t

Then remove t h e cover on t h e f i r s t

V e r i f i c a t i o n : 177666

Exceptions/Notes:

/%-

This completes t h e HRSVS f u n c t i o n a l i t y t e s t . she1 1 back over t h e HRSVS mechanical assembly.

Place t h e o u t e r cover

A-IO

Att-1-18


CAMERA TEMPERATURE TEST

Step 15: Place t h e HRSVS i n a p o s i t i o n so t h a t t h e heat f rom t h e l i g h t s w i l l n o t cause any hazard. Connect t h e temperature i n d i c a t i n g dev i ce t o t h e f r o n t f ace o f t h e HRSVS us ing a thermocouple under t h e cap screw nex t t o t h e l i g h t i n g .

Inst rument name and manufacturer :D: :h( &,+.I,,A~ Model Number: /-/- T i. - Standards Lab Number: 77n - 7 q - - 00% E x p i r a t i o n Date:

On t h e temperature data sheet, r e c o r d t h e i n i t i a l temperature (no camera l i g h t s ) . Turn on a l l l i g h t s us ing bu t tons G 1 through 64. Leave t h e camera l i g h t s on and begin t a k i n g temperature data and documenting on t h e temperature da ta sheet.

WARNINQ: CAMERA LIGHTS WILL GET HOT. ASSURE PERSONNEL ARE PROTECTED AGAINST THE HAZARDS.

/ I - / - 9 b

Data w i l l be taken every 5 minutes u n t i l t h e temperature s t a b i l i z e s (temperature has s t a b i l i z e d when t h e temperature change over a 5 minute i n t e r v a l i s 2 degrees o r l e s s f o r t h r e e consecut ive readings) . A f t e r complet ion, shut o f f t h e

V e r i f i c a t i o n : cog.

ExceptionsfNotes:

Th is completes t h e temperature t e s t .

Th i s completes t h e pos t d e l i v e r y t e s t o f t h e HRSVS. choose t h e b l u e "Screen Se lec t " b u t t o n on t h e HRSVS V I . "System Stop" but ton. power down t h e system.

To shutdown t h e system, Then choose t h e b lue

You may now c l o s e a l l windows i n t h e normal manner and

A-11

Att-1-19


FINAL POST DELIVERY TEST APPROVAL RECORD

Th is pos t d e l i v e r y t e s t has been completed and a l l except ions reso lved t o the s a t i s f a c t i o n o f a l l a p p l i c a b l e wi tnesses and t h a t t h e High Reso lu t i on Stereoscopic Video Camera System i s now a v a i l a b l e f o r i n t e g r a t i o n w i t h t h e L i g h t Duty U t i l i t y Arm Superv isory

LDUA End E f f e c t o r Cognizant Enginee

A-12

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15

20

25

30

35

40

TEHPERATURE DATA SHEET

The temperature o f t h e HRSVS system i s taken t o v e r i f y t h a t t h e e x t e r n a l temperature o f t h e p r o t e c t e d enc losure i s s u f f i c i e n t l y below t h e a u t o i g n i t i o n temperature o f t h e flammable gas w i t h i n t h e waste tank. The temperature read ing i s taken w i t h t h e thermocouple l o c a t e d adjacent t o t h e l i g h t s on the camera module which i s expected t o be t h e h o t t e s t area.

to 1 110 1 2 9 138 I4 b 157-

A-13

A t t - 1-2 1


PERSONNEL RECORDS

A-14

At t -1 -22


APPENDIX B

LIGHT DUTY UTIL ITY ARM

HIGH RESOLUTION STEREOSCOPIC VIDEO CAMERA SYSTEM COMPONENTS

Figures 2, 3, 4, 5, and 6 show the components used in the post delivery testing o f the HRSVS.

6- 1

Att-1-23


F i g u r e 2 High Resolut ion Stereoscopic Video Camera System on Test F i x t u r e

B-2

Att-1-24


Figure 3 Hypertronic Connection

8-3

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F igu re 4 Computer Interface

B-4

Att-1-26 ST GOPY A V


Figure 5 Stereographic Monitor and View Record System

6-5

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F igure 6 HRSVS w i t h t h e Outer S h e l l Removed.

8-6

At t -1 -28


ATTACHMENT 2

NONDESTRUCTIVE EXAMINATION LEAK TEST REPORT

OF HIGH RESOLUTION STEREOSCOPIC VIDEO CAMERA SYSTEN (HRSVS)

At t -2 -1

WHC-SD-TD-TRP-006, Rev. 0 P a w 1 01 1 NDE LEAK TEST PROCEDURE AND TEST REPORT UL-100

306 BLDG 300 AREA TEL 3 7 6 5 4 0 1

Westlnghouse NON DESTRUCTIVE EXAMINATION Hanford Company

Job No

96-25

~~

He AcCUm Time Callb Erp 3-12-99

bazFp&b7q- Z Q - 0 3 - 0 2 4 U N A

~ ~ " g c 0-10K SCCM N2 Additional Time.

Calib EXP 9-8-96

Company W U C l t O r

Technique Pic Approval LT LcvcllOate

Technician LT Level II I Reviewed b y

P r o p tiSyslcm1Woh PnckapclTravelcr NO

LIGHT DUTY UTILITY ARM END EFFECTOR. THE HIGH RESOLUTION

I1 WD PmK\Y I1

w?hluhA\L Dace o f Examination Dale 0-'

04/16/36 04/16/96 A,MXll-492 111194 A t t- 2- 2

icceptmce Sld sectlo" Para Date U N A

FOR INFORMATION ONLY

TEST CONDITIONS TEST EOVIPMENT Q NA

iemperaturc Device ID NA Manufacturer - 0 NA ldcnf NO -

Mach Sen - Barom =,,, c P,c..",c AMB.

ArmlcclsaslOtv i r r t ~ ~ e r ~ ~ ~ ~ 7 G~~ NITROGEN 0 NA Std No 584 4 0 03 __

INCHES OF WATER NA

Atmleclrcc ~ ~ , ~ ~ ~ ~ t r ~ t , ~ n APPROX. 100 % NA Std Leak

Other NA Calib Exp

SYSTEM SENSITIVITY Q NA NA Same as MSLD Calab or Bubble Solution

AtmlcclreclDiv Batch No sensmwty

0 NA Std NO - Gage 1 5854" R ~ ~ ~ c 0-10 IN. OF H20 Sld Leak - 534- 2 % - 09- 0 0 5

WD YJi<kL. AtmIccIscc

OW0 NO L4 NA

NCR Q N A clean in^ NA

Q w WHC PROCEDURE NO

NOT LT 5000 Rev - Re" - Appendix __

Specie1 Tech No

Work Inst

TEST TIME

He Rssponss Toma


0 Hood Method (Total Leak Rate) 0 Std. Leak at MSLD

Containing 1% H e

II 0 Helium Tracer Probe (Leakage Location)

rL Helium

m 4 S& JF-a ’ @Pressure Method

- V

I 0 Bell Jar (Hood)

Bell Jar or Other Vacuum Chamber

Test Part Containing He or He Bombed

System Fixtures

__

0 Detector Probe (Leakage Location) Quick Test Probe Length Response Time Std. No. Std. Leak Atmcclsec

Calib. Exp. Sensitivity

AtmcclseclDiv

Method

yr\ no0 me be-

A-6001.492R 1111941

A t t - 2 - 3


ATTACHMENT 3

LABVIEW VIRTUAL INSTRUMENTS USED DURING POST DELIVERY PROCEDURE

Att-3-1


L I S T I N G OF LABVIEW VIRTUAL INSTRUMENTS

CVEES MAIN.V I SERIAL PORT RESET.VI SERIAL PORT BUFFER S1ZE.V I GLOBE1 . V I C TO F TEMP CONVERSION.VI LASER CONVERSION.VI POSIT ION ARRAY > B I T S . V I PORT NUMBER GLOBAL.VI SERPCONFIG.VI SERPOPEN.VI OPEN SERIAL DRIVER.V I SERIAL PORT READ WITH TO.VI SERIAL PORT READ.VI SERIAL PORT WRITE.VI BYTES AT S E R I A L PORT.VI SERIAL PORT 1 N I T . V I OPT022 COMM.VI DEACTIVATE OUTPUTS . V I SET TEMP PROBE TYPE.V I OPTO I N I T . V I CONFIG POSITIONS.VI 1 N I T . V I OPTO ON/OFF.VI READ ANALOG 1NPUTS.VI WRITE TO DAC.VI READ TEMP INPUTS.VI LASER CHECK.VI TOGGLE.VI HRSVS.VI SSPS.VI OAS.VI

A t t - 3 - 2

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