IAD AD-E402 717 Technical Report ARAED-TR-95013 PALADIN LOCK VALVE HYDRAULIC TEST STAND UPGRADE AND BASELINE VALIDATION Paul Kida and William Zepp January 1996 U.S. ARMY ARMAMENT RESEARCH, DEVELOPMENT AND ENGINEERING CENTER US AFire Support Armaments Division S~US ARMY TANK AUTOMOTIVE AND ARMAMENTS COMMAND Picatinny Arsenal, New Jersey ARMAMENT RDE CENTER Approved for public release; distribution unlimited. 19960220 115_- The views, opinions, and/or findings contained in this report are those of the authors(s) and should not be construed as an official Department of the Army posi- tion, policy, or decision, unless so designated by other documentation. The citation in this report of the names of commercial firms or commercially available products or services does not constitute official endorsement by or approval of the U.S. Government. Destroy this report when no longer needed by any method that will prevent disclosure of its contents or recon- struction of the document. Do not return to the origi- nator. REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operation and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704- 0188), Washington, DC 20503. 1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED January 1996 1 4. TITLE AND SUBTITLE 5. FUNDING NUMBERS PALADIN LOCK VALVE HYDRAULIC TEST STAND UPGRADE AND BASELINE VALIDATION 6. AUTHOR(S) Paul Kida and William Zepp 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESSES(S) 8. PERFORMING ORGANIZATION REPORT NUMBER ARDEC, FDAC Artillery and Indirect Fire Division (AMSTA-AR-FSA-W) Picatinny Arsenal, NJ 07806-5000 9.SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(S) 10. SPONSORING/MONITORING AGENCY REPORT NUMBER ARDEC, DOIM Information Research Center (AMSTA-AR-IMC) Tecnical Report Picatinny Arsenal, NJ 07806-5000 ARFSD-TR-95013 11. SUPPLEMENTARY NOTES 12a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE Approved for public release; distribution is unlimited. 13. ABSTRACT (Maximum 200 words) A summary of the modifications done to the lock valve hydraulic test stand to enable verification of all drawing requirements is presented in this report. The validation of stand capabilities and the establishment of a performance baseline using production lock valves to KEMP manufacture. 14. SUBJECT TERMS 15. NUMBER OF PAGES Hydraulic test stand 16. PRICE CODE 17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT OF REPORT OF THIS PAGE OF ABSTRACT UNCLASSIFIED UNCLASSIFIED UNCLASSIFIED SAR NSN 7540-01 280-5500 Standard Form 298 (Rev. 2-89) Prescribed by ANSI Std. Z39-18 298-102 SUPPLEMENTARY INFOR..MATION ERRATA Technical Report ARAED-TR-95013 PALADIN LOCK VALVE HYDRAULIC TEST STAND UPGRADE AND BASELINE VALIDATION Paul Kida and William Zepp January 1996 April 1996 Please change the cover to reflect the correct ARDEC report number - ARFSD-TR- 95013. /996 A~~v4 So/7 CONTENTS Page Introduction 1 Background 1 Test Stand Modification 2 System Verification 4 Valve Test Procedure 4 KEMP Valve Baseline Performance 4 Conclusions 11 Recommendations 12 Appendices A Test Plan and Procedures 13 B Hydraulic Contamination Control 59 C On-Weapon Test Data Plots 63 Distribution List 77 INTRODUCTION The M109 155-mm Self-Propelled Howitzer was developed between 1957 and 1963 armed with a short 26 caliber cannon. The cannon elevation was controlled by a hydraulic system which contained a lock valve (P.N. 8744652) developed for the M48 Main Battle Tank, for maintaining the cannon elevation before, during, and after weapon firing. This valve was procured under source control from either Cadillac Gage or KEMP. In 1970, the system was up-gunned with the addition of a new and longer 39 caliber cannon. The addition of the longer tube and resulting higher dynamic loads on the elevation system overloaded the physical limits of the lock valve that was being used. A new lock valve design, physically and functionally interchangeable, but able to withstand the dynamic loading, was developed. A valve design from KEMP was successfully developed and fielded in 1985. As before, this valve was procured under source control, with the exception that KEMP was listed as the only source. High pressure hydraulic control valves are precision components and are costly. The addition of alternative sources creates competition and reduces procurement costs. Each alternative source must meet all of the drawing requirements. To verify compliance of the drawing requirements in a timely and cost efficient manner, a test stand was used to replicate the conditions on the weapon in place of the actual system for most tests. BACKGROUND To reduce procurement costs of the M109 lock valve (P.N. 11784023), a competi- tive procurement solicitation (DAAA09-91-B-0813) was issued on 13 November 1991 for a quantity of valves. To evaluate the samples submitted for consideration under the solicitation, a hydraulic test stand to verify compliance of drawing requirements was necessary. A contract was let to Technical Data Development, Inc. (TDDI) to fabricate the stand which was delivered to the government in August 1993. The sample valves delivered by six bidders under the procurement contract were tested using the stand during the fall of 1993. The test stand that was delivered and used was capable of testing some, but not all of the requirements. Requirements 1, 2, 3A, 3B, 4A, 4B, 5A, 6A, and 7 of table 1 and Notes 11 .B.3 at 1450F and 11 .B.4 of drawing 11784023 could be evaluated. However, requirements 3C through 6C of table 1 and Note 11 B.3 on the drawing at -50°F could not be evaluated. In 1994, additional requirements 8A and B, 9A and B, 10A and B, 11 A and B, and 12 were added to table 1 on drawing 11784023 and Note 11 A and 11B on drawing 11784023 were rewritten to define the valve requirements necessitated by use in the M109A6 PALADIN variant. PM PALADIN tasked this office, Weapons Branch, Artillery and Indirect Fire Division, to modify the test stand to enable testing of all requirements. TEST STAND MODIFICATION The original layout of the test stand is shown schematically in figure 1. To enable testing of requirements that this configuration could not test, a series of modifications were needed. ENFM7 211-0-200-2 /2-1/1 i'5.,F(cid:127):- i :OC, 52t,(cid:127), 1 9 8 - -EE N-F7 -M2 21ý--o1 -e&0e- 22 1 I2/ 2 1 -- I/1 ýAcE'- NT A SM 3-HYDRAFORCE 724~ S- 2"(cid:127)AECP2 iA/S- fiCE____________ 2V4 "CT/P1 S AINA NP AC RHEC eao (cid:127) 6N L- PI -- HEDLAND EeeeeA4 ' N- 72:-A: AAs- 121-1(cid:127)E/4 SAUL .-EAC FIT LND L(cid:127)PAP(/R AXH/A(cid:127),/ 012 Figure 1 TDDI test stand schmatic To verify compliance of requirements 3Cthrough 60 and 12 of table 1 of drawing 11784023, a higher pressure and viscosity capacity pump/motor assembly was needed. The originally installed pump/motor produced insufficient pressure under ambient conditions and was totally inadequate to meet test flow requirements at -50°F. After consulting with pump suppliers, a new gear pump driven by a 7.5 hp motor was determined to meet pressure and temperature requirements. This pump/motor assembly replaced the original pump/motor assembly. Requirements 8A and B, 9A and B, and & B, and 11 A and B on the drawing all need an independent second hydraulic power source. The tests demanded a constant pressure be applied to one port while the pressure applied to a different port was increased until flow through the valve was evident. The original pump/motor assembly was incorporated into the modified test stand to provide this capability. The requirement in Note 11 B.6 on the drawing to test at the revised upper temperature extreme of 250°F was satisfied by the addition of electric heater elements in the reservoir. To perform the tests required at the low temperature extreme of -500F, several modifications were required. The pump/motor had to be replaced to meet the viscosity at that temperature as mentioned earlier. The valve stand was made detachable to allow remote placement within a climatic cell. A hose bundle was provided to connect the valve stand, when in the climatic chamber, to the test stand that remains outside the chamber; and a refrigeration coil system was provided to maintain oil temperature. The resulting test stand configuration is depicted in figure 2. L - LF 10 LE A PSI P A L2 TV V2 LLI Figure 2 Test stand configuration 3 SYSTEM VERIFICATION The modified test stand was initially pressure tested to 3,000 psi to verify system integrity. This was followed by executing each individual test called out using a KEMP lock valve with a known history, free of any problems, and that had been used during the previous acceptance testing during the fall of 1993. Each test was successfully performed with the modified stand. VALVE TEST PROCEDURE The procedure followed while conducting the First Article Test called out in the Quality Assurance Provisions of drawing 11784023 is provided in appendix A. This procedure is based upon the original test stand operating instructions provided with the original test stand by TDDI and modified to test all requirements. As required by the First Article Test requirement stated in the Quality Assurance Provisions of drawing 11784023 and the valve cleanliness requirement stated on said drawing, a Procedural Plan was developed to insure compliance. This plan is provided in appendix B. Functional testing and endurance testing were conducted under all aspects of this plan within the clean room located in Building 3150. The climatic and on-weapon tests could not be conducted within a similar environment due to the size and location of the required environmental test cells. During these tests, precautions were taken to prevent exposure to contaminants while valves were changed and lines broken. Oil samples were taken throughout testing to verify compliance. KEMP VALVE BASELINE PERFORMANCE A sample of three unissued lock valves were obtained from Letterkenny Army Depot in their unopened original packaging. These valves were subjected to the test procedure described previously. Results of the subtests are presented in table 1 and appendix C. To aid in test summary, passing a requirement was scored a 1. Failing a requirement, but with the value within measurement accuracy uncertainty, was scored .9 or .8. All other failures were scored as 0. Table 1 Test data FEG SAMPLE FUNCT KEMP1 PASS KEMP2 PASS KEMP3 PASS TEST /FAIL /FAIL /FAIL START DATE: 7/24/95 7/24/95 7/24/95 START TIME: 13:37 7:50 9:40 TEST 1 P A LEAKAGE Y/N N N 1 N 1 N 1 P B LEAKAGE Y/N N N 1 N 1 N 1 TEST 2 PORT M1 FLOW (CC) 6.5 7.5 22 TIME (MIN) 5 5 5 FLOW 1 <X< 1.3 1.5 1 4.4 1 4