1.1 Test Types
ProCalV5 allows for the addition of different “Test Types” to the database that may be applied to any item master record whose required calibration does not fit perfectly into the typical ProCal template. Test types may be used to provide specific testing in addition to or instead of a standard calibration with target set points and as found/as left readings. Examples of some calibration test types that ProCalV5 normally could not accommodate efficiently are extreme values, linearity and standard deviation tests.
1.1.1 Set Up Test Type Packages Screen
The Set Up Test Type Packages screen (shown in Figure 1) is used to add, modify and if necessary delete test type packages from the database. This screen is invoked by selecting the “Set Up Test Type Packages…” option on the File menu when the System Options and Defaults screen is open.
1.1.2 Adding New Test Types
To add a new test type to your database you must first copy the required library file HEPAFilter.bpl and VLFHEPASummary.bpl into the folder labeled “bin” under the ProCalV5 directory (typically “C:\Program Files\Prime Technologies\ProCal V5\bin”) in Windows Explorer. The HEPAFilter.bpl and VLFHEPASummary.bpl files contains all the information necessary for the test type’s automatic and proper setup in ProCal. Once the file has been copied into the correct folder you may launch the Set Up Test Type Packages screen. Once the screen is open you may click the Add New Record button or select “New Record” from the screen’s File menu. This will invoke a browser screen titled Choose New Package File that automatically directs you to the “bin” folder in which all the “.bpl” files reside. Select the required file HEPAFilter.bpl and VLFHEPASummary.bpl and click the Open button or double-click the file name.
Once the correct file has been selected you will be returned to the new test type record which will already be set up for you. In this instance you can save the record, making it available for application to all types of item master records in the system (i.e. instruments, loops, systems, test instruments, in addition to any PM records that may require a calibration). Once a test type has been saved to the database, as long as it is marked as “Active”, it will be available for selection on the Test Type field’s drop-down list on the Calibration Points tab in all screens where that tab exists.
Although you will have no ability to change the test type’s calibration requirements, you do have the ability to make some customizations to it in terms of field label changes and also giving users the ability to edit target set points and such when entering calibrations using that test type.
1.1.3 Distributing Test Types
Test Types only need to be installed in the System Option and Defaults screen once, but for all Client, Administrator, or Mobile Workstations, the HEPAFilter.bpl and VLFHEPASummary.bpl files must be present in the “bin” directory one level down from the ProCalV5 installation directory.
1.1.4 Entering Item Records Using the HEPA Filter Check Test Type Package
When creating a new master record that uses the HEPA Filter Check Test Type, the test type must be applied to the record through the Calibration Points tab on the master record screen. Once a new group has been added to the record, click the Test Type drop-down list and select HEPA Filter Check from the available test types, as shown in Figure 2:
Once the test type has been selected, the inputs will change according to the settings defined by the library file. This test type package for ProCalV5 will be available to allow the user to perform HEPA Filter Integrity checks. The test type inputs used in this test should be entered through the Group Options box, which can be accessed by clicking the Show Group Options button on the right side of the screen. This interface is shown in Figure 3.
The inputs are as follows:
- Test Type - values are “HEPA” or “VLF”. This option will affect the operation of the TTP, discussed throughout this document. This is important for indicating whether the VLF HEPA Summary Test Type package will also be included to determine Pass/Fail [“VLF” mode], or if the user will manually determine the Pass/Fail [“HEPA” mode].
- Filter Height - Size of the Filter. Input for information only (in inches). This value will be displayed on the Visual Prompt screen
- Filter Width - Size of the Filter (in inches). Input for information only. This value will be displayed on the Visual Prompt screen
- Filter Frame Size - Size of the Filter Frame. Used to calculate the Filter Media size. It is the value used by the calibration screen to calculate “Media Height” and “Media Width” which determines the size of the filter media (in inches). These calculated values will be displayed on the Visual Prompt screen and used to calculate the “Filter Media Area SQ IN” value.
- Velocity Profile Cols - Number of columns in the readings grid. Max of 10. Option to configure the grid’s dimensions for the HEPA Filter Velocity Profile Inputs.
- Velocity Profile Rows - Number of rows in the readings grid. Max of 5. Options to configure the grid’s dimensions for the HEPA Filter Velocity Profile Inputs.
- Leak Test Cols - Number of columns in the leak test grid. Max of 10. Option to configure the grid’s dimensions for the HEPA Filter Leak Test inputs.
- Leak Test Rows - Number of rows in the leak test grid. Max of 5. Option to configure the grid’s dimensions for the HEPA Filter Leak Test inputs.
- Filter Max Repair Area Percent - Maximum percentage of filter media allowed to be repaired. Filter Max Repair Area field to designate the maximum repair area allowed for this test to be marked as successful.
1.1.5 Entering Item Records Using the VLF HEPA Summary Test Type Package
When creating a new master record that uses the VLF HEPA Summary Test Type, the test type must be applied to the record through the Calibration Points tab on the master record screen. Once a new group has been added to the record, click the Test Type drop-down list and select VLF HEPA Summary from the available test types, as shown in Figure 4:
Once the test type has been selected, the inputs will change according to the settings defined by the library file. This new Test Type Package for ProCalV5 will be available to summarize the results for the HEPA Filter Integrity tests (in VLF mode) and apply a pass/fail to the data. This interface is shown in Figure 5
The inputs are as follows:
The test point grid will not be used.
User will enter the following fields on the master record:
- Low and High Velocity fields to designate the minimum and maximum velocities allowed for each reading in the Velocity Profile tests of preceding HEPA Filter Integrity test groups using the VLF mode.
- Low and High Average Velocity fields to designate the minimum and maximum average velocity of all the readings in the Velocity Profile tests of preceding HEPA Filter Integrity test groups using the VLF mode.
The Additional test type inputs used in this test type package should be entered through the Group Options box, which can be accessed by clicking the Show Group Options button on the right side of the screen. This interface is shown in Figure 6
1.1.6 Entering Calibration Records
Once a Test Point Group has been created for a master item record that uses the HEPA Filter Check Test Type, a calibration record can be created and data can be entered on the Test Results tab on the Calibrations screen. It should be noted that the required inputs must be entered on the master item record as detailed above. See figure 7 below:
A visual prompt screen will be created with three tabs, “HEPA Filter Velocity Profile”, “HEPA Filter Leak Test” and “Acceptance”.These tabs can be viewed by pressing the “View/Enter Data” button, opening the VLF Filter Integrity Check window See Figure 8 below.
The “HEPA Filter Velocity Profile” tab will have the following fields:
- Filter Size (height and width, in inches).
- Filter Media Size (height and width, in inches).
- Frame Size (in inches)
- Filter Media Size (height and width, in inches) and Area (in square inches, rounded to two decimal places).
- Velocity Profile Grid to record the velocities. The grid will be sized based on the input values “Velocity Profile Cols” and “Velocity Profile Rows” entered on the master record. Readings are in FPM (feet per minute) and are whole numbers.
- Filter Media Area (in Sq Ft, rounded to two decimal places).
- Differential Pressure (entered by the technician during the test).
· This can be any value, numeric or non-numeric.
- Total Airflow Velocity (in CFM)
· This is rounded to a whole number
The “HEPA Filter Leak Test” tab will have the following fields as: shown in Figure 9 below.
- Record of Repairs Grid to record the repairs made to the filter. The grid will be sized based on the input values “Leak Test Cols” and “Leak Test Rows” entered on the master record. The user will enter either the size of the repair made in the filter during this test in the associated location on the grid or the letter “Z”, signifying that no repair was made. Resolution is 3 decimal places.
- Size of Previous Repair (read only). Read from the most recent calibration of this instrument. If no previous calibration is found then this value is set to zero.
- “Reset” button – resets the “Size of Previous Repair” field to zero. The technician will click this if the filter has been replaced between the last calibration and this one, or during this calibration.
- “Edit” button – Enables the “Size of Previous Repair” field to accept any value.
- Size of New Repairs. Sum of all the repairs in the “Record of Repairs Grid”.
- Total Repaired Area (read only).
- “Filter Max Repair Area Percent” (n) and calculated “Filter Max Repair Area” (m), displayed as follows:
o ≤ n% of Filter Media m Sq in
o The calculated will be displayed in an Out of Spec reading font color if it is beyond the maximum % of total area.
- Repair Type check boxes. Three boxes, “Media”, “Gasket”, and “Structural”.
The “Acceptance” tab will have the following fields: See Figure 10 below.
- A label with the text set to the following:
“Not greater than 0.01% leakage of the upstream challenge for filters with efficiency rating of 99.99%”.
- Acceptable Results radio box with two choices (“Have been Met” and “Have not Been Met”). For a HEPA test, the user sets it manually.
· For a VLF HEPA test, this field is not visible.
Media Height = Filter Height – Filter Frame Size
Media Width = Filter Width – Filter Frame Size
Filter Media Area SQ IN = Media Height X Media Width
Filter Media Area SQ FT = Filter Media Area SQ IN / 144
Temporary Value: Average Face Velocity = Mean of all the entered Velocity Data entered
Total Airflow Velocity = Average Face Velocity X Filter Media Area SQ FT (represents CFM)
Size of New Repairs = Sum of all the numeric values entered in the “Filter Repairs” grid.
Total Repaired Area = Size of Previous Repairs + Size of New Repairs
Filter Max Repair Area = Filter Media Area SQ IN X Filter Max Repair Area Percent
Average Face Velocity = Mean of all the entered Velocity Data entered in any preceding test point groups that use the “VLF” “Test Type” input value. See the details of the “HEPA Filter Check ” test type for more information.
Standard Deviation (S) is defined as:
Velocity RSD = (S / Xavg) * 100
This is calculated against the total set of data for all preceding groups using VLF HEPA data.
· For the HEPA test, the user decides the Pass/Fail manually by setting the “Acceptable Results” field on the Acceptance tab. If “Acceptable Results” field is marked as “Have not Been Met”, then the As Found and As Left result for the entire group will be marked as Failed.
· For the VLF HEPA test, the tests always Pass. The Pass/Fail of the calibration can only be determined by the VLF HEPA Summary test.
The VLF HEPA Summary Pass/Fail is calculated in a three step process, as follows:
· If all the velocity readings are within the “Low Velocity” and the “High Velocity” then the calibration passes.
· Else if the Average Face Velocity is between the “Low Avg Velocity” and the “High Avg Velocity” (LowAvg <= AvgFaceVel <= HighAvg) AND the RSD of the readings is less than or equal to the “Velocity Max RSD” then the calibration passes
· Else the calibration fails
· NOTE: The individual Average Result Pass/Fail and RSD Result Pass/Fail will be calculated and stored even if the Reading Result is Passed, but would not affect the Summary Result in this case.