p14474: hydrostatic test apparatus
DESCRIPTION
P14474: Hydrostatic Test Apparatus. Jake Manley Anushka Kalicharan Mitchell Sedore Brian Benner Kyle Abbott. Project Overview. Goals Control pressure, ramp rate, and time Test enclosures against UL1203, UL2225, and CSA 22.2 no. 30 - PowerPoint PPT PresentationTRANSCRIPT
P14474: Hydrostatic Test Apparatus
Jake ManleyAnushka KalicharanMitchell SedoreBrian BennerKyle Abbott
Project Overview
Goals● Control pressure, ramp rate,
and time● Test enclosures against
UL1203, UL2225, and CSA 22.2 no. 30
● Control test automatically with minimal operator interaction
Constraints:● Must reuse current fixed
displacement pump● 10,000 psi max pressure● Ability to capture results
during test○ Future Labview Integration
Customer Requirements
Top Customer Requirements ● Test Automation complies with
Standards● Ability to Interface with Current Cooper
Product Line● Ability to Acquire Data from Test● Complete Apparatus for On-Site Testing● Control of Pressure, Hold Time, and
Ramp Rate
Engineering Requirements
Engineering Requirements
Top Engineering Requirements● Deliver Maximum Required Pressure to
Enclosure● Withstand Maximum Internal System
Pressure● Deliver Minimum Required Pressure to
Enclosure● Pressure Ramp Rate● Hold Time for 4X Max Internal Explosion
Pressure● Hold Time for 1.5X Max Internal Explosion
Pressure
Functional Decomposition
Functional Decomposition
Functional Decomposition
Functional Decomposition
Concept Selection
Alternatives Considered
● Hold Components: Manifold vs. Inline● Data Transmission: Wired vs. Wireless● Test Control: Hybrid (Digital and
Manual) vs. Strictly Digital.
Manifold vs. Inline Design for Holding
ComponentsManifold
● Pro’s○ Compact, single unit○ Less plumbing
connections■ Less
opportunities for leakage
● Con’s○ Large manifold
■ Difficult to manufacture
○ Less flexibility in component placement
Inline● Pro’s
○ Flexible location of components
○ Small components■ Easy to
manufacture
● Con’s○ More parts and
connections
Ranking of Manifold vs. Inline
Wired vs. WirelessMethod for Data Transmission
Wired● Pro’s
○ Simple○ Reliable○ Inexpensive○ Secure
● Con’s○ Requires Physical
Routing○ Possible Data loss
due to Wire Damage
Wireless● Pro’s
○ Easy to add Components
● Con’s○ Expensive○ Less Secure○ Susceptible to
Interference
Ranking of Wired vs. Wireless
Hybrid vs. Strictly DigitalManner of Test Control
Hybrid● Pro’s
○ Fail-Safe○ Full Automation○ Allows for Manual
Override
● Con’s○ More Components○ More Complexity
Strictly Digital● Pro’s
○ More Compact○ Full Automation
● Con’s○ No Backup System
Ranking of Hybrid vs. Strictly Digital Controller
Selected Concept Overview
System Controller Overview
Risk Analysis
Risk Analysis
Highest Risk
Testing Plan
● Pressure Sensor(s)○ Apply varying pressures to sensor(s) to verify
output matches expected values.○ Calibrate sensor(s) as necessary.
● Structural Integrity of Piping and Hose.○ Perform calculations to determine
approximate pressure for conduit failure.○ Simulate stress experienced by conduit with
finite element model if deemed necessary from calculations.
Testing Plan
● System Controller○ Simulate logic before programming the controller
to debug as necessary.○ Apply stimulus to controller to recreate input from
pressure sensor and observe output waveforms to verify functionality.
● Pressure Control System○ Apply stimuli to pressure controller to simulate
input from test controller to verify functionality and response time.
○ Attach to test controller and apply stimuli to controller.■ This simulates input from pressure sensor and
can be used to verify reaction time and functionality of pressure controller.
Project Timeline
Questions?
BACKUP SLIDES
What is a Hydrostatic Test?
● Tests structural integrity of the product
○ Product: Electrical enclosures
○ Simulates explosion within the electrical enclosure
● �High Pressure Tests :
○ Proof Test
■ Hold time at specified pressure
○ Destructive Test
■ Test to failure
■ Determines safety factor (UL Standards)
Standards
● �UL1203
○ Electrical enclosure: 10 sec hold time without rupture
○ Safety factor of 4x internal explosion pressure
● �UL2225
○ Cable sealing: 10 sec hold time w/o rupture
○ Safety factor of 4x internal explosion pressure
○ Pressure: 100-600psi/min
● CSA22.2 no.30
Current Hydrostatic Test Apparatus
● �Fully functional
● �Manually controlled by technicians
● �Analog pressure and time measurements
● �Isolated Test Environment
● �Follows standards:
○ UL1203
○ �UL2225
○ �CSA22.2 no.30
Project Deliverables
● �Hardware
○ �Complete onsite test apparatus
● �Documentation
○ Maintenance Recommendations
○ �Model for fatigue predictions
○ �User guide for operation
○ �Engineering Drawings
Stakeholders
● �Cooper-Crouse Hinds
○ Joe Manahan
○ �Lab Technicians
○ �Secondary Customers
● RIT
○ MSD Group
○ �Ben Varela
○ �Mike Zona
Customer Requirements
Engineering Requirements
House of Quality
Photos
Photos