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 222 no 30 ID: 310647
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P14474: Hydrostatic Test Apparatus
Jake Manley
Anushka Kalicharan
Mitchell Sedore
Brian Benner
Kyle AbbottSlide2
Project Overview
Goals
Control pressure, ramp rate, and time
Test enclosures against UL1203, UL2225, and CSA 22.2 no. 30Control test automatically with minimal operator interactionConstraints:Must reuse current fixed displacement pump10,000 psi max pressureAbility to capture results during testFuture Labview IntegrationSlide3
Customer Requirements
Top Customer Requirements
Test Automation complies with Standards
Ability to Interface with Current Cooper Product LineAbility to Acquire Data from TestComplete Apparatus for On-Site TestingControl of Pressure, Hold Time, and Ramp RateSlide4
Engineering RequirementsSlide5
Engineering Requirements
Top Engineering Requirements
Deliver Maximum Required Pressure to Enclosure
Withstand Maximum Internal System PressureDeliver Minimum Required Pressure to EnclosurePressure Ramp RateHold Time for 4X Max Internal Explosion PressureHold Time for 1.5X Max Internal Explosion PressureSlide6
Functional DecompositionSlide7
Functional DecompositionSlide8
Functional DecompositionSlide9
Functional DecompositionSlide10
Concept SelectionSlide11
Alternatives Considered
Hold Components: Manifold vs. Inline
Data Transmission: Wired vs. Wireless
Test Control: Hybrid (Digital and Manual) vs. Strictly Digital.Slide12
Manifold vs. Inline
Design for Holding Components
Manifold
Pro’sCompact, single unitLess plumbing connectionsLess opportunities for leakageCon’sLarge manifoldDifficult to manufacture
Less flexibility in component placement
Inline
Pro’s
Flexible location of components
Small components
Easy to manufacture
Con’s
More parts and connectionsSlide13
Ranking of Manifold vs. InlineSlide14
Wired vs. Wireless
Method for Data Transmission
Wired
Pro’sSimpleReliableInexpensiveSecureCon’sRequires Physical RoutingPossible Data loss due to Wire Damage
Wireless
Pro’s
Easy to add Components
Con’s
Expensive
Less Secure
Susceptible to InterferenceSlide15
Ranking of Wired vs. WirelessSlide16
Hybrid vs. Strictly Digital
Manner of Test Control
Hybrid
Pro’sFail-SafeFull AutomationAllows for Manual OverrideCon’sMore ComponentsMore Complexity
Strictly Digital
Pro’s
More Compact
Full Automation
Con’s
No Backup SystemSlide17
Ranking of Hybrid vs. Strictly Digital ControllerSlide18
Selected Concept OverviewSlide19
System Controller OverviewSlide20
Risk AnalysisSlide21
Risk Analysis
Highest RiskSlide22
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.Slide23
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 SystemApply 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.Slide24
Project TimelineSlide25
Questions?Slide26
Slide27
What is a Hydrostatic Test?
Tests structural integrity of the product
Product: Electrical enclosures
Simulates explosion within the electrical enclosureHigh Pressure Tests :
Proof Test
Hold time at specified pressure
Destructive Test
Test to failure
Determines safety factor (UL Standards)Slide28
Standards
UL1203
Electrical enclosure: 10 sec hold time without ruptureSafety factor of 4x internal explosion pressureUL2225
Cable sealing: 10 sec hold time w/o rupture
Safety factor of 4x internal explosion pressure
Pressure: 100-600psi/min
CSA22.2 no.30Slide29
Current Hydrostatic Test Apparatus
Fully functional
Manually controlled by techniciansAnalog pressure and time measurements
Isolated Test Environment
Follows standards:
UL1203
UL2225
CSA22.2 no.30Slide30
Project Deliverables
Hardware
Complete onsite test apparatusDocumentation
Maintenance Recommendations
Model for fatigue predictions
User guide for operation
Engineering DrawingsSlide31
Stakeholders
Cooper-Crouse Hinds
Joe ManahanLab Technicians
Secondary Customers
RIT
MSD Group
Ben Varela
Mike ZonaSlide32
Customer RequirementsSlide33
Engineering RequirementsSlide34
House of QualitySlide35
PhotosSlide36
Photos