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