P14474: Hydrostatic Test Apparatus
Jake Manley-Project Lead/EEMitchell Sedore-ME
Brian Benner-MEAnushka Kalicharan-ME
Kyle Abbott-ME
AgendaProject BackgroundProblem Statement & DeliverablesCurrent Vs. New SystemStakeholdersStandardsList of needs
Customer requirements Engineering requirementsHouse of Quality
Project Plan
Problem StatementThe current, manually controlled, hydrostatic test apparatus needs to be redesigned so
that test automation can occur via a digital control interface. The interface includes
editable parameters for the pressure, ramp rate, and hold time of the test being
performed. Once these variables are set, the test is able to take place. All of these
parameters are automatically controlled within the system so that the technician can
observe the test and capture the results. The purposed design for the new test apparatus
must include minimal system maintenance, an easily programmable digital interface,
ability to interface with the existing pump and test enclosures, test automation, and able
to withstand a maximum internal pressure of 10,000 PSI. The apparatus is designed
around performing tests on electrical enclosures to ensure they meet the operational
specifications as outlined in standards UL1203, UL2225, and CSA22.2 no.30. These
standards provide the basis for all tests performed by the hydrostatic test apparatus.
What is a Hydrostatic Test?Tests structural integrity of the product
Product: Electrical enclosuresSimulates explosion within the electrical
enclosureHigh Pressure Tests :
Proof Test Hold time at specified pressure
Destructive Test Test to failure Determines safety factor (UL Standards)
StandardsUL1203
Electrical enclosure: 10 sec hold time without rupture
Safety factor of 4x internal explosion pressure UL2225
Cable sealing: 10 sec hold time w/o ruptureSafety factor of 4x internal explosion pressurePressure: 100-600psi/min
CSA22.2 no.30
Current Hydrostatic Test ApparatusFully functionalManually controlled by
techniciansAnalog pressure and time
measurementsIsolated Test
EnvironmentFollows standards:
UL1203UL2225CSA22.2 no.30
New Hydrostatic Test ApparatusProgrammable Digital
InterfaceHold time, Pressure, Ramp
rateAutomated test system Data logging capabilities
for external PCFuture Labview Integration
Retain existing hydraulic pressure sources
Project DeliverablesHardware
Complete onsite test apparatusDocumentation
Maintenance RecommendationsModel for fatigue predictionsUser guide for operationEngineering Drawings
StakeholdersCooper-Crouse Hinds
Joe ManahanLab TechniciansSecondary Customers
RITMSD GroupBen VarelaMike Zona
Customer RequirementsCustomer Rqmt. #
Importance
Description
CR1 9 Programable Digital InterfaceCR2 9 Test Automation complies with StandardsCR3 9 Future Labview IntegrationCR4 9 Control of Target PressureCR5 9 Control of Hold TimeCR6 9 Control of Ramp RateCR7 9 Ability to Interface with Current Cooper Product LineCR8 9 Safe Test EnviromentCR9 9 Ability to Aquire Data from Test
CR10 3 Use of Pressure Transducer(s)CR11 3 Mantainence RecommendationsCR12 3 Model for Fatigue PredictionCR13 3 Complete Apparatus for On-Site Testing CR14 3 Engineering DrawingsCR15 3 Operating ManualCR16 3 Maintanence ManualCR17 3 Cost approx $6000
Engineering Requirements
Rqmt. #Importanc
eSource Function Engr. Requirement (metric)
Unit of Measure
Target Value/Ran
ge
S1 9 CR2 Withstand Maximum Internal System Pressure PSI 10000
S2 9UL1203 & UL2225 Pressure Ramp Rate PSI/Min 100-600
S3 9 PRP Maximum Pressure in Enclosure PSI 10000
S4 9 UL1203 Minimum Pressure in Enclosure PSI >50
S5 9 UL1203 Maximum Conduit Trade Size in 1/2"
S6 9 UL1203 Minimum Conduit Trade Size in 1 1/2"
S7 9 UL1203 Hold Time for 4X Max Internal Explosion Pressure Sec 10
S8 9 US1203 Hold Time for 1.5X Max Internal Explosion Preassure Sec >10, <60
S9 9Customer Interview Ability to Alter Test Parameters Midtest Binary
S10 9 CR15 Number of Analog Outputs for Data Logging Decimal 8
S11 9 Store Peak Pressure Value Before Failure Binary
S12 9 CR16 Emergency Stop Binary
S13 9 PRP Test Controlable Outside Explosive Proof Area Binary
S14 3 Reaction time of Valve Sec <2
S15 3 Maximum Dimensionsft (L x W x
H 5 x 2 x 3