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

House of Quality

Preliminary Schedule

Questions?