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
● 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 Components
Manifold
● 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. Wireless
Method 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 Digital
Manner 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
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