PRO1ECT ON:

DESIGN & DEVELOPMENT OF HIGH PRESSURE

HYDROSTATIC TESTING SYSTEM



INDEX
S NO TITLE PAGE NO
1. PREFACE

2. PROJECT NARRATIVE

3. COMPANY PROFILE

4. OVERVIEW OF PUMPING SYSTEMS

5. PROBLEM STATEMENT

6. HYDROSTATIC PRESSURE TESTING

6.1 NEED FOR HYDROSTATIC PRESSURE
TESTING

6.2 STANDARD OPERATING PROCEDURE

7. DESIGN

8. SYSTEM COMPONENTS

8.1 PUMP

8.2 MOTOR

8.3 HOSE LINES

8.4 PRESSURE GAUGE

8.5 PRESSURE SWITCH

8.6 PRESSURE TRANSMITTER

9. CALCULATIONS

9.1 PUMP

9.2 MOTOR

9.3 HOSE LINES SELECTION

9.4 PRESSURE GAUGE SELECTION

9.5 PRESSURE TRANSMITTER SELECTION

10. SAFETY VALVE

11. SUCTION FILTER

11.1 IMPROVED DESIGN

11.1.1 CONSTRUCTION

11.1.2 WORKING

11.1.3 FILTER COMPONENTS

12. BASE PLATE

13. VARIOUS SYSTEM CONFIGURATIONS

13.1 MANUAL APPROACH

13.2 AUTOMATED APPROACH

13.2.1 PRESSURE SWITCH

13.2.2 PRESSURE TRANSMITTER

14. CONTROL BOX

15. COST SHEET

16. RESULT TABLE

16.1 PRESSURE SWITCH

16.2 PRESSURE TRANSMITTER

17. RESULT GRAPH

17.1 PRESSURE SWITCH

17.2 PRESSURE TRANSMITTER

18. OBSERVATION

19. FUTURE SCOPE

20. FINAL ASSEMBLY

21. BIBLIOGRAPHY




INDEX FOR FIGURES

S NO


TITLE

PAGE NO
1. PUMPING SYSTEM
2. STATIC HEAD
3. STATIC HEAD VS FLOW
4. CENTRIFUGAL PUMP
5. RECIPROCATING PUMP
6. RUPTURED IPPE
7. FAILED REACTOR VESSEL
8. BASIC LAYOUT
9. EXPLODED VIEW OF THE PUMP
10. EXPLODED VIEW OF THE MOTOR
11. WORKING OF A PRESSUER GAUGE
12. PRESSURE SWITCH
14. HOSE LINES
15. BOURDEN TUBE PRESSURE GAUGE MODEL
#232.53

16. PRESSURE TRANSMITTER
17. FILTER ASSEMBLY
18. FILTER CAP
19. COVER CAP
20. FILTER
21. GLASS SHELL
22. COVER END CAP
23. COVER STUD
24. BASE PLATE
25. MANUAL LAYOUT
26. AUTOMATED LAYOUT WITH PRESSURE
SWITCH

27. AUTOMATED LAYOUT WITH PRESSURE
TRANSMITTER (DEAD ENDED)


28. AUTOMATED LAYOUT WITH PRESSURE
TRANSMITTER (BYPASS)

29. ARRANGEMENT OF CONTROL BOX
30. ARRANGEMENT OF PID DIGITAL CONTROL
31. ELECTRIC CIRCUIT OF SYSTEM
32. DELIEVERY LINE PRESSURE GAUGE MOUNT
33. DELIEVERY LINE PRESSURE TRANSMITTER
MOUNT

34. DELIEVERY LINE SAFETY VALVE
35. COMPLETE DELIEVERY LINE MOUNTINGS
36. FRONT VIEW OF THE ASSEMBLY
37. TOP VIEW OF THE ASSEMBLY


INDEX FOR GRAPHS


S NO


TITLE

PAGE NO
A. FRICTIONAL HEAD VS FLOW

B. SYSTEM WITH HIGH STATIC HEAD

C. SYSTEM WITH LOW STATIC HEAD

D. PREFORMANCE CUVES OF PUMPS

E. EXPERIMENTAL EVIDENCE

F. PRESSURE SWITCH RESULT

G. PRESSURE TRANSMITTER RESULT








1. PREFACE

BeIore beginning with the elaborate report oI our year long project, I would like to
Iocus on one question that crosses the mind oI every Iinal year student, and I was
no exception.
Why is this activity so important that it is worth spending all this time, and why it
is required as part of the degree program?
During the course oI our project, we truly understood and imbibed the reason oI
the above presented query in our industrial work persona.
The answer to the above posed question is that knowledge, more so in a
proIessional course like engineering, engulIs both theoretical and practical
teachings. While the classroom takes care oI all the conceptual learning, there still
are a lot oI aspects to an industrial work experience that cannot be encountered in
the practical classes oI the curriculum.
These aspects include:
Working eIIectively as a part oI a team.
Understanding the real time problems through personal experience and
developing the problem statement through research and discussions.
Developing speciIication and design documents.
Developing prototypes.
Improving writing and oral presentation skills.
Hence at the end oI this ever so IulIilling experience, we are in a position to Iully
understand the importance oI this task in the Iinal year.
I have surely learnt a lot through this experience and have hopeIully been
successIul in giving you an insight into our endeavor, in the pages to Iollow.


. PRO1ECT NARRATIVE

Hydrostatic Pressure Testing is a process practiced in the industry to test all
hydraulic vessels, products & systems. It is one oI the most important tests carried
out to validate the saIety oI the product or the system and gauge the liIe oI the
same.
In this process, the product to be tested is connected to a pump; a reciprocating
pump is usually taken Ior this purpose. The product is then pressurized to its
maximum design pressure to check Ior its conIormation oI standards and saIe
working in real time. The system used Ior this purpose is constituted Irom various
hydraulic components. Such systems are to be designed depending on the job at
hand.
Over the years, the manual method oI perIorming this activity has been persistent
in the industry. But with the advent oI technology and with the ever so important
merge oI electronics and mechanical aspects oI engineering, there are Iaster, saIer
and more reliable options to perIorm this task.
Our project revolves around an industrial query made to our company by Thermax
Private Limited`. The query requested Ior an automated high pressure hydrostatic
pressure testing system with the Iollowing requirements:
S No Parameter Value
1. Pressure 100 bar (max)
2. Discharge 600 lph (max)


I have tried to utilize the knowledge gained over the period oI my Internship at
DampI Kolben Pvt. Ltd., as part oI my Iinal year project to design such a system.

. COMPANY PROFILE

DampI- Kolben Engineering Corporation is one the most reputed companies in the
city, dealing with the manuIacturing oI reciprocating pumps. They are the
exclusive business partners oI DESMI ROTAN PUMPS`, Denmark, in India.

They deal with the manuIacturing oI simplex, duplex and triplex type oI
reciprocating pumps up to maximum pressure oI 200bar and maximum discharge
oI 15000 liters/hr. These are primarily employed as boiler Ieed pumps, as high
pressure cleaning systems and the sorts.

They also manuIacture Pilot Plants and have supplied the same to NCL, McCoy
Corporation (South Korea), Thermax Pvt Ltd, JN Marshall Pvt Ltd, etc.

The pumps manuIactured by the company are thoroughly tested. The measurement
oI discharge is as per API 674 standards. These standards ensure the IulIilling oI
the minimum requirements by a reciprocating positive displacement pump.

The clause 674 states that 'A manuIacturer shall operate the complete pump in his
shop Ior a suIIicient period to obtain complete test data including speed, discharge
pressure, capacity (discharge) and power. Whence the pump is operated on the test
rig, the discharge should be within 0-3 oI the rated characteristics or the test
equivalent. II the Iacility does not have the capability to meet the rated conditions,
they may be run at either reduced speed or pressure.




. OVERVIEW OF PUMPING SYSTEMS
One oI the basic questions that needs to be catered Ior is
What are pumps and pumping systems?

Pumping systems account Ior nearly 20 oI the world`s electrical energy demand
and range Irom 25-50 oI the energy usage in certain industrial plant operations.

Here is an illustration oI a typical pumping system.


Fig 1. Pumping System

The main components oI a pumping system are:

O Pumps
O Prime movers ( electric motors, diesel engines or air system)
O Piping ( used to carry the Iluid)
O Valves ( used to control the Ilow in the system).
Pumps have two main purposes:

TransIer oI liquid Irom one place to another place (e.g. water Irom an
underground aquiIer into a water storage tank)

Circulate liquid around a system (e.g. cooling water or lubricants through
machines and equipment)

Pumping system characteristics

.1. Resistance of the system: Head`

Pressure is needed to pump the liquid through the system at a certain rate. This
pressure has to be high enough to overcome the resistance oI the system, which is
also called 'head. The total head is the sum oI static head and Iriction head:

a) Static head(hS)

Static head is the diIIerence in height between the source and destination oI the
pumped liquid (see Figure 4.1). Static head is independent oI Ilow (see Figure 4.2).

The static head at a certain pressure depends on the weight oI the liquid and can be
calculated with this equation:





Static head consists oI:

O Static suction head (hS), resulting Irom liIting the liquid relative to the pump
center line. The hS is positive iI the liquid level is above pump centerline,
and negative iI the liquid level is below pump centerline (also called
'suction liIt)



O Static discharge head (hd) is the vertical distance between the pump
centerline and the surIace oI the liquid in the destination tank.


Fig . Static Head Fig . Static Head Versus Flow

b) Friction head (hf)

This is the loss needed to overcome that is caused by the resistance to Ilow in the
pipe and Iittings. It is dependent on size, condition and type oI pipe, number and
type oI pipe Iittings, Ilow rate, and nature oI the liquid. The Iriction head is
proportional to the square oI the Ilow rate as shown in Iigure (4.3). A closed loop
circulating system only exhibits Iriction head (i.e. not static head).


A. Frictional Head versus Flow

In most cases the total head oI a system is a combination oI static head and Iriction
head as shown in Figures 4.4 and 4.5

B. System with High Static Head C. System with Low Static Head


. Types of Pumps

This section describes the various types oI pumps.2 Pumps come in a variety oI
sizes Ior a wide range oI applications. They can be classiIied according to their
basic operating principle as dynamic or positive displacement pumps.



Let us deal with some oI the major categories in some detail.

..1 Positive Displacements Pumps

Positive displacement pumps are distinguished by the way they operate: liquid is
taken Irom one end and positively discharged at the other end Ior every revolution.
Positive displacement pumps are widely used Ior pumping Iluids other than water,
mostly viscous Iluids.

Positive displacement pumps are Iurther classiIied based upon the mode oI
displacement:

O #eciprocating pump iI the displacement is by reciprocation oI a piston
plunger.

O #otary pumps iI the displacement is by rotary action oI a gear, cam or vanes
in a chamber oI diaphragm in a Iixed casing. Rotary pumps are Iurther
classiIied such as internal gear, external gear, lobe and slide vane etc.

In all positive displacement type pumps, a Iixed quantity oI liquid is pumped aIter
each revolution. So iI the delivery pipe is blocked, the pressure rises to a very high
value, which can damage the pump.



.. Dynamic Pumps

Dynamic pumps are also characterized by their mode oI operation: a rotating
impeller
converts kinetic energy into pressure or velocity that is needed to pump the Iluid.

There are two types oI dynamic pumps:

O entrifugal pumps
O $pecial effect pumps



We shall now discuss a little Iurther about the two most widely used pumps in the
industry, viz

O entrifugal pumps
O #eciprocating pumps


. Centrifugal Pumps


Fig . Centrifugal Pump



.5 Centrifugal Pump

O A centrifugal pump is a rotodynamic pump that uses a rotating impeller to
increase the pressure oI a Iluid.
O The Iluid enters the pump impeller along or near to the rotating axis and is
accelerated by the impeller, Ilowing radially outward into a diIIuser or
volute chamber (casing), Irom where it exits into the downstream piping
system.
O CentriIugal pumps are used Ior large discharge through smaller heads.
O Hence, in case oI large volume vessels, these pumps are initially used to Iill
up the vessel and then a reciprocating pump is brought to pressurize the
liquid.
. Reciprocating Pumps


Fig 5. Reciprocating Pump

O A reciprocating pump is a positive displacement device Ior pumping liquids.
O It can develop very high discharge pressures, which are limited only by the
strength oI the structural parts.
O Discharge is almost constant regardless oI discharge pressure, but it is
aIIected by leakages and speed Iluctuations oI the drive.
O Discharge can be controlled by varying the speed oI the drive.
O Since, these can develop large heads, they are perIect Ior hydrostatic
pressure testing and as boiler Ieed pumps.

.5 Pump performance curves

The head and Ilow rate determine the perIormance oI a pump, which is graphically
shown in Figure 4.6 as the perIormance curve or pump characteristic curve. The
Iigure shows a typical curve oI a centriIugal pump and a reciprocating pump
respectively, where the head gradually decreases with increasing Ilow Ior the
Iormer, while the Ilow remains more or less constant Ior various heads Ior the
latter.

As the resistance oI a system increases, the head will also increase. This in turn
causes the Ilow rate to decrease and will eventually reach zero. A zero Ilow rate is
only acceptable Ior a short period without causing to the pump to burn out.


D. Performance Curve of a Centrifugal & Reciprocating Pump




.6 Differences between Centrifugal pumps and Reciprocating Pumps


S No

Parameter

Centrifugal Pumps

Reciprocating Pumps

1. Optimum Flow
and Pressure
Applications
Medium/High Capacity,
Low/Medium Pressure

Low Capacity,
High Pressure

2. Maximum Flow
Rate
100,000 GPM

10,000 GPM

3. Low Flow Rate
Capability

No Yes
4. Maximum
Pressure

6,000 PSI

100,000 PSI

5. Requires Relief
Valve

No Yes
6. Variable or
Constant Flow

Variable

Constant

7. Costs

Lower Initial
Lower Maintenance
Higher Power

Higher Initial
Higher Maintenance
Lower Power






5. PROBLEM STATEMENT

Within the initial couple oI weeks, we learnt our problem statement Ior our project
work. A very interesting detail, we learnt whist working at the company was the
problem statement was not served to us on the platter.
To device our problem statement, our industry guides, Mr. Bapat and Mr. Bagul,
urged us to Iirst go through the entire company literature and understand the basic
layout oI the work carried out there. We spent our initial time in understanding
their work layout and shuttled between the literature and its practical application
when in doubt, and the cases were deIinitely more oIten than we had imagined.
Finally, our guides oIIered us to take on a project that could prove out to be helpIul
to the company as well, in days to come.

Our problem statement was decided to be as Iollows:
esign & evelopment of an Automated High Pressure
Hydrostatic 1esting $ystem."
The Iollowing content will help understand the intrinsic details and oIIer a detailed
explanation oI the inIerence oI the above mentioned statement.
O As mentioned earlier, hydrostatic pressure testing is used in industry to
veriIy the perIormance oI pressure vessels such as cylinders, boilers, tubes,
valves, etc.

O Our task was to design a system to Iacilitate this testing procedure.

O The industry relied on manual approach to this phenomenon (which will be
elaborated in the later sections) until very recently. Hence, we were
required to design an automated system, doing away with the manual
involvement, ensuring greater eIIiciency and reliability.



O The scope oI our project basically deals with designing a system to Iirst 1ill
up the vessel and then pressuri:e it to the required pressure and then empty
the system oI the test Iluid, post completion oI the test.

O Our project also engulIed the Iollowing query made by Thermax Pvt Ltd to
our company.









O The above system needs to be applied Ior the hydrostatic pressure testing oI
various pressure vessels.

O These pressure vessels are basically boilers oI various capacities, 1000 liters
onwards.



1hermax Pvt. Ltd. had requested Ior an Automated Hydrostatic Pressure Testing
System` to be installed at their Iacility, to DampI Kolben Pvt Ltd. This system is to
be used for the hydrostatic testing of various varying vessel sizes over 1000
liters. This was the same order which was allotted to us to assist with, as part oI the
project. The selection oI parts and the system design calculations are presented with
respect to this particular query.
They had given the Iollowing requirement:
Pressure 100 bar
Flow Rate 600 Liters/ hour


6. HYDROSTATIC PRESSURE TESTING
One oI the most vital procedures in the Iluid industry is that oI hydrostatic testing.
A hydrostatic test is a way in which leaks can be Iound in pressure vessels such as
pipelines and plumbing. The test involves placing water, which is oIten dyed Ior
visibility, in the pipe or vessel at the required pressure to ensure that it will not leak
or be damaged. It is the most common method employed Ior testing pipes and
vessels.
It also Iorms one oI the essentials Ior the commissioning oI these components.
Again, during re-commissioning the component at regular intervals, the process
dwells in the name oI proo1 pressure test. Using this test helps maintain saIety
standards and durability oI a vessel over time.
The process is oI utmost importance, since iI the vessels or the Iluid carrying
component is not hydro tested, there then exists a great amount oI risk oI
component rupture or even explosion causing huge property loss and human
damage.
The process consists oI Iilling the cylinder with a nearly incompressible liquid,
usually water, and examining it Ior leaks or permanent changes in shape. The test
pressure is always considerably more than the operating pressure to give a margin
Ior saIety. Typically, percent oI the operating pressure is used. Water is
commonly used as it is almost incompressible, and will only expand by a very
small amount. II high pressure gas was used, the gas could expand up to several
hundred times its compressed volume, running the risk oI serious injury.
Most countries have legislation or building code that requires pressure vessels to
be regularly tested, Ior example every two years (with a visual inspection annually)
Ior high pressure gas cylinders and every Iive or ten years Ior lower pressure ones
such as used in Iire extinguishers. Gas cylinders which Iail are normally destroyed
as part oI the testing protocol to avoid the dangers inherent in them being
subsequently used.
The saIety requirements and the testing protocol varies Irom material to material.
As such the underlying table depicts the saIety protocol along with the service liIe
oI some such vessels.
S No Vessel
Material
Testing
period
Hydrostatic
test life
Image
1. DOT-3AL
gas
cylinders
AIter
every 5
years
Unlimited
service liIe

2. DOT-3HT
gas
cylinders
AIter
every 3
years
24 years oI
service liIe

3. DOT-3AA
gas
cylinders
AIter
every 5
years
Unlimited
service liIe

4. Fully
wrapped
Kevlar
cylinders
AIter
every 3
years
15 years oI
service liIe




6.1 NEED FOR HYDROSTATIC PRESSURE
TESTING

All items and equipments that operate at a pressure above ambient need to be
tested beIore use, Ior Iunctionality and oI course saIety. The statement saIe to use`
is qualiIied because absolute saIety is never attainable, and this is particularly true
Ior pressure testing oI pressurized equipments. Indeed, there is one school oI
thought that emphasizes that pressure test only demonstrates that the equipment
passed the test only on the day oI the test and nothing more. However, there are
also believers oI the statement that much more can be learnt Irom a test apart Irom
this, like the estimation oI the behavioral pattern oI the equipment not only under
the prevailing conditions oI the test, but also under other active variables.
As mentioned earlier, the basic reason oI conducting a test oI this nature is the saIe
operation oI the equipment. In case the operating conditions diIIer Irom those
classiIied as saIe, then results are disastrous.
Some instances oI this are as shown below :

Fig 6. Ruptured Pipe


Fig 7. Failed Reactor Vessel
Both the above illustrated examples are an outcome oI a sudden release oI a large
amount oI energy. This situation is particularly acute during a pressure test since
this is the time one can be least sure oI the ability oI the pressurized system to
withstand the pressure without Iailure.

Hence hydrostatic pressure testing plays such a vital role in not only the saIe setup
and commissioning oI the equipment but also during the saIe operational liIe
through re-commissioning oI the equipment and retiring the equipment post its
service liIe.


To stress a little Iurther on the disastrous outcomes due to pressure destabilization
in hydraulic and pneumatic systems, I would like to present the Iollowing statistics:

E. Experimental evidence, Esparza and Baker





6. STANDARD OPERATING PROCEDURE

Following operational sequence is highly recommended and practiced in the
industry.
A) Test Preparation:-
1. The object to be hydro tested should be thoroughly cleaned Irom both inside and
outside.

2. Calibrated Pressure gauge (preIerably glycerin Iilled) should be Iitted on the
object.

3. Inlet and outlet should have either threaded or Ilanged connections.
4. A non-return valve should be installed on the inlet side oI the object. This will
ensure retention oI pressure even when either the pump is stopped or the high
pressure hose is disconnected at the NRV inlet. (Testing standards call Ior a
pressure hold-up time oI 15 min.)

5. Water outlet should be preIerably at the highest contour oI the object. This will
ensure Iorced escape oI all the entrapped air inside the object. Air bubbles iI leIt
out inside may prolong the testing duration substantially.

6. A Ball valve should be Iitted on the water outlet side oI the object.
7. A high pressure hose oI adequate operating pressure should be Iitted on the pump
discharge side, the other end oI which is connected to the inlet side oI the NRV.

8. A low pressure hose can be used on the suction side oI the pressure pump.
9. Proper Iiltration oI inlet water should be ensured. An inline Iilter can be Iitted at
any convenient point between the pump suction and the water tank.




10. Positive suction to the pump is highly recommended .This means that the water
level in the suction tank should be above the pump level. Due to this, leakages, iI
any, can be easily observed as water drips out Irom the Iaulty joints.

11. A Pressure gauge (preIerably glycerin Iilled) should be Iitted on the pump.
12. Proper electrical connections should be ensured Ior the pump prime mover
(Motor).

13. Pump and motor speciIications should be veriIied prior to the beginning oI
pressure test. (Pump Ilow, max. pressure, motor HP/speed etc.)

14. High pressure pistons/plunger pumps can develop inIinite pressure. Operating
pressures above the pump design pressure can instantly cause a severe damage to
the pump. Full closure oI the ball valve on the water outlet side shall result in
developing pressures above the required max. Pressure as well as the pump
design pressure. To avoid this, these pumps are automated using a pressure
switch or a pressure transmitter which automatically stops the pump as soon as
the desired test pressure is achieved. A bypass with a needle valve should be
provided on the pump. This needle valve in the bypass line should be used as a
throttling valve to achieve the desired pressure. This bypass system avoids the
sudden rise in the pressure caused due to the surge in the discharge line.









B) Testing Procedure:-

1. Bigger objects should be initially Iilled with water either by gravity or with the
help oI a centriIugal pump. (CentriIugal pumps normally deliver high Ilows but
can develop comparatively low pressures.).

2. During this Iill-up, the ball valve on the water outlet side should be kept open till
the time all the entrapped air inside the object is pushed out.

3. When a clear stream oI water (w/o entrapped air) is observed coming out oI
the water outlet, the ball valve should be slowly closed.

4. It is a MUST that the throttling valve (needle valve) in the bypass line is Iully
opened beIore the pump is started.

5. The piston/plunger pump, now, can be started.
6. To begin with, all the pump discharge shall take the bypass route. The throttling
needle valve being Iully open shall not develop any pressure in the line (the
pressure gauge may not show any signiIicant reading). This valve, now, should
be throttle slowly and careIully to built up pressure in the pump discharge line
and hence within the object. This pressure built up can be seen on both the
pressure gauges (on the pump as well as on the object). Alternately, a throttling
valve can be installed instead oI the ball valve on the water outlet side and can be
operated slowly and careIully till the time desired test pressure is achieved. The
Ilip side oI this option is that the pump has to be in running condition Ior the
entire test duration.

In case oI automated systems, the pump will automatically stop as soon as the
required pressure is achieved.








7. DESIGN

AIter the detailed explanation on hydrostatic pressure testing, its theory and the
standard testing procedure Iollowed in the industry, we shall now move on to
discuss the basic working oI the system & then Iurther talk about the components
that constitute this system, in the sections to come.

The basic layout oI the system is as shown below:


Fig 8. Basic Layout

The most prevalent method oI conducting hydrostatic pressure testing in the
industry was the manual method. This also Iorms the basic arrangement oI the
setup.

8. SYSTEM COMPONENTS

The above presented schematic oI the high pressure hydrostatic testing system
encompasses the Iollowing components.
O Reservoir
O In line suction Iilter
O Low pressure suction hose (pump)
O Pump
O Prime mover
O High pressure delivery hose line (pump)
O Pressure gauge (pump)
O Throttle valve (bypass line)
O Pressure switch / Pressure transmitter
O Non return valve (vessel inlet)
O Pressure gauge (vessel inlet)
O Ball valve (vessel end)
In the pages to come, we shall discuss each component in detail.









8.1 PUMP

Pump is a machine that draws a Iluid into itselI through an entrance port and Iorces
the Iluid out through an exhaust port. It pressurizes and transIers a deIinite volume
oI Iluid Irom one place to another.
SALIENT FEATURES OF DAMPF-KOLBEN PUMPS:-

Distinctly designed, machined and processed stainless steel valve seat
assemblies ensure excellent sealing, negligible back leakages and extra liIe.

Specially designed TeIlon washers ensure Iail saIe port sealing.

SpeciIic grade neoprene gland washers oIIer high wear resistance.

Throat bush restricts the contamination oI pump and the stuIIing box.

Fig 9. Exploded View of the Pump
Back cover with cooling increases radiation losses and keeps maximum oil
bath temperature within saIe zone, thereby increasing the liIe oI oil, bearings
and oils seals.

Breather plug avoids chocking oI vent holes & helps to enhance the liIe oI
oil, bearings, oil seals and the rotating parts.

Constant level oiler maintains the crack case oil at a predetermined level.

High tensile bolts with lock washers tightened to a speciIic torque ensure
perIect circularity oI connecting rod bearings.

Coated piston ensures better wear resistance & longer gland packing liIe.

Epoxy painting Ior better aesthetics and longer liIe.














8. MOTOR
An electric motor converts electrical energy into mechanical energy. Most electric
motors operate through interacting magnetic Iields and current-carrying conductors
to generate Iorce, although electrostatic motors use electrostatic Iorces.
They may be powered by direct current or by alternating current. Further
classiIication oI motors is the asynchronous motors, which require an induction
(slip) between the magnetic Iield and the winding to induce current, and the
synchronous motors, which do not require such an induction.
The most ubiquitous example oI asynchronous motors is the AC Induction motors
which Iind application in almost all modern day industries.




Fig 10. Exploded View of the Motor
8. HOSE LINES
A hose is a hollow tube designed to carry Iluids Irom one location to another.
Hoses are also sometimes called pipes (the word pipe usually reIers to a rigid tube,
whereas a hose is usually a Ilexible one), or more generally tubing. The shape oI a
hose is usually cylindrical (having a circular cross section).
Hose design is based on a combination oI application and perIormance.Common
Iactors are Size, Pressure Rating, Weight, Length, Straight hose or Coil hose
and Chemical Compatibility.
Hoses are made Irom one or a combination oI many diIIerent materials.
Applications mostly use nylon, polyurethane, polyethylene, PVC, or synthetic or
natural rubbers, based on the environment and pressure rating needed. In recent
years, hoses can also be manuIactured Irom special grades oI polyethylene (LDPE
and especially LLDPE). Other hose materials include PTFE (TeIlon), stainless
steel and other metals.
To achieve better pressure resistance hoses can be reinIorced with Iibers or steel
cord. Commonly used reinIorcement methods are braiding, spiraling, knitting and
wrapping oI Iabric plies. The reinIorcement increases the pressure resistance but
also the stiIIness. To obtain Ilexibility corrugations or bellows are used. Usually
circumIerential or helical reinIorcement rings are applied to maintain these
corrugated or bellowed structures under internal pressure.
HOSE SELECTION CRITERIA:
The basic criterion to select an eIIective pressure hose are as Iollows:
O Size
O Temperature
O Application
O Material to be conveyed
O Pressure
O Ends oI coupling
O Delivery
As visibly noticeable, an eIIective way to remember the criteria oI hose selection is
the word, STAMPED`.
a) Hose Size (Dash Number)
The inside diameter oI the hose must be adequate to keep pressure loss to a
minimum and avoid damage to the hose due to heat generation or excessive
turbulence.

The hydraulics industry has adopted a measuring system called ash
numbers to indicate hose and coupling size. The number which precedes the
hose or coupling description is the dash size.

The table showing the correlation oI internal diameter and the dash numbers
is displayed as under Ior your reIerence.




b) Temperature

When selecting a replacement assembly, two areas oI temperature must be
considered. These are Iluid temperature and ambient temperature. The hose
selected must be capable oI withstanding the minimum and maximum temperature
seen by the system. Care must be taken when routing near hot maniIolds and in
extreme cases a heat shield may be advisable.

c) Application
This is another point oI consideration. Every hose used in a system is selected
keeping in mind the requirements oI the application.

Hoses can be used in water or other liquid environments or to convey air or other
gases. Hoses are used to carry Iluids through air or Iluid environments, and they
are typically used with clamps, spigots, Ilanges, and nozzles to control Iluid Ilow.

d) Material to be carried
Some applications require specialized oils or chemicals to be conveyed through the
system. Hose selection must assure compatibility oI the hose tube, cover, couplings
and O-rings with the Iluid used. Additional caution must be exercised in hose
selection Ior gaseous applications such as reIrigerants and LPG.

e) Pressure
Most important in the hose selection process is knowing system pressure, including
pressure spikes. Published working pressures must be equal to or greater than the
system pressure. Pressure spikes greater than the published working pressure will
shorten hose liIe and must be taken into consideration.

f) Ends of Couplings
The ends oI couplings have to be identiIied reIerring to a standard industrial
manual.

g) Delivery
Ultimately, the discharge and the velocity oI Ilow play a very crucial part in
selection oI the hose.

8. PRESSURE GAUGE
Pressure gauges have been a reliable source oI accurate pressure measurement Ior
more than 100 years. The operation and design oI pressure gauges dates back to the
mid 1800s when Eugene Bourdon invented the Bourdon tube. This same principle
is used today, albeit with enhancements to last longer and resist corrosion.

Fig 11. Working of a Pressure Gauge
Most standard dial type pressure gauges use a bourdon tube-sensing element
generally made oI a copper alloy (brass) or stainless steel Ior measuring pressures
15 PSI and above. Bourdon tube gauges are widely used in all branches oI industry
to measure pressure and vacuum. The construction is simple yet rugged and
operation does not require any additional power source. The C-shaped or spirally
wound bourdon tube Ilexes when pressure is applied producing a rotational
movement, which in turn causes the pointer to indicate the measured pressure.
These gauges are generally suitable Ior all clean and non-clogging liquids and
gaseous media. Low pressure gauges typically use an extremely sensitive and
highly accurate capsule design Ior measuring gaseous media Irom as low as 15
INWC to 240 INWC (10 PSI). Digital gauges use an electronic pressure sensor to
measure the pressure and then transmit it to digital display readout.

8.5 PRESSURE SWITCH

A pressure switch is a type oI switch mechanism that is designed to initiate an
electrical connection when a certain amount oI pressure is placed on the switch.
There are many diIIerent types oI pressure switches, although all types can be
classiIied under two speciIic categories, known as the pneumatic and the hydraulic.


8.5.1 CONSTRUCTION

The pressure switch is housed in a transparent tough polycarbonate cover,
conIirming to IP 66 protection Iactor. The pressure capsule comprises an SS316
pressure housing, a disc and a plunger, sealed with a nylon reinIorced rubber
diaphragm, protected Irom the working medium with TeIlon. For hydraulic ranges
the sensing element is an O ring sealed piston. The electrical changeover is through
a snap action micro switch. A cable gland is provided Ior wiring.


Fig 1. Pressure Switch


8.5. PRINCIPLE OF OPERATION

The pressure in the pressure capsule is converted into Iorce by means oI a
reinIorced rubber diaphragm and a calibrated piston, which is balanced by a
compression spring Irom above. When the Iorce generated by the pressure in the
pressure capsule exceeds/Ialls beyond the balancing spring Iorce, an element is
actuated.

Pressure switches will generally have only one SPDT microswitch.


8.6 PRESSURE TRANSMITTER

Pressure transmitters and transducers convert an applied pressure into an electrical
signal. This signal is sent to computers, PLC's (programmable logic controllers),
chart recorders, digital panel meters or other devices that interpret this electrical
signal and use it to display, record and/or change the pressure in the system being
monitored.

The most popular signal used in industrial applications is a 4-20 milliamp (mA) 2-
wire current loop. Other signals used include 1-5 volts, 0-5 volts, 0.5-4.5 volts, 0-
10 volts (3 wire systems) and 0-100 millivolts (4 wire systems).
In many cases the display device that the transmitter is connected to can accept
more than one type oI output - Ior example, 4-20 mA or 0-5 volts. Because oI its
popularity, WIKA stocks a large inventory oI 4-20 mA output transmitters in many
diIIerent models.

A pressure transmitter converts an unampliIied signal such as 2mV/V into an
ampliIied signal like 4-20mA or 0-10V. A pressure transducer converts applied
pressure to an unampliIied signal such as 2mV/V. Many users reIer to transmitters
and transducers interchangeably. This can create some conIusion, but it may be
helpIul to note that general purpose pressure sensors are most commonly reIerred
to as pressure transducers.

WIKA S-10 and S-11 pressure transmitters are precision engineered to Iit most
industrial pressure measurement applications. The compact, rugged design makes
these instruments suitable Ior applications including hydraulics and pneumatics,
vacuum, test equipment, liquid level measurement, press control, compressor
control, pump protection and numerous other processing and control operations. A
wide range oI electrical connection and process connection options are available to
meet almost any requirement.




9. CALCULATIONS

BeIore proceeding with the design calculations, let us go through the requirements
oI the projects once again.









The system is to be used Ior the hydrostatic pressure testing oI pressure vessels.
These pressure vessels are large capacity boilers the capacities oI these boilers
range Irom anywhere Irom 1000 liters onwards.
The same system is to be used Ior all these boilers.





1hermax Pvt. Ltd. had requested Ior an Automated Hydrostatic Pressure Testing
System` to be installed at their Iacility, to DampI Kolben Pvt Ltd. This system is to
be used for the hydrostatic testing of various varying vessel sizes over 1000
liters. This was the same order which was allotted to us to assist with, as part oI the
project. The selection oI parts and the system design calculations are presented with
respect to this particular query.
They had given the Iollowing requirement:
Pressure 100 bar
Flow Rate 600 Liters/ hour
9.1 PUMP

Based on the pressure and Ilow rate requirements, we reIerred the company
catalogue to Iind the best suitable pump Ior the job.

M: - Manual. S: - Pressure Switch. T: - Pressure Transmitter.
The highlighted option was the best suitable option based on the pressure and Ilow
rate requirement.


Sr.
No. Model
System
Design Discharge Pressure Speed Power
max. max. max. max.
Su11ix LPH Bar RPM HP
1 1.5 DKH-1003 M / S / T 300 100 950 1.5
2 2 DKH-1303 M / S / T 300 130 950 2.0
3 3 DKH-2003 M / S / T 300 200 950 3.0
4 1.5 DKH-604 M / S / T 400 60 950 1.5
5 2 DKH-1004 M / S / T 400 100 950 2.0
6 3 DKH-1504 M / S / T 400 150 950 3.0
7 1.5 DKH-605 M / S / T 500 60 950 1.5
8 2 DKH-805 M / S / T 500 80 950 2.0
9 3 DKH-1005 M / S / T 500 100 950 3.0
10 1.5 DKH-406 M / S / T 600 40 950 1.5
11 2 DKH-606 M / S / T 600 60 950 2.0
12 3 DKH-906 M / S / T 600 90 950 3.0
13 3 DKH-1006 M / S / T 600 100 950 3.0
14 1.5 DKH-307 M / S / T 700 30 950 1.5
15 2 DKH-507 M / S / T 700 50 950 2.0
16 3 DKH-807 M / S / T 700 80 950 3.0
Hence the pump selected Irom the catalogue was 3 DKH- 1006.
9. MOTOR

Now, the pump selected on the basis oI pressure and Ilow rate was 3 DKH- 1005.
To calculate the power required to run the pump,
We shall use the Iollowing Iormula:

Power, P H* Q (kW) ... (i)
102 *
where, H` is in meters; Q is in m
3
/hr
|The speciIic gravity oI pumpage is taken to be unity, since the Iluid to be pumped
is water. Hence it has not been mentioned in the Iormula.|
Now, Pressure, p 100 bar
Flow rate, I 600 l / hr
EIIiciency oI pump () is saIely assumed to be 80 .
, P H * 10 * Q (kW)
3.6 * 102 *
where, H` is in bar; Q is in m
3
/hr

P 100 * 10 * 0.6 (kW)
3.6 * 102 * 0.8
600 (kW)
293.76
2.0425 kW
Or
P (2.0425/ 0.746) hp
2.74 hp
2.28 hp


Now that the power oI the motor is known, we now move on to Iind the number oI
poles oI the motor. AC Induction Motors operating on 50 or 60 Hz are restricted to
a set oI synchronous speeds deIined by the number oI motor poles. The
synchronous speed oI an induction motor is governed by the Irequency oI the AC
supply and the number oI poles oI the motor.
It is governed by the Iormula given below:
N 120 * (I / n) ... (ii)

where ; N : Synchronous speed (rpm)
I : Frequency oI the AC supply (Hz)
n : Number oI motor poles

Now, we know Irom the parameters oI the selected pump that the maximum speed
oI the pump is 950 rpm. Hence, the motor to be selected should satisIy this
requirement.

Hence using this value in equation (ii), we shall Iind out the number oI motor poles
required Ior our application.

n 120 * (I / N)
120 * (50/ 950)
n 6.31
n 6 poles
Hence, it is now known that a hp, 6 pole ac induction motor is to be used
for the given application.
Since, the next available option Ior a standard 3 phase induction motor beyond 2 hp is
only hp, which is the power rating oI the motor we need to select.

The Iollowing catalogue shows the product range oI Laxmi Hydraulics Pvt Ltd, the
sole provider oI pump motor to DampI Kolben Pvt. Ltd.
Based on the calculations conducted above, we select the standard induction motor
Iitting the criteria.

Thus the motor selected has the Iollowing parameters :
Output kW .0
Output hp
Number oI poles 6
Frame size 11M
Speed 1000 rpm

The dimensions oI the motor so selected are as Iollows. Attached herewith is an
extract oI the company catalogue.





9. HOSE SELECTION
Now, the system parameters available with us Ior the selection oI the most
suitable hose are as Iollows:
Size
*
3/8 inches
Temperature Ambient temperature
Application High pressure discharge line
Material to be transported Water
Pressure 100 bar
End Closure Threaded
Discharge 600 lph

The Society oI Automotive Engineers (SAE) standardizes various hydraulic hoses
Ior automotive and stationary equipments usage. For low to medium working
pressure conditions, it recommends the SAE100 R1S - AT series.
The size of the hose for the high pressure discharge line automatically is fixed
due to the discharge port size of the pump. This is /8 inches.
Thus, the hose is selected using this parameter Irom the table attached herewith.


Fig 1. Hose Lines
Dash DN

Hose
D
(inch)

Hose
D
(mm)
Braid
OD
(mm)
Hose
OD
(mm)
Maximum
Working
Pressure
Minimum Burst
Pressure
Minimum
Bend
Radius
Weight
Meter
Kgs/mtr
MPa bar psi MPa bar psi mm
-3 5
3/16 4.8 9.5 11.5 25.0 250 3625 100.0 1000 14500 90 0.175
-4 6
6.4 11.2 13.2 22.5 225 3263 90.0 900 13050 100 0.225
-5 8 5/16 7.9 13.0 15.0 21.5 215 3118 86.0 860 12470 115 0.275
-6 10 3/8 9.5 15.3 17.3 18.0 180 2610 72.0 720 10440 125 0.350
-8 12 12.7 18.5 20.6 16.0 160 2320 64.0 640 9280 180 0.410
-10 16 5/8 15.9 21.8 23.9 13.0 130 1885 52.0 520 7540 205 0.520
-12 19 19.0 25.4 27.6 10.5 105 1523 42.0 420 6090 240 0.645
-16 25 1 25.4 33.2 35.3 9.0 90 1305 36.0 360 5220 300 1.000
-20 31 1-1/4 31.8 40.9 43.2 6.3 63 914 25.2 252 3654 420 1.280
-24 38 1-1/2 38.1 47.0 50.7 5.0 50 725 20.0 200 2900 500 1.650
-32 51 2 50.8 60.2 64.2 4.0 40 580 16.0 160 2320 630 2.290
-40 63 2-1/2 63.5 76.0 79.0 5.0 50 725 20.0 200 2900 760 2.940
-48 76 3 76.2 89.0 92 3.5 35 508 14.0 140 2030 900 3.380
-64 102 4 101.6 112.0 117.0 2.5 25 363 10.0 100 1450 1250 4.000

The highlighted row reIers to the selected high pressure discharge hose.
O Its maximum working pressure is 180 bar, while the required is 100 bar.
Hence, condition satisIied.
O Its working temperature range is established between -40
o
C to 100
o
C.
O Constructional details :

Lining is oI oil resistant synthetic rubber (nitrile). This ensures
working oI the hose in the presence oI oil.
One braid oI high tensile brass coated steel wire is used as
reinIorcement.
The cover uses an oil and abrasion resistant synthetic rubber.




9. PRESSURE GAUGE SELECTION
The basic selection oI pressure gauges is done on the basis oI the maximum
pressure attainable in the system. In this case, it will be 100 bar or 1450 psi.
Hence a suitable pressure gauge was selected. The details oI the above mentioned
are presented as under.




Make Wika Instruments
Model Number .5
Maximum Pressure 15000 psi or 100 bar
Sizes ,
1
/

,
Material 16L Stainless Steel


Fig 15.
Applications:
1. Liquid Iilled case Ior high dynamic pressure pulsations.
2. Suitable Ior corrosive environment.
3. All stainless steel construction.
4. Excellent load cycle stability and shock resistance.

9.5 PRESSURE TRANSMITTER SELECTION
As a means oI monitoring activity in a number oI manuIacturing Iacilities, marine
research, and general production control, a pressure transmitter will not only help
to ensure positive results; it also can be a great way oI maintaining acceptable
levels oI saIety. Here are some examples oI what a pressure transmitter is designed
to do and how it can be used in several diIIerent settings.
When it comes to the monitoring oI pressure within a Iactory setting, a pressure
transmitter helps to accomplish two speciIic goals. First, pressure instruments
monitor the amount oI pressure applied to a part oI the process that is required in
order to achieve the desired result. Since the application oI too much or too little
pressure may result in product that cannot be sold, constant real-time
measurements oI the pressurized environment is absolutely necessary.
In other manuIacturing applications, a pressure transmitter may be used to make
sure that no machinery is building up pressure that is beyond levels that are
considered saIe Ior the operators. Should a machine malIunction push the pressure
beyond acceptable levels, the pressure transmitter alerts the operator, who can take
steps to shut down the machinery and thus avert an industrial accident.
Pressure transmitters perIorm the important job oI making sure machinery and
equipment is working properly, as well as providing warning when pressures are
building to unsaIe levels.
The pressure transmitter is selected on the basis oI the maximum system pressure.
For our particular application, the system maximum pressure is 100 bar i.e. around
1410 psi.











Fig 16. Pressure Transmitter

10. SAFETY VALVE
O Pressure relieI valves are used as a saIety device to protect equipment
Irom over-pressure occurrences in any Iluid process. Loss oI heating
and cooling, mechanical Iailure oI valves, and poor draining and
venting are some oI the common causes oI overpressure.
O The relieving system depends on the process at hand; pressure relieI
valves either bypass a Iluid to an auxiliary passage or open a port to
relieve the pressure to atmosphere. Some areas oI common usage
include reaction vessels and storage tanks.
O In our application, we have used a Spring Loaded Pressure Release
Valve as the SaIety Valve.

O The spring is adjusted Ior a speciIic pressure setting. As long as the
system pressure is below the spring tension, the bypass remains close.
O When the system pressure increases, the hydraulic Iluid Ilows against
the opposing spring tension and opens the bypass valve.
O Hence, the pressure oI the system drops, thereby protecting the system
Irom the dangerous aItermath oI excess pressure in the system.

11. SUCTION FILTER

O This is one oI the most important parts oI the entire system. This is the
suction line Iilter.
O When dealing with the suction Iilters Ior pumps, one has to be careIul about
the exposure oI the Iilter to Iree air.
O In case the Iilter is exposed to air, and the air manages to get into the suction
line, it will leads to cavitation.
O Cavitation is a phenomenon wherein, the entrapped air leads to the
Iormation oI bubbles. These bubbles burst upon contact with the pump parts
and this bursting oI the bubbles causes an immediate pressuer gradientin the
surrounding region.
O Water Irom the surrounding high pressure region rushes in to Iill into the
low pressure area created.
O This sudden Ilow oI high pressure liquid leads to the withering oI the metal
parts and reduce the liIe oI the pump.
O In order to avoid cavitation, the air needs to be prevented Irom entering the
suction line.
O This is done by using a completely submerged Iilter.
O But in case oI normally submerged Iilters the chances oI air entering the line
are not completely eliminated. In case, due to any reason, the position oI the
Iilter changes, the chances oI exposure to air increases.
O To counter this particular problem, we needed to alter the existing available
Iilters designs.
O Hence we came up with a new design.






11.1 IMPROVED DESIGN
O The principle employed is explained as Iollows.

Fig 17. Filter Assembly
11.1.1 CONSTRUCTION
O The pump suction line is Iitted at the lowermost port. Let us call this port
A`.
O A perpendicular port admits water into the Iilter. Let us call this port B`.
O The Iilter is engulIed in a glass cover. Hence, when the water is admitted
into the Iilter, the entire region surrounded by the glass is Iilled with water.
O Another port is provided at the top oI the cover. Let us call this port C`.
O It allows the water to Ilow out through it. This arrangement ensures that no
air is preset in the glass entrapped region.
O The Iilter inside the cover is nothing but a Iilter oI mesh grade oI about 120
microns. It is cylindrical in shape.
11.1. WORKING

O The water enters the arrangement through port B` and Ilows out
through port C`.
O This ensures that there is no air inside the glass covered region.
O The water now passes through the Iilter mesh and the waste particles
are restrained outside the Iilter cylinder.
O Thus, Iiltered water enters through port A` to the pump.
11.1. FILTER COMPONENTS

Fig 18. Filter Cap

Fig 19. Cover Cap


Fig 0. Filter

Fig 1. Glass Shell

Fig . Cover end Cap


Fig . Cover Stud


1. BASE PLATE

O The entire assembly is to be mounted on a base plate.
O The base plate houses the pump and the motor assembly.
O Since both the pump and the motor are not Iabricated products, the mounting
bolt positions oI both were approximated Irom the respective manuals.
O Accordingly a base plate was Iabricated.
O The base also accommodates the control box that is mounted right next to
the motor as can be seen in the Iinal assembly images.


Fig . Base Plate



COST SHEET - FILTER

S
NO
ITEM QTY M O C MATERIAL
COST / KG
WT
(KG)
CONVERSION
COST (Rs)
TOTAL
UNIT
COST
1. UPPER
BODY
COVER
1 ALUMINIUM 300 100 200
. FILTER
CAP
1 FIBRE PLASTIC BO BO BO 150
. FILTER 1 FIBRE PLASTIC BO BO BO 800
. GLASS
COVER
1 ACRYLIC BOUGHT
OUT(BO)
BO BOUGHT OUT 300
5. LOWER
BODY
COVER
1 ALUMINIUM 300 105 300
6. STUD 4 STAINLESS
STEEL
240 30 100
7. AIR
PLUG
1 BRASS BOUGHT
OUT
BO BOUGHT OUT 700
TOTAL COST 550/-









1. VARIOUS SYSTEM CONFIGURATIONS

1.1 MANUAL APPROACH

O The pump is shown to be driven by a prime mover, in this case a 3 phase
induction motor.


Fig 5. Manual Layout
O The pump takes in the working Iluid, water in this case, through the low
pressure suction line, Irom the reservoir.
O Due to the pumping action, the water is pressurized and is discharged
through the high pressure discharge line.
O At this point the bypass throttle valve and the ball valve at the end oI the
pressure vessel are kept Iully open.
O The water is allowed to return back to the reservoir completing the loop,
since the ball valve is open.
O The above procedure will help remove the air Irom the system, so as not to
cause any cavitation.
O AIter all the air is removed, and crystal water starts Ilowing back in the
reservoir, the ball valve is to be closed completely.
O Under this scenario, the path oI least resistance to the in Ilowing water is
through the bypass, since the bypass throttle valve is Iully open.
O The system is yet not pressurized.
O The bypass throttle valve is now manually throttled till the desired pressure
is reached.
O As soon as the operator sees the desired pressure at the pressure gauge, he
manually shuts off the pump by cutting oII the supply to the motor.
O This process, since it involves manual operation and coordination, is unsaIe
and not precise.
O II due to some reason, the operator is late to cut oII the supply, the pressure
in the line will exceed the saIe values and in the worst case scenario, the
pressure vessel becomes prone to burst. This will lead to disastrous eIIects.


The above considerations lead to realizing the need to automate the system.
The details regarding that are mentioned as Iollows.




















1. AUTOMATED APPROACH



O The basic setup remains more or less the same as that explained above.

O When the system is to be automated, the basic logic that is to be worked is
that the responsibility oI the operator to shut oII the supply is to be
withdrawn.

O To accomplish this, a pressure switch or a pressure transmitter is used.

O Upon conducting the initial tests on the automated system using the pressure
transmitter, it was realized that when the system was dead ended, there
was sudden surge of pressure beyond the required system pressure.

O The surge so produced was two to three times the system pressure.

O Now, since this was the conIiguration was to be delivered; the problem oI
surge was needed to be dealt with.

O This problem was addressed by eliminating the dead end. Instead a
bypass with manual throttling was provided.

O Initially the bypass throttle valve and the ball valve at the vessel exit are
open until a clear stream oI water exits Irom the vessel.

O When all the air is removed, the ball valve is completely closed but the
bypass valve was open.

O Now the bypass valve is slowly closed, thereby pressuring the vessel and the
corresponding line up to the required the required pressure.

O Thus a bypass is shown inclusive in both the conIigurations.




1..1 PRESSURE SWITCH

O A pressure switch uses a mechanical spring, which compresses due to the
incoming pressure, thereby physically cutting oII the supply.


Fig 6. Automated Layout with Pressure Switch

O It is Iitted in the discharge line.

O The desired pressure is adjusted against the spring resistance. The moment
the desired pressure overpowers the spring stiIIness, the spring compresses,
thereby shutting oI the supply to the motor. An elaborate detailing is given
in the Iollowing pages.

O The pressure switch is an electro-mechanical component.










1.. PRESSURE TRANSMITTER


O Another approach used is the pressure transmitter.

O Here, both illustrations have been shown;
a) Dead Ended b) Bypass


Fig 7. Automated Layout with Pressure Transmitter (Dead Ended)

O In the above case, when the ball valve is closed, the pressure shoots up
irrationally.

O This is the pressure surge observed in the line.

O To overcome this diIIiculty, a bypass line was introduced with a manual
throttle.

O As seen in the Iigure below, when the ball valve is closed the bypass throttle
valve is adjusted slowly so that the line pressure increases gradually and
avoids the surge.

O The pressure transmitter will cut oII the motor supply when the pressure
reaches the system pressure.


Fig 8. Automated Layout with Pressure Transmitter (Bypass)


O In this case the desired pressure is Ied into the digital input oI the device.
When the desired pressure is reached, the transmitter relays the command to
the receiver at the motor end, thereby shutting oII the supply.

O The pressure transmitter is completely an electronic component.














1. CONTROL BOX

O Control Box Iorms the brain` oI the automated system.
O It encompasses the pressure transmitter and the motor.
O The signal Irom the pressure transmitter is Ied into the control box,
which is then transIerred to the relay.
O The pressure transmitter produces the signal when the system pressure
reaches the set value.
O The signal, so produced is either a diIIerential voltage or current.
O Based on this signal, the relay either cuts oII the supply to the motor
or connects the circuit to the motor.




15. COST SHEET

15.1 COST TO COMPANY
SR NO.

ITEM QUANTITY UNIT COST (Rs.)
1 PUMP 1 24,600
2 MOTOR 1 12,000
3 FILTER 1 1,500
4 BASE PLATE 1 1,500
5 SAFETY VALVE 1 1,800
6 INLET HOSE 1 1,000
7 DELIVERY HOSE 1 1,000
8 PRESSURE GAUGE 1 700
9 PRESSURE
TRANSMITTER
1 8,000
10 CONTROL BOX 1 9,000
11 NEEDLE VALVE 2 300
COST TO COMPANY 61,00/-

15. OVERHEAD COST
S NO OPERATION COST (Rs)
1. SYSTEM ASSEMBLY 1000
2. PAINTING 500
3. MISCELLENEOUS 750
OVERHEAD COST 50/-

TOTAL COST RS 6,650/-

16. RESULT TABLE
16.1 PRESSURE SWITCH

TRIAL NUMBER


SET PRESSURE
(IN BAR)


ATTAINED VALUE
(IN BAR)

1.


5


5

2.


10

12

3.


15

15

4.


20

22

5.


25

27

6.


30

31

7.


35

37

8.


40

42

9.


45

47

10.


50

52

16. PRESSURE TRANMITTER

TRIAL
NUMBER


SET PRESSURE
(IN BAR)


ATTAINED VALUE
(IN BAR)

CORRECTED
VALUE
(IN BAR)

1.


5


15

7

2.


10

30

14

3.


15

50

28

4.

20

75

40


5.


25

90

50

6.


30

105

70

7.


35

120

85

8.


40

130

90

9.


45

140

95


10.


50

150

100










17. RESULT GRAPHS
17.1 PRESSURE SWITCH

H. Pressure Switch Result
0
10
20
30
40
30
60
1 2 3 4 3 6 7 8 9 10

k
L
S
S
U
k
L

I
N

8
A
k
MAkIMUM kLSSUkL DLVIA1ICN
SL1 8LSSu8L (8A8)
A11AlnLu vALuL (8A8)
17. PRESSURE TRANMITTER


I. Pressure Transmitter Result
0
20
40
60
80
100
120
140
160
1 2 3 4 3 6 7 8 9 10

k
L
S
S
U
k
L

I
N

8
A
k
MAkIMUM kLSSUkL DLVIA1ICN
SL1 8LSSu8L (8A8)
A11AlnLu vALuL (8A8)
CC88LC1Lu vALuL (8A8)

18. OBSERVATIONS

O It was observed during the testing oI the dead ended system that in case oI
the pressure transmitter, there was a surge in the line.

O The surge however, is not very much evident in case oI a pressure switch.

O The system pressure would shoot up irrationally in case oI the pressure
transmitter. This value was way above the desired or the set` value.

O The cause oI the pressure surge was not known at the time and hence was
required to be Iound out.

O The reason Ior the surge in the line was narrowed down to the trip time delay
oI the pressure transmitter.

O Every measuring instrument or any instrument Ior that matter has an
inherent system response time or the trip time` delay.

O Thus, the delay time or the response time oI the instrument was adjusted or
reduced to zero. This was the lowest it could go as negative delay time could
not be set Ior the system.

O But it was observed that even upon adjusting the delay time oI the device to
the minimum i.e. zero, the surge in the line was not eliminated, however it
was diminished to a great extent.

O Since the system needed to be dispatched, the problem was surge was
countered by introducing a bypass throttle in the line. The details oI this
conIiguration are already above.

O The result table and the graphs supporting these Iindings are as displayed
above.

O The result table shows the readings oI both before and after the adjustment
oI the trip time delay oI the pressure transmitter.

O Although no such surges were encountered in the pressure switches, a major
drawback oI the pressure switches was that whenever the maximum system
pressure requirement was to be changed, it needed to be done manually by
adjusting the spring tension. As such its use becomes very cumbersome.
















19. FUTURE SCOPE
O The current problem oI surge was eliminated by introducing a manual
bypass throttle. Since this manual involvement also needs to be eradicated,
the bypass throttling is considered to be motorized and linked to the control
box. Hence, when the ball valve will be completely closed, a signal will be
relayed to the bypass throttle motor and it will rotate the throttle by the
required amount.

O The Pressure Transmitter suIIers Irom the problem oI pressure surge in the
system, although it is a digital instrument and is more accurate than the
pressure switch.

O Pressure switches show no surges in the line. Although the problem with the
pressure switches is that the spring tension needs to be manually adjusted
every time the system maximum pressure requirement changes. Also,
pressure switch is an analog instrument.

O Hence, to counter this problem it would be ideal to put together the positive
aspects oI both the instruments in one.

O Currently, along with the initiative and the support oI the company, we are
trying to digitize the pressure switch.

O The pressure transmitter is solely an electronic device while the pressure
switch is an electromechanical device.

O Hence, the mechanical output oI the pressure needs to digitized and a
mechanism needs to be put in place that will change the spring tension
automatically upon change in the system pressure requirement.

O The work on this is underway in the company as part oI the R&D, in order to
increase the saIety, productivity and reliability oI the system.

0. FINAL ASSEMBLY

Fig . DELIEVERY LINE PRESSURE GAUGE MOUNT

Fig . DELIEVERY LINE PRESURE TRANSMITTER MOUNT

Fig . DELIEVERY LINE SAFETY VALVE

Fig 5. COMPLETE DELIEVERY LINE MOUNTINGS





Fig 6. FRONT VIEW OF THE ASSEMBLY










Fig 7. TOP VIEW OF THE ASSEMBLY






1. BIBLIOGRAPHY

O KLM Technology Group Practical Engineering Guidelines Ior Processing
Plant Solutions.

O Hydrostatic Pressure Testing` Corr Tech Inc

O Energy EIIiciency Guide Ior Industry in Asia UNEP 2006

O Pressure Test SaIety Department oI Chemical Engineering, Health and
SaIety Executive

O General Purpose Pressure Transmitters Datasheet WIKA Instruments

O Technical Manual LHP Motors