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Portable Hydraulic Relief Valve Test System

Tajinder Singh, and Amar Shah

Project 2 ME 316 October 2011.

Basic Information. In this project we are have to design and go through the preliminary design aspect for a Portable Hydraulic Relief Valve Test System. The Puget Sound Naval Shipyard and Intermediate Maintenance Facility wants us to design and develop a hydraulic test system that is portable, compact, and reusable so that they are able to remotely test pressure relief valves. The Puget Sound Naval Shipyard and Intermediate Maintenance Facility needs to be able to provide and verify relief valve and that they are under operational condition, the key is the quantity of valve and the distance required when testing these valves is very time consuming, as well as possible damage and loss during transport from shop to the testing location. A portable testing system would eliminate the additional time required as well as minimize the damage and or loss to the valve from shop to testing location. Since the valve testing system is sensitive to movement, by keeping it portable on the ship or on the testing location we minimize the probability of damaging it as well as the system being able to report accurate results during a test. Client

Puget Sound Naval Ship Yard 1400 Farragut Ave # 850 Bremerton, WA 98314-5001 (360) 476-3711
Team Member Amar Shah Tajinder Singh

General Specifications 1. Maximum weight of no more than 150lbs. 2. Up to 90psi of pressurized air 3. Power Source 120V Thermal Specifications 1. Must have a temperature of 135F 2. Oil should reach desired temperature with 4-6 minutes 3. Temperature gage to see what temperature oil is at. 4. Safety power control switch Oil Specifications 1. Must be able to hold at least 7 gallons of oil 2. Device to measure oil parameters 3. Must be able to bring oil to 3,000psi. 4. Automatic control switch 5. Connections must be able to withstand oil pressure.

Other Specifications 1. Oil must have a pressure head to attain given height. 2. All supplies must be portable and contained. 3. Needs to be mobile 4. Must be easy to operate by a single person. 5. Must include filter system that will prevent debris in oil from jamming system Conceptual Design

Function Structure In the conceptual design portion of the Portable Hydraulics Relief Valve we initially created a function structure with all sorts of idea that could potentially help us construct this testing system. If you follow our function structure you will notice that we started out with three main structures which would be signal, mass, and energy. The mass is the oil which is in the testing container. The testing container is connected to the pressure gage and the temperature gage which would control what the pressure is in the container and the temperature. The power control box is connected to the power source and provides power to the other functions. We also have a safety cut of list that would cut the power in case the pressure or the temperature become too high and would risk an explosion. We also have storage for additional oil just in case there is an overflow of oil, this would prevent a leak into the rest of the system.

Concept 1 Lifetime Cost Maintains Size Operations Reliable Efficiency Concept 2 Lifetime Cost Maintain Size Operations Reliable Efficiency

Tank + + + + + + Tank + + + + + +

Electrical Heat + + + + Electrical Heater + + + + -

Pump + + + + + + + Pump + + + + + + +

Digital Gage + + + + + + + Analog Gage + + + -

Automated Switch + + + + + Automated Switch + + + + +

Preliminary Design Our initial design was to take a tank with hydraulic oil and able to heat to the given temperature and to reach the given pressure or use the attached gear pump with motor to successfully test the relief valve. . A steel tank with thermometer is welded to the top of a portable base. We achieve this by using a simple cylinder tank attached to the base oil reservoir on one side and connected to two valves on the other side. One of them is to be tested and the other one is to ensure pressure doesnt exceed 3000psi. The attached CAD model represents our portable testing system. We also did static simulation on the cylinder for various thicknesses above 3000psi to find out the minimum value of thickness required. The test valve can be covered by
sliding the cover above them in order to save the splash of oil in case valve starts leaking. Base helps to easily transport it from one place to another. Motor assures that we maintain a constant pressure head. Portable cylinder with a heating coil has been used for maintaining a minimum temperature of 135F.

Figure 1: The Preliminary Design of Oil Tank

Figure 2: The Preliminary Design of Oil Tank

Feasible Study

Range on the side in the above figure shows the color corresponding to the individual stresses. Throughout the surface of the cylinder you can see that pressure never goes above on an average of 20MPa (2800psi). Our testing pressure is 3000psi and the cylinder can easily hold up to 4500psi which gives us a safety factor of almost 1.5.

. Displacements are shown on the scale are of the range of around .6mm. These displacements are not noticeable to the actual eye. Such level of displacements will not affect any process during the course of testing. Life of this system is around 5-10 years.

5.1Vendor List:

McMaster-Carr Atlanta www.mcmaster.com Grainger www.grainger.com Northern Tool and Equipment Automation Products Group Inc (APG) http://www.apgsensors.com/ http://www.northerntool.com/

www.valve-world.net/srv www.prentex.com/high_pressure_vessels.php

5.2 Part Cost

Parts List Analog Pressure Gage Hydraulic Fittings Hydraulic Pipe Top Plate Brackets Check valve Relief valve Filtration system Coarse filter Funnel Sleeve Funnel Funnel support Hydraulic Gear Pump Electric Motor Tank with thermostat and thermometer Test Valve

Number Needed misc misc 1 2 1 1 1 1 1 1 1 1 1

Color 1 grey grey brown grey blue grey pink grey grey grey black and red yellow grey

Vendor APG McMaster McMaster fabricate fabricate Grainger McMaster McMaster fabricate fabricate McMaster fabricate McMaster McMaster Grainger supplied by customer total estimated cost

Estimated Cost 250 150 50 25 25 50 200 180 40 20 30 10 150 250 350 0 $1,780

1 grey 1 red

An estimated guess for the labor that might be required is a minimum of 2 hours at a rate of 40$/hr. Therefore the labor cost is 40*2=80$. Total comes out to be 1780+80=1960$.