Garlock Expansion Joint (MSDI-P13671)edge.rit.edu/edge/P13671/public/FinalDocuments/...hex bar 1-14", 1' length Purchase McMaster 6512K48 2 2 $ 17.52 $ 35.04 $ 35.04 McCormick purchased

GARLOCK EXPANSION

JOINT (MSDI-P13671)Final Presentation

Palmyra, NY

May 10, 2013

1

P13671

Members

Left to Right:

Allison Feinberg (Member)

Sam Kulpinski (Member)

Don Thompson (Member)

Wayne Evans (Customer)

Elspeth Ochs (Member)

Joseph Harkins (Team Lead)

Danny McCormick (Member)

Dr. Jason Kolodziej (Faculty)

2

PROJECT OVERVIEWCustomer Needs & Project Specifications

3

Introduction to P13671

Timeframe: Winter &

Spring quarter MSD

Objective: Design and

build rig to test Garlock

Expansion joints under

high temperatures and

actuation until failure

while logging data

P13671 - Garlock Expansion Joint 4

Customer Needs

5

CN

#

Importance Category Need

1.1 5 Test EJs Accommodate various EJ diameters

1.2 5 Test EJs at various temperatures

1.3 5 Axially displace EJ

1.4 5 Uniform temperature distribution throughout EJ

2.1 3 Maintenance Easy to change EJs

2.2 3 Able to change working fluid

3.1

1

Design for

Future

Accommodate various pressure (do not need to

demonstrate)

3.2

1

Accommodate various media (do not need to

demonstrate)

3.3

1

Accommodate health monitoring (do not need to

demonstrate)

4.1 5 Safety Must be safe to operate and maintain

5.1 5 Portability Movable to Garlock

Project Specifications

6

ESMeets

CNMetric Units

Targe

t

Preferred

DirectionComment

ES1 1.1 EJ diameters accommodated in 2-12 range customer to confirm

ES2 1.3 Displacement in ± 1 up

ES3 1.3 Cycles per test # 500 up

ES4 1.2 max Temp demonstrated ºF 400 up

ES5 1.2 System temperature tolerance ºF ± 5 down

Customer to confirm - how

accurately do you want to

control T?

ES6 1.4Uniform temperature

distribution of media within EJ°F ± 5 down

ES7 1.1, 2.1 Time to change EJ min 45 down customer to confirm

ES8 2.2 Ability to flush media Y/N Y n/a customer to confirm

ES9 2.2 Time to replace media min 45 down customer to confirm

ES10 5.1 Footprint sq ft 4x6 down Dr. Kolodziej to confirm

ES11 5.1 Fit through std double door Y/N Y n/a

ES12 4.1All identified safety issues

addressedY/N Y n/a

ES13 3.3LabView-based monitoring

and controlY/N Y n/a

Customer to confirm -

preferred or acceptable?

ES

143.1

Provide list of improvements

needed for futureY/N Y n/a

C1 Cost $ 5000 down

CONCEPT SUMMARY

7

8

9

BOM

10

Part Name Material Manuf.

Method

Manufacturer Manufacturer Part # Distributor Distributor Part # Quantity

Needed

Unit MFG

Time (hrs)

Total MFG

Time (hrs)

Quantity

Ordered

Unit Price Predicted Total

Price

Total Spent Lead Time

(days)

Owner Status Shipping Comments

3/4" zinc plated bolts Steel Purchased Hillam Group 397839 Lowes 397839 16 0 0 16 2.06$ $ 32.96 $ 32.96 0 McCormick purchased received

3/4" zinc plated nuts Steel Purchased Hillam Group 307090 Lowes 307090 16 0 0 16 0.38$ $ 6.08 $ 6.08 0 McCormick purchased received

3/4" ID zinc plated flat washers Steel Purchased Hillam Group 61702 Lowes 61702 42 0 0 42 0.32$ $ 13.44 $ 13.44 0 McCormick purchased received

1/2" OD flexible tubing plastic Purchased Watts 22273 Lowes 22273 3 0 0 3 0.32$ $ 0.96 $ 0.96 0 McCormick purchased received

1/2"-13 nuts Steel Purchased Hillam Group 63304 Lowes 63304 8 0 0 8 0.20$ $ 1.60 $ 1.60 0 McCormick purchased received

3/4" ID zinc plated flat washers Steel Purchased Hillam Group Home Depot 12 0 0 32 0.35$ $ 11.20 $ 11.20 0 McCormick purchased received

Filter Steel purchase Flow EZ Filters EZY Flow Y2-40micron MSC Direct 127 1 0 0 1 $ 40.60 $ 40.60 $ 40.60 0 Feinberg purchased received

Circulation Heater steel purchase Watlow Antech Sales CBLS717e3sj 1 0 1 $ 1,390.00 $ 1,390.00 $ 1,390.00 Feinberg purchased received

EZ sone PM PID controller purchase Watlow Antech Sales PM6c1cc-aaaaaaa 1 0 0 1 $ 210.00 $ 210.00 $ 210.00 0 Feinberg purchased received

Fast acting Fuse 1 amp purchase Watlow Antech Sales ATM1 1 0 0 1 $ 7.05 $ 7.05 $ 7.05 Feinberg Purchased received

Fuse holder purchase Watlow Antech Sales USM1 1 0 0 1 $ 8.95 $ 8.95 $ 8.95 Feinberg purchased received

Din-A-Mite Power Control purchase Watlow Antech Sales DB20-24c0-0000 1 0 0 1 $ 179.00 $ 179.00 $ 179.00 Feinberg purchased received

Semi conductor Fuse for item 2 purchase Watlow Antech Sales 17-8020 2 0 0 2 $ 10.00 $ 20.00 $ 20.00 Feinberg purchased received

Fuse Holder purchase Watlow Antech Sales 17-5110 2 0 0 2 $ 13.00 $ 26.00 $ 26.00 Feinberg purchased received

Nema 4 Hinged Enclosure Steel Purchase Watlow Antech Sales sce-12108elj 1 0 0 1 $ 93.75 $ 93.75 $ 93.75 8-Jun Feinberg purchased received

Backpanel Steel Purchase Watlow Antech Sales sce-12P10J 1 0 0 1 $ 7.70 $ 7.70 $ 7.70 5-Mar Feinberg purchased received

accumulator Steel Purchase McMaster 4222T1 1 0 0 1 $ 59.51 $ 59.51 $ 59.51 5 Thompson purchased received

flex hose - 24" Steel Purchase McMaster 5793T16 1 0 0 1 $ 62.02 $ 62.02 $ 62.02 5 Thompson purchased received

sheet metal scrap for adapter purchase Rochester Steel 1 0 0 1 $ 52.80 $ 52.80 $ 52.80 purchased received

Flow Sight ductile iron purchase McMaster 4213K152 1 0 0 1 $ 119.85 $ 119.85 $ 119.85 0 Harkins purchased received

A Series Cylinder 8" Stroke Purchase Numarics E3AW-08A1F-AAA2 Empire Automation E3AW-08A1F-AAA2 1 0 0 1 $ 681.29 $ 681.29 $ 681.29 McCormick purchased received

8" Bore Tie Rod Brackets Purchase Numarics sb6-w01 Rochester Steel sb6-w01 3 0 0 3 $ 7.07 $ 21.21 $ 21.21 McCormick purchased received

Hall-Sourcing Pigtail Switch Purchase Numarics SH6-021 Empire Automation SH6-021 3 0 0 3 $ 49.74 $ 149.22 $ 149.22 McCormick purchased received

Pin Connector Cable Straight-5 meter

Cable

Purchase Numarics PXCST Empire Automation PXCST 3 0 0 3 $ 25.66 $ 76.98 $ 76.98 McCormick purchased received

2035 S PRT B SE PLGN Purchase Numarics 354BB53AMN00061 Empire Automation 354BB53AMN00061 1 0 0 1 $ 159.12 $ 159.12 $ 159.12 McCormick purchased received

NGT 3/4 W/Flush MAN REL W/Flow

Control

Purchase Numarics B121FM-FL Empire Automation B121FM-FL 2 0 0 2 $ 110.50 $ 221.00 $ 221.00 McCormick purchased received

Legend Check valve Legend Empire Automation 105-303 2 2 $ 13.23 $ 26.46 $ 26.46 Kulpinski purchased

Legend Ball Valve 1/2" Purchase Legend Empire Automation 0 1 0 0 1 $ 4.87 $ 4.87 $ 4.87 Kulpinski purchased

Panel Build (PLC/HMI, programming,

accessories)

Purchase Unitronics Empire Automation EAS-RITPANEL-01 1 0 0 1 $ 2,010.57 $ 2,010.57 $ 2,010.57 McCormick purchased

hex bar 1-14", 1' length Purchase McMaster 6512K48 2 2 $ 17.52 $ 35.04 $ 35.04 McCormick purchased received

2"x2"x5" steel blocks for mounts Purchase Rochester Steel 4 1 ? 4 $ 21.21 $ 84.84 $ 84.84 purchased received

3"x4"x6" steel block (clevis attach) Purchase McMaster 8910K302 1 ? ? 1 $ 84.59 $ 84.59 $ 84.59 McCormick purchased received

Threaded rod, 1"-12, 3' length Purchase McMaster 92580A119 1 1 $ 21.32 $ 21.32 $ 21.32 McCormick purchased received

1"-8 2"L bolts, grade 8 Purchase Fastenal 190049308 8 $ 3.47 $ 27.76 $ 27.76 received

1" HR Plate (32"x32") Steel Purchase Klein Steel Driect Rochester Steel 3 0 0 3 $ 253.75 $ 761.25 $ 761.25 3 McCormick purchased received

1" HR Plate (32"x32") MACHINING Tulex 1 $ 1,499.00 $ 1,499.00 $ 1,499.00 0 Garlock Spent purchased received

Surplus Structral Hot Roll Drops Steel Purchase Klein Steel Driect Rochester Steel 1 0 0 1 $ 23.65 $ 23.65 $ 23.65 3 Fienberg purchased received

Shafts Steel Purchase 6061K68 McMaster 6061K68 4 0 ? 4 $ 142.34 $ 569.36 $ 569.36 Thompson purchased received

Heavy Duty Workbench Legs Steel Purchase 9956T26 McMaster 9956T26 3 0 ? 3 $ 59.12 $ 177.36 $ 177.36 purchased received

Left hand tie rod ends Steel Purchase 4543T29 McMaster 4543T29 2 2 $ 18.52 $ 37.04 $ 37.04 purchased received

Right Hand tie Rod Ends Steel Purchase 6066K51 McMaster 6066k51 2 2 $ 14.34 $ 28.68 $ 28.68 purchased received

Tie rods Steel Purchase 6606k89 McMaster 66066k89 2 2 $ 16.02 $ 32.04 $ 32.04 purchased received

EJ adapter Plate sheet metal, leg

reinforcements

Steel Water Jet Rochester Steel 1 1 ? 1 $ 52.80 $ 52.80 $ 52.80 purchased received

1/4 Sheet plexiglass-49.75 x 24 plexiglass Purchase Curbell curbell 1/4 Sheet plexiglass-

49.75 x 24

1 48 48 1 $ 44.63 $ 44.63 $ 44.63 Thompson purchased received

1/4 Sheet plexiglass-51 x 34.5 plexiglass Purchase Curbell curbell 1/4 Sheet plexiglass-51

x 34.5


1/4 Sheet plexiglass-51 x 23.5 plexiglass Purchase Curbell curbell 1/4 Sheet plexiglass-51

x 23.5


1/4 Sheet plexiglass-34.5x15 plexiglass Purchase Curbell curbell 1/4 Sheet plexiglass-

34.5x15


1/4 Sheet plexiglass-36x34.5 plexiglass Purchase Curbell curbell 1/4 Sheet plexiglass-

34.5x18


Slotted Angle-1 1/2"x60" Zinc plated Steel Purchase 4664t18 McMaster 4664T18 12 0 0 12 $ 8.87 $ 106.44 $ 106.44 Thompson purchased received

T-Handle Cam Latch, Right Steel Purchase McMaster 1210A51 4 0 0 4 $ 14.16 $ 56.64 $ 56.64 Thompson purchased received

T-Handle Cam Latch, Left Steel Purchase McMaster 1210A91 4 0 0 4 $ 11.93 $ 47.72 $ 47.72 Thompson purchased received

Testi

ng

(pre

-rig

)

Bill of Materials

Str

uctu

re/E

ncasin

gA

ctu

ati

on

Total Project Cost $ 5,607.47 RIT Spent $ 5,607.47

Remaining of

$6,500 budget $ 892.53

Garlock Spent $4,849.72

Project Cost (Garlock Buys Actuator) SPENT TO DATE

System Architecture

11

DESIGN SUMMARY

12

EJ Displacement Bench Test

• Held during the

preliminary design

phase in MSDI

• Determined if a pump

would be required

13

EJ Bench Test & Results

y = 0.0005xR² = 0.957

0

0.2

0.4

0.6

0.8

1

1.2

0 500 1000 1500 2000

EJ D

isp

lace

me

nt

(in

)

Load (lb)

Displacement vs. Load EJ

Test 1

Test 2

y = 613.64xR² = 0.9831

0

0.2

0.4

0.6

0.8

1

1.2

0 200 400 600 800

EJ D

isp

lacem

en

t (i

n)

Displaced water Volume (mL)

EJ Displacement vs. Displaced Water Volume

Test 1

Test 2

14

Conclusion:

No pump required since a sizeable amount of liquid was displaced with the

actuation of a 6” EJ

System Structure

15

Photo seen here is the

design as planned for DDR,

however the design changed

during the build phase of our

senior design term.

System Fluid

Soybean Oil

16

Properties

Viscosity 40 cP

Thermal Conductivity 0.098 Btu/hr*ft*°F

Specific Heat .47 Btu/lb*°F

Density 57.78 lb/ft3

Cost $25/ 5 gal

Thermal System Simulation

𝜌𝑉𝐻𝑐𝑝 𝑇𝐻 = 𝑚𝑐𝑝 𝑇𝐸𝐽 − 𝑇𝐻 + 𝑞𝐻

𝜌𝑉𝐸𝐽𝑐𝑝 𝑇𝐸𝐽 = 𝑚𝑐𝑝 𝑇𝐻 − 𝑇𝐸𝐽 − 𝑞𝑜𝑢𝑡

17

Heating Component CalculationsVariables 6” EJ

Dynalene Specific Heat Capacity, Cp (KJ/Kg-K) 1.5

Density of Fluid (kg/m3) 973.25

Volume (m3) 0.0115

change in temperature (°C) 170

Time to heat 1hr 30min 25min 20 min 15min 10min 5min

Power Required (kW) 0.793 1.586 1.902 2.378 3.171 4.757 9.514

EJ Size 2" EJ 2.5" EJ 3" EJ 4" EJ 5" EJ 6" EJ 8" EJ 10" EJ 12" EJ

Volume /displacement (m3/in) 0.001 0.001 0.002 0.003 0.005 0.007 0.012 0.019 0.027

Total system volume (m3) 0.006 0.007 0.007 0.009 0.010 0.011 0.015 0.025 0.034

cycle to move total volume 8.426 5.903 4.364 2.980 2.173 1.716 1.275 1.367 1.279

actuation cycle time (min) 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500

Time cycle system fluid (min) 4.213 2.952 2.182 1.490 1.086 0.858 0.638 0.683 0.640

Required kW to heat in 1hr 0.432 0.473 0.504 0.612 0.697 0.793 1.047 1.754 2.364

18

Heating Component

• 240V 3 Phase

• Wattage: 3 KW

• Thermostat: Digital PID Controller

with thermocouple feedback

• Inlet and Outlet: ¾”

• Heating Element: Steel

• Housing: Stainless steel

19

Actuator

• Numatics Large Bore A Series

• 8” Diameter Piston

• Cycle time dependent on air supply CFM

• Supplied by Empire Automation

• Unitronics PLC/HMI for control?

• Brochure

20

../unitronicsbrochure.pdf

FINISHED PRODUCT

22

Finished Product

23

Finished Product

24

Finished Product

25

Finished Product

26

Finished Product

YouTube Video: http://www.youtube.com/wat

ch?v=OlmQSdTbpi

27

http://www.youtube.com/watch?v=OlmQSdTbpi

SATISFACTION OF

CUSTOMER REQUIREMENTSNeeds and Specs vs. Finished Product

28

EJ Diameters Accommodated

• Spec: 2-12 in diameter

EJ’s should be

accommodated

• Result: Specially

machined slotted

plates coupled with EJ

specific adapter plates

enable the use of

various diameter EJ’s

29

Displacement

• Spec: ±1 in actuation

of the EJ

• Result: Pneumatic

actuator with 8 in

stroke enables the

actuation of all EJ’s at

least ±1 in

30

Cycles per Test

• Spec: 500 cycles per test

• Result: Over the course of one day completed

over 1000 cycles

31

Max Temperature Demonstrated

• Spec: 400°F

• Result: All components

of system selected

have a maximum

operating temperature

of at least 400°F

32

Uniform Temperature Distribution Within

EJ

• Ran test with specially made EJ with embedded

thermocouples that showed an even distribution

of temperature within the EJ to a tolerance of

±5°F

33

Time to Change EJ

• Spec: EJ can be changed in less than 45 min

• Result: Removable panels on the sides of the test

stand enable access to all sides of the EJ and

enable easy access to the bolts

• Can fully change EJ in less than 30 min

34

Ability and Time to Flush Media

• The fluid can be drained by opening the globe

valve below the EJ and opening the drain in the

bottom of the heater

• A new fluid can be added after flushing the

system by adding fluid through the accumulator

35

Size

• Spec: 4’x6’ and able to fit through a standard

double door

• Result: Rig has a 3’x5’ footprint and has a 3”

clearance through a doorway

36

Safety

• Plexiglas panels protect user from fluid splatter

• Insulation around heater and pipes prevent user

from coming into contact with hot surfaces

• Mechanical stops prevent plate from falling on

user during EJ change

37

LabView-based monitoring and control

• PLC and PID have options to connect to

LabView/Lookout

• Thermocouples in system can be connected to

LabView/Lookout for data logging

38

Provide list of improvements needed for

future

• Included with test stand is an information packet

detailing operational and maintenance

procedures as well as any improvements that can

be made to accommodate higher pressures as

well as abrasive media

39

Cost

• Spec: $5000

• Final Result: ~$10,000

40

PROJECT OBJECTIVE

EVALUATIONSuccesses vs. Failures

41

Successes

• Fluid successfully pumped via actuation

• Fluid heats to 400°F with a uniform temperature

distribution

• Test stand is reliable and has run over 4000 cycles to date

42

Failures

• Overlooked small details with hardware and pipe sizing

leading to lost time and purchasing more than we needed

• Trapped air in the heater and EJ

• Overestimated amount of support from heater supplier

43

FUTURE OPPORTUNITIES(Or suggestions for future work, things we would’ve

done differently, lessons learned)

44

Questions?

45