1. Jake Manley-Project Lead/EE Mitchell Sedore-ME Brian Benner-ME Anushka Kalicharan-ME Kyle Abbott-ME

2. Agenda Project Background Problem Statement & Deliverables Current Vs. New System Stakeholders Standards List of needs Customer requirements Engineering requirements House of Quality Project Plan

3. Problem Statement The 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.

4. 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)

5. 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

6. 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

7. New Hydrostatic Test Apparatus Programmable Digital Interface Hold time, Pressure, Ramp rate Automated test system Data logging capabilities for external PC Future Labview Integration Retain existing hydraulic pressure sources

8. Project Deliverables Hardware Complete onsite test apparatus Documentation Maintenance Recommendations Model for fatigue predictions User guide for operation Engineering Drawings

9. Stakeholders Cooper-Crouse Hinds Joe Manahan Lab Technicians Secondary Customers RIT MSD Group Ben Varela Mike Zona

10. Customer Requirements Customer Rqmt. # ImportanceDescription CR19Programable Digital Interface CR29Test Automation complies with Standards CR39Future Labview Integration CR49Control of Target Pressure CR59Control of Hold Time CR69Control of Ramp Rate CR79Ability to Interface with Current Cooper Product Line CR89Safe Test Enviroment CR99Ability to Aquire Data from Test CR103Use of Pressure Transducer(s) CR113Mantainence Recommendations CR123Model for Fatigue Prediction CR133Complete Apparatus for On-Site Testing CR143Engineering Drawings CR153Operating Manual CR163Maintanence Manual CR173Cost approx $6000

11. Engineering Requirements Rqmt. #ImportanceSourceFunction Engr. Requirement (metric) Unit of Measure Target Value/Range S19CR2 Withstand Maximum Internal System PressurePSI10000 S29 UL1203 & UL2225 Pressure Ramp RatePSI/Min100-600 S39PRP Maximum Pressure in EnclosurePSI10000 S49UL1203 Minimum Pressure in EnclosurePSI>50 S59UL1203 Maximum Conduit Trade Sizein1/2" S69UL1203 Minimum Conduit Trade Sizein1 1/2" S79UL1203 Hold Time for 4X Max Internal Explosion PressureSec10 S89US1203 Hold Time for 1.5X Max Internal Explosion PreassureSec>10, <60 S99 Customer Interview Ability to Alter Test Parameters MidtestBinary S109CR15 Number of Analog Outputs for Data LoggingDecimal8 S119 Store Peak Pressure Value Before FailureBinary S129CR16 Emergency StopBinary S139PRP Test Controlable Outside Explosive Proof AreaBinary S143 Reaction time of ValveSec<2 S153 Maximum Dimensionsft (L x W x H5 x 2 x 3

12. House of Quality

13. Preliminary Schedule

14. Questions?