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Gardner Denver

Gardner Denver. Test Pump. Pump Head. Assembly & Structural FEA. Pump Head. Design Modeled after Gardner Denver 5” GWS fluid cylinder assembly (HOPI) Pump & Features are scaled to 40% of original size Material AISI 4330 Modified Steel. Components. 3. 4. Pump Head Assembly Pump Head-

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Gardner Denver

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  1. Gardner Denver Test Pump

  2. Pump Head Assembly & Structural FEA

  3. Pump Head Design • Modeled after Gardner Denver 5” GWS fluid cylinder assembly (HOPI) • Pump & Features are scaled to 40% of original size • Material • AISI 4330 Modified Steel

  4. Components 3 4 Pump Head Assembly • Pump Head- • End Cap- • Top Cap- • Outlet- • Inlet - 1 1 2 3 2 4 5 5

  5. Pump Head Pump Head FEA • Test Parameters • 280,000 elements • Max pressure of 5000 psi applied to the wetted surfaces • Bolt holes axially constrained • Connecting face fixed • Material • AISI 4330 Modified Steel

  6. Pump Head Pump Head FEA Test Results • AISI 4330 Modified Steel • 0.2% Offset Yield Strength • 100,000 psi • Ultimate Tensile Strength • 125,000 psi

  7. Pump Head Pump Head FEA Test Results • Maximum Stress • Von Mises ~ 28 ksi • Safety Factor ~ 3.5 • Maximum Stress at location of fracture of full scale pump

  8. Simulated Test Conditions Pump Head FEA • Pump head components were tested to withstand a maximum pressure of 8000 psi, “worst case” scenario

  9. End Cap Pump Head FEA • Test Parameters • 65,000 elements • Max pressure of 8000 psi applied to the face of the end cap • Bolt holes axially constrained • Material • 17-4 PH Stainless Steel • Modulus of Elasticity – 28,500,000 psi

  10. End Cap Pump Head FEA Test Results • 17-4 PH Stainless Steel • 0.2% Offset Yield Strength • 180,000 psi • Ultimate Tensile Strength • 195,000 psi

  11. End Cap Pump Head FEA Test Results • Maximum Stress • Von Mises ~ 90 ksi • Safety Factor ~ 2

  12. Top Cap Pump Head FEA • Test Parameters • 57,000 elements • Max pressure of 8000 psi applied to the inner face of the outlet • Bolt holes axially constrained • Material • 17-4 PH Stainless Steel • Modulus of Elasticity – 28,500,000 psi

  13. Top Cap Pump Head FEA Test Results • 17-4 PH Stainless Steel • 0.2% Offset Yield Strength • 180,000 psi • Ultimate Tensile Strength • 195,000 psi

  14. Top Cap Pump Head FEA Test Results • Maximum Stress • Von Mises ~ 40 ksi • Safety Factor ~ 5.5

  15. Outlet Pump Head FEA • Test Parameters • 52,000 elements • Max pressure of 8000 psi applied to the inner face of the outlet • Bolt holes axially constrained • Material • 17-4 PH Stainless Steel • Modulus of Elasticity – 28,500,000 psi

  16. Outlet Pump Head FEA Test Results • 17-4 PH Stainless Steel • 0.2% Offset Yield Strength • 180,000 psi • Ultimate Tensile Strength • 195,000 psi

  17. Outlet Pump Head FEA Test Results • Maximum Stress • Von Mises ~ 20 ksi • Safety Factor ~ 9

  18. Inlet Pump Head FEA • Test Parameters • 64,000 elements • Max pressure of 8000 psi applied to the inner faces of the Inlet • Bolt holes axially constrained • Material • 17-4 PH Stainless Steel • Modulus of Elasticity – 28,500,000 psi

  19. Inlet Pump Head FEA Test Results • 17-4 PH Stainless Steel • 0.2% Offset Yield Strength • 180,000 psi • Ultimate Tensile Strength • 195,000 psi

  20. Inlet Pump Head FEA Test Results • Maximum Stress • Von Mises ~ 66 ksi • Safety Factor ~ 2.7

  21. Bolted Connections Pump Head Assembly • Using the stresses calculated in the finite element analysis, bolts and O-rings where chosen • Bolts • Black-Oxide alloy steel • Comparable to Grade 8 steel • Maximum tensile strength – 180,000 psi • O-rings • Buna-N Hard O-rings • PTFE Split backup rings

  22. Fluid Block Assembly

  23. Components 1 • Fluid Block- • Stuff Box- • Brass Seal- • Pump Ram- • Pump Collar- Fluid Block Assembly 1 2 3 2 4 4 5 3 5

  24. Pump Cage Assembly & Structural FEA

  25. Components 1 • Fluid Block- • Pump Face - • Back Plate- • Side Plate x2- Pump Cage Assembly 1 2 2 3 4 4 3

  26. Pump Cage Pump Cage FEA • Test Parameters • 88,000 elements • 28000 lbfapplied to back plate of the cage • Bolt holes axially constrained • Material • Mild Steel

  27. Pump Cage Pump Cage FEA Test Results • AISI 1020 Steel • 0.2% Offset Yield Strength • 48,000 psi • Ultimate Tensile Strength • 65,000 psi

  28. Pump Cage Pump Cage FEA Test Results • Maximum Stress • Von Mises ~ 22 ksi • Safety Factor ~ 2.5

  29. Full Assembly Assembly

  30. Full Assembly Cage & Simplex Pump

  31. Full Assembly Cage, Simplex Pump & Fluid Block Assembly

  32. Full Assembly Cage, Simplex Pump, Fluid Block Assembly & Pump Head Assembly

  33. Completed Parts • Pump Head Assembly • Top Cap • End Cap • Inlet • Outlet • Fluid Block Assembly • Stuff Box • Brass Seal • Pump Ram

  34. Completed Parts • Fluid Block Assembly • Fluid Block • Pump Collar • Pump Cage • Pump Face • Back Plate • Side Plate X2

  35. Summary • All parts were tested to withstand a “worst case” scenario and passed • Sensors blah blah • A __ cycle time was achieved using __ hydraulic pump • Test bed proves to be able to move on to the next phase of project • Next phase – machine the pump heads and apply different coatings to test corrosion resistance

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