Senior Design: Validation of Design

1. Senior Design:Validation of Design December 15, 2008

2. What’s a Seal? A mechanical device used to prevent leakage from pumped fluids along a drive shaft. Mechanical seals increase efficiency and reliability of pumps.

3. John Crane • Designs and manufactures seals for the oil & gas, chemical, pharmaceutical, pulp & paper and mining sectors. • These seals can range from 20lbs to 1000lbs.

4. Purpose • As industrial equipment becomes increasingly large, so do the mechanical seals that John Crane maintains • John Crane needs a work station that can accommodate these large seals and aid in the lifting, assembly, disassembly, testing, and cleaning of them

5. Needs/Wants Needs: • A workbench to withstand the maximum weight of a mechanical seal (approximately 1000 lbs.) • Be able to translate parts coaxially for assembly and disassembly Wants: • Be able to rotate and translate seals as to aid in the ease of assembly • To lift the mechanical seal from a crate onto a workbench From here, the needs and wants were broken down into a detailed list of metrics that was approved by our sponsor

6. Preliminary Concepts Concept B Concept A Concept C

7. Concept Selection • Many concepts created for each subsystems • Combined to make three overall concept • Ranked against design metrics • Concept A received highest score

8. Project Design Back View Horizontal Seal Vertical Seal Front View

9. Project Design

10. How it Works

12. Support Frame • Support the weight and moment of the mechanical seal • The top bar supports the pulleys and winch that attach via wire to the slider bar • The large plates have holes so that the structure can be bolted to the floor

13. Slider Bar and Trolley System • Pulley system provides the vertical movement of the slider • Rotating fixture attaches to center of slider • Trolleys (not shown) fit inside column of frame

14. Rotating Fixture (RF) • Attaches to slider bar using two bearings • Utilizes motor, speed reducer and set of worm gears • Rotates at approximately 1 RPM

15. Tracks and Carriages • The tracks will be attached to rotating fixture • Allows for both large translations and fine translations • Connects to V-Clamp and IDS via a universal connection • Each carriage is rated for 400 lbs

16. V-Clamps • As thread base is turned, clamp converges to center point • 6 points of contact provide for moment resistance • Multiple sets may be used during removal from crate

17. Inside Diameter System (IDS) • Eight identical slider cranks • Sliders utilize an acme thread to translate along the seal’s axis • Rubber coated feet grip the seal and hold the seal while articulated

18. Scope Reduction • After the completion of the detailed design, the scope was reevaluated • Manufacturing reduced to clamping mechanisms only

19. Adjusted Needs/Wants for Clamping Mechanisms Needs: • IDS cannot damage inner diameter of sleeves • V-Clamps must support the weight of a seal if the bench fails and the seal is dropped Wants: • Create a clamping machine to hold seals from outer diameter • Create a clamping machine to hold seals from inner diameter • A way to keep seals stationary to resist torque for the disassembly

20. Deliverables • Built and tested V-Clamps and IDS • A complete design package • Operations manual

21. V-Clamps

22. V-Clamps (continued)

23. IDS

24. IDS (continued)

25. Testing – V-Clamp • Size Test • Purpose: Verify that the V-Clamp can accommodate seals from 8” to 20” • Method: Place an 8” and 20” seal in clamp • Result: Pass

26. Testing – V-Clamp • Support Test • Purpose: Verify that the clamp can support 400 lb • Method: Place increasingly heavy steel slugs in the V-Clamp • Result: Pass

27. Testing – V-Clamp • Support Test (continued) Seal = 118 lb Seal + Matt = 280 lb Seal + Matt + Bill = 440 lb

28. Testing – V-Clamp • Impact Test • Purpose: Verify that the V-Clamp will not drop seal, even if the carriage is left unsecured • Method: Place a steel slug in the V-Clamp; drop weight; measure slug displacement • Results: Maximum displacement was 1/2 inches

29. Testing – IDS • Size Test • Purpose: Verify the seal diameter range that the IDS accommodates • Method: Use calipers to measure fully open and fully closed seal • Results: The size range is 5 1/8” to 6 3/8”

30. Testing – IDS • Horizontal Support Test • Purpose: Verify that the IDS can support 30 lb held horizontally • Method: Place a steel slug on the IDS • Results: Pass

31. Testing – IDS • Vertical Support Test • Purpose: Verify that the IDS can support 30 lb held vertically • Method: Place a steel slug on the IDS • Results: Pass

32. Cost Analysis Prototypes V-Clamp material: $1,271 IDS material: $1,522 Welding: $520 Total: $3,413 Complete Workstation (Estimated) Frame: $6,090 RF: $2,150 Carriages: $4,930 V-Clamp: $1,670 IDS: $1,540 Assembly: $4,000 Total: $20,380

33. Project Schedule

34. Plan Forward • V-Clamp • Can be used as is on workbench • Replace thread with a twin lead thread • IDS • Can be used as is on workbench • Make links shorter • Add tracks to improved torque resistance • Workstation • Deliver drawing package (us) • Build workstation (John Crane) • Integrate built V-Clamp and IDS into workstation • Use to repair large seals

35. Questions?