Our Project
Welcome to our portfolio. From experimental passion projects to commissioned work for clients, our Group had the opportunity to create a project for this industry. our group thrives on creative challenges and enjoys building strong relationships along the way. In this project, we focussed on the drainage system of oil on transferring it back into its holding tank in the Oil Testing POU Mechanism. Explore our work below.
Oil Test POU System
The Oil Test POU (Point Of Use) system involves the complete design of a testing system for an assigned mechanism in the factory space, which checks for leaks in various heat exchange tubing units. They are used to check for the leaks that can occur at multiple parts of the units like gasket leaks, roll leaks, weld leaks, and joint leaks. The heat exchange units have 2 parts which are tested separately through similar processes. These parts include the heat exchange unit’s shell and the heat exchange unit’s tubing, which are shown in the figure below.
This system has 2 parts: The first focuses on filling the heat exchange unit with oil and pressurizing the unit to take note of any possible leaks. The second focuses on draining the oil from the unit and back into the initial tank. The original system was able to complete both parts without the need for external additions. However, at some point, the draining system stopped working. For this project, our task focuses on designing a drainage mechanism to improve upon the system which is currently being used to test the units.
Point of Use System Leak Tests
A leak test is used to find weak points in a product and to enhance its construction. The test is carried out under high pressure to see whether a pressure drop has occurred due to an accidental crack or hole.
Goals of the tests:
•Improvement of seals
•Identify the weak spot of a pressure component
•Determine min and max burst pressure
•Defining the product specifications
In order to meet safety and quality requirements, leak checks are often conducted prior to the delivery process. While many of the leak tests are damaging, there are some forms of leak tests that do not result in out-of-service parts:
•Test on leaks of repaired parts
•Check of leak tightness on connections
•Check of seal alignment
Our recorder systems or computer-controlled systems may record the pressure drop, and the test results are presented on certificates.
Pressurizing with gas is another form of leak testing. A gas leak can be detected with a gas detector sensor or by submerging the pressurized object in water and looking for bubbles.
Alternate Methods for detecting leaks in Heat Exchangers
Ultrasonic leak detection has been used for a wide range of purposes, including energy conservation by detecting compressed air leaks and quality assurance inspections such as locating wind noise and water leaks in automobiles. Understanding the essence of what types of leaks emit detectable ultrasound and what types do not, as well as the techniques that can be used for successful leak detection, is the key to success. Once learned, there are times when the detection limits can be increased to aid in the detection of a leak in difficult circumstances.
Typically, ultrasound leak detection is used to locate leaks where the pressure differential is enough to produce a turbulent flow as the gas moves from the high-pressure to the low-pressure side of a leak. One of the benefits of ultrasound is that it can detect leaks in several fluids. Leaks in all types of gas and fluid structures can be detected using this technology.
Improved Draining System
Group's Proposed Design fo the Drainage System.
The Point Of Use POU mechanism to which this group has been assigned has a draining system that requires modification and is not the original design of the system. Our goal is to improve on the system modifications that have already been made in order to make the system more efficient.
We are considering in our design to replace the existing pump with a stronger pump as well as increase the length of the return hose as to our client's requirement, which is meant to eliminate the need for the intermediate container and lower the amount of time it takes for the oil to be pumped back into the initial holding tank.
EndNote
The project's goal is to identify the major causes of the inaccuracies in the Oil test drainage system. Our long-term goal is to achieve and maintain a first-count accuracy rate of more than 90%. The goal of this design is to improve our understanding of how we made decisions and how successful they were in a factory setting. We will make progress toward our end goal, as we did under the excellent mentorship of our sponsor. Our group will receive the following deliverables when the project is completed in the first half of May. An efficient redesigned oil testing mechanism with a drainage system that saves them time and has fewer parts attached to the system results in low upkeep costs and a decade of service life.