HELITORCH VALVE MecE 460 Capstone Design Project Winter 2015 Brett Haldane Robert Klikach Thomas Reitsma Adam Wasyliw Cynthia Ying
Outline Background Design Objective Conceptual Design Concept Selection Final Design Design Analysis Cost Summary
Background Client: FP Innovations Forestry & Emergency Response Division Fire Operations and Helitorches Problem: Helitorch Valve gets stuck Images provided by client
Outline Background Design Objective Conceptual Design Concept Selection Final Design Design Analysis Cost and Schedule Summary
Design Objective Client vision of the helitorch valve: Highly reliable shutoff ( 100% ) Jam-free operation Key Specifications: Produces less than 20 kpa Pressure drop Operating at flow rate of up to 20 L/min 57 L/min Fits in the existing torch valve casing Easy to assemble and field-fixed
Design Objective Existing Valve Schematics:
Outline Background Design Objective Conceptual Design Concept Selection Final Design Design Analysis Cost Summary
Conceptual Design Concept 1 Modification of Existing Valve Concept 2 Inline Ball-Spring Valve Concept 3 Dual System Ball-Plug Valve
Concept 1: Modification of Existing Valve Central Guiding Rod Conical Compression Spring Dynamic Plunger ¾ THRD Inlet Connection Outlet Attachment Bottom Nut
Concept 1: Modification of Existing Valve Grooves to secure spring position Fixed-ends guiding rod for plunger alignment Fits in existing casing Easy Installation
Concept 2: Inline Ball-Spring Valve Dynamic Rod and Ball Plunger Spacer and Spacing bolts Valve body with ¾ THRD Inlet Spring Sleeve and linear spring Backing Plate
Concept 2: Inline Ball-Spring Valve Inline flow creates even pressure distribution Eliminates bending moments on the rod Fits in existing casing geometry Easy to assemble
Concept 3: Dual System Ball Plug Valve Climbing Rack Mechanism with idle gear Ball Plug Linear Spring Valve body with ¾ THRD Inlet 24V DC Motor attached to the casing Frontal cover removed to show climbing rack mechanism
Concept 3: Dual System Ball Plug Valve Electrical driven climbing rack mechanism Reinforces opening Increase Reliability Spring backup system to ensure operation Compatible with existing casing
Outline Background Design Objective Conceptual Design Concept Selection Final Design Design Analysis Cost Summary
Concept Selection Evaluation against key specifications Dimensions Weight Pressure Drop Ease of Installation Ease of Field Fix
Concept Selection & Final Design Original Concept 1 Final Design
Final Design Dynamic plunger (Ball-shape) Dynamic plunger (Disc-shape) Longer bolt with threads exposed to the heat and flow Shorter reversed bolt with threads away from heat and flow Flow-disrupting flow outlet Bolt fixer integrated with valve body Nozzle to remedy the flow outlet
Final Design - Materials Part Housing Outlet Attachment O-Ring Plunger Material A316 SS A316 SS Viton Teflon Brass Material Coefficient of Friction Brass 0.35 Teflon 0.2
Outline Background Design Objective Conceptual Design Concept Selection Final Design Design Analysis Cost Summary
Analysis Fluid Sample Pump Data Flow Characterization CFD Existing Valve CFD New Valve FEA New Valve Sizing O-Ring & Spring Fatigue and Preload
Analysis Flow Characterization
Analysis CFD Original Valve New Valve
Analysis CFD
Analysis Fatigue Loading Condition Internal pressure build up =110 kpa Top disc and valve body separation S.F =1.5 Maximum Load = 401.6 N (used in FEA) Mean Load = 344.2 N Alternating Load = 57.4 N Infinite cycles of loading Fatigue Safety Factor 11.1 for Bolt 4.03 for Nut
Analysis Preload Torque = 0.364 N m Preload = 401.6 N
Analysis FEA Bolt Fixer Tab Original Configuration Material: AISI 316 SS Yield Strength: 172.37 MPa Force Applied: 401.6 N Safety Factor Against Deflection Yielding
Analysis FEA Bolt Fixer Tab Final Configuration Material: AISI 316 SS Yield Strength: 172.37 MPa Force Applied: 401.6 N Safety Factor Deflection Against Yielding
Outline Background Design Objective Conceptual Design Design Selection Final Design Design Analysis Cost Summary
Cost Item Estimated Valve Pricing Cap Screw, nut, washer 3 Spring 10 ¾ Viton Gasket 1 1½ Viton Gasket 1 305mm length of 1½ Ø 316 SS round bar 40 305mm length of 1½ Ø 464 Naval Brass round bar 80 Labour: 8 hrs estimated machining time, $100/hr 800 Total per valve 935 Estimated Price ($CAD)
Outline Background Design Objective Conceptual Design Design Selection Final Design Design Analysis Cost Summary
Summary New Helitorch Valve: Fits in existing casing; 17.7 kpa Pressure drop Easy to assemble and replace parts Future work Accurate characterization of fluid Validate simulation results using prototype
Acknowledgement Tsegay Belay, Faculty Advisor, University of Alberta Katherine Evans, Course Coordinator, University of Alberta Roger Marchand Mark Ackerman Dave Finn Roy Campbell
References Brookfield Engineering. Rheology Papers. n.d. 03 2015, http://www.brookfieldengineering.com/education/rheology_papers_benchmark_products.asp. Carey, Jason. "MECE 360 Engineering Design II" 2014. D, Raboud. MECE 403 Mechanical Engineering Lab II. 2014. Dahlgren Division, Naval Surface Warfare Center. Identification and Development of a Gelled Fuel Through the Use of Liquid Gelling Agents. Government Research. Dahlgren, Virginia, 2008. DuPont Corporation. "DUPONT HANDBOOK." n.d. ww.rjchase.com/ptfe_handbook.pdf. 2015. Engineering Toolbox. Engineering Toolbox. n.d. 03 2015, http://www.engineeringtoolbox.com/friction-coefficients-d_778.html Groover, Mikiell P. Fundamentals of Modern Manufacturing: Materials, Processes, and System; 5th Edition. John Wiley & Sons, 2013 http://www.erietechnicalsystems.com/sub-sub.php?main=1&sub=2&id=24.n.d. 27 01 2015 Hyper Physics. hyperphysics viscosity. n.d. 03 2015. http://hyperphysics.phyastr.gsu.edu/hbase/tables/viscosity.htm Institute, American Petroleum. "Steel gate, globe, and check valves for sizes NPS 4 (DN 100) and smaller for the petroleum and natural gas industries." 2009. MITCALC.com. MITCALC Spring. n.d. 02 2015. http://mitcalc.com/doc/springs/help/en/springs Norton, R. Machine Design, An Integrated Approach. Pearson, 2011 phos-chek.com. phos-chek.com. n.d. 03 2015. Systems, Dassault. http://www.phoschek.com.au/sites/default/files/research%20_%20forest%20service%20_%20liquid%20gelling%20agents %20Feb%2008.pdf Systems, Dassault. SolidWorks Material Data Base. 2014
Brett Haldane Robert Klikach Thomas Reitsma Adam Wasyliw Cynthia Ying Questions?
Decision Matrix Design Evaluation Criterion The new design causes no change to overall existing torch design. The valve assembly has a maximum weight of 4.54 kg (10 lb) to maintain the same weight as current configuration for minimizing swinging during flight. Pressure drop is less than 20 kpa at flow rate of 20 L/min. Design provides reliable shutoff when the fuel pump is turned off. The design is adequate for an impact upon a hard landing. Item in Specification Matrix 1.1 1.6 2.1 3.1 3.3 Weight 5 3 5 5 1 Concept 1 Modification Concept 2 Inline Concept 3 Dual Score Weighted Score Score Weighted Score Score Weighted Score 5 25 3 15 2 10 4 12 5 15 3 9 1 5 5 25 3 15 3 15 3 15 5 25 5 5 5 5 4 4 The valve is easy to install onto the housing structure and 3.5 5 20 5 20 3 12 connection of the fuel line. 4 The valve is easy to take apart and reassemble for inspection and maintenance. Dismantling and reassembly should take no 3.6 3 12 5 20 2 8 longer than five minutes. 4 Client preference N/A 5 5 25 5 25 0 Total N/A N/A 119 140 83
Spring Details Conical Spring Only operate in its linear regime Small End OD = 25.79 mm (1-1/64") Large End OD = 31.75 mm (1-1/4") Wire Diameter = 5.08 mm (0.2 ) Spring Constant = 205.3 N/m Uncompressed Length = 110 mm Sealing Force Provided = 13.4 N