U S,Department of Energy

November 30, I995

Power Plant Heat Transfer Consultants

.

P.O. ^{Box 375,} Livingston, New Jersey 07039

Telephone:- Fax:

(201) ^{m 3 2 1} (a11 ^!3l3433

Mr. Elliott P. Levine, CE-521

US,

Department of Energy

Energy Related Inventions Program Forrestd Bldg.

1000 Independence Ave.

S.W.

Washington, DC 20585

Subject: Technical Progress Report No. 15 Hydraulic Test Unit and Plugs Grant No. DE-FGO1-90CE 15398 Gentlemen;

_ _

Please find our subject Technical Progress Report for 2nd quarter period 1995 (July 1, 1995-September 30, 1995) detailing activities carried out per respective grant projected tasks.

Grant schedule was officially extended through March 3 1, 1996 in July of this year. Please note that since Grant had expired March 31, 199410 fbrther activity was reported nor invoices submitted until extension approval was received in July 1995.

As per our correspondence of October 6, 1994, copy attached, wherein we requested a no cost t h e extension, a revised budget was generated to identifjl the reallocation of fbnds as of July 1, 1995. Please find attached financial table illustrating the reallocation of current balances to the respective tasks as requested.

The quantitative performance success as analyzed and reported in Technical Progress Report No.

14 regarding the developed MCC-ZOO0 Hydrotesting System was utilized for greater commercial improvement for both low pressure and high pressure tester applications. Design drawings were revised for more cost effective layout md component(s) costs for the MDD-2000 and MDD-l0,OOO models. The "roll bar" support structure was modified to allow the entire system to

fit into a 18" inanway which is typical for condenser, heater access. Layout design drawing is attached for itiformation. The details of the final component configuration are shown on separate drawing also attached. Design activities for Task I are complete. The balance of funds in this task shall be used for fabrication of the revised roll bar structure to be made from strong gage, however lighter weight aluminum tube material. Components previously purchased shall be reused ⁱⁱⁱ the final configuration. See attached Bill of Material (typical). The system shall be tested and checked upon completion.

TASK 11

Grant funds have afforded fabrication of extrapolated designs of various test plug geometries and sizes which have all been field tested and proven. The remaining activity in this grant task from a commercial aspect is to allow for a final phase of redesign to permit the lowest fabrication costs

€or the low pressure models. We have had some thoughts, and generated some sketches along these lines (see attached sketches of test plug assembly). We shall first investigate using heavy wall tbbing to fabricate the plug body. No further progress was made during this reporting period.

In an effort to be more commercially competitive in the lower operating pressure applications while still incorporating the Powerfect patented approach of utilizing elastomer seals and having the versatility of removable, reusable mechanical seal plug designs, we reviewed our Alpha atid Gamma plug component details. By utilizing standard fasteners, i.e. hex head bolts, washers and nuts we could save signifcant fabrication costs. We also wanted to shorten plug length configurations, which can be required in many low pressure applications. Standard fasteners, although not made to the same critical sizes and tolerances that are required in our high pressure models, could prove good enough €or less demanding service and are available in many different tnatekids and are usually stock items.

Initial designs were sketched for the .GOO-.660, 204 seal size range (see attached drawings).

Brass material

was selected for suitability in service water systems where brackish water is used for component cooling. Since our normal jaw materia!, 4140 Alloy, hardened steel, does not hold up well in brackish water, we researched and selected for trial the use of type 17-4 PH stainless steel which is heat treatable for the jaw components. An order was issued for fabrication of ten

prototype plugs to be made in this size. See photos of Model "Beta" plug, (originally called Alma design). Utilizing test pieces already on hand, these plugs were tested in many trials by our technicians in different configurations. Summary ofModel - Beta test results is as follows:

I

(I , ^{' /}

1.

Initial trials in a stainless steel test piece (size .645) proved plug, (with internal nut design) could withstahd approximately 2,000 psig (shell side dii-ection) before plug would extrude from test piece,

2. Same tests as in No. 1 above, except in tube side direction,.were much better (as expected).

Plug failed at 6,400 psig.

3. Repeat No. 1 configuration, shell side direction, in a carbon steel test piece, (better gripping of jaws) and plug held 5,400 psig for over ²⁰ minutes. No plug movement or damage.

4.

Additional test trials in larger clearance test pieces were conducted:

a. Size .620 Beta plug in a .700 stainless steel test piece (shell side direction), plug held

b,

Size oidy 800 psig-1,000 psig. ,620 Beta plug ^ih a 595 stainless steel test piece (tube side direction), plug failed at 4,800 psig.

5, Tests

*ele

dso

made with cat.bon steel test tube with jaws installed in reverse direction with

'

lnttthhal

^hut bii

plug

in

tube

side direction. Plug withstood 5,800 psig. No leakage, no movement,

ti0 datnee.

hi

essetlce the tibove tesults wete very encoataging sihce we would only market the Beta model pfUg

for

agphcatiohs

up

to 1,000 psig and there is good flexibility in design. This Beta model plug utilizihg stmdard fastefiers fot some componetlts could be made for one third the cost of our Ggh pressure plugs. We are continuing our effotts with this plug model in different sizes and different materials.

Relative to our high pressure Mechanical Seal Plugs more activity is planned for improvement of

our

double seal concepts for both Alpha

and

Gamma models. The objective is better performance white investigating lower fabrication costs.

This

^{concludes o w}

^TPRNo.

^{15, the}

^{first report} since Grant

schedule extention Should there be ahy questlohs, please do not hestiate to call.

-~

_ _ _

Power Plant Heat Trcnsfer Consultants P.O. Box 375, Livingston, New Jersey 07039

(201)-

503-0321

October 6. 1394

MI-, E l l i o t t P . L e v i n e , C E - 5 2 1

U

.

S. k p n r t m e n t of: E n e r g y

Eriergy R e l a t e d LnvcsnLions P r o g r a r ~ F o r t e s t a 1 B l d g .

1000 Inclependehce Ave. S W.

Washing ^toh, DC 2C1585

S l l b j e c t : R e q u e s t for ^{N o} Cost ^{T i m e} Extension Hydraulic Test U n i t and Plugs G r a n t No. DE-FGO1-9OCE 15398 Gentlemen:

We h e r e i n request c six (6) month "No C o s t " t i m e e x t e n s i o n 5~:- c o m p l e t i o n of our grant a c t i v i t i e s .

allotted hus e l a p s e d there ^is still f u n d i n g a v a i l a b l e which w o u i t t allow US t o 11 C C N I ~ J ~ ~ ~ ~ the. scope of work a s o r i g i n a l l y o u t l i n z d

i n ^{o u r} 5 t a t . e m e n t of Wcrk that would not o t h e r w i s e be completed s h o u l d we s t o p a t i-.lSis t i m e and ^{2 3} p r o v i d s a more c o m p l e t e f i n a l report, of o u r r e s u i h .

Although the .time p e r i o d

Also based on the r e s e a r c h results t o date, w e would l i l c e t o request a reallocation of the f u n d i n g a v a i l a b l e which ~ o u l d result i n what ^we b e l i e v e to be m o r e c o m m e r c i a l l y f e n s i b l a p r o c l u c t s . The a l l c ? e a t i a h (.ri>uld b e a5 follows:

Approximately S3800 balance of f u n d s for material is n v a i l a b i s p r i m a r i l y due to, our a b i l i t y Lo confirm *new extended .test p-?t.~g

designs through e x t . r n p o l s t i o n 0:: only (22 .krial c o n f i g u r a t i o n s ^ES o p p o s e d to twelve o r i g i n a l l y proposnd. A l s o money was saved by i l t i l i z i u g test. piace-s, t u b i i i g a n d pipe from ^{o u r} e x i s t i n g com- pany ^5~l;och at n o cl*iarge ko 421s DOE. In o r d e r to bring this ^task

t o c o m p l e t i o n wu r q u o s t . l l t i l i z i n g t h e f u n d s to f u r t h e r t h e devel.opmsnt of ^t.hsr,e p l u g s i n k 0 a mor2 cost e f f s c t i v s product through SQSS c o s t l y m a t e r i n l , easier to f a b r i c a t e and quic!(res t.0 install and u t i l i z - .

While k-he kesk p l u g s pr-oyc:~r,sd in ^{I L e m} 1 ^nhovs may ^prove the i i i u . l k . i - t u b s L s s t i r i g concept mors economically feasible for low pi:e.%urq a p p l icatioris, we feel ^khak commercialization of khi.6 testing ^approach, through i n f c 3 r m n l solicitation of our e:cisting customers, may he .somewhat limited. Ths s y s t e m is fully designed ancl can be f n b r i c a t s d af., ^{any .tiate} fur tiny n c t u a l application.

I I o w e v P r , to spend the. balance of ^{T a s k I I E} funding ^{t o} prove ^J s y s - t.em w h i c h w e ace confic1o.n.t will work ^may be s ~ = ~ r n e w h a t academic.

C o n v p s s e l y , our s f f o r t s in T a s k I13 through this funding have

p r o v e n to ^{t h e}

Plechanical S e a l Plug c o n c e p t s . Ws therefore, propose to renllo- cate k h e total balance [approximately 57,000) to further inves- t;ignte Inore cost effective m6terials, improvement of fabrication requirements with shorter designs related to lower pressure operating criteria. We feel this would be our ^most commercially f e a s i b l e product d e v a l o p s d t h r o u g h this funding baeed on initial i n terest of exi ski ng customers.

ti t i 11 nd ex e ^-5 t i ⁿⁱ a t; i on c, f p os ^.s i b 1 ³ i m ^{pi- o v ern} en t s

With regards to ^{T a s k} 1 we request transfer of remaining funding from C o n s u l k a n t a c t i v i t y to Material which will allow us to finalize t h e t e s t u n i t ccmfiyuration ^9.5 proven in actual field application. ^{A 1 5 0 T a s k} IV ^{3 r d} party testing activities cun be fi.lrt.her continued w i t 1 1 monies allocatted should extension be y ^{r d r l Led.}

W e t - h a n k you for your c o n s i d e r a t i o n in ^Lhis matter and a w a i t your clr?ci!.;iciri.

Y ^{I2 1.1} r ^si tr ^Ll 1 y ,

i

I

Hydraulic Test Unit and Plugs Grant NO. DE-FGO1-9OCE 15398

&Revised Budget as of July 1, 1995

‘(Grant Extension Approval)

TASK I Material consultants ,Design Technicians

TASK

^IIA Material Consultants Design Technicians

BUDGET

5,500.00 4,800.00 800.00 822.00

9,000.00 10,800.00

2,500.00 2,468.00

ACTUAL

5,207.21 4,080.00 800.00 693.98

5.114.56 9,280.00 2,500.00 2,43 1.52

BALANCE

292.79 720.00

0 128.02

3,885.44 1,520.00 36.48 0

REALLOCATION

OF FUNDS

350.00 500.00 0

290.8 1

2,94 1.92 500.00 1,000.00 1,000.00

BUDGET

ACTUAL

^BALANCE REALLOCATION

OF

^FUNDS

TASK

IIB

Material Consultants 'Design

Technicians

TASK 111 Material Consultants Design Technicians TASK

IV

Material Labor AMCMT Consulting

Administrative/Clencal

3,000.00 5,400.00 1,234.00 2,000.00

2,200.00 1,200.00 5,400.00

822.00

408.20 2,391 .SO 8,230.00

570.00 3,528.00

- 0

2,430.00 1,540.00 329.00

1,803.96 5,400.00 1,200.00

246.75

408.20 1,346.82 8,009.50 570.00 3,460.80

3,000.00 2,970.00 460.00 905.00

396.04 4,306.29

0 500.00

0 1,500.00

575.25 2,000.00

0

1,044.98 0

220.50 0

0

67.20 1,332.68

MDD-10,000 BILL OF MATERIALS

ITEM QTY. COMPONENTS SUPPLIER PART NO. PRICE DELIVERY REMARKS DATE REC'D

1 1 PUMP Berendsen IO-5OOOWO60 565.00 3 wks

2 1 MUFFLER ^I1 M-07 7 1 .oo ³ wks

3 1 FILTER Truesdell F26-04-000 34.50 3-4 WkS

4 1 REGULATOR ^II R21-04-000 45.53 3-4 Wks

5 1 LU B R I CAT0 R 1: L26-04-000 37.13 3-4 wks

6 2 10,000 Ib 1/4" dragon valve 1 OF053 57.00 3-4 wks $1 14.00 for (2)

7 1 GAGE

-

10,000 IbS Schneider US126629 87.20 4 wks

8 1 SNUBBER OPO 22s 25.16 stock

9 2 BALL VALVES Northland DIX SS BV50 29.15 I wk $58.30 for (2)

10 1 1/2" ELBOW RS Crum SS-8-E 31.20 1 wk

11 1 1/4" ELBOW SS-4-E-I OK 42.60 I wk

112 2 REDUCING NIPPLE SS-8-H RN-4-1 OK 79.80 1 wk $39.60 for (2)

1'3 : 1 1 /2" T SS-8-T-I OK 129.50 Iwk

14 ^' 2 1/2" HEX NIPPLE SS-8HN-I OK 16.50 I wk $33.00 for (2)

15 1 1/4" HEX NIPPLE SS-4HN-1 OK 10.70 1 wk

16 1 SYNFLEX HOSE x 20 OAL Van Sant 3900-041 04-39OVO4104 164.00 1 wk 17 1 SYNFLEX HOSE x 15 OAL 3900-041 04-39OVO4104 134.00 1 wk

11

II

II I1 II II II

II

18 3/4" OD .049 ALUM. TUBE Coventry 6061T6 366.60 5-7 wks

FLEXIBLE HOSE MSC 484 1701 8 17.00 page 2908

19 '1

20 6 PIPE NIPPLES 91 071 45 2.54 page 2908

21- 2 PIPE THREAD 91 07848 2.41

II II

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October 10,1995

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P.O.NU!G€R

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PART NAME- PART NUMBER- DATE-

DATE

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Hydraulic Test Unit and Plugs Grant No. DE-FG01-90CE15398

Initiql Prototype of brass "BETAi1 Plug