6. Apparatus
6.1 The basic system consists of the following (see Fig. 1):
6.1.1 AC Motor, 1200 r/min, or other suitable drive, with 11 kW (15 hp) as suggested minimum power requirement (Item 5, Fig. 1). The motor must have right hand rotation (counterclockwise rotation as viewed from the shaft end).
6.1.3 Rotary Vane Pump, replaceable cartridge type. A Vickers V104C or V105C or Conestoga USA B1 housing is used along with internal components from Conestoga USA, Inc. The assembly should produce 28.4 L/min flow at 1200 r/min with ISO Grade 32 fluid at 49 °C, at 6.9 MPa (Item 3, Fig. 1; Fig. 2; Fig. 3). (Warning - Eaton-Vickers test pump is rated at 6.9 MPa (1000 psi) but is being operated at 13.8 MPa (2000 psi). A protective shield around the pump is recommended.)
NOTE 1 - This test method has been written for the use of Conestoga USA Inc. internals along with an Eaton-Vickers or Conestoga USA housing and head. If components from other manufacturers are used, refer to Test Method D2882-00 for preparation and selection guidelines.
6.1.3.1 The replaceable cartridge consists of the cam ring, the rotor, two bushings, a set of twelve vanes, and an alignment pin.
6.1.3.2 The individual cartridge parts are purchased separately. Conestoga USA, Inc. part numbers for these items are: cam ring No. 2882-5, alignment pin No. 2882-10, rotor No. 2882-1C, bronze bushings No. 2882-4C and 2882-4E, and vane kit (12 vanes) No. 2882-V12.
6.1.3.3 There are to be no modifications to the pump housing such as plugging the drain hole in the pump body or drilling and tapping a hole in the head for an external drain.
6.1.4 Reservoir, (Item 1, Fig. 1).
6.1.4.1 The reservoir shall be equipped with a removable baffle and a close fitting lid, all of stainless steel construction. The reservoir can be square or rectangular (with a flat bottom) or cylindrical (with a spherical or cone shaped bottom) and must be designed so as to avoid air entrainment in the fluid.
NOTE 2 - A suitable reservoir design is presented in Test Method D2882-00.
6.1.4.2 To promote deaeration and thermal mixing of the fluid, the baffle shall be designed so that returning fluid will follow an indirect path from the return port to the outlet port.
6.1.4.3 To avoid air entrainment, the reservoir shall be designed so that the return line enters well below the fluid level, fluid flow does not cascade over the baffle, and there will be a minimum of 15 cm of fluid depth above the pump inlet line.
6.1.4.4 Fluid ports may be added as required by the user for the installation of a low level switch, reservoir temperature sensor, bottom drain, and so forth.
6.1.4.5 If the reservoir is positioned so that the contents cannot be visually checked for aeration by removing the lid, a fluid-tight glass viewing port may be located in the side of the reservoir.
6.1.5 Outlet Pressure Control Valve, Eaton-Vickers pressure relief valve (CT-06-C/3.4 to 13.8 MPa) with either manual or remote control (Item 8, Fig. 1).
6.1.6 Temperature Control Device, suitable for controlling coolant flow to the heat exchanger to maintain test fluid at the specified temperature (Item 11, Fig. 1).
6.1.7 Temperature Indicator, (Item 2, Fig. 1) shall have an accuracy of +/- 1 °C and shall have an appropriate sensor to monitor pump inlet temperature.
6.1.7.1 To prevent a flow restriction near the pump inlet port, the temperature probe shall have a diameter of not more than 6 mm.
6.1.7.2 The test fluid temperature shall be measured within 10.2 cm of the pump inlet (Dimension C, Fig. 1). The sensing probe shall be inserted into the midpoint of flow.
NOTE 3 - Some users have found the addition of a pump outlet temperature sensor to be a useful diagnostic tool. If used, it shall be suitable for 13.8 MPa duty and should be placed in the high pressure line between the pump and the relief valve (Item 18, Fig. 1).
6.1.8 Heat Exchanger, (Item 10, Fig. 1). The heat exchanger should be of adequate size and design to remove the excess heat from the test system when using the available coolant supply.
NOTE 4 - It is suggested that a shell-and-tube-type heat exchanger, if used, should be connected in reverse (the hydraulic fluid is passed through the tubes and not around them) so that the interior of the heat exchanger can be effectively cleaned between tests.
6.1.9 Pressure Indicator, (Item 6, Fig. 1) to measure pump discharge pressure shall have an accuracy of at least +/- 0.3 MPa at 13.8 MPa. The gauge shall be suitable for 13.8 MPa duty.
6.1.9.1 The pressure indicator should be snubbed (Item 7, Fig. 1) to prevent damage from pulsations or sudden fluctuations of system pressure.
6.1.10 Filter Unit (Item 9, Fig. 1), 3 µm (minimum Beta 3 ratio of 100) replaceable fiberglass element with housing. Two new filter elements are required for each test.
6.1.10.1 The filter housing shall be non-bypassing and shall be provided with dual pressure gauges (Item 13, Fig. 1) or another suitable indicator to monitor pressure across the filter to warn of impending collapse of the element.
6.1.10.2 If dual pressure gauges are used to monitor filter pressure, the rated collapse pressure of the filter element should be known. The collapse pressure should be within the range of the gage.
6.1.11 Flow Measuring Device, (Item 12, Fig. 1) with an accuracy of at least +/- 0.4 L/min.
6.1.12 While not required, it is suggested that low-level, high-pressure, high-temperature, and low-flow safety switches be incorporated into the system.
6.1.13 A check should be made to ensure that the flush and test fluid are not incompatible with hoses, seals, or any other materials in the system.
NOTE 5 - The use of galvanized iron, aluminum, zinc, and cadmium should be avoided because of their high potential for corrosion in the presence of many non-petroleum hydraulic fluids.
6.1.14 Flexible Motor Coupling, (Item 4, Fig. 1).
6.2 The various components of the test system shall be placed in the system as indicated in Fig. 1.
6.2.1 The test system shall be arranged and provided with necessary drain valves so that complete draining is possible with no fluid trap areas.
6.2.2 Good hydraulics piping practices should be used when constructing the test system to avoid air ingestment points and flow restrictions.
6.2.3 The pump should be mounted so that its internal surfaces can easily be inspected and cleaned, alignment can be checked, and the operator has comfortable access when torquing the head.
6.2.4 The reservoir shall be located above the pump so that the fluid level in the reservoir will be between 61 cm and 66 cm above the center line of the pump when the test system is fully charged with 19 L of test fluid (Dimension A, Fig. 1).
6.2.4.1 The reservoir should be mounted so that it can be cleaned and filled with ease and the contents may be readily inspected by removal of the reservoir lid.
6.2.5 The inlet line (from the reservoir to the pump intake) shall have an internal diameter of at least 25 mm and shall have a straight horizontal run of at least 15 cm to where it connects to the pump inlet port (Dimension B, Fig. 1). If a hose is used, it shall be rated for vacuum service. The B1 pump uses dual inlet hoses with an internal diameter of 22 mm.
NOTE 6 - Some users have found the addition of a compound pressure gage near the pump inlet port to be a useful diagnostic tool (Item 17, Fig. 1). However, exercise care to ensure that any ports added to the inlet line do not become air ingestment points.
NOTE 7 - The use of a solenoid valve, finger screen or other device which restricts pump inlet flow is discouraged. Inlet restrictions adversely affect pump performance.
NOTE 8 - When tubing is used for the pump inlet line, some users prefer to use a radius bend instead of an elbow near the pump inlet. If used, the straight run described in 6.2.5 shall be measured between the end of the bend and the pump inlet port. For optimal flow properties with 25 mm tubing, a 100 mm (4 in.) bend radius is recommended.
6.2.6 The high pressure discharge line (from the pump to the pressure control valve) shall be rated for 14 MPa (2000 psi) duty and have a minimum internal diameter of 15 mm. The B1 pump uses dual discharge hoses with an internal diameter of 10.4 mm.
6.2.7 The fluid return line and fittings (from the pressure control valve to the filter, flow counter, heat exchanger, and reservoir) shall be rated for 3 MPa duty and have a minimum internal diameter of 15 mm.
NOTE 9 - Some users find the addition of a shut off valve on the return line (Item 16, Fig. 1) to be a useful addition to the piping since it allows filter changes and other system maintenance to be performed without draining the reservoir.
6.2.7.1 (Warning - If a shut-off valve is installed in the fluid return line, the user shall take procedural steps to ensure that this valve has been opened before the pump is started. If the valve is not opened, low-pressure system components will rupture, possibly endangering personnel.)
NOTE 10 - Some users find the addition of a valve on the pump inlet line (Item 15, Fig. 1) to be a useful addition to the piping since it allows filter changes and other system maintenance to be performed without draining the reservoir. A full flow type of valve with an orifice of at least 25 mm (1 in.) is recommended.
6.2.7.2 (Warning - If a shut-off valve is installed in the pump inlet line, the user shall take procedural steps to ensure that this valve has been opened before the pump is started. If the valve is not opened, the pump will cavitate.)
6.2.8 The case drain hose for the B1 pump (Item 19, Fig. 1) shall be rated for 3 MPa duty and have a minimum internal diameter of 8 mm. The B1 case drain must connect to the return line so that the drain flow is unrestricted when the pump is in operation.
7. Reagents and Materials
7.1 Warning - Use adequate safety provisions with all solvents.
7.2 Aliphatic Naphtha, Stoddard Solvent, or equivalent is satisfactory. (Warning - Combustible. Vapor harmful.)
7.3 Precipitation Naphtha (Warning - Extremely flammable. Harmful if inhaled. Vapors can cause flash fire.)
7.4 Isopropanol (Warning - flammable.).
7.5 Warning - In instances when the solvents listed in Section 7 are not effective, alternative solvents may be used. It is the responsibility of the user to determine the suitability of alternative solvents and any hazards associated with their use.