Test Report. for Healy Science Incubator Supply on the bow of the USCGC Healy. Version Date: February 6, Instrument Lab

Transcription

1 Test Report for Healy Science Incubator Supply on the bow of the USCGC Healy Version Date: February 6, 2009 Author(s): Instrument Lab Lamont-Doherty Earth Observatory of Columbia University 1

2 Palisades, NY USA 2

3 1 Revision History of this document This section captures revisions to this document. Comments, corrections, additions, etc. should be sent to Date Author Comment Original Unknown Operating Instructions, scanned from old paper copy Tuesday, 11:32 Tuesday, 11:32 Feb 7,2009 Draft version Feb 8, 2009 Dale Chayes Changed footers to be save date Some edits w/ track-changes turned on Feb 10,2009 Accepted Changes made some more Tuesday, 11:32 Page 3 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

4 Table of Contents Introduction... 5 Configuration 10 System Valving Schematic 10 System Valve Disposition for HLY09TA Tests 11 Operating Procedures System Control and Pump # Test Session Test session # 2 Tests 13 thru Page 4 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

5 2Introduction The Science Seawater System (SSW) on the Healy is used to supply seawater to the foredeck to provide cooling water for science-supplied incubators. It also supplies water to the Biochem lab for the flow through sensors and to the lab sinks. These incubators, placed at various locations on the foredeck, are supplied with uncontaminated seawater provided by the Science Seawater System (SSW). Two, multi-tap manifolds, port and starboard, handle distribution of the seawater to individual incubators. The purpose of this study is to determine Maximum flow rate of seawater deliverable to the foredeck under typical operating conditions. Make a rough determination of the SSW foredeck capability relative to the flow requirements for cooling water during HLY0902 as outlined in the current cruise planning form for. By our interpretation of the form, this is approximately 77 gallons per minute (gpm.) Determine what, if any, changes in the system are needed to meet or exceed the original specified flow rates, Determine what, if any, changes or recommendations should be made to successfully meet the needs of HLY0902 and future users. 3Summary 3.1Operating at 60 pounds per square inch (psi) and a #2 pump speed of 60%, the maximum flow rate to the foredeck was measured to be in excess of 100 gpm. This flow rate was only obtainable when the brass garden hose faucet was replaced with a ¾ NPT ball valve coupled directly to the flow meter / pressure gauge which was employed for measurement. With a hose added to deliver water to an incubator, this flow will be reduced. 3.2Maximum flow rate through any one of the brass garden hose 60 psi & 60% pump speed was 10.37gpm through a 50 ft 5/8 inch diameter hose. 3.3Flow rates achieved through the ¾ NPT ball valves through various diameter 50 ft 60psi & 60% pump speed are: ¾ inch diameter hose yielded gpm. 5/8 diameter hose yielded gpm. Page 5 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

6 Tuesday, 11:31 Deleted: Space ½ inch diameter 0hose yielded gpm 3.4Note that of the various hoses available for this test there was a wide range in the measured size noted versus the nominal size of the hose especially among the 5/8-inch diameter which was most common. 3.5In addition the male and female fittings affixed to the same nominal 5/8 diameter hoses had orifices as small as ½ inch. 3.6Summary of Results Tap Type dia. psi Hose length Hose #1 flow- gpm #2 flow- gpm Pump total flow gpm Brass Hose Faucet 100 5/8 inch? Brass Hose Faucet 50 5/8 inch? /4 full port ball valve No Hose x /4 full port ball valve No Hose x /4 full port ball valve 50 3/4 inch /4 full port ball valve 50 5/8 inch /4 full port ball valve 50 1/2 inch /4 full port ball valve No Hose x Recommendations to improve the SW delivery to Foredeck 3.7.1Remove all brass garden hose faucets and replace with ¾ inch NPT full port ball valves. See appendix TBD for possible candidates TBD will be responsible for acquiring and installing the ball valves as well as any changes to WTD usage or operating procedures that might be required Note: that port spacing on the existing manifolds precludes the mounting adjacent ball valves without staggering, either horizontally or vertically. Page 6 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

7 Introduction of different length ¾ nipples or 45-degree elbows can accomplish this Note: Any extension to the port side SSW manifold may interfere with the opening of the port side passage way watertight door Hose selection for maximum performance is critical to the ability to meet the incubator criteria as outlined in the HLY0902 cruise plan All hoses should be ¾ inch ID. And, all hoses should be inspected visually to insure that the inlet and outlet fittings have a ¾ inch orifice TBD will attempt to identify part numbers and sources for suitable hoses Every effort should be made to locate incubators requiring high flow rates such that where feasible a single 50 ft hose with no extensions will suffice to supply the incubator To insure the Healy s ability to meet the foredeck seawater requirements, MsO will assume responsibility for coordinating incubator locations and reviewing hose recommendations to the chief scientist of HLY Test Methodology 4.1Test Conditions 4.1.1All tests were conducted in Straits of Juan de Fuca and vicinity during HLY09TA Tuesday, 11: As no ice was present during the period of testing pumps # 3, separator ice removal pump, and pump # 4, sea chest ice removal pump, were operated at between 2 to 5% of capacity. Just enough to provide flow through the overboard ice discharge system. (In moderate ice conditions, these pumps are typically run at % of full speed The Bleed Pressure regulator valve SSW V located in the Bio-Chem lab had been removed due to malfunction. This regulator is critical for protecting the sensors and plumbing in the TSG from over-pressure. A casualty report for this item is in process at this time Without the Bleed pressure Regulator valve in place we were forced to rely entirely on manual regulation of the operating pressure for the SSW system Lt Galvez and MKCS Jones determined that 60 psi would serve as an operational maximum for this test. Page 7 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

8 4.1.6The underway instrumentation supported by Scripps was shut down during each of the test periods to preclude any damage due to inadvertent pressure surges The foredeck supply manifolds as found were outfitted thusly: Starboard manifold 8 positions, five occupied by small orifice brass garden hose faucets. The shutoff valve for this manifold is SSW V Port manifold 8 positions, seven occupied by small orifice brass garden hose faucets. The shutoff valve for this manifold is SSW V NOTE: this valve leaks to some degree when shut off and should be repaired 4.1.8Pressures reported in the test were as measure on the operators console located in Main control. Percentage of pump speed was also derived from this readout. 5Test Instrumentation Test instrumentation furnished by LDEO consisted of two Great Plains Industries model TN 100 N digital flow meters having a ~3 to 100 GPM range. These meters are furnished with ¾ NPT inlet and outlet connections. Each test unit consisted of a flow meter preceded by a psi Ashcroft pressure gauge. All interconnecting plumbing was ¾ NPT copper or brass. Appropriate ¾ brass garden hose male and female adapter were inserted as required. GPI totalizer / flow meter ~3 to 100 gpm. Shown with Ashcroft 0 to 100 psig guage Page 8 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

9 Port Manifold with Brass garden hose faucets installed - Shown with SSW test manifold. Page 9 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

10 6Configuration 6.1 System Valving Schematic Page 10 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

11 6.2System Valve Disposition for HLY09TA Tests Valve Prefix SSW-V-4-XXX-X Function Disposition Main Valves SeaChest ice out Open remote SeaChest SW out Open remote Overboard Discharge Open remote 1 Serial wi Overboard Discharge Open- remote 1 Serial wi Pump #2 SW feed pressure Pump #2 Inlet Open Pump #2 Outlet Open Pump #2 Bypass Closed Pump #3 Separator Slurry Removal Separator outlet Open Pump #3 Inlet Open Pump #3 Outlet Open Pump #3 bypass Closed #3 to Overboard discharge Open Pump #4 SeaChest Ice discharge Pump #4 Inlet Open Pump #4 Outlet Open Pump #4 Bypass Closed Pump Isolation Valves Sub #3 for #2 NC Sub #3 for #4 NC # 3 to SW main Feed NC Distribution Valves Main SW Feed Open Feed Aft Open Foredeck Feed Open Page 11 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

12 7 Operating Procedures 7.1System Control and Pump # 2 For the no ice conditions encountered during these tests we operated pumps #3 & #4 at minimal speeds between 2% to 5%. Just so that some flow existed in the ice / slurry overboard discharge piping. The speed control for Pump #2 was used to control the pressure in the SSW system. An operational limit of 60% of pump #2 speed was chosen to best simulate operational limits, which, might be imposed during ice conditions. 7.2Test Session 1 Date January 30, 2009 Personnel Steve Hartz MSTC Mark Reig Lt. Silas Ayers MKCS Greg Jones. Test Session 1 Tests 1 through 9 Notes: 1. Based on an assessment of the foredeck SW requirements for the HLY0902 cruise it was determined to use 10 taps for this test. 2. Based on the most recent HLY0902 cruise planning document it was determined that a total of 77.8 GPM would be required to supply the proposed collection of incubators. 3. The largest single hose incubator feed (Lessard for each of two incubators) was 19.7 gpm. 4. Operationally it is desirable to initially open all the taps that are being used prior to turning on the pumps. 5. Subsequent turning off of one or more taps is more easily dealt with by the pump operator, reducing the occurrence of high-pressure spike which could potentially cause damage to the TSG sensors. 6. Based on the incubator deployment plan for the foredeck we wanted to utilize hose lengths which would be representative of those which might be required. Summary Tests 1-4 Page 12 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

13 1. 10 hoses with four attached to the starboard manifold and six attached to the port manifold. 2. One flow meter deployed to port and one to starboard. 3. Due to the mix of the hoses available most hoses were 5/8 inch diameter with a few being somewhat larger. 4. Hoses were led over the foredeck rail and the discharge ends dangling feet below the rail.. 5. Tests 1-4 were run per with the following settings Pump 35% - This pump pressurizes the Centrifugal separator Pump 2% - Seachest ice/ slurry overboard discharge Pump 2% - Centrifugal separator ice over board discharge These settings produced a psi pressure as measured at the console in main control. 6. Test one deployed nine 50 ft hoses and one 100 ft hose all 10 taps opened fully Flow meter 1 (starboard) on the 100 ft hose had a flow rate of 4.7 gpm, while the port flow meter reading was 5.79 gpm. 7. Reducing the 100foot hose to a 50 ft length yielded 5.62 gpm (Stbd) and 6 gpm to port. 8. Turning off first one and then 2 taps increased flow to a maximum observed 6.75 gpm starboard, 6.22 gpm portside. Summary Tests Pressure was raised to 60 psi as measured at the pump operatorʼs console psi is considered the practical maximum for the current system configuration in which the automatic overboard pressure relief valve has been removed for service or replacement. 3. Pump 50 to 60 % - This pump pressurizes the Centrifugal separator. The percentage of motor speed was varied to maintain 60 psi as number of taps open was varied. Pump 2% - Seachest ice/ slurry overboard discharge Pump 2% - Centrifugal separator ice over board discharge 4. Repeating the conditions used in test 1 we observed 8 Gpm on the 100 ft hose and 9.34 gpm on the port side 50 ft hose. Summary Test 9 1. Tests 5-8 demonstrated our inability to deliver the required 19.8 gpm (75Lpm) flows required for the Lessard incubators, which have only one SW input. 2. In consideration of the overall flow rate objectives we made a relatively crude attempt to reduce the flow to the levels required by users who required the lowest flow rates. 3. We operated again at Pump 45% - This pump pressurizes the Centrifugal separator Page 13 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

14 Pump 2% - Seachest ice/ slurry overboard discharge Pump 2% - Centrifugal separator ice over board discharge 4. So with 4 taps crudely set to 4 gpm and one crudely set to 6 gpm, while the remaining 5 taps were left wide open, we achieved GPM for the portside and 10.0 GPM for the starboard side. Observations and recommendations for the next round of tests 1. The maximum flow rates achieved so far with the 60 psi limiting pressure have failed to yield the expected nominal flow rates. 2. This is based on the calculations provided by University of Idaho See Garden_Hose.htm a. With a 60psi head, 50 ft. of ¾ inch hose predicted flow is 44 gpm. b. With a 60psi head, 50 ft. of 5/8 inch hose predicted flow is 28 gpm. c. With a 60psi head, 50 ft. of ½ inch hose predicted flow is 15 gpm. 3. We have achieved less than 11gpm in a configuration, which is representative of the expected requirements. 4. We note that at this time we have not confirmed the static no taps on pressure at the manifold is indeed 60 psi. 5. We have the means to measure this in the next iteration of testing. 6. We surmise the currently installed garden faucet valves used are very restrictive. 7. We will have the ability during the next round of testing to provide a ¾ NPT direct connection to the flow meter assembly. Page 14 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

15 Tuesday, 11:27 7.3Test session # 2 Tests 13 thru 20 Date February 2-4, 2009 Personnel Steve Hartz Lt Oscar Galvez Test Session 2 Notes; 1. We removed two of the ¾ NPT pipe plugs, one each from the starboard and port manifolds. 2. ¾ inch full port ball valves were attached to the manifolds. 3. Removing the inlet garden hose adapter from our flow meter/ pressure gauge set ups allowed us to use the 3/4npt inlet. Summary Tests With one tap to port and one to starboard we experienced flow rates of up to psi with a nominally 5/8 diameter 50 ft hose attached. 2. Removing the hose entirely (using only the ball valve and measurement manifold) we achieved a flow rate of 45+ gpm from this one tap. 3. Testing was temporarily suspended pending official approval for the release of substantial quantities of seawater on deck. 4. We decided to take actual measurements of hose orifices prior to conducting further tests. Summary of tests Test 19 two flow meter manifold only taps yielded & psi and 59% pump speed. 2. Test one flow meter manifold fitted with various sized hoses was tested See summary Table section Test 21 was performed at 70 psi and 95% in order to test an alternate operational mode for the underway instruments. a. A manual overboard discharge valve located within the Bio Chem lab was opened to increase the flow rate to that area. b. The delivery pressure for the seawater delivered to the TSG & flurometer was monitored and adjusted by hand by Steve Roberts & Dave Forcucci. c. Max acceptable pressure was determined to be 70 psi. d. At this time two-¾ ball valve connected flow meter manifolds were employed to measure seawater flow rates to the fore deck. Page 15 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

16 Tuesday, 11:29 Tuesday, 11:27 Tuesday, 11:29 Tuesday, 11:27 Added: Space Tuesday, 11:29 Tuesday, 11:28 Tuesday, 11:28 Added: Space e. Rates were & 52.2 gpm with a maximum achievable pressure of 62 95% pump speed. APPENDICES A. Proposed Alternatives for Current Operating Instructions Based on conversations with Lt. Ayers & Lt. Galvez, who both, have experience with the SSW system in ice conditions. 1. The idea is to remove as much ice as possible from the sea chest prior to its induction into the separator, 2. This is accomplished by running pump # 4 at 80% of maximum speed. This is considerable faster than spelled out in any of the various presently used operating modes. 3. Pump #3ʼs speed is kept low approximately 5% to prevent the formation of a surface to bottom outlet vortex which would carry ice down with it. 4. Some testing of this procedure was undertaken last season. The results of the tests, while promising were inconclusive, as the ship emerged from the ice before sufficient testing could take place. See Elog entries. 5. Lt Galvez offered some additional observations a. The foredeck manifolds appear to have a low flow dead zone at the closed end, leaveing that area prone to freezing. b. Running pump #4 at high speed appears to crate a zone of suction back to pump #3 causing it to overspeed. Lt. Galvez proposed that a check valve placed on the Pump #3 outlet prior to its joining the overboard discharge pipe be considered. c. Lt Galvez also noted the there exist photos which show a clear zone at the surface indicating the induction of ice slurry into the Sea Chest B. Ball Valves Some possible candidates for ¾ NPT full port ball valves. Verify full port with mfg. before purchase. Page 16 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

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18 Appendix C Current operating procedures Page 18 of 19 Healy Science Sea Water Test HLY09TA February 9, 2009

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