Pressure Transducer Design

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    A

    PROJECT REPORT

    ON

    DESIGN, FABRICATION AND TESTING OF A PRESSURETRANSDUCER FOR THE CONDITION MONITORING OF THE OIL

    LUBRICATION SYSTEM FOR GENERATOR SET

    SUBMITED TO THE UNIVERSITY OF PUNE,

    IN THE PARTIAL FULFILLMENT OF THE REQUIREMENTS

    FOR THE AWARD OF THE DEGREE

    OF

    BACHELOR OF ENGINEERING

    (MECHANICAL ENGINEERING)

    SUBMITTEED BY:

    SUMEET GHODKE B8310830

    KEDAR LELE B8310865

    RAVISH NAGARKAR B8310874

    DEPARTMENT OF MECHANICAL ENGINEERING

    PROGRESSIVE EDUCATION SOCIETYS

    MODERN COLLEGE OF ENGINEERING, SHIVAJINAGAR,

    PUNE-05.

    2011-2012

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    P. E. S. MODERN COLLEGE OF ENGINEERING, PUNE-05

    CERTIFICATE

    This is to certify that this project report entitledDesign, fabrication and testing of

    a pressure transducer for the condition monitoring of the oil lubrication system

    for generator setsubmitted by

    Sumeet Ghodke, University Seat No: B-8310830

    Kedar Lele, University Seat No: B-8310852

    Ravish Nagarkar, University Seat No: B-8310864

    is a partial fulfilment of BE Mechanical Engineering project work, under the

    University of Pune, year 2011-2012.

    Date: 16/06/2012 Place: Pune

    Internal Guide Head of Department

    Prof. M. M. Nadkarni Prof. Dr. A. D. Desai

    Prof. Dr. Mrs. K. R. Joshi EXAMINER

    Principal

    PESs MCOE, Pune-5

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    ACKNOWLEDGEMENT

    It is with great pleasure that we present the report on our project work at the end ofthe final year. We take this opportunity to share a few words of gratitude to all those

    who have supported us in making it possible. Our heartfelt gratitude to our project

    guide Prof. Mr. M. M. Nadkarni for his able and expert guidance. We would also like

    to thank Mr. V. S. Deshpande (M.D. Sam Integrations Pvt. Ltd.) for trusting us with

    this project and providing unconditional support and guidance.

    We are very thankful to Dr. Mr. Gajanan Ekbote (Chairman), Dr. Mrs. K. R. Joshi

    (Principal) and Prof. Mr. A. D. Desai (Vice Principal) for their moral support and

    encouragement. We are also indebted to our college including the staff members,

    technical assistants of various laboratories and other non-teaching staff for providing

    us with all the resources.

    Place: Pune

    Date: 16/06/2012

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    P. E. S. MODERN COLLEGE OF ENGINEERING, PUNE-5

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    LIST OF FIGURES

    Figure 1: Tank Unit for gensets ................................................................................................ 13

    Figure 2: S-series Fuel Indicator ............................................................................................... 13

    Figure 3: Fuel Indicator ............................................................................................................ 13

    Figure 4: Drain Pump ............................................................................................................... 13

    Figure 5: Fire Safety Equipments ............................................................................................. 13

    Figure 6: Fuel Filling Neck ........................................................................................................ 13

    Figure 7: Oil lubrication system ............................................................................................... 16

    Figure 8: Pressure gauge mounting on gen-set ....................................................................... 17

    Figure 9: Assembly of RICO pressure transducer ..................................................................... 23

    Figure 10: C-shaped bourdon tube .......................................................................................... 25

    Figure 11: Helical bourdon tube .............................................................................................. 26

    Figure 12: Spiral bourdon tube ................................................................................................ 26

    Figure 13: Flat diaphragm ........................................................................................................ 27

    Figure 14: Schematic diaphragm pressure gauge .................................................................... 27

    Figure 15: Convoluted diaphragm ........................................................................................... 28

    Figure 16: Capsule .................................................................................................................... 28

    Figure 17: Set of bellow pressure gauge .................................................................................. 29

    Figure 18: Single acting cylinder .............................................................................................. 29

    Figure 19: U-tube manometer ................................................................................................. 30

    Figure 20: Circumferential Stress ............................................................................................. 33

    Figure 21: Longitudinal Stress .................................................................................................. 33

    Figure 22: Von-mises stress in cylinder.................................................................................... 38Figure 23: Maximum principal stress on cylinder .................................................................... 38

    Figure 24: Maximum shear stress on cylinder ......................................................................... 39

    Figure 25: Total deformation on cylinder ................................................................................ 39

    Figure 26: Sequence of operation for cylinder manufacturing................................................ 41

    Figure 27: Cylinder ................................................................................................................... 41

    Figure 28: Sequence of operation for spring manufacturing .................................................. 46

    Figure 29: Spring ...................................................................................................................... 46

    Figure 30: Piston with two grooves ......................................................................................... 48

    Figure 31: Piston with one groove ........................................................................................... 49

    Figure 32: Piston with two split ring and one O-ring ............................................................... 50

    Figure 33: Teflon piston head and brass rod (Detachable) ...................................................... 51

    Figure 34: Threaded teflon piston head and brass rod (detachable) ...................................... 52

    Figure 35: Sequence of operation of Piston ............................................................................ 53

    Figure 36: Threaded joint used ................................................................................................ 54

    Figure 37: Von-mises stress on head hex ................................................................................ 55

    Figure 38: Maximum principal stress on head hex .................................................................. 55

    Figure 39: Maximum shear stress on head hex ....................................................................... 56

    Figure 40: Total deformation on head hex .............................................................................. 56

    Figure 41: Von-mises stress on end hex .................................................................................. 58

    http://d/SUMEET/project/FINAL/REPORT.docx%23_Toc327268522http://d/SUMEET/project/FINAL/REPORT.docx%23_Toc327268524http://d/SUMEET/project/FINAL/REPORT.docx%23_Toc327268524http://d/SUMEET/project/FINAL/REPORT.docx%23_Toc327268522
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    Figure 42: Maximum principal stress on end hex .................................................................... 58

    Figure 43: Maximum shear stress on end hex ......................................................................... 59

    Figure 44: Total deformation on end hex ................................................................................ 59

    Figure 45: Sequence of operation for hex nut manufacturing ................................................ 60

    Figure 46: Basic O-Ring ............................................................................................................ 61

    Figure 47: Basic Gland .............................................................................................................. 61

    Figure 48: Gland and O-Ring Seal ............................................................................................ 61

    Figure 49: O-Ring Installed ....................................................................................................... 62

    Figure 50: O-Ring under pressure ............................................................................................ 62

    Figure 51: O-Ring Extruding ..................................................................................................... 63

    Figure 52: O-Ring Under Extrusion Failure .......