Pressure Aging Vessel PAV3
Pressure Aging VesselPAV3
ContentsPreface4UnpackingWarrantyAfter-Sale Support4442.1 For Owners, Operators, & Maintenance2.2 Safety Instructions2.3 Warnings2.4 Cautions67783.1 General Description3.2 Specifications3.3 Environmental Conditions91011Section 1: IntroductionSection 2: SafetySection 3: System OverviewSection 4: Unpacking and Installation4.1 Unpacking4.2 Installation4.3 Pan Holder Leveling4.4 Air and Power ConnectionsSection 5: Operation569121212121316
ContentsSection 6: Verification436.1 Verifying Temperature6.2 Verifying Pressure4344Section 7: Troubleshooting457.1 Temperature Does Not Recover to Setpoint7.2 Troubleshooting the PAV Controller7.3 Reattaching the Flow Adjust Valve7.4 Updating the Software454647498.1 Preventive Maintenance8.2 Changing Fuses8.3 Spare Parts515152Section 8: MaintenanceAppendix A: WarrantyDeclaration of ConformityRevised January 2015515455
PrefaceUnpackingRetain all cartons and packing materials until the unit is operatedand found to be in good condition. If damage has occurredduring shipping, notify Applied Test Systems (ATS) and the carrierimmediately. If it is necessary to file a damage claim, retain thepacking materials for inspection by the carrier.WarrantyAll new ATS systems are shipped with a warranty. Units have awarranty against defective parts and workmanship for one full yearfrom date of shipment. Please see Appendix A of this manual forcomplete details on the warranty.NOTE: Please see the warranty information included with thecomputer. It details information that will ensure proper transfer ofthe computer warranty from ATS to the appropriate company.After-Sale SupportIf there are any questions concerning the operation of the unit orsoftware, contact the ATS Service Department at 1-724-283-1212.Before calling, please obtain the software revision number and theserial number from the unit’s data tag. A sample data tag is shownbelow and can be completed with the unit’s information for easyreference. Please be prepared to give a complete description of theproblem to ATS Service Engineers.4
Section 1: IntroductionThe Applied Test Systems (ATS) Pressure Aging Vessel (PAV)simulates in-service oxidative aging of asphalt binder according toprocedures developed by the Strategic Highway Research Program(SHRP). The PAV system is fully compliant with the most recentversions of ASTM standard D6521 and AASHTO standard methodR28.This information is related to the function, setup, safe operation,and maintenance of the PAV and its related components.This manual is intended for anyone who will be setting up and/oroperating the PAV.5
Section 2: SafetyAll ATS equipment is designed to be operated with the highest levelof safety. This manual and ATS endeavor to educate the operatorabout safety issues surrounding certain parts of the machinery byusing equipment labeling.2.1 For Owners, Operators, and MaintenancePersonnelRead and understand all instructions and safety precautions listedin this manual before installing or operating the unit. If there areany questions regarding operation of the unit or the instructions inthis manual, contact the ATS Service Department at 1-724-2831212.In addition to the safety warnings listed on the equipment,warnings are posted throughout this manual. Read and followthese important instructions. Failure to observe these instructionscan result in permanent damage to the unit, significant propertydamage, personal injury, or death.Read Operator’s ManualGeneral DangerProtective Earth (Ground)Burn Hazard (Hot Surface)Electrical Shock/ElectrocutionHand Crush Force From AboveEuropean Directive CE MarkNo Access for Unauthorized Persons6
2.2 Safety Instructions1. Read and follow all warning and caution statements in allrelated equipment manuals before attempting to operatethis machine. If in doubt about any statement or sequence,contact ATS Service.2. Installation of electrical devices must be accomplished bycompetent personnel and done in accordance with anycurrent local and national codes. Equipment grounding is aMUST for both safety and proper operation.3. Before supplying electrical power to the unit, turn all powerswitches and controls to an OFF or NEUTRAL position.2.3 WarningsThe following statements are warning statements. Unlike cautionstatements, warning statements alert the operator to conditionsthat may injure personnel. Operators must be aware of theseconditions in order to prevent injuries that may occur whileoperating this equipment.WARNING: Obey electrical code requirements. The ovenand control system must be wired and grounded inaccordance with national and local electrical coderequirements.WARNING: Be careful when working with equipment atelevated temperatures. In order to prevent burns, wearprotective clothing.WARNING: Use caution when opening the oven lid.Electrically-heated equipment can cause severe burns.WARNING: Allow adequate time to relieve all thepressure from the vessel before opening the oven lid andthe pressure vessel lid. Any unrelieved pressure cancause equipment damage and possible personal injury.WARNING: Unpack and operate on a stable surface.7
2.4 CautionsThe following statements are caution statements. Thesestatements alert the operator to conditions that may damageequipment. Operators must be aware of these conditions in orderto ensure safe operation of this equipment.CAUTION: Installation of electrical devices must beaccomplished by competent personnel and done inaccordance with any current local and national codes.CAUTION: The PAV must be grounded and wired inaccordance with national and local electrical coderequirements.CAUTION: Before energizing the electrical power to thePressure Aging Vessel, place all controls in an OFFposition.CAUTION: Do not exceed the maximum operatingtemperature. Refer to the specifications in Section 3 ofthis manual.CAUTION: Closing the flow adjust valve when the PAV isin operation will cause damage to the valve.CAUTION: All supporting and contacting surfaces must benon-flammable. Do not allow flammable materials tocontact the shell.CAUTION: If an emergency shutdown needs to beperformed, place ON/OFF switch in an OFF position. Unitwill depressurize automatically within 10-15 minutes.CAUTION: Do not overflow PAV pans. Refer to testspecifications for proper amount of material.8
Section 3: System Overview3.1 General DescriptionThe ATS Pressure Aging Vessel (PAV) is designed specifically toprepare specimens for tests developed by the Strategic HighwayResearch Program (SHRP) to simulate in-service oxidative agingthat occurs in asphalt binders during service.A PAV system consists of the following: ASME/CE code stainlesssteel pressure vessel enclosed in a stainless steel oven, pressureregulator, metering valve, pressure transducer and indicator, RTD,temperature controller with data logging, and pan holder.3.1.1 Vessel CertificationASME Code: Unless otherwise noted, the Pressure Aging Vessel(PAV) is designed, fabricated, inspected, tested, and stamped inaccordance with the ASME Boiler and Pressure Code, Section VIII,Divison 1, for service at a maximum pressure of 2.45 MPa/350 psigand a maximum temperature of 150 C/300 F. The ASME Boilerand Pressure Vessel Code is an Internationally RecognizedStandard.Contact ATS for the vessel certificate/U-IA Report and CEDeclaration of Conformity.9
3.2 SpecificationsBenchtop UnitIntegral Vessel/Oven DesignVertical Loading with FixtureSpecimen Capacity10 PansSpecimen PansPer AASHTO T 179Physical Dimensions30” high, 18” deep, 27 ½” wide(760 mm high, 460 mm deep, 700 mm wide)Weight290 lbs (130 kg)Operating Pressure304.5 psi (2.1 0.05 MPa)Temperature AccuracySetpoint 0.5 CTemperature Range80 C to 115 CRTD Temperature Measurement0.1 C Resolution and 0.1 AccuracyMicroprocessor Temperature ControlOvertemperature ProtectionASME Oven High Limit Switch 293 F(145 C)Power Requirements240 VAC, 10 amps, 50/60 HzVessel Per ASME Code Section VIII Division 1; 1992 A 93 Contact ATSwith the PAV’s serial number for acopy of the certification.Vessel Design Conditions325 psig (2.24 MPa) at 250 F (121 C)Pressure Safety Release Valve340 psiTemperature Uniformity 0.5 CPressure Display Accuracy 1%“TIME” Timer Accuracy0.1%“OUT OF RANGE” Timer Accuracy 0.1%10
Air InletMale ¼” NPT FittingSolenoid ValveClosed when power is applied. Inthe event of power loss, solenoidvalve will open and releaseany pressure in the PAV vessel.3.3 Environmental ConditionsOperation of the ATS Pressure Aging Vessel involves use of hightemperatures and contents being contained at high pressure.The location and placement of the PAV should always take theseelements into consideration to ensure a safe working environment.The PAV is meant for use in laboratory/factory settings in a dry andclean work environment. The work surface that the PAV is placedon should be a clean and sturdy work surface at a reasonableworking height and away from any water, gas, or electrical hazards.The work surface should be able to support more than the weightof the unit itself. The indoor area the PAV is placed in should bewell ventilated and containing no open flames or materials thatmay constitute a fire hazard.11
Section 4: Unpacking and Installation4.1 UnpackingCarefully unpack the equipment and inspect it for damage duringshipment. Retain all cartons and packaging materials until theunit is operated and found to be in good condition. If damage hasoccurred during shipping, notify the carrier and ATS immediately. Ifit is necessary to file a damage claim, retain the packing materialsfor inspection by the carrier.4.2 Installation1. Use an overhead crane or forklift to remove the PAV from thecrate and position it in the desired location.2. Position the PAV in the testing position, such as on the PAVheavy-duty steel stand or on a workbench or lift cart.CAUTION: All supporting and contacting surfaces mustbe nonflammable. Do not allow flammable materials tocontact the shell.3. Level the PAV by adjusting the screws on the four feet.4. Inspect the O-ring seal. Make sure it is clean and lightly coatedwith silicone grease. If the O-ring appears to be worn or damaged,contact ATS.4.3 Pan Holder Leveling1. Once the PAV is in place, verify that the ring located inside thebottom of the pressure vessel is level by placing the parallel barand a level across the top of the leveling ring.WARNING: When placing the level and the parallel baronto the ring, do not interfere with the RTD located inthe bottom of the pressure vessel. The RTD is factory-setand should not be moved.2. If the level indicates that the ring is not evenly balanced, makethe necessary corrections by rotating the three vertical-set screwsto lower or raise the ring. Use a 1/8” hex wrench to make thisadjustment.12
3. After leveling the ring, hand rotate the horizontal-set screws inorder to secure the ring in the bottom of the vessel.4.4 Air and Power Connections1. Install the air pressure line to the 1/4” male pipe-threaded fittingprovided on the back of the control cabinet.CAUTION: Use a regulated air supply of 340 to 350 psi(2.34 to 2.41 MPa). Do not exceed 350 psi (2.41 MPa) orthe PAV’s performance may be impaired by excessivepressure.2. A connector is provided with the unit. This connector maybe changed if it does not match the available receptacle. Powerrequirements are: 230-240 VAC, 5 V, 10 amp, single-phase, 50/60Hz.CAUTION: The PAV requires a minimum of 230 VAC tooperate correctly. Check the supply voltage to ensure it is230-240 VAC. If the supply voltage is less than230 VAC, a Step-Up or Buck-Boost transformer can besupplied to provide the proper operating voltages.Contact ATS. Be prepared to provide the ATS Servicerepresentative with information about the available ACvoltage so the correct transformer wiring configurationcan be provided.CAUTION: The PAV and control system must be groundedaccording to national and local code requirements.13
3. If equipped, connect the optional UPS battery backup supply.a. Use the supplied standard power cord to plug the UPSinto the wall. The system should charge for 24 hoursbefore connecting it to the PAV.b. Attach the supplied cord from the UPS to the PAV.c. See manufacturer’s literature for further setupinstructions.4. Check the flow adjust valve on the PAV (marked Flow Control)to ensure it is set at the correct values. This valve controls the rateat which the PAV depressurizes. When the flow adjust valve is setat the recommended setting, the PAV will depressurize at optimalrate. The unit will have a sticker (see below) with the correctvalues. Use the value marked Flow Adj.NOTE: See Section 7 for information on what to do if the flowadjust valve detaches.14
4.4.1 Regulator Connections1. Secure the air connection to the air tank using the supplied maleand female connections.2. Connect the hose to the regulator.NOTE: Do NOT connect the hose to the part marked FLOW. This isthe pressure relief valve, and nothing should be connected to it.NOTE: Outside of the United States, a different adapter may berequired. A CGA adapter is included.3. Attach the hose to the PAV using the quick connections. Connectthe male end of the hose to the female connection on the PAV bysliding the female connection towards the PAV, connecting thehose, and releasing the slide.4. Verify that all connections are tightly sealed by applying soapywater on the connections and turning on the air. If suds appear,apply more compound or tape to seal the leak.15
Section 5: Operation1. Power on the PAV by turning the Main Power switchlocated on the front of the PAV clockwise to the “ON”position.NOTE: Make sure the air is connected and set at 340-350 psi asdescribed in Section 4.4.16
2. Software/Setting up User Languagea. Select “View.” This will display the Informationscreen. The current version of the PAV softwarewill display.17
b. The PAV will display items in English as the defaultlanguage. To change the language from English toone of the preprogrammed languages, access theoptions from the touch-screen display.i. Select “View”ii. Select “Language”iii. Touch the desired language for the display.c. Select “Done” to return to the preheat startupscreen.18
3. Setting up a Basic Testa. Temperaturei. Set the chamber setpoint by touching thegreen box above “Chamber Setpoint.”ii. Enter the setpoint temperature in thekeypad that pops up.1. Temperature ranges areprogrammable from 50⁰ C - 150⁰C; however, only temperaturesbetween 80⁰ C - 115⁰ C arecalibrated to be within 0.5⁰ C ofthe setpoint.19
2. Do NOT enter a setpointtemperature higher than theactual temperature value whichwill be used for the AgingProcedure. The PAV is designed tooperate most efficiently when thePressure Vessel and Sample Rackare preheated to the temperatureat which Aging will be done.NOTE: Attempting to preheat thePressure Vessel and/or SampleRack to a higher temperature thanthe Aging procedure temperaturemay result in either a longerperiod of time required for thePAV to recover temperatureafter Pressure is applied and/ora poorer control of the chambertemperature after pressure isapplied to the chamber.iii. When finished, touch “ENT.”20
b. Aging Durationi. Set the desired duration to age thesamples by touching “View” and then“Time.” Touch the green box above“Duration of Test Time.”ii. Enter the amount of time desired forsample pressurization in the keypad thatpops up.1. Time is programmable from 1 to99 hours.2. ASTM D6521, AASHTO R28, andEN 14769 have specific timerequirements. Check the lateststandard for specific times iftesting to these requirements.21
c. Select “Done” to return to the “Preheat Startup”screen.d. To change the soak time, select Settings from theInformation screen. The soak time can be set atany time from 5-20 minutes.i. If using preheated samples, the soaktime can be reduced to five minutes.Ifthe samples are at room temperature,select 20 minutes for the soak time.This will preheat the samples to the agetemperature prior to aging.e. The heaters on the PAV can be set to automaticallyshut off once a test is completed. Select “On” forthis option. Selecting “Off” will cause the heatersto continue running after a test is complete.22
f.Insert the empty pan holder into the PAV and closethe vessel lid.NOTE: Do NOT load any samples into the PAV atthis time.NOTE: Bolt 1 in the diagram is a pivot bolt andshould only be loosened to allow the vessel lidto slide open and rest on the support block andto slide closed. This bolt should not be removed.Forcing this bolt may damage the bolt assembly.Pivot Bolt.DO NOT REMOVE.g. Slide the vessel lid closed and insert bolts. Thebolts only need to be engaged a turn or two. It isnot necessary at this time to completely tightenthe bolts. Close the oven lid and secure using thelatches.23
h. Select “Off” from the “Preheat Startup” screento start the preheating process. When the PAV isheating, the Heat Mode will display “Heating” anda flame symbol will appear.24
i.Once the PAV has reached the setpoint, the displaywill prompt the operator to insert the specimens,secure the lid, and select “Age.”i. Carefully remove the specimen holderfrom the PAV as it will be very hot.NOTE: The PAV needs to experience heatloss so it knows what to do after “Age” isselected. If it does not experience heatloss, the PAV gets confused and doesnot know what to do next. This heat lossshould happen when the specimens areloaded into the PAV.ii. Leave the vessel lid open. The PAV isdesigned to recover from the heat lossduring this stage. If the vessel lid is closedand the temperature doesn’t drop enough,the PAV may give erratic results and have adifficult time recovering to the setpoint.iii. Load specimens into rack.25
1. Load all ten pans into the sampleholder even if there are not tensamples to age.iv. Quickly and carefully return the sampleholder to the PAV. The vessel temperaturewill decrease when the oven and vessellids are open. To avoid a long temperaturerecovery, attempt to load the PAV andsecure the vessel and oven lids as quicklyand as safely as possible.NOTE: Do not load samples into the PAVuntil the PAV is heated to the setpoint andthe “Preheat Ready” screen is displayed.v. Close the vessel lid and secure the boltsaccording to the diagram.Pivot Bolt.DO NOT REMOVE.vi. Tighten in sequential order with thewrench provided. Go around twice totighten bolts to 55 inch/pounds.26
j.Once the vessel lid is secured, close the oven lidand secure with the latches.k. Immediately select “Age” from the touch screen.Do not wait for the temperature in the PAV torecover to the setpoint prior to selecting “Age.”l.The display will then resemble the image belowand will attempt to recover the heat lost duringspecimen loading.27
m. Within two hours of selecting the “Age” function,the PAV temperature will recover the temperaturelost while loading the samples. When thetemperature recovers to within 0.3 C of thesetpoint temperature, an approximate 20-minutedelay will begin. This is built into the softwareto allow the chamber temperature to stabilize.Following this, the PAV will begin to pressurize.The timer on the Aging Heat Up screen will displaythe total time from when the “Age” button waspressed until the PAV starts to pressurize. Whenthe PAV has pressurized to slightly above 2.00MPa, the aging cycle will automatically begin. Thescreen shown at this time will resemble the “AgingPressurized” screen.i. If the PAV does not reach the setpoint andpressurize within the two-hour time frameor has difficulty returning to the setpointafter pressurizing, check that the powerto the PAV is 230-240 volts. 230 voltselectricity is the minimum required for thePAV to operate correctly.If the power supply is 230-240 volts andthe temperature has not recovered,verify the following:a. Be sure that the vessellid remains open whenloading sample pans intothe sample holder.b. Verify that the samples arenot being heated ab
3.1.1 Vessel Certification ASME Code: Unless otherwise noted, the Pressure Aging Vessel (PAV) is designed, fabricated, inspected, tested, and stamped in accordance with the ASME Boiler and Pressure Code, Section VIII, Divison 1, for service at a maximum pressure of 2.45 MPa/350 psig and a maximum temperature of 150 C/300 F. The ASME Boiler
DESIGN ANALYSIS OF PRESSURE VESSEL USING PV ELITE A. Design of Pressure Vessel A pressure vessel horizontally placed on saddle supports was designed according to the design data input. SRAAC industry was planning to design a pressure vessel, as in need of a pressure vessel for storing chemical. As chemical storing
Toroidal Pressure vessel and Filament wound Pressure Vessel used to store CNG. The Toroidal Pressure vessel and Filament wound Pressure Vessel are modeled in 3D modeling software Creo 2.0. Theoretical calculations and analysis is also carried to determine stress and displacement values for toroidal pressure vessel.
vessel as, ASME code enables design of Horizontal or a Vertical vessel but there was no provision for an Inclined Vessel in it. The . Skirt Support for High Pressure Vessel Using Finite Element Method K Tamil Mannan et al. (2009) Pressure vessel is a closed cylindrical vessel for storing
pressure vessel using a handbook is troublesome and not interactive. In this Paper further improvement achieve using following steps, Design Pressure Vessel as per Problem statement Geometrical model of Pressure vessel is created using CATIA V5 R19. Optimization analysis of pressure vessel is carried out for optimum wall thickness.
change of state inside the pressure vessel. A rupture of a pressure vessel and thus an explosion leads to loss of lifetime and the reduced reliability of the pressure vessel. Regarding with the appropriate structural design of the pressure vessel, the optimization approach has paid much attention by many researchers both in practice and research.
Table 4.1: Analytical results for stresses on pressure vessel SR. NO. Type of stress Magnitude (MPa) 1 Table 6.2. Stress Analysis of Pressure Vessel with Two 10 Hoop Stress 50.52 2 Longitudinal stress 25.26 V. MODELING AND ANALYSIS OF PRESSURE VESSEL The 3D model of pressure vessel is created using a CAD software Creo Parametric.
Aging Facility (AP) Foundation Design 170-DBC-AP00-00100-000-00A 1. PURPOSE The purpose of this calculation is to perform a preliminary foundation design for aging pad 17P, shown in 170-P10-AP00-00102-000, Aging Facility General Arrangement Aging Pad 17P Plan (Reference 2.2.2), and for aging pad 17R, shown in 170-P10-AP00-00103-000, Aging Facility
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