1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW16701 Sealer Material Pumping Dispense Test Copyright 2012 General Motors Company All Rights Reserved June 2012 Originating Department: North American Engineering Standards Page 1 of 16 1 Scope Note: Nothing in this standard supercedes applicable la
2、ws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. This test procedure is used to measure the flow and pressure drop characteristics of sealer materials as tested through pumps, header, hoses and orifices typicall
3、y used in production dispense systems. The data from this procedure is specific to any individual sealer formula, and may also be used as a standard to compare to any future sealer batch for density or viscosity changes. 1.1 Purpose. This test provides information on material “pumping and flow” char
4、acteristics and can be used when designing a new sealer pumping, distribution and dispense system. It may also be used to check for throughput concerns on existing systems when materials are changing. 1.2 Foreword. Not applicable. 1.3 Applicability. 1.3.1 Data to be generated from this test procedur
5、e: 1.3.1.1 A Pumpability Worksheet (using Microsoft Excel Spreadsheet format) containing all data point entries (pressure drop and flow rate) and all other collected data from the Material Pumpability Test. 1.3.1.2 A graph of Pump Capacity showing the full range of pump flow rate output versus pump
6、pressure output for the material tested, from zero to the maximum capability of the pump. 1.3.1.3 A graph of Hose and Header Restrictors, showing the tested material flow rate through the restrictor versus pressure drop measured per meter length of the restrictor. The data points of each restrictor
7、shall be connected on the graph, to produce a “header or hose curve” of the sealers particular pressure drop and flow rate behavior for each restrictor tested. 1.3.1.4 A graph of smaller diameter Orifice Restrictors, each data coordinate showing the sampled material flow rate through the restrictor
8、orifice versus pressure drop measured per centimeter length of the restrictor. The data points of each Orifice Restrictor shall be connected on the graph, to produce an “orifice curve” of the sealers particular pressure drop and flow rate behavior for each restrictor tested. 2 References Note: Only
9、the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM D1475 ISO 3219 Z4 DIN SAE J1864 ASTM D2196 SAE J1524 2.2 GM Standards/Specifications. GMW6725 GMW15979 GMW16087 GMW15978 GMW16070 GMW16680 2.3 Additional References. None Copyright Ge
10、neral Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16701 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 2 of 16 3 Resources 3.
11、1 Facilities. Not applicable. 3.2 Equipment. 3.2.1 Equipment Required and Setup. 3.2.1.1 A 200 L (55 gal) Barrel Unloader Assembly: A 200 L (55 gal) elevator, follower plate, and Test Pump (assembled air motor and foot valve). Select the test pump, elevator and flower plate assembly which best simul
12、ates the model used in production in terms of pressure ratio, volumetric displacement and elevator/follower plate down pressure. The dimensions of internal pump parts which are subject to wear may be recorded at the beginning of the test procedure for comparison to the remeasured parts dimensions af
13、ter test to determine if there has been any pump component wear. 3.2.1.1.1 One side-port check (consistent with selected pump) 3.2.1.1.2 One outlet nipple (from side-port check): number 16 JIC male 3.2.1.1.3 One pump outlet hose: 25.4 mm (id) x 3.05 m (1 in diameter (dia) x 10 ft length) 3.2.1.1.4 T
14、emperature conditioning of the material pathway of the test equipment will be mandatory where the test environment is not controlled to 18.3 C (65 F). The follower plate must have water passages incorporated into it, and temperature conditioned jackets (incorporating water tubing pathways) must also
15、 cover the external body of the foot-valve of the pump, and side-port check. The Pump Outlet hose must be fully temperature conditioned also. 3.2.1.2 Air Supply to Air Motor. 3.2.1.2.1 For constant air supply to the test pump, an air supply hose of 25.4 mm (1 in) minimum diameter shall be used to de
16、liver air to the control regulator and ball valve which operate the Test Pump. 3.2.1.2.2 One 25.4 mm (1 in) National Pipe Thread (npt) Wilkerson air regulator (manually adjustable) number R30-80-000 model for setting the air motor pressures of each test sample. Alternatively, an electrically command
17、ed “proportional valve” may be used to deliver pilot control to a larger 25.4 mm (1 in) air regulator, for remotely commanded closed-loop control of air motor pressure 3.2.1.2.3 One 38.1 mm (1.5 in) npt electro-pneumatically operated ball valve, to open or close the regulated air passage to the air
18、motor inlet. 3.2.1.3 Restrictor Hoses. 3.2.1.3.1 All Restrictor Hoses shall have a maximum working pressure above 344.77 bar (5000 psi). Recommend Parker 731 series hose or equivalent. 3.2.1.3.2 Temperature conditioning of Restrictor Hoses is mandatory where the test environment is not controlled to
19、 18.3 C (65 F). Temperature conditioning jackets must cover the total length of the Restrictor Hose to ensure that an 18.3 C (65 F) material environment is maintained. 3.2.1.3.3 Length and Inner Diameter of Restrictor Hoses: 3.2.1.3.3.1 One 25.4 mm id x 6.1 m length (1 in dia x 20 ft length) 3.2.1.3
20、.3.2 One 19.0 mm id x 3.05 m length (3/4 in dia x 10 ft length) 3.2.1.3.3.3 One 12.7 mm id x 3.05 m length (1/2 in dia x 10 ft length) 3.2.1.3.3.4 One 9.5mm id x 3.05 m length (3/8 in dia x 10 ft length) 3.2.1.3.3.5 One 6.35 mm id x 3.05 m length (1/4 in dia x 10 ft length) 3.2.1.3.4 Each Restrictor
21、 Hose shall have a connection means to a 25.4 mm (1 in) npt high pressure tee at the inlet and outlet. Tee leg is required for installation of pressure transducers and pressure gauges. 3.2.1.4 Restrictor Orifices. 3.2.1.4.1 Restrictor orifices shall be stainless steel (440 hardened), with 12.7 mm (1
22、/2 in) npt male inlet threads 3.2.1.4.2 Length and inner diameter of Restrictor orifices: 3.2.1.4.2.1 One 6.35 mm dia x 12.7 mm (0.250 in dia x 0.500 in length) 3.2.1.4.2.2 One 3.97 mm dia x 12.7 mm (0.156 in dia x 0.500 in length) 3.2.1.4.2.3 One 3.17 mm dia x 12.7 mm (0.125 in dia x 0.500 in lengt
23、h) 3.2.1.4.2.4 One 2.38 mm dia x 12.7 mm (0.093 in dia x 0.500 in length) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16701 Copyright
24、 2012 General Motors Company All Rights Reserved June 2012 Page 3 of 16 3.2.1.4.2.5 One 1.59 mm dia x 12.7 mm (0.062 in dia x 0.500 in length) 3.2.1.5 Restrictor Headers. 3.2.1.5.1 Restrictor headers shall be Schedule 160 pipe, descaled and degreased. 3.2.1.5.2 Temperature conditioning of Restrictor
25、 Headers is mandatory where the test environment is not controlled to 18.3 C (65 F). To assure effective temperature control to 18.3 C (65 F), the Header Restrictor pipe must be must be enclosed within a shell of water temperature conditioning bath for direct contact of the external pipe surface wit
26、h the water medium (“shell and tube” design). 3.2.1.5.3 Length and Inner Diameter of Restrictor Headers. 3.2.1.5.3.1 One 2 in inner diameter Schedule 160 header x 20 ft length, (43.1 mm x 6.01 m length) 3.2.1.5.3.2 One 3 in inner diameter Schedule 160 header x 20 ft length, (66.7 mm x 6.01 m length)
27、 3.2.1.5.4 Diverter Wye and Ball Valve Outlet Assembly. 3.2.1.5.4.1 One 1-1/4 in (31.75 mm) npt Schedule 160 Y-Pipe assembly, with welded 90 degree Y-legs each 12 in (304.8 mm) long, with the root leg connectable to the 2 in (50.8 mm) and 3 in (76.2 mm) header restrictors, and the 1 in (25.4 mm) tee
28、 outlet of the hose restrictors. 3.2.1.5.4.2 Two 1-1/4 in (31.75 mm) npt air-actuated ball valve, each with independent electropneumatic solenoid control. The ball valves are to be installed at the outlet of the two Y-legs, one of which is to be a Waste Leg, and the other to be a Sample Leg. 3.2.1.6
29、 Setup Diagrams. 3.2.1.6.1 Figure A1 - test equipment setup for pump and header. 3.2.1.6.2 Figure A1 (replace header with test hoses and the orifices at the test leg of “Y”) - test equipment setup for pump, header, and hose and orifice. 3.2.1.6.3 Pumpability Worksheet (using Microsoft Excel Spreadsh
30、eet format) with cells designated for data entry and with internal calculation formulas to generate summary data. 3.2.1.7 Lab Measurement Equipment. 3.2.1.7.1 Two pressure measuring transducers (range = 0 to 350 bar/5000 psi). 3.2.1.7.2 One electropneumatic pump cycle sensor. 3.2.1.7.3 One pump cycl
31、e limit switch. 3.2.1.7.4 One Programmable Data Acquisition logging device (normally a package of PC-based software with data acquisition hardware interface). For the purposes of this specification, it shall be called the DAQ Controller. 3.2.1.7.4.1 Must be capable of simultaneously logging analog v
32、oltage inputs from two pressure transducer channels, plus one digital input channel for pump cycle sensor. 3.2.1.7.4.2 Must be capable of real time sensing of digital input data (from pump cycle counter), and programmed to trigger digital output signals to automatically operate the Air Motor ball va
33、lve and the Wye outlet Waste Leg and Sample Leg ball valves. 3.2.1.7.4.3 Must be capable of downloading measured data to a Microsoft Excel Spreadsheet. May be programmed to automatically populate dispense sample data directly into the designated cells of the Pumpability Worksheet. 3.2.1.7.4.4 Must b
34、e able to acquire digital and analog data on all channels at a sample rate of at least 40 samples per second. 3.2.1.7.5 One Electric Control Panel to integrate the DAQ Controller interface for pump cycle sensor, air motor, and Y-outlet ball valve controls. 3.2.1.7.6 One scale or balance with 0.0 to
35、5 kilogram range, measurement accuracy to 0.1 gram. 3.3 Test Vehicle/Test Piece. Not applicable. 3.4 Test Time. Not applicable. 3.5 Test Required Information. Not applicable. 3.6 Personnel/Skills. Not applicable. Copyright General Motors Company Provided by IHS under license with General Motors Comp
36、anyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16701 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 4 of 16 4 Procedure 4.1 Preparation. Not applicable. 4.2 Conditions. Not applicable. 4.2.1 Enviro
37、nmental Conditions. See section 4.3.1.5. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Dispense Test Procedure. 4.3.1.1 Materia
38、l to be provided for test: A full 200 L (55 gal) drum of material (minimum 189 L/50 gal) is required for this testing procedure. One additional empty drum shall also be supplied to recover the dispensed sample material. 4.3.1.2 Material Viscosity. Viscosity of the unpumped test material (drawn from
39、the drum) will be measured by Castor-Severs Press-Flow Viscosity method (SAE J1524), Brookfield Viscometer method (ASTM D2196) and Rheometric method (ISO 3219 Z4 DIN). Standard viscosity sample testing temperature is 25 C (0.5 C), however the press-flow orifice and sample cylinder pressure, and Broo
40、kfield spindle and rpm, shall be as specified in the GM Sealer Specifications (GMW6725, GMW16070, GMW16087, GMW15978, GMW15979 and GMW16680) for the material tested. 4.3.1.3 Material Density. The Density/Specific Gravity (ASTM D1475) of the test material shall be measured from a Gardco Series 300 We
41、ight per gallon cup. 4.3.1.4 Material Separation. A Material Separation Test must be conducted to measure whether any material liquids/solids will separate in the subject test sample after 72 hours at 206.85 bar (3000 psi). Reference SAE J1864 for (Separation-Check) SEP-Check test equipment, procedu
42、re, and reporting. 4.3.1.5 Test Environment Temperature. The facility that contains the test equipment and material to be tested must be maintained at a temperature of 18.3 C (65 F). If the material is to be tested in an uncontrolled environment, then the material pathway of the test equipment must
43、be temperature conditioned (to a set-point of 18.3 C) in a continuous unbroken manner from the material inlet of the pump follower plate and throughout the pump, 25.4 mm x 3048 mm (1 in x 10 ft) supply hose, the header or hose restrictor, and also through the material sample outlet of the 31.75 mm (
44、1-1/4 in) Diverter “Y”. 4.3.1.5.1 If an 18.3 C (65 F) controlled temperature room is used, then the material must reside in the room long enough to have stabilized at a measured 18.3 C (65 F) (usually 72 hours). It must be verified that material throughout the barrel has reached 18.3 C (65 F) before
45、 flow data may be taken. 4.3.1.6 Final Material and Equipment Preparations. 4.3.1.6.1 Remove lid from test material barrel, and fill three 12 oz. (354.8824 cc) Semco Tubes with unpumped material (vacuum fill method recommended). Cap and label the material tubes (Material Number, Lot Number, and Date
46、) and reserve for Density, SEP-Check, and Castor-Severs Viscosity testing. 4.3.1.6.2 Administer the Density Test (ASTM D1475) and Castor-Severs Press Flow, Brookfield Viscosity and Rheometer Viscosity Tests. 4.3.1.6.2.1 After the Density testing, enter the values for Specific Gravity in gram/cubic c
47、entimeter (g/cc), (or lb/gal) into the designated cells of the Pumpability Worksheet. 4.3.1.6.2.2 After the Castor-Severs test, enter the Press-Flow seconds (with orifice and pressure parameters) in the designated cell of the Pumpability Worksheet. 4.3.1.6.2.3 Prepare and administer the 72 hour SEP-
48、Check test (the 72 hour testing period will be concurrent with Pumpability testing). 4.3.1.6.2.4 Enter all Pumpability Test Serial Number, Material Number, Lot Number, and Date into designated cells of the Pumpability Worksheet. See (Appendix A Table A1: Example Worksheet) for example setup. 4.3.1.6
49、.3 Connect the Pump Supply 1 in x 10 ft material hose to the 66.7 mm id x 6.01 m (3 in x 20 ft) Restrictor Header inlet. Connect the Diverter “Y” assembly to the restrictor header outlet. 4.3.1.6.3.1 Install two pressure transducers at header inlet and outlet. 4.3.1.6.3.2 Apply air to Unloader and Pump Air Motor Controls, and Diverter “Y”. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking p
