# NOVA Extrusion Pressure Tester

# And First Results

Hans Jostlein November 2, 2007

### Introduction:

We have completed a new testing device for NOVA extrusions.

It uses water to pressurize 6 inch long samples of the 16-cell NOVA PVC
extrusion to failure.

The tester uses 4 hydraulic cylinders to seal the extrusion against
rubber mats, and an electric water pump. It can measure an extrusion in
about 8 minutes time.

### History

We have recently measured 11 extrusion samples with a primitive manual
setup.

Here is a picture of the setup:

**Test Setup**

We used pressurized water to keep the stored energy extremely low.

As result there is not only just a minimal safety risk, but also the
extrusions survive the failure event nearly intact, allowing meaningful
failure analysis by inspection.

Figure 1 is a drawing of the test device. A NOνA extrusion RPVC sample,
approximately six (6) inches long, was placed between two large aluminum
bars, measuring 2 7/8" H × 3 ¾" W × 32" L . The bottom face of the top
aluminum bar was machined creating a channel to allow pressurized water
to fill each of the sixteen cells of the sample. At one end of the
channel, a threaded fill hole was drilled through the bar. At the other
end of the channel, a second threaded hole was drilled to accommodate a
0--200 psi pressure gauge and a bleed-off value.

To ensure the ability to maintain internal pressure, two large
rectangular gaskets were manufactured. The gaskets were drilled with
sixteen (16) 3/4" holes with positions corresponding to the center of
the individual cells (See Figure 2.). The gaskets were placed between
the sample's top and bottom and the corresponding aluminum bar. To
enable the test device to maintain pressure, bolts, washer, and 1/2"
all-thread rods were used to clamp the top and bottom sections securely
together. A picture of the test device is included (See Figure 3.)

Water was placed in the sample cells through a hose connected to a
nearby sink. Air trapped in the cells was bled off. The test device was
then pressurized by a hand pump until failure. Each test average
forty-five (45) minutes in length. Figure 4 illustrates test results.

The Gasket:

### Example of a failed extrusion:

### 

### 

### ![](media/image3.jpeg){width="3.075in" height="3.6395833333333334in"} 

### Drawbacks and Limitations of the Manual Test

The manual test proved the concept, but was cumbersome and time
consuming.

Several tons of force are required to seal the ends of the extrusion
against a rubber mat.

Using threaded rod to provide the clamping force worked, but was quite
slow.

The hand pump used for pressurizing the water was supplying only a small
rate of flow, preventing it from pressurizing if there were even small
leaks.

Lastly, at each sample failure all the water ended up on the floor and
had to be mopped up.

It took about an hour for each test, and a large amount of frustration.

### The New Tester

We have completed construction of a more efficient, pressure test
device.

**The device is equipped with**

\--hydraulic cylinders to compress and seal the rubber gaskets

\--springs to release the sample after the test

\--a closed circuit water system, using an electric pump and a water
tank

\--valving to allow quick water filling,

followed by slow and controlled pressurizing through a separate needle
valve

### Here is an Assembly Drawing:

### 

### ![](media/image4.jpeg){width="5.991666666666666in" height="4.805555555555555in"}

### 

### Description of the New Tester:

The extrusion is clamped between a top aluminum bars against the bottom
I-beam, using rubber 1/2" thick gaskets , reinforced with fiberglass
mats.

For gasket compression, we use four hydraulic cylinders, all pressurized
from the same hand pump.

This assures sufficient force and uniform force distribution over the
length of the bar.

The hydraulic pressure is limited to 5000 psi, and the force on the
frame to 40,000#f.

The current pressure gauge has a range to 4000 psi, which provides a
maximum force of 32,000 \# f, which appears adequate to achieve a good
seal.

The cylinder forces are resisted by a steel frame made from steel I-beam
of 5 1/2 flange width, 8 3/8 height, with a moment of inertia of 58.7
in\^4.

The maximum stress in the I-beam at 40,000 #f is 11,600 psi.

The steel frame has been proof loaded to 4000 psi (32,000 #f) by
operating the hydraulic cylinders against cribbing material.

The steel frame sits in an open tank made form 1/16" stainless sheet.

The tank is 36" long by 18" wide by 36" high, and has a hinged half-inch
thick plastic cover.

The tank has a bottom drain which connects to a small circulation pump,
which is located below the tank. The circulation pumps provides the
positive pressure required by the high pressure test pump.

The high pressure pump is a Rice EL-1A pump rated at 3 gpm at 500 psi.

The pump outlet (the high pressure hose) connects to the top aluminum
bar.

The second hose connection at the top aluminum bar is used for air
bleeding and pressurization control, as follows:

A 10 f t high pressure water hose goes to the operator valve box,
mounted on the operator's control panel. (this is not shown on the above
diagram)

The operator valve box has a bleed valve which sends the air (and water,
as the case may be) back to the tank sump.

A pressure gauge is included to read the maximum pressure before
extrusion failure.

The pump is powered from a GFI outlet in an outdoor type outlet box.

To pressurize, the operator turns on the water pump while the outlet
valve from the extrusion is open. This flushes the air out of the test
extrusion and fills it with water.

When no air exits the extrusion (as seen through the transparent drain
hose), the operator closes the main input valve, and then the output
drain valve to the extrusion. Pressurized water enters the test
extrusion at low flow volume through the needle valve, causing the test
pressure to rise in the extrusion. The rate of rise is controlled by
this valve.

After the extrusion has failed, the operator turns the water pump
off,opens the bleed valve, and releases the hydraulic seal pressure in
preparation for the next sample.

The springs push the top bar up to free the failed extrusion and to
allow insertion of the next sample.

The operator uses the hydraulic hand pump to seal the new sample, closes
the tank lid, and proceeds to the operator control box for the next
cycle.

### Here are a few pictures of the Pressure tester:

![](media/image5.jpeg){width="5.631944444444445in"
height="4.223611111111111in"}

![](media/image6.jpeg){width="5.9944444444444445in"
height="4.511805555555555in"}

![](media/image7.jpeg){width="5.375694444444444in"
height="4.031944444444444in"}

![](media/image8.jpeg){width="5.9944444444444445in"
height="4.495833333333334in"}

## Initial Results

## 

## We have tested seven "vertical" extrusion that were made from NOVA 27-material in August 2007. All failed by having the end cell split at mid-level. This is the highest stress point as per Ang Lee's FEA calculations, thus indicating no flaws in material, knitting, or shapes.

## 

## The pressure at failure was

## Sample #4 330 psi

## Sample #5 340 psi,

## Sample #6 320 psi, time to test 4 minutes

## Sample #7 350 psi, time to test 7 minutes

## Sample #8 380 psi, time to test 6 minutes

## Sample #9 320 psi, time to test 6 minutes

## Sample #10 320 psi, time to test 5 minutes

The pressures at failure were quite similar between samples.

We will next test other samples , including horizontal samples and
samples made from problematic PVC runs, to verify that this device can
tell the difference between sound and flawed extrusions.

## Appendix: Details

###  ***The Pump***

+-----------------------------------------------------------------------+
| # Rice Hydro EL-1A Electric Hydrostatic Test Pump 3 GPM, 500 PSI      |
|                                                                       |
|  SKU                                                                  |
|                                                                       |
| ## EL-1A                                                              |
+-----------------------------------------------------------------------+

  ----------------------------------- -----------------------------------
                                      

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+-----------------------------------------------------------------------+
| +------------------------------------------------------------------+  |
| | **Features:**                                                    |  |
| |                                                                  |  |
| |                                                                  |  |
| |  --- ----------------------------------------------------------- |  |
| |   •   Hydrostatic Test Pump, designed for testing sprinkler      |  |
| |       systems, irrigation lines, pressure vessels, plant process |  |
| |       piping, and small diameter water lines                     |  |
| |                                                                  |  |
| |   •   1 HP Electric Motor, TEFC, 110/220 Volt, 50/60 HZ          |  |
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| |   •   Automatic Pressure regulator with inlet bypass             |  |
| |                                                                  |  |
| |   •   Stainless Steel liquid-filled gauge ensures accurate       |  |
| |       readings                                                   |  |
| |                                                                  |  |
| |   •   Rugged roll cage construction, protects pump from damage   |  |
| |                                                                  |  |
| |   •   Dimensions: 22x14x14, 1 Year Warranty from Manufacture     |  |
| |       Defect                                                     |  |
| |                                                                  |  |
| |  --- ----------------------------------------------------------- |  |
| +------------------------------------------------------------------+  |
|                                                                       |
|   ------------------------------------------------------------------  |
|   The EL-series is a low volume medium pressure line of hydrostatic   |
|   test pump designed for testing any small water line or pressure     |
|   system. This lightweight compact design combines the versatility    |
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|   Specifications\                                                     |
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|   3 GPM\                                                              |
|   500 PSI\                                                            |
|   Triplex Ceramic Plunger Pump\                                       |
|   High Pressure Outlet Hose\                                          |
|   1/2 HP, Single Phase, TEFC,\                                        |
|   115 volt, 50/60 HZ                                                  |
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![](media/image14.png){width="0.20833333333333334in"
height="0.15625in"}\

+---------------------------------------------------+------+----------+
| **Item**                                          | *    | **Qty.** |
|                                                   | *Pri |          |
|                                                   | ce** |          |
+---------------------------------------------------+------+----------+
| **Rice Hydro EL-1A Electric Hydrostatic Test Pump | **   | ![](me   |
| 3 GPM, 500 PSI** SKU EL-1A                        | \$1, | dia/imag |
|                                                   | 102. | e15.wmf) |
|                                                   | 00** |          |
|                                                   |      |          |
|                                                   | ~~   |          |
|                                                   | \$1, |          |
|                                                   | 160. |          |
|                                                   | 00~~ |          |
+---------------------------------------------------+------+----------+

### Hydraulic system

Hand pump: Choose P-392 with pressure gauge

+---------------------+------------------------------------------------+
| ### P series        | ### Lightweight Hand Pumps                     |
|                     |                                                |
| ![](media/imag      | -   Lightweight and compact design             |
| e16.jpeg){width="1. |                                                |
| 8444444444444446in" | -   Durable glass-filled nylon reservoir and   |
| height="1.6         |     nylon encapsulated aluminium pump base     |
| 347222222222222in"} |                                                |
|                     | -   Two-speed operation to reduce handle       |
|                     |     strokes                                    |
|                     |                                                |
|                     | -   Integral 4-way valve on P-842 for          |
|                     |     operation of double-acting cylinders       |
|                     |                                                |
|                     | -   Large oil capacities to power a wide       |
|                     |     variety of cylinders and tools             |
|                     |                                                |
|                     | -   Internal pressure relief valve for         |
|                     |     overload protection                        |
|                     |                                                |
|                     | > [Download](http:                             |
|                     | //www.enerpac.com/html/products/industrial_too |
|                     | ls/pumps_met/Cat_pages/P_lightw_e325e_GB.pdf)  |
|                     | > Catalog page pdf                             |
+---------------------+------------------------------------------------+

  ---------- ------------ -------------------------------------------------------------------------------------------- -------------- ------- ----------------------- --------- ---------- ----------- ------------
  **Pump\    **Usable\    Model\                                                                                       **Pressure\            **Oil                             **Max.\    **Piston\   **Weight**
  Typex**    Oil\         Number                                                                                       Rating\*\***           Displacement/Stroke**             Handle\    Stroke**    
             Capacity**                                                                                                                                                         Effort**               

                                                                                                                       bar                    cm^3^                                                    

             cm^3^                                                                                                     1st stage      2nd     1st stage               2nd stage kg         mm          kg
                                                                                                                                      stage                                                            

  Single-\   327          P-141                                                                                        \-             700     \-                      0,90      32,7       12,7        2,0
  Speed                                                                                                                                                                                                

             901          P-391                                                                                        \-             700     \-                      2,47      38,6       25,4        4,1

  Two-\      327          [P-142\*](http://www.enerpac.com/html/products/industrial_tools/cylinders_met/sc_metr.asp)   13             700     3,62                    0,90      35,4       12,7        2,0
  Speed                                                                                                                                                                                                

             901          P-202                                                                                        13             700     3,62                    0,90      28,6       12,7        3,4

             901          [P-392\*](http://www.enerpac.com/html/products/industrial_tools/cylinders_met/sc_metr.asp)   13             700     11,26                   2,47      42,2       25,4        4,1

             2540         P-802                                                                                        27             700     39,33                   2,47      43,1       25,4        8,2

             2540         P-842                                                                                        27             700     39,33                   2,47      43,1       25,4        10,0
  ---------- ------------ -------------------------------------------------------------------------------------------- -------------- ------- ----------------------- --------- ---------- ----------- ------------

\* [Available as
sets](http://www.enerpac.com/html/products/industrial_tools/cylinders_met/Cat_pag/SC_E325e_gb.pdf)
(Cylinder, gauge, couplers, hose and pump)

**Choose Cylinders: RC-102**

  ------------- ------------ --------------------------------------------------------------------------------------------------------------- ------------- ------------ ----------- ------------
  **Cylinder\   **Stroke**   **Model Number**                                                                                                **Cylinder\   **Oil        **Coll.     **Weight**
  Capacity**                                                                                                                                 Effective     Capacity**   Height**    
                                                                                                                                             Area**                                 

  ton (kN)      mm                                                                                                                           cm^2^         cm^3^        mm          kg

  5\            16           **RC-50**                                                                                                       6,5           10           41          1
  (45)                                                                                                                                                                              

                25           **RC-51**                                                                                                       6,5           16           110         1

                76           **RC-53**                                                                                                       6,5           50           165         1,5

                127          [**[RC-55\*]{.underline}**](http://www.enerpac.com/html/products/industrial_tools/cylinders_met/sc_metr.asp)    6,5           83           215         1,9

                177          **RC-57**                                                                                                       6,5           115          273         2,4

                232          **RC-59**                                                                                                       6,5           151          323         2,8

  10(101)       26           **RC-101**                                                                                                      14,5          38           89          1,8

                54           [**[RC-102\*]{.underline}**](http://www.enerpac.com/html/products/industrial_tools/cylinders_met/sc_metr.asp)   14,5          78           121         
  ------------- ------------ --------------------------------------------------------------------------------------------------------------- ------------- ------------ ----------- ------------