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\begin_body

\begin_layout Title
Agua Clara Inlet Manifold Fabrication Team
\end_layout

\begin_layout Author
Julia Morris, Andrew Gorodetsky, Heidi Rausch
\end_layout

\begin_layout Abstract
This report will cover the research that is currently being done in Cornell's
 AguaClara lab to create a fabrication method for the diffuser tubes on
 the inlet manifold.
 This team needs to develop a method by which the diffusers can be easily
 manufactured in Honduras.
 Very little work had been done on this fabrication process as this is a
 new part of the AguaClara plant.
 This report will first discuss the need for the diffusers and how they
 help the plant be more efficient.
 The diffusers must be fabricated in fast and efficient way and each diffuser
 should be identical to one another.
 It was concluded that the best method for fabrication of diffuser tubes
 is to use boiling water to heat the pipe and then a metal mold to expand
 the bottom of the pipe into the correct rectangular dimensions.
 
\end_layout

\begin_layout Abstract
\begin_inset Newpage pagebreak
\end_inset


\end_layout

\begin_layout Section*
Literature Review
\end_layout

\begin_layout Standard
The Inlet Manifold is a part of the sedimentation tank.
 The diffuser tubes which this team will be fabricating extend from this
 inlet manifold, see Figure_
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:sketch-of-the"

\end_inset

.
 The tubes are necessary because they help to create a uniform flow between
 the manifold ports by eliminating any horizontal velocity components and
 they also create a line source which will divide the two sides of the sedimenta
tion tank and suspend all flocs heading toward the center of the tank.
 The specifications for the design were determined in August 2011, and this
 is the design that will be fabricated for new plants beginning this fall.
 Suggestions for how the diffusers could be created include various ways
 of heating the PVC they will be made out of and then using a mold or a
 jack system to create the specified shape.
 
\end_layout

\begin_layout Standard
In August of 2011, a design to improve the ability of AguaClara plants to
 form floc blankets was discovered and this design will be built in Atima,
 Honduras.
 The conceptual design for the new system has been created.
 However, a new method is needed to fabricate the inlet manifold system.
\begin_inset script superscript

\begin_layout Plain Layout
1
\end_layout

\end_inset

 The preliminary design for the Atima plant calls for a 15.24 cm diameter
 manifold, 4.4 cm diameter ports every 12.1 cm, diffusers that are 7.62 cm
 in diameter and approximately 60 cm long.
 The diffusers pipes will be heated, reshaped, and stretched by 20% into
 a rectangle that is 3.2 cm wide and 12.1 cm long, see the Diffuser tube in
 Figure_
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:sketch-of-the"

\end_inset

-.
 The rectangular section should extend as long as possible so that there
 is a long distance for the fluid to approach uniform flow.
\begin_inset script superscript

\begin_layout Plain Layout
2
\end_layout

\end_inset


\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename sketch of design.png
	scale 50

\end_inset


\begin_inset Caption

\begin_layout Plain Layout
Sketch of the inlet manifold with diffuser tubes
\begin_inset CommandInset label
LatexCommand label
name "fig:sketch-of-the"

\end_inset


\end_layout

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Section*
Methods 
\end_layout

\begin_layout Standard
An easy and cheap method is needed to fabricate the new inlet manifold.
 In order to do this, PVC pipe should be heated and then molded into a rectangle
 that is 3.2 cm wide and 12.1 cm long.
 After some research was done, it was determined that PVC pipe could be
 heated using boiling water, a heating blanket, or a heat gun.
 
\end_layout

\begin_layout Subsection*
Boiling Water Method
\end_layout

\begin_layout Standard
Boiling water is by far the cheapest method and easiest resource to come
 across.
 An initial test was done to see whether boiling water could heat the PVC
 pipe up to a high enough temperature that it could be molded.
\end_layout

\begin_layout Enumerate
Place water in a microwaveable container that the PVC pipe fits in
\end_layout

\begin_layout Enumerate
Put the container full of water into the microwave
\end_layout

\begin_layout Enumerate
Heat the water using the microwave until it starts to boil
\end_layout

\begin_layout Enumerate
Submerge the PVC pipe in the boiling water
\end_layout

\begin_layout Enumerate
While the PVC pipe is heating, repeat steps 1-4 with another container
\end_layout

\begin_layout Enumerate
Put the PVC pipe in the new boiling water container and reheat the old one
\end_layout

\begin_layout Enumerate
Keep switching containers with boiling water until the PVC pipe is very
 hot
\end_layout

\begin_layout Enumerate
Using protective gloves, stretch the PVC pipe over the mold
\end_layout

\begin_layout Subsection*
Revised Boiling Water Method
\end_layout

\begin_layout Standard
Due to the fact that the initial boiling water method worked, the idea was
 revisited.
 This time, an efficient hot plate was used to heat up the water to a high
 enough temperature so that the PVC could be molded once it was placed in
 the water.
\end_layout

\begin_layout Enumerate
Place water in a glass beaker large enough to fit the PVC pipe
\end_layout

\begin_layout Enumerate
Put the container full of water on the hot plate and turn the hot plate
 to its highest setting
\end_layout

\begin_layout Enumerate
When the water comes to a full boil, place the PVC pipe into the water for
 3-5 minutes
\end_layout

\begin_layout Enumerate
While wearing protective gloves, take the hot PVC pipe out of the water
 and shove it onto the mold (the mold is discussed later)
\end_layout

\begin_layout Enumerate
Place the PVC pipe that is on the mold into cool water until it is room
 temperature
\end_layout

\begin_layout Enumerate
Use a hammer to remove the mold from the PVC pipe
\end_layout

\begin_layout Enumerate
Repeat steps 3 through 6 until the desired amount of PVC pipes are created
\end_layout

\begin_layout Subsection*
Design of the Mold
\end_layout

\begin_layout Standard
A plaster of paris mold has been created to press the hot PVC pipe onto
 so that it stretches to the dimensions at the end of the mold (See Figure
 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:mold-design-1"

\end_inset

).
 To make the mold the triangular sides of the mold were cut out from foam
 board (See Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Cut-outs-of"

\end_inset

).
 They were then laid down side by side and taped together.
 The plaster of paris was then poured into the poster board form and left
 to dry.
 The final product can be seen in Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Mold-for-3''"

\end_inset

.
 The mold is made of plaster of paris so that it can withstand the high
 temperatures and water that it will come into contact with when the PVC
 pipe is placed onto it.
 The plaster of paris mold has also been covered in a waterproof epoxy so
 that it will not be a problem for the mold to be constantly coming into
 contact with water.
 
\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename Mold.png
	scale 50

\end_inset


\begin_inset Caption

\begin_layout Plain Layout
Mold design
\begin_inset CommandInset label
LatexCommand label
name "fig:mold-design-1"

\end_inset


\end_layout

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename inlet manifold mold pic.JPG
	scale 30

\end_inset


\end_layout

\begin_layout Plain Layout
\begin_inset Caption

\begin_layout Plain Layout
Mold for 3'' pipe made out of plaster of paris and coated with polyurethane
\begin_inset CommandInset label
LatexCommand label
name "fig:Mold-for-3''"

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Plain Layout

\end_layout

\end_inset


\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename Inlet manifold mold cutouts.JPG
	scale 30

\end_inset


\end_layout

\begin_layout Plain Layout
\begin_inset Caption

\begin_layout Plain Layout
Cut outs of mold sides for plaster form 
\begin_inset CommandInset label
LatexCommand label
name "fig:Cut-outs-of"

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Plain Layout

\end_layout

\end_inset


\end_layout

\begin_layout Subsection*
Design of Jack System 
\end_layout

\begin_layout Standard
After the Mid-Semester Redesign (see below) the dimensions of the bottom
 of the diffuser pipe changed.
 Now that the pipe being used would be 2
\begin_inset Quotes erd
\end_inset

 pipe instead of 3
\begin_inset Quotes erd
\end_inset

 pipe, the rectangular bottom of the diffuser would be one centinmeter wide
 by eight centimeters long.
 To acheive this geometry it was suggested to us to try and use a jack system
 instead of a mold.
 The jack would consist of four steel bars connected with four moving joints.
 This apparatus was built in the CEE shop and can be seen being used below
 in figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Use-of-Jack"

\end_inset

.
 The jack system performed fairly well, but after using it once it was decided
 to also try using a new mold that would create the right size bottom geometry
 for the new size pipe.
 One problem that the jack system had was that since there was no support
 in between the two metal bars that created the main shape the pipe bowed
 in a bit in the middle.
 The deforming of the pipe could cause unwanted flow patterns in the water
 exiting the diffusers.
\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout

\end_layout

\begin_layout Plain Layout
\begin_inset Graphics
	filename Jack System 1.JPG
	scale 30

\end_inset


\begin_inset Graphics
	filename Jack System 2.JPG
	scale 30

\end_inset


\begin_inset Caption

\begin_layout Plain Layout
Use of Jack System
\begin_inset CommandInset label
LatexCommand label
name "fig:Use-of-Jack"

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Plain Layout

\end_layout

\end_inset


\end_layout

\begin_layout Subsection*
Design of Revised Mold (Metal) 
\end_layout

\begin_layout Standard
After the testing of the metal jack was completed a stainless steel mold
 was built to create the same dimensions the jack created.
 The mold was built in the CEE shop out of a solid piece of 1cm thick stainless
 steel.
 The mold itself can be seen in figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Stainless-Steel-Mold"

\end_inset

below.
 The mold also has an additional piece of steel attatched at the top which
 can be used to help press and/or hammer the mold down into the pipe.
 After the mold was used we discovered that it worked significantly better
 that the jack system.
 Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Comparison-of-the"

\end_inset

shows a section of pipe on which we used the the jack system to form one
 side and the mold to form the other side.
 The mold did not create the same bowing-in effect that the jack did, and
 the rectangle created with the mold was more defined than the rectangle
 created with the jack.
 More analysis of the differences between the two devices can be found in
 the anaylsis section of this report.
\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename Metal Mold.JPG
	scale 30

\end_inset


\begin_inset Caption

\begin_layout Plain Layout
Stainless Steel Mold
\begin_inset CommandInset label
LatexCommand label
name "fig:Stainless-Steel-Mold"

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Plain Layout

\end_layout

\end_inset


\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename Jack Result.JPG
	scale 30

\end_inset


\begin_inset Graphics
	filename Mold Result.JPG
	scale 30

\end_inset


\end_layout

\begin_layout Plain Layout
\begin_inset Graphics
	filename Jack vs. Mold.JPG
	scale 30

\end_inset


\end_layout

\begin_layout Plain Layout
\begin_inset Caption

\begin_layout Plain Layout
Comparison of the perfomance of the jack system versus the metal mold
\begin_inset CommandInset label
LatexCommand label
name "fig:Comparison-of-the"

\end_inset


\end_layout

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Section*
Mid-Semester Redesign
\end_layout

\begin_layout Standard
After meeting with the Design and Sedimentation Tank teams at the beginning
 of October we learned that a few changes to the diffuser tubes need to
 be made.
 The largest change is that, 2 inch pipe will now be used instead of 3 inch
 pipe.
 The sedimentation tank bottom geometry will also change (similar to 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:sketch-of-the"

\end_inset

).
 Instead of the rounded tip extending into the two angled sides there will
 now be a omega shaped bottom of the tank extending again into the two sides,
 now specifically angled at 50 degrees.
 The new bottom design will also include a piece of stainless steel extending
 from the tip in the middle of the omega shape up into a slit in the diffuser
 tube.
 This piece of metal has been added to help to keep the diffuser tube centered
 over the bottom of the sedimentation tank.
 See Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:New-design-for"

\end_inset

 for a preliminary design of the new bottom geometry.
\end_layout

\begin_layout Standard
After more redesigns made by the Sedimentation and Design teams, it has
 been decided that the final design for the bottom geometry of the sedimentation
 tank will be a simple half circle.
 However, this should not affect the fabricfication of the diffuser tubes
 too much.
 This new design does create the need for a new way to keep all the diffuser
 tubes in line.
 Ideas for how to accomplish this alignment problem are discussed in the
 future research section below.
 
\end_layout

\begin_layout Standard
\noindent
\align center
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename NewSedTankGeometry.png
	scale 50
	BoundingBox 0bp 0bp 100bp 480bp

\end_inset


\begin_inset Caption

\begin_layout Plain Layout
New design for bottom of sedimentation tank
\begin_inset CommandInset label
LatexCommand label
name "fig:New-design-for"

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Plain Layout

\end_layout

\end_inset


\end_layout

\begin_layout Section*
Analysis 
\end_layout

\begin_layout Standard
The method of using boiling water proved to be very successful in heating
 the PVC pipe up to an appropriate temperature.
 There was a bit of a problem in keeping the water hot because of the limited
 size of the microwave.
 It seemed that a hot plate would be a lot more efficient because it would
 keep the water at a constant boiling temperature so the PVC pipe can be
 heated a lot quicker and kept at the hotter temperature.
 
\end_layout

\begin_layout Standard
After testing with a hot plate we found that there were a lot of issuses
 we ran into.
 First, it is hard to find a suitable container large enough to hold the
 amount of water in which we needed to immerse the PVC.
 After deciding to use a large plastic container, we ran into problems when
 trying to heat up the water quickly as the plastic on the bottom on the
 container began to melt before the water was able to come to temperature.
 
\end_layout

\begin_layout Standard
The team first obtained a large metal cooking pot in order to boil water.
 It was found that the hot plate didn't get hot enough to be able to boil
 such a large quanitity of water.
 The team was then able to obtain a large glass beaker.
 Using the hot plate, the water in the glass beaker came to a boil.
 It was found that submerging the PVC pipe in the boiling water for about
 five minutes was enough to get the PVC malleable enough to be molded easily.
 
\end_layout

\begin_layout Standard
The team found that the jack system was hard to open to its full width due
 to the way that the joints were designed and that it puckered the PVC at
 the rectangular opening.
 The team ultimately ended up using the jack system as a sort of mold (opening
 it to its full width and shoving it into the pipe).
 Therefore it was concluded that a solid metal mold would be the best way
 to manipulate the PVC.
 A comparison of the performance of the jack and metal mold can be seen
 in Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Comparison-of-the"

\end_inset

.
 The metal mold produced a rectangular end that was more crisp than what
 the jack produced.
 Also the mold produced a wider rectangular end and a more gradual transition
 from circular to rectangular, which will help to create a line source of
 water at the bottom of the sedimentation tank.
\end_layout

\begin_layout Subsection*
Accuracy of Mold Method 
\end_layout

\begin_layout Standard
One of the goals of fabrication was to come up with a method that creates
 diffuser pipes that are identical to one another.
 Therefore, the team wanted to test the accuracy of the metal mold method
 by measuring the inner length and width of six different pipes (seen in
 Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Pipes-molded-using"

\end_inset

).
 This data can be seen in Table 
\begin_inset CommandInset ref
LatexCommand ref
reference "tab:Inner-widths-and"

\end_inset

.
 The average width was found to be 1.01 cm 
\begin_inset Formula $\pm$
\end_inset

.015 cm.
 This is close to the 1 cm width that was requested by the design team.
 The average length was found to be 8.62 cm 
\begin_inset Formula $\pm$
\end_inset

.05 cm.
 From this data, we can conclude that the mold method is accurate and creates
 diffuser pipes that are more or less identical.
 
\end_layout

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\begin_inset Caption

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Pipes molded using the metal mold
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<cell alignment="center" valignment="top" topline="true" bottomline="true" leftline="true" rightline="true" usebox="none">
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\begin_layout Plain Layout
0.05
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</row>
</lyxtabular>

\end_inset


\end_layout

\begin_layout Plain Layout
\begin_inset Caption

\begin_layout Plain Layout
Inner widths and lengths of the molded pipes
\begin_inset CommandInset label
LatexCommand label
name "tab:Inner-widths-and"

\end_inset


\end_layout

\end_inset


\end_layout

\end_inset


\end_layout

\begin_layout Section*
Conclusion 
\end_layout

\begin_layout Standard
It has been determined that using boiling water to heat up the PVC pipe
 and the metal mold to mold the pipe is the best method for fabricating
 the diffuser pipes.
 The exact methods used in the lab will probably not be used in Honduras
 though similar methods can be used to achieve the same result.
 For instance, instead of using a hot plate, an open fire or a stove might
 be used.
 An open fire and a stove will produce more heat than a hot plate; therefore,
 a metal pot instead of a glass beaker could be used to boil water in.
 
\end_layout

\begin_layout Standard
The team has decided that, at this time, no further research needs to be
 done on this topic.
 The problem of how to align the diffusers is discussed in the future research
 section.
 The team believes that the solution to this problem can be determined more
 easily in the field.
 
\end_layout

\begin_layout Section*
Future Research
\end_layout

\begin_layout Standard
A successful method has been tested using the boiling water method along
 with the mold made out of iron.
 Now, there are two more problems that need to be considered.
 The current mold stretches the pipe so that its outer diameter is about
 9 cm.
 The goal is to make a new mold to stretch the actual PVC pipe that is used
 in Honduras so that its outer diameter is 10 cm.
 Research needs to be done on the PVC pipe they use, its dimensions, and
 how much of a stretch the PVC pipe needs to endure in order to get to a
 length of 10 cm with a width of 1 cm.
 Once this is determined, a mold can be created similar to the one previously
 tested.
\end_layout

\begin_layout Standard
Another problem that needs to be investigated is how to line up all of the
 diffuser pipes once they are installed.
 Ideally, they will all be uniform and 10 cm long.
 This means that they can be placed next to each other so that they are
 all touching.
 However, there is still room for one or more of the diffuser pipes to shift
 sideways so that it falls off the line.
 A method needs to be created to line up all the pipes so that they are
 rigid and touching.
 One idea is to glue some material on both sides of the tubes making sure
 that they are all aligned.
 Making this material straight along the tubes could prove to be a problem,
 but this is the first idea that will be tested.
\end_layout

\begin_layout Standard
Based on recent suggestions from engineers in Honduras, using some type
 of glue or PVC cement is not the best solution for aligning the diffusers.
 They have suggested to instead perhaps to either tie the pipes to a rod
 or melting the pipe together.
 
\end_layout

\begin_layout Section*
References
\end_layout

\begin_layout Enumerate
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LatexCommand href
name "Floc Blanket Research"
target "https://confluence.cornell.edu/display/AGUACLARA/Floc+Blanket+Research"

\end_inset


\end_layout

\begin_layout Enumerate
\begin_inset CommandInset href
LatexCommand href
name "Inlet Manifold Fabrication"
target "https://confluence.cornell.edu/download/attachments/152026516/InletManifoldFabrication.pdf?version=1&modificationDate=1315238922000"

\end_inset


\end_layout

\end_body
\end_document
