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\begin_body

\begin_layout Title
Agua Clara Inlet Manifold Fabrication Team
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\begin_layout Author
Julia Morris, Andrew Gorodetsky, Heidi Rausch
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\begin_layout Abstract
This report will cover the research that is currently being done in Cornell's
 AgauClara 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.
 This report summarizes the research that is currently being done as well
 as plans for future research.
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\begin_layout Abstract
\begin_inset Newpage pagebreak
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\end_layout

\begin_layout Section*
Literature Review
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\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_
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LatexCommand ref
reference "fig:sketch-of-the"

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-.
 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.
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1
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 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"

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-.
 The rectangular section should extend as long as possible so that there
 is a long distance for the fluid to approach uniform flow.
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2
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\begin_inset Graphics
	filename ../../Downloads/sketch of design.png
	scale 50

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\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"

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\end_layout

\begin_layout Section*
Methods 
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\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
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\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
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\begin_layout Enumerate
Put the container full of water into the microwave
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\begin_layout Enumerate
Heat the water using the microwave until it starts to boil
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\begin_layout Enumerate
Submerge the PVC pipe in the boiling water
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\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
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\begin_layout Enumerate
Using protective gloves, stretch the PVC pipe over the mold
\end_layout

\begin_layout Subsection*
Design of the Mold
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\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"

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).
 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"

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).
 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''"

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.
 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.
 
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\begin_inset Caption

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Mold design
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name "fig:mold-design-1"

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\begin_inset Graphics
	filename ../../Downloads/inlet manifold mold pic.JPG
	scale 30

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\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''"

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	scale 30

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\begin_inset Caption

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Cut outs of mold sides for plaster form 
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name "fig:Cut-outs-of"

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\begin_layout Section*
Mid-Semester Redesign
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\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"

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).
 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.
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	filename ../../Downloads/NewSedTankGeometry.png
	scale 50
	BoundingBox 0bp 0bp 100bp 480bp

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\begin_inset Caption

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

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\begin_layout Plain Layout

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\end_layout

\begin_layout Section*
Analysis
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\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 we need to emerse the PVC in.
 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 Section*
Conclusion
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\begin_layout Standard
Though the boiling water method seemed promising, after actually testing
 this method it has been established that this will not be a good choice
 for the final fabrication process.
 Boiling water is too fickle and not enough direct heat.
 When testing with the hot plate the container we kept the water in got
 extremely hot, but the water and the pipe itself did not.
 
\end_layout

\begin_layout Section*
Future Research
\end_layout

\begin_layout Standard
If using the mold to shape the PVC does not work other options will need
 to be considered.
 A jack system could be used.
 In this system there would be two piecesof metal that would be the desired
 width of the rectangular shape at the bottom of the pipe and which would
 then be put into the pipe and then pulled apart until the desired length
 of the rectangle has been reached.
 
\end_layout

\begin_layout Standard
After deciding that heating with boiling water is not our best choice for
 heating the PVC we need to find other heating methods.
 One method that will most certainly be tested is using a heating gun, as
 we have access to one in the shop.
 Monroe has suggested this, as he used this method with some success when
 first testing how the fabrrication of the diffuser pipes may occur.
\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"

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

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\end_layout

\end_body
\end_document
