Final Design Validation Problem Background Testing TDI Root Cause Air Products has experienced multiple failures on a crucial pump used in the creation of pre polymers. The pumps are transferring Toluene Diisocyanate (TDI). Air Products needs validation of the root problem and a cost effective solution to eliminate failures. Final Design Testing Team verified freezing in lubrication ports Enclosure consistently heated at 1°F/Min Pump thaws top to bottom, front to back Approximately 30 minutes operation before lubrication resumes Aluminum enclosure Rigid polystyrene foam insulation Neoprene rubber sealant 2 x 90 Watt heat sheets Digital temperature controller to maintain enclosure at 80°F TDI Zero Exposure Chemical – Toxic at 5 Parts Per Billion High Freezing Point ~ 58°F Reacts with itself and separates at 104°F Root Cause As a result of many failures occurring during colder, winter months and the relatively high freezing point of TDI, internal solidification of the pump lubrication ports (marked with yellow arrows below) is the suspected failure cause. Value to Sponsor Team 5’s enclosure will decrease the number of pump changes required and increase overall process efficiency. In addition, by elongating the pump service life, the Paulsboro facility will see significant savings on pump rebuild costs and plant downtime. Validation Air Products sought verification of root cause and validation of our final concept Acknowledgements Team 5 would like to thank our advisor, Dr. Keefe, for his direction, Andrew Zeigler at Air Products for his support and Steve Beard for his assistance in the machine shop. Magnets Working Fluid (TDI) Impeller Bearings Team 5 built an acrylic replica of Air Products pump to perform this validation Acrylic allows the team to see freezing patterns and locations Acetic acid pumped through the model simulates TDI Similar dimensions, flow rates, and pressures allowed for accurate testing of enclosure effectiveness Project Goals Confirm failure mechanism and root cause Prove proposed enclosure will maintain specified temperature and prevent TDI from freezing in pump