Testing Plan (Updated 5/04/2011)
1) Refresh vessel volume of water
To test this requirement we will measure the amount of water flowing out of the malting vessel through the overflow drain in a specified time. These measurements will be taken with a certified stopwatch and a graduated cylinder.
2) Increase moisture content of barley
Before steeping the barley we will weigh it, then after steeping/couching we will weigh it again. We know that barley starts with a moisture content of around 10%, so when the barley is at a moisture content of 45% we can predict its weight by using our load cell. We will show that our load cell is in calibration by weighing known weights of barley or water. The barley will be held in a mesh bag to allow us to weigh it externally on a separate scale. We will also be able to shake out any excess water held between the grains to ensure accuracy.
3) Aeration rate through water
We will measure the volumetric flow rate of the air with a flow rate meter.
4) Allow control of steeping water temperature
Using our control system we will set the inflow water temperature at different levels. Then, using a calibrated thermometer, we will measure the temperature of the water. We will then compare the controlled temperature to the measured temperature.
5) Keep steeping grain temperature below maximum
Using a calibrated thermometer we can measure the maximum temperature the grain reaches. We will gather data on our thermocouple readings and make sure the grain temperature is below the maximum allowed. To show that our thermocouples are calibrated we will take the calibrated thermometer and measure the grain at different times and different locations during the steeping process with an emphasis on the middle of the deepest part of the grain bed where it will likely be hottest. We will record the temperature and compare our measured temperature to the temperature given to us by our thermocouples.
6) Drain steeping water
Using a certified stopwatch we will time how long it takes for the vessel to drain. Then we will remove the cleaning cap on the ducting to check that all water has drained from the grain.
7) Keep germinating grain temperature below maximum
Using a calibrated thermometer we can measure the maximum temperature the grain reaches. We will gather data on our thermocouple readings and make sure the grain temperature is below the maximum allowed. To show that our thermocouples are calibrated we will take the calibrated thermometer and measure the grain at different times and different locations during the germination process with an emphasis on the middle of the deepest part of the grain bed where it will likely be hottest. We will record the temperature and compare our measured temperature to the temperature given to us by our thermocouples.
8) Keep germinating grain temperature above minimum
Using a calibrated thermometer we can measure the minimum temperature the grain reaches. We will gather data on our thermocouple readings and make sure the grain temperature is above the minimum allowed. To show that our thermocouples are calibrated we will take the calibrated thermometer and measure the grain at different times and different locations during the process with an emphasis on the shallowest part of the grain bed where it will likely be coolest and record the temperatures. We will compare our measured temperatures to the temperatures given to us by our thermocouples. To make sure that the heating system works we will cool a temperature probe with ice water to "trick" the control system into turning the heat exchanger on.
9) Mix grain
Using a certified stopwatch we will measure the time it takes to complete one mixing cycle. A mixing cycle includes the time for one auger arm rotation about the chamber to be completed plus the amount of time until the auger arm begins its next rotation. Auger arm rotation will take around 5 minutes so the interval between rotations will be around 7 hours and 55 minutes. To make sure that grain is mixed uniformly we will place batches of colored barley grains in several locations of the grain bed and run the cycle. After the cycle runs we will view the grain bed. If all of the batches of colored grain have been visibly disturbed, we know that the augers are preventing matting, and mixing the grain.
10) Allow adjustment of airflow rate
Using an anemometer and varying the airflow rate we can verify that the malter can reach both the minimum and maximum air flow rate required. We will place the anemometer inside the ducting after the heat exchanger to make sure that the airflow rates are attained.
11) Allow temperature adjustment of air
Using a calibrated thermometer we can measure the temperature of the air as we vary it using the control system. We will measure the temperature in the duct after the heat exchanger and in the outlet duct.
12) Recirculate air
By placing an anemometer on the inlet side of the fan and on the outlet/recirculation duct we can measure what percentage of exhaust air is flowing back into the malting vessel.
13) Load barley in less than 15 minutes
We will load the maximum barley batch size and time it using a certified stopwatch and measure how long it takes.
14) Unload barley in less than 15 minutes
We will unload 98% of the maximum barley batch size and time it using a certified stopwatch and measure how long it takes.
15) Shall be less than 72" wide on one side
We will use a certified measuring tape and measure the dimensions of the malter on all sides to make sure it will fit through a double wide door. We will also move the malter through a door to make sure it fits.
16) Malter shall weigh less than 700 lbs. unloaded
Using a certified scale we will weigh the unloaded weight of the malter.
17) Process 150 lbs of barely
We will run the malter with both a minimum (150lb.) load and a maximum (300lb.) load to make sure it can function properly at both levels. We will show data and approval from our sponsors that the malter can successfully process 150 - 300 pounds of barley.
18) Cost less than $20,000 to build and test
We will tally our entire budget on the website and in our final report to make sure we stay below the maximum.
To test this requirement we will measure the amount of water flowing out of the malting vessel through the overflow drain in a specified time. These measurements will be taken with a certified stopwatch and a graduated cylinder.
2) Increase moisture content of barley
Before steeping the barley we will weigh it, then after steeping/couching we will weigh it again. We know that barley starts with a moisture content of around 10%, so when the barley is at a moisture content of 45% we can predict its weight by using our load cell. We will show that our load cell is in calibration by weighing known weights of barley or water. The barley will be held in a mesh bag to allow us to weigh it externally on a separate scale. We will also be able to shake out any excess water held between the grains to ensure accuracy.
3) Aeration rate through water
We will measure the volumetric flow rate of the air with a flow rate meter.
4) Allow control of steeping water temperature
Using our control system we will set the inflow water temperature at different levels. Then, using a calibrated thermometer, we will measure the temperature of the water. We will then compare the controlled temperature to the measured temperature.
5) Keep steeping grain temperature below maximum
Using a calibrated thermometer we can measure the maximum temperature the grain reaches. We will gather data on our thermocouple readings and make sure the grain temperature is below the maximum allowed. To show that our thermocouples are calibrated we will take the calibrated thermometer and measure the grain at different times and different locations during the steeping process with an emphasis on the middle of the deepest part of the grain bed where it will likely be hottest. We will record the temperature and compare our measured temperature to the temperature given to us by our thermocouples.
6) Drain steeping water
Using a certified stopwatch we will time how long it takes for the vessel to drain. Then we will remove the cleaning cap on the ducting to check that all water has drained from the grain.
7) Keep germinating grain temperature below maximum
Using a calibrated thermometer we can measure the maximum temperature the grain reaches. We will gather data on our thermocouple readings and make sure the grain temperature is below the maximum allowed. To show that our thermocouples are calibrated we will take the calibrated thermometer and measure the grain at different times and different locations during the germination process with an emphasis on the middle of the deepest part of the grain bed where it will likely be hottest. We will record the temperature and compare our measured temperature to the temperature given to us by our thermocouples.
8) Keep germinating grain temperature above minimum
Using a calibrated thermometer we can measure the minimum temperature the grain reaches. We will gather data on our thermocouple readings and make sure the grain temperature is above the minimum allowed. To show that our thermocouples are calibrated we will take the calibrated thermometer and measure the grain at different times and different locations during the process with an emphasis on the shallowest part of the grain bed where it will likely be coolest and record the temperatures. We will compare our measured temperatures to the temperatures given to us by our thermocouples. To make sure that the heating system works we will cool a temperature probe with ice water to "trick" the control system into turning the heat exchanger on.
9) Mix grain
Using a certified stopwatch we will measure the time it takes to complete one mixing cycle. A mixing cycle includes the time for one auger arm rotation about the chamber to be completed plus the amount of time until the auger arm begins its next rotation. Auger arm rotation will take around 5 minutes so the interval between rotations will be around 7 hours and 55 minutes. To make sure that grain is mixed uniformly we will place batches of colored barley grains in several locations of the grain bed and run the cycle. After the cycle runs we will view the grain bed. If all of the batches of colored grain have been visibly disturbed, we know that the augers are preventing matting, and mixing the grain.
10) Allow adjustment of airflow rate
Using an anemometer and varying the airflow rate we can verify that the malter can reach both the minimum and maximum air flow rate required. We will place the anemometer inside the ducting after the heat exchanger to make sure that the airflow rates are attained.
11) Allow temperature adjustment of air
Using a calibrated thermometer we can measure the temperature of the air as we vary it using the control system. We will measure the temperature in the duct after the heat exchanger and in the outlet duct.
12) Recirculate air
By placing an anemometer on the inlet side of the fan and on the outlet/recirculation duct we can measure what percentage of exhaust air is flowing back into the malting vessel.
13) Load barley in less than 15 minutes
We will load the maximum barley batch size and time it using a certified stopwatch and measure how long it takes.
14) Unload barley in less than 15 minutes
We will unload 98% of the maximum barley batch size and time it using a certified stopwatch and measure how long it takes.
15) Shall be less than 72" wide on one side
We will use a certified measuring tape and measure the dimensions of the malter on all sides to make sure it will fit through a double wide door. We will also move the malter through a door to make sure it fits.
16) Malter shall weigh less than 700 lbs. unloaded
Using a certified scale we will weigh the unloaded weight of the malter.
17) Process 150 lbs of barely
We will run the malter with both a minimum (150lb.) load and a maximum (300lb.) load to make sure it can function properly at both levels. We will show data and approval from our sponsors that the malter can successfully process 150 - 300 pounds of barley.
18) Cost less than $20,000 to build and test
We will tally our entire budget on the website and in our final report to make sure we stay below the maximum.
