Documente Academic
Documente Profesional
Documente Cultură
Optimizing and Testing Novel Fin Designs Fabricated with Additive Manufacturing
A Statement of Work for the development of a new heat exchanger tube using the process known as additive manufacturing, with the intent of operating in a fluid to air environment. Yes Intellectual Property Agreement Yes Non-Disclosure Agreement
Christopher Zerphey Dalton Tallia Derek M. Hall Marin Tola Frank Wolff
2/21/2012
Executive Summary
Large industrial pumps are extensively relied on in many industrial applications. Many of these pumps require cooling of their bearing oil for uninterrupted use. The fin structure in current commercial oil cooling systems is restricted to simple configurations imposed by traditional manufacturing processes. Recent strides in additive manufacturing have reached a point where printings of metal alloy structures with widths of 0.04 are now possible. This recent innovation in manufacturing technology allows for novel fin design beyond the capabilities of current fabrication techniques. In addition to the increase in design possibilities, this process wastes less material. This study focuses on incorporating this new technology into the production of bearing oil heat exchanger pipe fins for large industrial pumps. A series of pipes one foot in length with novel fin designs are to be designed and printed in a bronze infused stainless steel alloy. Each pipe will be tested in a custom designed Test Rig and compared to a standard pipe of an identical material. The Test Rig will consist of a hot oil reservoir, maintained at a constant temperature of 200300oF. The Test Rig will include temperature and pressure sensors on either side of a detachable foot long heat exchanger section that will be exposed to forced air convection. Oil will flow through the test section at 0.3 gallons per minute (gpm). The placement of the sensors will allow for accurate measurements of changing temperature and pressure across the test section. The collected data will allow for correlations to be derived comparing the designed fin geometries with existing extended surface designs. The data collected from these sensors will be used to determine the effectiveness of the printed designs.
Table of Contents
Executive Summary ................................................................................................................. 1 Table of Contents ..................................................................................................................... 2 Nomenclature ........................................................................................................................... 3 1.0 Introduction ........................................................................................................................ 4 1.1 Initial Problem Statement .................................................................................................. 4 1.2 Objectives......................................................................................................................... 4 2.0 Customer Needs................................................................................................................. 5 2.1 Gathering Customer Input ................................................................................................ 5 2.2 Weighing Customer Needs ............................................................................................... 5 3.0 External Search .................................................................................................................. 6 3.1 Patents ............................................................................................................................. 6 3.2 Existing Products .............................................................................................................. 8 4.0 Engineering Specifications ............................................................................................... 8 4.1 Establishing Target Specifications .................................................................................... 8 4.2 Relating Specifications to Customer Needs ...................................................................... 9 5.0 Concept Generation and Selection ..................................................................................10 5.1 Problem Clarification .......................................................................................................10 5.2 Concept Generation ........................................................................................................11 5.3 Concept Selection ...........................................................................................................15 6.0 System Level Design ........................................................................................................19 6.1 Test Rig ...........................................................................................................................19 6.2 Heat Exchanger Design ...................................................................................................24 7.0 Special Topics ...................................................................................................................24 7.1 Preliminary Economic Analysis- Budget and Vendor Purchase Information .....................24 7.2 Project Management .......................................................................................................25 7.3 Risk Plan and Safety .......................................................................................................26 7.4 Ethics Statement .............................................................................................................29 7.5 Environmental Statement ................................................................................................29 7.6 Communication and Coordination with Sponsor ..............................................................30 References ..............................................................................................................................31 Appendix .................................................................................................................................32 A1: Deliverables Agreement ..................................................................................................32 A2: Gantt Chart .....................................................................................................................33 A3: Resumes .........................................................................................................................34 A4: Miscellaneous Figures.....................................................................................................39 A5: Notes ..............................................................................................................................41
Nomenclature
A: Af: Cp: di: do: : T: g: gpm: Gr: h: L: k: : Nu: Pr: q: q: Ra: Re: : Rh: Ri: Ro: Rp: : U: : : : Area Fin Area Specific Heat Inner Diameter Outer Diameter Fin Efficiency Temperature Difference Gravitational Acceleration Gallons Per Minute Grashoff Number Convection heat transfer coefficient length Thermal Conductivity Mass Flow Rate Nusselt Number Prandtl Number Rate of heat transfer Heat flux Raleigh Number Reynolds Number Insulating Value Hot side Convection Resistance Insulation Resistance Cold Side Resistance Pipe Resistance Fin Thickness Overall heat transfer coefficient Coefficient for Thermal Expansion Viscosity Kinematic Viscosity
1.0 Introduction
1.1 Initial Problem Statement
Nearly all premature bearing failures in large pumps result from two common problem (Burge, 2010). Either the lubricant overheats or contaminants enter into the lubrication system (Burge, 2010). Therefore, effective and continuous cooling of bearing lubrication is an integral part of continuous operation of industrial pumps. One frequent application used to improve heat transfer is the fabrication of extended surfaces, also known as fins, along the tubing of a heat transfer device (Incropera, Dewitt, Bergman, & Lavine, 2006). However, the current fin structure in commercial oil cooling system tubes are limited by traditional manufacturing processes. By implementing a process known as additive manufacturing, fin designs can be improved and fabricated into lattices that would otherwise be impossible. Additive manufacturing differs from current manufacturing techniques as this technology builds models through layering a process (Gibson, Rosen, & Stucker, 2010). This layering process builds a model from the bottom up to produce the desired item rather than removing materials to make the model like traditional machining (Gibson et al, 2010). This layering approach is fundamentally different from current fabrication techniques and allows for intricate and complex designs both inside and outside a heat exchanger tube with no residual materials. Therefore, the primary focus of the project is to develop a new fluid to air heat exchanger pipe using additive manufacturing. Several designs are to be produced with a focus on complex lattice structures and novel fin designs. Three of these pipe designs will be printed and tested in a custom made Test Rig; the results of which will benchmark the performance of the new designs with current methods of heat exchange. The deliverables are the printed pipes and a Test Rig capable of measuring the temperature and pressure drop across different pipes in a fluid to air heat exchange.
1.2 Objectives
Harnessing the unique capabilities of additive manufacturing for fin design provides the challenge of maximizing a pipes heat transfer capabilities without imposing a large pressure drop within the system. Formulating a design that achieves these two conflicting requirements requires diligent analysis of the physical implications attached to adding additional fin structures. Therefore, a compromise between these two requirements will need to be made in order to construct the most effective design for industrial applications. The main objective is identifying what is an acceptable amount of pressure lost per unit of heat transferred. This challenge will be resolved with a thorough review of the fundamental laws of heat and mass transfer within in pipes. Another complication to be addressed is the construction of a Test Rig capable of measuring heat loss and pressure drops from each printed pipe. To do so in an accurate manner requires sensors placed in locations that minimize the uncertainty of the readings. As a result, another objective will be to design a Test Rig were measurements taken are representative of the pipe designs heat transfer effectiveness. This can be accomplished by conducting a review of the sensors available and selecting a sensor that best meets the customers needs.
means of comparing each need by numerical values; 0.5 for less importance, 1.0 for equal importance, and 2 for high importance. This matrix is tabulated in Table 2. The results allowed the team to focus on the most important customer needs in the concept generation process, as well as establish scoring criteria during the concept selection process to be discussed in Section 5.3 Table 1: Customer Needs Hierarchy Ranked by Importance for the Test Rig
No. 1 2 3 4 5 6 7 8 9 Test Rig Operates Safely Accurate Temperature Reading across the Heat Exchanger Allow Analysis of Data Obtained from the Experiment Capable of Handling Different Size Heat Exchangers Repeatable Test Results Low Maintenance Between Testing Operations Able to be Transported Accurate Pressure Reading across the Heat Exchanger Low Test Rig Production Cost Need Importance 1 1 2 2 1 3 3 2 1
Table 2: Analytical Hierarchy Process of Identified Specifications for the Test Rig
Criteria A B C D E F G H I A 1.00 1.00 0.50 0.50 2.00 0.50 0.50 0.50 1.00 B 1.00 1.00 1.00 0.50 1.00 0.50 0.50 0.50 1.00 C 2.00 1.00 1.00 1.00 1.00 0.50 0.50 0.50 1.00 D 2.00 2.00 1.00 1.00 2.00 0.50 0.50 1.00 2.00 E 0.50 1.00 1.00 0.50 1.00 0.50 0.50 0.50 1.00 F 2.00 2.00 2.00 2.00 2.00 1.00 1.00 2.00 2.00 G 2.00 2.00 2.00 2.00 2.00 1.00 1.00 2.00 2.00 H 2.00 2.00 2.00 1.00 2.00 0.50 0.50 1.00 2.00 I 1.00 1.00 1.00 0.50 1.00 0.50 0.50 0.50 1.00 Total Weight
A = Safety-Test Rig Operation B = Accurate Temp. Reading C = Allows analysis of resulting data D = Capable of meeting variable demands E = Repeatability F = Low Maintence G = Able to be Transported H = Accurate Pressure Reading I = Low Cost
is one approach that could be used in our project. In addition, one of our fin patterns could expand from this design with incremental innovations to this concept.
Figure 1 (a-b): U.S Patent 6668915 B1 Non-Uniform Fin Design. Another patent researched was United States Patent number 7,866,377B2, which is titled, Method of Using Minimal Surfaces and Minimal Skeletons to Make Heat Exchanger Components. Essentially, this patent goes over a type of additive manufacturing called stereolithography. By generating a stereolithography file the user can repeat two-dimensional patterns to produce a three-dimensional surface by depositing layers of material onto the top surface of a base (Slaughter, 2011). This concept is visualized in Figure 2. The inventor states that the process can reduce surface area, reduce manufacturing cost, improve efficiency, and provide good flow properties in the heat exchanger through the use of an additive process (Slaughter, 2011).
Figure 2: US Patent 7,866,377-B2 Heat Exchanger from Additive Manufacturing These characteristics show that additive manufacturing process is effective and encourage engineers to use them in heat exchanger design. The patent goes over a few possible ways to use stereolithography in the design of heat exchangers that minimize overall size without significantly compromising performance. Contrastingly, the group looks to maximize surface area with additive manufacturing to increase the heat exchanger effectiveness substantially.
United States Patent number US 7,871,578,578B2 is titled, Micro Heat Exchanger with Thermally Conductive Porous Network and outlines the mesh and lattice method of internal heat exchanger design. In the background section of the patent many assertions can be noted that directly apply to the Flowserve project. One of these assertions is that it is desirable to reduce the size of the heat exchanger for a given rate of heat exchange. In other words, as the surface areato-volume ratio increases, the contact area between the pipes fin structures and surrounding medium increases (Schmidt, 2011). The patent goes on to lay claim to several porous networks and designs that the inventor has outlined. These concepts will be considered when developing the groups designs for heat exchangers.
least 1000 watts so that there is sufficient power to overcome thermal losses from the reservoir, tubing, and heat exchanger. An insulation R value of greater than 2 was chosen to minimize losses through the reservoir walls. A more detailed explanation of thermal losses by the system can be seen in Section 6.0. With respect to the flow rate, the sponsor did not provide a specific flow rate for the oil. Thus the team looked at the Penn State Heat Transfer Laboratory Test Rig to determine an appropriate flow rate since it operated under similar conditions. Based on a 0.3 gpm flow rate a storage capacity of greater than six liters was chosen. This size will have a large volumetric ratio of stored hot oil with respect to the returning cold oil thus maintaining a stable reservoir temperature. It would take 5 minutes for the oil to be completely recirculated within the system. The temperature and pressure measurements across our heat exchanger are critical requirements to determine the heat exchanger effectiveness. A less than 2 percent accuracy error was chosen to reduce the compounding effect in error caused from using collected data in multiple equations. In addition, the two percent error correlates to accuracy limitations on commercial temperature sensors as shown in A4 of the Appendix. Table 3: Target Engineering Specifications
No. 1 2 3 4 5 6 7 8 9 Test Rig Storage Capacity Test Rig Production Cost T Measurement Uncertainty Test Rig Heating Element Output Test Rig Flow Rate P Measurement Uncertainty Data Reading Test Rig Insulation Simplified Design Metric Units L US$ % W gpm % / R / Value >6 500 <2 1000 0.20-0.50 <2 Yes >2 Yes
Table 4: Needs-Metrics Matrix for the Test Rig Test Rig Heating Element output
T Measurement Uncertainty
P Measurement Uncertainty
Need Test Rig Operates Safely Accurate Temperature Reading Allow Analysis of Data Obtained from the Experiment Capable Handling Different Size Heat Exchangers Repeatable of Test Results Low Maintenance Between Testing Operations Able to be Transported Accurate Pressure Reading Low Test Rig Production Cost
Metric
* * * * * *
* * *
* * * *
Simplified Design
Data Reading
Heat source
Substructure Material
Automotive Pumps
Infrared
Thermistor
12
With respect to pump selection, many different pump concepts were explored in order to find the best match to the system requirements. Before the sponsor disclosed the fluid and temperature constraints, lower priced plastic pumps, priced below $50, were an attractive solution because they could be purchased at a local distributor such as Home Depot or Lowes. For this idea, fountain and pond pumps were researched to see if they could provide the necessary flow at a low price. After the temperature constraints of 200-300F were set, the specifications for many products of that nature were found to be unable to operate in the assumed temperature range. Therefore, it was necessary to move to heavy-duty metal pumps. Grainger, an industrial supplier, was used to look for pumps that could handle the necessary temperature range. The Grainger search provided many pumps that could work, but revealed that most were rated for much higher flow rates than necessary and could not reach the upper limit of our temperature range. Various pumps from the Grainger search can be seen in Table 6. None of these pumps sufficiently suited the system needs, so an additional search was conducted for more options.
13
Table 6: Pump Specifications from Grainger Search BELL & DAYTON GOSSETT Rotary Gear TACO Pump, Pump, Pump Head, Circulator, Circulator, Pump Name 3/8 In., 1/3 HP 1/25hp 1/25hp Price ($) 198.75 130.70 138.60 Horsepower (HP) 0.33 0.04 0.04 Head (ft.) 7.5 9 15.00 Max Flow (gpm) 7.00 21.00 20.60 Temp (F) 210 240 240 Min. gpm @ Head (Ft.) n/a 4@9 10 @ 8
TACO Circulator Pump, 1/20 HP, 1.1 Amps 118.80 0.05 21.00 17.00 230 10 @ 10
The second Internet search provided better options that more closely suited the Test Rigs new requirements. A pump series made by the producer Grunfos was found to have various flow and head ranges that could suit the needs required by the Test Rig. Additionally, these pumps were cheaper than the pumps found in the initial search while still working in a similar temperature range. To supplement the Grunfos pumps, a search on eBay, an online bidding website, was conducted. This provided an additional option as one suitable pump was found. This pump was titled March High Temperature Pump for Brewing Home Brew and can be seen in Table 7 along with the Grunfos pumps. Displayed in Tables 6 and 7 are only the most relevant options, as many pumps were investigated prior to narrowing down the search to the ones listed in the tables. Overall, the search for a suitable pump provided many options for the group to pick from in the concept selection phase of the project. Table 7: Results from Grunfos and eBay Search Grundfos Grunfos Grundfos March High UP15-10F UP15-42F UP15-10B5 Temperature Circulator Recirculator Recirculator Pump for Pump Pump Pump Brewing (59896248) (59896155) (59896213) Home Brew
Pump Type
Grundfos UPS1558FRC 3Speed Circulator Pump w/ IFC, (59896343) $82.00 0.04 19.50 17.00 230
Price ($) Horsepower (HP) Head (ft.) Max Flow (gpm) Temp (F)
14
Our tubing layout will route hot oil from the reservoir to the pump, the oil will then travel vertically towards the testing section. After passing through the testing section the oil will return to the reservoir to repeat the process. There were multiple options that would satisfy our needs. One option was inexpensive ($1.29/foot) flexible high temperature tubing, but the high temperature specification from this manufacturer could only withstand temperatures of 140F. Other high temperature flexible tubes, like those from Texloc were able to withstand large temperature ranges from cryogenic to 1500F. The tubing from Garnet Midwest could withstand our required temperatures but could not be bought in small enough unit lengths for our needs. A third option would be to use common copper plumbing. Although not flexible and not as easily installed, both price and its ability to withstand temperature made it an attractive solution. Selection for the tubing can be shown in the Table 8. The selection was made on a basis of four factors that were rated from 1-10. The highest scoring option was the copper plumbing. It is able to withstand our temperature range, inexpensive, and available through online order as well as local hardware stores. Table 8: Concept Screening Matrix for Tubing Tubing Selection Tubing Type RF67-XFC from US-hose (flexible, high pressure SS hose) 10 2 6 8 26 PCSC TUBING COP 1/2ID L from Garnet Midwest (soft copper Tubing) Generic Copper Plumbing From local hardware store 9 8 10 5 32
6 5 6 8 25
Substructure: The tubing and other components will need to be supported by a substructure. The substructure will need to be both rigid and lightweight for transportation purposes. It will also need to be able to withstand contact with high temperature oil in the event of a system malfunction. A wooden frame will satisfy these needs. A completely metal frame and sheeting would also satisfy our requirements, although at a higher cost.
15
The team then selected a wooden substructure, which will make construction simpler, without a sacrificing the structural integrity. A concern was raised that using a combustible material in a high temperature application is dangerous. The ignition temperature of wood is well above 300F; therefore it is safe to use for this application. Reservoir and Heating: Three different techniques were considered for heating oil in the Test Rig. While gas propane is a valuable option it was eliminated since the team would like to use the Test Rig in an indoor environment. Also, using gas propane would require additional safety requirements without any additional benefits compared to an electric heating source. A submersible heating element was chosen over an external heating element to reduce risk to personnel and excess thermal loss. Once the use of a submersible heating element was chosen three options were considered for designing the reservoir and heating housing. Option 1 consisted of buying an industrial fryer that had an adequate heating element and volume but would cost $90-120. Option 2 consisted of buying a less expensive, $25-$35, deep fryer for the heating element and constructing our own reservoir with material from the Learning Factory. A later option introduced by the sponsor was Option 3; which was a pre-made hot fluid reservoir from a 2009 Penn State - Flowserve project. The selection was made on a basis of five factors that were rated from 1-10. Selection of the reservoir and heating element is shown below in Table 9. The team selected to use pre-made hot fluid reservoir with a 1000 watt heat source from Flowserve, this will reduce the total cost of the Test Rig. Table 9: Concept Screening Matrix for oil reservoir and heating element Storage and Heating Selection Option Price Heating element Availability Size Input/Output Total Industrial Fryer 1 7 7 6 3 24 Heating Elements 5 10 8 7 5 35 Flowserve Reservoir 10 5 6 8 10 39
Pressure Sensor: When it came to choosing a pressure sensor there were a few options. A regular u-tube monometer could be used, but it would create additional complications in the measurement process. Another option was a static pressure probe, which has the disadvantage of being sensitive to the orientation of flow. The best choice for pressure measurements will be a mechanical oil pressure gauge for an automobile. This type of pressure gauge has a range of 0 to 100 psi, can handle high temperatures and is accurate within two percent. This pressure range is within the operating conditions for our open flow system.
16
Selection for the pressure sensor can be shown in the Table 10 below. The selection was made on a basis of four factors that were rated from 1-10. The highest scoring option was the automotive oil pressure gauge. It is able to withstand high temperature, is inexpensive, accurate to two percent, and readily available online as well as local auto part stores. Table 10: Concept Screening Matrix for Pressure Sensors Pressure Sensor Selection Sensor Type Temp Range Price Accuracy Installation Ease Total Monometer 8 9 8 9 34 Pressure Probe 10 5 9 7 31 Oil gauge 10 10 9 10 39
Temperature: A variety of temperature sensors were considered for monitoring temperature change within the Test Rig. The specifications for Omega thermocouple types J, K, E and T, infrared scanners and thermistors were all researched and put into Table 11. Each option held its own merits and shortcomings. With respect to the customers priorities, the specifications below are rated based on accuracy being the highest priority and price being the second. The temperature range for each sensor was rated on a pass or fail basis as the Test Rigs temperature limits are 60- 300oF. These temperature limits originate from the highest temperature the pump models can withstand and the lowest temperature possible from the ambient temperature inside our testing location. The infrared scanner was the most expensive but it had the widest range of operating temperatures. Thermocouples had the advantage of being easy to setup and are inexpensive. The shortcoming of the thermocouple option was its accuracy. After comparing the customer needs to the differences in the specification for the three sensors, thermistors were selected as the best fit for the project. Table 11: Temperature Sensor Concept Matrix
Temperature Sensor Selection Sensor Type Price Accuracy Temperature Range Total Thermocouples 9 6 pass 15 Infrared Scanner 4 7 pass 11 Thermistor 9 8 pass 17
More detailed specification charts from Omega were placed in the Appendix under A4 Miscellaneous Figures. The charts in the appendix were used to formulate the sensor selection table.
17
Pump: The pump concept generation phase resulted in many potential options for the project. After narrowing down the results of the pump search, five pumps were selected for a concept screening matrix. The Grundfos pump had the cheapest price while providing a flow rate and head range within the systems requirements. The only downside of this pump is that the maximum workable temperature of 230F is at the lower end of our temperature range. The TACO and March High Temperature Pump both had higher temperature ranges at 240 and 250F respectively. The TACO pump was not selected due to the overly high flow and head ranges along with its high price. The March High Temperature Pump offered for sale on eBay was at first an appealing option. However, eBay is an online auction site and the price ended up exceeding the desired budget. Ultimately, the concept screening matrix showed that the Grundfos UP15-10F Circulator Pump was the best selection as it received the highest score as can be seen in Table 12. This matrix was completed by ranking each need on a scale from one to ten with, a ten signifying that the need was fully satisfied. The system head loss was calculated to be 5 feet. This head loss lowers the flow rate of the Grundfos pump to one that is very close to the value that is desired. See appendix A4 for a detailed specification of the Gundfos Pump. The group had concern about approaching the maximum head of the pump. After discussing the concern with the sponsor it was determined that this pump would satisfy the Test Rigs needs Table 12: Concept Screening Matrix for Pump Selection
Pump Selection Grundfos UPS1558FRC 3Speed Circulator Pump w/ IFC, (59896343) 8 5 4 4 21
Pump Type
2 3 8 7 20
4 7 2 5 18
18
Figure 8: Schematic of Test Rig Heat Source The selection of the heat source required an estimation of losses through the heat exchanger, tubing network, and oil reservoir. The desired temperature in the reservoir was set by the sponsor at 200-300F. The limitations of the pump forced us to select an operating temperature of 230F. This change in the temperature range was approved by the sponsor during the weekly meeting on February 3rd. The analysis through the tubing network was done by creating a thermal circuit extending from the flow in the pipe through the copper wall, insulation, and then to free convection. The flow inside the pipe will have a Reynolds number of 350 at the desired mass flow rate of 0.3 gpm. Using a Nusselt correlation the convection coefficient at this flow rate was determined to be 49 W/ (m2*K). The convection coefficient on the outer surface was found using free convection correlations. Important non-dimensional quantities used in the derivation were: Grashof (1.6*106), Raleigh (1.15*106), and Nusselt (8.85). These values resulted in a convection coefficient of 8.0 (W/m2*K). The conclusion from the thermal circuit was a loss of 2 watts for every meter of flow as demonstrated in equations 3 through 15. The designed tubing path will have less than 2 meters of flow leaving the resultant loss as negligible. Losses through the reservoir were made by creating a thermal circuit similar to the methods used in analyzing tubing loss and are shown in equations 16 through 18.
19
Heat Exchanger Losses: Losses through the heat exchanger were estimated using a thermal circuit. While preliminary designs are being produced for the heat exchanger there are no completed designs that can be used as of yet to model the losses. For this reason we selected to use a scenario in which very efficient fins ( = 1) are present on both the internal and external surfaces of the heat exchanger. The internal fin lengths were modeled as the full inner diameter of the tube, with a thickness = 3.175 mm. The external fins were given a length of 60 mm and a thickness = 6.0 mm. The number of fins placed on the interior and exterior surface was 100 and 400 respectively. Because the heat exchangers design is currently undetermined estimations were made for the interior and exterior convection coefficients. The value of hoil was selected at 100 (W/m2K), double that of the convection coefficient determined in the pipe. We expect to have a tripping action that moves the flow to turbulence in our test section and thus increase our rate of heat transfer. The exterior convection coefficient was found using the Churchill-Bernstein correlation for a cylinder in cross-flow. The resulting coefficient was found to be 51.314 (W/m2K); however because the exact contribution of the fins to the flow is unknown we doubled the value as a precautionary measure to 100 (W/m2K).
( [ *( ) ( )+ ) *( ) ( )+ ]
(1)
The losses can then be calculated with the known temperature difference between the hot oil and the cooling air. With the air at 70F and the oil at 230F a T can be determined. The resulting power loss through the heat exchanger is shown as: (2) Tubing Losses: Losses through the tubing were conducted using a thermal circuit approach and determined a final value based on watts per meter of the tubing length. The mean temperature difference between the oil and air was made to be the difference between reservoir temperature and that of the ambient air. Convection Coefficient inside Tube: (3)
(4)
(5)
20
{ Tube Resistance:
(6)
(10) ( ) (11)
(12)
(13)
(14)
(15)
Reservoir Losses: The losses throughout the reservoirs surface were estimated using a thermal circuit technique. Convection coefficients on both the internal and external surfaces were estimated. For free convection of air over a flat plate a high value would be 25 W/(m2*K), which is the estimated value on the external surface. A value of 100 W/(m2*K) was selected for the internal surface of the reservoir based on the 2009 Penn State-Flowserve report; in which a thermal analysis was also conducted on the reservoir.
21
Heat flux: [ Total Loss of Reservoir: (17) Total Thermal Losses from the Test Rig and Heat Exchanger: (18) Currently without a designed heat exchanger there had to be a fair amount of assumptions in determining a power loss. We attempted to model a scenario in which large losses would be observed across our heat exchanger; requiring the most power from our heat source to operate the test loop. As stated above we did this by selecting a large fin surface area with fins at 100% efficiency. Combining the losses from reservoir, piping travel, and across the heat exchanger itself, we expect to see 210.96 Watts across the system when a high performance heat exchanger is in place. We will be using a reservoir supplied from Flowserve that has a 1000 watt heating element. This is more than sufficient to regain the losses that we will dissipate through our system. Tubing Network: The tubing network will feature diameter insulated copper tubing. The diameter matches that of our anticipated heat exchanger designs. The diameter also results in laminar flow at a 0.3 gpm flow rate, which will minimize thermal losses as the hot oil enters the heat exchanger. As shown previously; considering laminar flow and the surrounding insulation the heat loss through the tubing will be negligible. The designed network will pull oil from the reservoir through the pump and then make a vertical climb to the testing section. This will be the highest point throughout the Test Rig, allowing oil to drain back to the reservoir while the heat exchanger is being exchanged. The oil will then pass through the test section and be returned to the reservoir. Pump: In the interest of cost we selected a 1/25 HP Circulator pump that can deliver a 0-8 gpm flow rate. The team will use a valve to maintain our desired flow rate. The pump is designed to operate at temperatures up to 230F fluid which is within our temperature range and the deciding factor for our thermal analysis. Pressure Loss Factors: These are the contributing factors for major and minor loss in the test loop. (19) ] (16)
(20)
22
Minor Losses: The contributing factors to minor losses in our system were the result of 6x90 (90 = 30) bends, one valve (valve = 470) and 4 T connectors (T = 20). , (21)
Major Losses: The head loss is a result of the loss due to friction as the oil travels the length of the pipe and is modeled by the above equation (20) for pressure loss P. The only factors left to be included are length and internal diameter, which are calculated below (22)
Head Loss: There is an additional loss that occurs as the oil has to make a climb to the test section. The contributing loss from the section is modeled by fluid statics. (23) HX Pressure Loss: Losses through the heat exchanger were done considering the interior fins as a lattice structure. With this assumption empirical correlations (Forchheimer Equation) were used for homogeneous isotropic foams with open cells. This modeled the pressure drop per unit length that we would observe in our heat exchanger. Where: is oil viscosity, is oil density, U is average oil velocity, and F and K are empirical coefficients. (24)
Factors F and K are found using the following correlations with: porosity (), ligament diameter (df), and pore diameter (Dp). ( ) { }
(25)
(26)
23
Total Pressure losses through the System: The total pressure drop through our system will then be: (28) The head loss through the system will then be 1.898 psi or 5 feet of water. Our selected pump is specified to run at a maximum of 5.58 ft of head. As the maximum operable head loss is reached the flow rate will decrease; this leaves our flow rate closer to the desired value of 0.3 gpm and will lower the need for the valve to restrict the flow. Data Acquisition: It is desired to collect the temperature and pressure difference of the oil across the heat exchanger. In addition, the air flow rate and temperature difference will be measured. Tconnectors will be implemented to accommodate both thermistors and pressure gages at both the entrance and exit of the heat exchanger. The anemometer will gather both flow rate and temperature of the air. Substructure: The substructure as seen in section 6.1 on Figure 8 of the Test Rig will use 2x4 lumber and oriented strand board (OSB). This simple light weight structure will have enough rigidity to support the hot fluid reservoir. The 2x4 structure will consist of three 30 boards connected on end by two 24 boards. Over this structure will be a sheet of the OSB board to support the reservoir and pump. A second sheet of OSB board will be attached orthogonally to the previous on a 2x4 frame. This section will separate the heat exchanger from the rest of the Test Rig. Figure 8 shows how the substructure will support both the heat reservoir and other components of the Test Rig while separating the heat exchanger from the rest of the system.
25
Gantt Chart
Days Month Deliverables Agreement Statement of Work Final Report DSR Concept Rig Design Customer Needs Evaluation Concept Generation Test Rig Patent Search Existing Technology Search Engineering Specifications Order Box Fan Order Piping Order Pump Order Heat Reservoir Order Data Collector Order Pressure Probe Order Temperature Probe Select Temperature Probe Select Pressure Probe Select Box Fan Select Heat Reservoir Select Data Collection Test Rig Construction Fin Concept Design Fin Concept Design 2 Fin Design Testing
7 January 14 21 28
Figure 9: Gantt Chart with Milestones in Green As mechanical engineers, the teams primary skill sets revolve around mechanical system design as well as heat transfer concepts. Other key skills that will be required for this project are machining and welding skills as well as software and electrical interfacing knowledge. While members of the team have strengths in these areas, the team is prepared to seek help from professors and outside resources to meet the design goals of the project. All tasks defined in the Gantt chart must be completed on time, in order to insure a complete and working Test Rig. After designing and performing calculations on the systems, Team Flow Gurus will first build the Test Rig structure as this will be the key building block which all data will be collected on. The structure must be able to hold at least 6 liters of oil and maintain a constant temperature within the reservoir. The team will next install the tubing with the proper connections to allow for easy access and interchangeability of the heat exchanger tube. Once the Test Rig is built and calibrated property, data will be collected for comparison between the different heat exchanger designs. What is expected by team Flow Gurus can has been disclosed in the deliverable agreement which can be seen in A1 of the Appendix.
tests as an additional safety measure. Prior to the testing of the heated fluids, a test will be performed at low temperatures to check for leaks or other possible safety concerns. Ultimately, if any issue arises the team will address it. This may be as severe as redesigning a component, but safety must come first. Additionally, collection bins placed under the rig will address any spill risk. Also, testing the assembly with water first will allow for any flaws in the system to be identified. This will prevent any damage that the hot oil could cause from occurring because all leaks will have been found and sealed. Other risks can come through setbacks in the projects development. A high risk comes in the form of schedule delays. At times the group will experience setbacks or require more time to complete a task. To combat this, the group will look to always stay days ahead of schedule at all times and at the worst complete tasks by the completion date on the Gantt Chart. Throughout the project the group will make sure that the critical path is a priority so that other tasks are not held up. Dealing with a customer also poses possible risks that the group must account for. The customer could request a change in design or be unsatisfied with current progress. To account for this the group will maintain constant contact with the sponsor throughout the project and provide updates of any changes with the project status. This should lead to a satisfied customer as they will know what to expect and will allow for any changes in design to quickly be identified. The final component that could be a risk to the development of the project concerns the actual materials being used. The group will have to order parts and expect for them to work. Any delays receiving the parts could be a major setback. Therefore, it is necessary to place orders far ahead of time. Additionally, the Test Rig is being developed first to account for any setbacks. These components could end up failing so fall back strategies have been put in place. Many risks have been identified and with actions to minimize them the project should progress as planned. The group will continue to identify and address possible problems throughout the progression of the project.
27
Risk
Schedule Delays Spills
Level
High
Actions To Minimize
-Keep up with Gant chart -Dont let setbacks delay other work -Collection bin under the Test Rig in case of spills -Test with water to minimize spill damage -Place some sort of large material between Test Rig and testers -Test Rig with water at low temperatures for leaks -Wear appropriate safety gear such as goggles, gloves, jackets -Appoint a safety manager
Moderate
Safety
High
Low
-Communicate throughout each step of the -Allow ample time for project modifications to design -Confirm design concept before getting parts produced -Prevent any damage from occurring to the data logger - Purchase pump capable of performing necessary work -Work pump within its specified capacity - Test early in case of failure -Place orders before spring break (3/1/2012) so that all materials will have arrived by the groups return (3/12/2012) -Design Test Rig first to allow for parts to be shipped - Borrow one from Reber or other campus source -Use warranty to get replacement pump - Purchase new pump -Modify design -Order parts early in the project
Low Low
Moderate
Moderate
-Sufficient planning and design -Change or modify design -Test with water at room temperature prior -Seal up all leaks to testing heated oil -Communicate throughout the process -If unsatisfied at any point find -Get a clear understanding of the customer out why needs -Find a new approach to satisfy the customer needs
Low
28
The Flow Gurus will also attempt to have as minimal of an environmental impact as possible by using as few resources as possible in the construction of the Test Rig. This will cut down on costs, but also prevent resources from being wasted. The group will also use electronic resources as opposed to paper in order to additionally minimize environmental impact.
On Thursday February 2nd at 12:30 PM the group had its first teleconference call with the sponsor using the meeting@pennstate software. The meeting place was on the 2nd floor of the Deike building in a study room. The Thursday meeting time is a weekly occurrence and will complement e-mail communication well. As stated before, a weekly memo is sent out the Tuesday prior to the teleconference so that the sponsor can get a general update of the groups progress. Communication through e-mails, memos, and teleconferences will provide ample contact between the sponsor and group. Any problems can be immediately addressed through email and can be taken into further detail through the teleconference.
30
References
Branson, Spencer T. Heat Exchangers: Types, Design, and Applications. Hauppauge, NY: Nova Science, 2011. Print. Burge, Phil. (2010). PUMP BEARINGS; Bearing down on failures. Process Engineering, 38. Centaur Communication Ltd. "Code of Ethics - American Society of Mechanical Engineers (ASME) Colorado Section." American Society of Mechanical Engineers. Web. 10 Feb. 2012. <http://sections.asme.org/colorado/ethics.html>. Gibson, I., Rosen, D., & Stucker, B. (2010). Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing (pp. 7-8). New York: Springer. Incropera, Dewitt, Bergman, & Lavine. (2006). Fundamentals of Heat and Mass Transfer (Sixth.). Wiley & Sons Inc. Materna, Peter.(2003). Optimized Fins For Convective Heat Transfer, U.S. Patent 6668915-B1. Schmidt, Wayde R. Micro Heat Exchanger With Thermally Conductive Porous Network. United Technologies Corporation, assignee. Patent US 7,871,578,578B2. 18 Jan. 2011. Print. Slaughter, Victor B. Method of Using Minimal Surfaces and Minimal Skeletons to Make Heat Exchanger Components. The Boeing Company, assignee. Patent 7,866,377B2. 11 Jan. 2011. Print. Thors, P. and Narayanamurthy, R. (2005). Heat Transfer Tube with Grooved Inner Surface, U.S. Patent 6883597 B2.
31
Appendix
A1: Deliverables Agreement
Date 2/10/12 Project Title Flowserve Heat Exchanger Sponsor Company Flowserve Company Contact Andrew Schevets Phone (908) 859-7389 Email ASchevets@flowserve.com Faculty Coach Dr. Santoro Email rjs@psu.edu Team Name Flow Gurus Student Team (primary contact) Chris Zerphey crz5019@psu.edu
Derek Hall Dalton Talia Frank Wolfe Marin Tola dmh5373@psu.edu djt5061@psu.edu flw108@psu.edu mit5078@psu.edu
Problem Statement: Design and create a heat exchanger utilizing the metal printing technique. The heat exchanger will cool a hot liquid by air with forced convection. The heat exchanger will be tested with a rig created by the team and will be delivered to Flowserve upon completion of the project.
Deliverables:
1) Signed Deliverables Agreement 2) Weekly update memos (status reports); delivery method: 3) Statement of Work (copies to sponsor and instructor) 4) Design Specification Report (copies to sponsor, instructor) 5) Final Report (copies to sponsor, instructor and Learning Factory) 6) Poster (32 x 40) for Showcase 7) One-Page Project Recap 8) Functioning Test Rig that operates interchangeable heat exchangers of a 12 inch
length and 0.5 inch inner diameter. The rig must circulate a hot fluid through the heat exchanger and provide air flow for forced conduction over the heat exchanger. The rig must be able to read inlet and outlet pressures and temperatures from the heat exchanger. 9) Multiple heat exchangers are to be produced in accordance with the budget of the project. They are to maximize the amount of energy that can be removed from the hot fluid by utilizing the metal printing technology.
Delivery Date
February 7th Wed. Memo, Weekly February 17th March 15th,22nd April 30th April 14th April 30th April 30th
April 30th
32
Gantt Chart
Days Month Deliverables Agreement Statement of Work Final Report DSR Concept Rig Design Customer Needs Evaluation Concept Generation Test Rig Patent Search Existing Technology Search Engineering Specifications Order Box Fan Order Piping Order Pump Order Heat Reservoir Order Data Collector Order Pressure Probe Order Temperature Probe Select Temperature Probe Select Pressure Probe Select Box Fan Select Heat Reservoir Select Data Collection Test Rig Construction Fin Concept Design Fin Concept Design 2 Fin Design Testing
7 January February 14 21 28 35 42 49
91
98
105
April
33
A3: Resumes
Derek M. Hall
1270 Circleville Road State College PA, 16803 Phone: (607) 342-5440 dmh5373@psu.edu Education
Bachelors Degree in Energy Engineering, 2009 Present; 3.75 GPA Minor in Electrochemical Engineering The Pennsylvania State University University Park, PA 16801
Work Experiences
Researcher, Energy Institute State College, Pennsylvania. March 2011 - Present Improved the existing design of a high temperature electrophoresis system. Used electrochemical techniques to evaluate system parameters. Created an operational manual for a future user facility. Researcher, National Geothermal Competition State College, Pennsylvania. November 2010 - June 2011 Worked with a theoretical power plant design team funded by NREL. Modeled the performance of a theoretical coal gasification reactor. Identified optimal operational parameters to maximize reactor performance.
Honors/Awards
Society of Energy Engineers, Vice President Energy Institutes Student Achievement Award ABET Program Evaluation, Energy Engineer Student Representative Lean Sigma, Yellow Belt Society of Energy Engineers, Accreditation Liaison 2011-2012 December 2011 August 2011 June 2011 2010-2011
Publications
1.
Chandra, D., Conrad, C., Hall, D., Montebello, N., Weiner, A., Narasimharaju, A., Rajput, V., Phelan, E., Pisupati, S., Turaga, U., Izadi, G., Ram Mohan, A., Elsworth, D. (2011) Combined scCO2-EGS IGCC to reduce carbon emissions from power generation in the desert southwestern United States. Trans. Geotherm. Res. Council. 20 pp. October. Chandra, D., Conrad, C., Hall, D., Montebello, N., Weiner, A., Narasimharaju, A., Rajput, V., Phelan, E., Pisupati, S., Turaga, U., Izadi, G., Ram Mohan, A., Elsworth, D. (2011) Pairing integrated gasification and EGS geothermal systems to reduce consumptive water usage in arid environments. Submitted for publication. Geothermics. 40 pp. 34
2.
FRANCIS L. WOLFF
967 Southgate Drive, State College, PA 16801 (570) 926-1551 flw108@psu.edu Education The Pennsylvania State University, University Park, PA Bachelor of Science, Mechanical Engineering (December 2012) GPA of 3.69/4.00, Deans list x6 Relevant Courses Thermodynamics Vibration of Mechanical Systems Principles of Turbo-machinery
Heat Transfer Strength and Properties of Materials Microstructure Design of Structural Materials
Experience PSU/ARL Metals and Ceramics Processing Department Intern (July 2009 - Present) Pennsylvania State University, State College, PA Performed material analysis including; sample preparation, optical microscopy, and hardness testing (Vickers and Rockwell) for industrial and government programs. Experienced with cold spray and spray metal forming technology. U.S. Army Reserves Sergeant (November 2006 - May 2010) 392nd Signal Battalion, Tobyhanna, PA Assisted military and civilian I.T. specialist in establishing communication networks. Trained soldiers on the new WIN-T equipment that was fielded to the 392nd Signal BN. Validated 8 Satellite Transportable Terminal (STT) systems so they could be used in overseas operations. U.S. Army Specialist (July 2003 - July 2006) Bravo Co. 2-70th Armor Battalion, Ft. Riley, KS Maintained 22 M1A1 Abrams tanks over a course of 2.5 years, including a 13 month deployment in support of Operation Iraqi Freedom. Identified faults and implemented corrective actions for electrical, hydraulic, and mechanical systems on both the turret and hull of the M1A1 Abrams Main Battle Tank. Performed routine Preventive Maintenance Checks and Services (PMCS) to prevent component failure while operating in the field. Skills and Achievements Experience with Microsoft Office, SolidWorks, Matlab, ABAQUS, and DAQ software. Graduated as the Distinguished Honor Graduate during my Army Basic Training and AIT. Graduated on the Commandants list during Warrior Leadership Training. Active Security Clearance DoD
35
36
37
38
39
40
A5: BOM
Rig Structure Part Description 2 X 4 substructure (8' sections) 1/4 x 4 x 8 Utility OSB .5" x 1' type K tubing T fittings 90 degree fitting 1/2" coupling Insulation Fasteners (75 ct. screws) Thermistors Heat Source (donated) Pump (Estimated) Pressure Gage Plexiglass Sheet Shipping Total Price/Unit 3.00 6.57 2.59 0.65 0.36 0.29 3.90 8.57 25 85 85 15 25.49 # of units 2 1 8 2 8 3 2 1 2 1 1 2 2 Cost of Part 6.00 6.57 20.72 1.30 2.88 0.87 7.80 8.57 100.00 0.00 85.00 30.00 50.98 50.00 421.67
41
Tuesday 1/17/2012Class
Met with group for the first time Exchanged contact information o Derrick, Dmh5737@psu.edu, 607-342-5440 o Chris, Crz5019@psu.edu, 717-725-2639 o Frank, Flw108@psu.edu, 570-926-1551 o Marin, Mit5078@psu.edu, 267-897-0351 o Dalton, Djt5061@psu.edu, 267-614-4756 Found out meeting times outside of class o Wednesday after 4:30 o Thursday 11-1 Began thinking about the project o Applications o Are there previous experiments or existing data o Are we making multiple designs Thought out what to say in our first contact email
Thursday 1/19/2012Class
Identified future needs o Team contract o Gantt Chart o Meeting time for visit o Meeting time for telecomm o What to wear to visit o Weekly memo Class lecture on workplace customs and memo overview
42
Tuesday 1/24/2012Class
Team discussion consisted of brainstorming possible questions for the Flowserve visit o Will the heat exchanger clog o Cross flow vs. counter flow o Two designs Microfins Microtubing o Rig design specifications: Laminar vs. Turbulent flow o Velocity and mass flow rate in pipe For the future o Notes and questions for the 1/25/2012 Flowserve visit o Look into work done by Ralph Webb o Business casual attire o Set up teleconference o Deliverables RIG CAD Experiment results
Tuesday 1/30/2012Class
Team discussion o Type of oil being used resembles bearing oil o Safety components Lab jackets, goggles, gloves, cover deep fryer, plexi-glass shield o Secondary failure Big leak, pipe break, etc Place big collection bucket underneath o How big will test rig be and how will it be transported o Will oil be flammable? MSDS charts needed o Have safety review or designate a safety person o Assume system will have 10 feet of pipe o Insulation? Future Considerations o February 9th major report due For Next Time o For teleconference Have budget outlined Can the group borrow Flowserves data acquisition system Discuss safety concerns
44
Thursday 2/2/2012Class
Risk Assessment overview o Risk= Magnitude x Frequency o Cost benefit analysis Good design, low cost ratios o Ford Pinto Problem fix vs. Eating the cost Publicity ended up killing them Money saved initially ended up costing them o Risk Factors Marketing- Somebody else makes it first Technical- Example of iPhone antenna Schedule Manufacturing Reliability Product safety o Integrate risk reduction into Gantt Chart
o SOW due Friday so heat exchanger design will be completed in upcoming weeks o Can Lattice Assembly be opened, need .stl opener For sponsor o Deliverables agreement o SOW on 2/16/2012 o See if .stl file can be opened o Address for package o Heat exchanger design before spring break
47