MER 439 Design of Thermal Fluid Systems

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MER 439 - Design of Thermal Fluid
Systems Professor Bruno Union College Fall Term
2006
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Outline of Lecture 1

• (1) What is Design? What are Thermal/Fluid
  Systems?
• (2) Design Overview and An Example
• (3) Why this course? Or What we will learn and
  how we will learn it.
• (4) Design Project 1 - Refrigeration Cycle
• Description of Problem
• Team Assignments
• Responsibilities of Team Members

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What is Design?
The design process involves the application of
of concepts from engineering science in a
generally specified manner coupled with a
creative touch. (Boehm, 1987) (1) Conception -
creativity (2) Synthesis - involves learned
information and creative insight (3)
Analysis - learned concepts
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Overview of Design Process
Five Distinct Stages (1) Understanding the
problem (2) Concept Development (3) Detailed
Design (4) Project Engineering (5) Service
From Bejan, et. al., (1996)
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What is THERMAL/FLUID Design?

• Implies calculations and activities based on
  principles of thermodynamics, heat transfer and
  fluid mechanics.
• Components- fans, pumps, compressors, engines,
  heat and mass exchangers, etc
• Thermal systems use large numbers of components
• Processes in involve fluid motion

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A Compressed Air System

• Example Thermal/Fluids Design Problem
• A compressed air system is to be installed in a
  manufacturing plant to operate compressed air
  tools
• Adapted from Burmeister (1998)

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Step 1 - Estimate System Load

• Step 1 - Estimate Load on System (rate at which
  compressed air will be used
• List tools to be supplied and location

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Step 1 - Estimate System Load
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Step 1 - Estimate System Load

• Load factor is fraction of time that a tool
  operates during a shift
• Peak rate 1380 cfm
• Average Rate 50 of peak 690 cfm

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Step 2 - Estimate Comp. Capacity

• allow for 10 leakage
• allow for increased activity 5 per year for 5
  years
• Compressor Capacity 1380 x (1 0.1 0.25)
  1900 cfm
• Delivery 100 psig (most tools operate at 90
  psig Plus loss through system)

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Step 2 - Estimate Comp. Capacity
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Step 2 - Estimate Comp. Capacity

• Adjust value to account for non-constant load
  (50)
• Ignore 25 expansion factor
• Adjusted value
• W 150 kW (201 hp)
• Factor of 2 uncertainty in this value

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Step 3 - Estimate Piping Diameter

• Piping layout

Machine Shop 55 cfm
Cleaning Room 530 cfm
Compressor Room
Assembly Room 130 cfm
100 ft
Shipping Room 45 cfm
100 ft
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Step 3 - Estimate Piping Diameter

• Piping diameter is sized to handle the cleaning
  room air (530 cfm) machine shop air (55 cfm)
  with half the available pressure drop

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Actual Installation
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Syllabus

• Course Objectives
• Work in teams / Lead and Manage Projects
• Communicate Effectively
• Apply design methods and techniques, including
  optimization techniques, to Thermal/Fluid systems
• Learn the basics of Engineering Economic Analysis
• Introduce Engineering Ethics
• Introduce Entrepreneurship and business models
• Consider Non-Technical Constraints
• Assessments (grades)
• Refer to Syllabus

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Project Grading

• No Late Project Reports Will Be Accepted For Any
  Reason! In real life If you miss the Bid date
  you simply dont get the contract.
• Group Grade based on oral and written report.
• Individual Deliverables and Oral Based on your
  Homework, Quizzes, and individual role in
  projects and reports.
• Peer Evaluation by your teammates.
• Your Evaluation of your peers
• Project Notebook
• NO EXAMS / FINAL

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My Roles

• Upper Management
• In this role I am either your boss (if you are
  the team leader) or your boss boss (if you are
  working under a team leader.)
• In this role assume that I just have an MBA, and
  no engineering education.
• You may come to me for help with team issues or
  project management issues.
• Customer
• In this role I will supply the requirements for
  each project. (Initial Handouts / Project Intro)
• You may treat me as an engineering contact
  person at the customers company. Use me as a
  resource to gain clarification on the project
  requirements but I cant supply help on how to
  do the project that is why we contracted with
  your firm!

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My Roles (Cont.)

• Technical Consultant
• In this role I play the part of an almost
  Omniscient PhD in the Thermal Fluid Sciences.
• This is the role which is closest to my real
  life position.
• You may come to me for technical help but
  consultants are expensive! (2 hrs per team per
  project for free thereafter its 2 points per
  hour!)
• Conceptual help on new material (economics,
  optimization etc.) is free from your friendly
  neighborhood professor.

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Your Roles

• Each Design Team will function as if they are
  from different companies competing for the same
  contract (customer).
• You may only consult with YOUR TEAM MEMBERS or
  with ME (in any one of my roles)Consulting with
  members of another design team constitutes
  cheating.
• Your individual Roles within the team, and your
  teammates will change from project to project.

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Odds and Ends

• Please Read (and follow) the guidelines for
  Project Notebooks.
• Please Read (and follow) the guidelines for the
  formal design reports.
• These are critical documents and I expect that
  importance to be reflected in the writing /
  production quality of the reports.
• The course Web site is available through at
  engineering.union.edu/brunob. All handouts (and
  much additional info) are there.
• Check the web site often for updates on the
  course schedule.