engineering, design & system integration 3,000 hp wind tunnel
TRANSCRIPT
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Engineering, Design &
System Integration
3,000 HP Wind Tunnel
Blower, Motor, VFD &
PLC Control System
OEA PRESENTATIONDecember 1, 2016
Philadelphia, PA
P 215.542.8700 F 215.542.5652
Visit us online
www.Maidaeng.com
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PROJECT CRITERIA
Engineering, Design and System Integration
� Subcontractor to Aerolab to provide a “Turnkey” Open Jet Wind
Tunnel Air Delivery System for Honeywell
� Responsible from Concept through Commissioning
� Designed in Philadelphia, PA and Built in Mexicali, Mexico.
� Components and Systems
� 415,000 CFM Blower with Dampers and Silencers
� 3,000 HP Medium Voltage Motor
� Coupling (Drive Train)
� 3,000 HP Medium Voltage Variable Frequency Drive
� PLC Based Monitoring and Control System
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PROJECT ANALOGY
Would be similar to a 3,000 HP Vehicle
� Runs at speeds from 0 MPH to 230 MPH, + 1 %.
� Can go from 230 MPH to 0 MPH in less than 18 seconds.
� Can operate continuously in an ambient temperature of 125°F
� Designed for Seismic Zone 4
� Custom Dashboard (HMI)
� Cruise Control
� Has a life expectancy of 25 year.
� Comes with a One to Four Year Warrantee
� Global Procurement and Assembly of Custom Components
� Runs like a Well Designed Machine
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PROJECT EXECUTION
SCHEDULE
Conceptual Engineering June to Sept, 2015
Blower, Motor and VFD Procurement Sept to Nov 2015
Factory Inspections March to June 2016
Detailed PLC Panel Installation Design Feb to June 2016
WTC/PLC Fabrication Procurement May 2016
Equipment Shipped to Mexico June and July 2016
Equipment and System Installations June to Nov 2016
PLC Programming and HMI Screens Aug to Nov 2016
Site Inspections and Acceptances June to Nov 2016
Commissioning ` Oct and Nov 2016
Warrantee Through Nov 2017
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CONCEPTUAL ENGINEERING
Concept:
Proposed 4 alternative
arrangements and
based on discussions
with the client, selected
the this arrangement.
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PROCUREMENT
Equipment Specifications and Selection
� Approach
� Performance Criteria
� Installation Criteria
� Desired Equipment Subcomponents
� Bearings – Blower and Motor
� Silencers - Blower
� Actuators - Blower
� Instrumentation – Blower, Motor and VFD
� Cooling Systems – Motor and VFD
� MV Input and Output Disconnects - VFD
� MV and LV Terminal Boxes – Motor and VFD
� Shafts
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DESIGN AND ANALYSIS
�Studies:
�Power Flow
�Torsional Analysis
�Harmonic
Analysis
�Coordination
�Arc Flash
�Coordination
�Aerolab
�Manufacturers
�Packaging
�Shippers
�Building Design Firm
�Contractors
Engineering Requirements – Maida’s Responsibility
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FAT AND SHIPPING
415,000 CFM Blower - Parts
built in Tennessee and
elsewhere were assembled in
Mexico
FACTORY INSPECTION, PACKAGING AND SHIPPING
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FAT AND SHIPPING
Came together for 1st time in
Mexicali, Mexico
3,000 HP, 4 KV TEWAC
Motor – Built in Helsinki,
Finland
3,000 HP, 4.16 KV
VFD Built in New
Berlin, Wisconsin
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FAT AND SHIPPING
WTC/PLC Control Panel –
Built in Bethlehem, PA
PLC System –
Programmed in
Philadelphia
FACTORY INSPECTION, PACKAGING AND SHIPPING
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DESIGN AND ASSEMBLY
Mechanical
Procurement
� Blower
� Coupling
� Damper
� Damper Actuator
Mechanical Design
�Wall Air Filters
� Cooling Water
System
� Foundation Details
� Baseplates
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DESIGN AND ASSEMBLY
Electrical Procurement
� 3,000 HP Motor
� 3,000 HP VFD
Electrical Design
� 5 KV VFD Branch
Circuit
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OEA AWARD CRITERIA
� Demonstrates engineering challenges and
innovative solutions
� Integrate a Blower, Motor and VFD that will
perform as required under harsh conditions
with no mistakes, thereby enabling
Honeywell to maintain its commitments.
� Modify commercially available equipment to
meet the operational requirements of the
wind tunnel.
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OEA AWARD CRITERIA
� Demonstrates the importance of the
engineering profession to society
� The wind tunnel will be used for
performance and endurance testing of
equipment enhancing the safety of large
commercial and military aircraft.
� The wind tunnel would not exist without the
blower, motor, VFD and PLC System which
are engineered products and systems.
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OEA AWARD CRITERIA
� Demonstrate a clear and tangible benefit to
the Delaware Valley Region 2.
� Local engineering and design talent
enabled us to perform this project without
no issues, within schedule and within
budget.
� Awaiting future turnkey projects to design
and build the power and control systems for
many more 2,000 to 3,000 HP Wind
Tunnels in the next five year.