P09451 Detailed Design Review

Bryan McCormick (ME) Project ManagerAndy Freedman (ME) Heat Transfer/Fluids Analysis & Design

John Kreuder (ME) Thermal ModelerKen McLoud (ME) Structural Designer

Jon Holdsworth (EE) Electrical System DesignerGabriela Santa Cruz (IE) Engineering Economics

Closer Look at the Solution

T=465K T=459K T=458K T=457KT=438K

Current System

Current System

Piping

Control System

0 5 10 15 20 25 300

0.5

1

1.5

2

2.5

3

3.5

4Power

Rload

pow

er

Control System – Plant Model

In1 Out1

plant

In1 Out1

mosfet

dpdr

To Workspace1

time

To Workspace

In1 Out1

PID controller

0

Constant

Clock

1

Out11s

Integrator

Kd

Gain2

Ki

Gain1

Kp

Gain

du/dt

Derivative

1

In1

Mosfet Compensation

Response - optimized

Response – non-optimal

Automated Peak Power

Impedance Matching Circuit for Peak Power

VariabletGSD

DS RVVkI

V

)(

1

ShuntVariableLoad RRR

Sensors

Total Sensors (Inputs to DAQ)      

Thermocouples On Modules 48  

  Before/Inbetween/After Zones 5  

  Inlet/Outlet of Cold Exhaust 4  

  Heater Inlet 1  

Mass Flows Air 1  

  Water 1  

Compression Force Flexi-Force Sensors 8  

Change in Air Pressure Pressure Transducers 3  

Voltages Load Voltages 4  

  Shunt Voltages 4  

    79 Total

Block Diagram

Layout

Data Collection

• Goal: Collect enough data to test for reliability and reproducibility of current measurements.

• Performed 4 tests under the same conditions (200 C and 100cfm)

• Assembled the unit twice by two different operators, tested two times for each assembly

Data Collection Process: Assembly and Set-up

Test 1 Test 2 ImprovementCleaning Cleaning 1:02 1:50  

Bottom Assembly

Applying Thermal Paste to Modules:      Three Modules, 1 side 4:12 3:46 Considered thermal pads, not feasibleThree Modules, 2nd side 3:38 3:16 Considered thermal pads, not feasible

Placing Insulation 1:04 1:02 Marked Places for Modules for easy placementSetting on Bottom Plate 1:22 0:52 Bolts attached to bottom plateSub Total 10:16 8:56  

Top Assembly

Applying Thermal Paste to Modules:      Three Modules, 1 side 3:51 3:04 Considered thermal pads, not feasibleThree Modules, 2nd side 2:47 2:21 Considered thermal pads, not feasible

Placing Insulation 0:38 0:44 Marked Places for Modules for easy placementSetting Top Plate 0:28 0:59  Sub Total 8:44 7:08  

Final Assembly

Placing Washers and Nuts 1:30 1:15  Tightening 3:01 4:21 Better Tool ClearanceOutside Insulation 1:26 1:59 More space to insert, less piecesThermocouples 6:50 5:54 Embeded in Power UnitSub Total 12:47 13:29  

Set-up in Stand

Set on Jacks and Lift 1:47 2:51 Block with Appropriate Height in Test StandAttaching to Stand 10:29 7:14 Better Tool ClearancePlugging into DAQ 6:54 6:01 Color CodingSub Total 18:10 16:06  

Total   49.57 45.39  

Issues/Solutions on Data Processing

Issue Solution

Long, tedious clean-up Record output with headers

Set up different output formats depending on the application.

Inconsistent data, uncertainty in the origin

Data constraints with LED indicator when out of range in front panel

Statistical Analysis

Hypothesis Testing: Difference Between Means

# of standard deviations away from the hypothesized zero difference

0:0:21210aHH

Reject Ho for |T|>2.093

2/t

21

21

11

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nnS

xxT

p

0:

0:

21

210

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2

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222

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Project Charter

Project Name Thermoelectric Module for Large Scale Systems Project Lead Bryan McCormickDate, Revision #   Project Sponsor Dresser-Rand: Paul Chilcott

Start Date 12/1/08 SDT Leader  Completion Date 5/22/09

Idea Submitter Dr. Robert StevensCurrent Phase Detailed Design

Element Description Team Charter

Process DefinitionThe business process in which opportunity exists. This project is aimed at acquiring an improved understanding of the workings of thermoelectric

(TE) devices as a means to recovering wasted energy from Dresser-Rand turbo machinery exhausts in the form of usable power.

Strategic Goal/ Business Case

Describe the opportunity as it relates to strategic business goals. A clear understanding of the workings, benefits and fallbacks of thermoelectric devices is important when deciding whether it is feasible to implement this technology in industry, and whether it is the best choice among alternative technologies.

ProblemStatement

State the significant issue(s) that needs to be addressed or opportunities to pursue. To better understand thermoelectrics and their potential applications in industry for energy recovery, it is important to have a reliable, flexible and efficient test stand to validate models. The current test stand requires long set-up times, does not provide readily available data and has too many variables that compromise the reliability of the acquired data. There are also different configurations that could be tested if the stand allowed for more flexibility, which would produce a wider range of data to draw conclusions from.

Benefits Impact ($)

What are the anticipated business results and when would the results be realized?

• Upgraded thermoelectric test rig utilizing interchangeable air-cooling on the cold side and capabilities for different configurations.• Upgraded data acquisition system.• Improved Power Unit.•Documented data on module performance for verification of theoretical results.(All these deliverables are expected to be ready by 05/22/09)

What is the preliminary budget estimate for the project cost?This project counts with a budget of $7500

Scope/Boundaries Describe the project's scope and boundaries. Describe what is in and outside the scope.

Activities within scope include:1. Implement air-cooling on cold side of thermo-electric array in addition to the water-cooling system.2. Be able to experimentally validate thermoelectric system models and enable more parameters to be explored.4. Improve set-up and shut-down procedures to reduce assembly times. 3. Improve user interface and data acquisition to allow greater ease of use of the test stand.The scope excludes:- Any study or design of the system that would eventually be implemented in industry.

Schedule/Milestones What are the start and completion dates of the project?

Starting Date: 12/01/08 System Level Design:01/02/09 Detailed Design:01/30/09 Project Completion:5/22/09

Benefit to CustomersWho are the Customers, what benefit will they see and what are their most critical

requirements?

Dresser-Rand: The results of experimentally testing valuable aspects of thermoelectric modules will provide insights on the feasibility of implementing this technology to provide energy recovery capabilities to Dresser-Rand's customers, which would further increase the value of the products, specially in applications in remote locations.RIT: This knowledge will help bring RIT to the forefront of this emerging technology.

Support Required (if any) Will you need any special capabilities, hardware, etc.?

Key Stakeholders Who has been identified as a Key Stakeholder(s) for this project?Primary Stakeholder: Dresser-Rand Secondary Stakeholder: RIT

BOMPart # Description Approximate Unit Price Quantity Cost Supplier Estimated Lead Time

Electrical SystemIRF640NPbF Power MOSFET $1.34 8 $10.72 Avnet <1 weekAavid Thermalloy: 6396BG MOSFET Heat Sinks $1.46 4 $5.84 Future Electronics <1 weekOhmite: TCH35P1R00JE Shunt Resistors $6.98 8 $55.84 Digikey <1 weekAavid Thermalloy: 593002B03400G Shunt Resistor Heat Sinks $0.68 4 $2.72 Future Electronics <1 week

Power Supply $300.00 1 $300.00PB-400 Breadboards $4.00 0 $0.00 All Electronics <1 week

DAQ expansion (32 channels) $480.00 0 $0.00Piping

4561T613 2" pipe 72" length $65.12 2 $130.24 McMaster-Carr4672T16 90 deg elbow $31.15 6 $186.90 McMaster-Carr4657T35 45 deg elbow $33.63 12 $403.56 McMaster-Carr4657T55 tees $58.19 4 $232.76 McMaster-Carr1JRL6  valves $47.70 3 $143.10 Grainger

Custom Headers 1 $0.00Power UnitHeatsink (linear ft) $387.72 1 $387.72 Aavid Thermalloy 2-3 daysPlate Aluminum $0.00Angle Aluminum $0.00 McMaster-CarrEndcap/Manifolds $0.00Cold plates $500.00 2 $1,000.00 Solid State Cooling

5591S Thermal gel pads (sheet) $15.52 0 $0.00 3MSensors and ModulesMelcor TE modules $26.50 40 $1,060.00 Melcor 2-3 weeksTaihauxing TE modules $30.00 40 $1,200.00 Taihauxing 2-3 weeksK type Thermocouples (1/16") $22.00 72 $1,584.00K type Thermocouples $22.00 3 $66.00K type Thermocouples $22.00 4 $88.00Thermocouple extension wire $138.00 1 $138.00 OmegaPressure Transducers $8.55 2 $17.10 Freescale SemiconductorFlexiforce sensors (sheet, 8 per sheet) $110.00 1 $110.00Op-Amps $0.34 16 $5.44 MicrochipManufacturingMachining $0.00Welding $0.00 Mahany