P11451 System Design ReviewCook Stove Test Stand Group

January 14th 2011

David Sam (ME)Huseyin Zorba (ISE)Phillip Amsler (ME)

Agenda• Project Description• Customer Needs• Engineering Specifications• System Level Work• Work Breakdown• Fish Bone Diagram• Schedule• Risk List• Test Stand Hardware Outputs• Modifications to Test Stand• Testing Extreme Conditions• Error Testing and Benchmarking• Particulate Measurement Concept Selection

Project Description

• The mission of P11451 is to define test methods and document testing procedures relevant to the Haitian customer needs

• Deliverables:– Functioning test stand– Documented testing procedure– Documented benchmark results against published

results– Produce results for project teams P11461 and P11462

Customer NeedsRevision #: 3

Customer Need #

Importance Description Comments/Status

CN1 1Accurate Statistical Results:Repeatable results, minimize variability and quantify uncertainty

Main customer need, by minimizing variability we can achieve repeatable results and quantify our uncertainty.

CN2 1 Document standardized water boil testDocument a water boil test or modified water boil test with a test procedure and user manual.

CN3 1 Document standardized quick stove test

Create and document a quick stove test procedure for teams to test under a range of scenarios with instant feedback. By changing one input, user should be able to identify the impact in the output. This test should have a user manual.

CN4 1 Document a field like test

Create and document a test procedure to test the stove under Haitian cooking style which may include longer time to boil. Procedure should be documented with a user manual.

CN5 1 Measure efficiency and it's uncertaintyMeasure the efficiency of the thermal versus chemical energy used.

CN6 1 Safety Test stand should be safe to operate for untrained users.

CN7 1 Benchmark against other stoves

Test and compare our stove versus rebar stove or another kind of stove under same test conditions. This will allow comparison of results such as fuel usage, emissions, and time to boil

CN8 1 Quantify emissions Greenhouse gases such as CO.

CN9 2 Quantify particulate matter Any solid matter output from the stove into the surrounding environment.

CN10 2 Durable Test stand should be durable and able to withstand years of testing

CN11 2 Ease of use Test stand should be ergonomic and easily used by one user. Also testing should be easily performed by any user.

CN12 2 Easily transportable Test stand should be easily transportable by one user

Engineering SpecificationsRevision #: 3Engr. Spec.

# Importance Source Specification (description) Unit of Measure

MarginalValue

Ideal Value Comments/Status

ES1 1

CN1, CN2, CN3, CN4,

CN7Repeatable time to boil Standard

deviation (%) <20% <10% Boiling time (mins) is an output of the WBT and customer need is to have these results be repeatable and to minimize variability

ES2 1

CN1, CN2, CN3, CN4,

CN7

Repeatable specific fuel consumption

Standard deviation (%) <20% <10%

Ratio of total amount of fuel (wood or charcoal) used to the amount of water (grams fuel/ grams of water) from WBT; this is a specification that can be used in benchmarking.

ES3 1

CN1, CN2, CN3,CN4, CN5, CN7

Repeatable thermal efficiency of stove

Coefficient of Variation (%) <20% <10%

Ratio of the work done by heating and evaporating water to the energy consumed by the fuel source. The thermal efficiency should be repeatable to ensure validity of testing.

ES4 1

CN1, CN2,CN3, CN4 CN7

Repeatable fuel rate consumption

Standard deviation (%) <10% <5%

Fuel rate consumption (g/min), by obtaining repeatable results, we can observe the differences in setting up the fuel source and lighting procedure to help us determine the best method and which is conserve fuel the best. Fuel consumption is defined as the amount of fuel to produce a unit output. (How much fuel to boil water)

ES5 1

CN1, CN2, CN3, CN4,

CN7

Repeatable firepower Standard deviation (%) <10% <5%

Firepower (Watts) is the rate of fuel energy consumed by the stove per minute which can give us the power output of the stove in watts. This can be calculated from WBT data and could also be useful benchmarking.

ES6 1

CN1, CN2, CN3, CN4, CN7, CN8

Accurate emission measurements

Std Dev g (grams)

<2.0 grams

< 1.0 grams

Based on Aprovecho WBT emission performance testing, cook stoves should emit less than 20 grams of CO and most forced air stoves emit less than 10 grams so we will look for a std dev less than 10%. (<2.0 grams)

ES7 1 CN6, CN10Number of accidents # Accidents 1 out of

30 tests 0Accidents relating to any burns, cuts, and shock should be zero for maximum safety during a standard WBT or any other test. This test stand must be safe for general use.

ES8 1CN2, CN3, CN4, CN8

User manual ease # Questions <3 0 Through documentation, any user should be able to read and set up the test stand and perform testing without any questions.

ES9 2

CN1, CN2, CN3, CN4, CN7, CN9

Accurate particulate measurements Std Dev (mg) <150 mg <50 mg

Based on Aprovecho WBT emission performance testing, cook stoves should emit less than 1500 grams of particulate matter so we will be looking for a std dev less than 10% (<150 mg)

ES10 2CN11CN12

Set up time minutes <20 < 10Related to ease of use, set up time for any single user should not take longer than 20 minutes. Goal would be 10 minutes from transporting stand and equipment to loading fuel and lighting fuel by one user.

System Level Work

System Specifications(Size, Fan, etc.)

Noise Factors

System

OutcomesPositives

a)EfficiencyNegatives

a)Emissionsb)Particulate Matter

System Level Work

InputsTest Standards

a)Charcoalb)Stove (Any Kind)c)Test Type (Short, Relevant, WBT)d)Lighting Technique

SYSTEM

Outputsa)Emissionsb)Solid Wastesc)Test Timed)Efficiencye)Statistical Accuracy

System Level Work

Improvement Assessment

Change in Design Waste Management

Impact Assessment

Ecological Health

Inventory

Quantify:Raw Material,Energy,Waste Perform the Test

Goal

Project Scope

Work Break Down

Fish Bone

Schedule

Risk ListID Risk Item Effect Cause

Likelihood

Severity

Importanc

e Action to Minimize Risk Owner

# Short description of project risk.

What is the effect on any or all of the project deliverables

if the cause actually happens?

What are the possible cause(s) of this risk?

    L*S

What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this

occurring?

Who is responsible for

following through on mitigation?

1 Test difficult to assemble or run.

Time lost in experiment, and likely require more than 1

person to run

Test stand difficult to push, multiple pieces to assemble, difficult to hook up wires.

3 1 3Minimize number of pieces in

assembly, and increase mobility of stand.

Huseyin

2Data acquisition

hardware failure/breakdown

Cost of new equipment, extra test needed.

Hotter fire from wood, general ware, or bad

weather (rain). 1 3 3

Careful handling of test equipment and solid repeatable procedure for good weather.

Phil

3Emission data inaccurate or

immeasurable

Emission data unknown, or could add noise to the system

output.

Emission sensor maxed out, not capable of reading

highly concentrated emissions, or placed in

unrepresentative location.

2 2 4Install researched and proven

Emission measurement device, and test to ensure repeatability

and accuracy. Dave

4Changing fuel type (hard/soft charcoal,

wood, vines, and combinations)

More variables, less repeatability, and more test

runs needed.

Changing, sizes, placement, brands, or types of

charcoal 2 2 4 Use one repeatable fuel type Dave

5 Ventilation Failure Emission data unknown, test will need to be redone.

Fan won’t start, chimney breaks, or won’t attach

properly. 2 2 4 Install dependable fan. Phil

6 Changing weather or atmospheric conditions

Noise added to experimental efficiency, etc.

Changing humidity, temperature, wind, etc. 3 2 6

Plan to standardize moisture in coal before the experiment, and

generally plan for tests during fair weather.

Phil

7

Metrics could be inaccurate or changing. (Charcoal Mass, Water Volume, Environmental

Effects)

Bad test, data neglected-repeatability decreases.

Bad test standards, poor measurement devices, procedure not followed properly, wind shaking

scale.

3 3 9

Solid repeatable procedure with proven measurement devices (i.e. beakers, scale, etc.) Also, limiting testing days to “ideal” weather normalizing data to a certain temperature . Installed

diffuser to minimize wind effect.

Huseyin

Test Stand Hardware OutputsCO Particulate

MatterUncertainties

CO Meter FilterNew

Vent Fan Testing Extreme Cases

EL-USB-CO SampleBig Fan Wait

time duringlighting

Wet/DryCharcoal

Whole Chimney Charcoal

sizes

Temp Range

Impede Chimney?

Relative Sample?

Δ Start TimeΔ Emissions

Solu

tion

Choi

ces

Prob

lem

s

Untested

Light Sensor

UCB particulate

monitor

Price

Old Test Stand

Current Test Stand

Testing Extreme ConditionsTest Wet/Dry Charcoal Varying Charcoal Sizes

1 Test with charcoal set at room humidity (~25%)

Use charcoal straight from the bag (1kg)

2 Test with charcoal set at high humidity (~75%)

Cut coal into uniform pieces and place piece by piece in stove. (1kg)

Error Testing and Benchmarking

• Test a range of stoves to get an idea of variability from wind, humidity, stove size, temperature, and other variabilitys.

• Test other stoves (i.e.. Rebar) for emissions– Compare to published WBT data– Check if test stand has systematic or arbitrary

errors• If test is successfully repeatable then we will

know how the P11461 stove compares.

Particulate Filter Placement

Whole Chimney % Sampling

Added Head Loss Unknown Relation Sample/Actual

Could Choke Chimney Assumes Uniform Concentration

Reverse QLeak Requires additional testing

Batch Sampling Batch Sampling

Unknown Flow Rate Can be complex

QVent

QStove

QLeak

Whole Chimney % Sampling

Known Particulate Mass

Negligible affect on flow rate

Simple Test Method (mass difference)

Cheap

Minimum Change in Test Stand

Pros

Cons

*Simple qualitative test with shirt or other impedance on Chimney will determine viability.

The UCB Monitor

Particulate Measurement Concept Selection

Follow Up Topics• Conceptual design approval• Further Modifications• UCB Monitor Purchase• Expectations for remainder of quarter

Questions?

Supporting Slides 1

CO Emission

020406080

100120140160

1. T

hree

Sto

ne F

ire

2. G

hana

Woo

d

3. M

ud/S

awdu

st

4. B

aldw

in V

ITA

5. C

ast

Iron

Sto

ve f

rom

Ind

ia

6. M

odifi

ed V

ITA

7. M

odifi

ed V

ITA

w/

Insu

latio

n

8. S

kirt

Sto

ve

9. M

etal

Ski

rted

Roc

ket

10.

Tal

l Hea

vy S

kirt

ed R

ocke

t

11.

Pre

viou

s Im

prov

ed

12.

Hea

vy S

kirt

ed R

ocke

t

13.

Pre

viou

s Im

prov

ed

14.

Insu

late

d B

rick

Roc

ket

15.

Sho

rt L

ight

Roc

ket

16.

Tw

o-P

ot R

ocke

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17.

Ext

ra S

mal

l Doo

r w

/ S

kirt

18.

Cas

t Ir

on R

ocke

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19.

Larg

e B

aldo

sa R

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20.

Sto

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ec W

ood

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21.

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s w

ith S

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22.

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or

23.

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s w

ith S

kirt

24.

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25.

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ifier

26.

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e G

asifi

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27.

Grid

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ered

Fan

28.

Bat

tery

Pow

ered

Fan

29.

Bot

tom

Air

Fan

Sto

ve

30.

Woo

d G

as

31.

Apr

ovec

ho R

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ith

32.

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35.

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36.

Pro

pane

(LP

G)

37.

Eth

anol

38.

Ker

osen

e

CO

Em

iss

ion

to

Co

mp

lete

WB

T (

g)

Simple Stoves Rocket Stoves Gasifiers Forced Air Charcoal Liquid/Gas

Supporting Slides 2

PM Emissions

0500

100015002000250030003500400045005000

1. T

hree

Sto

ne F

ire

2. G

hana

Woo

d

3. M

ud/S

awdu

st

4. B

aldw

in V

ITA

5. C

ast

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Sto

ve f

rom

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ia

6. M

odifi

ed V

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7. M

odifi

ed V

ITA

w/

Insu

latio

n

8. S

kirt

Sto

ve

9. M

etal

Ski

rted

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ket

10.

Tal

l Hea

vy S

kirt

ed R

ocke

t

11.

Pre

viou

s Im

prov

ed

12.

Hea

vy S

kirt

ed R

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13.

Pre

viou

s Im

prov

ed

14.

Insu

late

d B

rick

Roc

ket

15.

Sho

rt L

ight

Roc

ket

16.

Tw

o-P

ot R

ocke

t

17.

Ext

ra S

mal

l Doo

r w

/ S

kirt

18.

Cas

t Ir

on R

ocke

t

19.

Larg

e B

aldo

sa R

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t w

/

20.

Sto

veT

ec W

ood

Sto

ve

21.

Pre

viou

s w

ith S

kirt

22.

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or C

harc

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23.

Pre

viou

s w

ith S

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24.

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rcoa

l-Mak

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gasi

fier

25.

Exp

erim

enta

l Gas

ifier

26.

Larg

e G

asifi

er

27.

Grid

-Pow

ered

Fan

28.

Bat

tery

Pow

ered

Fan

29.

Bot

tom

Air

Fan

Sto

ve

30.

Woo

d G

as

31.

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an

32.

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33.

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35.

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36.

Pro

pane

(LP

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37.

Eth

anol

38.

Ker

osen

e

PM

Em

iss

ion

To

Co

mp

lete

WB

T (

mg

)

NOTE: Only 1 PM measurement for 9 stoves

Simple Stoves Rocket Stoves Gasifiers Forced Air Charcoal Liquid/Gas