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MER 439 Design of Thermal Fluid Systems

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Title: MER 439 Design of Thermal Fluid Systems


1
MER 439 - Design of Thermal Fluid
Systems Professor Bruno Union College Fall Term
2006
2
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

3
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
4
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)
5
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

6
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)

7
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

8
Step 1 - Estimate System Load
9
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

10
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)

11
Step 2 - Estimate Comp. Capacity
12
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

13
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
14
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

15
Actual Installation
16
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

17
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

18
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!

19
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.

20
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.

21
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.
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