The Pennsylvania State University Department of Mechanical and Nuclear Engineering

Optimizing and Testing Novel Fin Designs Fabricated with Additive Manufacturing
A Statement of Work for the development of a new heat exchanger tube using the process known as additive manufacturing, with the intent of operating in a fluid to air environment. Yes Intellectual Property Agreement Yes Non-Disclosure Agreement
Christopher Zerphey Dalton Tallia Derek M. Hall Marin Tola Frank Wolff

2/21/2012

Executive Summary
Large industrial pumps are extensively relied on in many industrial applications. Many of these pumps require cooling of their bearing oil for uninterrupted use. The fin structure in current commercial oil cooling systems is restricted to simple configurations imposed by traditional manufacturing processes. Recent strides in additive manufacturing have reached a point where printings of metal alloy structures with widths of 0.04 are now possible. This recent innovation in manufacturing technology allows for novel fin design beyond the capabilities of current fabrication techniques. In addition to the increase in design possibilities, this process wastes less material. This study focuses on incorporating this new technology into the production of bearing oil heat exchanger pipe fins for large industrial pumps. A series of pipes one foot in length with novel fin designs are to be designed and printed in a bronze infused stainless steel alloy. Each pipe will be tested in a custom designed Test Rig and compared to a standard pipe of an identical material. The Test Rig will consist of a hot oil reservoir, maintained at a constant temperature of 200300oF. The Test Rig will include temperature and pressure sensors on either side of a detachable foot long heat exchanger section that will be exposed to forced air convection. Oil will flow through the test section at 0.3 gallons per minute (gpm). The placement of the sensors will allow for accurate measurements of changing temperature and pressure across the test section. The collected data will allow for correlations to be derived comparing the designed fin geometries with existing extended surface designs. The data collected from these sensors will be used to determine the effectiveness of the printed designs.

Table of Contents
Executive Summary ................................................................................................................. 1 Table of Contents ..................................................................................................................... 2 Nomenclature ........................................................................................................................... 3 1.0 Introduction ........................................................................................................................ 4 1.1 Initial Problem Statement .................................................................................................. 4 1.2 Objectives......................................................................................................................... 4 2.0 Customer Needs................................................................................................................. 5 2.1 Gathering Customer Input ................................................................................................ 5 2.2 Weighing Customer Needs ............................................................................................... 5 3.0 External Search .................................................................................................................. 6 3.1 Patents ............................................................................................................................. 6 3.2 Existing Products .............................................................................................................. 8 4.0 Engineering Specifications ............................................................................................... 8 4.1 Establishing Target Specifications .................................................................................... 8 4.2 Relating Specifications to Customer Needs ...................................................................... 9 5.0 Concept Generation and Selection ..................................................................................10 5.1 Problem Clarification .......................................................................................................10 5.2 Concept Generation ........................................................................................................11 5.3 Concept Selection ...........................................................................................................15 6.0 System Level Design ........................................................................................................19 6.1 Test Rig ...........................................................................................................................19 6.2 Heat Exchanger Design ...................................................................................................24 7.0 Special Topics ...................................................................................................................24 7.1 Preliminary Economic Analysis- Budget and Vendor Purchase Information .....................24 7.2 Project Management .......................................................................................................25 7.3 Risk Plan and Safety .......................................................................................................26 7.4 Ethics Statement .............................................................................................................29 7.5 Environmental Statement ................................................................................................29 7.6 Communication and Coordination with Sponsor ..............................................................30 References ..............................................................................................................................31 Appendix .................................................................................................................................32 A1: Deliverables Agreement ..................................................................................................32 A2: Gantt Chart .....................................................................................................................33 A3: Resumes .........................................................................................................................34 A4: Miscellaneous Figures.....................................................................................................39 A5: Notes ..............................................................................................................................41

Nomenclature
A: Af: Cp: di: do: : T: g: gpm: Gr: h: L: k: : Nu: Pr: q: q: Ra: Re: : Rh: Ri: Ro: Rp: : U: : : : Area Fin Area Specific Heat Inner Diameter Outer Diameter Fin Efficiency Temperature Difference Gravitational Acceleration Gallons Per Minute Grashoff Number Convection heat transfer coefficient length Thermal Conductivity Mass Flow Rate Nusselt Number Prandtl Number Rate of heat transfer Heat flux Raleigh Number Reynolds Number Insulating Value Hot side Convection Resistance Insulation Resistance Cold Side Resistance Pipe Resistance Fin Thickness Overall heat transfer coefficient Coefficient for Thermal Expansion Viscosity Kinematic Viscosity

1.0 Introduction
1.1 Initial Problem Statement
Nearly all premature bearing failures in large pumps result from two common problem (Burge, 2010). Either the lubricant overheats or contaminants enter into the lubrication system (Burge, 2010). Therefore, effective and continuous cooling of bearing lubrication is an integral part of continuous operation of industrial pumps. One frequent application used to improve heat transfer is the fabrication of extended surfaces, also known as fins, along the tubing of a heat transfer device (Incropera, Dewitt, Bergman, & Lavine, 2006). However, the current fin structure in commercial oil cooling system tubes are limited by traditional manufacturing processes. By implementing a process known as additive manufacturing, fin designs can be improved and fabricated into lattices that would otherwise be impossible. Additive manufacturing differs from current manufacturing techniques as this technology builds models through layering a process (Gibson, Rosen, & Stucker, 2010). This layering process builds a model from the bottom up to produce the desired item rather than removing materials to make the model like traditional machining (Gibson et al, 2010). This layering approach is fundamentally different from current fabrication techniques and allows for intricate and complex designs both inside and outside a heat exchanger tube with no residual materials. Therefore, the primary focus of the project is to develop a new fluid to air heat exchanger pipe using additive manufacturing. Several designs are to be produced with a focus on complex lattice structures and novel fin designs. Three of these pipe designs will be printed and tested in a custom made Test Rig; the results of which will benchmark the performance of the new designs with current methods of heat exchange. The deliverables are the printed pipes and a Test Rig capable of measuring the temperature and pressure drop across different pipes in a fluid to air heat exchange.

1.2 Objectives
Harnessing the unique capabilities of additive manufacturing for fin design provides the challenge of maximizing a pipes heat transfer capabilities without imposing a large pressure drop within the system. Formulating a design that achieves these two conflicting requirements requires diligent analysis of the physical implications attached to adding additional fin structures. Therefore, a compromise between these two requirements will need to be made in order to construct the most effective design for industrial applications. The main objective is identifying what is an acceptable amount of pressure lost per unit of heat transferred. This challenge will be resolved with a thorough review of the fundamental laws of heat and mass transfer within in pipes. Another complication to be addressed is the construction of a Test Rig capable of measuring heat loss and pressure drops from each printed pipe. To do so in an accurate manner requires sensors placed in locations that minimize the uncertainty of the readings. As a result, another objective will be to design a Test Rig were measurements taken are representative of the pipe designs heat transfer effectiveness. This can be accomplished by conducting a review of the sensors available and selecting a sensor that best meets the customers needs.

2.0 Customer Needs

2.1 Gathering Customer Input
At the beginning of the project, the only customer input was the Project Summary that Flowserve had provided during the Project Kick-Off. This summary stated that Flowserve was interested in additive manufacturing technology to produce a novel heat exchanger design that was not possible to manufacture using conventional machining. The summary also stated that the design team will have to fabricate and assemble a Test Rig to execute experiments to determine heat exchanger efficiency. After attending the on-site visit to Flowserve and meeting with the project coordinator Andrew Schevets, a better understanding of the project was achieved. Mr. Schevets would like to use the company ProMetal, which has the capability to print our new heat exchanger designs. Additionally, Mr. Schevets is looking for a creative and unconventional approach since additive manufacturing is new to industry with unknown potential. With much of the projects requirements undefined, the team used the first several weeks and team meetings to come up with questions and options for the project. Some of the initial considerations can be seen in the team notes in A6 of the Appendix. For example, on Tuesday January 24th, approximately one week into the project, the team used time in class to discuss the possibilities of cross flow versus counter flow. Additionally, the team set out to define a velocity of the fluid and a mass flow rate. These possibilities were discussed, documented, and later discussed with the sponsor the next day at a Flowserve site visit. This is just one example of how the group went about turning discussion into an identification of customer needs. The group had a lot of freedom due to the lack of initial constraints and requirements of the system. This freedom allowed the group to brainstorm ideas that were later discussed with and rated by the sponsor. Additionally, this pushed the group to look at all possible system designs before ruling anything out with the sponsors input. Through these discussions with Mr. Schevets it was determined that the early part of the project schedule be dedicated to designing and constructing a Test Rig. The Test Rig needs to heat and maintain an oil temperature of 200-300F. In addition, the Test Rig has to accurately measure the temperature drop across the fabricated heat exchanger pipes. A secondary emphasis was placed on the ability to measure the pressure drop across the heat exchanger. The budget for the Test Rig was stressed to be as low as possible while maintaining accurate test results so that multiple heat exchanger pieces could be fabricated within the budget. Mr. Schevets requested that a best guess estimate should be determined for the cost of the Test Rig and reported to him at week four of the project. From this report, Mr. Schevets could determine if additional funds were needed. With all of the initial requirements identified and defined the group had the necessary information to progress. With the input from the sponsor a list of customer needs had been created which allowed for the group to progress into the next portion of the project.

2.2 Weighing Customer Needs

Weighting the customer needs is an important aspect of the customer needs assessment process as well as the design process. Weighting needs is used to decide what aspects of the customers needs are of the most important and how these needs can be met in the design process. In order to decide what aspects of the project are of greatest concern, the team utilized an unbiased means of ranking customer needs. The team first discussed and ranked the importance of the customer needs from 1 to 3 (see Table 1) as interpreted from the discussions by the team members. The team used the Analytical Hierarchy Process (AHP) to rank the customer needs. The AHP is a
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means of comparing each need by numerical values; 0.5 for less importance, 1.0 for equal importance, and 2 for high importance. This matrix is tabulated in Table 2. The results allowed the team to focus on the most important customer needs in the concept generation process, as well as establish scoring criteria during the concept selection process to be discussed in Section 5.3 Table 1: Customer Needs Hierarchy Ranked by Importance for the Test Rig
No. 1 2 3 4 5 6 7 8 9 Test Rig Operates Safely Accurate Temperature Reading across the Heat Exchanger Allow Analysis of Data Obtained from the Experiment Capable of Handling Different Size Heat Exchangers Repeatable Test Results Low Maintenance Between Testing Operations Able to be Transported Accurate Pressure Reading across the Heat Exchanger Low Test Rig Production Cost Need Importance 1 1 2 2 1 3 3 2 1

Table 2: Analytical Hierarchy Process of Identified Specifications for the Test Rig
Criteria A B C D E F G H I A 1.00 1.00 0.50 0.50 2.00 0.50 0.50 0.50 1.00 B 1.00 1.00 1.00 0.50 1.00 0.50 0.50 0.50 1.00 C 2.00 1.00 1.00 1.00 1.00 0.50 0.50 0.50 1.00 D 2.00 2.00 1.00 1.00 2.00 0.50 0.50 1.00 2.00 E 0.50 1.00 1.00 0.50 1.00 0.50 0.50 0.50 1.00 F 2.00 2.00 2.00 2.00 2.00 1.00 1.00 2.00 2.00 G 2.00 2.00 2.00 2.00 2.00 1.00 1.00 2.00 2.00 H 2.00 2.00 2.00 1.00 2.00 0.50 0.50 1.00 2.00 I 1.00 1.00 1.00 0.50 1.00 0.50 0.50 0.50 1.00 Total Weight

13.50 13.00 11.50 9.00 14.00 5.50 5.50 8.50 13.00

93.50

0.14 0.14 0.12 0.10 0.15 0.06 0.06 0.09 0.14

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A = Safety-Test Rig Operation B = Accurate Temp. Reading C = Allows analysis of resulting data D = Capable of meeting variable demands E = Repeatability F = Low Maintence G = Able to be Transported H = Accurate Pressure Reading I = Low Cost

3.0 External Search

3.1 Patents
The patent search was dedicated to fin design as this topic was the highest importance for the sponsor. To gain a better understanding of the current state of novel heat exchanger technology, a patent search was conducted. In 2000, U.S patent number 6668915 B1 claims to improve the value of heat transfer per unit pressure drop of the flowing fluid resulting from each fin (Materna, 2003). This approach differs from conventional fin design as the fins are not uniformly spaced throughout the heat transfer structure (Materna, 2003). Figure 1 clarifies the geometric details of this non-uniform fin distribution. Improving the heat transfer per unit of pressure drop
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is one approach that could be used in our project. In addition, one of our fin patterns could expand from this design with incremental innovations to this concept.

Figure 1 (a-b): U.S Patent 6668915 B1 Non-Uniform Fin Design. Another patent researched was United States Patent number 7,866,377B2, which is titled, Method of Using Minimal Surfaces and Minimal Skeletons to Make Heat Exchanger Components. Essentially, this patent goes over a type of additive manufacturing called stereolithography. By generating a stereolithography file the user can repeat two-dimensional patterns to produce a three-dimensional surface by depositing layers of material onto the top surface of a base (Slaughter, 2011). This concept is visualized in Figure 2. The inventor states that the process can reduce surface area, reduce manufacturing cost, improve efficiency, and provide good flow properties in the heat exchanger through the use of an additive process (Slaughter, 2011).

Figure 2: US Patent 7,866,377-B2 Heat Exchanger from Additive Manufacturing These characteristics show that additive manufacturing process is effective and encourage engineers to use them in heat exchanger design. The patent goes over a few possible ways to use stereolithography in the design of heat exchangers that minimize overall size without significantly compromising performance. Contrastingly, the group looks to maximize surface area with additive manufacturing to increase the heat exchanger effectiveness substantially.

United States Patent number US 7,871,578,578B2 is titled, Micro Heat Exchanger with Thermally Conductive Porous Network and outlines the mesh and lattice method of internal heat exchanger design. In the background section of the patent many assertions can be noted that directly apply to the Flowserve project. One of these assertions is that it is desirable to reduce the size of the heat exchanger for a given rate of heat exchange. In other words, as the surface areato-volume ratio increases, the contact area between the pipes fin structures and surrounding medium increases (Schmidt, 2011). The patent goes on to lay claim to several porous networks and designs that the inventor has outlined. These concepts will be considered when developing the groups designs for heat exchangers.

3.2 Existing Products, Test Rig

The first desire of the customer was that the team quickly fabricates a Test Rig. With this as our primary objective, the team researched existing test rigs that served a similar function. One existing product that functioned under similar conditions as our project required was currently operating in The University Park Heat Transfer Laboratory. The Heat Transfer Laboratory Test Rig is used for heat exchanger experiments where students analyze the efficiency of enhanced concentric tube and shell & tube heat exchangers. This gave the team ideas on how temperature and flow rates were measured in existing products. The lab Test Rig has a hot side temperature of 180F and a diameter piping in which they used a flow rate of 0.3gpm This existing test rigs flow rate, temperature and oval dimensions were used as a basis to estimate reasonable values within our Test Rig design. A second existing product that was used as a source of design concepts was a heat exchanger testing project that had been done between Penn State and Flowserve in 2009. In the report Design and Testing of Oil Cooling Systems for a Boiler Feed Water Pump Bearing Housing the previous Flowserve group had similar conditions of oil temperature and flow rate that our group is currently working with. Analyzing this document provided our team with reasonable values for the thermal losses expected from the Test Rig reservoir. In addition, it was recently decided that parts from this project are now being sent for use in the construction of our Test Rig.

3.3 Existing Products, Heat Exchangers

This section is part of phase two and will be updated in the DSR.

4.0 Engineering Specifications

4.1 Establishing Target Specifications
The team established target specifications based on customer needs and Test Rig requirements that are critical to acquiring accurate data and a low price. The initial Test Rig metrics are listed in Table 3 below. Although these target specifications are subject to change as further progress is made on the detailed design of the Test Rig, the team believes the metrics outlined in Table 3 are fully attainable based on the requirements for the project. The sponsor and our team have agreed to an upper limit for the price of the Test Rig. Test Rig Production was set at $500 because the sponsor would like to test as many heat exchanger designs as possible within the $1000 project budget. It should be noted that ProMetal estimates each heat exchanger tube will cost $300. The Heating Element Output was selected to have at
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least 1000 watts so that there is sufficient power to overcome thermal losses from the reservoir, tubing, and heat exchanger. An insulation R value of greater than 2 was chosen to minimize losses through the reservoir walls. A more detailed explanation of thermal losses by the system can be seen in Section 6.0. With respect to the flow rate, the sponsor did not provide a specific flow rate for the oil. Thus the team looked at the Penn State Heat Transfer Laboratory Test Rig to determine an appropriate flow rate since it operated under similar conditions. Based on a 0.3 gpm flow rate a storage capacity of greater than six liters was chosen. This size will have a large volumetric ratio of stored hot oil with respect to the returning cold oil thus maintaining a stable reservoir temperature. It would take 5 minutes for the oil to be completely recirculated within the system. The temperature and pressure measurements across our heat exchanger are critical requirements to determine the heat exchanger effectiveness. A less than 2 percent accuracy error was chosen to reduce the compounding effect in error caused from using collected data in multiple equations. In addition, the two percent error correlates to accuracy limitations on commercial temperature sensors as shown in A4 of the Appendix. Table 3: Target Engineering Specifications
No. 1 2 3 4 5 6 7 8 9 Test Rig Storage Capacity Test Rig Production Cost T Measurement Uncertainty Test Rig Heating Element Output Test Rig Flow Rate P Measurement Uncertainty Data Reading Test Rig Insulation Simplified Design Metric Units L US$ % W gpm % / R / Value >6 500 <2 1000 0.20-0.50 <2 Yes >2 Yes

4.2 Relating Specifications to Customer Needs

The Needs-Metrics matrix in Table 4 details how each customer need is being fulfilled by the metrics shown in Table 3. It can be seen that all the customer needs are being meet by at least one metric. The Safety and Repeatability Needs contain the most amounts of metrics which demonstrates that the highest rated customer needs are being addressed.

Table 4: Needs-Metrics Matrix for the Test Rig Test Rig Heating Element output

T Measurement Uncertainty

P Measurement Uncertainty

Test Rig Storage Capacity

Test Rig Production Cost

Test Rig Flow Rate

Test Rig Insulation

* * 10

Need Test Rig Operates Safely Accurate Temperature Reading Allow Analysis of Data Obtained from the Experiment Capable Handling Different Size Heat Exchangers Repeatable of Test Results Low Maintenance Between Testing Operations Able to be Transported Accurate Pressure Reading Low Test Rig Production Cost

Metric

* * * * * *

* * *

* * * *

5.0 Concept Generation and Selection

5.1 Problem Clarification
In the current stage of the project our teams focus is towards constructing the Test Rig. The following constraints on the Test Rig were developed between the sponsor and the design team. The sponsor and design team agreed on requirements of a flow rate of 0.3 gpm and a hot working fluid of 200-300F. In addition, the rig needs to monitor the temperature and pressure drop across a foot long heat exchanger with a internal diameter. Forced convection will also be applied over the exterior of the heat exchanger, the temperature and velocity of air will be monitored by an anemometer with an integrated temperature sensor. Refer to Figure 3 for a black box model that separates the Test Rig into its fundamental components. With respect to the heat exchanger design, our goal is to maximize the amount heat loss across the heat exchanger by making use of the metal printing technologys ability to produce complex fin geometries. In future reports we will have made further progress towards the design of heat exchangers and augment the statement of work as needed. Figure 4 shows a block box model on how energy is transferred out of the heat exchanger.

Simplified Design

Data Reading

Figure 3: Functional Decomposition Diagram of the Test Rig

Figure 4 Functional Decomposition Diagram for the Heat Exchanger

5.2 Concept Generation

During the concept generation phase, the team brainstormed concepts for possible solutions for each of the identified sub-components of the Test Rig which includes: tubing, substructure, heat source, oil reservoir, oil pump, pressure sensors and temperature sensors. Concepts for these components where compiled in a morphological chart and listed in Table 5. Potential solutions were sketched to visualize these concepts and encourage new ideas. Figure 5 illustrates the concepts for heating the oil while Figure 6 addresses how to divert the oil flow. Figure 7 illustrates some design patterns for the Test Rig layout.
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Table 5: Morphological chart for sub-sections

Tubing Copper External Heating Element Made of Metal Mechanical Pump Monometer Thermocouple Inside Tubing Concepts Flexible High Stainless Temperature Steel Tubing Submersible External Gas Heating Element Made of Made of Wood with Wood Metal Coating Electrical Pump Pressure Probe Thermocouple Outside Tubing Hot Tube or Pond Pump Oil Gauge Mix Flex and Metal

Heat source

Substructure Material

Pump Pressure Measurement Temperature Measurement

Automotive Pumps

Infrared

Thermistor

Figure 5: Concepts for Heating the Oil

Figure 6: Concepts for Tubing Network

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Figure 7: Concepts for Test Rig Layout

With respect to pump selection, many different pump concepts were explored in order to find the best match to the system requirements. Before the sponsor disclosed the fluid and temperature constraints, lower priced plastic pumps, priced below $50, were an attractive solution because they could be purchased at a local distributor such as Home Depot or Lowes. For this idea, fountain and pond pumps were researched to see if they could provide the necessary flow at a low price. After the temperature constraints of 200-300F were set, the specifications for many products of that nature were found to be unable to operate in the assumed temperature range. Therefore, it was necessary to move to heavy-duty metal pumps. Grainger, an industrial supplier, was used to look for pumps that could handle the necessary temperature range. The Grainger search provided many pumps that could work, but revealed that most were rated for much higher flow rates than necessary and could not reach the upper limit of our temperature range. Various pumps from the Grainger search can be seen in Table 6. None of these pumps sufficiently suited the system needs, so an additional search was conducted for more options.

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Table 6: Pump Specifications from Grainger Search BELL & DAYTON GOSSETT Rotary Gear TACO Pump, Pump, Pump Head, Circulator, Circulator, Pump Name 3/8 In., 1/3 HP 1/25hp 1/25hp Price ($) 198.75 130.70 138.60 Horsepower (HP) 0.33 0.04 0.04 Head (ft.) 7.5 9 15.00 Max Flow (gpm) 7.00 21.00 20.60 Temp (F) 210 240 240 Min. gpm @ Head (Ft.) n/a 4@9 10 @ 8

TACO Circulator Pump, 1/20 HP, 1.1 Amps 118.80 0.05 21.00 17.00 230 10 @ 10

The second Internet search provided better options that more closely suited the Test Rigs new requirements. A pump series made by the producer Grunfos was found to have various flow and head ranges that could suit the needs required by the Test Rig. Additionally, these pumps were cheaper than the pumps found in the initial search while still working in a similar temperature range. To supplement the Grunfos pumps, a search on eBay, an online bidding website, was conducted. This provided an additional option as one suitable pump was found. This pump was titled March High Temperature Pump for Brewing Home Brew and can be seen in Table 7 along with the Grunfos pumps. Displayed in Tables 6 and 7 are only the most relevant options, as many pumps were investigated prior to narrowing down the search to the ones listed in the tables. Overall, the search for a suitable pump provided many options for the group to pick from in the concept selection phase of the project. Table 7: Results from Grunfos and eBay Search Grundfos Grunfos Grundfos March High UP15-10F UP15-42F UP15-10B5 Temperature Circulator Recirculator Recirculator Pump for Pump Pump Pump Brewing (59896248) (59896155) (59896213) Home Brew

Pump Type

Grundfos UPS1558FRC 3Speed Circulator Pump w/ IFC, (59896343) $82.00 0.04 19.50 17.00 230

Price ($) Horsepower (HP) Head (ft.) Max Flow (gpm) Temp (F)

76 0.04 5.50 8.00 230

98.99 0.04 15.50 17.00 230

163.64 0.04 9.00 6.00 220

137.99 0.04 12.00 7.20 250

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5.3 Concept Selection

Tubing:

Our tubing layout will route hot oil from the reservoir to the pump, the oil will then travel vertically towards the testing section. After passing through the testing section the oil will return to the reservoir to repeat the process. There were multiple options that would satisfy our needs. One option was inexpensive ($1.29/foot) flexible high temperature tubing, but the high temperature specification from this manufacturer could only withstand temperatures of 140F. Other high temperature flexible tubes, like those from Texloc were able to withstand large temperature ranges from cryogenic to 1500F. The tubing from Garnet Midwest could withstand our required temperatures but could not be bought in small enough unit lengths for our needs. A third option would be to use common copper plumbing. Although not flexible and not as easily installed, both price and its ability to withstand temperature made it an attractive solution. Selection for the tubing can be shown in the Table 8. The selection was made on a basis of four factors that were rated from 1-10. The highest scoring option was the copper plumbing. It is able to withstand our temperature range, inexpensive, and available through online order as well as local hardware stores. Table 8: Concept Screening Matrix for Tubing Tubing Selection Tubing Type RF67-XFC from US-hose (flexible, high pressure SS hose) 10 2 6 8 26 PCSC TUBING COP 1/2ID L from Garnet Midwest (soft copper Tubing) Generic Copper Plumbing From local hardware store 9 8 10 5 32

Temp Range Price Availability Installation Ease Total

6 5 6 8 25

Substructure: The tubing and other components will need to be supported by a substructure. The substructure will need to be both rigid and lightweight for transportation purposes. It will also need to be able to withstand contact with high temperature oil in the event of a system malfunction. A wooden frame will satisfy these needs. A completely metal frame and sheeting would also satisfy our requirements, although at a higher cost.

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The team then selected a wooden substructure, which will make construction simpler, without a sacrificing the structural integrity. A concern was raised that using a combustible material in a high temperature application is dangerous. The ignition temperature of wood is well above 300F; therefore it is safe to use for this application. Reservoir and Heating: Three different techniques were considered for heating oil in the Test Rig. While gas propane is a valuable option it was eliminated since the team would like to use the Test Rig in an indoor environment. Also, using gas propane would require additional safety requirements without any additional benefits compared to an electric heating source. A submersible heating element was chosen over an external heating element to reduce risk to personnel and excess thermal loss. Once the use of a submersible heating element was chosen three options were considered for designing the reservoir and heating housing. Option 1 consisted of buying an industrial fryer that had an adequate heating element and volume but would cost $90-120. Option 2 consisted of buying a less expensive, $25-$35, deep fryer for the heating element and constructing our own reservoir with material from the Learning Factory. A later option introduced by the sponsor was Option 3; which was a pre-made hot fluid reservoir from a 2009 Penn State - Flowserve project. The selection was made on a basis of five factors that were rated from 1-10. Selection of the reservoir and heating element is shown below in Table 9. The team selected to use pre-made hot fluid reservoir with a 1000 watt heat source from Flowserve, this will reduce the total cost of the Test Rig. Table 9: Concept Screening Matrix for oil reservoir and heating element Storage and Heating Selection Option Price Heating element Availability Size Input/Output Total Industrial Fryer 1 7 7 6 3 24 Heating Elements 5 10 8 7 5 35 Flowserve Reservoir 10 5 6 8 10 39

Pressure Sensor: When it came to choosing a pressure sensor there were a few options. A regular u-tube monometer could be used, but it would create additional complications in the measurement process. Another option was a static pressure probe, which has the disadvantage of being sensitive to the orientation of flow. The best choice for pressure measurements will be a mechanical oil pressure gauge for an automobile. This type of pressure gauge has a range of 0 to 100 psi, can handle high temperatures and is accurate within two percent. This pressure range is within the operating conditions for our open flow system.

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Selection for the pressure sensor can be shown in the Table 10 below. The selection was made on a basis of four factors that were rated from 1-10. The highest scoring option was the automotive oil pressure gauge. It is able to withstand high temperature, is inexpensive, accurate to two percent, and readily available online as well as local auto part stores. Table 10: Concept Screening Matrix for Pressure Sensors Pressure Sensor Selection Sensor Type Temp Range Price Accuracy Installation Ease Total Monometer 8 9 8 9 34 Pressure Probe 10 5 9 7 31 Oil gauge 10 10 9 10 39

Temperature: A variety of temperature sensors were considered for monitoring temperature change within the Test Rig. The specifications for Omega thermocouple types J, K, E and T, infrared scanners and thermistors were all researched and put into Table 11. Each option held its own merits and shortcomings. With respect to the customers priorities, the specifications below are rated based on accuracy being the highest priority and price being the second. The temperature range for each sensor was rated on a pass or fail basis as the Test Rigs temperature limits are 60- 300oF. These temperature limits originate from the highest temperature the pump models can withstand and the lowest temperature possible from the ambient temperature inside our testing location. The infrared scanner was the most expensive but it had the widest range of operating temperatures. Thermocouples had the advantage of being easy to setup and are inexpensive. The shortcoming of the thermocouple option was its accuracy. After comparing the customer needs to the differences in the specification for the three sensors, thermistors were selected as the best fit for the project. Table 11: Temperature Sensor Concept Matrix
Temperature Sensor Selection Sensor Type Price Accuracy Temperature Range Total Thermocouples 9 6 pass 15 Infrared Scanner 4 7 pass 11 Thermistor 9 8 pass 17

More detailed specification charts from Omega were placed in the Appendix under A4 Miscellaneous Figures. The charts in the appendix were used to formulate the sensor selection table.
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Pump: The pump concept generation phase resulted in many potential options for the project. After narrowing down the results of the pump search, five pumps were selected for a concept screening matrix. The Grundfos pump had the cheapest price while providing a flow rate and head range within the systems requirements. The only downside of this pump is that the maximum workable temperature of 230F is at the lower end of our temperature range. The TACO and March High Temperature Pump both had higher temperature ranges at 240 and 250F respectively. The TACO pump was not selected due to the overly high flow and head ranges along with its high price. The March High Temperature Pump offered for sale on eBay was at first an appealing option. However, eBay is an online auction site and the price ended up exceeding the desired budget. Ultimately, the concept screening matrix showed that the Grundfos UP15-10F Circulator Pump was the best selection as it received the highest score as can be seen in Table 12. This matrix was completed by ranking each need on a scale from one to ten with, a ten signifying that the need was fully satisfied. The system head loss was calculated to be 5 feet. This head loss lowers the flow rate of the Grundfos pump to one that is very close to the value that is desired. See appendix A4 for a detailed specification of the Gundfos Pump. The group had concern about approaching the maximum head of the pump. After discussing the concern with the sponsor it was determined that this pump would satisfy the Test Rigs needs Table 12: Concept Screening Matrix for Pump Selection
Pump Selection Grundfos UPS1558FRC 3Speed Circulator Pump w/ IFC, (59896343) 8 5 4 4 21

Pump Type

DAYTON Rotary Gear Pump Head,

TACO Pump, Circulator

Grundfos UP15-10F Circulator Pump, (59896248) 9 5 8 8 30

March High Temperature Pump for Brewing Home Brew 4 8 5 6 23

Price Temperature Range Flow Rate Head Range Total

2 3 8 7 20

4 7 2 5 18

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6.0 System Level Design

6.1 Test Rig
The test stand design was separated into its fundamental pieces to simplify its design. A 3D model of the Test Rig is shown in Figure 8 with its major components identified. The rig is composed of: a substructure (1), heat source (2), pump (3), heat exchanger (4), and data collection devices not shown in Figure 8. Although they are the fundamental pieces to the rig, they are interrelated and an iterative approach was used in selecting each feature.

Figure 8: Schematic of Test Rig Heat Source The selection of the heat source required an estimation of losses through the heat exchanger, tubing network, and oil reservoir. The desired temperature in the reservoir was set by the sponsor at 200-300F. The limitations of the pump forced us to select an operating temperature of 230F. This change in the temperature range was approved by the sponsor during the weekly meeting on February 3rd. The analysis through the tubing network was done by creating a thermal circuit extending from the flow in the pipe through the copper wall, insulation, and then to free convection. The flow inside the pipe will have a Reynolds number of 350 at the desired mass flow rate of 0.3 gpm. Using a Nusselt correlation the convection coefficient at this flow rate was determined to be 49 W/ (m2*K). The convection coefficient on the outer surface was found using free convection correlations. Important non-dimensional quantities used in the derivation were: Grashof (1.6*106), Raleigh (1.15*106), and Nusselt (8.85). These values resulted in a convection coefficient of 8.0 (W/m2*K). The conclusion from the thermal circuit was a loss of 2 watts for every meter of flow as demonstrated in equations 3 through 15. The designed tubing path will have less than 2 meters of flow leaving the resultant loss as negligible. Losses through the reservoir were made by creating a thermal circuit similar to the methods used in analyzing tubing loss and are shown in equations 16 through 18.
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Heat Exchanger Losses: Losses through the heat exchanger were estimated using a thermal circuit. While preliminary designs are being produced for the heat exchanger there are no completed designs that can be used as of yet to model the losses. For this reason we selected to use a scenario in which very efficient fins ( = 1) are present on both the internal and external surfaces of the heat exchanger. The internal fin lengths were modeled as the full inner diameter of the tube, with a thickness = 3.175 mm. The external fins were given a length of 60 mm and a thickness = 6.0 mm. The number of fins placed on the interior and exterior surface was 100 and 400 respectively. Because the heat exchangers design is currently undetermined estimations were made for the interior and exterior convection coefficients. The value of hoil was selected at 100 (W/m2K), double that of the convection coefficient determined in the pipe. We expect to have a tripping action that moves the flow to turbulence in our test section and thus increase our rate of heat transfer. The exterior convection coefficient was found using the Churchill-Bernstein correlation for a cylinder in cross-flow. The resulting coefficient was found to be 51.314 (W/m2K); however because the exact contribution of the fins to the flow is unknown we doubled the value as a precautionary measure to 100 (W/m2K).
( [ *( ) ( )+ ) *( ) ( )+ ]

(1)

The losses can then be calculated with the known temperature difference between the hot oil and the cooling air. With the air at 70F and the oil at 230F a T can be determined. The resulting power loss through the heat exchanger is shown as: (2) Tubing Losses: Losses through the tubing were conducted using a thermal circuit approach and determined a final value based on watts per meter of the tubing length. The mean temperature difference between the oil and air was made to be the difference between reservoir temperature and that of the ambient air. Convection Coefficient inside Tube: (3)

(4)

(5)

20

{ Tube Resistance:

(6)

( ) (7) { Insulation: { Free Convection Outside of Tube: (9) } (8) }

(10) ( ) (11)

(12)

{ Overall Heat Transfer Coefficient: { Total Tubing Loss: }

(13)

(14)

(15)

Reservoir Losses: The losses throughout the reservoirs surface were estimated using a thermal circuit technique. Convection coefficients on both the internal and external surfaces were estimated. For free convection of air over a flat plate a high value would be 25 W/(m2*K), which is the estimated value on the external surface. A value of 100 W/(m2*K) was selected for the internal surface of the reservoir based on the 2009 Penn State-Flowserve report; in which a thermal analysis was also conducted on the reservoir.

21

Heat flux: [ Total Loss of Reservoir: (17) Total Thermal Losses from the Test Rig and Heat Exchanger: (18) Currently without a designed heat exchanger there had to be a fair amount of assumptions in determining a power loss. We attempted to model a scenario in which large losses would be observed across our heat exchanger; requiring the most power from our heat source to operate the test loop. As stated above we did this by selecting a large fin surface area with fins at 100% efficiency. Combining the losses from reservoir, piping travel, and across the heat exchanger itself, we expect to see 210.96 Watts across the system when a high performance heat exchanger is in place. We will be using a reservoir supplied from Flowserve that has a 1000 watt heating element. This is more than sufficient to regain the losses that we will dissipate through our system. Tubing Network: The tubing network will feature diameter insulated copper tubing. The diameter matches that of our anticipated heat exchanger designs. The diameter also results in laminar flow at a 0.3 gpm flow rate, which will minimize thermal losses as the hot oil enters the heat exchanger. As shown previously; considering laminar flow and the surrounding insulation the heat loss through the tubing will be negligible. The designed network will pull oil from the reservoir through the pump and then make a vertical climb to the testing section. This will be the highest point throughout the Test Rig, allowing oil to drain back to the reservoir while the heat exchanger is being exchanged. The oil will then pass through the test section and be returned to the reservoir. Pump: In the interest of cost we selected a 1/25 HP Circulator pump that can deliver a 0-8 gpm flow rate. The team will use a valve to maintain our desired flow rate. The pump is designed to operate at temperatures up to 230F fluid which is within our temperature range and the deciding factor for our thermal analysis. Pressure Loss Factors: These are the contributing factors for major and minor loss in the test loop. (19) ] (16)

(20)

22

Minor Losses: The contributing factors to minor losses in our system were the result of 6x90 (90 = 30) bends, one valve (valve = 470) and 4 T connectors (T = 20). , (21)

Major Losses: The head loss is a result of the loss due to friction as the oil travels the length of the pipe and is modeled by the above equation (20) for pressure loss P. The only factors left to be included are length and internal diameter, which are calculated below (22)

Head Loss: There is an additional loss that occurs as the oil has to make a climb to the test section. The contributing loss from the section is modeled by fluid statics. (23) HX Pressure Loss: Losses through the heat exchanger were done considering the interior fins as a lattice structure. With this assumption empirical correlations (Forchheimer Equation) were used for homogeneous isotropic foams with open cells. This modeled the pressure drop per unit length that we would observe in our heat exchanger. Where: is oil viscosity, is oil density, U is average oil velocity, and F and K are empirical coefficients. (24)

Factors F and K are found using the following correlations with: porosity (), ligament diameter (df), and pore diameter (Dp). ( ) { }

(25)

(26)

The result of the Forchheimer Equation is then: (27)

23

Total Pressure losses through the System: The total pressure drop through our system will then be: (28) The head loss through the system will then be 1.898 psi or 5 feet of water. Our selected pump is specified to run at a maximum of 5.58 ft of head. As the maximum operable head loss is reached the flow rate will decrease; this leaves our flow rate closer to the desired value of 0.3 gpm and will lower the need for the valve to restrict the flow. Data Acquisition: It is desired to collect the temperature and pressure difference of the oil across the heat exchanger. In addition, the air flow rate and temperature difference will be measured. Tconnectors will be implemented to accommodate both thermistors and pressure gages at both the entrance and exit of the heat exchanger. The anemometer will gather both flow rate and temperature of the air. Substructure: The substructure as seen in section 6.1 on Figure 8 of the Test Rig will use 2x4 lumber and oriented strand board (OSB). This simple light weight structure will have enough rigidity to support the hot fluid reservoir. The 2x4 structure will consist of three 30 boards connected on end by two 24 boards. Over this structure will be a sheet of the OSB board to support the reservoir and pump. A second sheet of OSB board will be attached orthogonally to the previous on a 2x4 frame. This section will separate the heat exchanger from the rest of the Test Rig. Figure 8 shows how the substructure will support both the heat reservoir and other components of the Test Rig while separating the heat exchanger from the rest of the system.

6.2 Heat Exchanger Design

Our current heat exchanger designs will make use of the additive manufacturing techniques by creating complex fin geometries. We will further update this section in the DSR.

7.0 Special Topics

7.1 Preliminary Economic Analysis- Budget and Vendor Purchase Information
Initial budget projections have been performed to determine project feasibility and to properly allocate budget resources. A preliminary budget table and bill of materials for the Test Rig are provided in Table 13 and in the A5 of the Appendix. Each item was priced at an average of what it would cost, this allows for a tolerance in the cost estimate to alleviate any unexpected modifications or expenditures. Team Flow Gurus does not intend to accrue travel expenses throughout the project. The team will do its best to make use of the resources available to acquire as many of the items at a reduced cost. The team has already been offered a heating element and reservoir from a previous project as well as thermocouples and anemometer which can be provided by the sponsor. Team Flow Gurus will also order supplies from reputable companies to assure quality and compatibility between parts.
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Table 13: Financial Estimate for the Test Rig

Rig Structure Part Description 2 X 4 Substructure (8' sections) 1/4 x 4 x 8 Utility OSB .5" x 1' type K tubing T fittings 90 degree fitting 1/2" coupling Insulation Fasteners (75 ct. screws) Thermistors Heat Source (donated) Pump (Estimated) Pressure Gage Plexiglass Sheet Shipping Total Price/Unit 3.00 6.57 2.59 0.65 0.36 0.29 3.90 8.57 25 85 85 15 25.49 # of units 2 1 8 2 8 3 2 1 4 1 1 2 2 Cost of Part 6.00 6.57 20.72 1.30 2.88 0.87 7.80 8.57 100.00 85.00 85.00 30.00 50.98 50.00 421.67

7.2 Project Management

The project Gantt chart is provided below as Figure 9 and in A2 of the Appendix. It is arranged in chronological order of major industry and class dates. There are two major parts to the Flowserve project; the Test Rig and the design of the heat exchanger tubes. The Test Rig is divided into subcategories that the team has developed to describe the projects components: thermistors, pressure glands, box fan, heat reservoir and sensors/software data collection. Team Flow Gurus has allocated its project schedule to be aggressive in the early stages. This allows the test rig components and design to be approved early, which will allow time to calibrate the Test Rig as well as make modifications if problems arise. The team felt this was appropriate considering the accuracy and consistency of the heat exchanger data is dependent on a properly built and calibrated Test Rig. Another consideration for the aggressive early scheduling is that the turn-around time for each heat exchanger tubes will be about three weeks.

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Gantt Chart
Days Month Deliverables Agreement Statement of Work Final Report DSR Concept Rig Design Customer Needs Evaluation Concept Generation Test Rig Patent Search Existing Technology Search Engineering Specifications Order Box Fan Order Piping Order Pump Order Heat Reservoir Order Data Collector Order Pressure Probe Order Temperature Probe Select Temperature Probe Select Pressure Probe Select Box Fan Select Heat Reservoir Select Data Collection Test Rig Construction Fin Concept Design Fin Concept Design 2 Fin Design Testing
7 January 14 21 28

Time left Milestones Passage of Time Behind Schedule

35 February 42 49 56 63 70 March 77 84 91 April 98 105

Figure 9: Gantt Chart with Milestones in Green As mechanical engineers, the teams primary skill sets revolve around mechanical system design as well as heat transfer concepts. Other key skills that will be required for this project are machining and welding skills as well as software and electrical interfacing knowledge. While members of the team have strengths in these areas, the team is prepared to seek help from professors and outside resources to meet the design goals of the project. All tasks defined in the Gantt chart must be completed on time, in order to insure a complete and working Test Rig. After designing and performing calculations on the systems, Team Flow Gurus will first build the Test Rig structure as this will be the key building block which all data will be collected on. The structure must be able to hold at least 6 liters of oil and maintain a constant temperature within the reservoir. The team will next install the tubing with the proper connections to allow for easy access and interchangeability of the heat exchanger tube. Once the Test Rig is built and calibrated property, data will be collected for comparison between the different heat exchanger designs. What is expected by team Flow Gurus can has been disclosed in the deliverable agreement which can be seen in A1 of the Appendix.

7.3 Risk Plan and Safety

The primary goal of this project is to keep everyone safe while performing experiments. Therefore, it is necessary to assess all possible safety risks along with other risks that could prevent the development of a successful heat exchanger. A Risk Analysis Chart can be seen in Table 14. Safety will be addressed using several different approaches. First, during testing everyone will be required to be wearing proper safety gear. At a minimum this includes goggles, gloves, and lab coats. A large protective material will be placed between the Test Rig and those performing the
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tests as an additional safety measure. Prior to the testing of the heated fluids, a test will be performed at low temperatures to check for leaks or other possible safety concerns. Ultimately, if any issue arises the team will address it. This may be as severe as redesigning a component, but safety must come first. Additionally, collection bins placed under the rig will address any spill risk. Also, testing the assembly with water first will allow for any flaws in the system to be identified. This will prevent any damage that the hot oil could cause from occurring because all leaks will have been found and sealed. Other risks can come through setbacks in the projects development. A high risk comes in the form of schedule delays. At times the group will experience setbacks or require more time to complete a task. To combat this, the group will look to always stay days ahead of schedule at all times and at the worst complete tasks by the completion date on the Gantt Chart. Throughout the project the group will make sure that the critical path is a priority so that other tasks are not held up. Dealing with a customer also poses possible risks that the group must account for. The customer could request a change in design or be unsatisfied with current progress. To account for this the group will maintain constant contact with the sponsor throughout the project and provide updates of any changes with the project status. This should lead to a satisfied customer as they will know what to expect and will allow for any changes in design to quickly be identified. The final component that could be a risk to the development of the project concerns the actual materials being used. The group will have to order parts and expect for them to work. Any delays receiving the parts could be a major setback. Therefore, it is necessary to place orders far ahead of time. Additionally, the Test Rig is being developed first to account for any setbacks. These components could end up failing so fall back strategies have been put in place. Many risks have been identified and with actions to minimize them the project should progress as planned. The group will continue to identify and address possible problems throughout the progression of the project.

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Table 14: Risk Analysis

Risk
Schedule Delays Spills

Level
High

Actions To Minimize
-Keep up with Gant chart -Dont let setbacks delay other work -Collection bin under the Test Rig in case of spills -Test with water to minimize spill damage -Place some sort of large material between Test Rig and testers -Test Rig with water at low temperatures for leaks -Wear appropriate safety gear such as goggles, gloves, jackets -Appoint a safety manager

Fall Back Strategy

-Set aside additional time for delays -Have additional team meetings -If there are leaks redesign or reconstruct the Test Rig -If there are any safety issues make sure they are addressed -Redesign or reconstruct if necessary

Moderate

Safety

High

Customer wants change in design Data Logger Breaks Pump Fails

Low

-Communicate throughout each step of the -Allow ample time for project modifications to design -Confirm design concept before getting parts produced -Prevent any damage from occurring to the data logger - Purchase pump capable of performing necessary work -Work pump within its specified capacity - Test early in case of failure -Place orders before spring break (3/1/2012) so that all materials will have arrived by the groups return (3/12/2012) -Design Test Rig first to allow for parts to be shipped - Borrow one from Reber or other campus source -Use warranty to get replacement pump - Purchase new pump -Modify design -Order parts early in the project

Low Low

Delays in order delivery

Moderate

Test Rig does not function properly Customer not satisfied

Moderate

-Sufficient planning and design -Change or modify design -Test with water at room temperature prior -Seal up all leaks to testing heated oil -Communicate throughout the process -If unsatisfied at any point find -Get a clear understanding of the customer out why needs -Find a new approach to satisfy the customer needs

Low

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7.4 Ethics Statement

As engineers it is necessary to abide by all established ethical standards. According to the American Society of Mechanical Engineers, there are three fundamental principles and eight fundamental canons under the Code of Ethics of Engineers (ASME, 2012). Concerning this project, the Flow Gurus will aim to satisfy each applicable code in order to ethically complete the task at hand. The most relevant ethic canons are outlined below. The first fundamental canon states, Engineers shall hold paramount the safety, health and welfare of the public in the performance of their professional duties. The general public may not come into contact with the testing rig because it is not being sold or distributed; however, it is necessary to make sure that any person near its operation is safe. In order to satisfy the project requirements, The Flow Gurus must work with dangerous conditions. With high temperature liquid flowing through the heat exchanger it is paramount to make sure that it cannot harm those in the room. A sound design can ensure this and along with additional safety measures this canon will be satisfied. Safety gloves, glasses, and coats will be worn at a minimum. Additionally, a protective shield will be between the liquid and personnel at all times. This will help ensure that even after its use at the Pennsylvania State University it can be safely operated. Another relevant canon is the fourth one, which states, Engineers shall act in professional matters for each employer or client as faithful agents or trustees, and shall avoid conflicts of interest or the appearance of conflicts of interest. As engineers working for a sponsor, Flowserve, it is necessary to act as professionally as possible in every aspect of the project. This can be done by maintaining communication and producing a high quality product that satisfies the customers needs. Listening to the customer and adjusting the products design accordingly will help to satisfy any problems that may be found. The Flow Gurus will look over all canons and principles in order to be able to complete this project as ethically as possible. While some codes and principles are more relevant than others, all must be accounted for and satisfied.

7.5 Environmental Statement

Throughout the development and experimentation of the Test Rig it is the Flow Gurus will meet and exceed all environmental standards. The primary environmental goal is to leave the surroundings unaffected by the work completed throughout the project. The Test Rig itself will eventually be transported to the Flowserve site where Flowserve representatives will set it up for future use. Therefore, recyclability of the Test Rig is not a concern as it will have future use after its life at the Pennsylvania State University. Addressing the oil used is an essential component of the environmental impact. The Flow Gurus will properly research and complete all necessary protocols for the oils disposal once the final oil type is determined. The group will locate proper material safety and data sheets (MSDS) in order to learn how to transport and dispose of the fluid. Another aspect that falls under environmental issues concerns the maintenance of the testing room that the rig will be held in. It is necessary to keep the work area clean and safe, which can be done by placing a secondary container under the rig. Additionally, the testing itself will expose the rig to high temperatures and by ensuring a safe Test Rig the group will be able to prevent any damage to the room through spills or leaks.
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The Flow Gurus will also attempt to have as minimal of an environmental impact as possible by using as few resources as possible in the construction of the Test Rig. This will cut down on costs, but also prevent resources from being wasted. The group will also use electronic resources as opposed to paper in order to additionally minimize environmental impact.

7.6 Communication and Coordination with Sponsor

Initial contact with the Flowserve representative, Andrew Schevets, was made on January 17th through an introductory e-mail. In this e-mail the group was able to ask several questions concerning the project in an attempt to gain a better understanding of the task at hand. Additionally, the group inquired about the preferred method of communication and a date to meet in person. On January 25th the Flow Gurus made a site visit to Flowserve at the Phillipsburg, New Jersey location. During this visit, the project was discussed in further detail and the group got a much better understanding of the conditions that the system should be held to. Following the visit, up until the first teleconference, contact with the sponsor was maintained through e-mails from the group leader Christopher Zerphey. During this period more questions were brought up particularly concerning the Test Rig and its design. On Tuesday January 24th the group submitted its first weekly memo to the Flowserve representative documenting the current project status, work performed in the past week, and agenda for the upcoming week. Submitting a Tuesday memo has become a weekly occurrence and is a good way to update the sponsor of the groups progress prior to teleconferences.

On Thursday February 2nd at 12:30 PM the group had its first teleconference call with the sponsor using the meeting@pennstate software. The meeting place was on the 2nd floor of the Deike building in a study room. The Thursday meeting time is a weekly occurrence and will complement e-mail communication well. As stated before, a weekly memo is sent out the Tuesday prior to the teleconference so that the sponsor can get a general update of the groups progress. Communication through e-mails, memos, and teleconferences will provide ample contact between the sponsor and group. Any problems can be immediately addressed through email and can be taken into further detail through the teleconference.

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References
Branson, Spencer T. Heat Exchangers: Types, Design, and Applications. Hauppauge, NY: Nova Science, 2011. Print. Burge, Phil. (2010). PUMP BEARINGS; Bearing down on failures. Process Engineering, 38. Centaur Communication Ltd. "Code of Ethics - American Society of Mechanical Engineers (ASME) Colorado Section." American Society of Mechanical Engineers. Web. 10 Feb. 2012. <http://sections.asme.org/colorado/ethics.html>. Gibson, I., Rosen, D., & Stucker, B. (2010). Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing (pp. 7-8). New York: Springer. Incropera, Dewitt, Bergman, & Lavine. (2006). Fundamentals of Heat and Mass Transfer (Sixth.). Wiley & Sons Inc. Materna, Peter.(2003). Optimized Fins For Convective Heat Transfer, U.S. Patent 6668915-B1. Schmidt, Wayde R. Micro Heat Exchanger With Thermally Conductive Porous Network. United Technologies Corporation, assignee. Patent US 7,871,578,578B2. 18 Jan. 2011. Print. Slaughter, Victor B. Method of Using Minimal Surfaces and Minimal Skeletons to Make Heat Exchanger Components. The Boeing Company, assignee. Patent 7,866,377B2. 11 Jan. 2011. Print. Thors, P. and Narayanamurthy, R. (2005). Heat Transfer Tube with Grooved Inner Surface, U.S. Patent 6883597 B2.

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Appendix
A1: Deliverables Agreement
Date 2/10/12 Project Title Flowserve Heat Exchanger Sponsor Company Flowserve Company Contact Andrew Schevets Phone (908) 859-7389 Email ASchevets@flowserve.com Faculty Coach Dr. Santoro Email rjs@psu.edu Team Name Flow Gurus Student Team (primary contact) Chris Zerphey crz5019@psu.edu
Derek Hall Dalton Talia Frank Wolfe Marin Tola dmh5373@psu.edu djt5061@psu.edu flw108@psu.edu mit5078@psu.edu

Problem Statement: Design and create a heat exchanger utilizing the metal printing technique. The heat exchanger will cool a hot liquid by air with forced convection. The heat exchanger will be tested with a rig created by the team and will be delivered to Flowserve upon completion of the project.

Deliverables:
1) Signed Deliverables Agreement 2) Weekly update memos (status reports); delivery method: 3) Statement of Work (copies to sponsor and instructor) 4) Design Specification Report (copies to sponsor, instructor) 5) Final Report (copies to sponsor, instructor and Learning Factory) 6) Poster (32 x 40) for Showcase 7) One-Page Project Recap 8) Functioning Test Rig that operates interchangeable heat exchangers of a 12 inch
length and 0.5 inch inner diameter. The rig must circulate a hot fluid through the heat exchanger and provide air flow for forced conduction over the heat exchanger. The rig must be able to read inlet and outlet pressures and temperatures from the heat exchanger. 9) Multiple heat exchangers are to be produced in accordance with the budget of the project. They are to maximize the amount of energy that can be removed from the hot fluid by utilizing the metal printing technology.

Delivery Date
February 7th Wed. Memo, Weekly February 17th March 15th,22nd April 30th April 14th April 30th April 30th

April 30th

32

Gantt Chart
Days Month Deliverables Agreement Statement of Work Final Report DSR Concept Rig Design Customer Needs Evaluation Concept Generation Test Rig Patent Search Existing Technology Search Engineering Specifications Order Box Fan Order Piping Order Pump Order Heat Reservoir Order Data Collector Order Pressure Probe Order Temperature Probe Select Temperature Probe Select Pressure Probe Select Box Fan Select Heat Reservoir Select Data Collection Test Rig Construction Fin Concept Design Fin Concept Design 2 Fin Design Testing
7 January February 14 21 28 35 42 49

Time left Milestones Passage of Time Behind Schedule

56 63 70 March 77 84

91

98

105

April

A2: Gantt Chart

33

A3: Resumes

Derek M. Hall
1270 Circleville Road State College PA, 16803 Phone: (607) 342-5440 dmh5373@psu.edu Education
Bachelors Degree in Energy Engineering, 2009 Present; 3.75 GPA Minor in Electrochemical Engineering The Pennsylvania State University University Park, PA 16801

Work Experiences
Researcher, Energy Institute State College, Pennsylvania. March 2011 - Present Improved the existing design of a high temperature electrophoresis system. Used electrochemical techniques to evaluate system parameters. Created an operational manual for a future user facility. Researcher, National Geothermal Competition State College, Pennsylvania. November 2010 - June 2011 Worked with a theoretical power plant design team funded by NREL. Modeled the performance of a theoretical coal gasification reactor. Identified optimal operational parameters to maximize reactor performance.

Honors/Awards
Society of Energy Engineers, Vice President Energy Institutes Student Achievement Award ABET Program Evaluation, Energy Engineer Student Representative Lean Sigma, Yellow Belt Society of Energy Engineers, Accreditation Liaison 2011-2012 December 2011 August 2011 June 2011 2010-2011

Publications
1.
Chandra, D., Conrad, C., Hall, D., Montebello, N., Weiner, A., Narasimharaju, A., Rajput, V., Phelan, E., Pisupati, S., Turaga, U., Izadi, G., Ram Mohan, A., Elsworth, D. (2011) Combined scCO2-EGS IGCC to reduce carbon emissions from power generation in the desert southwestern United States. Trans. Geotherm. Res. Council. 20 pp. October. Chandra, D., Conrad, C., Hall, D., Montebello, N., Weiner, A., Narasimharaju, A., Rajput, V., Phelan, E., Pisupati, S., Turaga, U., Izadi, G., Ram Mohan, A., Elsworth, D. (2011) Pairing integrated gasification and EGS geothermal systems to reduce consumptive water usage in arid environments. Submitted for publication. Geothermics. 40 pp. 34

2.

FRANCIS L. WOLFF
967 Southgate Drive, State College, PA 16801 (570) 926-1551 flw108@psu.edu Education The Pennsylvania State University, University Park, PA Bachelor of Science, Mechanical Engineering (December 2012) GPA of 3.69/4.00, Deans list x6 Relevant Courses Thermodynamics Vibration of Mechanical Systems Principles of Turbo-machinery

Heat Transfer Strength and Properties of Materials Microstructure Design of Structural Materials

Experience PSU/ARL Metals and Ceramics Processing Department Intern (July 2009 - Present) Pennsylvania State University, State College, PA Performed material analysis including; sample preparation, optical microscopy, and hardness testing (Vickers and Rockwell) for industrial and government programs. Experienced with cold spray and spray metal forming technology. U.S. Army Reserves Sergeant (November 2006 - May 2010) 392nd Signal Battalion, Tobyhanna, PA Assisted military and civilian I.T. specialist in establishing communication networks. Trained soldiers on the new WIN-T equipment that was fielded to the 392nd Signal BN. Validated 8 Satellite Transportable Terminal (STT) systems so they could be used in overseas operations. U.S. Army Specialist (July 2003 - July 2006) Bravo Co. 2-70th Armor Battalion, Ft. Riley, KS Maintained 22 M1A1 Abrams tanks over a course of 2.5 years, including a 13 month deployment in support of Operation Iraqi Freedom. Identified faults and implemented corrective actions for electrical, hydraulic, and mechanical systems on both the turret and hull of the M1A1 Abrams Main Battle Tank. Performed routine Preventive Maintenance Checks and Services (PMCS) to prevent component failure while operating in the field. Skills and Achievements Experience with Microsoft Office, SolidWorks, Matlab, ABAQUS, and DAQ software. Graduated as the Distinguished Honor Graduate during my Army Basic Training and AIT. Graduated on the Commandants list during Warrior Leadership Training. Active Security Clearance DoD

35

36

37

38

A4: Miscellaneous Figures

Pump Specs

39

Omega Thermocouple Specs

Omega Thermistor Specs

Omega Infrared Specs

40

A5: BOM
Rig Structure Part Description 2 X 4 substructure (8' sections) 1/4 x 4 x 8 Utility OSB .5" x 1' type K tubing T fittings 90 degree fitting 1/2" coupling Insulation Fasteners (75 ct. screws) Thermistors Heat Source (donated) Pump (Estimated) Pressure Gage Plexiglass Sheet Shipping Total Price/Unit 3.00 6.57 2.59 0.65 0.36 0.29 3.90 8.57 25 85 85 15 25.49 # of units 2 1 8 2 8 3 2 1 2 1 1 2 2 Cost of Part 6.00 6.57 20.72 1.30 2.88 0.87 7.80 8.57 100.00 0.00 85.00 30.00 50.98 50.00 421.67

41

A6: Team Notes

Tuesday 1/17/2012Class
Met with group for the first time Exchanged contact information o Derrick, Dmh5737@psu.edu, 607-342-5440 o Chris, Crz5019@psu.edu, 717-725-2639 o Frank, Flw108@psu.edu, 570-926-1551 o Marin, Mit5078@psu.edu, 267-897-0351 o Dalton, Djt5061@psu.edu, 267-614-4756 Found out meeting times outside of class o Wednesday after 4:30 o Thursday 11-1 Began thinking about the project o Applications o Are there previous experiments or existing data o Are we making multiple designs Thought out what to say in our first contact email

Thursday 1/19/2012Class
Identified future needs o Team contract o Gantt Chart o Meeting time for visit o Meeting time for telecomm o What to wear to visit o Weekly memo Class lecture on workplace customs and memo overview

Sunday 1/22/2012Team meeting, Hammond computer lab 5:00-5:30

Completed several tasks o Weekly memo o Team Contract o Gantt chart displayed

42

Tuesday 1/24/2012Class
Team discussion consisted of brainstorming possible questions for the Flowserve visit o Will the heat exchanger clog o Cross flow vs. counter flow o Two designs Microfins Microtubing o Rig design specifications: Laminar vs. Turbulent flow o Velocity and mass flow rate in pipe For the future o Notes and questions for the 1/25/2012 Flowserve visit o Look into work done by Ralph Webb o Business casual attire o Set up teleconference o Deliverables RIG CAD Experiment results

Wednesday 1/25/2012Flowserve Site Visit, 7:30AM-5:30PM

Discussed Project in more detail Examined examples of printing capabilities Went over project limitations Saw facilities Attained a better overall understanding

Sunday 1/29/2012Team Meeting, Hammond Computer Lab 5:00-6:00

Team Discussion o Went over the necessary system components and their price o Took a look at pipe and possible fittings o Looked into deep fryer specifications o Determined volumetric flow rate of 20 mL/s For pipe this takes 2 seconds to pass through a 12 section o Figured out wattage to account for losses For Next Time o What data acquisition system does Flowserve have o Each person given component of system to research Pump Basin Thermocouple 43

Fan Pressure gages

Tuesday 1/30/2012Class
Team discussion o Type of oil being used resembles bearing oil o Safety components Lab jackets, goggles, gloves, cover deep fryer, plexi-glass shield o Secondary failure Big leak, pipe break, etc Place big collection bucket underneath o How big will test rig be and how will it be transported o Will oil be flammable? MSDS charts needed o Have safety review or designate a safety person o Assume system will have 10 feet of pipe o Insulation? Future Considerations o February 9th major report due For Next Time o For teleconference Have budget outlined Can the group borrow Flowserves data acquisition system Discuss safety concerns

Wednesday 2/1/2012Hammond Computer Lab 4:00-7:00

Tasks Worked On o Group Met and Divided up Work o Began Statement of Work Report o Customer Needs Identified and SOW section completed for this o Worked on thermal circuit For Next Time o Continue to work on SOW sections individually o Teleconference for Thursday 2/2/2012

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Thursday 2/2/2012Deike Library Room 12:30-1:00

Sponsor had to cancel meeting around 12:00 due to travel

Thursday 2/2/2012Class
Risk Assessment overview o Risk= Magnitude x Frequency o Cost benefit analysis Good design, low cost ratios o Ford Pinto Problem fix vs. Eating the cost Publicity ended up killing them Money saved initially ended up costing them o Risk Factors Marketing- Somebody else makes it first Technical- Example of iPhone antenna Schedule Manufacturing Reliability Product safety o Integrate risk reduction into Gantt Chart

Friday 2/3/2012Team Teleconference Deike Library Room A 1:30-2:00

Make-up teleconference for the cancellation a day prior o Discussed budget in detail Each expert of a main component went over price and reasoning Suggestions made to each component Pump: Electric oil pump or turbocharger oil pump Pump is ultimate limiter Pump originally shown by sponsor is too expensive Questions asked about thermocouples o Open system- Low pressure o Box fan- 1500-2200 CFM o ProMetal accuracy between 4000 and 8000ths of an inch For Next Time o Sponsor provides Oil specifications Previous work performed by another group o Group supplies sponsor Deliverables agreement 45

Statement of work Ideas for piping

Tuesday 2/7/2012Class 12:15-12:45 Meeting with Professor

Due in class o Executive Summary Review o Deliverables Agreement Discussion with professor, suggestions given below o Avoid words cheaper, larger, expensive, bigger, smaller No meaning, hard to quantify o Gantt chart suggestion Final rig design portion- needs to be broken down into more detail o Forced Convection discussion, group needs to define this term 1500-2200 CFM by house box fan o Specify what the group is delivering o Fill in nondisclosure agreement/ IP Group should have copies o Splitting up SOW concerns Want someone to integrate it to account for different styles Different proofreaders For next class o Short 60-90 second presentation o Fill out team evaluation sheets o Statement of work due Friday o Visit Wayne Royer in Reber to get room North side on right to engineering C

Thursday 2/9/2012Teleconference Deike Building 12:30-1:00

What the group is receiving in future from Flowserve o DAQ and software o Basin for oil Will be 15-20 lbs o Fittings, anything else useful that can be found Discussion o Heating requirement discussion due to new heat source Is 1000 Watts sufficientyes Insulation will be needed o Oil Viscosity 32ftg Similar to 10W30 o Pump selection discussion Grundfus UP15-10F selected 46

o SOW due Friday so heat exchanger design will be completed in upcoming weeks o Can Lattice Assembly be opened, need .stl opener For sponsor o Deliverables agreement o SOW on 2/16/2012 o See if .stl file can be opened o Address for package o Heat exchanger design before spring break

Thursday 2/9/2012Class 1:00-2:15

In class o Group presentations for each project o Chris presents Flowserve project Future o SOW due 2/10/2012 at midnight Group plans work schedule to finish SOW

Friday 2/10/2012Hammond Lab 5:00-6:00

Group meets to go over SOW and final changes Will be submitted by Derek at 10:00 PM

Sunday 2/12/2012Group Meeting Hammond Lab 5:00-6:40

Team completed o Created SOW presentation slides o Modified CAD drawing to account for pump For future o Members must complete sides for the section they will be presenting Slides due Monday night so Chris can compile by Tuesday morning o Begin looking into fin designs

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