P08453 Flow Visualization 2/8/2008 System Level Review P08453 Flow Visualization 2/8/2008

Agenda Needs and Specifications High Level System Architecture Pump Design and Simulation Results Backend Plumbing Control System and Hardware

Needs

Design Specifications

Pump Housing

Pump Housing – Exploded View

Housing Front – SLA vs Machined

CFD Calculations for Strait Blades

CFD Results: SETTINGS BCs: RESULTS: Run # Geometry Depth Spacing Speed Inlet psi GPM dP 1 0.08 0.02 1700 16 3   4 2 0.18 0.28 5 0.38 6 0.48 7 8 9 15 10 30 11 1400 12 2500

CFD Results: Pump curves .38” impeller depth, .02” gap Pressure Increase (psi) Volumetric Flow Rage (gpm)

Rear end flow loop.

Flow Loop

Loss Calculations

Advantages to System. PVC pipe Dense Packaging Larger Reservoir More surface room Inherent head for possible cavitation Failsafe water to reservoir

Disadvantages Complicated Priming Inherent resistance of head if cavitation is not desired. Complicated ancillary system

Ancillary System Pump and valves for priming Necessary due to orientation of tank Better packaging Slightly more complicated to operate.

Outline and Bill of Materials Description Vendor Part Number QTY Ea. Total Comments Complete Computer System Dell Custom 1 $499.00   Tachometer - Photoelectric Dart Controls OPU $97.00 Second Choice, 1 Week Delivery Tachometer - PU-E (Bolt-On Hall Effect Sensor) PU-E $105.00 1st Choice, 1 Week Delivery Paddlewheel Flow & Temperature Sensor/Transmitter Omega FP7002 $365.00 High Accuracy Wet/Wet Differential Pressure Transmitter PX81D1-005DI $685.00 National Instruments Data Acquisition PCI Card NI NI PCI-6221 $476.00 Signal Conditioning Manifold SC-2345 $314.00 (already have from Wellin) Data Cable SHC68-68-EPM Cable (1m) $89.00 Current Input Module (flow, temp, pressure) NI SCC-CI20 3 $152.00 $456.00 (already have some) Frequency Input Module (tach) NI SCC-FV01 (may already have) VDC Power Supply DigiKey 179-2356-ND $138.72 Motor Controller Dart Controls, Inc. MDII Series, MD30E $866.00 1 Week Delivery Motor  TBD $1,000.00 (optional) May use Prof. Wellin's motor Grand Total $5,404.72

Computer System Dell Inspiron 530 Cost effective, reliable Ability to add in NI PCI-DAQ Ability to run LabVIEW and all control software

Tachometer Selection Dart Controls, Inc. Two Choices Photo Electric (0-600,000 RPM) Relatively easy to use Cheap Easy integration May require some clever positioning to obtain readings May take up extra space 2. Hall Effect (0-5000 RPM) Easiest to use (if we can tap back end of motor shaft, otherwise not applicable Simple integration into motor controller for RPM feedback

Flow Sensor/Temperature Sensor Omega, Inc. - Incorporates volumetric flow and temperature readings Simple integration (4-20mA outputs) Different size sensor housing and flow correction factor based on PVC pipe diameter. 0-30 GPM range 0-105°C range

Differential Pressure Omega, Inc. Will monitor pump inlet and outlet Industry standard 4-20mA output 1 NPT port for pump inlet 1 NPT port for pump outlet Only measures pressure difference between points, not individually. Chosen to improve overall accruracy, rather than 2 sensors cumulative error

Data Acquisition National Instruments, Inc. Can accept up to 16 inputs. Enough for this project and allows for future upgrades Use specific modules based on sensor outputs Simplifies sensor integration and signal conditioning Components 3x SCC-CI20 Current Input 1x PCI-6221 1x SC-2345 1x Data Cable

Motor Controller Dart Controls, Inc. MDII Series Uses feedback from tachometer sensor Communicates to PC via RS-232 Allows for remote control from PC Allows for LabVIEW control Closed loop feedback maintains RPM to +/- 1 RPM

Risks Assessment 1. Order sensors incompatible with ordered equipment (4-20mA sensor, but 0-5V needed)         a) Tachometer (photoelectric) - 0-5V Square Wave pulse         b) Differential Pressure - 4-20mA`         c) Volumetric Flow Meter - 4-20mA         d) Temperature Measurement (part of flow sensor) - 4-20mA       2. Not enough power to run sensors, or sensors may need auxiliary power supply     Excitation Needed:         a) Tach (x V)         b) Differential Pressure (x V)         c) Flow Meter (x V)         d) Temperature (x V) 3. Steep Learning Curve with LabVIEW, programming may be difficult         a) Utilize code from: http://zone.ni.com/devzone/cda/main 4. Sensors may be difficult to zero and calibrate         a) Obtain documentation for all sensors and follow calibration procedure 5. Sensors may have a measurement range too high or too low for our application         a) Based on design specifications located here 6. Sensors and hardware may be too expensive         a) Call up vendors if prices are not listed on the website 7. May short circuit a sensor and destroy it if wired incorrectly         a) Ask for assistance if a wiring diagram is unclear and have multiple group members verify connections 8. Flow sensor may disrupt pressure or flow too greatly         a) Make sure the correct size piping and lengths are used, based on manufacturers specifications 9. Electricity and water do not mix well, this project is just that: using electricity to measure flow characteristics.         a) Separate electronics from hydronics by utilizing two separate carts 10. Pressure sensor may be difficult to install         a) Refer to sensor manual for installation instructions 11. Controlling motor through controller from LabVIEW may be difficult         a) Refer to users manual for remote control 12. Hooking up photoelectric sensor to motor may be difficult         a) Communicate with hydronic and pump engineer to allow enough space for sensor installation         b) Install safety guard if rotating components could be touched