P09451 Detailed Design Review Bryan McCormick (ME) Project Manager Andy Freedman (ME) Heat Transfer/Fluids Analysis & Design John Kreuder (ME) Thermal Modeler Ken McLoud (ME) Structural Designer Jon Holdsworth (EE) Electrical System Designer Gabriela Santa Cruz (IE) Engineering Economics

Closer Look at the Solution T=465KT=459KT=458KT=457K T=438K

Current System

Piping

Control System

Control System – Plant Model Mosfet Compensation

Response - optimized

Response – non-optimal

Automated Peak Power Impedance Matching Circuit for Peak Power

Sensors Total Sensors (Inputs to DAQ) ThermocouplesOn Modules48 Before/Inbetween/After Zones5 Inlet/Outlet of Cold Exhaust4 Heater Inlet1 Mass FlowsAir1 Water1 Compression ForceFlexi-Force Sensors8 Change in Air PressurePressure Transducers3 VoltagesLoad Voltages4 Shunt Voltages4 79Total

Block Diagram

Layout

Data Collection Goal: Collect enough data to test for reliability and reproducibility of current measurements. Performed 4 tests under the same conditions (200 C and 100cfm) Assembled the unit twice by two different operators, tested two times for each assembly

Data Collection Process: Assembly and Set-up Test 1Test 2Improvement Cleaning 1:021:50 Bottom Assembly Applying Thermal Paste to Modules: Three Modules, 1 side4:123:46Considered thermal pads, not feasible Three Modules, 2nd side3:383:16Considered thermal pads, not feasible Placing Insulation1:041:02Marked Places for Modules for easy placement Setting on Bottom Plate1:220:52Bolts attached to bottom plate Sub Total10:168:56 Top Assembly Applying Thermal Paste to Modules: Three Modules, 1 side3:513:04Considered thermal pads, not feasible Three Modules, 2nd side2:472:21Considered thermal pads, not feasible Placing Insulation0:380:44Marked Places for Modules for easy placement Setting Top Plate0:280:59 Sub Total8:447:08 Final Assembly Placing Washers and Nuts1:301:15 Tightening3:014:21Better Tool Clearance Outside Insulation1:261:59More space to insert, less pieces Thermocouples6:505:54Embeded in Power Unit Sub Total12:4713:29 Set-up in Stand Set on Jacks and Lift1:472:51Block with Appropriate Height in Test Stand Attaching to Stand10:297:14Better Tool Clearance Plugging into DAQ6:546:01Color Coding Sub Total18:1016:06 Total

Issues/Solutions on Data Processing IssueSolution Long, tedious clean-upRecord output with headers Set up different output formats depending on the application. Inconsistent data, uncertainty in the origin Data constraints with LED indicator when out of range in front panel

Statistical Analysis Hypothesis Testing: Difference Between Means # of standard deviations away from the hypothesized zero difference Reject H o for |T|>2.093 Where

Project Charter Project Name Thermoelectric Module for Large Scale Systems Project Lead Bryan McCormick Date, Revision # Project Sponsor Dresser- Rand: Paul Chilcott Start Date 12/1/08 SDT Leader Completion Date 5/22/09 Idea Submitter Dr. Robert Stevens Current Phase Detailed Design ElementDescriptionTeam Charter Process Definition The business process in which opportunity exists. This project is aimed at acquiring an improved understanding of the workings of thermoelectric (TE) devices as a means to recovering wasted energy from Dresser- Rand turbo machinery exhausts in the form of usable power. Strategic Goal/ Business Case Describe the opportunity as it relates to strategic business goals. A clear understanding of the workings, benefits and fallbacks of thermoelectric devices is important when deciding whether it is feasible to implement this technology in industry, and whether it is the best choice among alternative technologies. Problem Statement State the significant issue(s) that needs to be addressed or opportunities to pursue. To better understand thermoelectrics and their potential applications in industry for energy recovery, it is important to have a reliable, flexible and efficient test stand to validate models. The current test stand requires long set-up times, does not provide readily available data and has too many variables that compromise the reliability of the acquired data. There are also different configurations that could be tested if the stand allowed for more flexibility, which would produce a wider range of data to draw conclusions from. Benefits Impact ($) What are the anticipated business results and when would the results be realized? Upgraded thermoelectric test rig utilizing interchangeable air- cooling on the cold side and capabilities for different configurations. Upgraded data acquisition system. Improved Power Unit. Documented data on module performance for verification of theoretical results. (All these deliverables are expected to be ready by 05/22/09) What is the preliminary budget estimate for the project cost? This project counts with a budget of $7500 Scope/Boundaries Describe the project's scope and boundaries. Describe what is in and outside the scope. Activities within scope include: 1. Implement air-cooling on cold side of thermo-electric array in addition to the water- cooling system. 2. Be able to experimentally validate thermoelectric system models and enable more parameters to be explored. 4. Improve set-up and shut- down procedures to reduce assembly times. 3. Improve user interface and data acquisition to allow greater ease of use of the test stand. The scope excludes: - Any study or design of the system that would eventually be implemented in industry. Schedule/Mileston es What are the start and completion dates of the project? Starting Date: 12/01/08 System Level Design:01/02/09 Detailed Design:01/30/09 Project Completion:5/22/09 Benefit to Customers Who are the Customers, what benefit will they see and what are their most critical requirements? Dresser-Rand: The results of experimentally testing valuable aspects of thermoelectric modules will provide insights on the feasibility of implementing this technology to provide energy recovery capabilities to Dresser-Rand's customers, which would further increase the value of the products, specially in applications in remote locations. RIT: This knowledge will help bring RIT to the forefront of this emerging technology. Support Required (if any) Will you need any special capabilities, hardware, etc.? Key Stakeholders Who has been identified as a Key Stakeholder(s) for this project? Primary Stakeholder: Dresser- Rand Secondary Stakeholder: RIT Project Charter Project Name Thermoelectric Module for Large Scale Systems Project Lead Bryan McCormick Date, Revision # Project Sponsor Dresser-Rand: Paul Chilcott Start Date 12/1/08 SDT Leader Completion Date 5/22/09 Idea Submitter Dr. Robert Stevens Current Phase Detailed Design ElementDescriptionTeam Charter Process Definition The business process in which opportunity exists.This project is aimed at acquiring an improved understanding of the workings of thermoelectric (TE) devices as a means to recovering wasted energy from Dresser-Rand turbo machinery exhausts in the form of usable power. Strategic Goal/ Business Case Describe the opportunity as it relates to strategic business goals.A clear understanding of the workings, benefits and fallbacks of thermoelectric devices is important when deciding whether it is feasible to implement this technology in industry, and whether it is the best choice among alternative technologies. Problem Statement State the significant issue(s) that needs to be addressed or opportunities to pursue.To better understand thermoelectrics and their potential applications in industry for energy recovery, it is important to have a reliable, flexible and efficient test stand to validate models. The current test stand requires long set-up times, does not provide readily available data and has too many variables that compromise the reliability of the acquired data. There are also different configurations that could be tested if the stand allowed for more flexibility, which would produce a wider range of data to draw conclusions from. Benefits Impact ($) What are the anticipated business results and when would the results be realized? Upgraded thermoelectric test rig utilizing interchangeable air-cooling on the cold side and capabilities for different configurations. Upgraded data acquisition system. Improved Power Unit. Documented data on module performance for verification of theoretical results. (All these deliverables are expected to be ready by 05/22/09) What is the preliminary budget estimate for the project cost? This project counts with a budget of $7500 Scope/Boundaries Describe the project's scope and boundaries. Describe what is in and outside the scope. Activities within scope include: 1. Implement air-cooling on cold side of thermo-electric array in addition to the water-cooling system. 2. Be able to experimentally validate thermoelectric system models and enable more parameters to be explored. 4. Improve set-up and shut-down procedures to reduce assembly times. 3. Improve user interface and data acquisition to allow greater ease of use of the test stand. The scope excludes: - Any study or design of the system that would eventually be implemented in industry. Schedule/Milestones What are the start and completion dates of the project? Starting Date: 12/01/08 System Level Design:01/02/09 Detailed Design:01/30/09 Project Completion:5/22/09 Benefit to Customers Who are the Customers, what benefit will they see and what are their most critical requirements? Dresser-Rand: The results of experimentally testing valuable aspects of thermoelectric modules will provide insights on the feasibility of implementing this technology to provide energy recovery capabilities to Dresser-Rand's customers, which would further increase the value of the products, specially in applications in remote locations. RIT: This knowledge will help bring RIT to the forefront of this emerging technology. Support Required (if any) Will you need any special capabilities, hardware, etc.? Key Stakeholders Who has been identified as a Key Stakeholder(s) for this project? Primary Stakeholder: Dresser-Rand Secondary Stakeholder: RIT

BOM