Precision AirConvey Internal Duct Cleaning System December 10, 2007 Sean Darras Nick Rakov Katie Sear Lindsay Martz

Introduction to PAC PAC has designed a pneumatic linen-refuse system.

Mock System

Project Scope UD must develop a method to clean PAC’s Linen and Refuse Removal System An inhibitor and deodorizer application must be developed

System Specifications/Constraints Duct Dimensions: ◦ Outside Diameter: 20” ◦ Thickness: Corners.135”, Straightaway.105” Access panels are ft apart Pressure drop is 50 lbf/in 2 Air flow is 55 ft/s ~ 60 mph Duct is made of (uncoated) steel Plaque is caused by liquid/debris in the system Most ‘Plaque’ builds up on the turns Bag path can include a double 90 degree turn System cleaned weekly

Design Criteria WantMetricTarget Value Maximize Cleaning Performance Plaque removal80-100% removed Durability# of uses or total miles traveled 3 to 5 runs without decreased performance Minimize TimeTime to clean one mile1 hour Maximize RangeDistance traveled at one time 1 mile Minimal Labor Involvement # of operators2 in-house maintenance men Inhibit and Deodorize Quarterly Swab TestDependent on Industry

Pre-existing Solutions Customer Opinion: ◦ No Umbilicals ◦ Requires Aggressive Cleaning ◦ Prefer Robot and Shuttle ideas Agitation DevicesRobots PIG

Concept Ideas ShuttleSpringSpinnerRocket Spider Rating Criteria: 1: Should surpass target value 0.5: Should easily reach target value 0.2: Will probably reach target value 0: Unknown Metric Importance (%)RocketSpiderShuttleSpinnerSpring Plaque Removal Durability Distance Traveled Time Liquid Coverage # of Operators Final Score%

Chosen Concept: Rocket Initial ConceptFinal Prototype

In the Duct Clearance between shuttle and inside duct walls approx = 2 inches Shuttle length greater than 20 in. to prevent yaw and pitch in the tube

Rocket- How it works Propelled by system Aluminum Frame Rotated by system Nylon Bristles

Brushes Stiff Nylon Fibers Channel is attached by brackets to main body ChannelBrushes

Rotor Variable fin pitch Variable number of fins

Liquid Application Prewash and Deodorizer Sponge ◦ Approximately 7 lbs (dry) ◦ Dimensions:  Height 21”  Diameter 19.8” Fogger Sponge

Prototyping Fabrication outsourced to local Machine Shop UD provided assembly instructions, detailed drawings, and fabrication support.

Objectives of Testing Determine : ◦ Durability ◦ Time to clean one mile ◦ Distance that can be traveled at one time ◦ Coverage of the prewash, inhibitor and deodorizer ◦ Cleaning technique that maximizes plaque removal

Maximum Cleaning Performance

Flat-Sheet Prewash Test Flat-Sheet Prewash Test Surface# of swipes Greased Lightening ZEP9 Dry20+ Air Chalk3

Sponge Testing BEFOREAFTER

Rotation Testing

36 degrees over 12 ft= ~1 Rotation per 120 ft 8 fins at 45 deg. gives maximum rotation

Final Verification Testing -Results agree with Flat-Sheet Prewash Test 90 Degree Rise

Conclusions Rocket needs to Rotate One Rotation/Foot Current Rocket only rotates ~1 Rotation per 120 ft With no rotation, Rocket would need 54 levels of brushes

Recommended Proposal Compromise : ◦ Double the amount of brushes ◦ Requires1/2 rotation/foot ◦ Increase rotor diameter ◦ Optimize fin design ◦ Clean more often

Total Cost to PAC MaterialAmountPrice Body 5052 Aluminum Sheet- 1/8"10 sq ft $2455 (Includes Labor) 5052 Aluminum Sheet- 1/16"10 sq ft Propeller 5052 Aluminum Sheet- 1/8"1 sq ft 3/8" x 3/8" 12 ft Brushes 2 Sets of Brushes $ Brackets Fogger Flex-a-lite 2600$300 Sponge2 Sponges$120 Filet Knife$30 Plaque MaterialsSoda, Eggs, Milk, Fake Snow, Air Chalk$25 Participation CostOne time fee$5000 PAC’s TimeVaries per employee$4,230* Total $13, *Best estimate

Questions?

Supporting Material-Rotor