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

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

3. Needs

4. Design Specifications

6. Pump Housing

7. Pump Housing – Exploded View

8. Housing Front – SLA vs Machined

9. CFD Calculations for Strait Blades

10. 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

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

12. Rear end flow loop.

13. Flow Loop

14. Loss Calculations

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

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

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

18. 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 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

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

20. 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 ( RPM)
Easiest to use (if we can tap back end of motor shaft, otherwise not applicable
Simple integration into motor controller for RPM feedback

21. 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

22. 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

23. 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

24. 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

25. 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 mA`         c) Volumetric Flow Meter mA         d) Temperature Measurement (part of flow sensor) mA       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: 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