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Heat Exchanger Learning Apparatus: Design and Development for Educational Purposes

This project aims to design and manufacture a heat exchanger learning apparatus to enhance students' understanding of heat exchangers and the parameters affecting their performance. The apparatus will feature three interchangeable bundles for studying internal components, utilize LabVIEW for data collection and display, and facilitate hands-on learning with a temperature differential of 20°F-30°F. The final design will include detailed manufacturing drawings and a comprehensive cost analysis, supported by industry and faculty advisors to ensure real-world relevance.

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Heat Exchanger Learning Apparatus: Design and Development for Educational Purposes

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  1. HeatExchangerLearningApparatus Senior Design Project Team Members: Robert Maduro (Team Leader) Adolfo Leyva Ricardo Gonzalez Luis Avila Industry Advisor: Wade Armer Justin Shepherd Faculty Advisor:Medhad El Nahas Paul Salgi Underclassmen: Jessica Ocampo

  2. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  3. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  4. Objective • To design and manufacture a heat exchanger learning apparatus and provide students with a comprehensive understanding of heat exchangers including the various parameters that affect its performance.

  5. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  6. What is a Heat Exchanger? • Heat exchangers are devices that provide the flow of thermal energy between two or more fluids at different temperatures.

  7. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  8. Goals • Include 3 interchangeable bundles to familiarize students with internal components of a heat exchanger • Utilization of LabVIEW to collect and display data • Incoming fluid will have a temperature difference of 20°F - 30°F during the transfer process • Provide a complete set of working drawings for manufacturing and welding processes

  9. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  10. Market Analysis

  11. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  12. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • Pumps • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  13. Total Dynamic Head

  14. Total Dynamic Head Calculations

  15. Pumps

  16. Pumps

  17. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • Tables • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  18. Table • Maximum width of 36” and be able to support 600lbs 18 http://www.homedepot.com/p/Trinity-EcoStorage-48-in-NSF-Stainless-Steel-Table-with-Wheels-TSC-WKT221C/203685982#.UVlg7ldYQdk http://www.umfmedical.com/index.php?page=instrument-table-ss8004 http://www.abreq.com/products/30_x_48_Commercial_Stainless_Steel_Work_Prep_Table_with_Casters-3812-0.html

  19. Table • Maximum width of 36” and be able to support 600lbs 19 http://www.homedepot.com/p/Trinity-EcoStorage-48-in-NSF-Stainless-Steel-Table-with-Wheels-TSC-WKT221C/203685982#.UVlg7ldYQdk http://www.umfmedical.com/index.php?page=instrument-table-ss8004 http://www.abreq.com/products/30_x_48_Commercial_Stainless_Steel_Work_Prep_Table_with_Casters-3812-0.html

  20. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • Tanks • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  21. Tanks 21 21 http://www.rakuten.com/prod/jaz-210-515-03-aluminum-fuel-cell-15-gallon-20-x-18-x-10/230136292.html?listingId=210867293 http://www.sandparts.com/servlet/the-1595/Actks1040--Stainless-Steel/Detail

  22. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • Heat Source • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  23. Wattage Calculations 23

  24. Heat Source Unkown 2E755 RHEEM 15A528 http://www.grainger.com/Grainger/Electric-Replacement-Water-Heater-Element-2E755?Pid=search http://www.grainger.com/Grainger/RHEEM-Resistored-HWD-Element-15A528?Pid=search • Voltage: 120V • 1650 watts • Insert length: 10.625in • Style: bolt on • $20 • Voltage: 120V • 2000 watts • Insert length: 7.56in • Copper element • $14

  25. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • LabVIEW • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  26. What is LabVIEW? • Software that provides a development environment for graphical programming & hardware integration • Key features: • Take measurements • Perform analysis & signal processing • Instrument control • Display data on user interface • Log data & generate reports http://www.nyu.edu/classes/mcdonough/m&eiii.htm

  27. LabVIEWRequirements

  28. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • Hardware • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  29. Hardware • Data acquisition (DAQ) devices measure electrical or physical signals from a variety of sensors Portable DAQ USB-6008 Desktop DAQ PCIe-6320 http://sine.ni.com/nips/cds/view/p/lang/en/nid/207404 http://sine.ni.com/nips/cds/view/p/lang/en/nid/201986 • Easy USB connection • 8 inputs / 2 outputs • Sampling rate: 10kS/s • Input resolution: 12 bits • $169 • PC slot • 16 inputs / 0 outputs • Sampling rate: 250kS/s • Input resolution: 16 bits • $977

  30. Hardware • Data acquisition (DAQ) devices measure electrical or physical signals from a variety of sensors Portable DAQ USB-6008 Desktop DAQ PCIe-6320 http://sine.ni.com/nips/cds/view/p/lang/en/nid/207404 http://sine.ni.com/nips/cds/view/p/lang/en/nid/201986 • Easy USB connection • 8 inputs / 2 outputs • Sampling rate: 10kS/s • Input resolution: 12 bits • $169 • PC slot • 16 inputs / 0 outputs • Sampling rate: 250kS/s • Input resolution: 16 bits • $977

  31. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • Temperature Sensors • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  32. Temperature Sensors • Primary requirement: range between 70°F-194°F Thermocouple THMK-A01L10-01 RTD RTD1-D08L10-01 http://www.automationdirect.com/static/specs/psthermoprobeais.pdf http://www.automationdirect.com/static/specs/psrtdprobeais.pdf • Self-powered • Accuracy: ±1°F • 32-900°F • Response time: 2.9s • $26 • Stable readings • Accuracy:±0.27°F • -58-572°F • Response time: 7s • $43.50

  33. Temperature Sensors Thermocouple THMK-A01L10-01 RTD RTD1-D08L10-01 http://www.automationdirect.com/static/specs/psthermoprobeais.pdf http://www.automationdirect.com/static/specs/psrtdprobeais.pdf • Self-powered • Accuracy: ±1°F • 32-900°F • Response time: 2.9s • $26 • Stable readings • Accuracy:±0.27°F • -58-572°F • Response time: 7s • $43.50

  34. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  35. TEMA - Types • Tubular • Exchanger • Manufacturers • Association

  36. Design Process Parameters Needed to be Changed Unacceptable Results

  37. Thermal Design Flow Stream Fractions

  38. Tubes Layout Case 2 Case 1 Case 3 • ¾” Tubes • 15 Tubes • ΔTH = 33 °F • v= 0.5 ft./sec • ½” Tubes • 14 Tubes • ΔTH = 28 °F • v= 0.9 ft./sec • ¾” Tubes • 7 Tubes • ΔTH = 18 °F • v= 1.0 ft./sec

  39. Flange Type Selection Slip On Weld Neck http://www.hiwtc.com/products/ansi-b16-5-welding-neck-flange http://www.nowsad-metal.pl/productionofsteelflanges,60,l2.html • Two Welds Required • Pipe length adjustable • Easy alignment • Fillet Weld • Single Weld • Most Expensive • V bevel Weld • High Pressure Applications

  40. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  41. Conceptual Design Layout

  42. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  43. Cost Analysis

  44. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  45. WBS In Progress Pending Completed

  46. Gantt Chart

  47. Risk Matrix Likelihood Impact

  48. Outline • Objective • What is a Heat Exchanger? • Goals • Market Analysis • System Components • Heat Exchanger Design • Conceptual Design Layout • Cost Analysis • Project Management • Tentative Sponsors

  49. Tentative Sponsors

  50. Questions?

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