Sustainable Technology For The Global Market Family of Projects

1. Sustainable Technology For The Global Market Family of Projects James Brown Rishitha Dias Casey Dill Neranjan Dharmadasa Kevin Klucher Eric MacCormack Colin Roy

2. Preliminary Schedule AY 2007-08 AY 2008-09 AY 2009-10 AY 2010-11 AY 2011-12 Remote Health Monitoring System • Reciprocation compressor revamp and interface • Preparation for new compressor arrival • Begin testing • Diagnostics • Wireless monitoring of DAQ Thermoelectric Waste Heat Recovery • Energy recovery from D-R VECTRA gas turbine • Make improvements on current test stand • Simulate sea bed conditions • Scale and install on compressor • Meet load requirements Turbo machinery Flow Visualization • Turbomachinery flow visualization • [table top] • Scale up & develop lab test stand • Develop modules to fit D-R compressor • Develop high speed camera system • Integrate modules on D-R compressor Robotic Arm • Pneumatic 3 and 5 fingered hand • Hydraulic • 5 fingered hand with wrist motion • Underwater use • Advanced tool use • Advanced controls system • Use with robotic platform Robotic Platform • Interchangeable propulsion/ • lighting modules • Design new platform for open source • Improve existing platform and interface • Scale up to D-R expectations • Integrate robotic arm and optimize design Process Improvement • Value • engineering in • manufacturing facility • Process Improvement Project

3. P09451: Thermo-Electric Module for Large Scale Systems 2008-2 through 2008-3 Neranjan Dharmadasa James Brown

4. Introduction • Thermoelectrics are very simple solid state devices with two basic modes of operation. • The Peltier Effect, involves the application of current through the module, absorbing heat from one side of the device and emitting from the other side. • Conversely, the Seebeck Effect can be used for power generation purposes. When a temperature gradient is applied across a TE module an electric current is produced.

5. Previous Projects P07442 P08451

6. Mission Statement The focus of this project will be to make improvements to last year's power module unit design, perform more extensive testing and address some issues that surfaces from the preliminary testing done last year. This year‘s team will develop a second generation prototype power module that would more closely simulate a power unit that might be deployed on the exhaust stream of a Dresser-Rand Vectra or other turbine. This unit may include the use of air cooling to simulate a power unit serving both as a power generator as well as a recuperator. The team will make improvements in temperature sensor locations to better monitor heat spreading and understand multidimensional conduction which is currently not accounted for in the modeling. The team will also design and implement strategies for max power tracking and the handling of module array mismatch due to differing temperature gradients.

7. Test Stand Improvements More fin options Design for power requirements Design for specific operating conditions Design for recuperative heating system Additional “zones” Customer Needs Test Stand Issues • GUI and data processing • Temperature measurements • Swapping T.E. modules • Max point tracking (power) • Pressure losses • Lack of sensors for multidimensional heat transfer

8. Staffing Requirements

9. Work Breakdown Structure

10. Team Values and Norms • Punctuality • Organized • Devoted/Committed • Professional and Ethical • Thorough • Accurate • Meet Guidelines • Meet Deliverables on Time

11. Required Resources • Current lab test stand • Machine shop • Time with Graduate Assistance • Time with Faculty Guide, Dr. Stevens • Time with Dresser-Rand contacts

12. Assumptions • Staffing requirements will be met throughout course of project • Estimated budget will be provided • Existing test stand can be used and improved for this year’s project

13. Constraints • Budget: $ 7500 • Technical Expertise: Familiarizing students with TE modules and the current system • Time: All deliverables must be performed within the allotted 22 week timeframe • Resources: Time required on machine shop towards building phase of project. Obtaining TE modules that operate under higher temperatures • Platform: The project must build upon the existing module and test stand • Safety

14. Intellectual Property • Project will be open source, open architecture. • Any information on Dresser-Rand products will be kept confidential • Currently established patents will be researched and taken into consideration with progress of project.

15. Issues and Risks • Availability of off the shelf TE modules • Delivery of parts on time • Parts exceeding budget • Data inaccessibility or loss

16. Outstanding Items • Deliverables over the course of the project are to be determined • Target specifications are yet to be established

17. P09454: Design and Testing of Centrifugal Pump Components 2008-2 through 2008-3

18. Project Status Update • Project Name • Design and Testing of Centrifugal Pump Components • Project Number • P09454 • Project Family • Sustainable Technology for the Global Market • Track • Turbomachinery Flow Visualization • Start Term • 2008-2 • End Term • 2008-3 • Faculty Guide • Dr. Stephen Day • Primary Customer • Dresser-Rand

19. Introduction • Particle Imaging Velocimetry (PIV) uses a sheet laser beam to illuminate particles that cross the sheet. • The particles will diffract the light of the laser and thereby allow for imaging. • Based on the data gathered from imaging these particles, the flow through the system can be visualized.

20. Starting Point • The existing test system was developed for MSD in 2007 -2 & 2007-3 quarters under P08453 • The system consisted of a centrifugal pump that sits within an automated and instrumented flow loop. • The apparatus and pump housing will be fabricated from optically clear materials to allow flow visualization within the pump using Particle Imaging Velocimetry • The system was designed and built with a modular construction so that design variations of impellers, diffusers, and housings may be easily exchanged.

21. Planning

22. Customer Needs • Perform PIV experiments to characterize different flows through the pump system • Use as an teaching tool for undergraduate coursework, projects & labs • Use for Graduate research & projects

23. Deliverables • Design & manufacture interchangeable Impellers & Diffusers (3 items each) • Set up & perform PIV measurement on pump system using new Impellers & Diffusers

24. Mission Statement The purpose of this project is to design & develop interchangeable impellers and diffusers which will work on the existing PIV system in order to characterize different flows through the pump system. Team will deliver 3 impellers & 3 diffusers for the existing system. Furthermore, team will also be responsible for setting up experiments and performing PIV reading using the new impellers & diffusers

25. Constraints Budget: $7,500 Technical Expertise: Not all KGCOE ME students possess the requisite knowledge in Turbomachinery Time: All deliverables must be performed within the allotted 22 week timeframe Resources: Impeller and diffuser manufacturing requires precision machining operation Platform: The project must build upon the existing PIV system (P08453)

26. Assumptions All roles planned this quarter will be filled during both quarters Existing test stand can be used and improved for this year’s project Existing test stand is in acceptable condition Outsourcing the manufacture of Impellers and Diffusers will not adversely effect the timeliness of the deliverables

27. Work Breakdown Structure

29. Intellectual Property Considerations • Project will be open source, open architecture • Thorough patent research must be carried out prior to starting design phase

30. Team Values & Norms • Punctual • Thorough • Accurate • Professional & Ethical • Committed • Good Communication – • Team members should make a conscious effort to keep all members in the team informed with new information, knowledge and project developments, especially the two leaders

31. Required Resources • Technical learning materials such as Turbomachinery text books, research papers • Access to existing (P08453) PIV pump system • Time with Faculty Guide, Dr. Day • Access to manufacturing resources: CNC machining, Rapid prototyping or outsourcing • CAD & Engineering software packages • EDGE

32. Concept Development

33. Customer Needs • Customers require a upgraded PIV system to perform reading on more sophisticated flow patterns provided by new impellers & diffusers. The new impellers and diffusers must be interchangeable and must fit with the existing pump system.

34. Brainstorming Questions • How can the team best familiarize themselves with turbomachinery concepts? • What material can be used to make the impellers & diffusers? • Which manufacturing method will be used to make the products?

35. Target Specifications • Impellers & Diffusers must be interchangeable • New parts should work interface with existing PIV system

36. Risk Assessment • Technical expertise of ME student might be inadequate for the design task at hand • Time needed for impeller manufacturing will affect the timeliness of deliverables • Existing PIV module may not function as desired

37. Risk Assessment • Flow parameters are not met by the design • Design stage leaks over allocated time due to complications • Manufacturing resources at RIT might be inadequate to produce the required parts • Budget might be insufficient to cover outsourcing of manufacturing

38. Risk Management • Team Lead, Lead Engineer will work with faculty advisor to develop a plan to learn the technical skills required to design turbomachinery • Team lead will look for alternative manufacturing methods to save time, cost ex: rapid prototyping, outsourcing

39. Risk Management • Lead engineer designs a study plan with the assistance of faculty advisor & consultants to learn the required skills • Project lead allocates excess time for manufacturing parts & reallocate labor & resources to expedite other processes.

40. Risk Management • Team Lead & Lead Engineer assigns a plan and adequate labor to ensure that the existing PIV system will meet required levels of operation • Team Lead & Lead Engineer will reevaluate and prioritize design goals to ensure timeliness of deliverables

41. Risk Management • Lead engineer will reevaluate design to ensure that products can be manufactured using resources at RIT (while meeting specifications) OR • Project Lead and Lead Engineer will work towards outsourcing the manufacturing to outside vendors

42. Risk Management • Project Lead will work with Faculty Advisor to reevaluate the budget OR • Reevaluate the scope of the deliverable to meet the existing budget

43. Project Status UpdateP09457 – Process Improvement Project Eric MacCormack (IE) Colin Roy (IE)

44. Project Status Update • Project Name • Process Improvement Project • Project Number • P09457 • Project Family • Sustainable Technology for the Global Market • Track • Process Improvement Innovations • Start Term • 2008-2 planned academic quarter for MSD1 • End Term • 2008-3 planned academic quarter for MSD2 • Faculty Guide • Professor John Kaemmerlen • Faculty Consultant • Dr. Kuhl, choice for simulation • Faculty Consultant • Dr. Carrano, choice for manufacturing processes • Primary Customer • Dresser-Rand with the point of contact being Dennis Rice at the Olean facility

45. Mission Statement • The mission of the Process Improvement Project is to implement lean principles into the piping and packaging line at Dresser-Rand Corporation’s Olean facility. • Goal: reduce cycle time by 30%. • Approach: improve the flow of products, warehousing of parts, visual controls, and reduce the waste within the line.

46. Current Layout Test Assembly Piping Assembly & Packaging Parts

47. Customer Needs • Reduce Cycle Time • Improve Flow of Product • Visual Controls System • Standardize Work Processes • Accurate Drawings • Free Up Floor Space • Maintain High Level of Safety

48. Staffing Requirements

49. Work Breakdown Structure P – D – C – A

50. Work Breakdown Structure