definition of the problem[1]

8/3/2019 Definition of the Problem[1]

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MAPP 1

Definition of the Problem

Compressed air supply is used in wide variety of production environment to operate

pneumatic tools. Although air is free, compressing it to be useful in workshop or plants is not.According to Norgren, energy costs account for 75% of buying and running a compressorthrough its lifetime. Therefore, any waste, or inefficiency associated with delivering pressurizedair, especially in this era of rising energy costs, penalizes for the production facility.

A significant source of waste is leakage in the air delivery system (Appendix 1). Leakagemay develop at couplings, pipelines, filter connections, or even due to corrosion in aging plants.While leakage may be impossible to eliminate, it could account for 20-30% loss of compressedair. As the compressor in a typical plant uses electrical power, one can state that money isdrained through leaky lines. In fact a study by Colorado State University Industrial AssessmentCenter for one such plant revealed that leaks cost that company $1670/yr (Appendix 2).Furthermore a study of potential cost of leak at this plant showed an accumulated leak equivalentto 1/16 orifice could cost a plant about $ 424/yr while for an accumulated leak of the cost isabout $6,195/yr (Appendix 3).

The cost of leakage is not limited to energy costs. Leakage also affects the operation of pneumatic tools, thereby hampering production. Moreover, leakage causes the compressor insuch systems to cycle more. This in turn increases the wear and tear on the compressor, whichincurs more cost in such plants.

Early detection of leakage would not only improve efficiency, but save companies a lotof money. Contrast the energy costs of accumulated leaks of 1/16 and 1/4, for example; for

four- fold increase in leakage, the increase in energy cost is sixteen fold. In light of this, a devicethat monitors the air delivery system and alerts plant personnel of the presence of leakage wouldtrim down energy cost as well as wear and tear on compressor.

Purpose

The purpose of this project is to design and provide manufacturers with a device tomonitor their air delivery system and detect any leaks in the system.


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MAPP 2

Objectives

The objectives of this project are: Provide detailed analysis of potential savings accrued from a properly maintained

compressed air source Identify situations where monetary loss due to leakage warrants a proactive means of

leak detection Devise method of monitoring pressurized air and detecting presence of leak in the

system Design simulations to analyze results of pneumatic system tests Design a cost effective device that monitors and detects leak in plants using pressurized

air Provide a design that is compatible with a majority of the leading pneumatic pressure

system platforms.

Faculty Member Mentor and Qualifications

Dr. Randall Manteufel will be the faculty member that would mentor this design project.Dr. Manteufel graduated from the Massachusetts Institute of Technology in 1991 with a Doctorof Philosophy in mechanical engineering. He received his Master of Science degree inmechanical engineering from the University of Texas in 1987. Dr. Manteufel has been thementor for many previous senior design projects and is familiar with the process andrequirements. He has been published on multiple occasions in the field of pneumatics. His mostrecent writings include Enhanced Low -Pressure Pneumatic Conveyance Using Swirl in 2010and Swirl Decay in Pneumatic Particulate Conveyance, also in 2010. His guidance andexpertise in the field will be pivotal in successfully completing the project.

Team Member Strengths and Qualifications

MAPP Solutions includes a team member who is familiar with energy auditing, whichespecially comes in handy when analyzing the potential energy savings. In addition, the sameteam member is familiar in programming and software/hardware design. This skill will help theteam in devising an electronic/logic circuit for the leak detector. Furthermore, the team includes

members are familiar with compressed pneumatic air supply, as well as strong background incontrol systems. Moreover, all members have good background in fluid mechanics as well asthermodynamics.

Besides strengths in subject matter area, all team members believe in four key criteria thatmake or break a team (as outlined in WP-1): communication, collaboration, decision making,and self-management. A project of this scope needs the collective effort of members to succeed,and the ability to work together is a crucial asset of the team.


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MAPP 3

Not every member is skilled in every area of the design problem. Therefore, tackling eachaspect of the problem, and bringing these facets may pose a challenge. The team plans to resolvesuch issues by letting a team member give briefings in areas where other team members wouldbe lacking. Not only would this help members stay in the same page, it would also aid membershone their presentation skills.

In addition, the class schedule of members precludes meeting during day time. Whileevening meetings allow team members to work together, finding a common time for bi-weeklymeetings with the instructor needs to be addressed. The team plans to schedule early meetings(7:15 am) on Mondays or Wednesdays. Contacts with Dr. Manteufel could be done individuallyor in pairs in a manner that would not disturb his schedule.

Outside Resources Required

At this phase in the design, product development is in Its nebulous stage. Hence, it is

hard to project what outside resources will be required in detail. In the analysis phase, the teamanticipates the need for current handbooks in compressed air system design. Such handbooksmay have to be borrowed or procured from external sources. In addition, the team foresees theneed to contact consultants beyond the schools settings to gain full picture of how to addressleakage problems. Although the school is equipped with NI software that could be used forsimulations, experimental set ups may require materials (couplings, gages) that may or may notbe readily available at the school. Finally, the team expects to procure microprocessors for theproduct from outside vendors


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MAPP 4

Appendix 1: Compressed Air System

Figure 1: Schematic of Compressed Air System

A compressed air system typically consists of a tank, filter/moisture trap, tank, regulator andpiping system. Leakages typically develop along couplings, pipes, pipe joints, thread sealants,and flow control devices.


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MAPP 5

Appendix 2:

Table 1: Breakdown of Energy Cost Analysis Performed on a Plant (Designated Plant 564) by the Colorado State UniversityIndustrial Assessment Center (USC-IAC). (From http://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdf )
http://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdfhttp://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdfhttp://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdfhttp://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdfhttp://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdfhttp://www.engr.colostate.edu/IAC/pdfs/AR%20No.%201%20-%20Repair%20Compressed%20Air%20Leaks_564.pdf


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MAPP 6

Appendix 3:

Table 2: Energy Cost vs. Leak Diameter for Plant in USC-IAC Study

Figure 2: Graph for Energy Cost vs. Leak Diameter for Plant in USC-IAC Study


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MAPP 7

Works Cited

" A R N o . 1 - R e p a i r C o m p r e s s e d A i r L e a k s . " e n g r. c o l o s t a t e . e d u . C o l o r a d oS t a t e U n i v e r s i t y, n . d . We b . 1 8 S e p 2 0 11 .< h t t p : / / w w w. e n g r. c o l o s t a t e . e d u / I A C / p d f s / A R % 2 0 N o . % 2 0 1 % 2 0 -% 2 0 R e p a i r % 2 0 C o m p r e s s e d % 2 0 A i r % 2 0 L e a k s _ 5 6 4 . p d f > .

B a r t l e t t , Te r r y, a n d S t e p h e n S c h n e i d e r. " P n e u m a t i c A i r L e a k s . " Wi s c -o n l i n e . c o m . Wi s c - o n l i n e . c o m , n . d . We b . 1 8 S e p 2 0 11 .< h t t p : / / w w w. w i s c -o n l i n e . c o m / o b j e c t s / Vi e w O b j e c t . a s p x ? I D = H Y P 1 9 0 6 > .

" H o w t o I m p r o v e E n e rg y E f f i c i e n c y. " e s k i m o . c o m . N o rg r e n , n . d . We b .1 8 S e p 2 0 11 .< h t t p : / / w w w. e s k i m o . c o m / ~ w f d / h t m l / O t h e r / e n e rg y s a v i n g . p d f > .

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