![• The PM was modeled in EES using manufacturer’s spec sheet data.
Method of energy recovery from the exhaust of the PM and other
components for satisfying the loads of the facility were fixed
• A Heat Recovery Steam Generator (HRSG) and absorption chiller were
selected based on the energy output. 5 configurations and their
resultant power levels were analyzed to select the best as the base
case via industry indicators like PURPA efficiency, thermal fraction etc.
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25
Electricalpower(MW)
Average demand Design I Design II Design III Design IV Design V
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Thermalpower[MMBtu/hr]
Absorption chiller exhaust mass flow fraction, y
Cooling Heating Total thermal
2
Performance of designs
Base case T-S diagram
Resultant loads for design with Chiller](https://image.slidesharecdn.com/final2-200513001603/85/Kalpak-Mechanical-Engineering-Project-Portfolio-9-320.jpg)
Kalpak Mechanical Engineering Project Portfolio
- 1. Kalpak Mukund Dhake Mechanical Engineering Portfolio
- 2. About me • A mechanical engineer obsessed with problem solving and pragmatism. The realization that problem is merely an opportunity to improve quality of life has led me to develop appreciation and passion for innovation and smart design • My goal is to continuously innovate while learning to brainstorm solutions to such problems starting from ideation to quantifying parameter tradeoffs to prototyping • Interested in contributing to developing creative, innovative and sustainable products in a cross functional team environment
- 3. Projects Timeline 1 Design of workout equipment for office spaces 2 Design and Economic Analysis of Large Scale Powerplant 3 Analysis of Pin Fin Heat Exchanger 4 FVM Solver Algorithm Development 5 Design and Analysis of Riser Pipe Inspection Tool 6 Capstone: Parametric Study & Prototype of Wind Turbine 7 Experimental Study of Emissions Characteristics 8 Numerical Study of Gas Atomization in Powder Production Aug ‘19 - Dec ’19 Jan ’19 - May ‘19 Aug ‘18 - Dec ‘18 Jan ‘18 - May ‘18 Jan ‘18 - May ‘18 Nov ‘16 - May ‘17 May ‘16 - July ‘16 Nov ‘15 - Jan ‘16
- 4. Design of workout equipment for office spaces Opportunity: Design an ergonomic, compact and customizable office space workout equipment which can be used with existing office furniture let employees to exercise at their desks • A concise and exhaustive survey was conducted after initial research. Data gathered from industry and academic employees was next analyzed and a GANNT chart was generated for a project roadmap • The survey data was analyzed and the House of Quality tool used to determine the interdependence of design factors used to drive key design decisions. A strength training application for an office chair was to be developed 1 ⚫⚪⚪⚪⚪⚪ | Team of 6
- 5. • A complete functional model was made to ease highlighting and selecting key mechanism and helped identify primary functions via brainstorming tools such as mind mapping and affinity diagrams • A morphological chart was created and decision matrix was used to create a ranked list for the final product idea by using different combinations • A fitness tracking system was formulated to track the progress of workout using sensors and use data to incentivize healthier habits for employees 1 Detailed functional model Requirements Mechanical Mass <50 lbs Load <250 lbs Physical Dim: 6’ x 6’ Noise OSHA standard (<70 dB) Stretching mechanism Connection to sensor Multiple resistence level Safety Instruction set MIL-STD- 142G, BIFMA/ ANSI standards Material BIFMA standards Tracking App Compatibility with fitness applications Functional Multiple muscle groups Chair motion restriction
- 6. • The 3-D CAD model was generated in SolidWorks while adhering to BIFMA regulations for equipment design • First order and Back of envelope calculations were done to ensure structural and mechanical functionality of the system • Product benchmarking was performed against similar current products by comparing engineering characteristics 1 Decision martix
- 7. • Manufacturing feasibility and material selection was done for each component and product as a whole • A BOM was generated for the product • PFMEA was performed to identify potential failure modes and causes 1 PFMEA matrix
- 8. Design and Economic Analysis of Large Scale Powerplant Opportunity: Design a powerplant from scratch for a large university and perform economic analysis to determine feasibility of final design • Monthly energy data provided was analyzed and demand generated for the facility • H/P or heat to power ratio for the year was used to select the appropriate prime mover to satisfy the demands for most of the year which was found to be Gas Turbines. ⚫⚪ | Team of 2 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 1 2 3 4 5 6 7 8 9 10 11 12 H/Pratio Month of the year 2 Cogeneration system configuration
- 9. • The PM was modeled in EES using manufacturer’s spec sheet data. Method of energy recovery from the exhaust of the PM and other components for satisfying the loads of the facility were fixed • A Heat Recovery Steam Generator (HRSG) and absorption chiller were selected based on the energy output. 5 configurations and their resultant power levels were analyzed to select the best as the base case via industry indicators like PURPA efficiency, thermal fraction etc. 0 5 10 15 20 25 Electricalpower(MW) Average demand Design I Design II Design III Design IV Design V 0 5 10 15 20 25 30 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Thermalpower[MMBtu/hr] Absorption chiller exhaust mass flow fraction, y Cooling Heating Total thermal 2 Performance of designs Base case T-S diagram Resultant loads for design with Chiller
- 10. 8.0 9.5 11.0 12.5 14.0 15.5 17.0 18.5 20.0 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 0 5,000 10,000 15,000 20,000 25,000 NPV(106$) PaybackandTimetoNPV=0 (years) IRRandROI(%/3) Gas turbine size (kW) Payback Period Time to NPV = 0 IRR ROI NPV • Economic report of the base case was generated based on additional demand using financial parameters like pay back period, net savings per year, NPV per year, tax rebates etc • Sensitivity of design parameters to see effect on the performance done • Business model for ownership & financing with partnership options ( Direct, third-party leasing and contracting) drafted • Final design used a 7.5 MW turbine and utilized a HRSG for cogeneration and yielded a pay back of 4.5 years -15 -10 -5 0 5 10 15 20 25 -15 -10 -5 0 5 10 15 PercentagechangeinPayback time(%) Percentage change in parameter (%) Gas turbine efficiency Exhaust mass flow Exhaust gases temperature 2 Sensitivity studyBusiness model for ownership
- 11. Analysis of Pin Fin Heat Exchanger Opportunity: Find the best type of analysis for a given PFHX and develop an app to optimize PFHX parameter selection • An air-cooled PFHX array was analyzed three ways: using simple pin fin method and bank of tubes method which were compared with base case numerical simulations • An n-factorial Design of Experiment study was formulated by varying the fin configuration (transverse-longitudinal), fin size and flow rates ⚫⚪⚪ | Team of 3 3
- 12. • The base plate + fin geometry were generated using SolidWorks design table using fixed constraints on the model • Numerical analysis was performed using medium meshes and results were post processed while all output parameters were mass averaged • Fin analysis was done using operating conditions for a single fin and then extrapolated for rest of the array • Bank of tubes theory analyses were performed by using existing Nusselt number correlations for both configurations of tubes. 𝑇1 𝑇2 𝑇3 𝑇𝑜𝑢𝑡𝑇𝑖𝑛 𝑄 𝑓𝑖𝑛 ሶ𝑚, 𝑇𝑖𝑛 ሶ𝑚, 𝑇𝑜𝑢𝑡 3
- 13. • As the ratio of fin spacing to fin decreases and mass flow rate increases, the models diverge • A simple Matlab app was developed which used the data generated by the DoE and user input regarding base plate geometry and inlet conditions to generate the optimum PHFX array configuration and pressure drop as a result of it 3 Error plots for each configuration
- 14. FVM solver algorithm development ⚫ | Individual Opportunity: Develop a program using the Semi Implicit Method for Pressure Linked Equations (SIMPLE) algorithm to solve 2D thermo-fluidic problems • The step by step algorithm formulation started with 1D steady state FVM program to predict temperature distribution for a sample geometry • A Gauss-Seidel method to declare convergence for the numerical solution was used to determine the optimum over relaxation factor • A 2D FVM program with energy equation solving capability using a 2D sweeping method was added 4
- 15. • The program built further to simulate 2D laminar flow through parallel plates • The classical lid driven cavity was used as the next test case to further develop the solver by using different mesh sizes and a grid convergence study. Results were validated with literature • Final test case used a heated downstream facing step and calculate reattachment length for the flow for different Reynolds numbers. Reynolds Number Calculated Reattachment Length (Xr/h) (Xr/h) from reference paper 100 3.38 3.71 200 6.00 6.04 300 7.50 8.36 4 Plots for benchmarking program with literature
- 16. Design & Analysis of a Subsea Flexible Pipe Riser Internal Inspection Tool Opportunity: Design a manufacturable internal inspection tool to detect damage or corrosion in flexible subsea pipe risers to fit bended pipes of variable diameter and hydraulically powered ⚫⚪⚪ | Team of 3
- 17. • Initial design review involved selection of driver system and tool geometry to ensure it can navigate the 20-D bend • A wheel driven design selected and power generation was done by a positive displace mud-motor used in directional drilling operation 5 Hydraulic hose Rotor Riser Mud motor design and power flow
- 18. • Powered wheel-track system was designed on both ends with a spring assembly in the middle to ensure right amount of “downforce” on the wheels to account for the variable ID of the pipe • An ultrasonic sensor for pipe anomaly detection was chosen to be kept inside a industrial grade IP5X housing to find the position of pitting, cracking, stripping, breaking, buckling or other anomalies in the metallic riser walls 5 Driver design
- 19. • Alloy 825, a Nickel Iron Chromium alloy with Titanium, Copper and Molybdenum added, specifically made to give superior resistance in corrosive oxidizing and reducing environments • Critical parts for structural analysis were identified and a grid convergent FEA study was performed on these parts using operating conditions calculated from first order calculations. The components were found to be operating well within the FOS specified 5 Structural FEA on critical components
- 20. Parametric Study & Prototype of Wind Turbine Opportunity: Perform a parametric study and 3D print a prototype of a small scale wind turbine (SSWT) to be used to power electronic devices such as a mobile phone, laptop etc • The capstone project started with literature review of required turbine blade and airfoil design along with the required application for this low Reynolds number case • Blade Element Theory was used to used to finalize the 3 chord design equations design using which the nonlinear chord and twist profiles were generated ⚫⚪⚪ | Team of 3 6
- 21. • The turbine blades were designed using CATIA modeling software • The rotor assembly was manufactured using VeroPlastic material and FDM method of additive manufacturing • During field tests, When the three turbine blades with a tip- speed ratio of 6 are exposed to the wind (industrial fan) with a free stream velocity within 3-8m/s, the setup produces voltage in the range of 2V-8V and current in the range of 0.05-0.15A which satisfies the intended application 0.13 0.09 0.07 0.06 0.05 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 5 10 15 20 25 Current(A) Resistance (ohm) Current vs Load Resistance at 700rpm 0.11 0.12 0.14 0.17 0.2 0 0.05 0.1 0.15 0.2 0.25 600 700 800 900 1000 Current(A) Rotational speed (rpm) Current vs Speed at 3 ohm 6 0 1 2 3 4 5 6 7 200 400 600 800 1000 1200 Voltage RPM Voltage vs RPM Turbine output w.r.t electricity measured
- 22. Experimental Study of Emissions Characteristics Opportunity: Experimentation of Envirofit PCS-1 natural draft cook stove and The Philips HD4012 forced draft cook • A research project which consisted of conducting controlled tests on both cook stoves. Central Composite Design (CCD) method of DoE was used to design a set of tests for collecting data which show dynamic performance of cook stove to the variation of firepower, fuel size, vessel size ⚫ | Individual H 2 3 4 5 72 03 2 33 2 3 52 02 15 10 5 33 63 iffE eziSleuF rewoPeriF urface Plot of Effi vs Fuel SiS e, Fire Powerz 7 Surface plot of efficiency vs Fuel size vs power
- 23. • Data collected was bulk mean temperature of water, ambient moisture level, flue gas spectroscopy and PM collected using a cyclone collector and all systems were connected to a DAS • Tests were conducted while adhering to BIS standards to ensure repeatable and relevant data for different power levels, fuel size and firing frequency and surface plots were generated • A preliminary mathematical model was developed to determine the thermal response constant of the systems Fuel Size15.5 Hold Values 2 3 4 5 3 4 5 10.0 5.7 0.5 5 5.21 10.0 6 OC ycneuqerF rewoPeriF urface Plot of COS s Frequency, Fire Powerv 7 Surface plot of CO level vs Fuel size vs frequency Real time PM measured data
- 24. Numerical Study of Gas Atomization in Powder Production Opportunity: Numerical analysis of annular nozzle in for liquid tin powder production • A CAD model was developed using machine drawings of the component in ANSYS workbench followed by imparting the right boundary conditions for numerical model and post processing • Once hydrodynamic and temperature results were obtained, they were compared with the experimental data collected in the physical system and its error analyzed ⚫ | Individual 8
- 25. Thank you for your time!