P13621: Chem Lab Equipment -- Conductive Heat Transfer
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Detailed Design

Table of Contents

Prototyping, Engineering Analysis, Simulation

Iterative activities to demonstrate feasibility.

VWR Chiller Feasibility Analysis

Cooling Capacity Analysis

Cooling Capacity Analysis

Operation Manual for VWR Chiller Model 1146D.

Operation Manual for VWR Chiller Model 1146D.

Table from Operation Manual for VWR Chiller Model 1146D. Shows we should use a mixture of 50% Ethlyene Glycol/ 50% Water.

Table from Operation Manual for VWR Chiller Model 1146D. Shows we should use a mixture of 50% Ethlyene Glycol/ 50% Water.

Specimen Dimension Analysis

Specimen dimensional analysis - Q from A/L.

Specimen dimensional analysis - Q from A/L.

Specimen dimensional analysis - T from Q.

Specimen dimensional analysis - T from Q.

Specimen dimensional analysis - dimension from A/L.

Specimen dimensional analysis - dimension from A/L.

Specimen dimensional analysis - cartridge heater selection.

Specimen dimensional analysis - cartridge heater selection.

Specimen dimensional analysis - graph of Q vs. A/L.

Specimen dimensional analysis - graph of Q vs. A/L.

Conclusions of specimen dimension analysis.

Conclusions of specimen dimension analysis.

Specimen dimension analysis - excel

Thermocouple Placement Analysis

Analysis for thermocouple placement. Needs to be confirmed during testing phase in MSD II.

Analysis for thermocouple placement. Needs to be confirmed during testing phase in MSD II.

Insulation Analysis

Insulation Calculation Model

Insulation Calculation Model

Insulation governing equation - Fourier's Law.

Insulation governing equation - Fourier's Law.

List of variables.

List of variables.

Parameters held constant and varied.

Parameters held constant and varied.

Complexity of model.

Complexity of model.

Error minimized using Excel Solver Function

Error minimized using Excel Solver Function

Insulation Histogram

Insulation Histogram

Insulation Cumulative Percentage

Insulation Cumulative Percentage

Insulation dimension analysis

Spec Sheets

VWR Chiller Spec Sheet

VWR Chiller Spec Sheet

Cold Plate Spec Sheet from McMaster-Carr

Cold Plate Spec Sheet from McMaster-Carr

Stud and Rod Spec Sheet from McMaster-Carr

Stud and Rod Spec Sheet from McMaster-Carr

Hex nuts Spec Sheet from McMaster-Carr

Hex nuts Spec Sheet from McMaster-Carr

Cartridge Heater Spec Sheet from McMaster-Carr

Cartridge Heater Spec Sheet from McMaster-Carr

Image of safety glasses - fits over prescription glasses.

Image of safety glasses - fits over prescription glasses.

Specs for safety glasses.

Specs for safety glasses.

Cold Finish Mild Steel Square 1018 Specimen

Cold Finish Mild Steel Square 1018 Specimen

304 Stainless Steel Specimen

304 Stainless Steel Specimen

2024 T351 Aluminum Specimen

2024 T351 Aluminum Specimen

360 H02 Extruded Brass Specimen

360 H02 Extruded Brass Specimen

Copper Square 110 H04 Heating Block

Copper Square 110 H04 Heating Block

Specimen Costs

Specimen Costs

Drawings, Schematics, Flow Charts, Simulations

CAD Drawings

CAD Drawing of the copper interfacing.

CAD Drawing of the copper interfacing.

CAD Drawing of the top plate of the fixture.

CAD Drawing of the top plate of the fixture.

CAD Drawing of the base plate of the fixture.

CAD Drawing of the base plate of the fixture.

CAD Drawing of the Heating Block

CAD Drawing of the Heating Block

CAD Drawing of Specimen 1-4

CAD Drawing of Specimen 1-4

Assembly Drawings

Assembly drawing for the heat transfer apparatus.

Assembly drawing for the heat transfer apparatus.

Assembly drawing for insulation.

Assembly drawing for insulation.

Assembly and disassembly instructions for apparatus.

Assembly and disassembly instructions for apparatus.

Assembly summary and analysis of heat losses p.1.

Assembly summary and analysis of heat losses p.1.

Assembly summary and analysis of heat losses p.2.

Assembly summary and analysis of heat losses p.2.

Process Flow Diagram

Process Flow Diagram

Process Flow Diagram

Piping and Instrumentation Diagram

Piping and Instrumentation Diagram

Piping and Instrumentation Diagram

Piping and Instrumentation Diagram Legend

Piping and Instrumentation Diagram Legend

ANSYS Simulations

Summary of ANSYS analysis

ANSYS Thermal Model - This is a two dimensional of the system created with area over key points. The upper blue rectangle represents the sample within the system. The highlighted purple area represents the copper heating block. The section within that area is the cartridge heater itself.

ANSYS Thermal Model - This is a two dimensional of the system created with area over key points. The upper blue rectangle represents the sample within the system. The highlighted purple area represents the copper heating block. The section within that area is the cartridge heater itself.

ANSYS Heat Flux Model - The sample was modeled to be a block of aluminum with a K value of 250. The copper block and the cartridge heater were modeled to have a K value of 403. Boundary conditions were set to have the cartridge heat at a temperature of 100 degrees while the very top of the sample was set to a heat flux of -140W/m2.

ANSYS Heat Flux Model - The sample was modeled to be a block of aluminum with a K value of 250. The copper block and the cartridge heater were modeled to have a K value of 403. Boundary conditions were set to have the cartridge heat at a temperature of 100 degrees while the very top of the sample was set to a heat flux of -140W/m2.

ANSYS Heat Flux Model with no convection - To account for heat loss into the insulation, convection was added to the edges with a film coefficient of 5 and a bulk temperature of 20. This was considered an acceptable representation by one of our heat transfer experts. This is the result.

ANSYS Heat Flux Model with no convection - To account for heat loss into the insulation, convection was added to the edges with a film coefficient of 5 and a bulk temperature of 20. This was considered an acceptable representation by one of our heat transfer experts. This is the result.

Experimental Basis

Experimental Model - Basis

Temperature vs. Steady State Graph for Aluminum Sample.

Temperature vs. Steady State Graph for Aluminum Sample.

Temperature vs. Steady State Graph for Copper Sample.

Temperature vs. Steady State Graph for Copper Sample.

Set up of current experiment in Chemical Principles Lab.

Set up of current experiment in Chemical Principles Lab.

Conclusions from Lab

Bill of Material (BOM)

Bill of Materials

First page of the Bill of Materials as of November 10, 2012.

First page of the Bill of Materials as of November 10, 2012.

Second page of the Bill of Materials as of November 10, 2012.

Second page of the Bill of Materials as of November 10, 2012.

Color key for the Bill of Materials.

Color key for the Bill of Materials.

Action Log & Gantt Chart

Action Log

Updated tasks in Gantt Chart to be completed weeks 6-11.

Updated tasks in Gantt Chart to be completed weeks 6-11.

Updated timeline in Gantt Chart to be for weeks 6-11.

Updated timeline in Gantt Chart to be for weeks 6-11.

Preliminary Work Breakdown Structure for MSD II.

Preliminary Work Breakdown Structure for MSD II.

Test Plans

Test Procedures

Test plan.

Test plan.

Risk Assessment

Updated Risk Assessment

Updated Risk Assessment - risks #1-6.

Updated Risk Assessment - risks #1-6.

Updated Risk Assessment - risks #7-11.

Updated Risk Assessment - risks #7-11.

Updated Risk Assessment - risks #12-20.

Updated Risk Assessment - risks #12-20.

Detailed Design Review

DDR Agenda

DDR Presentation

DDR Minutes

Action Log items from feedback during the Detailed Design Review.

Action Log items from feedback during the Detailed Design Review.

Action Log items from feedback during the Detailed Design Review.

Action Log items from feedback during the Detailed Design Review.

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