Friday, May 14, 2004SOFC Durability Test Stand1 Team 04032 Delphi Corporation Solid Oxide Fuel Cell...

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Friday, May 14, 2004 SOFC Durability Test Stand 1 Team 04032 Delphi Corporation Solid Oxide Fuel Cell Durability Test Stand •John Bagby •Joshua Gannon Mechanical Engineers Electrical Engineers •Michael Scholl •Gregory Tyminski •David White •Wai Meng Ng •Richard Yang Faculty Mentor •Margaret Bailey, Ph.D., PE Delphi Contact •Chris Mergler

Transcript of Friday, May 14, 2004SOFC Durability Test Stand1 Team 04032 Delphi Corporation Solid Oxide Fuel Cell...

Friday, May 14, 2004 SOFC Durability Test Stand 1

Team 04032Delphi Corporation

Solid Oxide Fuel Cell Durability Test Stand

•John Bagby

•Joshua Gannon

Mechanical Engineers Electrical Engineers

•Michael Scholl

•Gregory Tyminski

•David White

•Wai Meng Ng

•Richard Yang

Faculty Mentor•Margaret Bailey, Ph.D., PE

Delphi Contact•Chris Mergler

Friday, May 14, 2004 SOFC Durability Test Stand 2

Subgroup Structures

Test Stand

In

OutStructure

SOFC Controls

Air

Start-UpPower

Fuel

NG

Diesel

Gasoline

Heat

Sensors

Lab

Power

Data

Exhaust

Top

80/20

Enclosure

Safety

Sides

Mind Map

DurabilityStand

StandStructure

Inputs ControlsOutputs

AirStart-upPower

ExhaustFuel

NaturalGas

PowerData

DieselGasoline

SOFCInternal

Controller

Safety

DataCollection

Logic

AlgorithmsFuel

Control

FuelGas

PowerTemps Pressure

Enclosure Supports

ShelvesExhaust

Side

Lexan® Sides

Work Breakdown Structure - Subsystem Flowchart

(a) (b)

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Stand

Preliminary Design

1.5” x 1.5” 80/20 extruded aluminum built 36” tall

Double Anchor Bolt Fasteners for assembly

4 lengths 80/20 top rails supporting top plate

Post PDR Suggestions

32” height of stand

Elimination of 4 supporting 80/20 top rails

Final Decisions2” x 2” 80/20 extruded aluminum used due to in-stock supply

80/20 corner brackets and joining plates used for assembly due to in-stock supply

32” height of stand

Top rail elimination

Friday, May 14, 2004 SOFC Durability Test Stand 4

Stand and FEA

1

MN

MXX

Y

Z

-.003114

-.002768-.002422

-.002076-.00173

-.001384-.001038

-.692E-03-.346E-03

0

MAY 12 200411:17:58

NODAL SOLUTION

STEP=1SUB =1TIME=1UY (AVG)RSYS=0DMX =.003115SMN =-.003114

•Maximum Deflection under 700lb Load: 0.003in

Friday, May 14, 2004 SOFC Durability Test Stand 5

Enclosure

Preliminary Design80 / 20 Extruded Aluminum, 1” x 1” Cross Section

Supporting StructureCast Acrylic Plexiglas

Toggle Clamp Attachment for enclosure removalExcellent Clarity150 degree F tolerance

Firewall1850 degree F tolerance

Rubber SealFulfills airtight requirement

Aluminum PlateDue to high temperature requirement at exhaust outlet

Post PDR SuggestionsHinges for enclosure opening

Reduces manual lift of enclosure to supporting position on the stand base

Top Exhaust for CO startup leakExtra air draw through enclosure to reduce CO emissions into the room

Movable position of top plate within enclosure

Gives better inline positional placement of exhaust of SOFC to enclosure exhaust opening

Friday, May 14, 2004 SOFC Durability Test Stand 6

Enclosure

Final Decisions Hinges are to be used to open enclosure with support braces for a

propped position on stand No Top Exhaust addition

Relay on sensors and Labview within enclosure to shutdown stand if necessary

Movable plate within enclosure Top plate is anchored at its vertical position Enclosure hood is vertically movable

• Manual disassembly and reassembly of supporting 80/20 for vertical movement of enclosure

• Enclosure movement provides robust placement of SOFC in comparison to hood exhaust outlet

Friday, May 14, 2004 SOFC Durability Test Stand 7

Fuel Delivery System

Fuel Supply Delivery System System supplies natural

gas/diesel/gasoline fuels to SOFC. Refueling is accomplished without

interrupting the fuel flow to the SOFC. Fuel Pump supplies liquid fuel at 500kPa

to fuel injector. Redundant Automatic shutdown safety

feature.

Friday, May 14, 2004 SOFC Durability Test Stand 8

Swagelok Components

Warren Rupp Sandpiper II Diaphragm Pump

McMaster-Carr High Pressure Fuel Tanks

Fuel Delivery System

Body Side

Body Side

Body Side

Body Side

PumpFuel Filter

Fuel Tank #1

Pressure GaugeFuel Tank

SOFC

Purge Res.

V-1

Air Line From Gauge Block

V-2

V-3

V-4

N2 Line From Gauge Block

N2 Line From Gauge Block

V-5

T-2 V-6

V-8

P-1

V-9V-10

V-11

Pressure GaugeFuel Tank

V-12Fuel Tank #2

C-2C-3

C-4C-5

T-1

T-3

T-4

T-5 T-7T-6

Element

C-6

P-7

P-8

P-9

P-10

P-11P-12

P-13P-14 P-15

P-16

P-17P-18P-19

P-20

P-21P-23

P-24 P-25

P-26

P-27

P-28

C-22

V-13

V-14

DC powerSolenoid

DC Start-UP Power

DC powerSolenoid

ACWIRE TBD

P-36

P-37

Friday, May 14, 2004 SOFC Durability Test Stand 9

ControlsComponent Interface

Labview 6.1

The main view of the controls were already developed by Delphi. Our task was to integrate what we had with the given components.

Enclosure data, fuel pump enable and enclosure warnings.

E-stop is to be tied in with the e-stop sequence for SOFC unit.

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Data collection for enclosure’s thermocouples and gas sensors.

Detection of warning & e-stop violations.

Data logging writes to a new file each day.

Stand DAQ VI can be incorporated into Main VI as a sub VI with one input and two outputs.

Input for initialization

Two outputs for data values and warning signals.

Data Acquisition

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Financial Summary

REQ Number Subtotal (Less Tax) REQ Number Subtotal (Less Tax) REQ Number Subtotal (Less Tax)1 $735.80 10 $4,550.00 17 $629.003 $436.20 11 $574.08 18 $2,853.004 $518.30 12 $323.70 19 $17,150.005 $995.10 13 $71.46 20 $425.007 $408.00 14 $447.52 21 $3,830.008 $1,163.50 15 $512.32 22 $44.809 $258.60 16 $54.94 6* $2,000.00

* Quote Needed

Fuel Total $4,515.50 Stand Total $6,534.02 Controls Total $26,931.80

Subtotal $37,981.32

ControlsFuel Delivery Stand

Components Removed From Budget By Delphi Corporation•Many Swagelok, exhaust and computer components, stocked in house•Field Point Modules $4.2K•$12K Load Bank Replaces $17K Load Bank •Gas Sensor System $4.5K

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Tasks Outstanding

Finalize and debug Controls & DAQ Virtual Interface

Full installation into Laboratory environment: Plumb Air, NG, Exhaust lines

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Thank You:

R·I·T

Margaret Bailey, Ph.D., P.E.

Alan Nye, Ph.D.

Delphi Corporation

Mr. Chris Mergler

Mr. Chris DeMinco

Mr. Anthony DeRose

Mr. Kristian Whitehouse

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Questions