Often, service companies are faced with the challenge of redesigning existing pumps that have failed in the field with extremely quick turnaround times. While there are quick-fix methods to return these pumps into operation, other more complex problems may require taking a step back and analyzing how this particular pump could be redesigned based on its current operation. These engineering upgrades could solve recurring issues with failure modes of a certain machine, and they could also solve new capacity demands that are imposed by a customer based on their system’s upstream or downstream changes. While efficiency increases could be beneficial to the overall system, many times it is more important to solve capacity requirements and increase the life of the pump by decreasing the Net Positive Suction Head Required (NPSHr).
In this blog post, we will investigate how to move an existing centrifugal pump through the AxSTREAM platform in order to solve engineering challenges seen on common OEM pump upgrades. With the use of AxSTREAM’s integrated platform and reverse engineering module, many of the CAE tasks that are common in an analysis such as this one can be realized in record speed. The first step of the reverse engineering process occurs in obtaining the necessary geometrical information for the desired pump. Through AxSLICE, the user can take an STL, IGES, CURVE file, or a generated cloud of points and properly transform this 3D profile into a workable geometry inside the AxSTREAM platform. In a matter of minutes, the user can outline the hub and shroud and transform a blank 3D profile into a profile defined by a series of segments. Seen in Figure 1, the centrifugal pump is now defined by a hub, shroud, and intermediate section.
Because the most vital part of a refrigeration and HVAC system is to function optimally, compressors are used to raise the temperature and pressure of the low superheated gas to move fluid into the condenser. Consequently, refrigeration compressors must be properly maintained through regular maintenance, testing and inspection. There are a couple conditions which would indicate compressor problem or failures. However, with the right supervision it is possible to avoid further damage. Through this post we will identify and discuss some of these conditions: Read More
The helicopter is a sophisticated, versatile and reliable aircraft of extraordinary capabilities. Its contribution to civil and military operations due to its high versatility is significant and is the reason for further research on the enhancement of its performance. The complexity of helicopter operations does not allow priority to be given for any of its components. However, the main engine is key for a successful flight. In case of engine failure, the helicopter can still land safely if it enters autorotation, but this is dictated by particular flight conditions. This article will focus on the possible threats that can cause engine failure or deteriorate its performance.
When a helicopter is operating at a desert or above coasts, the dust and the sand can challenge the performance of the engine by causing erosion of the rotating components, especially the compressor blades. Moreover, the cooling passages of the turbine blade can be blocked and the dust can be accumulated in the inner shaft causing imbalance and unwanted vibration. The most common threat of this kind is the brownout which is caused by the helicopter rotorwash as it kicks up a cloud of dust during landing.
Variable Frequency Drive is found to be very effective in assisting with energy management for HVAC systems. The main objective of this technology is to ensure that the motor only generates enough energy to power the compressor and no more. VFD provides constant load-matching capacity which results in the elimination of over-capacity running. Recently studied, current variable frequency drive benefits goes beyond the advantage of energy savings or energy efficiency. In conventional common application, the installation of variable frequency drive saves about 35% to 50% energy used by matching system capacity to the actual load.
Historically turbomachinery development began with empirical rules postulated by early pioneers. With the need for jet engine for aircraft propulsion, dimensionless analysis became popular, followed by the 1 D mean line design and 2D meridional methods. Today 2D meridional methods with 3D blade to blade CFD/FEA methods are a necessity as efficiency and reliability requirements are further pushed.
One key aspect of 2D meridional design is S1-S2 optimization, which is a time consuming, laborious task and hence subject to human errors. S1-S2 optimization is a task of reviewing, adjusting and optimizing the flow path in the Tangential (S1 or blade-to-blade or pitchwise) and the Meridional (S2 or span wise) planes. The main purpose is to:
Fit the flow path to specific meridional dimensional constraints
Adjust blade-to-blade parameters while taking into account structural constraints.
Freon (brand name by DuPont) used to be the regulated and most used refrigerant in the HVAC market. The chemical (R-22) was introduced to the refrigerant system in 1920. It consisted of hydrogen, carbon, fluorine and chlorine. HCFC was used in replacement to CFC or chloro-fluoro-carbon which is considered more dangerous. Within a few years, HCFC took over CFC’s role as the safer option.
Even though it was found to be safer than the alternative at the time, various recent studies state that R-22 is detrimental to the environment as it is a substantial ozone depleting substance that leads to greenhouse effects. Since January 2015, the maintenance or servicing of existing refrigeration, air condition and heat pump equipment using R22 has been prohibited by the EPA (Environmental Protection Agency) and related international agencies. Based on the Montreal Protocol, which prevents more damage to the ozone layer by banning all ozone deteriorating substances, R22 can no longer be used in any kind of application.
In its natural state, heat flows from higher to lower temperature regions. Refrigeration cycles are utilized to modify or reverse this cycle, using work obliging heat to flow with the direction that is desired, and align with increasing temperature from low temperature region to higher.
During the earliest records of the “cooling” process being invented, people harvested ice to refrigerate, cool and conserve food. As time progressed, humanity’s basic needs changed and new ways to manipulate temperature started being explored. Major research into refrigeration began with the creation of pup to create a partial vacuum container which absorbs heat from the air. That being said, while the experiment was successful it did not have any practical applications.
– Input a set of boundary conditions, geometrical parameters and constraints that are known to the user.
Step 2: Design space generation
– Thousands of machine flow path designs can be generated from scratch
– Explore a set of design solution points using the Design Space Explorer
– Adjusting geometric parameters while retaining the desired boundary conditions is also possible
Optimization (or parametric studies) of a twin spool bypass turbofan engine with mixed exhaust and a cooled turbine can be considered one of the most complex problem formulations. For engine selection, determining the thrust specific fuel consumption and specific thrust is necessary against variables such as design limitations (Inlet temp, etc.), design choices (fan pressure ration, etc.) and operating conditions (speed & altitude). The task involves cycle level studies following machine, module, stage and component level optimization. This calls for an integrated environment (IE) and it is desirable to have such an IE operating on a “single” platform.
Historically IE was developed for the design of axial turbines (mainly steam). Later, it was expanded for gas turbines (especially blade cooling calculations) and axial compressors via plug-in modules. The new challenge designers face today is developing mixed flow machinery. An effective system for modern turbomachinery design needs to do the following:
The majority of HVAC installations dating back to the 1990s have R-22 as their main working fluid. However, recent studies have proven that R-22 or as we commonly known as “Freon” (brand type) is not as environmentally friendly as we once thought it was. Ergo the use of this refrigeration type has been banned by the Environmental Protection Agency along with other substances which contributes to ozone depletion. With phasing out of R-22, HVAC manufacturers and end-users are forced to look into other comparable refrigerants which won’t negatively impact the environment as much.
R-410A offers a few benefits when compared to the traditional R-22 fluid – one of which is greater energy efficiency which translates into lower operational costs. This hydro-fluorocarbon has been approved for use in new systems and is classified as a non-ozone-depleting HFC. One note that has to be taken into consideration is that R-410A operates on roughly a 50% higher pressure than R-22, thus can only work with high pressure limit equipment.