Engineering, Design & System Integration 3,000 HP Wind Tunnel Blower, Motor, VFD & PLC Control System
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1 Engineering, Design & System Integration 3,000 HP Wind Tunnel Blower, Motor, VFD & PLC Control System OEA PRESENTATION December 1, 2016 Philadelphia, PA P F Visit us online 1
2 PROJECT CRITERIA Engineering, Design and System Integration Subcontractor to Aerolab to provide a Turnkey Open Jet Wind Tunnel Air Delivery System for Honeywell Responsible from Concept through Commissioning Designed in Philadelphia, PA and Built in Mexicali, Mexico. Components and Systems 415,000 CFM Blower with Dampers and Silencers 3,000 HP Medium Voltage Motor Coupling (Drive Train) 3,000 HP Medium Voltage Variable Frequency Drive PLC Based Monitoring and Control System 2
3 PROJECT ANALOGY Would be similar to a 3,000 HP Vehicle Runs at speeds from 0 MPH to 230 MPH, + 1 %. Can go from 230 MPH to 0 MPH in less than 18 seconds. Can operate continuously in an ambient temperature of 125 F Designed for Seismic Zone 4 Custom Dashboard (HMI) Cruise Control Has a life expectancy of 25 year. Comes with a One to Four Year Warrantee Global Procurement and Assembly of Custom Components Runs like a Well Designed Machine 3
4 PROJECT EXECUTION SCHEDULE Conceptual Engineering June to Sept, 2015 Blower, Motor and VFD Procurement Sept to Nov 2015 Factory Inspections March to June 2016 Detailed PLC Panel Installation Design Feb to June 2016 WTC/PLC Fabrication Procurement May 2016 Equipment Shipped to Mexico June and July 2016 Equipment and System Installations June to Nov 2016 PLC Programming and HMI Screens Aug to Nov 2016 Site Inspections and Acceptances June to Nov 2016 Commissioning ` Oct and Nov 2016 Warrantee Through Nov
5 CONCEPTUAL ENGINEERING Concept: Proposed 4 alternative arrangements and based on discussions with the client, selected the this arrangement. 5
6 PROCUREMENT Equipment Specifications and Selection Approach Performance Criteria Installation Criteria Desired Equipment Subcomponents Bearings Blower and Motor Silencers - Blower Actuators - Blower Instrumentation Blower, Motor and VFD Cooling Systems Motor and VFD MV Input and Output Disconnects - VFD MV and LV Terminal Boxes Motor and VFD Shafts 6
7 DESIGN AND ANALYSIS Engineering Requirements Maida s Responsibility Studies: Power Flow Torsional Analysis Harmonic Analysis Coordination Arc Flash Coordination Aerolab Manufacturers Packaging Shippers Building Design Firm Contractors 7
8 FAT AND SHIPPING FACTORY INSPECTION, PACKAGING AND SHIPPING 415,000 CFM Blower - Parts built in Tennessee and elsewhere were assembled in Mexico 8
9 FAT AND SHIPPING 3,000 HP, 4.16 KV VFD Built in New Berlin, Wisconsin Came together for 1 st time in Mexicali, Mexico 3,000 HP, 4 KV TEWAC Motor Built in Helsinki, Finland 9
10 FAT AND SHIPPING FACTORY INSPECTION, PACKAGING AND SHIPPING WTC/PLC Control Panel Built in Bethlehem, PA PLC System Programmed in Philadelphia 10
11 DESIGN AND ASSEMBLY Mechanical Procurement Blower Coupling Damper Damper Actuator Mechanical Design Wall Air Filters Cooling Water System Foundation Details Baseplates 11
12 FOUNDATION - PEDESTAL BLOWER BUILDING MAJOR EQUIPMENT ARRANGEMENT 12
13 FOUNDATION - PEDESTAL 13
14 FOUNDATION - PEDESTAL 14
15 FOUNDATION BED PLATES 15
16 AIR FILTERS 16
17 DETAILED DESIGN 5 KV VFD MOTOR BRANCH CIRCUIT INSTALLATION DETAIL 17
18 DESIGN AND ASSEMBLY Electrical Procurement 3,000 HP Motor 3,000 HP VFD Electrical Design 5 KV VFD Branch Circuit 18
19 WTC/PLC Panel Design Procurement Programming Commissioning WTC/PLC PANEL 19
20 INSTRUMENT AND CONTROL 20
21 DETAILED DESIGN 21
22 PLC PROGRAM & HMI SCREENS 22
23 OEA AWARD CRITERIA Demonstrates engineering challenges and innovative solutions Integrate a Blower, Motor and VFD that will perform as required under harsh conditions with no mistakes, thereby enabling Honeywell to maintain its commitments. Modify commercially available equipment to meet the operational requirements of the wind tunnel. 23
24 OEA AWARD CRITERIA Demonstrates the importance of the engineering profession to society The wind tunnel will be used for performance and endurance testing of equipment enhancing the safety of large commercial and military aircraft. The wind tunnel would not exist without the blower, motor, VFD and PLC System which are engineered products and systems. 24
25 OEA AWARD CRITERIA Demonstrate a clear and tangible benefit to the Delaware Valley Region 2. Local engineering and design talent enabled us to perform this project without no issues, within schedule and within budget. Awaiting future turnkey projects to design and build the power and control systems for many more 2,000 to 3,000 HP Wind Tunnels in the next five year. 25
26 OEA AWARD WINNER LOW SPEED OPERATION Smoke 2.m4v Smoke 1.m4v QUESTIONS 26
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