HIGH TEMPERATURE HEPA FILTER TEST UNIT UPGRADES Final Design Report DECEMBER 9, 2015 TEAM FLASHPOINT Alex Krippner, Ian Corcorran, Michael Burlando Table of Contents List of Figures ............................................................................................................................................... 4 List of Tables ................................................................................................................................................ 5 Chapter 1 – Introduction ............................................................................................................................... 6 Sponsor background and needs ................................................................................................................. 6 Previous Development of the HTTU .................................................................................................... 6 Current State of the HTTU.................................................................................................................... 7 Formal Problem Definition ....................................................................................................................... 8 Chapter 2 – Background ............................................................................................................................... 9 Comparable Systems ................................................................................................................................. 9 Institute for Clean Energy Technology (ICET) .................................................................................... 9 Advanced Thermal Systems CLWT-115 ............................................................................................ 10 NASA Langley High Temperature Tunnel ......................................................................................... 10 Chapter 3 – Design Development ............................................................................................................... 11 Discussion of Conceptual Designs .......................................................................................................... 11 Heaters ................................................................................................................................................ 11 Insulations ........................................................................................................................................... 12 Other Concerns ................................................................................................................................... 13 Concept Selection ................................................................................................................................... 14 Concept Design 1 ................................................................................................................................ 14 Concept Design 2 ................................................................................................................................ 15 Supporting Preliminary Analysis ............................................................................................................ 16 Chapter 4 – Final Design Statement ........................................................................................................... 18 Overall Description/Layout with labeled solid model ............................................................................ 18 Detailed Design Description ................................................................................................................... 20 Manifold .............................................................................................................................................. 20 Faceplate ............................................................................................................................................. 20 Immersion Tube .................................................................................................................................. 21 24 inch Duct Section ........................................................................................................................... 21 Assembly............................................................................................................................................. 21 Material, Geometry, Component Selection ............................................................................................. 22 Watlow 5 Inch ANSI Flanged Immersion Heater ............................................................................... 22 Insulation ................................................................................................................................................ 23 Maftec Ceramic Blanket ..................................................................................................................... 23 Pyrotape 682-TB Thermal Barrier Ceramic Tape ............................................................................... 24 1 AREMCO 840-M High-Temperature High-Emissivity Coating ........................................................ 25 Incorporation of Existing Elements ........................................................................................................ 25 Analysis Results (Details in Appendix E) ............................................................................................... 25 Heat loss .............................................................................................................................................. 25 Heat addition ....................................................................................................................................... 26 Insulation improvement ...................................................................................................................... 27 Cost Analysis .......................................................................................................................................... 28 Safety Considerations ............................................................................................................................. 28 FMEA ................................................................................................................................................. 28 Electrical ............................................................................................................................................. 28 Heat ..................................................................................................................................................... 29 Maintenance and repair considerations ................................................................................................... 29 Chapter 5 – Prototype Build ....................................................................................................................... 29 Design Changes ...................................................................................................................................... 29 Control System........................................................................................................................................ 31 Fabrication .............................................................................................................................................. 32 Chapter 6 – Design Verification Plan ......................................................................................................... 34 Test Descriptions .................................................................................................................................... 34 Chapter 7 – Project Management Plan ........................................................................................................ 35 Team Assignments .................................................................................................................................. 35 Project Milestones ................................................................................................................................... 35 Chapter 8 – Conclusions and Recommendations ........................................................................................ 36 References ................................................................................................................................................... 37 Appendix A QFD, Decision Matrices ......................................................................................................... 38 Appendix B Drawing Packet....................................................................................................................... 41 Appendix C List of Vendors, Contact information and pricing .................................................................. 46 Vendor List ............................................................................................................................................. 47 Appendix D Vendor supplied Component Specifications and Data Sheets................................................ 49 1. Watlow FNNA25J5X ...................................................................................................................... 49 2. Maftec Ceramic Blanket Insulation .................................................................................................... 57 3. Pyrotape 682-TB Thermal Barrier Ceramic Tape ..........................................................................